Tuff Country 14611 - GM 69-72 2 box kit (systems with rear springs) - Manual (Page 3)

Please Follow Instruction Carefully
Before installation begins, drive and check to make
sure there are no uncommon sounds and or frame
damage. Also at this time measure from the center of
the hub to the bottom of the fender well and record
measurements below.
Pre Installation Measurements:
Driver Side Front:______________________________
Passenger Side Front:__________________________
Driver Side Rear:______________________________
Passenger Side Rear:__________________________
At the end of the installation take the same
measurements and compare to the pre-installation
measurements.
Post Installation Measurements:
Driver Side Front:______________________________
Passenger Side Front:__________________________
Driver Side Rear:______________________________
Passenger Side Rear:__________________________
Front End Installation:
1. To begin installation, block the rear tires of the vehicle
so that the vehicle is stable and can’t roll backwards.
Safely lift the front of the vehicle and support the frame
with jack stands. Place a jack stand on both the driver
and passenger side. Next remove the wheels and tires
from both sides.
2. Working on the driver side, remove the stock shock
from the stock upper and lower mounting point and save
hardware for later re-installation. The stock shocks may
be discarded. Special Note: New longer front shocks
are needed, if you have not already ordered shocks,
please contact Tuff Country or your local Tuff
Country dealer and order the proper shocks. Tuff
Country recommends using a 20” fully extended
nitrogen gas shock when installing a 2” suspension
system and a 23” fully extended nitrogen gas shock
when installing a 4” suspension system. Repeat
procedure on the passenger side.
3. Working on the driver side, disconnect the stock brake
line at the frame mount. Let the stock brake line hang.
Special Note: Brake fluid is going to leak out, it is a
good idea to place a bucket under the vehicle to
catch the brake fluid that will leak out. After the
installation is complete, the brake lines will need to
be bleed. Repeat procedure on the passenger side.
See Illustration # 1
4. Working on the driver side, remove the stock cotter pin
and caster nut that connects the stock drag link ball joint
to the stock steering arm. If you are not going to replace
the stock steering arm with a raised steering arm, save
the stock cotter pin and caster nut for later re-installation.
Remove the stock drag link from the stock steering arm
and let the stock drag link hang. Special Note: Tuff
Country EZ-Ride Suspension highly recommends
installing a raised steering arm once a 4”
suspension system has been installed. If you have
not already ordered your raised steering, please
contact Tuff Country or your local Tuff Country
dealer and order part # 70100. If you are installing a
2” suspension system, you may skip this step.
5. Place a pair of hydraulic floor jacks under the front
axle. Place one hydraulic floor jack on the driver side and
one on the passenger side.
6. Working on the driver side, remove the stock U-bolts
from the stock location. The stock U-bolts and hardware
may be discarded. Repeat procedure on the passenger
side.
7. Carefully lower down on both hydraulic floor jacks at
the same time approximately 5”. This will allow enough
room for the new front springs to be installed into the
stock location.
8. Working on the driver side, remove the stock spring
from the stock location. The stock front spring, stock
front spring hanger hardware and stock front spring
shackle hardware may be discarded. Repeat procedure
on the passenger side.
9. Locate the new front leaf springs. Working on the front
and rear eyelet’s of the front springs, remove the new
sleeves and bushings from each end and set a side for
later re-installation.
10. Locate the new polyurethane lube packs. Spread the
new polyurethane over the new bushings that were
removed from step # 9 and re-install them back into the
new front spring assembly. Make sure to re-install the
new sleeves. Special Note: Make sure to use the new
polyurethane lube packs prior to inserting the new
bushings back into the new front springs. This will
increase the life of the bushing, prevent squeaking
and help with ride quality.
11. Locate the new front spring eye hardware. Working
on the driver side, install the new front spring into the
stock location and secure using the new spring eye
hardware. Make sure to use thread locker or locktite
on these bolts. Torque the front spring eye hanger
hardware to 120 ft lbs. Special Note: Do not torque
the front spring eye shackle hardware at this time.
Once the vehicle is lowered to the ground, the front
spring eye shackle will be torque to 40 ft lbs. Repeat
procedure on the passenger side.
See Illustration # 2 / Front Spring Hanger
See Illustration # 3 / Front Spring Shackle