Tuff Country 14965 - GM 00-03 Suburban / Tahoe K1500 4 kit - Manual (Page 6)

stock passenger side rear lower control arm mounting
point. The (2) stock bolts may be discarded.
See Illustration # 5
35. Working on the driver side, measure 2 1/8” towards
the inside of the vehicle from the stock rear lower control
arm mounting point, scribe a mark on the stock rear
cross member. Using a hacksaw or suitable cutting tool,
carefully cut off the stock rear cross member along the
line that was scribed earlier in this step. The stock rear
cross member may be discarded. Special Note: When
making this cut, make sure that you cut all the way
through the stock rear lower control arm mounting
point. If this cut is not performed properly, the stock
front differential will not seat properly when the front
differential is lowered into the new one piece lower
sub frame. Also, Tuff Country EZ-Ride highly
recommends not using a cutting torch when
performing step # 35. Clean and dress up any
exposed metal.
See Illustration # 6
36. Working on the driver side, carefully cut flush, the
remainder of the stock rear cross member that is located
on the rear portion of the stock rear lower control arm
mounting bracket. Refer to illustration # 6 for proper
cut line. Special Note: Take special care not to cut
into the stock rear lower control arm mounting
bracket. Tuff Country recommends not using a
cutting torch when performing step # 36. Clean and
dress up any exposed metal.
37. Place a pair of hydraulic floor jacks under the front
differential, and carefully raise up on both hydraulic floor
jacks at the same time, until they come into contact with
the front differential.
38. Locate the wiring harness that connects the 4WD
control panel to the front differential. Disconnect the 4WD
wiring harness from the front differential. Tie the 4WD
wiring harness up and out of the way. Special Note:
Take special care not to kink wiring.
39. Disconnect any other vent hoses and/or wiring that is
connected to the front differential.
40. Working on the driver side, remove the stock
hardware that connects the upper driver side tab of the
stock front differential to the stock location. Save the
stock hardware for later re-installation.
41. Working on the passenger side, remove the (2) stock
nuts that connect the passenger side of the stock front
differential to the stock location and save the stock
hardware for later re-installation.
42. Carefully lower down on both hydraulic floor jacks at
the same allowing enough room to remove the front
differential completely from the vehicle. Remove the front
differential completely from underneath the vehicle.
43. Working on the driver side of the stock front
differential upper tab, measure 2” from the stock
mounting point and scribe a mark on the front differential.
Using a sawzall, carefully cut the upper tab off of the
stock front differential and discard. Refer to illustration #
7 for proper cut line.
See Illustration # 7
44. Locate the new driver side differential relocation
bracket, (1) 7/16” X 3” bolt, (1) 7/16” unitorque nut, (2)
7/16” flat washers and (1) 7/16” lock washer from
hardware bag 14965NB2. Also, locate (2) MO2050 poly
bushings and (1) 9/16” x 2 1/8” anti crush sleeve from
hardware bag 14965SL. Install the new poly bushings
and anti crush sleeve into the new driver side relocation
bracket. Special Note: Make sure to use a lithium or
moly base grease prior to inserting the new bushings
into the new driver side differential relocation
bracket. This will increase the life of the bushing as
well as prevent squeaking. Referring to illustration # 8,
remove the (4) stock differential mounting bolts that
connect to two half’s of the front differential together.
Save the stock hardware for later re-installation. Secure
the new driver side differential relocation bracket to the
stock front differential using the stock hardware that was
removed earlier in this step. Special Note: Get all (4)
stock bolts started but do not tighten at this point.
Also, make sure to use thread locker or lock tite.
Secure the lower portion of the new driver side
differential relocation bracket to the stock front
differential, using the new 7/16” x 3” bolt and hardware.
Torque to 34 Ft. lbs. Go back to the (4) stock bolts that
hold the new differential relocation bracket to the stock
front differential and torque to 34 ft lbs. Special Note:
Make sure not to over tighten the stock and new
hardware associated with the front differential. If
bolts are over tighten, the stock front differential
could crack.
See Illustration # 8
45. Working on the passenger side stock rear lower
control arm pocket. Carefully cut off the front corner of
the stock passenger side stock rear lower control arm
pocket. This will allow enough room for the stock front
differential to seat properly when the new passenger side
differential drop bracket is installed. Refer to the cut line
in illustration # 9
See Illustration # 9
46. Locate the new passenger side differential drop
bracket and the stock hardware that was removed from
step # 41. Install the new upper passenger side
differential drop bracket into the stock location and
secure using the stock hardware. Do not tighten at this
point. Special Note: There is a front and a rear of this
bracket, refer to illustration # 10 for proper placement
of the new passenger side differential drop bracket.
Make sure to use thread locker or lock tite.
See Illustration # 10