Tuff Country 14965 - GM 00-03 Suburban / Tahoe K1500 4 kit - Manual (Page 7)

47. Locate (2) 9/16” x 1 3/4” bolts, (4) 9/16” flat washers,
(2) 9/16” unitorque nuts and (2) 9/16” lock washers from
hardware bag 14965NB4. Carefully install the passenger
side of the stock front differential to the previously
installed passenger side differential drop bracket. Secure
using the new 9/16” x 1 3/4” bolts and hardware. Do not
tighten at this point. Also, make sure to use thread
locker or lock tite. Using a bungee cord, carefully tie
the driver side of the stock front differential up and
out of the way so that the new one piece lower sub
frame can be installed.
See Illustration # 11
48. Locate the new one piece lower sub frame and the
stock lower control arm mounting hardware that was
removed from step # 31. On the driver side, install the
front and rear part of the new one piece sub frame into
the stock front and rear lower control arm mounting
points using the stock hardware. Do not tighten at this
point. Make sure to use thread locker or lock tite.
Repeat procedure on passenger side.
See Illustration # 12 / Front Location
See Illustration # 13 / Rear Location
49. Carefully remove the bungee cord that is holding the
driver side of the front differential up and out of the way.
Let the stock front differential rest on the newly installed
one piece lower sub frame.
50. Locate the stock hardware that was removed from
step # 33. Install the rear portion of the front differential
into the tab on the rear portion of the new one piece
lower sub frame. Secure using the stock hardware. Do
not tighten at this point. Make sure to use thread
locker or lock tite.
See Illustration # 14
51. Locate the stock hardware that was removed from
step # 40. Secure the newly installed front differential
relocation bracket to the front portion of the new one
piece lower sub frame. Secure using the stock hardware.
Do not tighten at this point. Make sure to use thread
locker or lock tite.
See Illustration # 15
Note: If you are going to re-install the stock front
upper skid plate, please follow step #’s 52 - 54
Note: If you are not going to install the stock front
upper skid plate please skip to step # 56
52. Locate the stock front upper skid plate and the
mounting hardware that was removed from step # 3.
Secure the stock front upper skid plate to the upper stock
location using the (3) stock bolts. Do not tighten at this
point. Make sure to use thread locker or lock tite.
53. Install the lower portion of the stock front skid plate
between the newly installed one piece lower sub frame
and the stock front cross member. Using a pair of
hydraulic floor jacks, carefully raise up on the front
portion on the one piece lower sub frame, and smash the
stock upper skid plate between the stock front cross
member and front portion of the newly installed one piece
sub frame.
54. Locate (2) stock upper skid plate lower bolts that
were removed from step # 3. Working on the driver side,
secure the newly installed one piece lower sub frame to
the stock front cross member using the stock hardware.
Torque to 38 ft lbs. Special Note: Make sure to use
thread locker or lock tite. Also, make sure that the
bolts secure the lower portion of the stock upper skid
plate into the stock location. Repeat procedure on the
passenger side. Move back to the (3) stock upper bolts
and torque to 38 ft lbs. Carefully remove both hydraulic
floor jacks from under the front portion of the one piece
lower sub frame.
Note: If you installed the stock front upper skid plate,
please skip to step # 57
55. Using a pair of hydraulic floor jacks, carefully raise up
on the front portion on the one piece lower sub frame
until the one piece lower sub frame sits flush with the
stock front cross member.
56. Locate (2) stock upper skid plate lower bolts that
were removed from step # 3. Working on the driver side,
secure the newly installed one piece sub frame to the
stock front cross member using the stock hardware.
Torque to 38 ft lbs. Special Note: Make sure to use
thread locker or lock tite. Repeat procedure on the
passenger side. Carefully remove both hydraulic floor
jacks from under the front portion of the one piece lower
sub frame.
57. Move back to all the new and stock hardware
associated with the front differential, and the new one
piece sub frame and torque to proper specifications.
Refer to the torque setting sheet at the end of the
installation manual for proper torque.
58. Reconnect the 4WD wiring to the front differential.
Also, reconnect any other vent hoses and/or wiring that
was connected to the stock front differential.
59. Locate (2) poly bump stops from hardware bag
14965SL. Also, locate (2) 3/8” unitorque nuts, (2) 3/8” flat
washers and (2) 3/8” lock washers from hardware bag
14965NB1. Working on the driver side rear portion of the
newly installed one piece lower sub frame, secure the
new poly bump stop using the new 3/8” hardware.
Torque to 28 ft lbs. Repeat procedure on the passenger
side. Make sure to use thread locker or lock tite.
See Illustration # 16
60. Locate (2) 5/8” x 4 1/2” bolts, (2) 5/8” x 5 1/2” bolts,
(8) 5/8” flat washers, (4) 5/8” unitorque nuts and (4) 5/8”
lock washers from hardware bag 14965NB5. Also locate