Tuff Country 16711 - GM 73-87 6 1/2 ton box kit (systems with rear springs) - Manual (Page 5)

new spring eye hardware. Make sure to use thread
locker or locktite on these bolts. Torque the rear
spring eye hanger hardware to 120 ft lbs. Special Note:
Do not torque the rear spring eye shackle hardware
at this time. Once the vehicle is lowered to the
ground, the rear spring eye shackle will be torque to
40 ft lbs. Repeat procedure on the passenger side.
Special Note: The new rear springs have an off set
centering bolt, the longer end of the spring needs to
be installed towards the rear of the vehicle.
32. Carefully raise up on both hydraulic floor jacks at the
same time until the newly installed rear springs seat
properly to the stock rear spring perches.
33. Locate (2) new 5/8” x 3” x 7 5/8” Round U-bolts, (4)
5/8” U-bolt High Nuts and (4) 5/8” U-bolt Washers.
Working on the driver side, install (2) new 5/8” x 3” x 7
5/8” round U-bolts into the stock location and secure
using the new 5/8” high nuts and washers. Torque to
130 ft lbs. Repeat procedure on passenger side.
Special Note: With a suitable cutting tool, cut off the
excess U-bolt threads on all (4) rear U-bolts.
See Illustration # 9
34. Working on the driver side, install the new rear
shocks absorbers using the stock hardware removed
from step # 27. Special Note: New longer rear 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 30” fully extended
nitrogen gas shock when installing a 6” suspension
system. Repeat procedure on the passenger side.
See Illustration # 9
35. Place a pair of hydraulic floor jacks under the stock
transfer case cross member. Place one hydraulic floor
jack on the driver side and one on the passenger side.
Carefully raise up on both hydraulic floor jacks at the
same time until they come into contact with the stock
transfer case cross member.
36. Working on the driver side, remove the stock
hardware that connects the stock transfer case cross
member to the stock frame rail. The stock hardware may
be discarded. Repeat procedure on the passenger side.
37. Carefully lower down on both hydraulic floor jacks at
the same time approximately 2”. This will allow enough
room for the new transfer case drop kit to be installed.
38. Locate (2) transfer case drop tubes, (4) 7/16” x 3”
bolts, (4) 7/16” flat washers and (2) 7/16” unitorque nuts.
Working on the driver side, install the new transfer case
drop tube between the stock transfer case cross member
and the stock frame rail. Secure using the new 7/16” x
3” bolts and hardware. Torque to 35 ft lbs. Special
Note: The transfer case drop tubes are the tubes that
measure 1 1/2” tall. Repeat procedure on the
passenger side.
See Illustration # 10
39. Carefully remove both hydraulic floor jacks from
under the transfer case cross member.
40. Check and double check to make sure that all step
related with the front and rear end were performed
properly. Check and double check to make sure that all
stock and new hardware is torque to proper torque
specifications. Use the torque sheet at the beginning of
the installation manual.
41. Install the tires and wheels and safely lower the
vehicle to the ground.
42. With the weight of the vehicle on the ground, torque
the top and bottom spring eye shackle bolts on the driver
and passenger side to 40 ft lbs.
43. Once the installation is complete, make sure to bleed
the brake lines. Also, using the proper brake fluid, make
sure to top off the brake fluid level.
CONGRATULATIONS INSTALLATION
COMPLETE
Special Note: After the completion of the
installation, Tuff Country EZ-Ride
Suspension recommends taking the vehicle
to an alignment shop and having a proper
front end alignment performed.
It is also a good idea to keep a close watch
on the front and rear drive line U-joints. If
they start to wear out, make sure to replace
them.
If you have any questions or concerns,
please feel free to contact Tuff Country or
your local Tuff Country dealer.