Tuff Country 16810 - GM 88-98 K1500 / K2500 6 lug 6 kit - Manual (Page 8)

57. Move back to all associated hardware that connects
the stock lower control arms to the new one piece lower
sub frame and torque 125 ft. lbs.
58. Locate the stock rotors that were removed from step
# 14. Working on the driver side, install the stock rotors
into the stock location. Repeat procedure on the
passenger side.
59. Locate the stock hardware that was removed from
step # 13. Working on the driver side, re-install the stock
brake caliper to the new spindle using the stock
hardware. Make sure to use thread locker or lock tite.
Torque to 90 ft lbs. Repeat procedure on the passenger
side.
60. Working on the driver side, reconnect the stock ABS
lines back together. Also reconnect all other stock
mounting points on the stock ABS line. Repeat procedure
on the passenger side.
61. Locate (2) front brake line relocation brackets, (2)
5/16” x 1 1/4” bolts, (4) 5/16” flat washers, (2) 5/16”
unitorque nuts (2) 5/16” lock washers from hardware bag
16810NB1. Also, locate the stock hardware that was
removed from step # 11. Working on the driver side,
install the new brake line relocation bracket to the stock
location using the stock hardware. Do not tighten at this
point. Make sure to use thread locker or lock tite.
Next, secure the stock brake line bracket to the newly
installed brake line relocation bracket and secure using
the new 5/16” x 1 1/4” bolt and hardware. Make sure to
use thread locker or lock tite. Torque the stock and
new hardware to 15 ft lbs.
See Illustration # 20
62. Locate (2) new sway bar end links, (8) sway bar end
links washers and (8) sway bar end links bushings from
hardware bag 16810SL. Also, locate (2) 3/8” x 10” bolts
and (2) 3/8” unitorque nuts from hardware bag
16810NB1. Working on the driver side, install the new
sway bar end link and hardware to the stock sway bar
and the stock lower control arm. Torque to 32 ft lbs.
Repeat procedure on the passenger side. Special Note:
If you did not invert the stock sway bar in step # 12,
invert it before you install the new sway bar end
links.
See Illustration # 21
63. Locate the driver side torsion bar that was removed in
step # 10. Install the stock torsion bar into the stock lower
control arm. Make sure that you push the stock torsion
bar as far forward as you can, this will allow you to install
the stock torsion cross member. Special Note: Make
sure that you install the stock torsion bar the same
way that it was removed. Example: driver side vs.
passenger side and front vs. rear. Repeat procedure
on passenger side.
64. Locate (2) new torsion bar drop blocks. (10) 7/16” x 1
1/2” bolts, (2) 7/16” x 2 1/2” bolts, (24) 7/16” flat washers,
(12) 7/16” unitorque nuts and (12) lock washers from
hardware bag 16810NB2. Working on the driver side of
the stock torsion bar cross member that was removed
from step # 9, install the new torsion bar drop block to the
stock torsion bar cross member and secure using (1)
7/16” x 2 1/2” bolt and hardware in the center of the new
torsion bar drop block and the stock torsion bar cross
member. Use (2) 7/16” x 1 1/2” bolts and hardware on
the outer (2) bottom holes. Make sure to use thread
locker or lock tite. Torque the (3) 7/16” bolts to 35 ft
lbs. Special Note: Install the stock torsion bar cross
member to the inside of the new torsion bar drop
blocks. Repeat procedure on the passenger side.
65. Working on the driver side, install the stock torsion
bar cross member and the newly installed torsion bar
drop blocks to the stock location on the bottom of the
stock frame rail and secure using the new 7/16” x 1 1/2”
bolt and hardware. Make sure to use thread locker or
lock tite. Torque to 35 ft lbs. Repeat procedure on the
passenger side.
See Illustration # 22
66. Locate the stock driver and passenger side torsion
bar key’s that were removed from step # 8. Working on
the driver side, install the stock torsion bar key back into
the stock torsion bar cross member. Holding the stock
torsion bar key into the stock location, slide the driver
side torsion bar into the stock torsion bar key. Repeat
procedure on the passenger side.
67. Locate the small metal adjusting blocks and bolts that
were removed from step # 7. Working on the driver side,
attach the torsion bar removing tool, making sure that the
unloading bolt in the center tool is in the small divot of the
torsion bar key. Adjust the torsion bar key up high
enough so that the small metal adjusting block and stock
bolt can be re-installed, Refer back to step # 6 and adjust
the stock bolt to the stock location. Repeat procedure on
passenger side. Remove the torsion bar adjusting tool.
68. Move back to all newly installed brackets and make
sure that all stock and new hardware is torqued to proper
specifications. Now re-connect the front differential vent
hose. Refer to the torque setting sheet on the first
page of the installation manual and torque to proper
settings.
69. Locate (2) 5/8” x 2 1/2” poly shock bushings and (2)
1/2” x 2 1/2” shock sleeves from hardware bag 16810SL.
Also, locate the stock upper and lower shock hardware
that was removed from step # 3 and the new shock
boots. Install the new shock boots onto the new shocks.
Insert the new poly shock bushings and sleeves into the
upper eyelet of the new shocks. Special Note: Shocks
are not included with this suspension system,
shocks need to be ordered as a separate part
number, Tuff Country EZ Ride suspension