Tuff Country 16830 - GM 92-98 K1500 Suburban and 2-door Tahoe 6 kit - Manual (Page 10)

80. Working on the driver side, remove the stock sway
bar end link from the stock location. The stock sway bar
end link may be discarded. Save the stock hardware for
later re-installation. Repeat procedure on the passenger
side.
81. Working on the driver side, remove the stock shock
and save the stock hardware for later re-installation.
Longer shocks are needed, so the stock shocks may be
discarded. Special Note: Shocks are not included with
this suspension system and need to be ordered as a
separate part number, Tuff Country EZ-Ride
Suspension recommends using a 30” fully extended
nitrogen gas shocks. Repeat procedure on passenger
side.
82. Working on the driver side, remove the (2) stock rear
U-bolts and discard. Set the upper and lower U-bolt
plates a side for later re-installation. Repeat procedure on
passenger side
83. Lower down on both hydraulic floor jacks at the same
time until the stock springs separate from the stock rear
axle. Lower down approximately 5”. Special Note: Make
sure not to over extended any brake lines or hoses
when lowering axle. This will allow you enough room for
the new rear blocks and add-a-leafs to be installed.
84. Locate (2) new rear add-a-leafs. (2) 3/8” centering
bolts and nuts from hardware bag CB38. Working on the
driver side, place a pair of “C” clamps around the rear
springs about 2” from the stock spring clamps. Safely
remove the stock centering bolt and discard. Install the
new add-a-leaf to the stock spring assembly. Secure the
new rear add-a-leaf to the stock spring assembly using
the new 3/8” center bolt and nut. Special Note: The new
add-a-leaf should be installed into the stock spring
assembly in progression in order. The new add-a-leaf
should be installed between the stock overload and
the stock spring pack. The stock overload is usually
the un-arched spring at the bottom of the stock leaf
pack. Also Tuff Country EZ-Ride Suspension
recommends not using any air tools when installing
the new add-a-leafs into the stock spring assembly. If
air tools are used the centering bolt may strip,
causing the stock spring assembly to come apart.
Torque the new centering bolt and nut to 28 ft. lbs.
Remove the “C” clamps from the stock spring assembly.
With a suitable cutting tool, cut off the thread from the
new centering bolt. Repeat procedure on passenger side.
See Illustration # 27
85. Locate (2) new 4” lifted rear blocks. Working on the
driver side, install (1) new 4” lifted block between the
stock rear axle and the stock spring assembly. Special
Note: The new 4” lifted block has a slight taper to it,
the small end of the new block needs to be installed
with the small end towards the front of the vehicle.
Repeat procedure on passenger side.
See Illustration # 27
86. Raise up on both hydraulic floor jacks at the same
time until the driver and passenger side stock spring
assembly seats flush with newly installed 4” block.
87. Locate (4) new 9/16” x 2 3/4” x 14 5/8” Square U-
bolts. (8) 9/16” U-bolt high nuts, (8) 9/16” U-bolt washers
from hardware bag 916NW. Also locate the stock upper
and lower U-bolt plates that were removed from step #
82. Working on the driver side, install (2) new 9/16” x 2
3/4” x 14 5/8” square U-bolts into the stock location and
secure using the new 9/16” high nuts and washers.
Torque to 120 ft lbs. Repeat procedure on passenger
side.
See Illustration # 27
88. Working on the driver side, install the new rear
shocks absorbers using the stock hardware removed
from step # 81. 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 recommends using a 30” fully
extended nitrogen gas shocks. Locate the new rear
upper clevis mount and install the new clevis mount into
the upper eyelet of the rear shock before installation.
Repeat procedure on passenger side.
89. Locate (2) new rear sway bar end links and (8)
4902G sway bar poly bushings and (4) crush sleeves
from hardware bag 16830SBPL. Install the new poly
bushings and sleeves into each end of the new rear sway
bar end link. Special Note: Make sure to use a lithium
or moly base grease prior to inserting the new
bushings and sleeves into the new rear sway bar end
links. This will increase the life of the bushing as well
as prevent squeaking.
90. Locate the stock rear sway bar end link hardware that
was removed from step # 80. Working on the driver side,
install the new sway bar end link into the stock location
and secure using the stock hardware Do not tighten at
this point. Make sure to use thread locker or lock tite.
Repeat procedure on the passenger side. Once both new
sway bar end links are secure to the stock location,
torque the stock hardware to 45 ft lbs. Special Note: If
you are not able to connect the new rear sway bar
end link to the stock location, the weight of the
vehicle may need to be on the ground. If this is the
case, perform this step once the tires have been
installed and the vehicle is on the ground.
See Illustration # 28
91. 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. Refer to the torque setting sheet on the
first page of the installation manual.
92. Carefully remove both hydraulic floor jacks from
under the rear axle.