Tuff Country 16830 - GM 92-98 K1500 Suburban and 2-door Tahoe 6 kit - Manual (Page 9)

recommends using a 23” fully extended nitrogen gas
shock. Make sure to use a lithium or moly base
grease prior to inserting the new bushings into the
new shock. This will increase the life of the bushing
as well as prevent squeaking. Install the lower shock
bushing and sleeve into the lower eyelet of the new
shock. Special Note: Make sure to use a lithium or
moly base grease prior to inserting the new bushings
into the new shock. This will increase the life of the
bushing as well as prevent squeaking. Working on the
driver side, install the new shock into the stock location
and secure using the stock hardware. Torque the upper
and lower stock hardware to 70 ft lbs. Repeat procedure
on passenger side.
70. Locate the stock inner rubber fender splash guards
that were removed from step # 2. Working on the driver
side, re-install the inner rubber fender splash guard.
Repeat procedure on the passenger side.
71. Locate (2) rear lateral compression mounts. (2) 1/2” x
1 1/4” spacer sleeves from hardware bag 16810SL. (2)
1/2” x 2 1/4” bolts, (4) 1/2” flat washers, (2) 1/2” unitorque
nuts and (2) 1/2” lock washers from hardware bag
16810NB3. Working on the driver side stock transfer
case cross member carefully drill a 1/2” hole into the
upper part of the stock transfer case cross member.
Special Note: There is an existing hole in the lower
part of the stock transfer case cross member, use
this hole as a guide to drill the new 1/2” hole in the
upper part of the stock transfer case cross member.
Install the new rear lateral compression arm mount to the
stock transfer case cross member. Secure using (1) 1/2”
x 2 1/4” bolt, spacer sleeve and hardware. Torque to 38
ft lbs. Special Note: The new 9/16” x 1 1/4” anti crush
sleeve needs to go into the stock transfer case cross
member, this will not allow the transfer case cross
member to crush when the bolt is torqued. Repeat
procedure on passenger side.
See Illustration # 23
72. Locate (2) front lateral compression arms. (8)
PB2408G poly bushings and (4) 9/16” x 2 1/8” crush
sleeves. Install the new poly bushing into each end of the
new front lateral compression arms. Next, install the new
anti crush sleeve into the newly installed poly bushing.
Special Note: Make sure to use a lithium or moly
base grease prior to inserting the new bushings and
sleeves into the new front lateral compression arms.
This will increase the life of the bushing as well as
prevent squeaking.
73. Locate (4) 1/2” x 3 1/2” bolts, (8) 1/2” flat washers, (4)
1/2” unitorque nuts and (4) 1/2” lock washers from
hardware bag 16810NB3. Working on the driver side,
secure (1) new lateral compression arm to the new front
lateral compression arm mount on the newly installed
one piece lower sub frame and secure using the new 1/2”
x 3 1/2” bolt and hardware. Do not tighten at this point.
Make sure to use thread locker or lock tite. Next,
secure the new lateral compression arm to the previously
installed rear lateral compression arm mount. Secure
using the new 1/2” x 3 1/2” bolt and hardware. Torque the
front and rear mount to 85 ft lbs. Repeat procedure on
the passenger side
See Illustration # 24 / Front Location
See Illustration # 25 / Rear Location
74. Re-install the tires and wheels and carefully lower the
vehicle to the ground.
75. Check and double check to make sure that all steps
were performed properly. Check and double check to
make sure that all new and stock hardware has been
torque to proper torque specifications. Refer to the
torque setting sheet on the first page of the
installation manual.
76. An exhaust modification is required once the
suspension system has been completed. After the rear
end installation is complete take the vehicle directly to a
muffler shop and have the exhaust modification
performed. Once the exhaust modification has been
performed re-install the stock front drive line back into the
stock location using the stock hardware that was
removed from step # 5. Torque to 35 ft lbs.
Congratulation, Front End Installation Complete!
Rear End Installation:
77. To begin installation, block the front tires of the
vehicle so that the vehicle is stable and can’t roll forward.
Safely lift the rear of the vehicle and support the frame
with a pair of jack stands. Place a jack stand on both the
driver and passenger side. Next remove the wheels and
tires from both sides.
78. Locate (1) rear brake line extending bracket. (1) 5/16”
x 1 1/4” bolt, (2) 5/16” flat washers, (1) 5/16” unitorque
nut and (1) 5/16” lock washer from hardware bag
16810NB1. Remove the stock brake line bracket from the
rear differential and save stock bolt for later re-
installation. Secure the new brake line bracket to the rear
differential housing using the stock bolt. Special Note:
Make sure to use thread locker or lock tite. Next,
attach the stock brake line bracket to the newly installed
brake line bracket and secure using the new 5/16” x 1
1/4” bolt and hardware. Torque to 16 ft. lbs. Special
Note: If you feel that the stock rear brake line is to
tight, wait and perform this step once the rear end
installation is complete and the weight of the vehicle
is on the ground.
See Illustration # 26
79. Position a pair of hydraulic floor jacks under the rear
axle. Place one jack stand on the driver side and one on
the passenger side. Raise up on both hydraulic floor
jacks at the same time until they make contact with the
rear axle.