Tuff Country 16958 - GM 01-06 K1500 HD 4WD 6 kit - Manual (Page 6)

point. If this cut is not performed properly, the stock
front differential will not seat properly when the front
differential is lowered into the new one piece lower
sub frame. Also, Tuff Country EZ-Ride highly
recommends not using a cutting torch when
performing step # 30. Clean and dress up any
exposed metal.
Photo # 6
31. Working on the driver side, carefully cut flush, the
remainder of the stock rear cross member that is located
on the rear portion of the stock rear lower control arm
mounting bracket. Special note: Take special care not
to cut into the stock rear lower control arm mounting
bracket. Tuff Country recommends not using a
cutting torch when performing step # 31. Clean and
dress up any exposed metal.
32. Locate the wiring harness that connects the 4WD
control panel to the front differential. Disconnect the 4WD
wiring harness from the front differential. Tie the 4WD
wiring harness up and out of the way. Special note:
Take special care not to kink any wiring.
Photo # 7
33. Place a pair of hydraulic floor jacks under the front
differential, and carefully raise up on both hydraulic floor
jacks at the same time, until they come into contact with
the front differential.
34. Disconnect any other vent hoses and/or wiring that is
connected to the front differential.
35. Working on the driver side, remove the stock
hardware that connects the upper driver side tab of the
stock front differential to the stock location. Save the
stock hardware for later re-installation.
36. Working on the passenger side, remove the (2) stock
nuts that connect the passenger side of the stock front
differential to the stock location and save the stock
hardware for later re-installation.
37. Carefully lower down on both hydraulic floor jacks at
the same allowing enough room to remove the front
differential completely from the vehicle. With the help
from a buddy, carefully remove the front differential
completely from underneath the vehicle and set the stock
front differential on the ground or on a work bench.
38. Working on the driver side of the stock front
differential upper tab, measure 2” from the stock
mounting point and scribe a mark on the stock front
differential. Using a sawzall, carefully cut the upper tab
off of the stock front differential and discard.
Photo # 8 / side view
Photo # 9 / pre cut view
Photo # 10 / nose cut off of the front differential
39. Locate the new driver side differential relocation
bracket. Locate (2) PB2408 poly bushings from hardware
bag 16985PL and (1) S10082 crush sleeve from
hardware bag 16985SL. Install the new poly bushings
and crush sleeve into the new driver side differential
relocation bracket. Special note: Make sure to use a
lithium or moly base grease prior to inserting the new
bushings into the new driver side differential
relocation bracket. This will increase the life of the
bushing as well as prevent squeaking.
40. Locate (1) 7/16” X 3” bolt, (1) 7/16” unitorque nut, (2)
3/8” USS flat washers, (4) 10 mm x 60 mm bolts and (4)
10 mm lock washers from hardware bag 14985NB. Also,
locate the S10120 that is packaged with the installer copy
of the installation manual. Remove the (4) stock
differential mounting bolts that connect to two halves of
the front differential together. The stock hardware may be
discarded. Secure the new driver side differential
relocation bracket to the stock front differential using the
new 10 mm x 60 mm bolts and hardware. Special note:
Get all (4) new 10 mm x 60 mm bolts started but do
not tighten at this point and make sure to use thread
locker or lock tite. Secure the lower portion of the new
driver side differential relocation bracket to the stock front
differential using the new 7/16” x 3” bolt and hardware.
Special note: Make sure to install the new S10120
sleeve between the new driver side differential
relocation bracket and the front differential. Also, you
will notice that there are (2) holes in the new driver
side differential relocation bracket where the new
S10120 sleeve will go, we need to match the hole that
is on the front differential. Torque to 34 ft. lbs. Go back
to the (4) new 10 mm x 60 mm bolts that hold the new
driver side differential relocation bracket to the stock front
differential and torque to 34 ft lbs. Special note: Do not
use an air gun when installing the new hardware.
Make sure not to over tighten the stock and new
hardware associated with the front differential. If
bolts are over tightened, the stock front differential
could crack. Also, Tuff Country EZ-Ride Suspension
highly recommends adding a minimum of 1 pint, but
no more that 1 1/2 pints, of proper front differential
fluid into the front differential. To achieve this, you
may have to fill the differential with it on its side or
you may have to insert the fluid through the vend
tube opening. On occasion, the customer may find
burping of fluid coming out of the front vent tube.
41. Locate the new passenger side differential drop
bracket and the stock hardware that was removed from
step # 36. Working on the passenger side, install the new
passenger side differential relocation bracket into the
stock upper location and secure using the stock
hardware. Special note: Make sure to use thread
locker or lock tite and do not tighten at this point.
Also, there is a “F” cut out in this bracket, the “F” will
go towards the front of the vehicle and also if you are
standing on the passenger side wheel well looking at
the new passenger side differential relocation
bracket, you should not be able to see the mounting