Tuff Country 16987 - GM 00-06 K2500 HD 2wd 6 kit - Manual (Page 3)

installation. The stock shock may be discarded. Special
Note: New longer front 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
23” fully extended nitrogen gas shock. Repeat
procedure on the passenger side.
4. Measure exposed threads on the torsion bar
adjustment bolt and record measurement here for a later
reference.
Record Driver Side measurement here:______________
Record Passenger Side measurement here:__________
See Illustration # 1
5. Working on the driver side, attach the torsion bar
removing tool to the stock torsion bar cross member,
making sure that the unloading bolt in the center of the
torsion bar removing tool is in the small divot of the stock
torsion bar key. Adjust the torsion bar key up high
enough so that the stock small metal adjusting block and
bolt can be removed. Set the stock torsion bar block and
hardware a side for later re-installation. Repeat
procedure on passenger side.
See Illustration # 2
6. Mark both torsion bars before removal so that they can
be re-installed back into the same location. Example:
Driver vs. Passenger and front vs. rear. Tap the stock
torsion bars forward until the stock torsion bar cross
member can be removed.
7. Working on the driver side, remove the stock bolt that
connects the stock torsion bar cross member to the stock
mounting point. Save the stock hardware for later re-
installation. Repeat procedure on the passenger side.
Remove the stock torsion bar cross member from the
stock location and set a side for later re-installation.
8. Working on the driver side, slide the stock torsion bar
out of the stock rear lower control arm and set a side for
later re-installation. Repeat procedure on passenger side.
9. Working on the driver side, remove the stock sway bar
end link from the stock location and discard the stock end
link and all the stock hardware. Repeat procedure on the
passenger side. Special Note: At this time, invert the
stock sway bar.
10. Working on the driver side, remove the stock brake
line bracket that connects to the stock steering knuckle
and discard the stock hardware. Also remove any other
brake line mounting points on the stock steering knuckle
and stock upper control arm. Repeat procedure on the
passenger side.
11. Working on the driver side, remove the (2) stock bolts
that connect the stock brake caliper to the stock hub
assembly. Save the stock hardware for later re-
installation. Using a bungee cord, carefully tie the stock
brake caliper up and out of the way in the fender well.
Special Note: Take special care not to kink or over
extend the stock brake line.
12. Working on the driver side, remove the stock rotor
and set a side for later re-installation.
13. Working on the driver side, locate the ABS line quick
disconnect located above the stock upper control arm.
Disconnect the ABS lines from each other. Also
disconnect the ABS line from any other mounting points.
14. Working on the driver side, loosen the stock nut that
connects the stock upper control arm ball joint to the
stock steering knuckle. Do not remove the stock nut
completely. Carefully break the stock taper on the stock
upper control arm ball joint. Special Note: Take special
care not to rip or tear the stock ball joint dust boot.
15. Working on the driver side, loosen the stock nut that
connects the stock lower control arm ball joint to the
stock steering knuckle. Do not remove the stock nut
completely. Carefully break the stock taper on the stock
lower control arm ball joint. Special Note: Take special
care not to rip or tear the stock ball joint dust boot.
16. Working on the driver side, loosen the stock nut that
connects the stock outer tie rod ball joint to the stock
steering knuckle. Do not remove the stock nut
completely. Carefully break the stock taper on the stock
outer tie rod ball joint. Special Note: Take special care
not to rip or tear the stock outer tie rod ball joint dust
boot.
17. Working on the driver side, move back to the stock
nuts holding the upper control arm ball joint, the lower
control arm ball joint and the outer tie rod ball joint to the
stock steering knuckle and remove completely. Save all
(3) nuts and washers for later re-installation.
18. Carefully remove the stock hub assembly and the
stock steering knuckle form the stock location.
19. Working on the driver side stock hub assembly,
remove the stock cup located on the inner part of the
stock hub assembly, save for later re-installation. Next,
remove the (4) stock bolts that connect the stock hub
assembly to the stock steering knuckle. Save the stock
hardware and stock hub assembly for later re-installation.
Also, carefully remove the stock rubber “O” ring located in
the stock steering knuckle and save for later re-
installation. A new steering knuckle is used, the stock
steering knuckle can be discarded.
20. Locate the new driver side steering knuckle. Using
the stock rubber “O” ring that was removed in step # 19,
carefully re-install the stock rubber “O” ring into the new
driver side knuckle. Using the stock hardware that was
removed from step # 19, secure the new driver side
steering knuckle to the stock hub assembly. Install the
stock cup back into the stock location, on the stock hub
assembly. Torque to 92 ft lbs. Special Note: Make sure