Tuff Country 16987 - GM 00-06 K2500 HD 2wd 6 kit - Manual (Page 4)

locker or lock tite.
21. Set the new driver side steering knuckle and hub
assembly a side for later re-installation.
22. Working on the driver side, remove the stock front
and rear hardware that connects the stock lower control
arm to the stock location. Save the stock hardware for
later re-installation. Set the stock lower control arm a side
for later re-installation.
23. Repeat step’s 10 - 22 on the passenger side.
24. Working on the driver side, remove the (2) stock bolts
that connect the stock rear cross member to the stock
driver side rear lower control arm mounting point and
save stock hardware for later re-installation. Repeat
procedure on the passenger side.
See Illustration # 3
25. Locate the new one piece sub frame and the stock
lower control arm mounting hardware that was removed
from step # 22. On the driver side, install the front and
rear part of the new one piece sub frame into the stock
front and rear lower control arm mounting points and
secure using the stock hardware. Do not tighten at this
point. Make sure to use thread locker or lock tite.
Repeat procedure on passenger side.
See Illustration # 4 / Front Location
See Illustration # 5 / Rear Location
26. Locate (2) 6199 poly bump stops, “Special Note:
There are (6) poly bump stops located in the poly and
sleeve bag, (4) are the same size and (2) are taller,
locate (2) of the shorter poly bump stops” (2) 3/8”
unitorque nuts, (2) 3/8” flat washers and (2) 3/8” lock
washers. Working on the driver side rear portion of the
newly installed one piece sub frame, secure the new poly
bump stop using the new 3/8” hardware. Torque to 28 ft
lbs. Repeat procedure on the passenger side. Make
sure to use thread locker or lock tite.
See Illustration # 6
27. Locate (2) 5/8” x 4 1/2” bolts, (2) 5/8” x 5 1/2” bolts,
(8) 5/8” flat washers, (4) 5/8” unitorque nuts and (4) 5/8”
lock washers. Also locate the stock lower control arms
that were removed from step # 22. Working on the driver
side, install the stock lower control into the newly installed
one piece sub frame’s front location and secure using the
new 5/8” x 4 1/2” bolt and hardware. Do not tighten at
this point. Make sure to use thread locker or lock tite.
Install the stock lower control into the newly installed one
piece sub frame’s rear location and secure using the new
5/8” x 5 1/2” bolt and hardware. Do not tighten at this
point. Make sure to use thread locker or lock tite.
See Illustration # 7 / Front Location
See Illustration # 8 / Rear Location
28. Locate the new driver side steering knuckle and stock
hub assembly, the stock hardware for the upper control
arm ball joint, lower control arm ball joint and outer tie rod
ball joint that was removed from step # 17. Using the
stock hardware, secure the new driver side steering
knuckle and stock hub assembly to the stock upper
control arm ball joint, the stock lower control arm ball joint
and the stock outer tie rod assembly. Torque the stock
hardware on the upper and lower ball joints to 85 ft lbs.
Torque the outer tie rod ball joint hardware to 68 ft. lbs.
Special Note: When installing the new driver side
spindle, make sure that the stock brake line is
located towards the inside of the vehicle. Make sure
to use thread locker or lock tite. Repeat procedure on
the passenger side using the passenger side steering
knuckle.
See Illustration # 9
29. Move back to all associated hardware that connects
the stock lower control arms to the new one piece sub
frame and torque 125 ft. lbs.
30. Working on the driver side, reconnect the stock ABS
lines back together. Repeat procedure on the passenger
side.
31. Locate the new rear cross member support bracket,
(2) 1/2” x 1 1/4” bolts, (4) 1/2” flat washers, (2) 1/2”
unitorque nut, (2) 1/2” lock washers and the stock
hardware that was removed from step # 24. Working on
the rear portion of the newly installed sub frame, secure
the new rear cross member support bracket to the new
one piece sub frame using the new 1/2” x 1 1/4” bolts and
hardware. Do not tighten at this point. Make sure to
use thread locker or lock tite. Next, secure the other
end of the new support bracket to the passenger side
stock rear cross member location using the stock
hardware. Torque the stock and new 1/2” hardware to 85
ft lbs.
See Illustration # 10
32. Locate the stock brake caliper hardware that was
removed in step # 11. Working on the driver side, re-
install the stock brake caliper to the stock hub assembly
and secure using the stock hardware. Torque to 76 ft.
lbs. Repeat procedure on the passenger side. Special
Note: make sure to re-install the stock rotor.
33. Locate (10) shock ties. Working on the driver side,
secure the stock brake line bracket to the stock upper
control arm using the stock hardware that was removed
from step # 11. Next, shock tie the stock ABS line and
the stock brake line to the newly installed spindle. Also,
shock tie together the stock ABS line and the stock brake
lines together. Repeat procedure on the passenger side.
See Illustration # 11
34. Working on the front portion of the new one piece sub
frame, using the one piece sub frame as a guide, drill (2)
7/16” holes into the bottom of the stock frame. Locate (2)
7/16” x 1 1/4” bolts, (4) 7/16” flat washers, (2) 7/16”
unitorque nuts and (2) 7/16” flat washers. Secure the
front portion of the new one piece sub frame to the stock