Tuff Country 16987 - GM 00-06 K2500 HD 2wd 6 kit - Manual (Page 5)

procedure on the passenger side.
42. Locate the torsion bar adjusting blocks and hardware
that was removed from step # 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 re-
installed back into the stock location. Refer back to the
measurements that were made in step # 4 and set to the
stock setting. Repeat procedure on the passenger side.
Remove the torsion bar removing tool from the stock
torsion bar cross member.
43. Locate (2) 3/8” x 7” bolts, (2) 3/8” unitorque nuts, (2)
new sway bar end links and the new stock sway bar end
link bushings and washers. Special Note: If you did not
invert the stock sway bar in step # 10, invert the
stock sway bar now. Working on the driver side, install
the new sway bar end link and hardware into the stock
location and torque to 32 ft lbs. Repeat procedure on
passenger side.
See Illustration # 15
44. Locate (2) front lateral compression arms, (8) 2408
poly bushings and (4) 916218SLWOH and 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.
45. Locate (2) 1/2” x 3 1/2” bolts, (4) 1/2” flat washers, (2)
1/2” unitorque nuts and (4) 1/2” lock washers. 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 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.
Repeat procedure on the passenger side.
46. Working on the driver side, measure from the new
lateral compression arm mount located on the previously
installed one piece sub frame back to the center of the
stock transfer case cross member. Special Note: Chevy
has a variation on the placement of the stock transfer
case cross member. Your measurement should either
be 31” or 32” long. Remember the measurement, this
measurement is needed in step # 47.
47. Locate (2) 1/2” x 3 1/2” bolts, (4) 1/2” flat washers, (2)
1/2” unitorque nuts and (4) 1/2” lock washers. Also locate
(2) rear lateral compression mounts. Working on the
driver side, if the measurement that you had in step # 46
was 31”, secure the new lateral compression arm to the
frame using the new 7/16” x 1 1/4” bolt and hardware.
Torque to 42 ft lbs.
35. On the driver side of the stock frame rail, scribe a
mark in the center of the (2) stock lower holes where the
stock torsion bar bracket was located.
See Illustration # 12
36. Locate (2) new torsion bar drop brackets, (4) 4902
poly bushings and (2) 9/16” x 1 1/4” anti crush sleeve.
Install the new poly bushings and sleeves into the new
torsion bar drop brackets. 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.
37. Working on the driver side, hold the new torsion bar
drop bracket to the bottom of the stock frame rail. Line up
the mark that was scribe in step # 35 with the center of
the new torsion bar drop bracket. Scribe a mark on the
bottom of the stock frame rail where the new torsion bar
bracket should go. Carefully drill a 1/2” hole in the bottom
of the stock frame rail. Take Special care not to drill
into any stock hoses and/or lines running down the
inside of the stock frame rail. Repeat procedure on the
passenger side of the vehicle.
38. Locate (4) 1/2” x 1 1/2” bolts, (8) 1/2” flat washers, (4)
1/2” unitorque nuts and (4) 1/2” lock washers. Working on
the driver side, secure the new driver side torsion bar
drop bracket to the bottom side of the stock frame rail
using the new 1/2” x 1 1/2” bolt and hardware. Make
sure to use thread locker or lock tite. Torque to 76 ft
lbs. Repeat procedure on the passenger side.
See Illustration # 13
39. Locate the stock torsion bars that were removed from
step # 8. Refer to the marks that were made in step # 6.
This will allow you to re-install the stock torsion bars back
into the stock location. Example: Driver vs. Passenger
and Front vs. Rear. Working on the driver side, slide the
stock torsion bar back into the stock rear lower control
arm. Slide the stock torsion bar far enough forward so
that the stock torsion bar cross member can be re-
installed. Repeat procedure on the passenger side.
40. Locate the stock torsion bar cross member and stock
hardware that was removed from step # 7. Install the
stock torsion bar cross member to the newly installed
torsion bar drop brackets and secure using the stock
hardware. Make sure to use thread locker or lock tite.
Torque to 90 ft lbs.
See Illustration # 14
41. Locate the stock torsion bar keys that were removed
from step # 5. Working on the driver side, install the stock
torsion bar key back into the stock location in the stock
torsion bar cross member. Slide the stock torsion bar
back into the previously installed torsion bar key. Repeat