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

54. 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
specification sheet at the end of the installation manual.
Front end Installation Complete!
Rear End Installation:
55. 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.
56. Working on the driver side, remove the stock shock
from the stock upper and lower mounting points and save
hardware for later re-installation. The stock shocks may
be discarded. Special Note: New longer rear 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 30” fully extended
nitrogen gas shock. Repeat procedure on the
passenger side.
57. Place a pair of hydraulic floor jack under the rear
differential and raise up on both hydraulic floor jacks at
the same time until they come into contact with the rear
differential.
58. Working on the driver side, remove the stock U-bolts
from the stock location and discard the stock U-bolts and
hardware. Set the stock upper and lower U-bolt plates a
side for later re-installation. Repeat procedure on
passenger side.
59. Carefully lower down both hydraulic floor jacks at the
same time approximately 5”. Special Note: Take special
care not to over extend any brake lines and/or hoses.
Working on the driver side, if so equipped, remove and
discard the stock rear block. Repeat procedure on the
passenger side.
60. Locate (2) new 4” lifted blocks. Working on the driver
side, install the new 4” lifted block into the stock location.
Special Note: The new 4” lifted block has a taper to it,
make sure that smaller end of the new block is
pointing towards the front of the vehicle. Repeat
procedure on the passenger side.
See Illustration # 20
61. Carefully raise up on both hydraulic floor jacks at the
same time until the stock spring assembly sits flush with
the newly installed 4” lifted block.
62. Locate (4) 5/8” x 2 3/4” x 13 5/8” square U-bolts, (8)
5/8” U-bolt high nuts, (8) U-bolt washers and the stock
new rear lateral compression arm mount rear hole using
the new 1/2” x 3 1/2” bolt and hardware. Do not tighten
at this point. Special Note: Refer to Illustration # 16
for proper placement. If the measurement that you had
in step # 46 was 32”, secure the new lateral compression
arm to the new rear lateral compression arm mount front
hole using the new 1/2” x 3 1/2” bolt and hardware. Do
not tighten at this point. Special Note: Refer to
Illustration # 16 for proper placement. Hold the new
lateral compression arm and mount up to the stock
transfer case cross member and scribe a mark on the
transfer case cross member where the new mount will
go. Repeat procedure on the passenger side.
See Illustration # 16
48. Working on the driver side, carefully drill a 5/16” hole
in the bottom of the stock transfer case cross member.
Refer to the mark that was scribe in step # 46. Repeat
procedure on the passenger side.
49. Working on the driver side lateral compression arm,
remove the new lateral compression arm mount from the
new lateral compression arm and save hardware for later
re-installation. Repeat procedure on the passenger side.
50. Locate (2) 3/8” x 1 1/4” self threading bolts, (2) 3/8”
flat washers and the new rear lateral compression arm
mounts that were removed from step # 49. Working on
the driver side, secure the new rear lateral compression
arm mount to the previously drilled hole in the stock
transfer case cross member. Use the new 3/8” x 1 1/4”
self threading bolt and washer. Torque to 28 ft lbs.
Repeat procedure on the passenger side. Special Note:
make sure that the longer leg of the new lateral
compression arm is towards the rear of the vehicle.
Refer to illustration # ? for proper placement.
See Illustration # 17
51. 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 # 18 / Front Location
See Illustration # 19 / Rear Location
52. Locate the new front shocks. 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. Working on the
driver side, install the new shock into the stock location
using the stock hardware on the bottom mount and the
new hardware on the top mount. Repeat procedure on
the passenger side.
53. Re-install the tires and wheels and carefully lower the
vehicle to the ground.