Tuff Country 16987 - GM 00-06 K2500 HD 2wd 6 kit - Manual (Page 7)

Congratulations installation complete. Check
and double check to make sure that all steps
were performed properly. Check torque settings
to make sure that all stock and new hardware
has been torque to proper torque specifications
Take vehicle directly to an alignment shop for
proper alignment.
Special Note: After the vehicle has been aligned,
drive to see if there is any drive line vibrations. If
drive live vibrations occur, please follow step #
69 & 70
69. Place a pair of hydraulic floor jacks under the stock
transfer case cross member. Carefully raise up on both
hydraulic floor jacks at the same time until the hydraulic
floor jacks come into contact with the stock transfer case
cross member. Working on the driver side, remove the
(2) stock bolts and hardware that connects the stock
transfer case cross member to the bottom sides of the
stock frame rail. On the side of the stock frame rail
remove the stock transfer case support bracket and
hardware. The stock transfer case support bracket and
stock hardware may be discarded. Repeat procedure on
the passenger side.
See Illustration # 24
70. Carefully lower down on both hydraulic floor jacks at
the same time about 3/4”. Locate (8) transfer case
lowering shims, (4) 1/2” x 2” bolt, (8) 1/2” flat washers, (4)
1/2” unitorque nuts and (4) 1/2” lock washers. Working on
the driver side, install (4) shims, (2) in the forward hole
and (2) in the rearward hole, between the stock transfer
case cross member and the stock frame rail. Secure
using the new 1/2” x 2” bolt and hardware. Torque to 85
ft lbs. Repeat procedure on the passenger side. Remove
both hydraulic floor jacks.
See Illustration # 25
Torque Settings:
5/16” 15—18 ft lbs.
3/8” 28—32 ft lbs.
7/16” 30—35 ft lbs.
1/2” 65—85 ft lbs.
9/16” 85—120 ft lbs.
5/8” 95—130 ft lbs.
3/4” 100—140 ft lbs.
Also refer to the Vehicle owners manual for proper
torque specifications on any stock hardware.
If you have any question and/or concerns about the
installation, please feel free to contact Tuff Country
or your local Tuff Country dealer.
upper and lower U-bolt plates that were removed from
step # 58. Working on the driver side, install the new U-
bolts into the stock location and secure using the new
high nuts and washers. Special Note: Make sure to re-
install the stock upper and lower U-bolt plates.
Torque to 135 ft lbs. Repeat procedure on passenger
side.
See Illustration # 20
63. Working on the driver side, install the new shock into
the stock location and secure using the stock hardware
that was removed in step # 56. 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.
64. Carefully remove the (2) hydraulic floor jack from
under the rear differential.
65. Locate (2) 6199 poly bump stops, (2) 6052 poly bump
stop, (4) 3/8” unitorque nuts and (4) 3/8” flat washers.
Working on the driver side of the stock rear spring
assembly. Remove the (2) stock teflon insert located on
the stock over load in the stock spring assembly. Discard
the stock teflon inserts. Install (1) 6052 (taller poly bump
stop) in front location on the stock spring assembly.
Secure using the new 3/8” hardware. Torque to 28 ft lbs.
Install (1) 6199 (shorter poly bump stop) in the rear
location on the stock spring assembly. Secure using the
new 3/8” hardware. Torque to 28 ft lbs. Repeat
procedure on the passenger side.
See Illustration # 21 / Front Location
See Illustration # 22 / Rear location
66. Carefully place a hydraulic floor jack under the rear
driveline near the stock carrier bearing mounting location.
Raise up on the hydraulic floor jack until it comes into
contact with the rear driveline. Remove the stock
hardware that connects the stock carrier bearing to the
stock location and discard the stock hardware.
67. Locate the new rear carrier bearing drop, (2) 1 3/4”
crush sleeves, (2) 3/8” x 3 1/2” bolt, (4) 3/8” flat washers
and (2) 3/8” unitorque nuts. Install the new carrier bearing
drop bracket between the stock carrier bearing and the
stock mounting point. Secure using the new 3/8” x 3 1/2”
bolt, crush sleeves and hardware. Torque to 28 ft lbs.
Remove the hydraulic floor jack from under the rear drive
line. Special Note: The stock carrier bearing mount
has slotted holes, make sure that when you torque
the new 3/8” hardware that the new carrier bearing is
pushed as far forward as possible.
See Illustration # 23
68. Install the tires and wheels and carefully lower the
vehicle to the ground.