Tuff Country 16990 - GM 2001-06 HD 3500 6 kit - Manual (Page 12)

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.
103. Check and double check to make sure that all steps
were performed properly and then check again. Check
and make sure that all new and stock hardware has been
torqued to proper torque specification. Refer to the torque
specification at the end of the installation manual.
104. Take the vehicle directly to an alignment shop for a
proper front end alignment.
If you have any questions regarding the installation,
please contact the technical department @ Tuff
Country. (801) 280-2777
Special note: After the vehicle has been aligned, in
2WD, test drive the vehicle to check for any drive line
vibrations. If drive live vibrations occur, the stock
drive line may need to be rebalanced. If the stock
drive line is rebalanced and vibration still occurs,
please follow steps 105 — 106
105. 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 and discard the stock transfer case support
bracket and hardware. Repeat procedure on the
passenger side.
106. Carefully lower down on both hydraulic floor jacks at
the same time about 3/4”. Locate (8) 2” x 2” square
washers. Also, locate (4) 1/2” x 2” bolts, (8) 7/16” USS
flat washers and (4) 1/2” unitorque nuts from hardware
bag 16985NB3. 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.
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
torqued to proper torque specifications
Also refer to the Vehicle owners manual for proper
torque specifications on any stock hardware.
If you have any questions and/or concerns about the
installation, please feel free to contact Tuff Country
or your local Tuff Country dealer.
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.
Special post installation procedure: Tuff
Country EZ-Ride Suspension highly
recommends adding a minimum of 1 pint,
but no more that 1 1/2 pints, of proper front
differential fluid into the front differential. To
achieve this, you may have to fill the
differential with it on its side or you may
have to insert the fluid through the vend
tube opening. On occasion, the customer
may find burping of fluid coming out of the
front vent tube.