Tuff Country 16990 - GM 2001-06 HD 3500 6 kit - Manual (Page 8)

54. Locate (2) 5/8” x 4 1/2” bolts, (2) 5/8” x 5 1/2” bolts,
(8) 9/16” USS flat washers and (4) 5/8” unitorque nuts
from hardware bag 16985NB5. Also, locate the stock
lower control arms that were removed from step # 26.
Working on the driver side, install the stock lower control
arm into the newly installed one piece lower 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 lower 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. Repeat
procedure on the passenger side.
55. Locate the new driver side steering knuckle and stock
hub assembly, the stock hardware for the upper control
arm ball joint and the lower control arm ball joint that was
removed in step # 22. Using the stock hardware, secure
the new driver side steering knuckle and stock hub
assembly to the stock upper control arm ball joint and the
stock lower control arm ball joint. Special note: Do not
install the stock outer tie rod to the new steering
knuckle at this point. Torque the stock upper ball joint
hardware to 74 ft lbs. and the stock lower ball joint
hardware to 101 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.
56. Locate the stock CV axles that were removed from
step # 19. Working on the driver side, carefully install the
stock CV axle back into the stock hub assembly. Repeat
procedure on the passenger side.
57. Locate (12) 10 mm x 35 mm bolt and (12) 10 mm lock
washers. Also, locate (2) 9802 CV axle shims. Working
on the driver side, install (1) new CV axle shim between
the stock front differential and the stock CV axle. Secure
using the new 10 mm x 35 mm bolts and hardware.
Torque to 45 ft. lbs. Make sure to use thread locker or
lock tite. Special note: Make sure that the stock axle
is re-installed back into the stock location on the
stock front differential. Refer to the scribe mark that
was made in step # 18. Repeat on the passenger side.
58. Locate the stock hardware that connects the stock
front axle to the stock hub assembly that was removed in
step # 17. Also, locate the stock hub assembly caps that
were removed in step # 16. Working on the driver side,
secure the stock front axle to the hub assembly using the
stock hardware. Torque to 154 ft. lbs. Make sure to use
thread locker or lock tite. Re-install the stock hub
assembly cap back into the stock location. Repeat
procedure on the passenger side.
59. Working on the driver side, reconnect the stock ABS
lines back together. Also reconnect all other stock
mounting points on the stock ABS line. Repeat procedure
on the passenger side.
60. Locate the stock rotors that were removed in step #
15. Working on the driver side, install the stock rotor into
the stock location. Repeat procedure on the passenger
side.
61. Locate the stock brake caliper hardware that was
removed in step # 12. Working on the driver side, re-
install the stock brake caliper to the new driver side
spindle and secure using the stock hardware. Torque to
96 ft. lbs. Make sure to use thread locker or lock tite.
Repeat procedure on the passenger side.
62. Locate the stock brake line hardware that was
removed in step # 12. Also, 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. Next, shock tie the stock ABS line and the
stock brake line to the newly installed spindle. Also,
shock tie the stock ABS line and the stock brake lines
together. Repeat procedure on the passenger side.
Special note: In this step make sure that once you
shock tie the stock brake lines and ABS lines to the
spindle, there will be no contact on the new wheels
and tires. If contact occurs, the stock brake lines or
ABS lines may be damaged.
63. Locate the stock outer tie rod ball joint hardware that
was removed from step # 11. Working on the driver side,
install the stock outer tie rod to the new steering knuckle
using the stock hardware. Make sure to use thread locker
or lock tite and torque to 53 ft. lbs. Special note: The
new steering knuckle has a reverse taper on it where
the stock outer tie rod mounts to it, make sure to
install the outer tie rod the proper way. The stock
outer tie rod nut will now be installed on the bottom
side of the new steering knuckle.
64. Locate (2) new torsion bar cross member relocation
brackets. Locate (4) PB4902 poly bushings from
hardware bag 16985PL. Also, locate (2) S10074 sleeves
from hardware bag 16985SL. Install the new poly
bushings and sleeves into the new torsion bar cross
member relocation brackets. Special note: Make sure to
use a lithium or moly base grease prior to inserting
the new bushings and sleeves into the new torsion
bar cross member relocation brackets. This will
increase the life of the bushing as well as prevent
squeaking.
65. Working on the driver side, hold the new torsion bar
cross member relocation bracket to the new location on
the stock frame rail. Special note: Using the larger cut
out holes in the torsion bar cross member relocation
bracket over the stock rivets on the bottom of the
stock frame rail with help center the new torsion bar
cross member relocation bracket. With the new torsion
bar cross member relocation bracket in place, use a pair