Tuff Country 35920 - Dodge 94-02 Ram 2500 / 3500 4.5 kit - Manual (Page 4)

reference when installing the new front lower control
arms. Repeat procedure on the passenger side.
Illustration # 1
5. Working on the driver side, remove the stock castle nut
and cotter pin from the stock track bar at the stock track
bar location. Save the stock castle nut for later re-
installation. The stock cotter pin may be discarded, a new
cotter pin is provided.
Illustration # 2
6. If the vehicle that you are working on is equipped with
a stock steering stabilizer, remove the stock steering
stabilizer from the stock location and discard the stock
steering stabilizer and the stock hardware. If the vehicle
that you are working on is not equipped with a stock
steering stabilizer, please discard step # 6.
7. Working on the driver side, remove the stock castle nut
and cotter pin from the stock tie rod end that connects to
the stock pitman arm. Save the stock castle nut and
stock cotter pin for later re-installation. Special note: The
new pitman arm looks identical to the stock pitman
arm but the new pitman arm has a reverse taper on it
where the stock tie rod connects to it. At this point,
rotate the stock tie rod 180 degrees.
8. Working on the stock steering box, remove the stock
nut and the stock lock washer from the sector shaft on
the stock steering box. Save the stock nut and the stock
lock washer for later re-installation. Using a pitman arm
puller, carefully remove the stock pitman arm from the
stock location. The stock pitman arm may be discarded.
9. Working on the driver side, scribe a mark on the stock
coil spring and another directly across on the stock lower
coil spring pocket. Special note: scribe the mark on the
bottom of the stock coil spring and one directly
across on the lower coil spring pocket. This will allow
you to re-install the stock coil spring back into the
stock location at a later step. Repeat procedure on
passenger side.
10. Working on the driver side, locate the top of the stock
shock absorber stud in the engine compartment. Remove
the stock nut, retainer washer and grommet. The stock
upper shock nut, retainer washer and grommets may be
discarded. Repeat procedure on passenger side.
Illustration # 3
11. Working on the driver side, remove the stock (3) nuts
from the stock upper shock tower and discard the stock
nuts. Set the stock upper shock tower a side for later re-
installation. Repeat procedure on the passenger side.
Illustration # 4
12. Working on the driver side, remove the stock lower
shock bolt that connects the stock shock to the stock
lower mounting location. Save the stock hardware for
later re-installation. Remove the stock shock by lifting the
stock shock up through the engine compartment. The
stock shock may be discard. Special note: New longer
front shocks are needed once this suspension
system has been installed and the front shocks need
to be ordered as a separate part #. If you have not
already ordered your new front shocks, please feel
free to contact Tuff Country or your local Tuff
Country dealer and order your new front shocks. Tuff
Country recommends installing a 30” fully extended
nitrogen gas shock in the front. Repeat procedure on
the passenger side.
13. Working on the driver side, remove the stock upper
control arm from the stock frame location and the stock
axle location. Save the stock hardware. The stock upper
control arm may be discarded. Repeat procedure on the
passenger side.
14. Working on the driver side, remove the stock lower
control arm from the stock frame location and the stock
axle location. Save the stock hardware. The stock lower
control arm may be discarded. Repeat procedure on the
passenger side.
15. Working on the driver side, remove the stock brake
line bracket that is located between the stock upper and
lower control arm mounting point that is located on the
stock front axle. The stock hardware may be discarded.
Let the stock brake line bracket hang. Repeat procedure
on the passenger side.
16. Carefully lower down on both hydraulic floor jacks at
the same time approximately 6”. Working on the driver
side, remove the stock coil spring from the stock location
and set aside for later re-installation. Next, remove the
stock rubber isolation pad and stock shock ring from the
stock upper shock pocket. Set the stock rubber isolation
pad aside for later re-installation. The stock shock ring
may be discarded. Repeat procedure on passenger side.
Special note: Before removal of the stock coil spring,
make sure that you scribed a mark on the stock coil
spring and the stock coil spring pocket in step # 9.
17. Locate (2) 1/4” x 1” bolts, (4) 1/4” flat washers and (2)
1/4” unitorque nuts from hardware bag 35910NB.
Working on the driver side, move the stock brake line
bracket to the top of the stock upper control arm axle
mount bracket and secure using the new 1/4” x 1” bolt
and hardware. Make sure to use thread locker or lock
tite. Torque to 12 ft lbs. Repeat procedure on the
passenger side. Special note: If the stock upper
control arm axle mount bracket does not have a hole,
carefully drill a 1/4” hole into the top of the stock
upper control arm axle mount bracket.
Special note: If the vehicle that you are working on
was manufactured before 09/01/01 please follow
steps # 18 — 26.