Tuff Country 35920 - Dodge 94-02 Ram 2500 / 3500 4.5 kit - Manual (Page 6)

insert the stock coil spring into the stock lower location.
Special note: Make sure that the marks that were
scribed in step # 9 line up with each other. Repeat
procedure on the passenger side. Carefully raise up on
both hydraulic floor jacks at the same time until the driver
side and passenger side new upper coil spring spacers
and stock coil springs seat properly into the stock upper
location. Special note: There is (1) 3/8” x 1 1/2” bolt
that is welded to the new upper coil spring spacer,
this bolt needs to be line up with the back side stock
hole. This will make installation easier to tighten the
new nut down.
38. Locate the new front shocks. 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 end of your vehicle.
Locate (2) new S10107 upper shock washers and (2)
PB8297 front upper shock bushings from hardware bag
35910NB1. Install the new bushings and proper sleeves
into each end of the new shocks. Special note: The new
bushings and sleeves are supplied with your new
shocks. Also, make sure to use a lithium or moly
base grease prior to inserting the new bushings and
sleeves into the new shocks. This will increase the
life of the bushings and will help prevent squeaking.
Install the new shock boots onto the new shocks. Special
note: The new shock boots are not included with this
suspension system and the new shock boots need to
be ordered as a separate part #. If you have not
already ordered your new shock boots, please feel
free to contact Tuff Country or your local Tuff
Country dealer and order your new shock boots.
Once the new shock boots have been installed, working
on the driver side, install the new shock into the stock coil
spring by inserting it through the engine compartment.
Install the upper shock washer and the new front upper
shock bushing onto the stud of the new shock. Repeat
procedure on the passenger side.
39. Locate the stock lower shock mounting hardware that
was removed in step # 12. Working on the driver side,
secure the newly installed front shock into the stock lower
location and secure using the stock hardware. Make
sure to use thread locker or lock tite. Do not tighten at
this point. Repeat procedure on the passenger side.
40. Locate the stock upper shock tower brackets that
where removed in step # 11. Locate (2) new S10107
upper shock washers and (2) PB8297 front upper shock
bushings from hardware bag 35910NB1. Also, locate the
new upper shock nut that was included with your new
front shocks. Working on the driver side, install the stock
upper shock tower to the new stud on top of the newly
bracket, refer to the reference mark that were made in
step # 4 and re-install into the same location. Make sure
to use thread locker or lock tite. Do not fully tighten
at this point. Special note: Raising the axle to ride
height and moving the axle up and down will help
make installation of the new lower control arm a little
easier. Slight prying of the stock control arm bracket
also may be needed to make installation easier.
Repeat procedure on passenger side.
Illustration # 5
31. Locate the new upper control arms that are included
in this suspension system. Special note: The new
upper control arms are the shorter arms that are
included in this suspension system. Also, locate (8)
PB2408 poly bushings from poly bag D3IPL. Insert the
new poly bushings into each end of the new upper
control arms. Special Note: Make sure to use a lithium
or moly base grease prior to inserting the new
bushings into the new upper control arms. This will
increase the life of the bushing as well as prevent
squeaking.
32. Locate (4) new S10042 crush sleeves from sleeve
bag D5ISL. Insert the new S10042 crush sleeves into the
previously installed poly bushings in the new upper
control arms.
33. Locate (4) sert fitting from hardware bag 35910NB.
Carefully install the sert fittings into each end of the new
lower control arms. Special note: Take special care not
to damage the sert fittings during installation.
34. Locate the stock upper control mounting hardware
that was removed in step # 13. Working on the driver
side, install the new upper control arm into the stock
frame mount location and the axle mount location and
secure using the stock hardware. Make sure to use
thread locker or lock tite. Do not fully tighten at this
point. Special note: Raising the axle to ride height
and moving the axle up and down will help make
installation of the new upper control arm a little
easier. Slight prying of the stock control arm bracket
also may be needed to make installation easier.
Repeat procedure on passenger side.
Illustration # 6
35. Move back to the stock upper and lower control arm
hardware and torque to 85 ft lbs. Special note: On the
stock axle mount hardware on the new lower control
arms make sure that the alignment marks that were
made in step # 4 are still lined up.
36. Locate the new upper coil spring spacers and the
stock rubber isolator pads that were removed in step #
16. Insert the stock rubber isolator pads inside the recess
in the new upper coil spring spacer.
37. Working on the driver side, place the new upper coil
spring spacer on the top of the stock coil spring and