Tuff Country 35920 - Dodge 94-02 Ram 2500 / 3500 4.5 kit - Manual (Page 8)

more so that the cotter pin can be installed. Also, the
new pitman arm looks identical to the stock pitman
arm but the new pitman arm has a reverse taper were
the stock tie rod connects to it. Before re-installation
of the tie rod to the new pitman arm, the stock tie rod
needs to be rotated 180 degrees.
52. Carefully remove both hydraulic floor jacks from
under the vehicle.
53. Check and double check to make sure that all steps
were performed properly. Install the new tires and wheels
on both the driver and passenger side and safely lower
the vehicle to the ground.
54. If you were not able to install the stock track bar into
the newly installed track bar relocation bracket in step #
47, perform step # 47 now that the weight of the vehicle
is on the ground.
55. If you were not able to install the stock sway bar to
the newly installed sway bar drop brackets in step # 49,
perform step # 49 now that the weight of the vehicle is on
the ground.
Front end installation complete
Rear end installation
56. To begin installation, block the front tires of the
vehicle so that the vehicle is stable and can’t roll forward.
Safely lift the rear of the vehicle and support the frame
with a pair of jack stands. Place a jack stand on both the
driver and passenger side. Next, remove the wheels and
tires from both sides.
57. Place a pair of hydraulic floor jacks under the driver
and passenger side rear axle. Carefully raise up on both
hydraulic floor jacks at the same time until they make
contact with the rear axle.
58. Working on the driver side, remove the stock rear
shock from the stock upper and lower location and save
the stock hardware for later re-installation. The stock rear
shock may be discarded. Special note: New longer rear
shocks are needed once this suspension system has
been installed and the rear shocks need to be
ordered as a separate part #. If you have not already
ordered your new rear shocks, please feel free to
contact Tuff Country or your local Tuff Country
dealer and order your new rear shocks. Tuff Country
recommends installing a 30” fully extended nitrogen
gas shock in the rear. Repeat procedure on the
passenger side.
59. Working on the driver side, remove the stock rear u-
bolts from the stock location. The stock rear u-bolts and
hardware may be discarded. Set the stock upper and
lower u-bolt plates a side for later re-installation. Repeat
procedure on passenger side.
stock hardware. Make sure to use thread locker or
lock tite. Do not tighten at this point. Repeat
procedure on the passenger side. Special note: The
new driver and passenger side sway bar drop
brackets are mirror images of each other. Once the
new driver and passenger side sway bar drop bracket
are installed the stock sway bar will be moved down
and forward.
49. Locate (4) 7/16” x 1 1/2” bolt, (8) 3/8” USS flat
washers and (4) 7/16” unitorque nuts from hardware bag
35910NB. Working on the driver side, install the stock
sway bar to the previously installed sway bar drop
brackets and secure using the new 7/16” x 1 1/2” bolts
and hardware. Make sure to use thread locker or lock
tite. Do not tighten at this point. Repeat procedure on
the passenger side. Special note: If you are not able to
install the stock sway bar to the newly installed sway
bar drop bracket, the weight of the vehicle may need
to be on the ground. If this is the case perform this
step at the end of the installation once the tires and
wheels have been installed. Once the stock sway bar is
attached to the newly installed relocation brackets, torque
the stock and new hardware on the driver and passenger
side to 28 ft lbs.
Illustration # 10
Special note: Dodge comes with two different size
pitman arms. Part # 70500 will work on the 1/2 ton
and 3/4 ton vehicle that were manufactured from 1994
— 2000. Also, part # 70500 will work on the 1/2 ton
that was manufactured in 2001. Part # 70501 will work
on the 3/4 ton that was manufactured in 2001 and all
3/4 vehicles that were manufactured in 2002. The
pitman arm is not included with this suspension
system and needs to be ordered as a separate part
number. If you have not already done so, please
contact Tuff Country or your local Tuff Country
dealer and order the proper pitman arm.
50. Locate the stock sector shaft nut and lock washer
that was removed in step # 8. Working on the driver side,
install the new pitman arm into the stock location on the
stock sector shaft and secure using the stock hardware.
Torque stock nut to 180 ft lbs. Special note: If the stock
lock washer is damaged, Tuff Country EZ-Ride
suspension highly recommends replacing the stock
lock washer.
51. Locate the stock tie rod castle nut and cotter pin that
was removed in step # 7. Re-install the stock tie rod end
into the newly installed pitman arm and secure using the
stock hardware. Torque to 65 ft lbs. Install the stock
cotter pin into the stock tie rod and castle nut. Special
note: Once the stock tie rod castle nut has been
torqued, install the stock cotter pin. If the stock
cotter pin can not be installed because the hole in the
stock tie rod does not line up with the stock castle
nut, DO NOT loosen the stock castle nut so that the
cotter pin can fit, tighten the stock castle nut some