Tuff Country 35920 - Dodge 94-02 Ram 2500 / 3500 4.5 kit - Manual (Page 9)

66. Locate the new 5.5” lifted blocks. Working on the
driver side, install the new 5.5” lifted block into the stock
location. Special Note: The new 5.5” lifted blocks have
a taper to them, the small end of the block needs to
be installed towards the front of the vehicle. Repeat
procedure on the passenger side.
67. Carefully raise up on both hydraulic floor jacks at the
same time until the stock spring assembly sits flush with
the newly installed 5.5” lifted blocks.
68. Locate the new rear 9/16” x 3” x 14 5/8” square u-
bolts. Locate (8) new 9/16” u-bolt high nuts and (8) new
u-bolt washers from hardware bag 916NW. Also, locate
the stock upper and lower u-bolt plates that were
removed in step # 55. Working on the driver side, install
the new U-bolts into the stock location and secure using
the new high nuts and washers. Torque to 120 ft lbs.
Repeat procedure on passenger side.
Illustration # 12
69. Locate the new rear shocks. 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 end of your vehicle.
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.
Locate the stock rear shock hardware that was removed
in step # 58. Working on the driver side, install the new
shock into the stock upper and lower location. Make sure
to use thread locker or lock tite. Torque the stock
upper and lower hardware to 75 ft lbs. Repeat procedure
on the passenger side.
If the vehicle that you are working on does not have a
stock rear sway bar, please skip to step # 72
70. Locate the new rear sway bar drop brackets from
hardware bag 35920NB2. Also, locate (4) 7/16” x 3”
bolts, (8) 3/8” USS flat washers and (4) 7/16” unitorque
nuts from hardware bag 35920NB. Also, locate the stock
rear sway bar end link brackets that were removed in
If the vehicle that you are working on does not have a
stock rear sway bar, please skip to step # 62
60. Working on the driver side, carefully remove the stock
rear sway bar end link from the stock rear sway bar end
link bracket and save the stock hardware for later re-
installation. Repeat procedure on the passenger side. Let
the stock rear sway bar hang.
61. Working on the driver side. Carefully remove the
stock rear sway bar end link bracket that connects to the
stock frame rail. Set the stock rear sway bar end link
bracket a side for later re-installation. The stock hardware
may be discarded. Repeat procedure on the passenger
side.
62. Carefully lower down on both hydraulic floor jacks at
the same time allowing enough room for the new rear
blocks and add-a-leafs to be installed. Special note:
Take special care not to kink or over extend the stock
rear brake line.
63. Working on the driver side, remove the stock rear
block and discard. Repeat procedure on passenger side.
64. Working on the driver side, place a pair of “C” clamp
vise grips on each side of the stock centering bolt.
Carefully remove the stock centering bolt and nut and
discard. Carefully remove the “C” clamp vise grips that
are holding the stock springs together. Special Note: Be
very carefully when removing the “C” clamps, the
stock springs are under tension and can be
dangerous. Repeat procedure on passenger side.
65. Locate the new rear add-a-leafs. Locate the new 1/2”
x 6” centering bolts and the new 1/2” fine nut from
hardware bag CB12. Working on the driver side, Install
the new rear add-a-leaf into the stock spring assembly.
Secure the new rear add-a-leaf to the stock spring
assembly using the new 1/2” center bolt and nut. Torque
to 32 ft. lbs. Special Note: The new rear add-a-leaf has
and offset center hole location, place the longest side
of the new rear add-a-leaf towards the rear of the
vehicle. Also the new add-a-leaf should be installed
into the stock spring assembly in progression in
order, from longest to shortest. The new add-a-leaf
should be installed between the stock overload and
the stock spring pack. The stock overload is usually
the un-arched spring at the bottom of the stock leaf
pack. Also, Tuff Country EZ-Ride Suspension highly
recommends NOT using any air tools when installing
the new rear add-a-leafs into the stock spring
assembly. If air tools are used the centering bolt may
strip, causing the stock spring assembly to come
apart. With a suitable cutting tool, cut off the extra thread
from the new centering bolt. Repeat procedure on
passenger side.
Illustration # 11