Tuff Country 55900 - Toyota Tundra 99-04 4.5 kit - Manual (Page 10)

55. Locate (1) BLR09 (relocation bracket) from hardware
bag 55906NB2. Locate (1) 5/16” x 1” bolt, (2) 1/4” USS flat
washers and (1) 5/16” unitorque nut from hardware bag
55900NB1. Also, locate the rack and pinion hi pressure line
mounting hardware. Install the new relocation bracket to the
rack and pinion hi pressure lines and secure using the new
5/16” x 1” bolt and hardware. Do not tighten at this point.
Next secure the previously installed relocation bracket to the
rack and pinion and secure using the stock hardware. Make
sure to use loctite and torque to 12 ft lbs. Move back to the
new 5/16” x 1” bolt installed earlier in this step and add some
loctite and torque the new 5/16” x 1” bolt to 14 ft lbs.
56. Working on the driver side, install the control arm back
into the OE location. Secure using the OE hardware. Do not
tighten at this point. Repeat procedure on the passenger
side.
57.Locate the new upper strut spacers. Also, locate the driv-
er and passenger side strut’s and the upper stock strut hard-
ware. Working on the driver side strut, secure the new upper
strut spacer to the top of the strut using the stock hardware.
Make sure to use loctite and torque to 45 ft lbs. Repeat pro-
cedure on the passenger side strut.
58. Locate (6) 3/8” unitorque nuts and (6) 5/16” USS flat
washers from hardware bag 55900NB1. Working on the driv-
er side, install the driver side strut back into the upper loca-
tion and secure using the new 3/8” hardware. Make sure to
add loctite and torque to 38 ft lbs. Repeat procedure on pas-
senger side.
59. Locate the lower strut bolts and hardware. Working on
the driver side, secure the strut to the lower control arm
using the OE hardware. Make sure to use loctite and torque
to 85 ft lbs. Repeat procedure on passenger side.
60. Locate the (2) bags that have the new ball joint spacers
in them. Follow the instruction from Toyota on how to install
the new dust boot cover on the new ball joints.
61. Locate the new upper ball joint castle nuts and cotter
pins that were packaged with the new upper ball joint spac-
ers. Working on the driver side, install the new ball joint
spacer to the upper control arm and secure using the new
castle nut and cotter pin that was packaged with the ball joint
spacers. Torque to 80 ft lbs. Making sure that the hole in the
new castle nut and the new upper ball joint are lined up and
install the new cotter pin. Special note: If the new cotter
pin can not be installed because the hole in the new cas-
tle nut does not line up with the new ball joint, DO NOT
loosen the new castle nut so that the cotter pin can fit,
tighten the new castle nut some more so that the new
cotter pin can be installed.
62. Working on the driver side, move back to the hardware
attaching the upper control arm into the OE location and add
some loctite and torque to 85 ft lbs. Repeat procedure on
the passenger side.
63. Locate (2) knuckle washers T5I-12L from hardware bag
55900NB2. Working on the driver side, press the spacer
plate into the knuckle. Special Note: The holes in the
spacer plate need to face towards the inside of the vehi-
cle. This will allow you to install the ball joint spacer with
the big hole facing towards the inside of the vehicle.
Repeat procedure on the passenger side.
64. Locate the driver and passenger side knuckle support
bracket. Locate (4) new 5/16” x 1 3/16” x 2” round u-bolts
and (8) new 5/16” flange lock nuts from hardware bag
55900NB2. Also, locate (4) 7/16” x 1 1/2” bolts, (4) 7/16” lock
washers and (2) 3/8 x 1 1/2” bolts from hardware bag