Tuff Country 55905 - Toyota Tundra 99-03 knuckle 5 lift kit - Manual (Page 10)

Country recommends using a 26” fully extended
nitrogen gas shock. Repeat procedure on passenger
side.
100. Working on the passenger side of the rear axle,
remove the stock brake proportioning valve bracket from
the stock location and save the stock hardware for later
re-installation.
101. Working on the driver side, remove the stock rear
brake line from the stock upper and lower location. Save
the stock upper brake line clip for later re-installation.
The stock brake line may be discarded. Special note:
Brake fluid will drain out, so place something under
the vehicle to catch the fluid as it drains out.
102. Working on the driver side, remove the stock u-bolts
from the stock location and discard the stock u-bolts and
u-bolt hardware. Set the stock upper bump stop and
lower u-bolt plate a side for later re-installation. Repeat
procedure on the passenger side.
103. Carefully lower down on both hydraulic floor jacks at
the same time approximately 4.5”. Take special care not
to kink on over extend any brake lines and/or hoses.
104. Locate (2) new 4” lifted blocks. Working on the
driver side, install the new 4” lifted block between the
stock spring assembly and the stock axle. Special note:
The new 4” lifted block has a slight taper to it, make
sure that when you install the new block that you
install it with the taper going towards the front of the
vehicle. Repeat procedure on the passenger side.
105. Carefully raise up on both hydraulic floor jacks at
the same time until the new 4” lifted rear blocks seat
properly to the stock rear springs.
106. Locate (4) 9/16” x 2 1/2” x 10 5/8” square u-bolts.
Locate the (8) new 9/16” U-bolt high nuts and (8) new u-
bolt harden washers from hardware bag 916NW. Also,
locate the stock upper bump stops and the stock lower
U-bolt plates that removed in step # 102. Working on the
driver side, install the stock upper bump stop, lower U-
bolt plate and the new U-bolts into the stock location and
secure using the new high nuts and harden U-bolt
washers. Torque to 115 ft lbs. Repeat procedure on the
passenger side.
Illustration # 25
107. Carefully remove both hydraulic floor jacks from
under the vehicle.
108. Locate (1) new rear brake proportioning valve
bracket. Also, locate the stock rear brake proportioning
valve bracket hardware that was removed in step # 100.
Install the new rear brake proportioning valve bracket to
the stock location using the stock hardware. Special
note: Make sure to use thread locker or lock tight.
Illustration # 26
18 ft lbs. Repeat procedure on the passenger side.
92. Locate the stock passenger side rack and pinion hi
pressure and return line hardware that was removed in
step # 18. Locate the new passenger side rack and
pinion hi pressure and return line relocation bracket.
Also, locate (1) 5/16” x 1” bolt, (2) 5/16” flat washers, (1)
5/16” unitorque nut and (1) 5/16” lock washer from
hardware bag 55905NB. Working on the passenger side,
install the new relocation bracket to the passenger side
of the stock rack and pinion using the stock hardware.
Special note: Make sure to use thread locker or lock
tite. Do not tighten at this point. Next, secure the stock
rack and pinion hi pressure and return line to the newly
installed relocation bracket and secure using the new
5/16” x 1” bolt and hardware. Special note: Make sure
to use thread locker or lock tite. Torque the stock and
new hardware to 14 ft lbs.
93. Locate the stock upper skid plate and the stock
upper skid plate hardware that was removed in step # 2.
Install the stock upper skid plate into the stock location
and secure using the stock hardware. Make sure to use
thread locker or lock tite and torque to 18 ft lbs.
94. Install the tires and wheels and carefully lower the
vehicle to the ground.
95. With the weight of the vehicle on the ground, working
on the driver side, torque the stock cam bolts that attach
the stock front lower control arm to the newly installed
one piece lower sub frame to 96 ft lbs. Repeat
procedure on the passenger side.
96. Check and double check to make sure that all steps
were performed properly. And then check them again.
Front End Installation Complete:
Rear End Installation:
97. 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 rear wheels
and tires from both sides.
98. Using a pair of hydraulic floor jacks, place one
hydraulic floor jack on the driver side of the rear axle and
one on the passenger side.
99. Working on the driver side, remove the stock shock
from the stock upper and lower location. The stock shock
and the stock upper hardware may be discarded. Save
the stock lower hardware for later re-installation. Special
Note: New longer rear shocks are needed, if you
have not already ordered your new rear shocks,
please contact Tuff Country or your local Tuff
Country dealer and order the proper shocks. Tuff