Tuff Country 55905 - Toyota Tundra 99-03 knuckle 5 lift kit - Manual (Page 7)

lower sub frame using the new 9/16” x 2 1/2” bolt and
hardware. Special note: Do not tighten at this point.
Make sure to use thread locker or lock tite.
Illustration # 10
58. Locate (1) 9/16” x 2 1/2” bolt, (1) 9/16” flat washer
and (1) 9/16” lock washer from hardware bag 55905NB.
Working on the center of the stock rack and pinion,
secure the center of the stock rack and pinion to the
newly installed one piece lower sub frame using the new
9/16” x 2 1/2” bolt and washers. Special note: Do not
tighten at this point and make sure to use thread
locker or lock tite.
Illustration # 11
59. Locate the stock driver side rack and pinion
hardware that was removed from step # 22. Also, locate
(2) S10077 over size washers from hardware bag
55905SL. Working on the driver side of the stock rack
and pinion, secure the stock rack and pinion to the newly
installed one piece lower sub frame using the stock
hardware and the new over size washers. Special note:
Do not tighten at this point and make sure to use
thread locker or lock tite. See photo # 14 for proper
over size washer placement.
Illustration # 11
60. Locate (2) 5/16” x 1 1/2” bolts, (4) 5/16” flat washers,
(2) 5/16” lock washers and (2) 5/16” unitorque nuts from
hardware bag 55905NB. Working on the driver side,
install the stock rack and pinion flange to the previously
installed steering shaft extension bracket and secure
using the new 5/16” x 1 1/2” bolts and hardware. Special
note: Do not tighten at this point and make sure to
use thread locker or lock tite. Also, make sure that
the marks that were made in step # 20 on the stock
steering shaft flange and the stock rack and pinion
flange are lined up.
Illustration # 12
61. Working on the passenger side, torque the stock
upper all thread nut that connects the stock rack and
pinion to the stock rear cross member to 85 ft lbs. Also,
torque the new 9/16” x 2 1/2” bolt that connects the stock
rack and pinion to the newly installed one piece lower
sub frame to 95 ft lbs.
62. Working on the center of the stock rack and pinion,
torque the new 9/16” x 2 1/2” bolt that connects the stock
rack and pinion to the newly installed one piece lower
sub frame to 95 ft lbs.
63. Working on the driver side, torque the stock
hardware that connects the stock rack and pinion to the
newly installed one piece lower sub frame to 110 ft lbs.
64. Working on the driver side, torque the stock
hardware that connects the stock steering shaft to the
new steering shaft extension bracket to 18 ft lbs. Also,
torque the new 5/16” x 1 1/2” bolts that connect the new
and pinion, install the new bushings and sleeves into the
stock rack and pinion. Special note: Make sure to use
a lithium or moly base grease prior to inserting the
new bushings into the stock rack and pinion. This
will increase the life of the bushings as well as
prevent squeaking.
53. Working on the center of the stock rack and pinion,
remove the stock bushing and sleeve from the stock
location. The stock bushing and sleeve may be
discarded.
54. Locate (2) MO3354 rack and pinion bushings and (1)
S10075 rack and pinion sleeve from hardware bag
55905SL. Working on the center of the stock rack and
pinion, install the new bushings and sleeves into the
stock rack and pinion. Special note: Make sure to use
a lithium or moly base grease prior to inserting the
new bushings into the stock rack and pinion. This
will increase the life of the bushings as well as
prevent squeaking.
55. Working on the driver side inner frame rail, carefully
cut the front corner of the stock sway bar mounting
bracket. See photo # 11 for proper cut line and
measurements. Special note: Tuff Country does not
recommend using a torch when making this cut. Tuff
Country recommends using a die grinder to make
this cut. The stock gas line runs on the inside of the
stock frame rail, take special care not to cut the
stock gas lines. Also when making this cut, take
special care not to cut into the stock frame rail.
Clean up any exposed slag from the trimming
performed in this installation step.
Illustration # 8
56. Locate the new driver side steering shaft extension
bracket and the stock steering shaft hardware that was
removed from step # 21. Working on the driver side,
install the new steering shaft extension bracket to the
stock steering shaft using the stock hardware. Special
note: Do not tighten at this point. Make sure to use
thread locker or lock tite. Also, make sure to line up
the alignment marks that were made in step # 20.
Illustration # 9
57. Locate the stock passenger side lower rack and
pinion all thread nut that was removed from step # 25,
(1) 9/16” x 2 1/2” bolt, (1) 9/16” lock washer from
hardware bag 55905NB. Also, locate the new rack and
pinion support bracket. Remove and re-install the stock
rack and pinion mounting bracket in the upside down
position around the stock rack and pinion. Secure the
upper part of the bracket with the stock all thread nut.
Special note: Do not tighten at this point. Make sure
to use thread locker or lock tite. Also, make sure to
install the rack and pinion support bracket between
the upper stock mounting point, lower mounting
point to the new one piece sub frame and the stock
rack and pinion mounting bracket. Secure the bottom
part of the stock bracket to the newly installed one piece