Tuff Country 54900 - Toyota Tacoma 95-04 5 lift kit - Manual (Page 5)

member and save the stock hardware for later re-
installation. The stock front driver side differential drop
bracket may be discarded.
34. Working on the passenger side, remove the (2) stock
bolts that connect the stock front differential drop bracket
to the stock front differential. Save the stock hardware for
later re-installation. Next, remove the stock front
differential drop bracket from the stock front cross
member and save the stock hardware for later re-
installation. The stock front passenger side differential
drop bracket may be discarded.
35. Disconnect all the stock wiring and hoses that are
attached to the stock front differential so that the stock
front differential can be removed from the vehicle.
Carefully lower down on both hydraulic floor jacks at the
same time allowing the front differential to be removed
from the vehicle. Special Note: This step is done to
make it easier to make a cut on the stock driver side
rear lower control arm pocket.
36. Working on the stock driver side rear lower control
arm pocket, carefully cut the stock driver side rear lower
control arm pocket to allow for proper clearance for the
stock rack and pinion high pressure lines. Please see
photo # 3 for proper cut lines. Special Note: Tuff
Country does not recommend using a torch when
making this cut. Tuff Country recommends using a
sawzall or die grinder to make this cut. Take special
care not to cut any lines, hoses or wires. This is not
and easy step, please take your time and do not cut
out more material than is necessary. If you have any
questions, please do not hesitate to call the
technical department @ Tuff Country.
Photo # 3
37. Locate the new driver side differential drop bracket.
Locate (2) PB2408 poly bushings and (1) S10082 crush
sleeve from hardware bag 54900SL. Install the new poly
bushings into the new driver side differential drop
bracket. Next, install the new anti crush sleeve into the
newly installed poly bushings. Special Note: Make sure
to use a lithium or moly base grease prior to
inserting the new bushings into the new driver side
differential drop bracket. This will increase the life of
the bushings as well as prevent squeaking.
38. Locate the stock driver side front differential
hardware that was removed in step # 33. With the front
differential out of the vehicle, secure the new driver side
differential drop bracket to the stock front differential
using the stock hardware. Special Note: Do not tighten
at this point. Make sure to use thread locker or lock
tite.
Photo # 4
39. Locate the new passenger side differential drop
bracket. Locate (2) PB2408 poly bushings and (1)
S10082 crush sleeve from hardware bag 54900SL.
26. Working on the passenger side, remove the stock
rack and pinion mounting all thread bolt and discard.
27. Locate and remove the stock nut that connect the
stock front differential rear mounting point to the stock
rear cross member. Save the stock nut for later re-
installation.
28. Working on the driver side, remove the stock cam
bolts that secure the stock lower control arm to the stock
front and rear lower control arm mounting points. Set the
stock lower control arm and stock cam bolts a side for
later re-installation. Repeat procedure on the passenger
side.
29. Working on the driver side, measure from the stock
rear lower control arm mounting point towards the inside
of the vehicle 2 1/2”. Scribe a mark on the stock rear
cross member. Using a suitable cutting tool, carefully cut
the stock rear cross member. Special Note: Tuff
Country does not recommend using a torch when
making this cut. Tuff Country recommends using a
sawzall to make this cut. Also, take special care not
to cut any lines, hoses or wires.
Photo # 1
30. Working on the passenger side, measure from the
stock rear lower control arm mounting point towards the
inside of the vehicle 6 1/4”. Scribe a mark on the stock
rear cross member. Using a suitable cutting tool,
carefully cut the stock rear cross member. Special Note:
Tuff Country does not recommend using a torch
when making this cut. Tuff Country recommends
using a sawzall to make this cut. Also, take special
care not to cut any lines, hoses or wires. The stock
rear cross member that was cut out may be discarded.
Photo # 2
31. Working on the stock front drive line, remove the
stock front drive line from the stock front differential and
the stock transfer case. Set the stock front drive line and
hardware a side for later re-installation. Special Note:
When removing the stock front drive line from the
vehicle, take special care that the slip yoke on the
stock front drive line does not come apart. If the slip
yoke comes apart and it does not get re-installed
back into the stock location, it may cause the stock
front driveline to be out of balance.
32. Place a pair of hydraulic floor jacks under the front
differential. Place one on the driver side and one on the
passenger side. Carefully raise up on both hydraulic floor
jacks at the same time until they come into contact with
the front differential.
33. Working on the driver side, remove the (3) stock
bolts that connect the stock front differential drop bracket
to the stock front differential. Save the stock hardware for
later re-installation. Next, remove the stock front
differential drop bracket from the stock front cross