Tuff Country 54900 - Toyota Tacoma 95-04 5 lift kit - Manual (Page 7)

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 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.
Photo # 14
60. Locate (1) 9/16” x 2 1/2” bolt, (1) 9/16” flat washer
and (1) 9/16” lock washer from hardware bag 54900NB.
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.
Photo # 15
61. Locate the stock driver side rack and pinion
hardware that was removed from step # 21. Also, locate
(2) S10077 over size washers. 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 # 16 for proper over size washer placement.
Photo # 16
62. 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.
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 # 19 on the stock steering shaft flange
and the stock rack and pinion flange are lined up.
Photo # 17
63. Working on the passenger side, torque the stock
upper bolt that connects the stock rack and pinion to the
stock rear cross member to 110 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.
64. 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.
65. 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.
53. Working on the driver side 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) MO2382 rack and pinion bushings and (1)
S10076 rack and pinion sleeve. Working on the driver
side 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 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.
56. Locate (2) MO3354 rack and pinion bushings and (1)
S10075 rack and pinion sleeve. 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.
57. Working on the driver side inner frame rail, carefully
cut the front corner of the stock sway bar mounting
bracket. See photo # 13 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.
Photo # 13
58. Locate the new driver side steering shaft extension
bracket and the stock steering shaft hardware that was
removed from step # 20. 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.
59. Locate the stock passenger side lower rack and
pinion bolt that was removed from step # 25, (1) 9/16” x
2 1/2” bolt, (1) 9/16” lock washer from hardware bag
54900NB. 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 hardware. Special Note: Do not
tighten at this point. Make sure to use thread locker