Tuff Country 55906 - Toyota Tundra 2004 knuckle 5 lift kit - Manual (Page 6)

re-installation. Set the stock lower control arms aside for
later re-installation. Repeat procedure on the passenger
side.
Photo # 31
30. Working on the driver side, measure from the stock rear
lower control arm mounting point towards the inside of the
vehicle 3 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.
Photo # 32
31. Working on the passenger side, measure from the
stock rear lower control arm mounting point towards the
inside of the vehicle 5 3/4”. 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 # 33
Photo # 34
32. Place a hydraulic floor jack under the front differential
and carefully raise up on the hydraulic floor jack until it
makes contact with the front differential.
33. Working on the driver side, remove the stock mounting
hardware that connects the stock driver side differential
bracket to the stock front cross member. Save the stock
hardware for later re-installation. Repeat procedure on the
passenger side.
Photo # 35
34. Working on the driver side, remove the (3) stock bolts
that connect the driver side differential bracket to the stock
front differential. Save the stock hardware for later
re-installation. Repeat procedure on the passenger side.
Special note: On the passenger side, the stock
differential bracket is attached to the stock front
differential with (2) stock bolts.
Photo # 36
Photo # 37
35. With a tie down strap, carefully tie the stock front
differential to the stock frame rail. This is done so the front
differential will hang. With the front differential hanging,
remove the hydraulic floor jack from under the front
differential.
Photo # 38
36. Locate the new driver and passenger side differential
relocation brackets. Locate (4) PB2408 poly bushings and
(2) S10082 sleeves from hardware bag 55906NB1. Install
the new poly bushings into the new driver and passenger
side differential relocation brackets. Next, install the new
sleeves 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
and passenger side differential relocation brackets.
This will increase the life of the bushings as well as
prevent squeaking.
37. Locate the new driver side differential relocation
bracket. Locate the (3) stock mounting bolts that were
removed in step # 34. Also, locate (3) 9/16” USS flat
washers from hardware bag 55907NB. Working on the
driver side, install the new driver side differential relocation
bracket to the stock front differential and secure using the
stock mounting bolts and the new 9/16” USS flat washers.
Do not tighten at this point.
Photo # 39
38. Locate the new passenger side differential relocation
bracket. Locate the (2) stock mounting bolts that were
removed in step # 34. Also locate (2) 9/16” USS flat
washers from hardware bag 55907NB. Working on the
passenger side, install the new passenger side differential
relocation bracket to the stock front differential and secure
using the stock mounting bolts and the new 9/16” USS flat
washers. Do not tighten at this point.
Photo # 40
39. Locate the stock driver and passenger side mounting
hardware that attached the stock differential brackets to the
stock front cross member that were removed in step # 33.
Working on the driver side, install the new driver side
differential relocation bracket to the stock front cross
member using the stock hardware. Do not tighten at this
point. Repeat procedure on the passenger side.
40. Locate (2) 3/4” x 5 1/2” bolts, (2) 3/4” x 5” bolts, (8) 3/4”
flat washers and (4) 3/4” unitorque nuts from hardware bag
55907NB. Also, locate the new one piece lower sub frame.
Install the new one piece lower sub frame into the stock
front and rear lower control arm pockets and secure using
the new 3/4” x 5 1/2” bolts into the front location and the
new 3/4” x 5” bolts and hardware into the rear location.
Special note: Do not tighten at this point. Also, when
installing the new one piece lower sub frame, make
sure that the rear mounting stud on the rear portion of
the front differential seats properly into the new one
piece lower sub frame.
Photo # 41
41. Locate (1) 1/2” x 1 1/2” bolt, (2) 7/16” USS flat washers,
and (1) 1/2” unitorque nut from hardware bag 55907NB.
Working on the driver side, install the newly installed one
piece lower sub frame to the newly installed driver side
differential relocation bracket and secure using the new
1/2” x 1 1/2” bolt and hardware. Special note: Do not
tighten at this point. Also, when installing the new