Tuff Country 55907 - Toyota Tundra 05-06 knuckle 5 lift kit - Manual (Page 12)

out the stock skid plate on the lines that were scribed
earlier in this step.
Photo # 121
Photo # 122
103. Locate the stock skid plate hardware that was
removed in step # 2. Install the stock 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.
Photo # 123
104. Locate the stock rack and pinion outer ball joint cotter
pin and nut that was removed in step # 6. Working on the
driver side, install the stock rack and pinion outer ball joint
to the stock lower ball joint plate and secure using the stock
nut. Torque to 75 ft lbs. Making sure that the holes in the
stock castle nut and the stock rack and pinion outer ball
joint lined up, install the stock cotter pin. Special note: If
the stock cotter pin can not be installed because the
hole in the stock castle nut does not line up with the
stock rack and pinion ball joint, DO NOT loosen the
stock castle nut so that the cotter pin can fit, tighten
the stock castle nut some more so that the stock
cotter pin can be installed. Repeat procedure on the
passenger side.
Photo # 124
105. Install the tires and wheels and carefully lower the
vehicle to the ground.
106. 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.
107. 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:
108. 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.
109. 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.
110. 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 Country recommends
using a 26” fully extended nitrogen gas shock. Repeat
procedure on passenger side.
111. 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.
Photo # 125
112. Working on the driver side, remove the stock
emergency brake cable bracket from the bottom of the
stock frame rail. Save the stock hardware for later
re-installation.
Photo # 126
113. Locate the new rear brake line. Remove the stock rear
brake line from the stock upper and lower location. The
stock upper brake line clip and 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. For now, install the new brake line to the
stock upper and lower location and just hand tighten. This
will help eliminate some brake fluid from draining out.
114. With a hammer, carefully hit the stock upper brake line
bracket that is attached to the stock rear cross member. Hit
with a hammer until the bracket is pointing directly down.
Photo # 127
Photo # 128
115. Locate (1) new S10137, rear brake line bracket, from
hardware bag 55907NB1. Using a pair of vise grips, clamp
the new brake line bracket to the stock brake line bracket.
Photo # 129
116. Locate (1) new S10138, 1/4” x 3/4” self tapping screw
from hardware bag 55907NB1. Using a 1/8” drill bit and
using the new brake line bracket as a guide, carefully drill
a 1/8” hole into the stock brake line bracket. Now install the
new 1/4” x 3/4” self tapping screw to secure the new brake
line bracket to the stock brake line bracket. Remove the
pair of vise grips.
Photo # 130
117. Remove the new brake line from the stock hard mount
and install the new brake line and hard mount back
together at the new brake line bracket. Torque to 26 ft lbs.
Now torque to bottom mount of the new brake line to the
stock bottom mount to 26 ft lbs.
Photo # 131
118. Locate (1) new e-clip from hardware bag 55907NB1.
Install the new e-clip into the stock location.
Photo # 132
119. Working on the driver side, remove the stock u-bolts