Tuff-country 14993 - GM 01-09 K2500 HD 4wd 4 kit User Manual download pdf (Page 10)

and Front vs. Rear. Working on the driver side, slide the

stock torsion bar back into the stock rear lower control arm.

Slide the stock torsion bar far enough forward so that the

stock torsion bar cross member can be re-installed. Repeat

procedure on the passenger side.

75. Locate the stock torsion bar cross member and stock

hardware that was removed from step # 4. Install the stock

torsion bar cross member to the newly installed torsion bar

cross member relocation brackets and secure using the

stock hardware. Make sure to use thread locker or lock tite

and torque to 90 ft lbs.

Photo # 69

76. Move back to the new 7/16” x 1 1/2” bolts attaching the

new driver and passenger side torsion bar cross member

relocation bracket to the stock frame rail and add some

thread locker or lock tite and torque all (8) bolts to 70 ft lbs.

77. Locate the stock torsion bar keys that were removed in

step # 3. Working on the driver side, install the stock torsion

bar key back into the stock location in the stock torsion bar

cross member. Slide the stock torsion bar back into the

previously installed torsion bar key. Repeat procedure on

the passenger side. Special note: Make sure that the

torsion bars are installed in the stock location in the

stock lower control arm and the stock torsion bar key.

Refer to the marks that were scribed in step # 3.

78. Locate the torsion bar adjusting blocks and hardware

that was removed from step # 2. Working on the driver side,

attach the torsion bar removing tool to the stock torsion bar

cross member, making sure that the unloading bolt in the

center of the torsion bar removing tool is in the small divot

of the stock torsion bar key. Adjust the torsion bar key up

high enough so that the stock small metal adjusting block

and bolt can be re-installed back into the stock location.

Remove the torsion bar removal tool front he stock torsion

bar cross member. Special note: Set the driver and the

passenger side torsion bar bolt so that there is 3/4” of

thread showing between the head of the bolt and the

adjusting block. Repeat on the passenger side.

79. Locate (2) 3/8” x 7” bolts and (2) 3/8” unitorque nuts

from hardware bag 14985NB. Locate (2) S10067 sway bar

end link sleeves from hardware bag 14985SL. Also, locate

(8) sway bar end link poly bushings and (8) sway bar end

link washers from hardware bag 14985PL. Special note: If

you did not invert the stock sway bar in step # 9, invert

the stock sway bar now. Working on the driver side,

install the new sway bar end link and hardware into the

stock location . Do not tighten at this point. Repeat

procedure on passenger side.

80. Locate the stock skid plate that was removed in step #

7. Referring to photo # 70, measure 2 5/8” from the leading

edge of the stock skid plate and scribe a mark. Carefully cut

along the scribed mark.

Photo # 70 / 2 5/8” measurement

Photo # 71 / post cut view

81. Locate the (3) stock upper skid plate mounting

hardware that we removed in step # 7. Install the newly

modified skid upper skid plate to the stock upper location

using the stock hardware. Special note: Make sure to use

thread locker or lock tite and torque to 28 ft lbs.

82. Holding the stock skid plate to the front cross member,

carefully drill a 3/16” hole through the stock skid plate and

the stock front cross member.

Photo # 72

83. Locate (1) 1/4” x 1” self threading bolt from hardware

bag 14985NB. Secure the stock skid plate to the stock

cross member using the new 1/4” x 1” self threading bolt.

Photo # 73

84. Re-install the tires and wheels and carefully lower the

vehicle to the ground.

85. Check and double check to make sure that all steps

were performed properly and check again.

86. There are still a couple of steps that need to be

completed on the front end but these steps will not be

completed until the rear end installation is completed and

the weight of the vehicle is on the ground. These steps

include the tightening of the front sway bar end links and

the tightening of the new hardware that connects the stock

lower control arms to the newly installed front and rear

cross member.

Rear end installation:

87. 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 wheels and tires from

both sides.

88. Working on the driver side, remove the stock shock

from the stock upper and lower mounting points and save

the stock hardware for later re-installation. The stock

shocks may be discarded. Special note: New longer rear

shocks are needed, if you have not already ordered

shocks, please contact Tuff Country or your local Tuff

Country dealer and order the proper shocks. Tuff

Country recommends using a 30” fully extended

nitrogen gas shock. Repeat procedure on the passenger

side.

89. Place a pair of hydraulic floor jacks under the rear

differential and carefully raise up on both hydraulic floor

jacks at the same time until they come into contact with the

rear differential.

90. Working on the driver side, remove the stock u-bolts

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Tuff-country 14993 - GM 01-09 K2500 HD 4wd 4 kit User Manual Page 10

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