Tuff-country 14993 - GM 01-09 K2500 HD 4wd 4 kit User Manual download pdf (Page 5)

Disconnect the ABS lines from each other. Also, disconnect

the ABS line from any other mounting points on the stock

frame rail. Repeat procedure on the passenger side.

13. Working on the driver side, remove the (2) stock bolts

that connect the stock brake caliper to the stock knuckle.

Save the stock hardware for later re-installation. Using a

bungee cord, carefully tie the stock brake caliper up and

out of the way in the fender well. Special note: Take

special care not to kink or over extend the stock brake

line. Repeat procedure on the passenger side.

Photo # 10 / Photo # 11

14. Working on the driver side, remove the stock rotor and

set aside for later re-installation. Repeat procedure on the

passenger side.

Photo # 12

15. Working on the driver side, remove the stock cap right

in the middle of the stock hub assembly. Set the stock cap

aside for later re-installation. Repeat procedure on the

passenger side.

Photo # 13

16. Working on the driver side, remove the stock hardware

that connects the stock axle to the stock hub assembly.

Save the stock hardware for later re-installation. Repeat

procedure on the passenger side.

Photo # 14

17. Working on the driver side, scribe a mark on the CV

plate and another directly across to the stock differential.

This will allow you to re-install the stock CV back into the

stock location at a later step. Repeat procedure on the

passenger side.

Photo # 15

18. Working on the driver side, remove the (6) stock bolts

holding the inner CV axle to the stock front differential.

Discard the stock hardware. Carefully remove the stock CV

axle from the stock location and set the stock CV axle aside

for later re-installation. Special note: During the removal

of the stock CV axle, take special care not to damage

the threads of the CV axle or the CV axle dust boot.

Repeat procedure on the passenger side.

Photo # 16

19. Working on the driver side, loosen but do not remove

the stock nut that connects the stock upper control arm ball

joint to the stock steering knuckle. Carefully break the stock

taper by striking the stock knuckle with a hammer. Special

note: Take special care not to damage the stock upper

control arm ball joint or rip the stock upper control arm

ball joint dust boot. For now, leave the stock upper

control arm attached to the stock knuckle. We want to

just break the stock taper for now. Repeat procedure on

the passenger side.

Photo # 17 / Photo # 18

20. Working on the driver side, loosen but do not remove

the stock nut that connects the stock lower control arm ball

joint to the stock steering knuckle. Carefully break the stock

taper by striking the stock knuckle with a hammer. Special

note: Take special care not to damage the stock lower

control arm ball joint or rip the stock lower control arm

ball joint dust boot. For now, leave the stock lower

control arm attached to the stock knuckle. We want to

just break the stock taper for now. Repeat procedure on

the passenger side.

Photo # 19 / Photo # 20

21. Working on the driver side, move back to the stock nuts

holding the stock upper control arm ball joint and the stock

lower control arm ball joint to the stock steering knuckle

and remove completely. Save the stock hardware for later

re-installation. Carefully remove the stock hub assembly

and the stock steering knuckle from the stock location and

set aside for later re-installation. Repeat procedure on the

passenger side.

22. Working on the driver side stock hub assembly, remove

the (4) stock bolts that connect the stock hub assembly to

the stock steering knuckle. Save the stock hardware and

stock hub assembly for later re-installation. Also, carefully

remove the stock rubber “O” ring located in the stock

steering knuckle and save for later re-installation. A new

steering knuckle is used, the stock steering knuckle can be

discarded. Repeat procedure on the passenger side

knuckle.

Photo # 21 / Photo # 22

Photo # 23

23. Locate the new driver side steering knuckle. Using the

stock rubber “O” ring that was removed in step # 22,

carefully re-install the stock rubber “O” ring into the new

driver side knuckle. Using the stock hardware that was

removed from step # 22, secure the new driver side

steering knuckle to the stock hub assembly. Special note:

Make sure that the ABS line fits in the grove of the new

steering knuckle once the hub assembly has been

torqued down. Torque to 133 ft lbs. Make sure to use

thread locker or lock tite. Repeat procedure on the

passenger side knuckle.

Photo # 24 / Photo # 25

24. Set the new driver side steering knuckle and hub

assembly aside for later re-installation.

25. Working on the driver side, remove the stock front and

rear hardware that connects the stock lower control arm to

the stock location. Set the stock hardware and the stock

lower control arm aside for later re-installation. Repeat

procedure on the passenger side.

Photo # 26 / Photo # 27

26. Working on the driver side, remove the stock bolt that

connects the lower rear portion of the stock front

differential to the stock rear cross member. Save the stock

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Tuff-country 14993 - GM 01-09 K2500 HD 4wd 4 kit User Manual Page 5

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