Tuff-country 14993 - GM 01-09 K2500 HD 4wd 4 kit User Manual download pdf (Page 8)

sure to use thread locker or lock tite. Repeat procedure

on the passenger side. Carefully remove the hydraulic floor

jack from under the front cross member.

Photo # 51

51. Move back to the stock and new hardware that is

attaching the new passenger side differential relocation

bracket to the stock location and the stock differential and

and some thread locker or lock tite and torque the stock

hardware to 75 ft lbs. and the new 9/16” hardware to 85 ft

lbs.

Photo # 52

52. Locate the new 4” integrating skid plate. Also, locate (6)

1/2” x 1 1/2” bolts, (12) 7/16” USS flat washers and (6) 1/2”

unitorque nuts from hardware bag 14959NB1. Install the

new 4” integrating skid plate to the front and rear cross

members and secure using the new 1/2” x 1 1/2” bolts and

hardware. Do not tighten at this point.

Photo # 53

53. Working on the driver side, move back to the stock

hardware attaching the new front cross member into the

stock lower control arm pocket and add some thread

locker or lock tite and torque to 105 ft lbs. Repeat

procedure on the passenger side.

Photo # 54

54. Working on the driver side, move back to the stock

hardware attaching the new rear cross member into the

stock lower control arm pocket and add some thread

locker or lock tite and torque to 105 ft lbs. Repeat

procedure on the passenger side.

Photo # 55

55. Working on the driver side, move back to the stock

hardware attaching the newly installed driver side

differential relocation bracket to the newly installed front

cross member and add some thread locker or lock tite and

torque to 75 ft lbs.

Photo # 56

56. Working on the driver side, move back to the stock

hardware attaching the rear portion of the stock front

differential to the newly installed rear cross member and

add some thread locker or lock tite and torque to 75 ft lbs.

Photo # 57

57. Move back to the new hardware attaching the new skid

plate to the front and rear cross member and add some

thread locker or lock tite on all (6) bolts and torque all (6)

bolts to 70 ft lbs.

Photo # 58 / Photo # 59

58. Reconnect the 4WD wiring to the front differential. Also,

reconnect any other vent hoses and/or wiring that was

connected to the stock front differential.

Photo # 60

59. Locate the stock front drive line hardware that was

removed in step # 29. Re-install the stock front drive line to

the stock front differential using the stock hardware. Make

sure to use thread locker or lock tite and torque to 18 ft lbs.

Photo # 61

60. Locate (2) PB6199 poly bump stops from hardware bag

14985PL. Special note: There are (6) poly bump stops

located in the poly bag, (4) are the same size and (2)

are taller, locate (2) of the shorter poly bump stops.

Also, locate (2) 3/8” unitorque nuts and (2) 5/16” USS flat

washers from hardware bag 14985NB. Working on the

driver side rear portion of the newly installed rear cross

member, secure the new poly bump stop using the new

3/8” hardware. Torque to 28 ft lbs. Repeat procedure on

the passenger side. Make sure to use thread locker or lock

tite.

Photo # 62 / Photo # 63

61. Locate the new driver side steering knuckle and the

stock hub assembly. Also, locate the stock hardware for the

upper control arm ball joint and the lower control arm ball

joint that was removed in step # 21. Using the stock

hardware, secure the new driver side steering knuckle and

stock hub assembly to the stock upper control arm ball joint

and the stock lower control arm ball joint using the stock

hardware. Torque the stock upper control hardware to 74 ft

lbs. and the stock lower control arm hardware to 101 ft lbs.

Make sure to use thread locker or lock tite. Repeat

procedure on the passenger side using the passenger side

steering knuckle.

62. Locate the stock CV axles that were removed from step

# 18. Working on the driver side, carefully install the stock

CV axle back into the stock hub assembly. Repeat

procedure on the passenger side.

63. Locate (2) axle half shaft spacers. Also, locate (12) 10

mm x 35 mm hex bolts and (12) 10 mm lock washers from

hardware bag 14985NB. Working on the driver side, install

(1) new axle spacer between the stock front differential and

the stock CV axle. Secure using the new 10 mm x 35 mm

bolts and hardware. Make sure to use thread locker or lock

tite and torque to 65 ft. lbs. Special note: Make sure that

the stock axle is re-installed back into the stock loca-

tion on the stock front differential. Refer to the scribe

mark that was made in step # 17. Repeat on the

passenger side.

Photo # 64

64. Locate the stock hardware that connects the stock front

axle to the stock hub assembly that was removed in step #

16. Working on the driver side, secure the stock front axle

to the stock hub assembly using the stock hardware. Make

sure to use thread locker or lock tite and torque to 112 ft.

lbs. Also, re-install the hub assembly center cap that was

removed from step # 15. Repeat procedure on the

passenger side.

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Tuff-country 14993 - GM 01-09 K2500 HD 4wd 4 kit User Manual Page 8

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