Tuff-country 14993 - GM 01-09 K2500 HD 4wd 4 kit User Manual download pdf (Page 9)

65. Working on the driver side, reconnect the stock ABS

lines back together. Also reconnect all other stock

mounting points on the stock ABS line. Repeat procedure

on the passenger side.

66. Locate the stock rotors that were removed in step # 14.

Working on the driver side, install the stock rotor into the

stock location. Repeat procedure on the passenger side.

67. Locate the stock brake caliper hardware that was

removed in step # 13. Working on the driver side, re-install

the stock brake caliper to the newly installed knuckle and

secure using the stock hardware. Make sure to use thread

locker or lock tite and torque to 76 ft. lbs. Repeat

procedure on the passenger side.

68. Locate the stock brake line hardware that was removed

in step # 11. Working on the driver side, secure the stock

brake line bracket to the stock upper control arm using the

stock hardware. Carefully open up the stock bracket line

bracket. Next, secure the stock brake line bracket to the

new brake line bracket on the inside of the new knuckle.

Secure using the hardware that was supplied on the new

brake line bracket. Also, use some shock ties that were

packaged with the installer copy of the installation manual

and shock tie the stock ABS line and the stock brake lines

together. Repeat procedure on the passenger side.

Special note: In this step make sure that once you

shock tie the stock brake lines and ABS lines to the

spindle, there will be no contact on the new wheels and

tires. If contact occurs, the stock brake lines or ABS

lines may be damaged.

Photo # 65 / Photo # 66

69. Locate the new front shocks. Special note: New

longer front 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 23” fully extended

nitrogen gas shock. Locate (2) S10073 from hardware

bag 14985SL. Also, locate (4) PB8297 upper shock

bushings and (4) S10107 upper shock washers from

hardware bag 14985PL. Working on the new shocks, install

the new lower shock bushing into the lower eyelet and

install the new S10073 shock sleeves into the previously

installed bushings. Special note: Make sure to use a

lithium or moly base grease prior to inserting the new

lower shock bushings and sleeves into the new lower

shock eyelet. This will increase the life of the bushing

as well as prevent squeaking. Working on the driver side,

install the new shock into the stock location using the stock

hardware on the bottom mount that was removed in step #

8 and the new hardware on the top mount. Repeat

procedure on the passenger side. Special note: Make

sure to use the new upper bushings and upper shock

washers. Torque the lower shock mount to 65 ft lbs.

and the upper hardware to 22 ft lbs. Repeat on

passenger side. Special note: Tuff Country EZ-Ride

Suspension highly recommends that the shocks are

installed with shock boots. If shock boots are not

installed, damaged my occur to the piston of the new

shock.

70. Locate the stock outer tie rod ball joint hardware that

was removed from step # 10. Working on the driver side,

install the stock outer tie rod to the new steering knuckle

using the stock hardware. Make sure to use thread locker

or lock tite and torque to 53 ft. lbs. Special note: The new

steering knuckle has a reverse taper on it where the

stock outer tie rod mounts to it, make sure to install the

outer tie rod the proper way. The stock outer tie rod nut

will now be installed on the bottom side of the new

steering knuckle. Repeat procedure on the passenger

side.

71. Locate (2) new torsion bar cross member relocation

brackets. Locate (4) MO2220 poly bushings from hardware

bag 14985PL. Also, locate (2) S10074 sleeves from

hardware bag 14985SL. Install the new poly bushings and

sleeves into the new torsion bar cross member relocation

brackets. Special note: Make sure to use a lithium or

moly base grease prior to inserting the new bushings

and sleeves into the new torsion bar cross member

relocation brackets. This will increase the life of the

bushing as well as prevent squeaking.

72. Working on the driver side, hold the new torsion bar

cross member relocation bracket to the new location on the

stock frame rail. Special note: Using the larger cut out

holes in the torsion bar cross member relocation

bracket over the stock rivets on the bottom of the stock

frame rail with help center the new torsion bar cross

member relocation bracket. With the new torsion bar

cross member relocation bracket in place, use a pair of vice

grips and secure the new torsion bar drop bracket to the

stock frame rail. Using the new torsion bar cross member

relocation bracket as a guide, carefully drill (4) 7/16” holes

into the stock frame. (2) on the side of the frame rail and (2)

on the bottom. Special note: take special care not to drill

into any stock hoses and/or lines running down the

inside of the stock frame rail. Remove the pair of vice

grips that is holding the new torsion bar cross member

relocation bracket to the frame rail. Repeat procedure

on the passenger side of the vehicle.

73. Locate (8) 7/16” x 1 1/2” bolts, (16) 3/8” USS flat

washers and (8) 7/16” unitorque nuts from hardware bag

14985NB. Working on the driver side, secure the new

driver side torsion bar cross member relocation bracket to

the stock frame rail using the new 7/16” x 1 1/2” bolt and

hardware. Do not tighten at this point. Repeat procedure on

the passenger side.

Photo # 67 / photo # 68

74. Locate the stock torsion bars that were removed from

step # 5. Refer to the marks that were made in step # 3.

This will allow you to re-install the stock torsion bars back

into the stock location. Example: Driver vs. Passenger

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Tuff-country 14993 - GM 01-09 K2500 HD 4wd 4 kit User Manual Page 9

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