Tuff Country 14840 - GM 94-98 Tahoe 4-door K1500 4 - Manual (Page 4)

steering knuckle. Do not remove the stock nut
completely. Carefully break the stock taper on the stock
outer tie rod ball joint. Special Note: Take special care
not to rip or tear the stock outer tie rod ball joint dust
boot.
19. Working on the driver side, move back to the stock
nuts holding the upper control arm ball joint, the lower
control arm ball joint and the outer tie rod ball joint to the
stock steering knuckle and remove completely. Save
hardware for later re-installation.
20. Working on the driver side, use a suitable removal
tool to remove the stock axle from the hub assembly.
Special Note: Take special care not to damage the
stock threads on the stock axle.
21. Carefully remove the stock hub assembly and the
stock steering knuckle from the stock location.
22. Working on the driver side stock hub assembly,
remove the (3) 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.
A new steering knuckle is used, the stock steering
knuckle can be discarded.
23. Locate the new driver side steering knuckle. Using
the stock hardware that was removed from step # 21,
secure the new driver side steering knuckle to the stock
hub assembly. Torque to 92 ft lbs. Special Note: Make
sure to use thread locker or lock tite.
24. Set the new driver side steering knuckle and hub
assembly a side for later re-installation.
25. 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.
See Illustration # 4
26. Working on the driver side, unbolt and remove the (6)
stock bolts holding the inner CV to the stock differential.
Discard the stock hardware. Set the stock axle a side for
later re-installation.
27. Working on the driver side, remove the stock front
and rear hardware that connects the stock lower control
arm to the stock front and rear location. Save the stock
hardware for later re-installation. Set the stock lower
control arms a side for later re-installation.
28. Repeat step’s 13 - 27 on the passenger side.
29. Working on the driver side, locate the stock lower
bracket that wraps around the rear lower half of the stock
front differential. Remove the stock bolt that connects the
lower portion of the stock front differential to the stock
bracket. Save the stock hardware for later re-installation.
Using the stock mounting point on the rear lower control
arm as a reference point, measure 3” towards the inside
of the vehicle and scribe a line on the stock bracket that
wraps around the rear portion of the stock front
differential. Using a hacksaw or suitable cutting tool, cut
along the line that was scribe earlier in this step. Special
Note: Tuff Country recommends not using a cutting
torch when performing step # 29. Clean and dress up
any exposed metal.
See Illustration # 5
30 . Locate the new one-piece lower sub frame and the
stock lower control arm hardware that was removed in
step # 27. Working on the driver side, install the front and
rear part of the new one-piece lower sub frame into the
stock front and rear lower control arm stock pockets and
secure using stock hardware. Do not tighten at this
point. Make sure to use thread locker or lock tite.
Repeat procedure on passenger side.
See Illustration # 6 / Front Location
See Illustration # 7 / Rear Location
31. Place a pair of hydraulic floor jacks under the front
differential. Place one on the driver side and one and the
passenger side. Carefully raise up on both hydraulic floor
jacks at the same time until the come in contact with the
front differential.
32. Working on the drivers side, remove the stock upper
bolt that connects the stock front differential into the stock
upper location and save the stock hardware for later re-
installation. Special Note: The front driver side upper
stock mounting point is up high and difficult to see.
33. On the passenger side, remove the (2) stock nuts
that hold the passenger side of the front differential into
the stock location and save the stock hardware for later
re-installation.
34. Disconnect the stock vent hoses on the front
differential.
35. Locate the stock rear driver side differential mounting
bracket hardware that was removed from step # 29.
Carefully lower down on both hydraulic floor jacks at the
same time, until the rear portion of the front differential
seat properly into the previously installed lower one-piece
sub frame. Secure using the stock hardware. Do not
tighten at this point. Make sure to use thread locker
or lock tite.
See Illustration # 8
36. Carefully remove both hydraulic floor jack from under
the front differential.
37. On the driver side of the stock front differential upper
tab, measure 2” from the stock mounting point and scribe
a mark on the front differential. Using a sawzall, cut the
upper tab off of the stock front differential and discard.
See Illustration # 9