Tuff Country 14840 - GM 94-98 Tahoe 4-door K1500 4 - Manual (Page 5)

38. Locate the new driver side differential relocation
bracket, (2) MO2050 poly bushings and (1) 9/16” x 2 1/8”
anti crush sleeve. Install the new poly bushings and the
anti crush sleeve into the new driver side relocation
bracket. Special Note: Make sure to use a lithium or
moly base grease prior to inserting the new bushings
into the new driver side differential relocation
bracket. This will increase the life of the bushing as
well as prevent squeaking.
39. Locate (1) 7/16” X 3” bolt, (1) 7/16” unitorque nut, (2)
7/16” flat washers and (1) 7/16” lock washer. Referring to
illustration # 10, remove the (4) stock differential
mounting bolts that connect to two half’s of the front
differential together. Save the stock hardware for later re-
installation. Secure the new driver side differential
relocation bracket to the stock front differential using the
stock hardware that was removed earlier in this step.
Torque to 34 ft. lbs. Special Note: Make sure to use
thread locker or lock tite. Secure the lower portion of
the new driver side differential relocation bracket to the
stock front differential, using the new 7/16” x 3” bolt and
hardware. Torque to 34 Ft. lbs. Special Note: Make
sure not to over tighten the stock and new hardware
associated with the front differential. If bolts are over
tighten, the stock front differential could crack.
See Illustration # 10
40. Locate the new passenger side differential drop
bracket and the stock hardware that was removed from
step # 33. Install the new passenger side differential drop
bracket into the stock location and secure using the stock
hardware. Do not tighten at this point. Special Note:
Make sure to use thread locker or lock tite.
See Illustration # 11
41. Locate the stock upper front differential hardware that
was removed from step # 32. Working on the driver side,
secure the new driver side relocation bracket to the front
part of the newly installed one piece lower sub frame and
secure using the stock hardware. Do not tighten at this
point. Make sure to use thread locker or lock tite.
See Illustration # 12
42. Locate (2) 9/16” x 1 1/2” bolt , (4) 9/16” flat washers,
(2) 9/16” unitorque nuts and (2) 9/16” lock washers.
Working on the passenger side, secure the passenger
side of the stock front differential to the newly installed
passenger side differential drop bracket using the new
9/16” x 1 1/2“ bolt and hardware. Do not tighten at this
point. Make sure to use thread locker or lock tite.
See Illustration # 13
43. Locate (2) 1/2”x 1 1/4” bolts, (2) 1/2” unitorque nuts,
(4) 1/2” flat washers and (2) 1/2” lock washers. Using the
holes in the front part of the new lower one-piece sub
frame as a guide, drill (2) 1/2” holes into the frame.
Secure using new 1/2” x 1 1/4” bolts and hardware.
Torque to 85 ft lbs. Make sure to use thread locker or
lock tite.
See Illustration # 14
44. Move back to all stock and new hardware associated
with the new driver and passenger side differential drop
brackets, the rear portion of the stock front differential
that mounts to the new one piece sub frame and the
stock mounting points were the new one-piece sub frame
mounts. Torque all hardware to proper torque
specifications. Refer to the torque setting sheet at the
end of the installation manual.
45. Locate the (2) poly bump stops, (2) 3/8” lock nuts, (2)
3/8” flat washers and (2) 3/8” lock washers. Working on
the driver side, install the new poly bump stop into the
newly installed lower one-piece sub frame and secure
using the new 3/8” hardware. Torque to 28 ft. lbs. Make
sure to use thread locker or lock tite. Repeat
procedure on passenger side.
See Illustration # 15
46. Locate (2) 5/8” x 4 1/2” bolts, (2) 5/8” x 5 1/2”, (4) 5/8”
unitorque nuts, (8) 5/8” flat washers, (4) 5/8” unitorque
nuts, (4) 5/8” lock washers and the driver and passenger
side lower control arms that were removed from step #
27. Working on the driver side, install the stock lower
control into the newly installed one-piece sub frame front
location and secure using the new 5/8” x 4 1/2” bolt and
hardware. Next, secure the rear portion of the stock lower
control arm into the rear portion of the newly installed
one-piece lower sub frame and secure using the new 5/8”
x 5 1/2” bolt and hardware. Do not tighten at this point.
Make sure to use thread locker or lock tite. Repeat
procedure on passenger side.
See Illustration # 16 / Front Location
See Illustration # 17 / Rear Location
47. Locate 2 new axle half shaft spacers, the stock half
shaft hardware and the stock front axles that were
removed from step # 26. Working on the driver side,
install (1) new axle spacer between the stock front
differential and the stock axle. Secure using the stock
hardware. Torque to 65 ft. lbs. Make sure to use thread
locker or lock tite. Special Note: Make sure that the
stock axle is re-installed back into the stock location
on the stock front differential. Refer to the marks that
were scribe in step # 25. Repeat on the passenger side.
See Illustration # 18
48. Locate the new driver side steering knuckle and stock
hub assembly, the stock hardware for the upper control
arm ball joint, lower control arm ball joint and outer tie rod
ball joint that was removed from step # 19. Using the
stock hardware, secure the new driver side steering
knuckle and stock hub assembly to the stock upper
control arm ball joint, the stock lower control arm ball joint
and the stock outer tie rod assembly. Torque the stock
hardware on the upper and lower ball joints to 85 ft lbs.
Torque the outer tie rod ball joint hardware to 68 ft. lbs.
Make sure to use thread locker or lock tite. Also
when performing this step, slide the stock axle into
the stock hub assembly location. Repeat procedure on
the passenger side using the passenger side steering