Tuff Country 14840 - GM 94-98 Tahoe 4-door K1500 4 - Manual (Page 6)

knuckle.
See Illustration # 19
49. Locate the stock cotter pins that were removed from
step # 16 and 17. Install the stock cotter pins back into
the stock location on the stock upper and lower control
arm ball joints.
50. Locate the stock hardware that connects the stock
front axle to the stock hub assembly that was removed in
step # 14. Working on the driver side, secure the stock
front axle to the hub assembly using the stock hardware.
Torque to 112 ft. lbs. Make sure to use thread locker
or lock tite. Repeat procedure on the passenger side.
51. Move back to all associated hardware that connects
the stock lower control arms to the new one-piece lower
sub frame and torque 125 ft. lbs.
52. Locate the stock hardware that was removed from
step # 13. Working on the driver side, re-install the stock
brake caliper to the stock rotor using the stock hardware.
Make sure to use thread locker or lock tite. Torque to
90 ft lbs. Repeat procedure on the passenger side.
53. 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.
54. Locate (2) front brake line relocation brackets, (2)
5/16” x 1 1/4” bolts, (4) 5/16” flat washers, (2) 5/16”
unitorque nuts (2) 5/16” lock washers and the stock
hardware that was removed from step # 11. Working on
the driver side, install the new brake line relocation
bracket to the stock location using the stock hardware.
Make sure to use thread locker or lock tite. Next,
secure the stock brake line bracket to the newly installed
brake line extending bracket and secure using the new
5/16” x 1 1/4” bolt and hardware. Make sure to use
thread locker or lock tite. Torque the stock and new
hardware to 15 ft lbs.
See Illustration # 20
55. Locate (2) new sway bar end links, (2) 3/8” x 10”
bolts, (8) sway bar end links washers, (8) sway bar end
links bushings, (2) 3/8” flat washers and (2) 3/8”
unitorque nuts. Working on the driver side, install the new
sway bar end link and hardware to the stock sway bar
and the stock lower control arm. Torque to 32 ft lbs.
Repeat procedure on the passenger side. Special Note:
If you did not invert the stock sway bar in step # 12,
invert it before you install the new sway bar end
links.
See Illustration # 21
56. Working on the driver side, carefully remove the (2)
stock rivet's on the bottom side of the stock frame rail.
Special Note: If using a drill, take special care not to
drill into any stock hoses and/or lines running down
the inside of the stock frame rail. The stock torsion bar
drop bracket may be discarded. Repeat procedure on the
passenger side.
57. Locate (2) new torsion bar drop brackets, (4) PB4902
poly bushings and (2) 1/2” x 1 1/2” anti crush sleeve.
Install the new poly bushings and sleeves into the new
torsion bar drop brackets. Special Note: Make sure to
use a lithium or moly base grease prior to inserting
the new bushings and sleeves into the new front
lateral compression arms. This will increase the life
of the bushing as well as prevent squeaking.
58. Working on the driver side, hold the new torsion bar
drop bracket to the new location on the stock frame rail.
Special Note: Make sure to center the new torsion bar
drop bracket where the stock torsion bar drop
bracket was located. With the new torsion bar 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 drop 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. Take Special care not
to drill into any stock hoses and/or lines running
down the inside of the stock frame rail. Repeat
procedure on the passenger side of the vehicle.
59. Locate (8) 7/16” x 1 1/2” bolts, (16) 7/16” flat
washers, (8) 7/16” unitorque nuts and (8) 7/16” lock
washers. Working on the driver side, secure the new
driver side torsion bar drop bracket to the stock frame rail
using the new 7/16” x 1 1/2” bolt and hardware. Make
sure to use thread locker or lock tite. Torque to 76 ft
lbs. Repeat procedure on the passenger side. Remove
the pair of vice grips holding the new torsion bar drop
bracket to the new location.
See Illustration # 22
60. Locate the driver side torsion bar that was removed
on step # 7. Install the stock torsion bar into the stock
lower control arm. Make sure that you push the stock
torsion bar as far forward as you can, this will allow you
to install the stock torsion cross member. Special Note:
Make sure that you install the stock torsion bar the
same way that it was removed. Example: driver side
vs. passenger side and front vs. rear. Repeat
procedure on passenger side.
61. Working on the driver side, install the stock torsion
bar cross member to the newly installed torsion bar drop
brackets and secure using the stock hardware. Make
sure to use thread locker or lock tite. Torque to 95 ft
lbs. Repeat procedure on the passenger side.
See Illustration # 23
62. Locate the stock driver and passenger side torsion
bar key’s that were removed from step # 6. Working on
the driver side, install the stock torsion bar key back into
the stock torsion bar cross member. Holding the stock
torsion bar key into the stock location, slide the driver