Tuff Country 14840 - GM 94-98 Tahoe 4-door K1500 4 - Manual (Page 7)

side torsion bar into the stock torsion bar key. Repeat
procedure on the passenger side.
63. Locate the small metal adjusting blocks and bolts that
were removed from step # 6. Working on the driver side,
attach the torsion bar removing tool, making sure that the
unloading bolt in the center tool is in the small divot of the
torsion bar key. Adjust the torsion bar key up high
enough so that the small metal adjusting block and stock
bolt can be re-installed, Refer back to step # 5 and adjust
the stock bolt to the stock location. Repeat procedure on
passenger side.
64. Move back to all newly installed brackets and make
sure that all stock and new hardware is torqued to proper
specifications. Now re-connect the front differential’s
electronic coupler and vent hose. Special Note: Refer to
the torque sheet and torque to proper settings.
65. Locate (2) 5/8” x 2 1/2” poly shock bushings, (2) 1/2”
x 2 1/2” shock sleeves, the stock upper and lower shock
hardware that was removed from step # 3 and the new
shock boots. Install the new shock boots onto the new
shocks. Insert the new poly shock bushings and sleeves
into the upper eyelet of the new shocks. Special Note:
Shocks are not included with this suspension
system, shocks need to be ordered as a separate
part number, Tuff Country EZ — Ride Suspension
recommends using a 23” fully extended nitrogen gas
shock. Make sure to use a lithium or moly base
grease prior to inserting the new bushings into the
new shock. This will increase the life of the bushing
as well as prevent squeaking. Install the lower shock
bushing and sleeve into the lower eyelet of the new
shock. Special Note: Make sure to use a lithium or
moly base grease prior to inserting the new bushings
into the new shock. 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
and secure using the stock hardware. Torque the upper
and lower stock hardware to 70 ft lbs. Repeat procedure
on passenger side.
66. Locate the stock inner rubber fender splash guards
that were removed from step # 2. Working on the driver
side, re-install the inner rubber fender splash guard.
Repeat procedure on the passenger side.
67. Re-install the tires and wheels and carefully lower the
vehicle to the ground.
68. Check and double check to make sure that all steps
were performed properly. Check and double check to
make sure that all new and stock hardware has been
torque to proper torque specifications. Refer to the torque
specification sheet at the end of the installation manual.
69. Carefully lower the vehicle to the ground.
70. An exhaust modification is required once the
suspension system has been completed. After the rear
end installation is complete take the vehicle directly to a
muffler shop and have the exhaust modification
performed. Once the exhaust modification has been
performed re-install the stock front drive line back into the
stock location using the stock hardware that was
removed from step # 5. Torque to 35 ft lbs.
Congratulation, Front End Installation Complete!
Rear End Installation:
71. To begin installation, block the front tires of the
vehicle so that the vehicle is stable and can’t roll forward.
Safely lift the rear of the vehicle and support the frame
with a pair of jack stands. Place a jack stand on both the
driver and passenger side. Next remove the wheels and
tires from both sides.
72. Locate (1) rear brake line extending bracket, (1) 5/16”
x 1 1/4” bolt, (2) 5/16” flat washers, (1) 5/16” unitorque
nut and (1) 5/16” lock washer. Remove the stock brake
line bracket from the rear differential and save stock bolt
for later re-installation. Secure the new brake line bracket
to the rear differential housing using the stock bolt.
Special Note: Make sure to use thread locker or lock
tite. Next, attach the stock brake line bracket to the newly
installed brake line bracket and secure using the new
5/16” x 1 1/4” bolt and hardware. Torque to 16 ft. lbs.
See Illustration # 24
73. Position a pair of hydraulic floor jacks under the rear
axle. Place one jack stand on the driver side and one on
the passenger side. Raise up on both hydraulic floor
jacks at the same time until they make contact with the
rear axle.
74. Working on the driver side, remove the stock shock
and save the stock hardware for later re-installation.
Longer shocks are needed, so the stock shocks may be
discarded. Special Note: Shocks are not included with
this suspension system, shocks need to be ordered
as a separate part number, Tuff Country EZ-Ride
Suspension recommends using a 30” fully extended
nitrogen gas shocks. Repeat procedure on passenger
side.
75. Working on the driver side, remove the stock sway
bar end links for the stock upper and lower location. Save
the stock hardware. The stock end link may be
discarded. Repeat procedure on the passenger side.
76. Working on the driver side, remove the (2) stock rear
U-bolts and discard. Set the upper and lower U-bolt
plates a side for later re-installation. Repeat procedure on
passenger side
77. Lower down on both hydraulic floor jacks at the same
time until the stock springs separate from the stock rear
axle. Lower down approximately 4”. Special Note: Make
sure not to over extended any brake lines or hoses
when lowering axle.