Tuff Country 16840 - GM 94-98 K1500 Tahoe 4-door 6 kit - Manual (Page 4)

Please Follow Instructions Carefully:
Before installation begins, measure from the center
of the hub, to the bottom of the fender well, and
record measurements below.
Pre-Installation Measurements:
Driver Side Front:______________________________
Passenger Side Front:__________________________
Driver Side Rear:______________________________
Passenger Side Rear:__________________________
At the end of the installation, take the same
measurements and compare to the pre-installation
measurements.
Post-Installation Measurements:
Driver Side Front:______________________________
Passenger Side Front:__________________________
Driver Side Rear:______________________________
Passenger Side Rear:__________________________
Please follow instructions carefully:
Front End Installation:
1. To begin installation, block the rear tires of the vehicle
so that the vehicle is stable and can’t roll backwards.
Safely lift the front 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 tires and
wheels from both sides.
2. Working on the driver side, remove the stock inner
rubber fender splash guard and save the stock inner
rubber fender splash guard and hardware for later re-
installation. Repeat procedure on passenger side.
3. Working on the driver side, remove the stock shock
from the stock location 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 and
need to be ordered as a separate part number, Tuff
Country EZ-Ride Suspension recommends using a
23” fully extended nitrogen gas shocks. Repeat
procedure on passenger side.
4. Remove the stock front differential skid plate. The
stock front differential skid plate and hardware can be
discarded.
5. Remove the stock front driveline from the stock front
differential and the stock transfer case. Save the stock
driveline and hardware for later re-installation.
6. Measure exposed threads on the torsion bar adjusting
bolt and record measurement here for a later reference.
Record Driver Side measurement here:______________
Record Passenger Side measurement here:__________
See Illustration # 1
7. Working on the driver side, attach the torsion bar
removing tool, making sure that the unloading bolt in the
center of the torsion bar removing tool is in the small
divot of the stock torsion bar key. Adjust the torsion bar
key up high enough so that the stock small metal
adjusting block and bolt can be removed. Save the stock
hardware for later re-installation. Repeat procedure on
passenger side.
See Illustration # 2
8. Mark both torsion bars before removal so that they can
be re-installed back into the same location. Example:
Driver vs. Passenger and front vs. rear. Tap the stock
torsion bars forward until the stock torsion bar cross
member can be removed. Once you tap the stock torsion
bar out of the stock torsion bar cross member, the stock
torsion bar key will fall out. Set the stock torsion bar key a
side for later re-installation. Repeat procedure on the
passenger side.
9. Working on the driver side, remove the stock bolt that
connect the stock torsion bar cross member to the stock
mounting point and save the stock hardware for later re-
installation. Special Note: The stock mounting point is
on the inside of the stock frame rail. Repeat procedure
on the passenger side. Remove the stock torsion bar
cross member from the stock location and set a side for
later re-installation.
10. Working on the driver side, slide the stock torsion bar
out of the stock rear lower control arm and set a side for
later re-installation. Repeat procedure on passenger side.
11. Working on the driver side, remove the stock brake
line bracket from the stock upper control arm bracket and
save the stock hardware for later re-installation. Repeat
procedure on passenger side.
12. Working on the driver side, remove the stock front
sway bar end link from the stock sway bar and the stock
lower control arm location. The stock end link and
hardware may be discarded. Repeat procedure on
passenger side. Special Note: At this time, invert the
stock sway bar.
13. Working on the driver side, remove the (2) stock bolts
that connect the stock brake caliper to the stock spindle.
Save the stock hardware for later re-installation. Using a
bungee cord, carefully tie
the stock brake caliper up and
out of the way in the fender well. Special Note: Take
special care not to kink or over extend the stock
brake line.
14. Working on the driver side, remove the stock rotor
from the stock location and set a side for later re-
installation.