Tuff Country 16840 - GM 94-98 K1500 Tahoe 4-door 6 kit - Manual (Page 5)

15. Working on the driver side, remove the stock nut that
connects the stock axle to the stock hub assembly. Save
the stock nut for later re-installation.
See Illustration # 3
16. Working on the driver side, disconnect the ABS lines
from each other. Also disconnect the ABS line from any
other mounting points.
17. Working on the driver side, remove the stock nut that
connects the stock outer tie rod ball joint to the stock
spindle. Save the stock hardware for later re-installation.
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.
18. Working on the driver side, remove the stock cotter
pin from the stock castle nut that connects the stock
upper control arm ball joint to the stock steering knuckle.
Save the stock cotter pin for re-installation. Loosen
the stock nut that connects the stock upper control arm
ball joint to the stock steering knuckle. Do not remove
the stock nut completely. Carefully break the stock
taper on the stock upper control arm ball joint. Special
Note: Take special care not to rip or tear the stock
ball joint dust boot.
19. Working on the driver side, remove the stock cotter
pin from the stock castle nut that connects the stock
lower control arm ball joint to the stock steering knuckle.
Save the stock cotter pin for re-installation. Loosen
the stock nut that connects the stock lower control arm
ball joint to the stock steering knuckle. Do not remove
the stock nut completely. Carefully break the stock
taper on the stock lower control arm ball joint. Special
Note: Take special care not to rip or tear the stock
ball joint dust boot.
20. Working on the driver side, move back to the stock
nuts holding the upper control arm ball joint and the lower
control arm ball joint to the stock spindle and remove
completely. Save the stock hardware for later re-
installation.
21. Working on the driver side, use a suitable removal
tool to remove the stock axle from the stock hub
assembly. Special Note: Take special care not to
damage the stock threads on the stock axle.
22. Working on the driver side, carefully remove the stock
hub assembly and the stock spindle from the stock
location.
23. Working on the driver side stock hub assembly,
remove the (3) stock bolts that connect the stock hub
assembly to the stock spindle. Save the stock hardware
and stock hub assembly for later re-installation. Carefully
remove the stock axle seal from the stock spindle and set
a side for later re-installation. A new spindle is used, the
stock spindle can be discarded.
24. Locate the new driver side spindle. Carefully install
the stock axle seal that was removed from step # 23 to
the new driver side spindle. Using the stock hardware
that was removed from step # 23, secure the new driver
side spindle to the stock hub assembly. Torque to 92 ft
lbs. Special Note: Make sure to use thread locker or
lock tite.
25. Set the new driver side spindle and hub assembly a
side for later re-installation.
26. 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
27. Working on the driver side, unbolt and remove the (6)
stock bolts holding the inner CV axle to the stock
differential. Discard the stock hardware. Set the stock CV
axle a side for later re-installation.
28. 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 arm aside for later re-installation.
29. Repeat step’s 13 - 28 on the passenger side.
30. 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 # 30. Clean and dress up
any exposed metal.
See Illustration # 5
31. Place a pair of hydraulic floor jacks under the front
differential, and carefully raise up on both hydraulic floor
jacks at the same time, until they come into contact with
the front differential.
32. Locate the wiring harness that connects the 4WD
control panel to the front differential. Disconnect the 4WD
wiring harness from the front differential. Tie the 4WD
wiring harness up and out of the way. Special Note:
Take special care not to kink the 4WD wiring harness.
33. Disconnect any other vent hoses and/or wiring that is
connected to the front differential.