Tuff Country 16840 - GM 94-98 K1500 Tahoe 4-door 6 kit - Manual (Page 8)

57. 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.
58. Locate the stock rotors that were removed from step
# 14. Working on the driver side, install the stock rotors
into the stock location. Repeat procedure on the
passenger side.
59. Locate the stock hardware that was removed from
step # 13. Working on the driver side, re-install the stock
brake caliper to the new spindle using the stock
hardware. Make sure to use thread locker or lock tite.
Torque to 90 ft lbs. Repeat procedure on the passenger
side.
60. 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.
61. 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 from hardware bag
16810NB1. Also, locate 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. Do not tighten at this
point. Make sure to use thread locker or lock tite.
Next, secure the stock brake line bracket to the newly
installed brake line relocation 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
62. Locate (2) new sway bar end links, (8) sway bar end
links washers and (8) sway bar end links bushings from
hardware bag 16810SL. Also, locate (2) 3/8” x 10” bolts
and (2) 3/8” unitorque nuts from hardware bag
16810NB1. 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
63. 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.
64. Locate (2) new torsion bar drop brackets, (4) PB4902
poly bushings and (2) 1/2” x 1 1/2” anti crush sleeve from
hardware bag 16840SL. 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 torsion bar drop brackets. This
will increase the life of the bushing as well as prevent
squeaking.
65. 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.
66. 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 from hardware bag 16840NB2. 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. Do not tighten at this point. 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
67. Locate the driver side torsion bar that was removed in
step # 10. 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.
68. Locate the stock torsion bar cross member and stock
torsion bar hardware that was removed from step # 9.
Working on the driver side, secure the stock torsion bar
to the newly installed torsion bar drop bracket and secure
using the stock hardware. Make sure to use thread
locker or lock tite. Do not tighten at this point. Repeat
procedure on the passenger side. Once the driver and
passenger side torsion bar stock hardware has been
installed torque the stock hardware to 95 ft lbs. Move
back to the new 7/16” x 1 1/2” bolts and hardware that is
holding the new torsion bar drop brackets to the stock
frame rail and torque to 76 ft lbs.
See Illustration # 23
69. Locate the stock driver and passenger side torsion
bar key’s that were removed from step # 8. Working on
the driver side, install the stock torsion bar key back into