Tuff Country 16840 - GM 94-98 K1500 Tahoe 4-door 6 kit - Manual (Page 9)

the stock torsion bar cross member. Holding the stock
torsion bar key into the stock location, slide the driver
side torsion bar into the stock torsion bar key. Repeat
procedure on the passenger side.
70. Locate the small metal adjusting blocks and bolts that
were removed from step # 7. 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 # 6 and adjust
the stock bolt to the stock location. Repeat procedure on
passenger side. Remove the torsion bar adjusting tool.
71. 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 vent
hose. Refer to the torque setting sheet on the first
page of the installation manual and torque to proper
settings.
72. Locate (2) 5/8” x 2 1/2” poly shock bushings and (2)
1/2” x 2 1/2” shock sleeves from hardware bag 16810SL.
Also, locate 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.
73. 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.
74. Locate (2) rear lateral compression mounts. (2) 1/2” x
1 1/4” spacer sleeves from hardware bag 16810SL. (2)
1/2” x 2 1/4” bolts, (4) 1/2” flat washers, (2) 1/2” unitorque
nuts and (2) 1/2” lock washers from hardware bag
16810NB3. Working on the driver side stock transfer
case cross member carefully drill a 1/2” hole into the
upper part of the stock transfer case cross member.
Special Note: There is an existing hole in the lower
part of the stock transfer case cross member, use
this hole as a guide to drill the new 1/2” hole in the
upper part of the stock transfer case cross member.
Install the new rear lateral compression arm mount to the
stock transfer case cross member. Secure using (1) 1/2”
x 2 1/4” bolt, spacer sleeve and hardware. Torque to 38
ft lbs. Special Note: The new 9/16” x 1 1/4” anti crush
sleeve needs to go into the stock transfer case cross
member, this will not allow the transfer case cross
member to crush when the bolt is torqued. Repeat
procedure on passenger side.
See Illustration # 24
75. Locate (2) front lateral compression arms. (8)
PB2408G poly bushings and (4) 9/16” x 2 1/8” crush
sleeves. Install the new poly bushing into each end of the
new front lateral compression arms. Next, install the new
anti crush sleeve into the newly installed poly bushing.
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.
76. Locate (4) 1/2” x 3 1/2” bolts, (8) 1/2” flat washers, (4)
1/2” unitorque nuts and (4) 1/2” lock washers from
hardware bag 16810NB3. Working on the driver side,
secure (1) new lateral compression arm to the new front
lateral compression arm mount on the newly installed
one piece lower sub frame and secure using the new 1/2”
x 3 1/2” bolt and hardware. Do not tighten at this point.
Make sure to use thread locker or lock tite. Next,
secure the new lateral compression arm to the previously
installed rear lateral compression arm mount. Secure
using the new 1/2” x 3 1/2” bolt and hardware. Torque the
front and rear mount to 85 ft lbs. Repeat procedure on
the passenger side
See Illustration # 25 / Front Location
See Illustration # 26 / Rear Location
77. Re-install the tires and wheels and carefully lower the
vehicle to the ground.
78. 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 setting sheet on the first page of the
installation manual.
79. 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!