Tuff Country 16990 - GM 2001-06 HD 3500 6 kit - Manual (Page 11)

teflon inserts located on the stock over load in the stock
spring assembly. Discard the stock teflon inserts. Install
(1) 6052 (taller poly bump stop) in front location on the
stock spring assembly. Secure using the new 3/8”
hardware. Torque to 28 ft lbs. Install (1) 6199 (shorter
poly bump stop) in the rear location on the stock spring
assembly. Secure using the new 3/8” hardware. Torque
to 28 ft lbs. Repeat procedure on the passenger side.
Illustration # 24 / front location
Illustration # 25 / rear location
If the vehicle that you are working on has a 2 piece
rear drive shaft, please follow step 98 — 99
If the vehicle that you are working on does not have a
2 piece rear drive shaft, please skip to step # 100
98. Carefully place a hydraulic floor jack under the rear
driveline near the stock carrier bearing mounting location.
Raise up on the hydraulic floor jack until it comes into
contact with the rear driveline. Remove the stock
hardware that connects the stock carrier bearing to the
stock location and discard the stock hardware. Carefully
lower down on the hydraulic floor jack allowing enough
room for the new rear carrier bearing drop bracket to be
installed.
99. Locate the new rear carrier bearing drop. Locate (2)
S10007 crush sleeves from hardware bag 16985SL.
Also, locate (2) 3/8” x 3 1/2” bolts, (4) 5/16” USS flat
washers and (2) 3/8” unitorque nuts from hardware bag
16985NB1. Install the new carrier bearing drop bracket
between the stock carrier bearing and the stock mounting
point. Secure using the new 3/8” x 3 1/2” bolts, crush
sleeves and hardware. Torque to 28 ft lbs. Carefully
remove the hydraulic floor jack from under the rear drive
line. Special note: The stock carrier bearing mount
has slotted holes, make sure that when you torque
the new 3/8” hardware that the new carrier bearing is
pushed as far forward as possible.
Illustration # 26
100. Install the tires and wheels and carefully lower the
vehicle to the ground.
Step # 101 and # 102 needs to be performed with the
weight of the vehicle on the ground.
101. Working on the driver side, move back to the new
5/8” hardware attaching the stock lower control arms to
the newly installed one piece lower sub frame and torque
to 125 ft lbs. Repeat procedure on the passenger side.
102. Locate (2) 3/8” x 7” bolts and (2) 3/8” unitorque nuts
from hardware bag 16985NB1. Locate (2) S10067 sway
bar end link sleeves from hardware bag 16985SL. Also,
locate (8) sway bar end link poly bushings and (8) sway
bar end link washers from hardware bag 16985PL.
Special note: If you did not Invert the stock sway bar
in step # 10, invert the stock sway bar now. Working
91. Carefully lower down both hydraulic floor jacks at the
same time approximately 5”. Special note: Take special
care not to over extend any brake lines and/or hoses.
92. Locate (2) new rear 4” lifted blocks. Working on the
driver side, install the new 4” lifted block into the stock
location. Repeat procedure on the passenger side.
93. Carefully raise up on both hydraulic floor jacks at the
same time until the stock spring assembly sits flush with
the newly installed 4” lifted block.
94. Locate (4) 5/8” x 2 3/4” x 16 1/2” square u-bolts.
Locate (8) 5/8” u-bolt high nuts and (8) u-bolt washers
from hardware bag 58NW. Also, locate the stock upper
and lower u-bolt plates that were removed from step #
90. Working on the driver side, install the new u-bolts into
the stock location and secure using the new 5/8” high
nuts and washers. Special note: Make sure to re-install
the stock upper and lower u-bolt plates. Torque to 135
ft lbs. Repeat procedure on passenger side.
95. Working on the driver side. Special note: New
longer rear shocks are needed, if you have not
already ordered shocks, please contact Tuff Country
or your local Tuff Country dealer and order the
proper shocks. Tuff Country recommends using a
30” fully extended nitrogen gas shock. Locate (2)
S10074 from hardware bag 16985SL. Working on the
new shocks, install the new shock bushing into the upper
and lower eyelets of the new shocks. Next, install the
new shock sleeves into the previously installed shock
bushings. Special note: Use the new S10074 shock
sleeves and the proper shock sleeves that are
located in the new sleeve bag that was provide with
your new shocks. Make sure to use a lithium or moly
base grease prior to inserting the new lower shock
bushings and sleeves into the new lower shock
eyelet. 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 that was removed in step # 88.
Special note: Make sure to use thread locker or lock
tite and torque to 75 ft lbs. Repeat procedure on the
passenger side. Special note: Tuff Country EZ-Ride
Suspension highly recommends that the shocks are
installed with shock boots. If shock boots are not
installed, damaged my occur to the piston of the new
shock.
Photo # 23 / complete installation of the new blocks,
u-bolts and shocks.
96. Carefully remove the (2) hydraulic floor jacks from
under the rear differential.
97. Locate (2) 6199 poly bump stops and (2) 6052 poly
bump stops from hardware bag 16985PL. Also, locate (4)
3/8” unitorque nuts and (4) 5/16” USS flat washers from
hardware bag 16985NB1. Working on the driver side of
the stock rear spring assembly. Remove the (2) stock