Tuff Country 16990 - GM 2001-06 HD 3500 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:__________________________
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. Remove the stock front upper and lower skid plates.
The stock lower skid plate and stock hardware may be
discarded. Save the stock upper skid plate and the (3)
stock upper bolts for later re-installation.
3. Remove the stock front driveline from the stock
location on the front differential and the transmission.
Save the stock driveline and hardware for later re-
installation.
4. Working on the driver side, remove the stock hardware
on the top of the stock shock. The upper stock hardware
may be discarded. Remove the stock hardware on the
lower shock mount and save the stock hardware for later
re-installation. The stock shock may be discarded.
Special note: New longer front 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 23” fully extended nitrogen gas shock.
Repeat procedure on the passenger side.
5. Measure the exposed threads on the torsion bar
adjustment bolt and record measurement here for a later
reference.
Record driver side measurement here:______________
Record passenger side measurement here:__________
Photo # 1
6. Working on the driver side, attach the torsion bar
removing tool to the stock torsion bar cross member,
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. Set the stock torsion bar block and
hardware a side for later re-installation. Repeat
procedure on passenger side.
7. 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.
8. Working on the driver side, remove the stock hardware
that connects the stock torsion bar cross member to the
stock mounting point. Set the stock hardware a side 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.
9. 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.
10. Working on the driver side, remove the stock sway
bar end link from the stock location and discard the stock
end link and all the stock hardware. Repeat procedure on
the passenger side. Special note: At this time, invert
the stock sway bar.
11. Working on the driver side, remove the stock nut that
connects the stock outer tie rod ball joint to the stock
steering knuckle. Set the stock nut a side for later re-
installation. Carefully break the stock taper on the stock
outer tie rod ball joint and remove the stock outer tie rod
from the stock knuckle. Special note: Take special care
not to rip or tear the stock outer tie rod ball joint dust
boot.
12. Working on the driver side, remove the stock brake
line bracket that connects to the stock steering knuckle
and discard the stock hardware. Next, remove the stock
brake line mounting point that connects to the stock
upper control arm. Save the stock hardware for later re-
installation. Also, remove any other brake line mounting
points on the stock steering knuckle and stock upper
control arm.
13. Working on the driver side, locate the ABS line quick
disconnect located above the stock upper control arm.