Tuff Country 16990 - GM 2001-06 HD 3500 6 kit - Manual (Page 5)

Disconnect the ABS lines from each other. Also,
disconnect the ABS line from any other mounting points.
14. Working on the driver side, remove the (2) stock bolts
that connect the stock brake caliper to the stock knuckle.
Save the stock hardware for later re-installation. Using a
bungee cord, carefully tie the stock brake caliper up and
out of the way in the fender well. Special note: Take
special care not to kink or over extend the stock
brake line.
15. Working on the driver side, remove the stock rotor
and set a side for later re-installation.
16. Working on the driver side, remove the stock cap
right in the middle of the stock hub assembly. Set the
stock cap a side for later re-installation.
17. Working on the driver side, remove the stock
hardware that connects the stock axle to the stock hub
assembly. Save the stock hardware for later re-
installation.
18. 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.
Photo # 2
19. Working on the driver side, remove the (6) stock bolts
holding the inner CV axle to the stock front differential.
The stock hardware may be discarded. Carefully remove
the stock CV axle from the stock location and set the
stock CV axle a side for later re-installation. Special
note: During the removal of the stock CV axle, take
special care not to damage the threads of the CV axle
or the CV axle dust boot.
20. Working on the driver side, loosen but do not remove
the stock nut that connects the stock upper control arm
ball joint to the stock steering knuckle. Carefully break
the stock taper by striking the stock knuckle with a
hammer. Special note: Take special care not to
damaged the stock upper control arm ball joint or rip
the stock upper control arm ball joint dust boot. For
now, leave the stock upper control arm attached to the
stock knuckle. We want to just break the stock taper for
now.
21. Working on the driver side, loosen but do not remove
the stock nut that connects the stock lower control arm
ball joint to the stock steering knuckle. Carefully break
the stock taper by striking the stock knuckle with a
hammer. Special note: Take special care not to
damaged the stock lower control arm ball joint or rip
the stock lower control arm ball joint dust boot. For
now, leave the stock lower control arm attached to the
stock knuckle. We want to just break the stock taper for
now.
22. Working on the driver side, move back to the stock
nuts holding the stock upper control arm ball joint and the
stock lower control arm ball joint to the stock steering
knuckle and remove completely. Save the stock
hardware for later re-installation. Carefully remove the
stock hub assembly and the stock steering knuckle from
the stock location and set a side for later re-installation.
23. Working on the driver side stock hub assembly,
remove the (4) stock bolts that connect the stock hub
assembly to the stock steering knuckle. Save the stock
hardware and stock hub assembly for later re-installation.
Also, carefully remove the stock rubber “O” ring located
in the stock steering knuckle and save for later re-
installation. A new steering knuckle is used, the stock
steering knuckle can be discarded.
24. Locate the new driver side steering knuckle. Using
the stock rubber “O” ring that was removed in step # 23,
carefully re-install the stock rubber “O” ring into the new
driver side knuckle. Using the stock hardware that was
removed from step # 23, secure the new driver side
steering knuckle to the stock hub assembly. Special
note: Make sure that the ABS line fits in the grove of
the new steering knuckle once the hub assembly has
been torqued down. Torque to 133 ft lbs. Make sure
to use thread locker or lock tite.
Photo # 3
25. Set the new driver side steering knuckle and hub
assembly a side for later re-installation.
26. Working on the driver side, remove the stock front
and rear hardware that connects the stock lower control
arm to the stock location. Set the stock hardware and the
stock lower control arm a side for later re-installation.
27. Repeat step’s 11 - 26 on the passenger side.
28. Working on the driver side, remove the stock bolt that
connects the lower rear portion of the stock front
differential to the stock rear cross member. Save the
stock hardware for later re-installation.
Photo # 4
29. Working on the passenger side, remove the (2) stock
bolts that connect the stock rear cross member to the
stock passenger side rear lower control arm mounting
point. The (2) stock bolts may be discarded.
Photo # 5
30. Working on the driver side, measure 2” towards the
inside of the vehicle from the stock rear lower control arm
mounting point, scribe a mark on the stock rear cross
member. Using a hacksaw or suitable cutting tool,
carefully cut off the stock rear cross member along the
line that was scribed earlier in this step. The stock rear
cross member may be discarded. Special note: When
making this cut, make sure that you cut all the way
through the stock rear lower control arm mounting