Tuff Country 16993 - GM 01-09 K2500 HD 4wd 6 kit - Manual (Page 10)

and Front vs. Rear. Working on the driver side, slide the
stock torsion bar back into the stock rear lower control arm.
Slide the stock torsion bar far enough forward so that the
stock torsion bar cross member can be re-installed. Repeat
procedure on the passenger side.
75. Locate the stock torsion bar cross member and stock
hardware that was removed from step # 4. Install the stock
torsion bar cross member to the newly installed torsion bar
cross member relocation brackets and secure using the
stock hardware. Make sure to use thread locker or lock tite
and torque to 90 ft lbs.
Photo # 69
76. Move back to the new 7/16” x 1 1/2” bolts attaching the
new driver and passenger side torsion bar cross member
relocation bracket to the stock frame rail and add some
thread locker or lock tite and torque all (8) bolts to 70 ft lbs.
77. Locate the stock torsion bar keys that were removed in
step # 3. Working on the driver side, install the stock torsion
bar key back into the stock location in the stock torsion bar
cross member. Slide the stock torsion bar back into the
previously installed torsion bar key. Repeat procedure on
the passenger side. Special note: Make sure that the
torsion bars are installed in the stock location in the
stock lower control arm and the stock torsion bar key.
Refer to the marks that were scribed in step # 3.
78. Locate the torsion bar adjusting blocks and hardware
that was removed from step # 2. 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 re-installed back into the stock location.
Remove the torsion bar removal tool front he stock torsion
bar cross member. Special note: Set the driver and the
passenger side torsion bar bolt so that there is 3/4” of
thread showing between the head of the bolt and the
adjusting block. Repeat on the passenger side.
79. 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 #
9, invert the stock sway bar now. Working on the driver
side, install the new sway bar end link and hardware into
the stock location. Do not tighten at this point. Repeat
procedure on passenger side.
80. Locate the stock skid plate that was removed in step #
7. Referring to photo # 70, measure 2 5/8” from the leading
edge of the stock skid plate and scribe a mark. Carefully cut
along the scribed mark.
Photo # 70 / 2 5/8” measurement
Photo # 71 / post cut view
81. Locate the (3) stock upper skid plate mounting
hardware that we removed in step # 7. Install the newly
modified skid upper skid plate to the stock upper location
using the stock hardware. Special note: Make sure to use
thread locker or lock tite and torque to 28 ft lbs.
82. Holding the stock skid plate to the front cross member,
carefully drill a 3/16” hole through the stock skid plate and
the stock front cross member.
Photo # 72
83. Locate (1) 1/4” x 1” self threading bolt from hardware
bag 16985NB1. Secure the stock skid plate to the stock
cross member using the new 1/4” x 1” self threading bolt.
Photo # 73
84. Locate (2) front lateral compression arms. Locate (8)
PB2408 poly bushings from hardware bag 16985PL. Also,
locate (4) S10058 crush sleeves from hardware bag
16985SL. Install the new poly bushings into each end of the
new front lateral compression arms. Next, install the new
crush sleeve into the newly installed poly bushings.
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.
85. Locate (2) 1/2” x 3 1/2” bolts, (4) 7/16” USS flat
washers and (2) 1/2” unitorque nuts from hardware bag
16985NB3. Working on the driver side, secure (1) new
lateral compression arm to the new front lateral
compression arm mount on the newly installed rear cross
member using the new 1/2” x 3 1/2” bolt and hardware. Do
not tighten at this point and make sure to use thread
locker or lock tite. Repeat procedure on the passenger
side.
86. Working on the driver side, measure from the new
lateral compression arm mount located on the previously
installed rear cross member back to the center of the stock
transfer case cross member. Special note: Chevy has a
variation on the placement of the stock transfer case
cross member. Your measurement should either be 31”
or 32” long. Remember the measurement, this
measurement is needed in step # 87.
87. Locate (2) 1/2” x 3 1/2” bolts, (4) 7/16” USS flat
washers and (2) 1/2” unitorque nuts from hardware bag
16985NB3. Also, locate (2) rear lateral compression
mounts. Working on the driver side, if the measurement
that you had in step # 86 was 31”, secure the new lateral
compression arm to the new rear lateral compression arm
mount rear hole using the new 1/2” x 3 1/2” bolt and
hardware. Do not tighten at this point. If the measurement
that you had in step # 86 was 32”, secure the new lateral
compression arm to the new rear lateral compression arm