Tuff Country 16993 - GM 01-09 K2500 HD 4wd 6 kit - Manual (Page 11)

mount front hole using the new 1/2” x 3 1/2” bolt and
hardware. Do not tighten at this point. Hold the new
lateral compression arm and mount up to the stock transfer
case cross member and scribe a mark on the transfer case
cross member where the new mount will go. Repeat
procedure on the passenger side.
88. Working on the driver side, carefully drill a 5/16” hole in
the bottom of the stock transfer case cross member. Refer
to the mark that was scribe in step # 87. Repeat procedure
on the passenger side.
89. Working on the driver side lateral compression arm,
remove the new lateral compression arm mount from the
new lateral compression arm and save the new hardware
for later re-installation. Repeat procedure on the passenger
side.
90. Locate (2) 3/8” x 1 1/2” self threading bolts from
hardware bag 16985NB1. Also, locate the new rear lateral
compression arm mounts that were removed from step #
89. Working on the driver side, secure the new rear lateral
compression arm mount to the previously drilled hole in the
stock transfer case cross member. Use the new 3/8” x 1
1/2” self threading bolt. Torque to 28 ft lbs. Make sure to
use thread locker or lock tite. Repeat procedure on the
passenger side. Special note: Make sure that the longer
leg of the new lateral compression arm is towards the
rear of the vehicle. Refer to Photo # 74 for proper
placement.
Photo # 74
91. Working on the driver side, 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
Photo # 75 / Front Location
Photo # 76 / Rear Location
92. Re-install the tires and wheels and carefully lower the
vehicle to the ground.
93. Check and double check to make sure that all steps
were performed properly and check again.
94. There are still a couple of steps that need to be
completed on the front end but these steps will not be
completed until the rear end installation is completed and
the weight of the vehicle is on the ground. These steps
include the tightening of the front sway bar end links and
the tightening of the new hardware that connects the stock
lower control arms to the newly installed front and rear
cross member.
Rear end installation:
95. To begin installation, block the front tires of the vehicle
so that the vehicle is stable and can’t roll forward. Safely lift
the rear 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 wheels and tires from
both sides.
96. Working on the driver side, remove the stock shock
from the stock upper and lower mounting points and save
the stock hardware for later re-installation. The stock
shocks may be discarded. 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. Repeat procedure on the passenger
side.
97. Place a pair of hydraulic floor jacks under the rear
differential and carefully raise up on both hydraulic floor
jacks at the same time until they come into contact with the
rear differential.
98. Working on the driver side, remove the stock u-bolts
from the stock location and discard the stock u-bolts and
hardware. Set the stock upper and lower u-bolt plates a
side for later re-installation. Repeat procedure on
passenger side.
99. 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.
100. 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.
101. Carefully raise up on both hydraulic floor jacks at the
same time until the stock spring assembly sits flush with the
newly installed 2” lifted block.
102. Locate (4) 5/8” x 2 3/4” x 14” square u-bolts. Also,
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 # 98.
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.
103. 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