Tuff Country 16993 - GM 01-09 K2500 HD 4wd 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:___________________________
Front end installation:
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 the
passenger side. Next, remove the front wheels and tires
from both sides.
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 removed. Set the stock torsion bar block and hardware
aside for later re-installation. Repeat procedure on
passenger side.
Photo # 1 / Photo # 2
3. 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
aside for later re-installation. Repeat procedure on the
passenger side.
Photo # 3 / Photo # 4
4. 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 aside 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
aside for later re-installation.
Photo # 5
5. Working on the driver side, slide the stock torsion bar out
of the stock rear lower control arm and set aside for later
re-installation. Repeat procedure on passenger side.
6. Remove the stock lower skid plate and discard the stock
lower skid plate and the stock hardware.
Photo # 6
7. Remove the stock upper skid plate from the stock
location. Save the stock upper skid plate and stock
hardware for later re-installation.
Photo # 7
8. 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.
9. 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.
10. 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 aside 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: Hitting the stock
knuckle with a hammer will make removal of the stock
outer tie rod easier. Take special care not to rip or tear
the stock outer tie rod ball joint dust boot. Repeat
procedure on the passenger side.
Photo # 8 / Photo # 9
11. 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 and save the
stock hardware for later re-installation. Repeat procedure
on the passenger side.
12. Working on the driver side, locate the ABS line quick
disconnect located above the stock upper control arm.