Tuff Country 16993 - GM 01-09 K2500 HD 4wd 6 kit - Manual (Page 7)

tighten the stock and new hardware associated with
the front differential. If bolts are over tightened, the
stock front differential could crack. Also, Tuff Country
EZ-Ride Suspension highly recommends adding a
minimum of 1 pint, but no more that 1 1/2 pints, of
proper front differential fluid into the front differential.
To achieve this, you may have to fill the differential
with it on its side or you may have to insert the fluid
through the vent tube opening. On occasion, the
customer may find burping of fluid coming out of the
front vent tube.
Photo # 43
39. Locate the new passenger side differential relocation
bracket and the stock hardware that was removed from
step # 34. Working on the passenger side, install the new
passenger side differential relocation bracket into the stock
upper location and secure using the stock hardware. Do
not tighten at this point. Special note: There is a “6F” cut
out in this bracket, the “6F” will go towards the front of
the vehicle and also if you are standing on the
passenger side wheel well looking at the new
passenger side differential relocation bracket, you
should not be able to see the mounting hardware. This
will help you make sure that the bracket is installed
properly.
40. With the help from a buddy, carefully lift the modified
front differential back onto a pair of hydraulic floor jacks and
move the hydraulic floor jacks back underneath the vehicle
so that the newly modified front differential can be
re-installed.
41. Locate (2) 9/16” x 1 3/4” bolts, (4) 1/2” USS flat
washers and (2) 9/16” unitorque nuts from hardware bag
16985NB4. Carefully install the passenger side of the stock
front differential to the previously installed passenger side
differential drop bracket. Secure using the new 9/16” x 1
3/4” bolts and hardware. Do not tighten at this point. Also
at this time, use a tie down strap and tie the driver side of
the front differential up and out of the way so that the
hydraulic floor jacks can be removed. Remove both
hydraulic floor jacks from under the front differential.
Photo # 44
42. Locate (2) 7/16” x 1 1/2” bolts and (2) 3/8” USS flat
washers from hardware bag 16985NB2. Working on the
driver side, install (1) 7/16” x 1 1/2” bolt and hardware
through the stock cross member and let hang. Repeat
procedure on the passenger side.
Photo # 45
43. Locate the new front cross member. Also, locate the
stock lower control arm front mounting hardware that was
removed in step # 25. Install the new front cross member to
the stock front lower control arm pockets and secure using
the stock hardware. Special note: Make sure to install
the stock hardware from the front of the vehicle
towards the rear of the vehicle. Do not tighten at this
point. Also, make sure that the 7/16” x 1 1/2” bolts that
were installed in step # 42 slide through the holes in
the new front cross member.
Photo # 46
44. Locate the new rear cross member. Also, locate the
stock lower control arm rear mounting hardware that was
removed in step # 25. Install the new rear cross member to
the stock rear lower control arm pockets and secure using
the stock hardware. Special note: Make sure to install
the stock hardware from the front of the vehicle
towards the rear of the vehicle. Do not tighten at this
point.
Photo # 47
45. Carefully loosen the tie down strap and allow the driver
side of the stock front differential to seat properly into the
rear cross member and the newly installed driver side
differential relocation bracket can be installed to the front
cross member. Do not remove the tie down strap at this
point.
46. Locate the stock hardware that was removed from step
# 33. Secure the newly installed front differential relocation
bracket to the newly installed front cross member. Secure
using the stock hardware. Do not tighten at this point.
Photo # 48
47. Locate the stock hardware that was removed from step
# 26. Install the rear portion of the front differential into the
tab on the newly installed rear cross member. Secure using
the stock hardware. Do not tighten at this point. Once
this bolt is installed, carefully remove the tie down strap that
is holding the driver side of the front differential.
Photo # 49
48. Locate (2) 5/8” x 4 1/2” bolts, (2) 5/8” x 5 1/2” bolts, (8)
9/16” USS flat washers and (4) 5/8” unitorque nuts from
hardware bag 16985NB5. Also, locate the stock lower
control arms that were removed from step # 25. Working on
the driver side, install the stock lower control arm into the
newly installed front cross member and secure using the
new 5/8” x 4 1/2” bolt and hardware. Do not tighten at this
point. Install the stock lower control arm into the newly
installed rear cross member and secure using the new 5/8”
x 5 1/2” bolt and hardware. Do not tighten at this point.
Repeat procedure on the passenger side.
Photo # 50
49. Using a hydraulic floor jack, carefully raise up on the
front portion on the newly installed front cross member until
the newly installed front cross member sits flush with the
stock front cross member.
50. Locate (2) 3/8” USS flat washers and (2) 7/16”
unitorque nuts from hardware bag 16985NB2. Working on
the driver side, secure the newly installed front cross
member to the stock front cross member using the new
7/16” x 1 1/2” bolts that were installed in step # 42 and the