Tuff Country 16993 - GM 01-09 K2500 HD 4wd 6 kit - Manual (Page 9)

65. Working on the driver side, reconnect the stock ABS
lines back together. Also reconnect all other stock
mounting points on the stock ABS line. Repeat procedure
on the passenger side.
66. Locate the stock rotors that were removed in step # 14.
Working on the driver side, install the stock rotor into the
stock location. Repeat procedure on the passenger side.
67. Locate the stock brake caliper hardware that was
removed in step # 13. Working on the driver side, re-install
the stock brake caliper to the newly installed knuckle and
secure using the stock hardware. Make sure to use thread
locker or lock tite and torque to 76 ft. lbs. Repeat
procedure on the passenger side.
68. Locate the stock brake line hardware that was removed
in step # 11. Working on the driver side, secure the stock
brake line bracket to the stock upper control arm using the
stock hardware. Carefully open up the stock bracket line
bracket. Next, secure the stock brake line bracket to the
new brake line bracket on the inside of the new knuckle.
Secure using the hardware that was supplied on the new
brake line bracket. Also, use some shock ties that were
packaged with the installer copy of the installation manual
and shock tie the stock ABS line and the stock brake lines
together. Repeat procedure on the passenger side.
Special note: In this step make sure that once you
shock tie the stock brake lines and ABS lines to the
spindle, there will be no contact on the new wheels and
tires. If contact occurs, the stock brake lines or ABS
lines may be damaged.
Photo # 65 / Photo # 66
69. Locate the new front shocks. 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. Locate (2) S10073 from hardware
bag 16985SL. Also, locate (4) PB8297 upper shock
bushings and (4) S10107 upper shock washers from
hardware bag 16985PL. Working on the new shocks, install
the new lower shock bushing into the lower eyelet and
install the new S10073 shock sleeves into the previously
installed bushings. Special note: Make sure to use a
lithium or moly base grease prior to inserting the new
lower shock bushings and sleeves into the new lower
shock eyelet. This will increase the life of the bushing
as well as prevent squeaking. Working on the driver side,
install the new shock into the stock location using the stock
hardware on the bottom mount that was removed in step #
8 and the new hardware on the top mount. Repeat
procedure on the passenger side. Special note: Make
sure to use the new upper bushings and upper shock
washers. Torque the lower shock mount to 65 ft lbs.
and the upper hardware to 22 ft lbs. Repeat on
passenger side. Special note: Tuff Country EZ-Ride
Suspension highly recommends that the shocks are
installed with shock boots. If shock boots are not
installed, damage may occur to the piston of the new
shock.
70. Locate the stock outer tie rod ball joint hardware that
was removed from step # 10. Working on the driver side,
install the stock outer tie rod to the new steering knuckle
using the stock hardware. Make sure to use thread locker
or lock tite and torque to 53 ft. lbs. Special note: The new
steering knuckle has a reverse taper on it where the
stock outer tie rod mounts to it, make sure to install the
outer tie rod the proper way. The stock outer tie rod nut
will now be installed on the bottom side of the new
steering knuckle. Repeat procedure on the passenger
side.
71. Locate (2) new torsion bar cross member relocation
brackets. Locate (4) MO2220 poly bushings from hardware
bag 16985PL. Also, locate (2) S10074 sleeves from
hardware bag 16985SL. Install the new poly bushings and
sleeves into the new torsion bar cross member relocation
brackets. Special note: Make sure to use a lithium or
moly base grease prior to inserting the new bushings
and sleeves into the new torsion bar cross member
relocation brackets. This will increase the life of the
bushing as well as prevent squeaking.
72. Working on the driver side, hold the new torsion bar
cross member relocation bracket to the new location on the
stock frame rail. Special note: Using the larger cut out
holes in the torsion bar cross member relocation
bracket over the stock rivets on the bottom of the stock
frame rail with help center the new torsion bar cross
member relocation bracket. With the new torsion bar
cross member relocation bracket in place, use a pair of vice
grips and secure the new torsion bar drop bracket to the
stock frame rail. Using the new torsion bar cross member
relocation bracket as a guide, carefully drill (4) 7/16” holes
into the stock frame. (2) on the side of the frame rail and (2)
on the bottom. Special note: take special care not to drill
into any stock hoses and/or lines running down the
inside of the stock frame rail. Remove the pair of vice
grips that is holding the new torsion bar cross member
relocation bracket to the frame rail. Repeat procedure
on the passenger side of the vehicle.
73. Locate (8) 7/16” x 1 1/2” bolts, (16) 3/8” USS flat
washers and (8) 7/16” unitorque nuts from hardware bag
16985NB2. Working on the driver side, secure the new
driver side torsion bar cross member relocation bracket to
the stock frame rail using the new 7/16” x 1 1/2” bolt and
hardware. Do not tighten at this point. Repeat procedure on
the passenger side.
Photo # 67 / photo # 68
74. Locate the stock torsion bars that were removed from
step # 5. Refer to the marks that were made in step # 3.
This will allow you to re-install the stock torsion bars back
into the stock location. Example: Driver vs. Passenger