Tuff Country 34000 - Dodge 03-07 Ram 2500 / 3500 4.5 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:___________________________
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:__________________________
Front end installation:
1. Working on the driver side, remove the stock sway bar
from the stock sway bar end link. Save the stock sway bar
end link hardware for later re-installation. Repeat the
procedure on the passenger side. Now remove the stock
sway from the stock end links and let the stock sway bar
hang.
Photo # 1
Step # 1 needs to be performed with weight of the vehi-
cle on the ground. If this step is not performed with the
weight of the vehicle on the ground, damage will occur
to the stock sway bar end links.
2. 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 passenger side.
Next, remove the tires and wheels from both sides.
3. Place a pair of hydraulic floor jacks under the front axle.
Place one on the driver side and one on the passenger side.
Carefully raise up on both hydraulic floor jacks at the same
time until the hydraulic floor jacks come into contact with the
front axle.
4. Working on the driver side, remove the stock nut that con-
nects the stock tie rod end to the stock pitman arm. Save the
stock nut for later re-installation. Using a hammer, carefully
break the taper on the stock tie rod that connects to the stock
pitman arm. Special note: Take special care not to rip or
tear the stock outer tie rod boot. The new pitman arm
has a reverse taper on it, after the new pitman arm has
been installed, the stock outer tie rod needs to be rotat-
ed 180 degrees.
Photo # 2
5. Next, remove the stock nut and lock washer from the
sector shaft on the stock steering box. Save the stock hard-
ware for later re-installation. Using a pitman arm puller,
carefully remove the stock pitman arm from the stock sector
shaft. The stock pitman arm may be discarded.
Photo # 3 / Photo # 4
6. Open the hood of your vehicle. Working on the driver side,
locate and remove the upper stock shock nut. Also, remove
the upper stock shock retainer washer and grommet. The
stock nut, retainer washer and grommet may be discarded.
Repeat procedure on the passenger side.
Photo # 5
7. Working on the driver side, remove the (3) stock nuts that
hold the upper stock shock tower to the stock location. The
stock hardware may be discarded. Set the upper stock
shock tower aside for later re-installation. Repeat procedure
on the passenger side.
Photo # 6
8. Working on the driver side, Scribe a reference mark on the
bottom of the stock coil spring and the stock coil spring pock-
et. This will allow you to re-install the stock coil spring and
spacer back into the stock location at a later step. Repeat
procedure on the passenger side. Remove the stock lower
shock bolt from the stock mounting location and save the
stock hardware for later re-installation. Carefully lower down
on the hydraulic floor jack holding the driver side axle about
2”. Remove the stock shock and the stock coil spring from
the stock location. The stock upper coil mounting ring may
be discarded. Save the stock isolator and coil spring for later
re-installation. Special note: Shocks are not included with
this kit box and the shocks need to be ordered as a sep-
arate part number. Tuff Country EZ-Ride Suspension
recommends using a 30” fully extended nitrogen gas
shock. If you have not already ordered your shocks,
please contact Tuff Country or your local Tuff Country
dealer and order your new front shocks. Repeat proce-
dure on the passenger side.
Photo # 7 / Photo # 8
9. Working on the driver side, remove the stock hardware
that connects the stock track bar to the stock location. Save
the stock retaining nut for later re-installation. The stock bolt
may be discarded.
Photo # 9
10. Working on the driver side, remove the stock brake line
bracket that connects the stock brake line between the stock
upper and lower control arm mounts on the axle. Save the
stock hardware for later re-installation. Repeat procedure on
the passenger side.
Photo # 10
11. Working on the driver side lower control arm mounting
bracket that is located on the stock front axle, scribe a mark
on the stock alignment cams and another directly across on
the reinforcement bracket. This will give you a good
alignment reference until you get the vehicle to an alignment
shop for a proper front end alignment. Repeat procedure on
the passenger side.
Photo # 11