Tuff Country 34000 - Dodge 03-07 Ram 2500 / 3500 4.5 kit - Manual (Page 7)

mounting hardware. Working on the driver side, install the
new driver side sway bar relocation bracket to the to the
stock frame location and secure using the stock hardware.
Do not tighten at this point. Repeat procedure on the pas-
senger side. Special note: When the new driver and pas-
senger side sway bar relocation brackets are installed,
the stock sway bar will be moved down and forward.
34. Locate (4) 7/16” x 1 1/2” bolts, (8) 3/8” USS flat washers
and (4) 7/16” unitorque nuts from hardware bag 36000NB1.
Also, locate the stock sway bar. Working on the driver side,
install the stock sway bar to the previously installed driver
side sway bar relocation bracket and secure using the new
7/16” x 1 1/2” bolt and hardware. Do not tighten at this
point. Repeat procedure on the passenger side. For now let
the stock sway bar hang.
35. Check and double check to make sure that all step were
performed properly. Check and double check to make sure
that all new and stock hardware is torqued to proper torque
settings. The upper and lower control arms still need to be
torqued to specs and this will be done once the rear end
installation has been completed and the weight of the vehi-
cle is on the ground. Also, the stock sway bar end links need
to be re-installed and this will also be done once the weight
of the vehicle is on the ground.
36. Install the tires and wheels and carefully lower the
vehicle to the ground.
37. If you were not able to install the stock track bar to the
newly installed track bar relocation bracket, perform this step
now that the weight of the vehicle is on the ground.
The rear end u-bolts for part # 34000 are not included in
this box kit. The rear end u-bolt kit needs to be ordered
as a separate part #.
If the vehicle that you are working on is a Dodge Ram
2500 that does not have the 24 valve high output rear
end, and you have not already ordered the rear end u-
bolt kit, please contact Tuff Country or your local Tuff
Country dealer and order part # 34001.
If the vehicle that you are working on is a Dodge Ram
2500 that has the 24 valve high output rear end or a
Dodge Ram 3500, and you have not already ordered the
rear end u-bolt kit, please contact Tuff Country or your
local Tuff Country dealer and order part # 34002.
Rear end installation:
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 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 rear:______________________________
Passenger side rear:__________________________
38. 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.
39. Position a pair of hydraulic floor jacks under the rear
axle. Place one jack stand on the driver side and one on the
passenger side. Raise up on both hydraulic floor jacks at the
same time until they make contact with the rear axle.
40. Working on the driver side, remove the stock shock from
the stock location and save the stock upper and lower
hardware for later re-installation. The stock shock may be
discarded. Special note: Shocks are not included with
this suspension system, shocks need to be ordered as
a separate 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 the proper front shocks.
Repeat procedure on the passenger side.
41. Working on the driver side, remove the (2) stock rear
u-bolts. The stock rear u-bolts and hardware may be
discarded. Set the stock upper u-bolt plate aside for later
re-installation. Repeat procedure on passenger side.
42. Carefully lower down on both hydraulic floor jacks at the
same time until the stock springs separate from the stock
rear axle. Lower down approximately 2”. Special note:
Make sure not to over extended any brake lines or hoses
when lowering axle.
43. Locate (2) new 2” lifted rear blocks. Working on the
driver side, install (1) new 2” lifted block between the stock
rear axle and the stock spring assembly. Repeat procedure
on passenger side.
44. Raise up on both hydraulic floor jacks at the same time
until the driver and passenger side stock spring assembly
seats flush with newly installed 2” block.
If the vehicle that you are working on is a Dodge Ram
2500 that does not have the 24 valve high output rear
end please follow step # 45.
If the vehicle that you are working on is a Dodge Ram
2500 that has the 24 valve high output rear end or a
Dodge Ram 3500, please follow step # 46.
45. Locate (4) new 9/16” x 3 1/2” x 12 5/8” round u-bolts, (8)