Tuff Country 34003 - Dodge 03-07 Ram 2500 / 3500 4.5 kit - Manual (Page 6)

x 5 1/2” bolt, 1/2” USS flat washer (on the outside of the
stock frame rail), 9/16” u-bolt harden washer (on the inside
of the stock frame rail) and the new nut bracket. Next, install
the new upper control arm to the stock mounting location on
the stock front axle. Secure using the new 9/16” x 4” bolt and
hardware. Do not tighten at this point. Special note:
Carefully pushing the stock exhaust over to the driver
side will help make clearance to perform this step on the
passenger side.
Photo # 16 / passenger side upper mount
Photo # 17 / driver side upper mount
22. Locate the new lower control arms. Locate (8) control
arm bushings from hardware bag 34000PL. Also, locate (4)
S10060 lower control arm sleeves from hardware bag
36005SL. Special note: The new lower control arms are
the longer of the 2 arms. Insert the new poly bushings into
each end of the new lower control arms. Special note: Make
sure to use a lithium or moly base grease prior to insert-
ing the new bushings into the new lower control arms.
This will increase the life of the bushing as well as pre-
vent squeaking. Next, install the new lower control arm
sleeves into the previously installed poly bushings.
23. Locate the stock lower control arm mounting hardware.
Working on the driver side, install the new lower control arm
to the stock frame mount location and secure using the stock
hardware. Do not tighten at this point. Next, install the new
lower control arm to the stock mounting location on the stock
front axle. Secure using the stock hardware. Special note:
Raising the axle to ride height and moving the axle up
and down will make for easier lower control arm instal-
lation. Slight prying of the stock control arm bracket
also may be needed to make installation easier. Add
some thread locker or lock tite to the stock lower axle mount-
ing hardware and refer back to the marks that were scribed
in step # 11 and torque the stock hardware to 85 ft lbs.
Photo # 18 / driver side frame mount
Photo # 19 / passenger side axle mount
24. Locate the new track bar relocation bracket. Locate (1)
9/16” x 3 1/2” bolt, (2) 1/2” USS flat washers and (1) 9/16”
unitorque nut from hardware bag 36000NB1. Also, locate (1)
S10061 crush sleeve from hardware bag 36005SL. Working
on the driver side, install the new track bar relocation
bracket into the stock location and secure using the new
9/16” x 3 1/2” bolt, crush sleeve and hardware. Do not
tighten at this point.
Photo # 20 / Photo # 21
Photo # 22
25. Hold the newly installed track bar relocation bracket up
flush with the stock track bar location. Use the holes in the
new track bar relocation bracket as guides, carefully drill (2)
1/2” holes into the stock track bar location. Special Note: To
make drilling easier, remove the (3) stock bolts that hold
the stock steering box to the inside of the stock frame
rail. Move the stock steering box out of the way during
drilling. After the (2) 1/2” holes have been drilled into the
stock track bar bracket, re-install the stock steering box
back into the stock location using the stock hardware.
Make sure to use thread locker or lock tite. Torque the
stock steering box hardware to 95 ft lbs.
Photo # 23
26. Locate (1) 1/2” x 4” bolt, (2) 7/16” USS flat washers and
(1) 1/2” unitorque nut from hardware bag 36000NB1. Also
locate (1) S10062 crush sleeve from hardware bag
36005SL. Secure the new track bar bracket to the
previously drilled holes using the new 1/2” x 4 1/4” bolt,
crush sleeve and hardware. Make sure to use thread locker
or lock tite. Torque the new 1/2” bolt to 85 ft lbs. Move back
to the new 9/16” x 3 1/2” bolt that was installed in step # 25
and add some thread locker or lock tite and torque to 95 ft
lbs.
Photo # 24 / Photo # 25
27. Locate (1) 14 mm x 80 mm bolt and (2) 14 mm flat
washers from hardware bag 36000NB1. Also, locate the
stock retaining nut. Install the stock track bar into the newly
installed track bar relocation bracket and secure using the
new 14 mm x 80 mm bolt, flat washers and stock retaining
nut. Make sure to use thread locker or lock tite. Torque to
110 ft lbs. Special note: If you are not able to install the
stock track bar into the previously installed track bar
relocation bracket, you will need to perform this step
once the weight of the vehicle is on the ground.
28. Locate the new pitman arm and the stock pitman arm
hardware. Install the new pitman arm into the stock location
on the stock sector shaft and secure using the stock hard-
ware. Make sure to use thread locker or lock tite. Torque the
stock nut on the sector shaft to 225 ft lbs.
Photo # 26
29. Locate the stock outer tie rod hardware. Special note:
The new pitman arm has a reverse taper on it, if you
have not already rotated the stock outer tie rod 180
degrees, rotate the stock outer tie rod at this point.
Secure the stock outer tie rod to the previously installed new
pitman arm using the stock hardware. Make sure to use
thread locker or lock tite. Torque to 85 ft lbs.
Photo # 27
30. Locate the stock brake line bracket hardware. Working
on the driver side, install the stock brake line bracket to the
stock location and secure using the stock hardware. Make
sure to use thread locker or lock tite and torque to 12 ft lbs.
Repeat procedure on the passenger side.
Photo # 28
31. Carefully remove both hydraulic floor jacks from under
the front differential.
32. Working on the driver side, remove the stock sway bar
from the stock frame location and save the stock hardware.
Repeat procedure on the passenger side. Set the stock
sway bar aside for later re-installation.
Photo # 29
33. Locate the new driver and passenger side sway bar
relocation brackets. Also, locate the stock sway bar