Tuff Country 54900 - Toyota Tacoma 95-04 5 lift kit - Manual (Page 6)

45. Locate (1) 1/2” x 1 1/2” bolt, (2) 1/2” flat washers, (1)
1/2” lock washer and (1) 1/2” unitorque nut from
hardware bag 54900NB. Working on the driver side,
secure the newly installed one piece lower sub frame to
the newly installed driver side differential drop bracket
and secure using the new 1/2” x 1 1/2” bolt and
hardware. Special Note: Do not tighten at this point.
Make sure to use thread locker or lock tite.
Photo # 9
46. Locate (1) 1/2” x 1 1/2” bolt, (2) 1/2” flat washers, (1)
1/2” lock washer and (1) 1/2” unitorque nut from
hardware bag 54900NB. Working on the passenger side,
secure the newly installed one piece lower sub frame to
the newly installed passenger side differential drop
bracket and secure using the new 1/2” x 1 1/2” bolt and
hardware. Special Note: Do not tighten at this point.
Make sure to use thread locker or lock tite.
Photo # 10
47. Locate the stock nut that was removed in step # 22
that connected the stock front differential rear mounting
point to the stock rear cross member. Secure the stock
front differential rear mounting point to the newly
installed one piece lower sub frame using the stock nut.
Torque to 64 ft lbs.
Photo # 11
48. Move back to the new 3/4” x 4 1/2” bolts and the new
3/4” x 5” bolts that secure the new one piece lower sub
frame to the stock front and rear lower control arm
pockets and torque to 130 ft lbs.
49. Move back to the driver side differential drop bracket
and torque the stock hardware to 116 ft lbs. Also, torque
the stock hardware that connects the new driver side
differential drop bracket to the stock front cross member
to 101 ft lbs.
50. Move back to the passenger side differential drop
bracket and torque the stock hardware to 116 ft lbs.
Also, torque the stock hardware that connects the new
passenger side differential drop bracket to the stock front
cross member to 85 ft lbs.
51. Working on the driver side, torque the new 1/2” x 1
1/2” bolt and hardware that connects the new driver side
differential drop bracket to the new one piece lower sub
frame to 80 ft lbs. Repeat procedure on the passenger
side.
52. Locate the stock driver and passenger side lower
control arms that were removed in step # 28. Also, locate
the stock driver and passenger side cam bolts. Working
on the driver side, install the stock lower control arm into
the newly installed one piece lower sub frame and
secure using the stock cam bolts. Do not tighten at this
point. Repeat procedure on the passenger side.
Photo # 12
Install the new poly bushings into the new passenger
side differential drop bracket. Next, install the new anti
crush sleeve into the newly installed poly bushings.
Special Note: Make sure to use a lithium or moly
base grease prior to inserting the new bushings into
the new passenger side differential drop bracket.
This will increase the life of the bushings as well as
prevent squeaking.
40. Locate the stock passenger side front differential
hardware that was removed in step # 34. With the front
differential out of the vehicle, secure the new passenger
side differential drop bracket to the stock front differential
using the stock hardware. Special Note: Do not tighten
at this point. Make sure to use thread locker or lock
tite.
Photo # 5
41. Locate the driver side stock hardware that connected
the stock front differential drop bracket to the stock front
cross member that was removed in step # 33. Also,
locate the passenger side stock hardware that connected
the stock front differential drop bracket to the stock front
cross member that was removed in step # 34. At the
same time, carefully raise up on both hydraulic floor
jacks that are holding the stock front differential until the
new driver and passenger side differential drop bracket
can be attached to the front cross member. Secure the
new driver and passenger side differential drop brackets
to the front cross member using the stock hardware.
Special Note: Do not tighten at this point. Make sure
to use thread locker or lock tite. Also, the stock over
size washers needs to be inverted. Make sure to
invert the stock over size washer before installation.
Photo # 6 / Driver side
Photo # 7 / Passenger Side
42. Carefully remove both hydraulic floor jacks from
under the front differential.
43. Reconnect all the wiring and hoses that were
removed from the stock front differential in step # 35.
44. Locate (2) 3/4” x 4 1/2” bolts, (2) 3/4” x 5” bolts, (8)
3/4” flat washers, (4) 3/4” lock washers and (4) 3/4”
unitorque nuts from hardware bag 54900NB. Also, locate
the new one piece lower sub frame. Install the new one
piece lower sub frame into the stock front and rear lower
control arm pockets and secure using the new 3/4” x 5”
bolts into the front location and the new 3/4” x 4 1/2”
bolts and hardware into the rear location. Special Note:
Do not tighten at this point. Make sure to use thread
locker or lock tite. Also, when installing the new one
piece lower sub frame, make sure that the rear
mounting stud on the rear portion of the front
differential seats properly into the new one piece
lower sub frame.
Photo # 8 / Front location shown