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Part # 12034
2011 Chevy/GMC 4WD 2500/3500 HD
2” box kit with rear blocks
Part
# Description
Qty.
12904-03 Torsion bar key 2
BL101 Rear lifted block 2
5U-3431412S 3/4” x 3 1/4” x 12” square 4
12004NB Hardware bag 1
34NW Hardware bag 1
12034INST Instruction manual 2
MIRRORHANGER
Rear view mirror hanger 1
WARNINGDECAL
Warning decal 1
Congratulations on your selection to purchase a Tuff
Country EZ-Ride Suspension System. We at Tuff
Country EZ-Ride Suspension are proud to offer a high
quality product at the industries most competitive pricing. Thank you for your confidence in us and our product.
If you desire to return your vehicle to stock, it is the
customers responsibility to save all stock hardware
and components.
The Tuff Country EZ-Ride Suspension product safety
label that is included in your kit box must be installed
inside the cab in plain view of all occupants.
Please see the end of the installation manual for a picture of the hard parts that are included in this suspension system.
Installation manual
2” box kit with rear blocks
2011 Chevy / GMC 4WD
2500 / 3500 HD
Part # 12034
sj04212011rev.01
Important customer information:
Tuff Country EZ-Ride Suspension highly recommends
that a qualified or a certified mechanic performs this
installation.
It is the responsibility of the customer/installer to wear
safety glasses at all times when performing this installation.
It is the customers/installers responsibility to read and
understand all steps before installation begins. If you
have any questions or concerns, please contact our
technical department @ (801) 280-2777. Also, the OEM
manual should be used as a reference guide.
This vehicles reaction and handling characteristics
may differ from standard cars and/or trucks.
Modifications to improve and/or enhance off road performance may raise the intended center of gravity.
Extreme caution must be utilized when encountering
driving conditions which may cause vehicle imbalance
or loss of control. DRIVE SAFELY! Avoid abrupt
maneuvers: such as sudden sharp turns which could
cause a roll over, resulting in serious injury or death.
It is the customers responsibility to make sure that a
re-torque is performed on all hardware associated with
this suspension system after the first 100 miles of
installation. It is also the customers responsibility to
do a complete re-torque after every 3000 miles or after
every off road use.
After the original installation, Tuff Country EZ-Ride
Suspension also recommends having the alignment
checked every 6 months to ensure proper tracking,
proper wear on tires and front end components. Tuff
Country EZ-Ride Suspension takes no responsibility
for abuse, improper installation or improper suspension maintenance.
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Limited lifetime warranty
Notice to all Tuff Country EZ-Ride Suspension
customers: It is your responsibility to keep your
original sales receipt! If failure should occur on any
Tuff Country EZ-Ride Suspension component, your
original sales receipt must accompany the warranted
unit to receive warranty. Warranty will be void if the
customer can not provide the original sales receipt. Do
not install a body lift in conjunction with a suspension
system. If a body lift is used in conjunction with any
Tuff Country EZ-Ride Suspension product, your Tuff
Country EZ-Ride Suspension WARRANTY WILL BE
VOID. Tuff Country Inc. (“Tuff Country” ) suspension
products are warranted to be free from defects in
material and workmanship for life if purchased,
installed and maintained on a non-commercial vehicle;
otherwise, for a period of twelve (12) months, from the
date of purchase and installation on a commercial
vehicle, or twelve thousand (12,000) miles (which ever
occurs first). Tuff Country does not warrant or make
any representations concerning Tuff Country Products
when not installed and used strictly in accordance
with the manufacturer’s instructions for such
installation and operation and accordance with good
installation and maintenance practices of the
automotive industry. This warranty does not apply to
the cosmetic finish of Tuff Country products nor to
Tuff Country products which have been altered,
improperly installed, maintained, used or repaired, or
damaged by accident, negligence, misuse or racing.
(“Racing is used in its broadest sense, and, for
example, without regards to formalities in relation to
prizes, competition, etc.) This warranty is void if the
product is removed from the original vehicle and
re-installed on that or any other vehicle. This warranty
is exclusive and is in lieu of any implied warranty of
merchantability, fitness for a particular purpose or
other warranty of quality, whether express or implied,
except the warranty of title. All implied warranties are
limited to the duration of this warranty. The remedies
set forth in this warranty are exclusive. This warranty
excludes all labor charges or other incidental of
consequential damages. Any part or product returned
for warranty claim must be returned through the
dealer of the distributor from whom it was purchased.
Tuff Country reserves the right to examine all parts
returned to it for warranty claim to determine whether
or not any such part has failed because of defect in
material or workmanship. The obligation of Tuff
Country under this warranty shall be limited to
repairing, replacing or crediting, at its option, any part
or product found to be so defective. Regardless of
whether any part is repaired, replaced or credited
under this warranty, shipping and/or transportation
charges on the return of such product must be prepaid
by the customer under this warranty.
Important information that needs to be read before
installation begins:
Tuff Country EZ-Ride Suspension requires that a proper torsion bar unloading tool be used when performing this installation. If you do not have one, please contact your local GM
dealer to purchase one from them.
Tuff Country recommends NOT installing the Torsion Bar
Keys in conjunction with another aftermarket lifted suspension system. If the Torsion Bar Keys are installed with another aftermarket lifted suspension system your Warranty will
be void.
Tuff Country EZ-Ride Suspension packages (2) sets of
instruction sheets with this box kit. (1) is for the installer and
(1) is for the customer. The (1) for the customer has some
post installation procedure literature and it is the installers
responsibility to make sure that the customer receives a
copy of the installation manual along with the literature.
Before installation begins, Tuff Country EZ-Ride Suspension
highly recommends that the installer performs a test drive
on the vehicle. During the test drive, check to see if there are
any uncommon sounds or vibrations. If uncommon sounds
or vibrations occur on the test drive, uncommon sounds or
vibrations will be enhanced once the suspension system
has been installed. Tuff Country EZ-Ride Suspension highly
recommends notifying the customer prior to installation to
inform the customer of these issues if they exist
Make sure to use thread locker or loctite on all new and
stock hardware associated with the installation of this suspension system.
Special note: Before installation begins, it is the customers/installers responsibility to make sure that all parts
are on hand. If any parts are missing, please feel free to call
one of our customer service representatives @ (801) 280-
2777.
Hardware bag 12004NB includes:
Description
Quantity
S10229 (1.000” x .500” x .625”) 4
M12WA (12 mm flat washer) 4
M12UN (12 mm unitorque nut) 4
Hardware bag 34NW includes:
Description
Quantity
DN-34 (3/4” u-bolt high nut) 8
SUW-34 (3/4” u-bolt washer) 8
Recommended tools selection:
Torsion bar puller
Torque wrench
Standard socket set
Standard wrench set
Metric socket set
Metric wrench set
Tape measure
Floor jacks
Hydraulic floor jacks
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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. To begin installation, 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. Remove the tires and wheels from both sides.
2. Working on the driver side strut, remove the nuts from the
stock upper location and discard.
3. Working on the driver side, scribe a mark on the torsion
bar and the lower control arm. Special note: This is done
so that the torsion bar can be put back into the same
location on the lower control arm once the new torsion
bar key has been installed.
4. Working on the driver side and using a proper torsion bar
removal tool. Special note: Tuff Country EZ-RIde
Suspension requires that a proper torsion bar unloading
tool be used when performing this installation. If you do
not have one, please contact your local GM dealer to
purchase one from them. Carefully remove the stock tor-
sion bar bolt and block. Set the stock torsion bar bolt and
block aside. Remove the stock torsion bar unloading tool
from the stock cross member.
5. Working on the driver side, tap the stock torsion bar forward until the stock torsion bar key can be removed.
Remove and discard the stock torsion bar key.
6. Locate the new torsion bar key and install into the stock
location on the driver side. Tap the stock torsion bar back
into the torsion bar cross member until it seats properly into
the new torsion bar key. Special note: Make sure that the
line that was scribed on the torsion bar and the lower
control arm line up. Using the torsion bar unloading tool,
adjust the new torsion bar key up high enough so that the
stock torsion bar block and bolt can be re-installed.
7. Locate the stock torsion bar bolt and block and install into
the stock location. Working on the driver side, adjust the
stock bolt so that there is 1” from the block to the head of the
bolt. After the completion of the installation, if more or less
height is needed, adjust the stock bolt to achieve the proper
height. Special note: For each 1/4” of adjustment on the
stock bolt equals 1” of height. Also, these pictures are
of the passenger side.
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Special note: If the stock torsion bar bolt is over adjusted, ride quality issues will occur and over adjusting the
bolt is not recommended.
8. Locate (2) new S10229 crush sleeves, (2) 12 mm unitorque nuts and (2) 12 mm flat washers from hardware bag
12004NB. Working on the driver side, install the new spacer
sleeves onto the upper bolts of the stock shock and secure
the stock shock into the stock location using the new 12 mm
hardware. Make sure to use thread locker or loctite and
torque to 45 ft lbs.
Repeat step # 2 - 8 on the passenger side.
9. Install the tires and wheels on the driver and passenger
side and check to make sure that all steps were performed
properly and check again. Carefully lower the vehicle to the
ground.
10. 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. Remove the
tires and wheels from both sides.
11. Place a hydraulic floor jack under the driver and passenger side rear axle. Carefully raise up on both floor jacks until
they make contact with the rear axle.
12. Working on the driver side, remove the stock shock from
the axle mount. Save the stock hardware. Repeat procedure
on the passenger side.
13. Working on the driver side, remove the stock u-bolt from
the stock location. The stock u-bolts and hardware may be
discarded. Place the upper and lower u-bolt plates aside.
Repeat procedure on the passenger side.
14. Carefully lower down on both hydraulic floor jacks at the
same time approximately 2”. Special note: Take special
care not to over extend any brake lines and/or hoses.
15. Locate (2) new rear 1” lifted blocks. Working on the driver side, install the new 1” lifted block into the stock location.
Repeat procedure on the passenger side.
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16. Carefully raise up on both hydraulic floor jacks at the
same time until the stock spring assembly sits flush with the
newly installed 1” lifted block.
17. Locate (4) 3/4” x 3 1/4” x 12” square u-bolts. Also, locate
(8) 3/4” u-bolt high nuts and (8) u-bolt washers from hardware bag 34NW. Also, locate the stock upper and lower ubolt plates. Working on the driver side, install the new u-bolts
into the stock location and secure using the new 3/4” high
nuts and washers. Special note: Make sure to re-install
the stock upper and lower u-bolt plates. Torque to 150 ft
lbs. Repeat procedure on passenger side.
18. Working on the driver side, install the stock shock back
into the axle mount using the stock hardware. Make sure to
use thread locker or loctite and torque to 75 ft lbs. Repeat
procedure on the passenger side.
19. Remove the hydraulic floor jacks from under the vehicle.
20. Install the tires and wheels and carefully lower the vehicle to the ground.
21. Check and check again to make sure that all steps were
performed properly.
Congratulations, installation complete!
Special note: After the completion of the installation,
Tuff Country EZ-Ride Suspension recommends taking
the vehicle to an alignment shop and having a proper
front end alignment performed.
Tuff Country EZ-Ride Suspension recommends that a
complete re-torque is done on all bolts associated with
this suspension system. It is the customers responsibility to make sure that a re-torque is performed on all
hardware associated with this suspension system after
the first 100 miles of installation. It is also the customers
responsibility to do a complete re-torque after every
3000 miles or after every off road use. Neglect of following these steps could cause brackets to come loose and
cause serious damage to the suspension system and to
the vehicle.
Tuff Country EZ-Ride Suspension packages (2) sets of
instruction sheets with this box kit. (1) is for the installer
and (1) is for the customer. The (1) for the customer has
some post installation procedure literature and it is the
installers responsibility to make sure that the customer
receives a copy of the installation manual along with the
literature.
If you have any questions or concerns, please feel free
to contact Tuff Country or your local Tuff Country dealer.
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