Tuff Country 14045 User Manual
Part # 14045
2004 - 2006 GM Colorado / Canyon
4” Suspension system
Parts list:
Part
#
Description Qty.
14045-01 Driver side knuckle 1
14045-02 Passenger side knuckle 1
14045-03 Front cross member 1
14045-04 Rear cross member 1
14045-05 Front lower skid plate 1
14045-06 Driver side differential
relocation bracket 1
14045-07 Passenger side differential
relocation bracket 1
14045-09 Front driver and passenger side
sway bar relocation brackets 2
14045-10 Front driver and passenger side
extended bump stops 2
14045-11 Front drive shaft spacer 1
95130 Front extended brake line kit 1
TCI-R26 Rear add-a-leaf’s 2
14045NB Hardware bag 1
14045NB1 Hardware bag 1
14045SL Sleeve bag 1
14045INST Instruction manual (customer) 1
14045INST Instruction manual (installer) 1
MIRRORHANGER
Rear view mirror hanger 1
WARNINGDECAL
Warning decal 1
DECAL Window sticker 1
Congratulations on your selection to purchase a Tuff
Country EZ-Ride Suspension System. We at Tuff
Country are proud to offer a high quality product at the
industries most competitive pricing. Thank you for
your confidence in us, and our product.
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.
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.
Installation manual
4” Suspension system
2004 - 2006
GM Colorado / Canyon
Part # 14045
sj030107rev.02
Important customer information:
Tuff Country EZ-Ride Suspension highly recommends
that a qualified and/or certified mechanic performs
this installation.
If you desire to return your vehicle to stock, it is the
customers responsibility to save all stock hardware.
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.
It is the responsibility of the customer or the
mechanic 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.
OEM manual should be used as a reference guide.
Make sure to use locktite on all new and stock
hardware associated with this installation.
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.
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:
The stock wheels will not work in conjunction with this
suspension system. New wheels with a 4.5” back
spacing is required. Tuff Country recommends a
285/70/16 tire and wheel package. If larger than a
285/70 tire is installed on your vehicle in conjunction
with part # 14045; Tuff Country assumes no liability
and the warranty will be VOID. Also, 15” wheels will
not work in conjuction wiht this suspension system.
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.
New longer front and rear shocks are needed after this
suspension system has been installed and the front
and rear shocks need to be ordered as a separate part
#. If you have not already ordered your front and rear
shocks, please feel free to contact Tuff Country or
your local Tuff Country dealer and order your front and
rear shocks. Tuff Country recommends installing a 21”
fully extended nitrogen gas shock in the front and a
26” fully extended nitrogen gas shock in the rear.
Torque settings:
5/16” 15—18 ft lbs.
3/8” 28—32 ft lbs.
7/16” 30—35 ft lbs.
1/2” 65—85 ft lbs.
9/16” 85—120 ft lbs.
5/8” 95—130 ft lbs.
3/4” 100—140 ft lbs.
Hardware bag 14045NB includes:
Description
Quantity
5 mm x 12 mm hex cap bolts 4
5 mm flat washers 4
10 mm x 40 mm bolts 4
10 mm split lock washers 4
10 mm x 26 mm sock head cap screws 4
14 mm x 50 mm bolts 4
14 mm flat washers 4
14 mm lock washers 4
3/8” x 3/4” bolts 4
3/8” x 1” bolts 2
5/16” USS flat washers 8
3/8” split lock washers 6
3/8” nylock nuts 2
7/16” x 2” bolts 2
7/16” x 2 1/2” bolts 4
3/8” USS flat washers 10
7/16” unitorque nuts 6
1/2” x 1 1/4” bolts 6
1/2” x 2 1/4” bolts 2
7/16” USS flat washers 12
1/2” unitorque nuts 8
9/16” x 3 1/2” bolts 4
1/2” USS flat washers 8
9/16” unitorque nuts 4
5/8” x 4 1/2” bolts 2
9/16” USS flat washers 4
5/8” unitorque nuts 2
Sert fitting 2
S10107 (Over size washers) 4
Hardware bag 14045NB1 includes:
Description
Quantity
14045-08 (ABS relocation brackets) 2
S10116 (Heim joints) 4
SUW-12 (1/2” harden washers) 2
PB8297 (Poly bushings) 4
PB6199 (Poly bump stops) 2
PB6052 (Poly bushings) 2
PB2456 (Poly bushings) 4
P98 (rear shock clevis mounts) 2
CB5162 (rear centering bolts) 2
516FN (5/16” fine nuts) 2
Hardware bag 14045SL includes:
Description
Quantity
S10115 (.875” x .635” x 3.360” sleeve) 2
S10117 (.750” x 7.500” tapped sleeve) 2
S10118 (.750” x .510” x .310 sleeve) 4
S10123 (spacer sleeve) 2
S10124 (milled sleeve) 2
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.
Spherical rod end links are a precision part and require
frequent cleaning and lubricating to enhance proper
maximum performance. Failure to do this could cause
failure of Spherical rod end links.
Recommended tools selection;
Cut off wheel
Sawzall
Torque wrench
Standard socket set
Standard wrench set
Metric socket set
Metric wrench set
Tape measure
Hydraulic floor jacks
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:___________________________
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 front:______________________________
Passenger side front:__________________________
Driver side rear:_______________________________
Passenger side rear:___________________________
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. Place a jack stand on both the driver and the
passenger side. Next, remove the front wheels and tires
from both sides.
2. Working on the driver side, remove the torsion bar
adjusting bolt and block and set aside for later
re-installation. Repeat procedure on the passenger side.
Photo # 1
3. Working on the driver side, using white out, scribe a
mark on the rear portion of the torsion bar and the torsion
bar key. Also, at this time, scribe a mark on the front portion
of the torsion bar and the torsion bar bracket bolted to the
stock lower control arm. Repeat procedure on the
passenger side. Special note: It is also a good idea to
mark the driver and passenger side torsion bars. Also
mark the front of the torsion bar. This will help to make
sure that the torsion bars are re-installed back into the
stock location.
Photo # 2
Photo # 3
4. Working on the driver side, push up on the stock torsion
bar and remove the stock torsion bar key. Set the stock
torsion bar key aside for later re-installation. Remove the
driver side torsion bar from the vehicle and set aside for
later re-installation. Repeat procedure on the passenger
side.
Photo # 4
5. Working on the driver side, carefully remove the (2) stock
ABS line mounts that attach the stock ABS line to the stock
upper control arm. Next remove the stock ABS line bracket
that is attached to the stock knuckle using a 7 mm wrench.
The stock hardware may be discard. Repeat procedure on
the passenger side.
Photo # 5
Photo # 6
6. Working on the driver side, loosen but do not remove the
stock nut holding the stock outer tie rod to the stock
knuckle. Using a hammer, carefully hit the knuckle to break
the taper. Special note: Take special care not to rip or
damage the stock outer tie rod dust boot. Once the
taper has been broke, remove the stock nut completely and
set aside for later re-installation. Remove the outer tie rod
from the stock knuckle. Repeat procedure on the
passenger side.
Photo # 7
Photo # 8
Photo # 9
7. Working on the driver side, remove the stock shock from
the stock upper and lower location. Special note: To make
removal of the upper nut easier, an allen head wrench
maybe needed to hold the shock from spinning. Set the
stock lower hardware aside for later re-installation. The
stock upper hardware and the stock shock may be
discarded. Special note: New longer front shocks are
needed after this suspension system has been
installed and the front shocks need to be ordered as a
separate part #. If you have not already ordered your
front shocks, please feel free to contact Tuff Country or
your local Tuff Country dealer and order your front
shocks. Tuff Country recommends installing a 21” fully
extended hydraulic shock in the front.
Photo # 10
Photo # 11
8. Working on the driver side, remove the (2) stock bolts
that connect the stock brake caliper to the stock knuckle.
Set the stock bolts aside for later re-installation. Carefully
tie the stock brake caliper up and out of the way in the
fender well. Repeat procedure on the passenger side.
Photo # 12
9. Working on the front of the vehicle, remove the stock
skid plate from the stock location. Save the stock skid plate
and the stock hardware for later re-installation.
Photo # 13
10. Working on the driver side, remove the stock sway bar
end link from the stock lower control arm. The stock
hardware may be discarded. Repeat procedure on the
passenger side.
Photo # 14
11. Working on the driver side, remove the stock sway bar
from the bottom of the stock frame rail. The stock hardware
may be discarded. Repeat procedure on the passenger
side. Set the stock sway bar aside for further instructions.
Photo # 15
12. With the stock sway bar out of the vehicle, remove the
stock driver and passenger side end links from the stock
sway bar and discard the stock end links and hardware. Set
the stock sway bar aside for later re-installation.
13. Working on the driver side, remove the stock CV axle
nut that connects the stock CV axle to the stock knuckle.
Set the stock CV axle nut and washer aside for later
re-installation.
Photo # 16
14. Working on the driver side, loosen but do not remove
the stock upper ball joint nut that connects that stock upper
control arm to the stock knuckle. Repeat procedure on the
passenger side.
Photo # 17
15. Working on the driver side, loosened but do not remove
the stock lower ball joint nut that connects the stock lower
control arm the stock knuckle. Repeat procedure on the
passenger side.
Photo # 18
16. Working on the driver side and using a hammer,
carefully hit the knuckle to brake the taper on the upper
control arm ball joint. Special note: Take special care not
to rip or damage the stock upper control arm dust
boot. Repeat procedure on the passenger side.
Photo # 19
17. Working on the driver side and using a hammer,
carefully hit the knuckle to brake the taper on the lower
control arm ball joint. Special note: Take special care not
to rip or damage the stock lower control arm dust boot.
Repeat procedure on the passenger side.
Photo # 20
18. Working on the driver side, push the stock ABS line
bracket out of the stock location in the fender well.
Disconnect the stock ABS line from the quick disconnect.
Repeat procedure on the passenger side.
Photo # 21
Photo # 22
19. Working on the driver side, move back to the stock nuts
holding the upper and lower control arm to the knuckle and
remove completely. Set the upper and lower hardware
aside for later re-installation. Carefully remove the knuckle
from the vehicle and set aside for further instructions.
Repeat procedure on the passenger side.
Photo # 23
20. Working on the driver side, remove the stock hardware
that connects the stock lower control arm into the stock rear
mounting location. Set the stock bolt aside for later
re-installation. Remove the stock hardware that connects
the stock lower control arm into the stock front mounting
location. Set the stock hardware aside for later
re-installation. Also set the stock lower control arm aside for
later re-installation. Repeat procedure on the passenger
side.
Photo # 24
Photo # 25
Photo # 26
21. Place a pair of hydraulic floor jacks under the front
differential. Carefully raise up on both hydraulic floor jacks
at the same time until they come into contact with the front
differential.
22. Working on the driver side, remove the (2) stock bolts
that connect the stock differential to the bottom of the stock
frame rail. The stock hardware may be discarded. Repeat
procedure on the passenger side. Carefully lower down on
both hydraulic floor jacks at the same time allowing enough
room for the new driver and passenger side differential
relocation bracket to be installed.
Photo # 27
23. Locate the new driver and passenger side differential
relocation brackets. Locate (4) 14 mm x 50 bolts, (4) 14 mm
flat washers and (4) 14 mm lock washers from hardware
bag 14045NB. Working on the driver side, install the new
differential relocation bracket to the bottom side of the
stock frame rail and secure using the new 14 mm x 50 mm
bolts and hardware. Do not tighten at this time. Special
note: the taller portion of the new differential relocation
bracket needs to be installed towards the front of the
vehicle. Repeat procedure on the passenger side.
Photo # 28
24. Locate (4) 9/16” x 3 1/2” bolts, (8) 1/2” USS flat
washers and (4) 9/16” unitorque nuts from hardware bag
14045NB. Carefully raise up on both hydraulic floor jacks
until the stock front differential can be attached to the newly
installed differential relocation brackets. Working on the
driver side, secure the stock differential to the newly
installed differential relocation bracket using the new 9/16”
x 3 1/2” bolts and hardware. Do not tighten at this point.
Repeat procedure on the passenger side.
Photo # 29
25. Working on the driver side, apply some thread locker or
lock tite to the new 14 mm x 50 mm bolts and torque to 85
ft lbs. Apply some thread locker or lock tite to the new 9/16”
x 3 1/2” bolt and torque to 85 ft lbs. Repeat procedure on
the passenger side. Carefully remove the hydraulic floor
jacks from under the vehicle.
26. Working on the driver side front lower control arm
pocket, measure 1” from the leading edge towards the
inside of the vehicle and scribe a mark from the front of the
vehicle to the rear. Repeat procedure on the passenger
side.
Photo # 30
27. Working on the driver side, using a die grinder,
carefully cut the stock front cross member as indicated in
photo # 31 & 32. Repeat procedure on the passenger side.
Special note: Tuff Country highly recommends NOT
using a torch when making this cut.
Photo # 31
Photo # 32
28. Locate the new driver and passenger side front sway
bar relocation bracket. Also, locate (4) 10 mm x 26 mm
socket head cap screws from hardware bag 14045NB.
Working on the driver side, install the new driver side sway
bar relocation bracket to the stock sway bar location on the
bottom side of the stock frame rail. Make sure to use thread
locker or lock tite and torque to 25 ft lbs. Repeat procedure
on the passenger side.
Photo # 33
29. Locate the (4) 3/8” x 3/4” bolts, (4) 5/16” USS flat
washers and (4) 3/8” lock washers from hardware bag
14045NB. Also locate the stock front sway bar. Install the
driver side of the stock sway bar to the newly installed sway
bar relocation bracket and secure using the new 3/8” x 3/4”
bolt and hardware. Repeat procedure on the passenger
side. Do not tighten fully but tighten enough so that the
sway bar can be pushed up and out of the way. These bolts
will be torqued once the new sway bar end links have been
installed.
Photo # 34
30. Locate the stock skid plate and the stock hardware.
Install the stock skid plate into the stock location and
secure using the stock hardware. Make sure to install
thread locker or lock tite and torque to 18 ft lbs.
31. Locate the new front cross member and the stock front
lower control arm hardware. Install the new front cross
member into the stock front lower control arm pockets and
secure using the stock lower control arm hardware. Do not
tighten at this point.
Photo # 35
32. Locate the new rear cross member. Also, locate (2) new
grease sert fitting from hardware bag 14045NB. Install the
new grease sert fitting into the new rear cross member.
Take special care not to damage the new grease sert fitting
during installation.
Photo # 36
33. Locate (4) PB2456 poly bushings from hardware bag
14045NB1. Also, locate (2) S10115 sleeves from sleeve
bag 14045SL. Install the new bushings and sleeves into the
new rear cross member. Special note: Make sure to use
a lithium or moly base grease prior to inserting the new
bushings and sleeves into the new rear cross member.
This will increase the life of the bushing as well as
prevent squeaking. Installer note: It is recommended to
inform the customer that these bushings need to be
lubed regularly. A suggestion is to make sure that
these bushings are lubed through the sert fitting every
time the customer has their oil changed. Failure to lube
the bushings properly could cause the bushing to fail
prematurely.
Photo # 37
34. Locate (4) 7/16” x 2 1/2” bolts, (8) 3/8” USS flat
washers and (4) 7/16” unitorque nuts from hardware bag
14045NB. Working on the driver side, install the new rear
cross member into the rear lower control arm pocket and
secure using the new 7/16” x 2 1/2” bolts and hardware. Do
not tighten at this point. Repeat procedure on the
passenger side.
Photo # 38
35. Due to some inconsistencies, the stock rear lower
control arm mounting points may need to be dremelled so
that the new rear cross members can be installed. If this is
the case on the vehicle that are working on, refer to photo
# 39 & 40 and open up the stock holes so that the new rear
cross member can be installed.
Photo # 39 / driver side
Photo # 40 / passenger side
36. Locate the new lower skid plate. Also, locate (6) 1/2” x
1 1/4” bolts, (12) 7/16” USS flat washers and (6) 1/2”
unitorque nuts from hardware bag 14045NB. Install the
new lower skid plate to the newly installed front and rear
cross member and secure using the new 1/2” x 1 1/4” bolts
and hardware. Do not tighten at this point.
Photo # 41
37. Move back to the (4) 7/16” x 2 1/2” bolts securing the
new rear cross member into the rear lower control pocket
and add some thread locker or lock tite and torque to 45 ft
lbs.
38. Locate the driver and passenger side stock lower
control arms. On the longer leg of the rear portion of the
control arms, measuring 3” from the leading edge of the
control arms and scribe a mark. Now measure 1/4” from the
inside towards the outside of the lower control arms and
scribe a mark. On the shorter leg of the control arms,
measure 2” from the leading edge of the stock lower
control arms and scribe a mark. Now measure 1/4” from the
from the inside towards the outside of the lower control
arms and scribe a mark.
Photo # 42 / longer leg
Photo # 43 / shorter leg
39. Using a die grinder carefully cut out the material that
was measured in step # 38 on both the driver and
passenger side control arms. Special note: Tuff Country
highly recommends NOT to use a torch when
performing this step.
Photo # 44
40. Working on the driver side lower control arm and
referring to photo # 45, remove just one stock torque head
mounting hardware that connects the stock torsion bar
bracket to the stock lower control arm. Set the stock
hardware aside for later re-installation. Repeat procedure
on the passenger side lower control arm.
Photo # 45
41. Locate (2) new 5/8” x 4 1/2” bolts, (4) 9/16” USS flat
washers and (2) 5/8” unitorque nuts from hardware bag
14045NB. Also, locate the stock rear mounting hardware
was was removed in step # 20. Working on the driver side,
install the modified stock lower control arm into the newly
installed front and rear cross members. Secure the front
portion of the lower control arm to the front cross member
using the new 5/8” x 4 1/2” bolts and hardware. Do not
tighten at this point. Secure the rear portion of the lower
control arm to the rear cross member using the stock
hardware. Make sure to use thread locker or lock tite and
torque to 133 ft lbs. Repeat procedure on the passenger
side.
Photo # 46
42. Working on the driver side, remove the stock bump stop
from the stock bump stop cup and discard. Repeat
procedure on the passenger side.
Photo # 47
43. Locate (2) 3/8” x 1” bolts, (2) 5/16” USS flat washers
and (2) 3/8” lock washers from hardware bag 14045NB.
Also locate (2) new bump stop relocation brackets. Working
on the driver side, install the new bump stop bracket into
the stock bump stop cup and secure using the new 3/8” x
1” bolt and hardware. Make sure to use thread locker or
lock tite and torque to 22 ft lbs. Special note: the recess
on the new bump stop bracket will slide up into the
stock bump stop cup. Repeat procedure on the
passenger side.
Photo # 48
Photo # 49
44. Locate (2) new PB6052 poly bump stops from
hardware bag 14045NB1. Special note: There are (2)
different sizes of bump stops in hardware bag
14045NB1, the PB6052 is the taller of the (2) bump
stops. Working on the driver side, install the new bump
stop to the newly installed bump stop bracket. Make sure to
sure thread locker or lock tite and hand tighten. Repeat
procedure on the passenger side.
Photo # 50
45. Locate the stock torqued head torsion bar mounting
bolt that was removed in step # 40. Working on the driver
side, re-install the stock torqued head torsion bar mounting
bolt into the stock location and secure using the stock nut.
Make sure to use thread locker or lock tite and torque to 45
ft lbs. Repeat procedure on the passenger side.
Photo # 51
46. Locate the driver and passenger side stock knuckles.
Remove the (4) stock bolts that connect the stock knuckle
to the stock hub assembly. Save the stock hardware for
later re-installation. Carefully remove the stock hub
assembly from the stock knuckle. Special note: Take
special care not to damage the stock hub assembly
during removal. Also, notice the placement of the
stock ABS sensor ring and wire. The stock knuckle may
be discarded. Repeat procedure on the passenger side
stock knuckle.
Photo # 52 / bolt removal
Photo # 53 / hub removal
46. Locate the new driver and passenger side knuckles.
Install the stock hub assemblies into the new knuckles and
secure using the stock hardware that was removed in step
# 45. Make sure to use thread locker or lock tite and torque
to 92 ft lbs. Special note: Take special care not to
damage the stock hub assembly during installation.
Also, make sure that the stock ABS sensor ring and
wire is installed back into the stock position.
Photo # 54
47. Working on the new knuckles and the stock hub
assemblies, remove the stock ABS retaining mounting
bracket from the stock ABS line and discard.
Photo # 55
48. Locate the stock upper and lower control arm mounting
hardware that was removed in step # 19. Working on the
driver side, install the new driver side knuckle into the stock
upper and lower control arm and secure using the stock
hardware. Do not tighten at this point. Repeat procedure on
the passenger side.
49. Locate (2) new ABS line clips from brake line bag
95130. Locate (2) 14045-08 ABS line clips from hardware
bag 14045NB1. Also, locate (4) 5 mm x 12 mm hex cap
bolts and (4) M5 flat washers from hardware bag 14045NB.
Working on the driver side, install the new ABS line clips
and ABS lines to the new knuckles and secure using the
new 5 mm x 12 mm hex cap bolts and hardware. Make sure
to use thread locker or lock tite. Special note: Using a
hammer, carefully hammer the upper ABS line clip
closed so that the ABS line will not come out of the
bracket. Repeat procedure on the passenger side.
Photo # 56
Photo # 57
50. Working on the driver side, torque the lower control arm
ball joint nut to 107 ft lbs. and the upper control arm ball
joint nut to 55 ft lbs. Repeat procedure on the passenger
side.
51. Locate the stock CV axle nuts and washers that were
removed in step # 13. Working on the driver side, secure
the stock CV axle to the new knuckle and stock hub
assembly using the stock CV axle nut and washer. Make
sure to use thread locker or lock tite and torque to 184 ft
lbs. Repeat procedure on the passenger side.
Photo # 58
52. Locate the stock brake caliper mounting hardware that
was removed in step # 8. Working on the driver side,
secure the stock brake caliper to the new knuckle and
secure using the stock hardware. Make sure to use thread
locker or lock tite and torque to 129 ft lbs. Repeat
procedure on the passenger side.
53. Working on the driver side, attach the stock ABS line
back to the stock location on the stock upper control arm.
Now re-connect the stock ABS line back to the quick
release clip and secure the stock ABS line bracket to the
back side of the stock fender well. Repeat procedure on the
passenger side.
54. Working on the driver side and using a pair of vise
grips, clamp off the stock brake line. Repeat procedure on
the passenger side.
Photo # 59
55. Working on the driver side, remove the stock brake line
from the stock upper mounting location and at the stock
brake caliper. Save the stock lower mounting hardware.
Repeat procedure on the passenger side. Special note:
Once the stock brake line has been removed, brake
fluid is going to leak out. If is a good idea to have
something to catch the fluid so it does not leak out all
over the floor.
56. Locate the new brake lines from bag 95130. Working
on the driver side, install the new brake line into the upper
location and use the new brake line clip to hold it into the
upper location. Next, secure the lower portion of the brake
line to the stock brake caliper using the stock hardware.
Repeat on passenger side.
Photo # 60 / upper location
Photo # 61 / lower location
57. Working on the driver side, carefully drill out the stock
sway bar bracket that is attached to the stock lower control
arm to 1/2”. Repeat procedure on the passenger side.
Photo # 62
58. Working on the driver side, carefully dremel out the
stock sway bar so that it will accept a 7/16” bolt. Repeat
procedure on the passenger side.
Photo # 63
59. Locate (4) S10116 heim joints from hardware bag
140045NB1. Also locate (2) S10117 sway bar end links
from hardware bag 14045SL. Install the new heim joints
into each end of the new sway bar end links. Tighten the
heim joints all the way down until their is no more threads.
60. Locate (2) new 1/2” x 2 1/4” bolts and (2) 1/2” unitorque
nuts from hardware bag 14045NB. Locate (4) S10118
spacer sleeves from hardware bag 14045SL. Also, locate
(2) SUW-12 from hardware bag 14045NB1. Working on the
driver side, attach the new sway bar end link heim joint to
the stock sway bar bracket that is attached to the stock
lower control arm. Do not tighten at this point. Please refer
to photo # 64 for proper installation. Repeat procedure on
the passenger side.
Photo # 64
61. Locate (2) new 7/16” x 2” bolts, (2) 3/8” USS flat
washer and (2) 7/16” unitorque nuts from hardware bag
14045NB. Also, locate (2) S10123 spacer sleeves and (2)
S10124 taper spacer sleeve from hardware bag 14045SL.
Working on the driver side, secure the top heim joint on the
new sway bar end link to the stock sway bar using the new
7/16” x 2” bolts, hardware and spacer sleeves. Do not
tighten at this point. Please refer to photo # 65 for proper
installation. Repeat procedure on the passenger side.
Photo # 65
62. Working on the driver side, torque the lower 1/2” sway
bar bolt to 65 ft lbs. and the upper 7/16” sway bar bolt to
45 ft lbs. Repeat procedure on the passenger side.
Photo # 66
63. Working on the driver side, place a hydraulic floor under
the driver side lower control arm. Carefully raise up on the
lower control arm until the upper control arm clears the
stock upper bump stop. Locate (2) new PB6199 poly bump
stops from hardware bag 14045NB1. Special note: There
are (2) different sizes of bump stops in hardware bag
14045NB1, the PB6199 is the shorter of the (2) bump
stops. Also, locate (2) 3/8” nylock nuts and (2) 5/16” USS
flat washers from hardware bag 14045NB. Working on the
driver side, install the new bump stop to the stock upper
bump stop bracket (hole is already provided) and secure
using the new hardware. Torque to 28 ft lbs. Repeat
procedure on the passenger side.
Photo # 67
64. Locate the stock outer tie rod end hardware that was
removed in step # 6. Working on the driver side, rotate the
stock outer tie rod 180 degrees from the stock location and
install the stock outer tie rod into the new knuckle and
secure using the stock hardware. Make sure to use thread
locker or lock tite and torque to 45 ft lbs. Repeat procedure
on the passenger side.
Photo # 68
65. Remove the stock front drive shaft from the transfer
case mounting mount. The stock hardware may be
discarded.
Photo # 69
66. Locate the new drive shaft spacer. Also, locate (4) new
10 mm x 40 mm bolts and (4) 10 mm lock washers from
hardware bag 14045NB. Install the new driver shaft spacer
between the stock drive shaft and the stock transfer case
and secure using the new 10 mm x 40 mm bolts and
hardware. Make sure to use thread locker or lock tite and
torque to 35 ft lbs.
Photo # 70
Loading...