Tuff Country 14840 User Manual
PART NUMBER : 14840
1992 - 1998 CHEVY / GMC 6 LUG
4 DOOR TAHOE, YUKON AND SUBURBAN
4” SUSPENSION SYSTEM WITH FRONT SPINDLES
PARTS LIST:
Part # Description Qty.
14810-01 Lower One Piece Sub Frame 1
14810-03 Driver Side Differential
Relocation Bracket 1
14810-04 Passenger Side Differential
Relocation Bracket 1
C4I-114 Passenger Side Spindle 1
C4I-115 Driver Side Spindle 1
16985-16 Torsion Bar Drop Brackets 2
C4I1SN-31 Rear Sway Bar End Links 2
SBPL Rear Sway Bar Bushings & Sleeves 2
BL401 4” Lifted Blocks 2
5U-9262S 9/16” x 2 3/4” x 12 5/8” Square U-Bolts 4
916NW 9/16” U-bolt High Nuts & Washers 1
14810SL Sleeve and Poly Bag 1
14840NB Hardware Bag 1
BLR01 Rear Brake Line Extension Bracket 1
BLR02 Front Brake Line Extension Bracket 2
P98 Rear Shock Clevis Mounts 2
9801 Axle Spacers 2
14840INST Instruction Sheet 1
Shocks are not include in this suspension system. If
you have not already done so, please contact Tuff
Country or your local Tuff Country dealer and order
the proper shocks for this suspension system.
Tuff Country EZ-Ride Suspension recommends
using a 4.5” back spacing on the tire and wheel
combination. The stock wheels will not work in
combination with the new spindle design.
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 representative @
(800) 288-2190.
Make sure to use locktite on all new and stock
hardware associated with this installation.
Tuff Country EZ-Ride Suspension highly
recommends that a qualified and or certified
mechanic performs this installation.
INSTALLATION MANUAL
4” I.F.S. SUSPENSION 1992 - 1998
CHEVY / GMC 1500 6 LUG
4 DOOR TAHOE, YUKON & SUBURBAN
PART # 14840
SJ100702
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.
IMPORTANT CUSTOMER INFORMATION
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 500 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
check every 6 months to ensure proper tracking,
proper wear on tires and front end components. Tuff
Country EZ-Ride Suspension take 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.
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.
It is the responsibility of the installers to make sure
that the rear view mirror hanger is hung from the
rear view mirror. The rear view mirror hanger has
instructions on proper post installation procedure.
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.
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 reinstalled 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.
Tuff Country
Important Customer Information
General Motors has introduced a new transfer case
option that uses the name “Auto Trac”. Auto Trac is a
full time 4WD system. This options pertains to the
Tahoe (2 or 4 door), Suburban and some pick up
trucks. To identify this, see the transfer case selection panel located on the dash board. Below the 2HI
button it will read “Auto 4WD” or “Auto”. Vehicles
with the “Auto Trac” transfer case may encounter a
front drive line vibration when the lift kit is installed.
After installation, if the vehicle that you are working
on encounters any front driveline vibration, please
feel free to contact Tuff Country @ (800) 288-2190 or
your local Tuff Country dealer and order part #
C9598DL to replace your stock driveline.
General Motors has also introduced and upgrade on
the front ABS system for vehicle manufactured between 1992—1995. If the vehicle that you are working
on has the upgrade ABS system on it, the new spindle design WILL NOT work due to the ABS upgraded
sensor. If this is the case on the vehicle that you are
working on and you still want to install a Tuff Country
EZ-Ride Suspension, please contact Tuff Country or
your local Tuff Country dealer and order part # 14843.
NON SPINDLE DESIGN
After the completion of the installation a front end
alignment is required. Also an exhaust modification
is needed.
For a list of all parts, please refer to the Parts Description Page, at the end of the Installation Manual.
Please Follow Instruction Carefully
Before installation begins, drive and check to make
sure there are no uncommon sounds and or frame
damage. Also at this time 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:__________________________
Please follow instructions carefully:
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 jack stands. Place a jack stand on both the driver
and passenger side. Next remove the wheels and tires
from both sides.
2. Working on the driver side, remove the inner rubber
fender splash guard and save for later re-installation.
Repeat procedure on passenger side.
3. Working on the driver side, remove the stock shock
from the stock location and save the stock hardware for
later re-installation. Longer shocks are needed, so the
stock shocks may be discarded. Special Note: Shocks
are not included with this suspension system and
need to be ordered as a separate part number, Tuff
Country EZ-Ride Suspension recommends using a
23” fully extended nitrogen gas shocks. Repeat
procedure on passenger side.
4. Remove the stock differential skid plate. The stock
front differential skid plate can be discarded. Also at this
time remove the stock front driveline and save the
stock driveline and hardware for later re-installation.
5. Measure exposed threads on the torsion bar
adjustment bolt and record measurement here for a later
reference.
Record Driver Side measurement here:______________
Record Passenger Side measurement here:__________
See Illustration # 1
6. Working on the driver side, attach the torsion bar
removing tool, making sure that the unloading bolt in the
center of the torsion bar removing tool is in the small
divot of the stock torsion bar key. Adjust the torsion bar
key up high enough so that the stock small metal
adjusting block and bolt can be removed. Save the stock
hardware for later re-installation. Repeat procedure on
passenger side.
See Illustration # 2
7. Mark both torsion bars before removal so that they can
be re-installed back into the same location. Example:
Driver vs. Passenger and front vs. rear. Tap the stock
torsion bars forward until the stock torsion bar cross
member can be removed.
8. Working on the driver side, remove the stock bolt that
connect the stock torsion cross member to the stock
mounting point and save hardware for later reinstallation. Special Note: The stock mounting point is
on the inside of the stock frame rail. Repeat procedure
on the passenger side
9. Remove the stock torsion bar cross member from the
stock location and set a side for later re-installation.
10. Working on the driver side, slide the stock torsion bar
out of the stock rear lower control arm and set a side for
later re-installation. Repeat procedure on passenger side.
11. Working on the driver side, remove the stock brake
line bracket from the stock upper control arm bracket and
save hardware for later re-installation. Repeat procedure
on passenger side.
12. Working on the driver side, remove the front sway bar
end link from the stock sway bar and the stock lower
control arm location. The stock end link and hardware
may be discarded. Repeat procedure on passenger side.
Special Note: At this time invert the stock front sway
bar.
13. Working on the driver side, remove the (2) stock bolts
that connect the stock brake caliper to the stock rotor.
Save the stock hardware for later re-installation. Using a
bungee cord, carefully tie the stock brake caliper up and
out of the way in the fender well. Special Note: Take
special care not to kink or over extend the stock
brake line.
14. Working on the driver side, remove the stock nut that
connects the stock axle to the stock hub assembly. Save
the stock nut for later re-installation.
See Illustration # 3
15. Working on the driver side, disconnect the ABS lines
from each other. Also disconnect the ABS line from any
other mounting points.
16. Working on the driver side, remove the stock cotter
pin from the stock castle nut that connects the stock
upper control arm ball joint to the stock steering knuckle.
Save the stock cotter pin for re-installation.
Loosen
the stock nut that connects the stock upper control arm
ball joint to the stock steering knuckle. Do not remove
the stock nut completely. Carefully break the stock
taper on the stock upper control arm ball joint.
Special
Note: Take special care not to rip or tear the stock
ball joint dust boot.
17. Working on the driver side, remove the stock cotter
pin from the stock castle nut that connects the stock
lower control arm ball joint to the stock steering knuckle.
Save the stock cotter pin for re-installation. Loosen
the stock nut that connects the stock lower control arm
ball joint to the stock steering knuckle. Do not remove
the stock nut completely. Carefully break the stock
taper on the stock lower control arm ball joint. Special
Note: Take special care not to rip or tear the stock
ball joint dust boot.
18. Working on the driver side, loosen the stock nut that
connects the stock outer tie rod ball joint to the stock
steering knuckle. Do not remove the stock nut
completely.
outer tie rod ball joint. Special Note: Take special care
not to rip or tear the stock outer tie rod ball joint dust
boot.
19. Working on the driver side, move back to the stock
nuts holding the upper control arm ball joint, the lower
control arm ball joint and the outer tie rod ball joint to the
stock steering knuckle and remove completely. Save
hardware for later re-installation.
20. Working on the driver side, use a suitable removal
tool to remove the stock axle from the hub assembly.
Special Note: Take special care not to damage the
stock threads on the stock axle.
21. Carefully remove the stock hub assembly and the
stock steering knuckle from the stock location.
22. Working on the driver side stock hub assembly,
remove the (3) stock bolts that connect the stock hub
assembly to the stock steering knuckle. Save the stock
hardware and stock hub assembly for later re-installation.
A new steering knuckle is used, the stock steering
knuckle can be discarded.
23. Locate the new driver side steering knuckle. Using
the stock hardware that was removed from step # 21,
secure the new driver side steering knuckle to the stock
hub assembly. Torque to 92 ft lbs. Special Note: Make
sure to use thread locker or lock tite.
24. Set the new driver side steering knuckle and hub
assembly a side for later re-installation.
25. Working on the driver side, scribe a mark on the CV
plate and another directly across to the stock differential,
this will allow you to re-install the stock CV back into the
stock location at a later step.
26. Working on the driver side, unbolt and remove the (6)
stock bolts holding the inner CV to the stock differential.
Discard the stock hardware. Set the stock axle a side for
later re-installation.
27. Working on the driver side, remove the stock front
and rear hardware that connects the stock lower control
arm to the stock front and rear location. Save the stock
hardware for later re-installation. Set the stock lower
control arms a side for later re-installation.
28. Repeat step’s 13 - 27 on the passenger side.
29. Working on the driver side, locate the stock lower
bracket that wraps around the rear lower half of the stock
front differential. Remove the stock bolt that connects the
lower portion of the stock front differential to the stock
bracket. Save the stock hardware for later re-installation.
Carefully break the stock taper on the stock
See Illustration # 4
Using the stock mounting point on the rear lower control
arm as a reference point, measure 3” towards the inside
of the vehicle and scribe a line on the stock bracket that
wraps around the rear portion of the stock front
differential. Using a hacksaw or suitable cutting tool, cut
along the line that was scribe earlier in this step.
Note: Tuff Country recommends not using a cutting
torch when performing step # 29. Clean and dress up
any exposed metal.
See Illustration # 5
.
30
Locate the new one-piece lower sub frame and the
stock lower control arm hardware that was removed in
step # 27. Working on the driver side, install the front and
rear part of the new one-piece lower sub frame into the
stock front and rear lower control arm stock pockets and
secure using stock hardware. Do not tighten at this
point. Make sure to use thread locker or lock tite.
Repeat procedure on passenger side.
See Illustration # 6 / Front Location
See Illustration # 7 / Rear Location
31. Place a pair of hydraulic floor jacks under the front
differential. Place one on the driver side and one and the
passenger side. Carefully raise up on both hydraulic floor
jacks at the same time until the come in contact with the
front differential.
32. Working on the drivers side, remove the stock upper
bolt that connects the stock front differential into the stock
upper location and save the stock hardware for later reinstallation. Special Note: The front driver side upper
stock mounting point is up high and difficult to see.
33. On the passenger side, remove the (2) stock nuts
that hold the passenger side of the front differential into
the stock location and save the stock hardware for later
re-installation.
34. Disconnect the stock vent hoses on the front
differential.
35. Locate the stock rear driver side differential mounting
bracket hardware that was removed from step # 29.
Carefully lower down on both hydraulic floor jacks at the
same time, until the rear portion of the front differential
seat properly into the previously installed lower one-piece
sub frame. Secure using the stock hardware. Do not
tighten at this point. Make sure to use thread locker
or lock tite.
36. Carefully remove both hydraulic floor jack from under
the front differential.
37. On the driver side of the stock front differential upper
tab, measure 2” from the stock mounting point and scribe
a mark on the front differential. Using a sawzall, cut the
upper tab off of the stock front differential and discard.
See Illustration # 8
See Illustration # 9
Special
38. Locate the new driver side differential relocation
bracket, (2) MO2050 poly bushings and (1) 9/16” x 2 1/8”
anti crush sleeve. Install the new poly bushings and the
anti crush sleeve into the new driver side relocation
bracket. Special Note: Make sure to use a lithium or
moly base grease prior to inserting the new bushings
into the new driver side differential relocation
bracket. This will increase the life of the bushing as
well as prevent squeaking.
39. Locate (1) 7/16” X 3” bolt, (1) 7/16” unitorque nut, (2)
7/16” flat washers and (1) 7/16” lock washer. Referring to
illustration # 10, remove the (4) stock differential
mounting bolts that connect to two half’s of the front
differential together. Save the stock hardware for later reinstallation. Secure the new driver side differential
relocation bracket to the stock front differential using the
stock hardware that was removed earlier in this step.
Torque to 34 ft. lbs. Special Note: Make sure to use
thread locker or lock tite. Secure the lower portion of
the new driver side differential relocation bracket to the
stock front differential, using the new 7/16” x 3” bolt and
hardware. Torque to 34 Ft. lbs. Special Note: Make
sure not to over tighten the stock and new hardware
associated with the front differential. If bolts are over
tighten, the stock front differential could crack.
See Illustration # 10
40. Locate the new passenger side differential drop
bracket and the stock hardware that was removed from
step # 33. Install the new passenger side differential drop
bracket into the stock location and secure using the stock
hardware.
Do not tighten at this point. Special Note:
Make sure to use thread locker or lock tite.
See Illustration # 11
41. Locate the stock upper front differential hardware that
was removed from step # 32. Working on the driver side,
secure the new driver side relocation bracket to the front
part of the newly installed one piece lower sub frame and
secure using the stock hardware.
Do not tighten at this
point. Make sure to use thread locker or lock tite.
See Illustration # 12
42. Locate (2) 9/16” x 1 1/2” bolt , (4) 9/16” flat washers,
(2) 9/16” unitorque nuts and (2) 9/16” lock washers.
Working on the passenger side, secure the passenger
side of the stock front differential to the newly installed
passenger side differential drop bracket using the new
9/16” x 1 1/2“ bolt and hardware. Do not tighten at this
point. Make sure to use thread locker or lock tite.
See Illustration # 13
43. Locate (2) 1/2”x 1 1/4” bolts, (2) 1/2” unitorque nuts,
(4) 1/2” flat washers and (2) 1/2” lock washers. Using the
holes in the front part of the new lower one-piece sub
frame as a guide, drill (2) 1/2” holes into the frame.
Secure using new 1/2” x 1 1/4” bolts and hardware.
Torque to 85 ft lbs. Make sure to use thread locker or
lock tite.
See Illustration # 14
44. Move back to all stock and new hardware associated
with the new driver and passenger side differential drop
brackets, the rear portion of the stock front differential
that mounts to the new one piece sub frame and the
stock mounting points were the new one-piece sub frame
mounts. Torque all hardware to proper torque
specifications. Refer to the torque setting sheet at the
end of the installation manual.
45. Locate the (2) poly bump stops, (2) 3/8” lock nuts, (2)
3/8” flat washers and (2) 3/8” lock washers. Working on
the driver side, install the new poly bump stop into the
newly installed lower one-piece sub frame and secure
using the new 3/8” hardware. Torque to
28 ft. lbs. Make
sure to use thread locker or lock tite. Repeat
procedure on passenger side.
See Illustration # 15
46. Locate (2) 5/8” x 4 1/2” bolts, (2) 5/8” x 5 1/2”, (4) 5/8”
unitorque nuts, (8) 5/8” flat washers, (4) 5/8” unitorque
nuts, (4) 5/8” lock washers and the driver and passenger
side lower control arms that were removed from step #
27. Working on the driver side, install the stock lower
control into the newly installed one-piece sub frame front
location and secure using the new 5/8” x 4 1/2” bolt and
hardware. Next, secure the rear portion of the stock lower
control arm into the rear portion of the newly installed
one-piece lower sub frame and secure using the new 5/8”
x 5 1/2” bolt and hardware.
Do not tighten at this point.
Make sure to use thread locker or lock tite. Repeat
procedure on passenger side.
See Illustration # 16 / Front Location
See Illustration # 17 / Rear Location
47. Locate 2 new axle half shaft spacers, the stock half
shaft hardware and the stock front axles that were
removed from step # 26. Working on the driver side,
install (1) new axle spacer between the stock front
differential and the stock axle. Secure using the stock
hardware. Torque to
65 ft. lbs. Make sure to use thread
locker or lock tite. Special Note: Make sure that the
stock axle is re-installed back into the stock location
on the stock front differential. Refer to the marks that
were scribe in step # 25.
Repeat on the passenger side.
See Illustration # 18
48. Locate the new driver side steering knuckle and stock
hub assembly, the stock hardware for the upper control
arm ball joint, lower control arm ball joint and outer tie rod
ball joint that was removed from step # 19. Using the
stock hardware, secure the new driver side steering
knuckle and stock hub assembly to the stock upper
control arm ball joint, the stock lower control arm ball joint
and the stock outer tie rod assembly. Torque the stock
hardware on the upper and lower ball joints to 85 ft lbs.
Torque the outer tie rod ball joint hardware to
68 ft. lbs.
Make sure to use thread locker or lock tite. Also
when performing this step, slide the stock axle into
the stock hub assembly location. Repeat procedure on
the passenger side using the passenger side steering
knuckle.
See Illustration # 19
49. Locate the stock cotter pins that were removed from
step # 16 and 17. Install the stock cotter pins back into
the stock location on the stock upper and lower control
arm ball joints.
50. Locate the stock hardware that connects the stock
front axle to the stock hub assembly that was removed in
step # 14. Working on the driver side, secure the stock
front axle to the hub assembly using the stock hardware.
Torque to
or lock tite.
112 ft. lbs. Make sure to use thread locker
Repeat procedure on the passenger side.
51. Move back to all associated hardware that connects
the stock lower control arms to the new one-piece lower
sub frame and torque 125 ft. lbs.
52. Locate the stock hardware that was removed from
step # 13. Working on the driver side, re-install the stock
brake caliper to the stock rotor using the stock hardware.
Make sure to use thread locker or lock tite. Torque to
90 ft lbs. Repeat procedure on the passenger side.
53. Working on the driver side, reconnect the stock ABS
lines back together. Also reconnect all other stock
mounting points on the stock ABS line. Repeat procedure
on the passenger side.
54. Locate (2) front brake line relocation brackets, (2)
5/16” x 1 1/4” bolts, (4) 5/16” flat washers, (2) 5/16”
unitorque nuts (2) 5/16” lock washers and the stock
hardware that was removed from step # 11. Working on
the driver side, install the new brake line relocation
bracket to the stock location using the stock hardware.
Make sure to use thread locker or lock tite.
Next,
secure the stock brake line bracket to the newly installed
brake line extending bracket and secure using the new
5/16” x 1 1/4” bolt and hardware.
thread locker or lock tite.
Make sure to use
Torque the stock and new
hardware to 15 ft lbs.
See Illustration # 20
55. Locate (2) new sway bar end links, (2) 3/8” x 10”
bolts, (8) sway bar end links washers, (8) sway bar end
links bushings, (2) 3/8” flat washers and (2) 3/8”
unitorque nuts. Working on the driver side, install the new
sway bar end link and hardware to the stock sway bar
and the stock lower control arm. Torque to 32 ft lbs.
Repeat procedure on the passenger side. Special Note:
If you did not invert the stock sway bar in step # 12,
invert it before you install the new sway bar end
links.
See Illustration # 21
56. Working on the driver side, carefully remove the (2)
stock rivet's on the bottom side of the stock frame rail.
Special Note: If using a drill, take special care not to
drill into any stock hoses and/or lines running down
the inside of the stock frame rail. The stock torsion bar
drop bracket may be discarded. Repeat procedure on the
passenger side.
57. Locate (2) new torsion bar drop brackets, (4) PB4902
poly bushings and (2) 1/2” x 1 1/2” anti crush sleeve.
Install the new poly bushings and sleeves into the new
torsion bar drop brackets. Special Note: Make sure to
use a lithium or moly base grease prior to inserting
the new bushings and sleeves into the new front
lateral compression arms. This will increase the life
of the bushing as well as prevent squeaking.
58. Working on the driver side, hold the new torsion bar
drop bracket to the new location on the stock frame rail.
Special Note: Make sure to center the new torsion bar
drop bracket where the stock torsion bar drop
bracket was located. With the new torsion bar bracket in
place, use a pair of vice grips and secure the new torsion
bar drop bracket to the stock frame rail. Using the new
torsion bar drop bracket as a guide, carefully drill (4)
7/16” holes into the stock frame. (2) on the side of the
frame rail and (2) on the bottom. Take Special care not
to drill into any stock hoses and/or lines running
down the inside of the stock frame rail.
Repeat
procedure on the passenger side of the vehicle.
59. Locate (8) 7/16” x 1 1/2” bolts, (16) 7/16” flat
washers, (8) 7/16” unitorque nuts and (8) 7/16” lock
washers. Working on the driver side, secure the new
driver side torsion bar drop bracket to the stock frame rail
using the new 7/16” x 1 1/2” bolt and hardware. Make
sure to use thread locker or lock tite.
Torque to
76 ft
lbs. Repeat procedure on the passenger side. Remove
the pair of vice grips holding the new torsion bar drop
bracket to the new location.
See Illustration # 22
60. Locate the driver side torsion bar that was removed
on step # 7. Install the stock torsion bar into the stock
lower control arm. Make sure that you push the stock
torsion bar as far forward as you can, this will allow you
to install the stock torsion cross member. Special Note:
Make sure that you install the stock torsion bar the
same way that it was removed. Example: driver side
vs. passenger side and front vs. rear. Repeat
procedure on passenger side.
61. Working on the driver side, install the stock torsion
bar cross member to the newly installed torsion bar drop
brackets and secure using the stock hardware. Make
sure to use thread locker or lock tite.
Torque to
95 ft
lbs. Repeat procedure on the passenger side.
See Illustration # 23
62. Locate the stock driver and passenger side torsion
bar key’s that were removed from step # 6. Working on
the driver side, install the stock torsion bar key back into
the stock torsion bar cross member. Holding the stock
torsion bar key into the stock location, slide the driver
side torsion bar into the stock torsion bar key. Repeat
procedure on the passenger side.
63. Locate the small metal adjusting blocks and bolts that
were removed from step # 6. Working on the driver side,
attach the torsion bar removing tool, making sure that the
unloading bolt in the center tool is in the small divot of the
torsion bar key. Adjust the torsion bar key up high
enough so that the small metal adjusting block and stock
bolt can be re-installed, Refer back to step # 5 and adjust
the stock bolt to the stock location. Repeat procedure on
passenger side.
64. Move back to all newly installed brackets and make
sure that all stock and new hardware is torqued to proper
specifications. Now re-connect the front differential’s
electronic coupler and vent hose.
Special Note: Refer to
the torque sheet and torque to proper settings.
65. Locate (2) 5/8” x 2 1/2” poly shock bushings, (2) 1/2”
x 2 1/2” shock sleeves, the stock upper and lower shock
hardware that was removed from step # 3 and the new
shock boots. Install the new shock boots onto the new
shocks. Insert the new poly shock bushings and sleeves
into the upper eyelet of the new shocks.
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 23” fully extended nitrogen gas
shock. Make sure to use a lithium or moly base
grease prior to inserting the new bushings into the
new shock. This will increase the life of the bushing
as well as prevent squeaking.
Install the lower shock
bushing and sleeve into the lower eyelet of the new
shock. Special Note: Make sure to use a lithium or
moly base grease prior to inserting the new bushings
into the new shock. This will increase the life of the
bushing as well as prevent squeaking. Working on the
driver side, install the new shock into the stock location
and secure using the stock hardware. Torque the upper
and lower stock hardware to
70 ft lbs.
Repeat procedure
on passenger side.
66. Locate the stock inner rubber fender splash guards
that were removed from step # 2. Working on the driver
side, re-install the inner rubber fender splash guard.
Repeat procedure on the passenger side.
67. Re-install the tires and wheels and carefully lower the
vehicle to the ground.
68. Check and double check to make sure that all steps
were performed properly. Check and double check to
make sure that all new and stock hardware has been
torque to proper torque specifications. Refer to the torque
specification sheet at the end of the installation manual.
69. Carefully lower the vehicle to the ground.
70. An exhaust modification is required once the
suspension system has been completed. After the rear
end installation is complete take the vehicle directly to a
muffler shop and have the exhaust modification
performed. Once the exhaust modification has been
performed re-install the stock front drive line back into the
stock location using the stock hardware that was
removed from step # 5. Torque to
35 ft lbs.
Congratulation, Front End Installation Complete!
Rear End Installation:
71. 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.
72. Locate (1) rear brake line extending bracket, (1) 5/16”
x 1 1/4” bolt, (2) 5/16” flat washers, (1) 5/16” unitorque
nut and (1) 5/16” lock washer. Remove the stock brake
line bracket from the rear differential and save stock bolt
for later re-installation. Secure the new brake line bracket
to the rear differential housing using the stock bolt.
Special Note: Make sure to use thread locker or lock
tite. Next, attach the stock brake line bracket to the newly
installed brake line bracket and secure using the new
5/16” x 1 1/4” bolt and hardware. Torque to 16 ft. lbs.
See Illustration # 24
73. 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.
74. Working on the driver side, remove the stock shock
and save the stock hardware for later re-installation.
Longer shocks are needed, so the stock shocks 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 shocks.
Repeat procedure on passenger
side.
75. Working on the driver side, remove the stock sway
bar end links for the stock upper and lower location. Save
the stock hardware. The stock end link may be
discarded. Repeat procedure on the passenger side.
76. Working on the driver side, remove the (2) stock rear
U-bolts and discard. Set the upper and lower U-bolt
plates a side for later re-installation. Repeat procedure on
passenger side
77. Lower down on both hydraulic floor jacks at the same
time until the stock springs separate from the stock rear
axle. Lower down approximately 4”. Special Note: Make
sure not to over extended any brake lines or hoses
when lowering axle.
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