Tuff Country 14956 User Manual
Installation manual
4” Suspension system
2006
Chevy or GMC 1500
PART # 14956
Sj011106rev.01
Part # 14956
2006 Chevy or GMC 1500
4” Suspension system
Parts contained in Box 1 of 3
Part # Description Qty.
14955-33 One piece sub-frame 1
81350 Rear add-a-leaf kit box 1
14955NB Hardware bag 1
Parts contained in Box 2 of 3
Part # Description Qty.
DSDIFF-01 DS differential relocation bracket 1
14955-07 PS differential relocation bracket 1
TBD99-01 Torsion bar relocation brackets 2
DSFSB-01 DS front shock relocation bracket 1
PSFSB-01 PS front shock relocation bracket 1
BL302 Rear lifted blocks 2
5U-9296S 9/16” x 2 3/4” x 12 5/8” square u-bolts 4
916NW Hardware bag 1
14955PL Hardware bag 1
14955SL Hardware bag 1
9804 1” axle spacers 2
14956INST Instruction sheet (installer copy) 1
14956INST Instruction sheet (customer copy) 1
MIRRORHANGER Rear view mirror hanger 1
WARNINGDECAL Warning decal 1
DECAL Window sticker 1
Parts contained in Box 3 of 3
Part # Description Qty.
C4I1SN-35M Driver side knuckle 1
C4I1SN-36M Passenger side knuckle 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.
For a list of all parts, please refer to the Parts
Description Page, at the end of the Installation
Manual.
Make sure to use thread locker or locktite on all new
and stock hardware associated with the installation
of this suspension system.
It is the responsibility of the installers to make sure
that they give a copy of the installation manual, along
with the warning decals to the customer. This
information contains post installation procedures
and warranty information.
Important customer information
Tuff Country EZ-Ride Suspension highly
recommends that a qualified or a certified mechanic
performs this installation.
If you desire to return your vehicle to stock, it is the
customers responsibility to save all stock hardware.
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 or the installers responsibility to
read and understand all steps before installation
begins. 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.
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.
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 information that needs to be read before
installation begins;
This suspension system will not work in conjunction
with vehicles that are equipped with stabilitrac.
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.
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.
After installation, some vehicles may encounter a
front drive line vibration. If this is the case on the
vehicle that you are working on, the stock drive line
may need to be rebalanced. If the stock drive line is
rebalanced and the vibration still occurs, a new drive
line may be needed.
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.
Hardware Bag 14955SL Includes:
Description Quantity
S10074 (.700” x .563” x 1.500”) 4
S10082 (.875” x .563” x 2.080”) 1
S10110 (.750” x .563” x 9.500”) 2
Hardware Bag 14955PL Includes:
Description Quantity
PBBS1 (bump stop) 2
PB2408 (poly bushing) 2
PB4902 (poly bushing) 4
MO2516 (Sway bar bushing) 8
S10113 (Sway bar end link washer) 8
PB8297 (front shock upper bushing) 4
S10107 (front shock upper washer) 4
LUBE (poly lube pack) 2
Hardware Bag 14955NB Includes:
Bag # 1
Description Quantity
3/8” unitorque nuts 2
5/16” USS flat washers 2
10 mm x 55 mm bolts 12
10 mm x 60 mm all thread bolt 4
10 mm lock washers 16
1/4” USS flat washer 2
Bag # 2
Description Quantity
7/16” x 1 1/2” bolts 10
7/16” x 3” bolts 1
7/16” unitorque nuts 11
3/8” USS flat washers 22
Bag # 3
Description Quantity
1/2” x 3 1/4” bolts 4
1/2” unitorque nuts 6
7/16” USS flat washers 8
1/2” x 15” bolts 2
Bag # 4
Description Quantity
9/16” x 1 3/4” Bolts 2
9/16” unitorque nuts 2
1/2” USS flat washers 10
Bag # 5
Description Quantity
5/8” x 4 1/2” bolts 2
5/8” x 5 1/2” bolts 2
5/8” unitorque nuts 4
9/16” USS flat washers 8
Hardware Bag 916NW Includes:
Description Quantity
9/16” u-bolt high nuts 8
9/16” u-bolt harden washers 8
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.
Special post installation procedure: Tuff Country EZRide Suspension highly recommends adding a
minimum of 1 pint, but no more that 1 1/2 pints, of
proper front differential fluid into the front
differential. To achieve this, you may have to fill the
differential with it on its side or you may have to
insert the fluid through the vend tube opening. On
occasion, the customer may find burping of fluid
coming out of the front vent tube.
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:__________________________
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 a pair of jack stands. Place a jack stand on both the
driver and passenger side. Next, remove the tires and
wheels from both sides.
2. Remove the stock lower skid plate and discard the
stock lower skid plate and hardware.
3. Remove the stock front upper plate. If you are going to
re-install the stock upper skid plate back into the stock
location, save the (3) stock upper bolts, (2) stock lower
bolts and the stock front upper skid plate for later reinstallation. If you are not going to re-install the stock
front upper skid plate, save (2) stock bolts and discard all
the other stock hardware and the stock front upper skid
plate.
4. Remove the stock front driveline from the stock
location, and save the stock driveline and hardware for
later re-installation.
5. Working on the driver side, remove the stock shock
from the stock location. The stock shock and hardware
may be discarded. Special note: New longer front
shocks are needed, if you have not already ordered
shocks, please contact Tuff Country or your local
Tuff Country dealer and order the proper shocks. Tuff
Country recommends using a 23” fully extended
nitrogen gas shock. Repeat procedure on the
passenger side.
6. Measure the 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:__________
Photo # 1
7. Working on the driver side, attach the torsion bar
removing tool to the stock torsion bar cross member,
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. Set the stock torsion bar block and
hardware aside for later re-installation. Repeat procedure
on passenger side.
8. 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. Once you tap the stock torsion
bar out of the stock torsion bar cross member, the stock
torsion bar key will fall out. Set the stock torsion bar key a
side for later re-installation. Repeat procedure on the
passenger side.
9. Working on the driver side, remove the stock hardware
that connects the stock torsion bar cross member to the
stock mounting point. Set the stock hardware aside for
later re-installation. Special note: The stock mounting
point is on the inside of the stock frame rail. Repeat
procedure on the passenger side. Remove the stock
torsion bar cross member from the stock location and set
aside 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 aside for
later re-installation. Repeat procedure on passenger side.
11. Working on the driver side, remove the stock sway
bar end link from the stock location and discard the stock
end link and stock hardware. Special note: New end
links and bushings are included with this suspension
system. Repeat procedure on the passenger side.
12. Working on the driver side, remove the stock nut that
connects the stock outer tie rod ball joint to the stock
steering knuckle. Set the stock nut aside for later reinstallation. Carefully break the stock taper on the stock
outer tie rod ball joint and remove the stock outer tie rod
from the stock knuckle. Special note: Take special care
not to rip or tear the stock outer tie rod ball joint dust
boot.
Photo # 2
13. Working on the driver side, remove the stock brake
line bracket that connects to the top of the stock steering
knuckle, and save the stock hardware. Next, remove the
stock bolt that connects the stock brake line bracket to
the stock upper control arm, and save hardware for later
re-installation.
Photo # 3
14. Working on the driver side, locate the ABS line quick
disconnect located above the stock upper control arm.
Disconnect the ABS lines from each other. Also,
disconnect the ABS line from any other mounting points.
15. Working on the driver side, remove the (2) stock bolts
that connect the stock brake caliper to the stock knuckle.
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.
16. Working on the driver side, remove the stock rotor
and set a side for later re-installation.
17. Working on the driver side, remove the stock cap
right in the middle of the stock hub assembly. Set the
stock cap a side for later re-installation.
Photo # 4
18. Working on the driver side, remove the stock
hardware that connects the stock axle to the stock hub
assembly. Save the stock hardware for later reinstallation.
19. 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.
Photo # 5
20. Working on the driver side, remove the (6) stock bolts
holding the inner CV axle to the stock front differential.
Discard the stock hardware. Carefully remove the stock
CV axle from the stock location and set the stock CV axle
a side for later re-installation. Special note: During the
removal of the stock CV axle, take special care not to
damage the threads of the CV axle or the CV axle
dust boot.
21. Working on the driver side, loosen but do not remove
the stock nut that connects the stock upper control arm
ball joint to the stock steering knuckle. Carefully break
the stock taper by striking the stock knuckle with a
hammer. Special note: Take special care not to
damaged the stock upper control arm ball joint or rip
the stock upper control arm ball joint dust boot. For
now, leave the stock upper control arm attached to the
stock knuckle. We want to just break the stock taper for
now.
22. Working on the driver side, loosen but do not remove
the stock nut that connects the stock lower control arm
ball joint to the stock steering knuckle. Carefully break
the stock taper by striking the stock knuckle with a
hammer. Special note: Take special care not to
damaged the stock lower control arm ball joint or rip
the stock lower control arm ball joint dust boot. For
now, leave the stock lower control arm attached to the
stock knuckle. We want to just break the stock taper for
now.
23. Working on the driver side, move back to the stock
nuts holding the stock upper control arm ball joint and the
stock lower control arm ball joint to the stock steering
knuckle and remove completely. Save the stock
hardware for later re-installation. Carefully remove the
stock hub assembly and the stock steering knuckle from
the stock location and set a side for later re-installation.
Photo # 6
24. 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.
25. Locate the new driver side steering knuckle. Using
the stock hardware that was removed from step # 24,
secure the new driver side steering knuckle to the stock
hub assembly. Torque to 133 ft lbs. Special note: make
sure to use thread locker or lock tite.
Photo # 7
26. Set the new driver side steering knuckle and hub
assembly 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 location. Set the stock hardware and the
stock lower control arm a side for later re-installation.
28. Repeat step’s 12 - 27 on the passenger side.
29. Working on the driver side, remove the stock bolt that
connects the lower rear portion of the stock front
differential to the stock rear cross member. Save the
stock hardware for later re-installation.
Photo # 8
30. Working on the passenger side, remove the (2) stock
bolts that connect the stock rear cross member to the
stock passenger side rear lower control arm mounting
point. The (2) stock bolts may be discarded.
Photo # 9
31. Working on the driver side, measure 2 1/8” towards
the inside of the vehicle from the stock rear lower control
arm mounting point, scribe a mark on the stock rear
cross member. Using a hacksaw or suitable cutting tool,
carefully cut off the stock rear cross member along the
line that was scribed earlier in this step. The stock rear
cross member may be discarded. Special note: When
making this cut, make sure that you cut all the way
through the stock rear lower control arm mounting
point. If this cut is not performed properly, the stock
front differential will not seat properly when the front
differential is lowered into the new one piece lower
sub frame. Also, Tuff Country EZ-Ride highly
recommends not using a cutting torch when
performing step # 31. Clean and dress up any
exposed metal.
Photo # 10
32. Working on the driver side, carefully cut flush, the
remainder of the stock rear cross member that is located
on the rear portion of the stock rear lower control arm
mounting bracket. Special note: Take special care not
to cut into the stock rear lower control arm mounting
bracket. Tuff Country recommends not using a
cutting torch when performing step # 32. Clean and
dress up any exposed metal.
33. Place a pair of hydraulic floor jacks under the front
differential, and carefully raise up on both hydraulic floor
jacks at the same time, until they come into contact with
the front differential.
34. Locate the wiring harness that connects the 4WD
control panel to the front differential. Disconnect the 4WD
wiring harness from the front differential. Tie the 4WD
wiring harness up and out of the way. Special Note:
Take special care not to kink wiring.
Photo # 11
35. Disconnect any other vent hoses and/or wiring that is
connected to the front differential.
36. Working on the driver side, remove the stock
hardware that connects the upper driver side tab of the
stock front differential to the stock location. Save the
stock hardware for later re-installation.
37. Working on the passenger side, remove the (2) stock
nuts that connect the passenger side of the stock front
differential to the stock location and save the stock
hardware for later re-installation.
38. Carefully lower down on both hydraulic floor jacks at
the same allowing enough room to remove the front
differential completely from the vehicle. With the help
from a buddy, carefully remove the front differential
completely from underneath the vehicle and set the stock
front differential on the ground or on a work bench.
39. Working on the driver side of the stock front
differential upper tab, measure 2” from the stock
mounting point and scribe a mark on the stock front
differential. Using a sawzall, carefully cut the upper tab
off of the stock front differential and discard.
Photo # 12 / side view
Photo # 13 / pre cut view
Photo # 14 / nose cut off of the front differential
40. Locate the new driver side differential relocation
bracket. Locate (2) PB2408 poly bushings from hardware
bag 14955PL and (1) S10082 crush sleeve from
hardware bag 14955SL. Install the new poly bushings
and crush sleeve into the new driver side differential
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.
41. Locate (1) 7/16” X 3” bolt, (1) 7/16” unitorque nut and
(2) 3/8” USS flat washers from hardware bag 14955NB2.
Locate (4) 10 mm x 60 mm bolts and (4) 10 mm lock
washers from hardware bag 14955NB1. Referring to
photo # 15, remove the (4) stock differential mounting
bolts that connect to two halves of the front differential
together. The stock hardware may be discarded. Secure
the new driver side differential relocation bracket to the
stock front differential using the new 10 mm x 60 mm
bolts and hardware. Special note: Get all (4) new 10
mm x 60 mm bolts started but do not tighten at this
point and 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. Go back to the (4) new 10 mm x 60 mm bolts that
hold the new driver side differential relocation bracket to
the stock front differential and 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 tightened, the stock front differential
could crack. Also, Tuff Country EZ-Ride Suspension
highly recommends adding a minimum of 1 pint, but
no more that 1 1/2 pints, of proper front differential
fluid into the front differential. To achieve this, you
may have to fill the differential with it on its side or
you may have to insert the fluid through the vend
tube opening. On occasion, the customer may find
burping of fluid coming out of the front vent tube.
Photo # 15
42. Working on the passenger side stock mounting
location on the stock front differential, carefully cut off the
passenger side rear corner of the stock mounting
surface.
Photo # 16 / pre cut view
Photo # 17 / post cut view
43. Locate the new passenger side differential drop
bracket and the stock hardware that was removed from
step # 37. Working on the passenger side, install the new
passenger side differential relocation bracket into the
stock upper location and secure using the stock
hardware. Special note: Make sure to use thread
locker or lock tite and do not tighten at this point.
Also, there is a “F” cut out in this bracket, the “F” will
go towards the front of the vehicle and also if you are
standing on the passenger side wheel well looking at
the new passenger side differential relocation
bracket, you should not be able to see the mounting
hardware. This will help you make sure that the
bracket is installed properly.
44. With the help from a buddy, carefully lift the modified
front differential back onto a pair of hydraulic floor jacks
and move the hydraulic floor jacks back underneath the
vehicle so that the newly modified front differential can be
re-installed.
45. Locate (2) 9/16” x 1 3/4” bolts, (4) 1/2” USS flat
washers and (2) 9/16” unitorque nuts from hardware bag
14955NB4. Carefully install the passenger side of the
stock front differential to the previously installed
passenger side differential drop bracket. Secure using
the new 9/16” x 1 3/4” bolts and hardware. Do not
tighten at this point and make sure to use thread
locker or lock tite.
Photo # 18
46. Working on the driver side, using a tie down strap or
bungee cord, carefully tie the driver side of the stock front
differential up and out of the way so that the new one
piece lower sub frame can be installed. Once the driver
side of the front differential is tied up and out of the way,
remove the hydraulic floor jacks from under the front
differential.
Photo # 19
47. Locate the new one piece lower sub frame and the
stock lower control arm mounting hardware that was
removed from step # 27. 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 mounting
points using the stock hardware. Do not tighten at this
point and make sure to use thread locker or lock tite.
Repeat procedure on passenger side.
48. Carefully remove the tie down strap or the bungee
cord that is holding the driver side of the stock front
differential up and out of the way. Let the stock front
differential rest on the newly installed one piece lower
sub frame.
49. Locate the stock hardware that was removed from
step # 29. Install the rear portion of the front differential
into the tab on the rear portion of the new one piece
lower sub frame. Secure using the stock hardware. Do
not tighten at this point and make sure to use thread
locker or lock tite.
Photo # 20
50. Locate the stock hardware that was removed from
step # 36. Secure the newly installed front differential
relocation bracket to the front portion of the new one
piece lower sub frame. Secure using the stock hardware.
Do not tighten at this point and make sure to use
thread locker or lock tite.
Photo # 21
Note: If you are going to re-install the stock front
upper skid plate, please follow step #’s 51 - 53
Note: If you are not going to install the stock front
upper skid plate please skip to step # 54
51. Locate the stock front upper skid plate and the
mounting hardware that was removed from step # 3.
Secure the stock front upper skid plate to the upper stock
location using the (3) stock bolts. Do not tighten at this
point and make sure to use thread locker or lock tite.
52. Install the lower portion of the stock front skid plate
between the newly installed one piece lower sub frame
and the stock front cross member. Using a pair of
hydraulic floor jacks, carefully raise up on the front
portion on the one piece lower sub frame, and smash the
stock upper skid plate between the stock front cross
member and front portion of the newly installed one piece
sub frame.
53. Locate (2) stock upper skid plate lower bolts that
were removed from step # 3. Working on the driver side,
secure the newly installed one piece lower sub frame to
the stock front cross member using the stock hardware.
Torque to 38 ft lbs. Special note: Make sure to use
thread locker or lock tite. Also, make sure that the
bolts secure the lower portion of the stock upper skid
plate into the stock location. Repeat procedure on the
passenger side. Move back to the (3) stock upper bolts
and torque to 38 ft lbs. Carefully remove both hydraulic
floor jacks from under the front portion of the one piece
lower sub frame.
Note: If you installed the stock front upper skid plate,
please skip to step # 56
54. Using a pair of hydraulic floor jacks, carefully raise up
on the front portion on the one piece lower sub frame
until the one piece lower sub frame sits flush with the
stock front cross member.
55. Locate (2) stock upper skid plate lower bolts that
were removed from step # 3. Working on the driver side,
secure the newly installed one piece sub frame to the
stock front cross member using the stock hardware.
Torque to 38 ft lbs. Special note: Make sure to use
thread locker or lock tite. Repeat procedure on the
passenger side. Carefully remove both hydraulic floor
jacks from under the front portion of the one piece lower
sub frame.
56. Working in this order, torque the following stock and
new hardware to proper torque specifications. First, on
the driver side of the vehicle, torque the stock hardware
that connects the rear portion of the stock front
differential into the rear pocket of the new one piece
lower sub frame to 75 ft lbs. Next, working on the
passenger side, torque the stock hardware that connects
the new passenger side differential drop bracket to the
stock location to 75 ft lbs. Next, working on the
passenger side, torque the new hardware that connects
the stock front differential to the new passenger side
differential drop bracket to 85 ft lbs. Next, working on the
driver side, torque the stock hardware that connects the
new driver side differential relocation bracket to the front
tabs located on the front portion of the new one piece
lower sub frame to 75 ft lbs. Next, working on the driver
side, torque the stock hardware that connects the new
one piece lower sub frame to the stock front and rear
lower control arm pockets to 105 ft lbs. Finally, working
on the passenger side, torque the stock hardware that
connects the new one piece lower sub frame to the stock
front and rear lower control arm pockets to 105 ft lbs.
57. Reconnect the 4WD wiring to the front differential.
Also, reconnect any other vent hoses and/or wiring that
was connected to the stock front differential.
58. Locate (2) poly bump stops from hardware bag
16955PL. Also, locate (2) 3/8” unitorque nuts, (2) 5/16”
USS flat washers from hardware bag 14955NB1.
Working on the driver side rear pocket of the newly
installed one piece lower sub frame, secure the new poly
bump stop using the new 3/8” hardware. Torque to 28 ft
lbs. Repeat procedure on the passenger side. Make
sure to use thread locker or lock tite.
59. Locate (2) 5/8” x 4 1/2” bolts, (2) 5/8” x 5 1/2” bolts,
(8) 9/16” USS flat washers and (4) 5/8” unitorque nuts
from hardware bag 14955NB5. Also locate the stock
lower control arms that were removed from step # 27.
Working on the driver side, install the stock lower control
arm into the newly installed one piece lower sub frame’s
front location and secure using the new 5/8” x 4 1/2” bolt
and hardware. Do not tighten at this point and make
sure to use thread locker or lock tite. Install the stock
lower control arm into the newly installed one piece lower
sub frame’s rear location and secure using the new 5/8” x
5 1/2” bolt and hardware. Do not tighten at this point
and make sure to use thread locker or lock tite.
Repeat procedure on the passenger side.
Photo # 22
60. Locate the new driver side steering knuckle and the
stock hub assembly. Also, locate the stock hardware for
the upper control arm ball joint and the lower control arm
ball joint that was removed in step # 23 . Using the stock
hardware, secure the new driver side steering knuckle
and stock hub assembly to the stock upper control arm
ball joint and the stock lower control arm ball joint using
the stock hardware. Torque the stock upper control
hardware to 74 ft lbs. and the stock lower control arm
hardware to 101 ft lbs. Make sure to use thread locker
or lock tite. Repeat procedure on the passenger side
using the passenger side steering knuckle.
61. Locate the stock CV axles that were removed from
step # 20. Working on the driver side, carefully install the
stock CV axle back into the stock hub assembly. Repeat
procedure on the passenger side.
62. Locate (2) axle half shaft spacers, (12) 10 mm x 55
mm hex bolts and (12) 10 mm lock washers from
hardware bag 14955NB1. Working on the driver side,
install (1) new axle spacer between the stock front
differential and the stock CV axle. Secure using the new
10 mm x 55 mm bolts and 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 scribe mark that was made in
step # 19. Repeat on the passenger side.
Photo # 23
63. Locate the stock hardware that connects the stock
front axle to the stock hub assembly that was removed in
step # 18. Working on the driver side, secure the stock
front axle to the stock hub assembly using the stock
hardware. Torque to 112 ft. lbs. Make sure to use
thread locker or lock tite. Also, re-install the hub
assembly center cap that was removed from step #
17. Repeat procedure on the passenger side.
64. 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.
65. Locate the stock rotors that were removed in step #
16. Working on the driver side, install the stock rotor into
the stock location. Repeat procedure on the passenger
side.
66. Locate the stock brake caliper hardware that was
removed in step # 15. Working on the driver side, reinstall the stock brake caliper to the newly installed
knuckle and secure using the stock hardware. Torque to
76 ft. lbs. Make sure to use thread locker or lock tite.
Repeat procedure on the passenger side.
67. Locate the stock brake line hardware that was
removed in step # 13. Working on the inside of the newly
installed driver side knuckle, reconnect the stock brake
line bracket to the new driver side knuckle. Secure using
the stock hardware. Torque to 18 ft lbs. Make sure to
use thread locker or lock tite. Also reconnect the stock
brake line bracket to the stock upper control arm using
the stock hardware. Torque to 18 ft lbs. Make sure to
use thread locker or lock tite. Repeat procedure on the
passenger side. Special note: If need be, the stock
bracket line bracket that wraps around the stock
brake line may need to be opened up so that the
brake line does not get kinked.
68. Locate the stock outer tie rod ball joint hardware that
was removed from step # 12. Working on the driver side,
install the stock outer tie rod to the new steering knuckle
using the stock hardware. Make sure to use thread locker
or lock tite and torque to 53 ft. lbs. Special note: The
new steering knuckle has a reverse taper on it where
the stock outer tie rod mounts to it, make sure to
install the outer tie rod the proper way. The stock
outer tie rod nut will now be installed on the bottom
side of the new steering knuckle.
69. Locate the new driver and passenger side front shock
relocation bracket. Locate (4) 1/2” USS flat washers from
hardware bag 14955NB4. Locate (2) 7/16” x 1 1/2” bolt,
(4) 3/8” USS flat washers and (2) 7/16” unitorque nuts
from hardware bag 14955NB2. Locate (2) 1/2” x 3 1/4”
bolts, (4) 7/16” USS flat washers and (2) 1/2” unitorque
nuts from hardware bag 14955NB3. Working on the
driver side, install the new driver side shock relocation
bracket to the stock location and secure using the new
1/2” x 3 1/4” bolt and hardware. Do not tighten at this
point. Make sure to use thread locker or lock tite.
Special note: When installing the new shock
relocation bracket, make sure to use (2) 1/2” USS flat
washers as spacers on the front lower portion of the
new shock relocation bracket and the stock location.
Using the driver side shock relocation bracket as a guide,
drill a 7/16” hole into the stock lower control arm bump
stop location. Secure the new driver side bracket to the
stock lower control arm using the new 7/16” x 1 1/2” bolt
and hardware. Torque to 42 ft lbs. Make sure to use
thread locker or lock tite. Torque the new 1/2” x 3 1/4”
bolt to 110 ft lbs. Repeat procedure on the passenger
side.
Photo # 24
70. Working on the driver side, using a die grinder,
carefully cut off the front corner of the stock front bump
stop. This will allow clearance so the front shock does not
contact the front corner of the stock front bump stop.
Special note: Make sure to check that there is
clearance once the new shock is installed. If contact
occurs, carefully cut more out of the front corner of
the stock front bump stop. Repeat procedure on the
passenger side.
Photo # 25
71. Locate (2) new torsion bar cross member relocation
brackets. Locate (4) PB4902 poly bushings from
hardware bag 14955PL. Also, locate (2) S10074 sleeves
from hardware bag 14955SL. Install the new poly
bushings and sleeves into the new torsion bar cross
member relocation brackets. Special note: Make sure to
use a lithium or moly base grease prior to inserting
the new bushings and sleeves into the new torsion
bar cross member relocation brackets. This will
increase the life of the bushing as well as prevent
squeaking.
72. Working on the driver side, hold the new torsion bar
cross member relocation bracket to the new location on
the stock frame rail. Special note: Using the larger cut
out holes in the torsion bar cross member relocation
bracket over the stock rivets on the bottom of the
stock frame rail with help center the new torsion bar
cross member relocation bracket. With the new torsion
bar cross member relocation 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 cross
member relocation 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. Remove the
pair of vice grips that is holding the new torsion bar cross
member relocation bracket to the frame rail. Repeat
procedure on the passenger side of the vehicle.
73. Locate (8) 7/16” x 1 1/2” bolts, (16) 3/8” USS flat
washers and (8) 7/16” unitorque nuts from hardware bag
14955NB2. Working on the driver side, secure the new
driver side torsion bar cross member relocation 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.
See Illustration # 26
74. Locate the stock torsion bars that were removed from
step # 10. Refer to the marks that were made in step # 8.
This will allow you to re-install the stock torsion bars back
into the stock location. Example: Driver vs. Passenger
and Front vs. Rear. Working on the driver side, slide the
stock torsion bar back into the stock rear lower control
arm. Slide the stock torsion bar far enough forward so
that the stock torsion bar cross member can be reinstalled. Repeat procedure on the passenger side.
75. Locate the stock torsion bar cross member and stock
hardware that was removed from step # 9. Install the
stock torsion bar cross member to the newly installed
torsion bar cross member relocation brackets and secure
using the stock hardware. Make sure to use thread
locker or lock tite. Torque to 90 ft lbs.
76. Locate the stock torsion bar keys that were removed
from step # 8. Working on the driver side, install the stock
torsion bar key back into the stock location in the stock
torsion bar cross member. Slide the stock torsion bar
back into the previously installed torsion bar key. Repeat
procedure on the passenger side.
77. Locate the torsion bar adjusting blocks and hardware
that was removed from step # 7. Working on the driver
side, attach the torsion bar removing tool to the stock
torsion bar cross member, 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 reinstalled back into the stock location. Refer back to the
measurements that were made in step # 6, and set to the
torsion bar adjusting bolt to the stock setting. Repeat
procedure on the passenger side. Carefully remove the
torsion bar removing tool from the stock torsion bar cross
member.
78. Locate the new front shocks. Special note: New
longer front shocks are needed, if you have not
already ordered shocks, please contact Tuff Country
or your local Tuff Country dealer and order the
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