Tuff Country 14960 User Manual

Part # 14960
2006 Chevy or GMC 1500
Strong 4”suspension system

Parts contained in Box 1 of 3

Part

# Description Qty

.

14955-39 Front cross member 1
14955-40 Rear cross member 1
14955-41 4” integrating skid plate 1
81350 Rear add-a-leaf / kit box 1
14955NB Hardware box 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 cross member bracket 2
DSFSB-01 DS front shock relocation bracket 1
PSFSB-01 PS front shock relocation bracket 1
BL302 3” rear lifted block 2
5U-9262S 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
14959NB1 Hardware bag 1
9804 1” axle spacers 2
S10120 DS differential sleeve 1
14960INST Instruction manual (customer copy) 1
14960INST Instruction manual (Installer 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 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.

Installation manual

Strong 4” suspension system

2006

Chevy or GMC 1500

Part # 14960

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 lock tite 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
33x12.50 tire package. If larger than a 33x12.50 tire is
installed on your vehicle in conjunction with part #
14960; Tuff Country assumes no liability and the
warranty will be VOID.

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 vehicle may encounter a front
drive line vibration. If this is the case on the vehicle
that you are working on, the stock front drive line may
need to be rebalanced. If the stock front drive line is
rebalanced and the vibration still occurs, a new front
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. Tuff Country recommends installing a 23”
fully extended nitrogen gas shock in the front and a
30” fully extended nitrogen gas shock in the rear.

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.

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 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

PB6199 (bump stop) 2
PB2408 (poly bushing) 2
MO2220 (poly bushing) 4
PB106300018 (Sway bar bushing) 8
S10113 (Sway bar end link washer) 8
PB8297 (front shock upper bushing) 4
S10107 (front shock upper washer) 4
SUW-916 (9/16” u-bolt washer) 2
BLR01 (brake line relocation bracket) 1
5161B (5/16” x 1” bolt) 1
14WA (1/4” USS flat washer) 2
516UN (5/16” unitorque nuts) 1
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 8

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 14959NB1 includes:

Description

Quantity

1/2” x 1 1/2” bolts 6
7/16” USS flat washers 12
1/2” unitorque nuts 6

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 @ [phone].

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 vent tube opening. On occasion, the
customer may find burping of fluid coming out of the
front vent tube.

Recommended tools selection:

Torsion bar puller
(Part # 7822A / LSP code: 769 006 21)
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, 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.

Photo # 1 / Photo # 2

3. 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
aside for later re-installation. Repeat procedure on the
passenger side.

Photo # 3 / Photo # 4

4. 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.

Photo # 5

5. 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.

6. Remove the stock lower skid plate and discard the stock
lower skid plate. Save the (2) stock mounting bolts for later
re-installation. The rear mounting hardware may be
discarded.

Photo # 6

7. Remove the stock upper skid plate from the stock
location. Save the stock upper skid plate and stock
hardware for later re-installation.

Photo # 7

8. 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.

Photo # 8 / Photo # 9

9. 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. Repeat procedure on the
passenger side.

Photo # 10

10. 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
re-installation. 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: Hitting the stock

knuckle with a hammer will make removal of the stock
outer tie rod easier. Take special care not to rip or tear
the stock outer tie rod ball joint dust boot. Repeat

procedure on the passenger side.

Photo # 11 / Photo # 12

11. 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. Repeat procedure on the passenger side.

Photo # 13 / Photo # 14

12. 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 on the stock

frame rail, stock upper control arm and the stock brake line
bracket that was removed from the stock knuckle in step #

11. Repeat procedure on the passenger side.

Photo # 15 / Photo # 16
Photo # 17 / Photo # 18

13. 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. Repeat procedure on the passenger side.

Photo # 19 / Photo # 20

14. Working on the driver side, remove the stock rotor and
set aside for later re-installation. Repeat procedure on the
passenger side.

Photo # 21

15. Working on the driver side, remove the stock cap right
in the middle of the stock hub assembly. Set the stock cap
aside for later re-installation. Repeat procedure on the
passenger side.

Photo # 22

16. 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 re-installation. Repeat
procedure on the passenger side.

Photo # 23

17. 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. Repeat procedure on the
passenger side.

Photo # 24

18. 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 aside
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.

Repeat procedure on the passenger side.

Photo # 25

19. 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 damage 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. Repeat procedure on

the passenger side.

Photo # 26 / Photo # 27

20. 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 damage 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. Repeat procedure on

the passenger side.

Photo # 28 / Photo # 29

21. 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 aside for later re-installation. Repeat procedure on the
passenger side.

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 for
later re-installation. Carefully remove the stock knuckle
from the stock hub assembly. Special note: Striking the

stock hub assembly with a hammer will make removal
easier. Also, take special care not to damage the stock
hub assembly during removal. Set the stock hub

assembly aside for further instructions. A new steering
knuckle is used, the stock steering knuckle can be
discarded. Repeat procedure on the passenger side
knuckle.

Photo # 30 / Photo # 31

23. Locate the new driver side steering knuckle. Using the
stock hardware that was removed from step # 22, 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. Set the new driver side
steering knuckle and hub assembly aside for further
instructions. Repeat procedure on the passenger side.

Photo # 32

24. 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 aside for later re-installation. Repeat
procedure on the passenger side.

Photo # 33 / Photo # 34

25. 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 # 35

26. 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. Working on the driver
side, remove the (2) stock bolts holding the stock rear cross
member to the stock bracket that is welded to the stock rear
lower control arm pocket. The (2) stock bolts and the stock
rear cross member may be discarded.

Photo # 36 / Photo # 37

27. 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 rear cross member. Also, at this

time, cut the rest of the stock bracket off the stock rear
lower control arm pocket. Take special care not to cut into
the stock rear lower control arm pocket. Special note: Tuff

Country EZ-Ride highly recommends not using a
cutting torch when performing step. Clean and dress
up any exposed metal.

Photo # 38 / Photo # 39

Photo # 40

28. Remove the stock front drive line from the stock front
differential. Carefully tie the stock front drive line up and out
of the way. Save the stock hardware for later re-installation.

Photo # 41 / Photo # 42

29. Working on the passenger side of the stock front
differential, 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. Also, disconnect the
4WD wire harness from any other attaching points of
the front differential.

Photo # 43

30. Working on the driver side of the stock front differential,
locate and pull the vent tube off of the differential.

Photo # 44

31. 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.

32. 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.

Photo # 45

33. 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.

Photo # 46

34. 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.

35. 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 # 47 / side view

Photo # 48 / pre cut view

Photo # 49 / nose cut off of the front differential

36. 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.

37. 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. Also, locate (1)
S10120 sleeve that was packaged with the installer copy of
the instruction manual. Working on the front differential,
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. 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 and new spacer sleeve. Add some
thread locker or lock tite and torque to 34 ft. lbs. Move 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 add some thread locker or lock tite 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 vent tube opening. On occasion, the
customer may find burping of fluid coming out of the
front vent tube.

Photo # 50

38. 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 # 51 / Photo # 52

39. Locate the new passenger side differential relocation
bracket and the stock hardware that was removed from
step # 33. Working on the passenger side, install the new
passenger side differential relocation bracket into the stock
upper location and secure using the stock hardware. Do
not tighten at this point. Special note: 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.

40. 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.

41. 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. Also
at this time, remove the hydraulic floor jack holding the
passenger side of the differential ONLY. Make sure not to
remove the hydraulic floor jack holding the driver side of the
front differential at this time.

Photo # 53 / Photo # 54

42. Locate the new rear cross member. Also, locate the
stock lower control arm rear mounting hardware that was
removed in step # 24. Install the new rear cross member to
the stock rear lower control arm pockets and secure using
the stock hardware. Special note: Make sure to install

the stock hardware from the front of the vehicle
towards the rear of the vehicle. Do not tighten at this
point.

Photo # 55 / Photo # 56

43. Locate the new front cross member. Also, locate the
stock lower control arm front mounting hardware that was

removed in step # 24. Install the new front cross member to
the stock front lower control arm pockets and secure using
the stock hardware. Special note: Make sure to install

the stock hardware from the front of the vehicle
towards the rear of the vehicle. Do not tighten at this
point.

Photo # 57

44. Carefully lower down on the hydraulic floor jack holding
the driver side of the stock front differential until the front
differential seats properly into the rear cross member and
the newly installed driver side differential relocation
bracket can be installed to the front cross member.

45. Locate the stock hardware that was removed from step
# 32. Secure the newly installed front differential relocation
bracket to the newly installed front cross member. Secure
using the stock hardware. Do not tighten at this point.

Photo # 58

46. Locate the stock hardware that was removed from step
# 25. Install the rear portion of the front differential into the
tab on the newly installed rear cross member. Secure using
the stock hardware. Do not tighten at this point.

Photo # 59

47. Carefully remove the hydraulic floor jack that is holding
the driver side of the stock front differential.

48. 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 # 24. Working on
the driver side, install the stock lower control arm into the
newly installed front cross member and secure using the
new 5/8” x 4 1/2” bolt and hardware. Do not tighten at this
point. Install the stock lower control arm into the newly
installed rear cross member and secure using the new 5/8”
x 5 1/2” bolt and hardware. Do not tighten at this point.
Repeat procedure on the passenger side.

Photo # 60

49. Using a hydraulic floor jack, carefully raise up on the
front portion on the newly installed front cross member until
the newly installed front cross member sits flush with the
stock front cross member.

50. Locate (2) stock upper skid plate lower bolts that were
removed from step # 6. Working on the driver side, secure
the newly installed front cross member 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 the hydraulic floor jack from under the
front cross member.

Photo # 61 / Photo # 62

51. Move back to the stock and new hardware that is
attaching the new passenger side differential relocation

bracket to the stock location and the stock differential and
add some thread locker or lock tite and torque the stock
hardware to 75 ft lbs. and the new 9/16” hardware to 85 ft

lbs.

Photo # 63

52. Locate the new 4” integrating skid plate. Also, locate (6)
1/2” x 1 1/2” bolts, (12) 7/16” USS flat washers and (6) 1/2”
unitorque nuts from hardware bag 14959NB1. Install the
new 4” integrating skid plate to the front and rear cross
members and secure using the new 1/2” x 1 1/2” bolts and
hardware. Do not tighten at this point.

Photo # 64

53. Working on the driver side, move back to the stock
hardware attaching the new front cross member into the
stock lower control arm pocket and add some thread
locker or lock tite and torque to 105 ft lbs. Repeat
procedure on the passenger side.

Photo # 65

54. Working on the driver side, move back to the stock
hardware attaching the new rear cross member into the
stock lower control arm pocket and add some thread
locker or lock tite and torque to 105 ft lbs. Repeat
procedure on the passenger side.

Photo # 66

55. Working on the driver side, move back to the stock
hardware attaching the newly installed driver side
differential relocation bracket to the newly installed front
cross member and add some thread locker or lock tite and
torque to 75 ft lbs.

Photo # 67

56. Working on the driver side, move back to the stock
hardware attaching the rear portion of the stock front
differential to the newly installed rear cross member and
add some thread locker or lock tite and torque to 75 ft lbs.

Photo # 68

57. Move back to the new hardware attaching the new skid
plate to the front and rear cross member and add some
thread locker or lock tite on all (6) bolts and torque all (6)
bolts to 70 ft lbs.

Photo # 69 / Photo # 70

58. 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.

Photo # 71

59. Locate the stock front drive line hardware that was
removed in step # 28. Re-install the stock front drive line to
the stock front differential using the stock hardware. Make
sure to use thread locker or lock tite and torque to 18 ft lbs.

Photo # 72

60. Locate (2) poly bump stops from hardware bag

14955PL. Also, locate (2) 3/8” unitorque nuts and (2) 5/16”
USS flat washers from hardware bag 14955NB1. Working
on the driver side rear pocket of the newly installed rear
cross member, secure the new poly bump stop using the
new 3/8” hardware. Make sure to use thread locker or lock
tite and torque to 28 ft lbs. Repeat procedure on the
passenger side.

Photo # 73 / Photo # 74

61. 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 # 21. 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.

Photo # 75 / Photo # 76
Photo # 77 / Photo # 78

62. Locate the stock CV axles that were removed from step
# 18. Working on the driver side, carefully install the stock
CV axle back into the stock hub assembly. Repeat
procedure on the passenger side.

63. Locate (2) axle half shaft spacers. Also, locate (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. Make sure to use thread
locker or lock tite and torque to 65 ft. lbs. 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 # 17. Repeat

on the passenger side.

Photo # 79

64. Locate the stock hardware that connects the stock front
axle to the stock hub assembly that was removed in step #

16. Working on the driver side, secure the stock front axle
to the stock hub assembly using the stock hardware. Make
sure to use thread locker or lock tite and torque to 112 ft.
lbs. Also, re-install the hub assembly center cap that was
removed from step # 15. Repeat procedure on the
passenger side.

Photo # 80

65. 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.

Photo # 81

66. Locate the stock rotors that were removed in step # 21.

Working on the driver side, install the stock rotor into the
stock location. Repeat procedure on the passenger side.

67. Locate the stock brake caliper hardware that was
removed in step # 13. Working on the driver side, re-install
the stock brake caliper to the newly installed knuckle and
secure using the stock hardware. Make sure to use thread
locker or lock tite and torque to 76 ft. lbs. Repeat
procedure on the passenger side.

68. Locate the stock brake line hardware that was removed
in step # 11. Working on the driver side, attach the stock
brake line bracket to the stock upper control arm and
secure using the stock hardware. Make sure to use thread
locker or lock tite and torque to 18 ft lbs. Now 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. Make sure
to use thread locker or lock tite and torque to 18 ft lbs.
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.

Photo # 82 / Photo # 83

69. Locate the new driver and passenger side front shock
relocation bracket. Locate (2) 1/2” USS flat washers from
hardware bag 14955NB4. Locate (2) SUW-916 u-bolts
washers from hardware bag 14955PL. 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
into the stock shock location on the stock lower control arm.
Secure using the new 1/2” x 3 1/4” bolts and hardware. Do

not tighten at this point. Special note: We want to
install (1) 9/16” u-bolts washer as a spacer between the
new bracket and the front of the stock location. Please
see photo # 84 for proper washer placement. Also, we
want to use (1) 1/2” USS flat washer as a spacer
between the new bracket and the rear of the stock
location. Please see photo # 85 for proper washer
placement. Repeat procedure on the passenger side.

Photo # 84 / Photo # 85

70. 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.
Working on the driver side, push the new driver side shock
relocation bracket towards the inside of the vehicle and
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 shock relocation
bracket to the stock lower control arm using the new 7/16”
x 1 1/2” bolt and hardware. Do not tighten at this point.

Photo # 86 / Photo # 87

71. Move back to the new 1/2” x 3 1/4” bolt holding the new
driver side shock relocation bracket into the stock location
and add some thread locker or lock tite and torque to 80 ft

lbs. Repeat procedure on the passenger side.

Photo # 88

72. Move back to the new 7/16” x 1 1/2” bolt holding the
new driver side shock relocation bracket to the stock bump
stop on the stock lower control arm and add some thread
locker or lock tite and torque to 42 ft lbs. Repeat procedure
on the passenger side.

Photo # 89

73. Working on the driver side and using a sawzall or 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 # 90

74. 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 proper shocks.
Tuff Country recommends using a 23” fully extended
nitrogen gas shock. Locate the new lower poly bushings

and proper shock sleeves that are packaged with the new
shocks and install the new lower shock bushings and
proper shock sleeves into the lower eyelet of the new
shocks. Special note: If need be, locate (2) S10074
sleeves from hardware bag 14955SL. Make sure to use
a lithium or moly base grease prior to inserting the new
lower shock bushings and sleeves into the new lower
shock eyelet. This will increase the life of the bushing as
well as prevent squeaking. Locate (4) PB8297 upper shock
bushings and (4) S10107 upper shock washers from
hardware bag 14955PL. Working on the driver side, install
the new shock into the stock upper location and secure
using the new shock nut that was packaged with the new
shock. Also, make sure to use the new upper shock
bushings and upper shock washers. Torque to 28 ft lbs.
Repeat procedure on the passenger side. Tuff Country

EZ-Ride Suspension highly recommends that the
shocks are installed with shock boots. If shock boots
are not installed, damaged my occur to the piston of
the new shock.

75. 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. Also, locate (2) 1/2” USS flat washers from
hardware bag 14955NB4. Working on the driver side,
secure the bottom of the new shock to the newly installed
shock relocation bracket using the new 1/2” x 3 1/4” bolt
and hardware. Make sure to use thread locker or lock tite
and torque the lower 1/2” bolt to 80 ft lbs. Special note:

When installing the new shock into the lower shock
relocation bracket, make sure to use (1) 1/2” USS flat
washers as a spacers on the front lower portion of the
new shock relocation bracket. Repeat procedure on the
passenger. Special note: After the installation of the