Tuff Country 14965 User Manual

PART NUMBER : 14965
2000—CURR. SUBURBAN W/ REAR COIL SPRINGS
4” SUSPENSION SYSTEM WITH FRONT SPINDLES

PARTS LIST:

Part # Description Qty.

C4I1SN-07 Passenger Side Differential Drop 1
C4I1SN-23 Driver Side Front Shock Bracket 1
C4I1SN-24 Passenger Side Front Shock Bracket 1
C4I1SN-25 Driver Side Rear Shock Bracket 1
C4I1SN-26 Passenger Side Rear Shock Bracket 1
C4I1SN-27 Driver Side Torsion Bar Bracket 2
C4I1SN-28 Passenger Side Torsion Bar Bracket 2
C4I1SN-29 Rear Track Bar Bracket 1
C4I1SN-30 Rear Coil Spring Spacers 2
C4I1SN-33 Lower One Piece Sub Frame 1
C4I1SN-35 Driver Side Spindle 1
C4I1SN-36 Passenger Side Spindle 1
C4I1SN-37 Driver Side Differential Drop 1
BP-01 Rear Sway Bar End Links 2
S10019 Rear Shock Spacer Sleeve 2
S10020 Torsion Bar Sleeve 2
9804 Axle Spacers 2
14965NB Hardware Box 1
14965SL Poly Bushing & Sleeve Bag 1
14965INST Instruction Sheet 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.

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 the rear view mirror hanger is hung from the rear
view mirror. The rear view mirror hanger has
instructions on proper post installation procedure.

Special Note: Chevy Suburban and Yukon XL came
with two different shock options. One with Air Ride
Load Sensor Shocks and one with out. Part # 14965
will work on both. If the vehicle that you are working
on DOES NOT have the Air Ride Load Sensor
Shocks, the stock shocks may be re-installed in
conjunction with the new shock relocation brackets.
Or if you prefer, after market shocks may be installed
into the stock location. If the vehicle that you are
working on has the Air Ride Load Sensor Shocks, the
stock shocks need to be re-installed in conjunction
with the new shock relocation brackets. This option
is for the front and rear of the vehicle.

INSTALLATION MANUAL

4” I.F.S. SUSPENSION 2000 - CURR.

CHEVY SUBURBAN / YUKON XL

(WITH 5 LINK REAR END)

PART # 14965

Sj042403rev.03

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/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.

For a list of all parts, please refer to the Parts
Description Page, at the end of the Installation
Manual.

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:

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.

If the vehicle that you are working on has the stock
transfer case cross member that is bolted to the
bottom side of the stock frame rail, and you would
like to install new lateral compression arms, please
contact Tuff Country or your local Tuff Country
dealer and order part # 10906.

If the vehicle that you are working on has the stock
transfer case cross member that is bolted to brackets
that are welded to the inside of the stock frame rail,
and you would like to install new lateral compression
arms, please contact Tuff Country or your local Tuff
Country dealer and order part # 10907.

If you would like to install an aftermarket lower skid
plate, please contact Tuff Country or your local Tuff
Country dealer and order part # 90055.

If you would like to install an aftermarket pre-runner
style skid plate, please contact Tuff Country or your
local Tuff Country dealer and order part # 90056.

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. If a new drive line is needed, you
may contact Tuff Country or your local Tuff Country
dealer and order part # 10902.

Hardware Bag 14965SL Includes:

Description Quantity

Poly Bushings (PB2408G) 2
Crush Sleeve (9/16” x 2 1/2”) 1
9 1/2” Long Sway Bar End Links 2
Poly Bushings (PB4902G) 12
Crush Sleeves (1/2” x 1 1/2”) 4
Crush Sleeves (9/16” x 1 1/2”) 2
Poly Bump Stops 2
Poly Lube Pack 2
Sway Bar End Link Washers 8
Sway Bar End Link Bushings 8

Hardware Bag 14965NB Includes:

Bag # 1

Description Quantity
3/8” x 13” Bolts 2
3/8” Unitorque Nuts 4
3/8” Flat Washers 2
3/8” Lock Washers 2
3/8” x 1 1/4” Self Threading Bolts 6
10 mm x 55 mm Bolts 12
10 mm Lock Washers 12

Bag # 2

Description Quantity
7/16” x 1 1/4” Bolts 2
7/16” x 1 1/2” Bolts 2
7/16” x 3” Bolts 1
7/16” Unitorque Nuts 5
7/16” Flat Washers 10
7/16” Lock Washers 5

Bag # 3

Description Quantity
1/2” x 1 1/4” Bolts 1
1/2” x 2 1/2” Bolts 4
1/2” Unitorque Nuts 5
1/2” Flat Washers 10
1/2” Lock Washers 5

Bag # 4

Description Quantity
9/16” x 1 3/4” Bolts 2
9/16” x 3” Bolts 4
9/16” x 3 1/2” Bolts 5
9/16” Unitorque Nuts 11
9/16” Flat Washers 26
9/16” Lock Washers 11

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
5/8” Flat Washers 8
5/8” Lock Washers 4

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].

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 passenger side. Next, remove the wheels and
tires 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, discard the (3) stock upper bolts
and the stock front upper skid plate, but keep the (2)
stock lower bolts for later re-installation.

4. Remove the stock front driveline from the stock
location, and save the stock driveline and hardware for
later re-installation.

If the vehicle that you are working on is equipped
with Air Ride Load Sensor Shocks, please follow step
# 5

If the vehicle that you are working on is not equipped
with Air Ride Load Sensor Shocks, please follow step
# 6

5. Working on the driver side, carefully remove the load
sensor valve located at the top of the stock shock.

Special Note: Take special care not to damage during

removal. Remove the stock hardware on the top of the

stock shock and save hardware for later re-installation.
Remove the stock hardware on the lower shock mount
and save hardware for later re-installation. Save the
stock shock for later re-installation. Repeat procedure on
the passenger side.

6. Working on the driver side, remove the stock hardware
on the top of the stock shock and save hardware for later
re-installation. Remove the stock hardware on the lower
shock mount and save hardware for later re-installation. If
you desire to re-install the stock shock, save the stock
shock for later re-installation. If you desire to install a new
after market shock, the stock shock may be discarded.
Repeat procedure on the passenger side.

If the vehicle that you are working on is equipped
with the Air Ride Load Sensor Shocks, please follow
step # 7

If the vehicle that you are working on is not equipped
with Air Ride Load Sensor Shocks, please skip to
step # 8

7. Working on the driver side, carefully remove the stock
actuator rod and set a side for later re-installation.
Repeat procedure on the passenger side.

8. Measure exposed threads on the stock 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

9. 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 key and
hardware a side for later re-installation. Repeat
procedure on passenger side.

See Illustration # 2

10. 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.

11. Working on the driver side, remove the stock bolt that
connects the stock torsion bar cross member to the stock
mounting point. The stock hardware may be discarded.

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 a side for later
re-installation.

12. 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.

13. 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.

14. 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. Also, remove the
stock bolt that connects the stock brake line bracket to
the stock upper control arm and save hardware for later
re-installation.

15. 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.

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.

18. Working on the driver side, remove the stock nut that
connects the stock axle to the hub assembly. Save the
stock nut for later re-installation.

See Illustration # 3

19. 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.

20. Working on the driver side, 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.

21. Working on the driver side, 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.

22. 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.

Carefully break the stock taper on the stock

outer tie rod ball joint. Special Note: Take special care

not to rip or tear the stock outer tie rod ball joint dust
boot.

23. 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.

24. 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.

25. Carefully remove the stock hub assembly and the
stock steering knuckle from the stock location and stock
axle.

26. 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.

27. Locate the new driver side steering knuckle. Using
the stock hardware that was removed from step # 25,
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.

28. Set the new driver side steering knuckle and hub
assembly aside for later re-installation.

29. 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.

See Illustration # 4

30. Working on the driver side, unbolt and remove the (6)
stock bolts holding the inner CV axle to the stock
differential. Discard the stock hardware. Set the stock
axle aside for later re-installation.

31. 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.

32. Repeat step’s 14 - 31 on the passenger side.

33. 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.

34. 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.

See Illustration # 5

35. 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 # 35. Clean and dress up any
exposed metal.

See Illustration # 6

36. 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. Refer to illustration # 6 for proper

cut line. 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 # 36. Clean and
dress up any exposed metal.

37. 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.

38. 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.

39. Disconnect any other vent hoses and/or wiring that is
connected to the front differential.

40. 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.

41. 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.

42. Carefully lower down on both hydraulic floor jacks at
the same allowing enough room to remove the front
differential completely from the vehicle. Remove the front
differential completely from underneath the vehicle.

43. 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 front differential.
Using a sawzall, carefully cut the upper tab off of the
stock front differential and discard. Refer to illustration #

7 for proper cut line.

See Illustration # 7

44. Locate the new driver side differential relocation
bracket, (1) 7/16” X 3” bolt, (1) 7/16” unitorque nut, (2)
7/16” flat washers and (1) 7/16” lock washer from
hardware bag 14965NB2. Also, locate (2) MO2050 poly
bushings and (1) 9/16” x 2 1/8” anti crush sleeve from
hardware bag 14965SL. Install the new poly bushings
and 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. Referring to illustration # 8,

remove the (4) stock differential mounting bolts that
connect to two half’s of the front differential together.
Save the stock hardware for later re-installation. Secure
the new driver side differential relocation bracket to the
stock front differential using the stock hardware that was
removed earlier in this step. Special Note: Get all (4)

stock bolts started but do not tighten at this point.
Also, 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) stock bolts that
hold the new 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 tighten, the stock front differential
could crack.

See Illustration # 8

45. Working on the passenger side stock rear lower
control arm pocket. Carefully cut off the front corner of
the stock passenger side stock rear lower control arm
pocket. This will allow enough room for the stock front
differential to seat properly when the new passenger side
differential drop bracket is installed. Refer to the cut line

in illustration # 9

See Illustration # 9

46. Locate the new passenger side differential drop
bracket and the stock hardware that was removed from
step # 41. Install the new upper passenger side
differential drop bracket into the stock location and
secure using the stock hardware. Do not tighten at this

point. Special Note: There is a front and a rear of this
bracket, refer to illustration # 10 for proper placement
of the new passenger side differential drop bracket.
Make sure to use thread locker or lock tite.

See Illustration # 10

47. Locate (2) 9/16” x 1 3/4” bolts, (4) 9/16” flat washers,
(2) 9/16” unitorque nuts and (2) 9/16” lock washers from
hardware bag 14965NB4. 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, make sure to use thread
locker or lock tite. Using a 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.

See Illustration # 11

48. Locate the new one piece lower sub frame and the
stock lower control arm mounting hardware that was
removed from step # 31. On the driver side, install the
front and rear part of the new one piece sub frame into
the stock front and rear lower control arm mounting
points using the stock hardware. Do not tighten at this

point. Make sure to use thread locker or lock tite.

Repeat procedure on passenger side.

See Illustration # 12 / Front Location

See Illustration # 13 / Rear Location

49. Carefully remove the bungee cord that is holding the
driver side of the front differential up and out of the way.
Let the stock front differential rest on the newly installed
one piece lower sub frame.

50. Locate the stock hardware that was removed from
step # 33. 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. Make sure to use thread
locker or lock tite.

See Illustration # 14

51. Locate the stock hardware that was removed from
step # 40. 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. Make sure to use thread
locker or lock tite.

See Illustration # 15

Note: If you are going to re-install the stock front
upper skid plate, please follow step #’s 52 - 54

Note: If you are not going to install the stock front
upper skid plate please skip to step # 56

52. 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. Make sure to use thread locker or lock tite.

53. 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.

54. 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 # 57

55. 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.

56. 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.

57. Move back to all the new and stock hardware
associated with the front differential, and the new one
piece sub frame and torque to proper specifications.
Refer to the torque setting sheet at the end of the
installation manual for proper torque.

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.

59. Locate (2) poly bump stops from hardware bag
14965SL. Also, locate (2) 3/8” unitorque nuts, (2) 3/8” flat
washers and (2) 3/8” lock washers from hardware bag
14965NB1. Working on the driver side rear portion 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.

See Illustration # 16

60. Locate (2) 5/8” x 4 1/2” bolts, (2) 5/8” x 5 1/2” bolts,
(8) 5/8” flat washers, (4) 5/8” unitorque nuts and (4) 5/8”
lock washers from hardware bag 14965NB5. Also locate

the stock lower control arms that were removed from step
# 31. Working on the driver side, install the stock lower
control arm into the newly installed one piece 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. Make sure

to use thread locker or lock tite.

Install the stock lower
control arm into the newly installed one piece 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. Make sure

to use thread locker or lock tite.

Repeat procedure on

the passenger side.

See Illustration # 17 / Front Location

See Illustration # 18 / Rear Location

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, lower control arm ball
joint and outer tie rod ball joint that was removed from
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, 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. Special Note: When
installing the new driver side spindle, make sure that
the stock brake line is located towards the inside of
the vehicle. Make sure to use thread locker or lock

Repeat procedure on the passenger side using the

tite.

passenger side steering knuckle.

See Illustration # 19

62. Locate (2) axle half shaft spacers, (12) 10 mm x 55
mm hex bolts and (12) 10 mm lock washers from
hardware bag 14965NB1. Also locate the stock front
axles that were removed from step # 30. Working on the
driver side, install (1) new axle spacers between the
stock front differential and the stock axle. Secure using
the new 10 mm x 55 mm bolts. 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 # 28.

Repeat on the passenger side.

See Illustration # 20

63. 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.

64. 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 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.

65. Move back to all associated hardware that connects
the stock lower control arms to the new one piece sub
frame and torque 125 ft. lbs.

66. 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.

67. Locate the stock brake caliper hardware that was
removed in step # 15. Working on the driver side, re­install the stock brake caliper to the stock rotor and
secure using the stock hardware. Torque to

Make sure to use thread locker or lock tite.

76 ft. lbs.

Repeat

procedure on the passenger side.

68. Locate the stock brake line hardware that was
removed in step # 14. Working on the inside of the newly
installed driver side spindle, reconnect the stock brake
line bracket to the new driver side spindle. 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.

See Illustration # 21

If the vehicle that you are working on is equipped
with Air Ride Load Sensor Shocks or you are going
to re-install the stock shock, please follow step
# 69 — 70

If the vehicle that you are working on is going to have
new after market shocks installed, please skip to step
# 74

69. Locate the new driver and passenger side front shock
relocation bracket, (2) PB4902 poly bushings and (2)
916112SL anti crush sleeves from hardware bag
14965SL. Install the new poly bushing and anti crush
sleeve into the new driver and passenger side shock
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 driver side and
passenger side front shock relocation brackets. This
will increase the life of the bushing as well as prevent
squeaking.

70. Locate (2) 9/16” x 3“ bolts, (8) 9/16” flat washers, (2)
9/16” unitorque nuts, (2) 9/16” lock washers from
hardware bag 14965NB4. Also, locate (2) 7/16” x 1 1/2”
bolt, (4) 7/16” flat washers, (2) 7/16” unitorque nuts and
(2) 7/16” lock washers from hardware bag 14965NB2.
Working on the passenger side, install the new
passenger side shock relocation bracket to the stock
location and secure using the new 9/16” x 3” bolt and
hardware. Do not tighten at this point. Special Notice:

When installing the new shock relocation bracket,
make sure to use (2) 9/16” flat washers as spacers on

the front lower portion of the new shock relocation
bracket and the stock location.

Refer to illustration # 22
for proper 9/16” flat washer placement. Using the
passenger side shock relocation bracket as a guide, drill
a 7/16” hole into the stock lower control arm. Secure the
new passenger 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. Torque the new 9/16” bolt 110 ft lbs.
Repeat procedure on the driver side.

See Illustration # 22

If the vehicle that you are working on is equipped
with the Air Ride Load Sensor Shocks, please follow
step # 71 — 72

If the vehicle that you are working on is not equipped
with Air Ride Load Sensor Shocks but you are going
to re-install the stock shocks, please follow step # 73

71. Locate the stock load sensor shocks and hardware
that was removed from step # 5. Working on the driver
side, re-install the lower mount on the stock load sensor
shock to the newly installed relocation bracket and
secure using the stock hardware. Do not tighten at this

Secure the upper mount on the stock load sensor

point.

shock to the stock location and secure using the stock
hardware. Torque the upper hardware to 18 ft lbs.
Torque the lower stock mount to 95 ft lbs. Next,
reconnect the load sensor valve bracket back on the top
of the stock shock. Repeat procedure on the passenger
side. Special Note: After the installation of the stock

load sensor shock, check to make sure that there is
proper clearance between the stock load sensor
shock and the stock bump stop bracket. If there is
contact between the stock load sensor shock and the
stock bump stop bracket, carefully cut off the corner
of the stock bump stop bracket for proper shock
clearance.

72. Locate the stock actuator rods that were removed
from step # 7. Working on the driver side, install the stock
actuator rod into the stock upper and lower location.
Repeat procedure on the passenger side.

73. Locate the stock shock and hardware that was
removed from step # 5. Working on the driver side, re­install the stock shock to the newly installed shock
relocation bracket and secure using the stock hardware.
Do not tighten at this point. Secure the upper mount of
the stock shock into the stock location and secure using
the stock hardware. Torque the upper hardware to 18 ft

Torque the lower stock mount to

lbs.

95 ft lbs.

Repeat

procedure on the passenger side.

See Illustration # 23

74. Locate the new front shocks and the stock hardware
that was removed from step # 5. Working on the driver
side, install the new front shock into the stock upper and
lower location. Secure using the stock hardware. 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. Also, after the
installation of the new front shock, check to make
sure that there is proper clearance between the new
front shock and the stock bump stop bracket. If there
is contact between the new front shock and the stock
bump stop bracket, carefully cut off the corner of the
stock bump stop bracket for proper shock clearance.

75. Locate (4) new torsion bar drop plates, (2) 9/16” x 3
1/2” bolts, (4) 9/16” flat washers, (2) 9/16” unitorque nuts
and (2) lock washers from hardware bag 14965NB4.
Working on the driver side, install the new torsion bar
drop plates to the stock torsion bar cross member
location and secure using the new 9/16” x 3 1/2” bolt and
hardware.

Do not tighten at this point. Make sure to

use thread locker or lock tite. Repeat procedure on the

passenger side.

See Illustration # 24

76. Locate the stock torsion bars that were removed from
step # 12. Refer to the marks that were made in step #

10. 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 re-installed. Repeat procedure on the passenger side.

77. Locate (2) 9/16” x 3 1/2” bolt, (4) 9/16” flat washers,
(2) 9/16” unitorque nuts and (2) 9/16” lock washers from
hardware bag 14965NB4. Also, locate (2) S10020 crush
sleeves that were packaged with your instruction sheet
and the stock torsion bar cross member that was
removed from step # 10. Working on the driver side,
install the stock torsion bar cross member to the newly
installed torsion bar drop plates and secure using the
new 9/16” x 3 1/2” bolt, hardware and crush sleeve.

Special Note: The stock nut that is attached to the
stock torsion bar cross member needs to be removed
before installing the stock torsion bar cross member
to the new torsion bar drop plates. Do not tighten at
this point. Make sure to use thread locker or lock tite.
Special Note: Refer to the illustration # 25 on how to
install the new crush sleeve. On the rear tab of the
stock torsion bar cross member, you will notice that
this hole is larger in diameter than the front hole, the
new crush sleeve will be small enough for the tab of
the stock torsion bar cross member to slide over the
sleeve.

Repeat procedure on the passenger side. Torque

the upper and lower mounting bolt to 95 ft lbs.

See Illustration # 25

78. Locate the stock torsion bar keys that were removed
from step # 9. 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 stock torsion bar key.
Repeat procedure on the passenger side.

79. Locate the torsion bar adjusting blocks and hardware
that was removed from step # 9. 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 # 8 and set to the
stock setting. Repeat procedure on the passenger side.
Remove the torsion bar removing tool from the stock
torsion bar cross member.

80. Locate (2) 3/8” x 13” bolts and (2) 3/8” unitorque nuts
from hardware bag # 14965NB1. Also, locate (2) new
sway bar end links, (8) sway bar end link bushings and
(8) sway bar end link washers from hardware bag
14965SL. Working on the driver side, install the new
sway bar end link and hardware into the stock location
and torque to 32 ft lbs. Repeat procedure on passenger
side.

See Illustration # 26

81. Locate the stock front drive line and hardware that
was removed from step # 4. Re-install the stock front
drive line back into the stock location and secure using
the stock hardware.

82. Re-install the tires and wheels and carefully lower the
vehicle to the ground.

83. 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.

Congratulation, Front End Installation Complete

Rear End Installation:

84. 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.

85. Place a pair of hydraulic floor jack under the rear axle
and raise up on both hydraulic floor jacks at the same
time until they come into contact with the rear axle.

86. Working on the driver side, remove the stock
hardware that connects the stock sway bar end link to the
stock location. The stock sway bar end link and hardware
may be discarded. Repeat procedure on the passenger
side.

If the vehicle that you are working on is equipped
with Air Ride Load Sensor Shocks please follow step
# 87 — 105

If the vehicle that you are working on is not equipped
with Air Ride Load Sensor Shocks but you are going
to re-install the stock shocks, please follow step
# 106 — 122

If the vehicle that you are working on is not equipped
with Air Ride Load Sensor Shocks and you want to
install new after market shock, please follow step
123 — 140

87. Working on the driver side, carefully remove the ball
joint coupler from the stock shock actuator rod. Carefully
remove the stock actuator rod from the top and bottom
ball joint caps. The rear stock actuator can be discarded.
Repeat procedure on the passenger side.

88. Working on the driver side, remove the stock rear
lower shock mounting bolt from the stock rear location
and save the stock hardware for later re-installation.

Special Note: The stock shock will be re-installed.
The stock upper mounting point does not need be
removed, let the stock shock hang. Repeat procedure

on passenger side.

89. Working on the driver side, remove the stock bolt that
connects the stock rear track bar to the stock rear track
bar location. Save the stock hardware for later re­installation.

90. Working on the driver side, scribe a mark on the
stock rear coil spring and another directly across on the
stock coil spring pocket. This will allow you to re-install

the stock coil spring back into the stock location.

Repeat procedure on passenger side. Carefully lower
down on both hydraulic floor jacks at the same time
about 4” - 4.5”. Special Note: Take special care not to

kink or over extend any brake lines and/or hoses.

Remove the stock driver and passenger side coil springs
and set a side for later re-installation.

91. Locate (2) rear coil spring spacer. Working on the
driver side, hold the new coil spring spacer into the upper
coil spring pocket. With a marker, using the new bracket
as a guide, scribe (3) marks on the stock upper coil
spring pocket. Remove the new coil spring spacer and
set a side for later re-installation. Repeat procedure on
the passenger side.

92. Working on the driver side, carefully drill 5/16” holes
into the stock upper coil spring pocket where the marks
were scribe in step # 91.