Tuff Country 16090 User Manual
Part # 16090
2011 Chevy or GMC 3500 HD
6” suspension system
Parts contained in Box 1 of 3
Part
# Description
Qty.
16085-03 Front cross member 1
16085-04 Rear cross member 1
16085-07 DS torsion bar relocation bracket 1
16085-08 PS torsion bar relocation bracket 1
16085-09 Torsion bar cover plate 2
16085-10 DS CV axle spacer 1
16085-15 Upper shock relocation bracket 2
16085-17 Lower sway bar end link bracket 2
16085-19 Rear brake line relocation bracket 1
16085-21 Torsion bar skid plate mounting bracket 1
56900-15 E-brake cable relocation bracket 2
16085NB Hardware bag 1
BL406 Rear lifted block 2
BL-01 Front brake line jumpers 2
16085INST Instruction manual 2
MIRRORHANGER Rear view mirror hanger 1
WARNINGDECAL
Warning decal 1
SHOCKTIE Zip ties 4
Parts contained in Box 2 of 3
Part
# Description Qty.
16085-05 DS differential relocation bracket 1
16085-06 PS differential relocation bracket 1
16085-11 DS front upper bump stop 1
16085-12 PS front upper bump stop 1
16085-13 DS lower shock/bump stop bracket 1
16085-14 PS lower shock/bump stop bracket 1
16085-16 Lower skid plate 1
16085-18 Rear bump stop extension 2
16085-20 Torsion bar cross member skid plate 1
16085PL Hardware bag 1
SB-07 Sway bar end link 2
5U-3431418S 3/4” x 3 1/4” x 18” square 4
34NW Hardware bag 1
Parts contained in Box 3 of 3
Part
# Description Qty.
16085-01 DS knuckle 1
16085-02 PS knuckle 1
Installation manual
6” suspension system
2011 Chevy or GMC 3500HD
Part # 16090
sj09062011rev.01
Important customer information:
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.
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 EZRide 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 loctite 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 tires and wheels will work in conjunction
with part # 16090 but a large size tire and the stock
wheels will not work in conjunction with part # 16090.
Once part # 16090 has been installed with larger tires,
new wheels will be needed. Here are the approved rim
sizes. 17” x 8” with 5” - 5.25” of back spacing or less.
18” x 8” to 9” with 5” - 5.5” of back spacing or less.
20” x 8.5” to 10” with 5” - 6” of back spacing or less.
Tuff Country recommends a 35x12.50 tire package. If
larger than a 35x12.50 tire is installed on your vehicle
in conjunction with part # 16090; 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.
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
#. Tuff Country has designed after market upper and
lower front shock bracket for this vehicle. 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 loop to loop style shock in the front
and a 30” fully extended nitrogen gas loop to loop
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 16085PL includes:
Description Quantity
MO2220 (poly bushing) 4
S10026 (.680” x .500” x 1.500” sleeve) 2
38FN (3/8” fine nut) 2
S10049 (coned washer) 4
PB8016 (poly bushing) 4
S10102 (.630” x .500” x .260” sleeve) 2
Hardware bag 16085NB includes:
Bag # 1
Description
Quantity
1434B (1/4” x 3/4” bolt) 2
14UN (1/4” unitorque nut) 2
14WA (1/4” USS flat washer) 10
5161B (5/16” x 1” bolt) 3
5161STB (5/16” x 1” self threading bolt) 8
51634STB (5/16” x 3/4” self threading bolt) 4
516UN (5/16” unitorque nut) 3
381STB (3/8” x 1” self threading bolt) 10
716134B (7/16” x 1 3/4” bolt) 4
38WA (3/8” USS flat washer) 8
716UN (7/16” unitorque nut) 4
Bag # 2
Description
Quantity
12112B (1/2” x 1 1/2” bolt) 2
12112CB (1/2” x 1 1/2” carriage bolt) 2
12114B (1/2” x 1 1/4” bolt) 10
12212B (1/2” x 2 1/2” bolt) 2
12234B (1/2” x 2 3/4” bolt) 2
122B (1/2” x 2” bolt) 2
12312B (1/2” x 3 1/2” bolt) 1
12LWA (1/2” lock washer) 2
12UN (1/2” unitorque nut) 20
12WA (1/2” USS flat washer) 16
716WA (7/16” USS flat washer) 45
Bag # 3
Description
Quantity
9163B (9/16” x 3” bolt) 4
9164B (9/16” x 4” bolt) 2
916UN (9/16” unitorque nut) 6
M1080B (10 mm x 80 mm bolt) 8
M1240B (12 mm x 40 mm bolt) 3
M12UN (12 mm unitorque nut) 2
M18130B (18 mm x 130 mm bolt) 2
M18150B (18 mm x 150 mm bolt) 2
M18UN (18 mm unitorque nut) 4
M18WA (18 mm washer) 8
916WA (9/16” USS flat washer) 2
Hardware bag 34NW includes:
Description
Quantity
3/4” u-bolt high nuts 8
3/4” 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.
Recommended tools selection:
Torsion bar puller
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:____________________________
Front end installation:
1. To begin installation, block the rear tires of the vehicle so
that the vehicle is stable and can’t roll backwards. Safely lift
the front of the vehicle and support the frame with a pair of
jack stands. Place a jack stand on both the driver and the
passenger side. Next, remove the front wheels and tires
from both sides.
2. Working on the driver side, remove the shock from the
upper and lower location. Save the lower hardware, The
upper nuts and shock may be discarded. Repeat procedure
on the passenger side. New longer front shocks are
needed after this suspension system has been
installed and the front shocks need to be ordered as a
separate part #. Tuff Country has designed after market
upper and lower shock bracket for this vehicle. If you
have not already ordered your front shocks, please feel
free to contact Tuff Country or your local Tuff Country
dealer and order your front shocks. Tuff Country recommends installing a 23” fully extended nitrogen gas
loop to loop style shock in the front.
3. Remove the upper skid plate and set aside along with
the hardware.
4. Remove the lower skid plate and discard the skid plate
and hardware.
5. Working on the driver side, attach the torsion bar
removing tool to the 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 torsion bar key.
Adjust the torsion bar key up high enough so that the small
metal adjusting block and bolt can be removed. Set the torsion bar block and hardware aside for later re-installation.
Repeat procedure on passenger side.
6. 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. Also, place a
mark on the lower control arm and one lining up on the
torsion bar.
7. Working on the driver side, tap the torsion bar forward
until the torsion bar key can be removed. Set the torsion
bar key aside. Special note: Take special care not to
damage the CV axle when tapping the torsion bar forward. Also, the torsion bar can not be removed until
the torsion bar cross member has been removed.
Repeat procedure on the passenger side.
8. Working on the driver side, remove the hardware that
connects the torsion bar cross member to the mounting
point. Set the hardware aside for later re-installation.
Repeat procedure on the passenger side. Remove the torsion bar cross member from the vehicle and set aside for
later re-installation.
9. Working on the driver side, slide the torsion bar out of the
lower control arm and set aside for later re-installation.
Repeat procedure on passenger side.
10. Working on the driver side, remove the nut that connects the outer tie rod ball joint to the steering knuckle. Set
the nut aside for later re-installation. Carefully break the
taper on the outer tie rod ball joint and remove the stock
outer tie rod from the knuckle. Special note: Hitting the
knuckle with a hammer will make removal of the outer
tie rod easier. Take special care not to rip or tear the
outer tie rod ball joint dust boot. Repeat procedure on
the passenger side.
11. Working on the driver side, remove the sway bar end
link from the stock location and discard the end link and all
the hardware. Repeat procedure on the passenger side.
12. Working on the driver side, remove the hub bearing cap
and set aside. Repeat procedure on the passenger side.
13. Working on the driver side, remove the hardware that
connects the axle to the hub assembly and set aside.
Repeat procedure on the passenger side.
14. Working on the driver side, remove the brake line and
ABS line from the knuckle. Also, remove the brake line
bracket from the knuckle and set the bracket and hardware
aside. Repeat procedure on the passenger side.
15. Working on the driver side, remove the (2) bolts that
connect the brake caliper to the knuckle. Save the hardware for later re-installation. Using a bungee cord, carefully tie the 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.
16. Working on the driver side, remove the rotor retaining
bolt. Remove the rotor and set the rotor and bolt aside.
Repeat procedure on the passenger side.
17. Working on the driver side, remove the CV axle from
the differential. The hardware may be discarded. Remove
the CV axle from the hub assembly and set aside for later
re-installation. Repeat procedure on the passenger side but
make sure to save the OE hardware.
18. Working on the driver side, disconnect the ABS sensor
from the hub and move the ABS line up and out of the way.
Save the hardware for later re-installation. Repeat procedure on the passenger side.
19. Working on the driver side, loosen but do not remove
the nut that connects the upper control arm ball joint to the
steering knuckle. Carefully break the taper by striking the
knuckle with a hammer. Special note: Take special care
not to damage the upper control arm ball joint or rip the
upper control arm ball joint dust boot. For now, leave
the upper control arm attached to the knuckle. We want
to just break the taper for now. Repeat procedure on the
passenger side.
20. Working on the driver side, loosen but do not remove
the nut that connects the lower control arm ball joint to the
steering knuckle. Carefully break the taper by striking the
knuckle with a hammer. Special note: Take special care
not to damage the lower control arm ball joint or rip the
lower control arm ball joint dust boot. For now, leave
the lower control arm attached to the knuckle. We want
to just break the stock taper for now. Repeat procedure
on the passenger side.
21. Working on the driver side, move back to the nuts holding the upper control arm ball joint and the lower control
arm ball joint to the steering knuckle and remove completely. Save the hardware for later re-installation. Carefully
remove the hub assembly and the steering knuckle from
the OE location and set aside for later re-installation.
Repeat procedure on the passenger side.
22. Working on the driver side, remove the lower control
arm. Set the control arm and hardware aside. Repeat procedure on the passenger side.
23. Place a mark on the front drive line and front differential. Remove the front drive line from the front differential
and tie up and out of the way. Save the hardware.
24. Working on the driver side, remove the rear cross member from the driver side rear lower control arm pocket.
Repeat procedure on the passenger side. The rear cross-
member and hardware may be discarded.
25. 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.
26. Working on the driver side, remove the (3) bolts holding
the differential to the OE bracket. Save the (2) front bolts
but the back bolt may be discarded.
27. Working on the passenger side, remove the (2) nuts
that connect the passenger side of the front differential to
the OE location and save the hardware for later re-installation.
28. Working on the front differential, disconnect the 4WD
wiring harness and vacuum hose 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.
29. 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 front differential on the
ground or on a work bench.
30. Working on the driver side, measure 3 1/2” from the
inside leading edge of the driver side rear lower control arm
pocket and scribe a mark. Using a hacksaw or suitable cut-
Loading...