Tuff Country 16840 User Manual

INSTALLATION MANUAL

6” I.F.S. SUSPENSION 1992 - 1998

CHEVY / GMC 1500 6 LUG

4 DOOR TAHOE, YUKON & SUBURBAN

PART # 16840

Sj061603rev.01

PART NUMBER : 16840
1992— 1998 CHEVY / GMC 1500 6 LUG
4 DOOR TAHOE, YUKON AND SUBURBAN
6” SUSPENSION SYSTEM WITH FRONT SPINDLES

PARTS LIST:

Part # Description Qty.

16810-03 Driver Side Differential Drop Bracket 1
16810-04 Passenger Side Differential
Drop Bracket 1
16810-06 Rear Lateral Compression Arm Mounts 2
16810-09 One Piece Lower Sub Frame 1
16810-11 Lateral Compression Arms 2
16985-16 Torsion Bar Drop Brackets 2
C6I-118M Driver Side Spindle 1
C6I-119M Passenger Side Spindle 1
SB-01 Rear Sway Bar End Links 2
9803 Axle Spacers 2
BL401 4” Lifted Blocks 2
5U-9295S 9/16” x 2 3/4” x 12 5/8” Square U-Bolts 4
TCI-R25 Rear Add-a-Leaf 2
BLR01 Rear Brake Line Extension Bracket 1
BLR02 Front Brake Line Extension Bracket 2
16810SL Poly and Sleeve Bag 1
16840NB Hardware Bag 1
16840SL Poly and Sleeve Bag 1
916NW Hardware Bag 1
CB38 Hardware Bag 1
16840INST 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.

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

Make sure to use thread locker or locktite on all new
and stock hardware associated with the installation
of this suspension system.

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.

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.

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.

IMPORTANT CUSTOMER INFORMATION

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.

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.

General Motors has introduced a new transfer case
option that uses the name “Auto Trac”. Auto Trac is a
full time 4WD system. This options pertains to the
Tahoe (2 or 4 door), Suburban and some pick up
trucks. To identify this, see the transfer case
selection panel located on the dash board. Below the
2HI button it will read “Auto 4WD” or “Auto”.
Vehicles with the “Auto Trac” transfer case may
encounter a front drive line vibration when the lift kit
is installed. After installation, if the vehicle that you
are working on encounters any front driveline
vibration, the stock driveline may need to be
replaced. If this is the case on the vehicle that you
are working on, please feel free to contact Tuff
Country or your local Tuff Country dealer and order
part # 10820 to replace your stock driveline.

General Motors has also introduced and upgrade on
the front ABS system for vehicle manufactured
between 1992—1995. If the vehicle that you are
working on has the upgrade ABS system on it, the
new spindle design WILL NOT work due to the ABS
upgraded sensor. If this is the case on the vehicle
that you are working on and you still want to install a
Tuff Country EZ-Ride Suspension, please contact
Tuff Country or your local Tuff Country dealer and
order part # 16843. NON SPINDLE DESIGN

After the completion of the installation a front end
alignment is required. Also an exhaust modification
is 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.

If the vehicle that you are installing Part # 16840 was
manufactured in 1998, you must order an additional
axle extension kit. The part # that needs to be
ordered is part # 10806.

Hardware Bag 16810SL Includes:

Description Quantity

Poly Bushings (PB2408G) 10
Crush Sleeve (9/16” x 2 1/8”) 1
Crush Sleeve (1/2” x 2 1/8”) 4
Crush Sleeve (1/2” x 1 1/8”) 2
Shock Bushings (PB8004G) 2
Shock Sleeves (1/2” x 2 1/2”) 2
Poly Bump Stops 2
6” Long Sway Bar End Links 2
Sway Bar End Link Washers 8
Sway Bar End Link Bushings 8
Poly Lube Pack 2

Hardware Bag 16840NB Includes:

Bag # 1

Description Quantity
5/16” x 1 1 /4” Bolts 3
5/16” Unitorque Nuts 3
5/16” Flat Washers 6
5/16” Lock Washers 3
3/8” x 10” Bolts 2
3/8” Unitorque Nuts 4
3/8” Flat Washers 2
3/8” Lock Washers 2
10 mm x 70 mm Bolts 12
10 mm Lock Washers 12

Bag # 2

Description Quantity
7/16” x 1 1/2” Bolts 8
7/16” x 3” Bolts 1
7/16” Unitorque Nuts 9
7/16” Flat Washers 18
7/16” Lock Washers 9

Bag # 3

Description Quantity
1/2” x 1 1/4” Bolts 2
1/2” x 2 1/4” Bolts 2
1/2” x 3 1/2” Bolts 4
1/2” Unitorque Nuts 8
1/2” Flat Washers 16
1/2” Lock Washers 8

Bag # 4

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

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

Hardware Bag 16840SL Includes:

Description Quantity
Poly Bushings (PB4902G) 12
Crush Sleeves (.690 x .400 x 1 1/2”) 4
Crush Sleeves (.690 x .500 x 1 1/2”) 2

Hardware Bag 916NW Includes:

Description Quantity
9/16” U-Bolt High Nuts 8
9/16” U-bolt Harden Washers 8

Hardware Bag CB38 Includes:

Description Quantity
3/8” x 6” Centering Bolt 2
3/8” Centering Bolt Fine Nut 2

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: Once the new
Suspension System has been installed. Check the
fluid level in the front differential. Top off the fluid
with proper differential fluid. On occasion customer
may find burping of fluid coming out of the front vent
tube.

Please Follow Instructions Carefully:

Before installation begins, measure from the center
of the hub, to the bottom of the fender well, and
record measurements below.

Pre-Installation Measurements:

Driver Side Front:______________________________
Passenger Side Front:__________________________
Driver Side Rear:______________________________
Passenger Side Rear:__________________________

At the end of the installation, take the same
measurements and compare to the pre-installation
measurements.

Post-Installation Measurements:

Driver Side Front:______________________________
Passenger Side Front:__________________________
Driver Side Rear:______________________________
Passenger Side Rear:__________________________

Please follow instructions carefully:

Front End Installation:

1. To begin installation, block the rear tires of the vehicle
so that the vehicle is stable and can’t roll backwards.
Safely lift the front of the vehicle, and support the frame
with a pair of jack stands. Place a jack stand on both the
driver and passenger side. Next, remove the tires and
wheels from both sides.

2. Working on the driver side, remove the stock inner
rubber fender splash guard and save the stock inner
rubber fender splash guard and hardware for later re­installation. Repeat procedure on passenger side.

3. Working on the driver side, remove the stock shock
from the stock location and save the stock hardware for
later re-installation. Longer shocks are needed, so the
stock shocks may be discarded.

are not included with this suspension system and
need to be ordered as a separate part number, Tuff
Country EZ-Ride Suspension recommends using a
23” fully extended nitrogen gas shocks.

procedure on passenger side.

4. Remove the stock front differential skid plate. The
stock front differential skid plate and hardware can be
discarded.

5. Remove the stock front driveline from the stock front
differential and the stock transfer case. Save the stock
driveline and hardware for later re-installation.

6. Measure exposed threads on the torsion bar adjusting
bolt and record measurement here for a later reference.

Special Note: Shocks

Repeat

Record Driver Side measurement here:______________
Record Passenger Side measurement here:__________

See Illustration # 1

7. Working on the driver side, attach the torsion bar
removing tool, making sure that the unloading bolt in the
center of the torsion bar removing tool is in the small
divot of the stock torsion bar key. Adjust the torsion bar
key up high enough so that the stock small metal
adjusting block and bolt can be removed. Save the stock
hardware for later re-installation. Repeat procedure on
passenger side.

See Illustration # 2

8. Mark both torsion bars before removal so that they can
be re-installed back into the same location. Example:

Driver vs. Passenger and front vs. rear.

torsion bars forward until the stock torsion bar cross
member can be removed. Once you tap the stock torsion
bar out of the stock torsion bar cross member, the stock
torsion bar key will fall out. Set the stock torsion bar key a
side for later re-installation. Repeat procedure on the
passenger side.

9. Working on the driver side, remove the stock bolt that
connect the stock torsion bar cross member to the stock
mounting point and save the stock hardware for later re­installation. Special Note: The stock mounting point is

on the inside of the stock frame rail.

on the passenger side. Remove the stock torsion bar
cross member from the stock location and set a side for
later re-installation.

10. Working on the driver side, slide the stock torsion bar
out of the stock rear lower control arm and set a side for
later re-installation. Repeat procedure on passenger side.

11. Working on the driver side, remove the stock brake
line bracket from the stock upper control arm bracket and
save the stock hardware for later re-installation. Repeat
procedure on passenger side.

12. Working on the driver side, remove the stock front
sway bar end link from the stock sway bar and the stock
lower control arm location. The stock end link and
hardware may be discarded. Repeat procedure on
passenger side. Special Note: At this time, invert the

stock sway bar.

13. Working on the driver side, remove the (2) stock bolts
that connect the stock brake caliper to the stock spindle.
Save the stock hardware for later re-installation. Using a
bungee cord, carefully tie
out of the way in the fender well. Special Note: Take

special care not to kink or over extend the stock
brake line.

14. Working on the driver side, remove the stock rotor
from the stock location and set a side for later re­installation.

the stock brake caliper up and

Tap the stock

Repeat procedure

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

See Illustration # 3

16. Working on the driver side, disconnect the ABS lines
from each other. Also disconnect the ABS line from any
other mounting points.

17. Working on the driver side, remove the stock nut that
connects the stock outer tie rod ball joint to the stock
spindle. Save the stock hardware for later re-installation.
Carefully break the stock taper on the stock outer tie rod
ball joint.

tear the stock outer tie rod ball joint dust boot.

Special Note: Take special care not to rip or

18. Working on the driver side, remove the stock cotter
pin from the stock castle nut that connects the stock
upper control arm ball joint to the stock steering knuckle.
Save the stock cotter pin for re-installation. Loosen
the stock nut that connects the stock upper control arm
ball joint to the stock steering knuckle. Do not remove
the stock nut completely. Carefully break the stock
taper on the stock upper control arm ball joint. Special

Note: Take special care not to rip or tear the stock
ball joint dust boot.

19. Working on the driver side, remove the stock cotter
pin from the stock castle nut that connects the stock
lower control arm ball joint to the stock steering knuckle.
Save the stock cotter pin for re-installation. Loosen
the stock nut that connects the stock lower control arm
ball joint to the stock steering knuckle.

Do not remove
the stock nut completely. Carefully break the stock
taper on the stock lower control arm ball joint. Special
Note: Take special care not to rip or tear the stock
ball joint dust boot.

20. Working on the driver side, move back to the stock
nuts holding the upper control arm ball joint and the lower
control arm ball joint to the stock spindle and remove
completely. Save the stock hardware for later re­installation.

21. Working on the driver side, use a suitable removal
tool to remove the stock axle from the stock hub
assembly. Special Note: Take special care not to

damage the stock threads on the stock axle.

22. Working on the driver side, carefully remove the stock
hub assembly and the stock spindle from the stock
location.

23. Working on the driver side stock hub assembly,
remove the (3) stock bolts that connect the stock hub
assembly to the stock spindle. Save the stock hardware
and stock hub assembly for later re-installation. Carefully
remove the stock axle seal from the stock spindle and set
a side for later re-installation. A new spindle is used, the
stock spindle can be discarded.

24. Locate the new driver side spindle. Carefully install
the stock axle seal that was removed from step # 23 to
the new driver side spindle. Using the stock hardware
that was removed from step # 23, secure the new driver
side spindle to the stock hub assembly. Torque to 92 ft

lbs. Special Note: Make sure to use thread locker or
lock tite.

25. Set the new driver side spindle and hub assembly a
side for later re-installation.

26. 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

27. 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 CV
axle a side for later re-installation.

28. Working on the driver side, remove the stock front
and rear hardware that connects the stock lower control
arm to the stock front and rear location. Save the stock
hardware for later re-installation. Set the stock lower
control arm aside for later re-installation.

29. Repeat step’s 13 - 28 on the passenger side.

30. Working on the driver side, locate the stock lower
bracket that wraps around the rear lower half of the stock
front differential. Remove the stock bolt that connects the
lower portion of the stock front differential to the stock
bracket. Save the stock hardware for later re-installation.
Using the stock mounting point on the rear lower control
arm as a reference point, measure 3” towards the inside
of the vehicle and scribe a line on the stock bracket that
wraps around the rear portion of the stock front
differential. Using a hacksaw or suitable cutting tool, cut
along the line that was scribe earlier in this step.

Special
Note: Tuff Country recommends not using a cutting
torch when performing step # 30. Clean and dress up
any exposed metal.

See Illustration # 5

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. 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 the 4WD wiring harness.

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

34. 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.

35. 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.

36. 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.

37. 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 #

6 for proper cut line. Take special care not to cut into
the stock front differential housing.

See Illustration # 6

38. 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 16810NB2. Also, locate (2) PB2408G poly
bushings and (1) 9/16” x 2 1/8” anti crush sleeve from
hardware bag 16810SL. 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 # 7,

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
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
may crack.

39. Locate the new passenger side differential drop
bracket and the stock hardware that was removed from
step # 35. Install the new passenger side differential drop
bracket into the stock upper location and secure using

34 Ft. lbs.

Go back to the (4) stock bolts that

See Illustration # 7

the stock hardware. Do not tighten at this point.
Special Note: Make sure to use thread locker or lock
tite.

See Illustration # 8

40. 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 16810NB4. Carefully raise up on both
hydraulic floor jacks at the same time until the passenger
side of the stock front differential sits flush with the newly
installed passenger side differential drop bracket. 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. Also, at this
time re-connect the 4WD wiring harness back into the
stock location on the stock front differential.

See Illustration # 9

41. Carefully remove both hydraulic floor jacks from
under the stock front differential.

.

42

Locate the new one-piece lower sub frame and the
stock lower control arm hardware that was removed in
step # 28. Working on the driver side, install the front and
rear part of the new one piece lower sub frame into the
stock front and rear lower control arm stock pockets and
secure using stock hardware.

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

Repeat procedure on passenger side.

See Illustration # 10 / Front Location

See Illustration # 11 / Rear Location

43. 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.

44. Locate the stock rear driver side differential mounting
bracket hardware that was removed from step # 30.
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.
Special Note: During this procedure the front
differential is being lower in relation to the frame. On
some I.F.S vehicles this can cause a clearance
problem between the cooling fins on the stock front
differential and the stock rear lower control arm
pocket. If contact occurs, it may cause binding and
damage to the differential housing. The differential
also must be centered to allow the proper amount of
inner CV joint plunge. When the cooling fins contact
the frame, the differential is pushed to the passenger
side. This causes the left axle to over extend causing
the inner CV joint to pull out of the housing. When

Do not tighten at this

cooling fin contact occurs the aluminum fins must be
trimmed to allow the differential to center without
contacting the stock rear lower control arm pocket or
the stock frame rail. These fins are important for the
cooling of the differential. When trimming the cooling
fins you should only remove enough material to
allow for proper clearance.

See Illustration # 12

45. Locate the stock upper front differential hardware that
was removed from step # 34. Working on the driver side,
secure the new driver side relocation bracket to the front
part of the newly installed one piece lower sub frame and
secure using the stock hardware.

Do not tighten at this

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

See Illustration # 13

46. Using a pair of hydraulic floor jacks, carefully raise up
on the front portion on the new one piece lower sub
frame until the new one piece lower sub frame sits flush
with the stock front cross member. Using the holes in the
front part of the new one piece lower sub frame as a
guide, carefully drill (2) 1/2” holes into the stock front
cross member.

47. Locate (2) 1/2” x 1 1/4” bolts, (2) 1/2” unitorque nuts,
(4) 1/2” flat washers and (2) 1/2” lock washers from
hardware bag 16810NB3. Secure the new one piece
lower sub frame to the stock front cross member using
the new 1/2” x 1 1/4” bolts and hardware. Torque to 85 ft

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

See Illustration # 14

48. Carefully remove both hydraulic floor jacks from
under the front portion of the new one piece lower sub
frame.

49. Move back to all the stock and new hardware
associated with the new driver and passenger side
differential drop brackets, the rear portion of the stock
front differential that mounts to the new one piece lower
sub frame and the stock mounting points were the new
one piece lower sub frame mounts. Torque all hardware
to proper torque specifications.

Refer to the torque
setting sheet on the first page of the installation
manual.

50. Locate (2) poly bump stops from hardware bag
16810SL. Also, locate (2) 3/8” lock nuts, (2) 3/8” flat
washers and (2) 3/8” lock washers from hardware bag
16810NB1. Working on the driver side, install the new
poly bump stop into the newly installed one piece lower
sub frame and secure using the new 3/8” hardware.
Torque to 28 ft. lbs. Make sure to use thread locker or

lock tite. Repeat procedure on passenger side.

See Illustration # 15

51. Locate (2) 5/8” x 4 1/2” bolts, (2) 5/8” x 5 1/2”, (4) 5/8”
unitorque nuts, (8) 5/8” flat washers, (4) 5/8” unitorque
nuts, (4) 5/8” lock washers from hardware bag
16810NB5. Also, locate the stock driver and passenger

side lower control arms that were removed from step #

28. Working on the driver side, install the stock lower
control into the newly installed one piece lower sub frame
front location and secure using the new 5/8” x 4 1/2” bolt
and hardware. Next, secure the rear portion of the stock
lower control arm into the rear portion of the newly
installed one piece lower sub frame and secure using the
new 5/8” x 5 1/2” bolt and hardware. Do not tighten at
this point. Make sure to use thread locker or lock tite.
Repeat procedure on passenger side.

See Illustration # 16 / Front Location

See Illustration # 17 / Rear Location

52. Locate (12) 10 mm x 70 mm bolts and (12) 10 mm
lock washers from hardware bag 16810NB1. Locate (2)
new axle half shaft spacers. Also, locate the stock driver
and passenger side CV axles that were removed from
step # 27. Working on the driver side, install (1) new axle
spacer between the stock front differential and the stock
axle. Secure using the new 10 mm x 70 mm bolts and
hardware. Torque to

65 ft. lbs. Make sure to use thread
locker or lock tite. Special Note: Make sure that the
stock axle is re-installed back into the stock location
on the stock front differential. Refer to the marks that
were scribe in step # 26.

Repeat on the passenger side.

See Illustration # 18

53. Locate the new driver side spindle and the stock hub
assembly, the stock hardware for the upper control arm
ball joint and the lower control arm ball joint that was
removed from step # 20. Using the stock hardware,
secure the new driver side spindle and stock hub
assembly to the stock upper control arm ball joint and the
stock lower control arm ball joint. Torque the stock
hardware on the upper and lower ball joints to 85 ft lbs.
Also, when performing this step, slide the stock axle into
the stock hub assembly location. Repeat procedure on
the passenger side using the passenger side steering
knuckle.

See Illustration # 19

54. Locate the stock cotter pins that were removed from
step # 18 and 19. Install the stock cotter pins back into
the stock location on the stock upper and lower control
arm ball joints.

55. Locate the stock hardware that was removed from
step # 17. Working on the driver side, install the stock
outer tie rod ball joint to the newly installed driver side
spindle, secure using the stock hardware. Torque the
outer tie rod ball joint hardware to 68 ft. lbs. Make sure

to use thread locker or lock tite.

Repeat procedure on

passenger side.

56. Locate the stock hardware that connects the stock
front axle to the stock hub assembly that was removed in
step # 15. 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.

Repeat procedure on the passenger side.

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

58. Locate the stock rotors that were removed from step
# 14. Working on the driver side, install the stock rotors
into the stock location. Repeat procedure on the
passenger side.

59. Locate the stock hardware that was removed from
step # 13. Working on the driver side, re-install the stock
brake caliper to the new spindle using the stock
hardware.
Torque to

Make sure to use thread locker or lock tite.
90 ft lbs.

Repeat procedure on the passenger

side.

60. 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.

61. Locate (2) front brake line relocation brackets, (2)
5/16” x 1 1/4” bolts, (4) 5/16” flat washers, (2) 5/16”
unitorque nuts (2) 5/16” lock washers from hardware bag
16810NB1. Also, locate the stock hardware that was
removed from step # 11. Working on the driver side,
install the new brake line relocation bracket to the stock
location using the stock hardware. Do not tighten at this

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

Next, secure the stock brake line bracket to the newly
installed brake line relocation bracket and secure using
the new 5/16” x 1 1/4” bolt and hardware. Make sure to

use thread locker or lock tite.

Torque the stock and

new hardware to 15 ft lbs.

See Illustration # 20

62. Locate (2) new sway bar end links, (8) sway bar end
links washers and (8) sway bar end links bushings from
hardware bag 16810SL. Also, locate (2) 3/8” x 10” bolts
and (2) 3/8” unitorque nuts from hardware bag
16810NB1. Working on the driver side, install the new
sway bar end link and hardware to the stock sway bar
and the stock lower control arm. Torque to 32 ft lbs.
Repeat procedure on the passenger side.

Special Note:
If you did not invert the stock sway bar in step # 12,
invert it before you install the new sway bar end
links.

See Illustration # 21

63. Working on the driver side, carefully remove the (2)
stock rivet's on the bottom side of the stock frame rail.

Special Note: If using a drill, take special care not to
drill into any stock hoses and/or lines running down
the inside of the stock frame rail. The stock torsion bar

drop bracket may be discarded. Repeat procedure on the
passenger side.

64. Locate (2) new torsion bar drop brackets, (4) PB4902
poly bushings and (2) 1/2” x 1 1/2” anti crush sleeve from
hardware bag 16840SL. Install the new poly bushings

and sleeves into the new torsion bar drop brackets.

Special Note: Make sure to use a lithium or moly
base grease prior to inserting the new bushings and
sleeves into the new torsion bar drop brackets. This
will increase the life of the bushing as well as prevent
squeaking.

65. Working on the driver side, hold the new torsion bar
drop bracket to the new location on the stock frame rail.

Special Note: Make sure to center the new torsion bar
drop bracket where the stock torsion bar drop
bracket was located. With the new torsion bar bracket in

place, use a pair of vice grips and secure the new torsion
bar drop bracket to the stock frame rail. Using the new
torsion bar drop bracket as a guide, carefully drill (4)
7/16” holes into the stock frame. (2) on the side of the
frame rail and (2) on the bottom.

Take Special care not
to drill into any stock hoses and/or lines running
down the inside of the stock frame rail. Repeat

procedure on the passenger side of the vehicle.

66. Locate (8) 7/16” x 1 1/2” bolts, (16) 7/16” flat
washers, (8) 7/16” unitorque nuts and (8) 7/16” lock
washers from hardware bag 16840NB2. Working on the
driver side, secure the new driver side torsion bar drop
bracket to the stock frame rail using the new 7/16” x 1
1/2” bolt and hardware. Make sure to use thread locker
or lock tite. Do not tighten at this point. Repeat
procedure on the passenger side. Remove the pair of
vice grips holding the new torsion bar drop bracket to the
new location.

See Illustration # 22

67. Locate the driver side torsion bar that was removed in
step # 10. Install the stock torsion bar into the stock lower
control arm. Make sure that you push the stock torsion
bar as far forward as you can, this will allow you to install
the stock torsion cross member. Special Note: Make

sure that you install the stock torsion bar the same
way that it was removed. Example: driver side vs.
passenger side and front vs. rear.

Repeat procedure

on passenger side.

68. Locate the stock torsion bar cross member and stock
torsion bar hardware that was removed from step # 9.
Working on the driver side, secure the stock torsion bar
to the newly installed torsion bar drop bracket and secure
using the stock hardware.

Make sure to use thread

locker or lock tite. Do not tighten at this point. Repeat

procedure on the passenger side. Once the driver and
passenger side torsion bar stock hardware has been
installed torque the stock hardware to

95 ft lbs.

Move
back to the new 7/16” x 1 1/2” bolts and hardware that is
holding the new torsion bar drop brackets to the stock
frame rail and torque to 76 ft lbs.

See Illustration # 23

69. Locate the stock driver and passenger side torsion
bar key’s that were removed from step # 8. Working on
the driver side, install the stock torsion bar key back into

the stock torsion bar cross member. Holding the stock
torsion bar key into the stock location, slide the driver
side torsion bar into the stock torsion bar key. Repeat
procedure on the passenger side.

70. Locate the small metal adjusting blocks and bolts that
were removed from step # 7. Working on the driver side,
attach the torsion bar removing tool, making sure that the
unloading bolt in the center tool is in the small divot of the
torsion bar key. Adjust the torsion bar key up high
enough so that the small metal adjusting block and stock
bolt can be re-installed, Refer back to step # 6 and adjust
the stock bolt to the stock location. Repeat procedure on
passenger side. Remove the torsion bar adjusting tool.

71. Move back to all newly installed brackets and make
sure that all stock and new hardware is torqued to proper
specifications. Now re-connect the front differential vent
hose. Refer to the torque setting sheet on the first

page of the installation manual and torque to proper
settings.

72. Locate (2) 5/8” x 2 1/2” poly shock bushings and (2)
1/2” x 2 1/2” shock sleeves from hardware bag 16810SL.
Also, locate the stock upper and lower shock hardware
that was removed from step # 3 and the new shock
boots. Install the new shock boots onto the new shocks.
Insert the new poly shock bushings and sleeves into the
upper eyelet of the new shocks.

Special Note: Shocks
are not included with this suspension system,
shocks need to be ordered as a separate part
number, Tuff Country EZ Ride suspension
recommends using a 23” fully extended nitrogen gas
shock. Make sure to use a lithium or moly base
grease prior to inserting the new bushings into the
new shock. This will increase the life of the bushing
as well as prevent squeaking. Install the lower shock
bushing and sleeve into the lower eyelet of the new
shock. Special Note: Make sure to use a lithium or
moly base grease prior to inserting the new bushings
into the new shock. This will increase the life of the
bushing as well as prevent squeaking. Working on
the driver side, install the new shock into the stock
location and secure using the stock hardware.
Torque the upper and lower stock hardware to 70 ft
lbs. Repeat procedure on passenger side.

73. Locate the stock inner rubber fender splash guards
that were removed from step # 2. Working on the driver
side, re-install the inner rubber fender splash guard.
Repeat procedure on the passenger side.

74. Locate (2) rear lateral compression mounts. (2) 1/2” x
1 1/4” spacer sleeves from hardware bag 16810SL. (2)
1/2” x 2 1/4” bolts, (4) 1/2” flat washers, (2) 1/2” unitorque
nuts and (2) 1/2” lock washers from hardware bag
16810NB3. Working on the driver side stock transfer
case cross member carefully drill a 1/2” hole into the
upper part of the stock transfer case cross member.

Special Note: There is an existing hole in the lower

part of the stock transfer case cross member, use
this hole as a guide to drill the new 1/2” hole in the
upper part of the stock transfer case cross member.

Install the new rear lateral compression arm mount to the
stock transfer case cross member. Secure using (1) 1/2”
x 2 1/4” bolt, spacer sleeve and hardware. Torque to

38
ft lbs. Special Note: The new 9/16” x 1 1/4” anti crush
sleeve needs to go into the stock transfer case cross
member, this will not allow the transfer case cross
member to crush when the bolt is torqued.

Repeat

procedure on passenger side.

See Illustration # 24

75. Locate (2) front lateral compression arms. (8)
PB2408G poly bushings and (4) 9/16” x 2 1/8” crush
sleeves. Install the new poly bushing into each end of the
new front lateral compression arms. Next, install the new
anti crush sleeve into the newly installed poly bushing.

Special Note: Make sure to use a lithium or moly
base grease prior to inserting the new bushings and
sleeves into the new front lateral compression arms.
This will increase the life of the bushing as well as
prevent squeaking.

76. Locate (4) 1/2” x 3 1/2” bolts, (8) 1/2” flat washers, (4)
1/2” unitorque nuts and (4) 1/2” lock washers from
hardware bag 16810NB3. Working on the driver side,
secure (1) new lateral compression arm to the new front
lateral compression arm mount on the newly installed
one piece lower sub frame and secure using the new 1/2”
x 3 1/2” bolt and hardware. Do not tighten at this point.
Make sure to use thread locker or lock tite. Next,
secure the new lateral compression arm to the previously
installed rear lateral compression arm mount. Secure
using the new 1/2” x 3 1/2” bolt and hardware. Torque the
front and rear mount to 85 ft lbs. Repeat procedure on
the passenger side

See Illustration # 25 / Front Location

See Illustration # 26 / Rear Location

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

78. 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 setting sheet on the first page of the
installation manual.

79. An exhaust modification is required once the
suspension system has been completed. After the rear
end installation is complete take the vehicle directly to a
muffler shop and have the exhaust modification
performed. Once the exhaust modification has been
performed re-install the stock front drive line back into the
stock location using the stock hardware that was
removed from step # 5. Torque to 35 ft lbs.

Congratulation, Front End Installation Complete!