Tuff Country 16985 User Manual
Part # 16985
2001 - 2010 Chevy or GMC Silverado 2500HD
6” suspension system
Parts contained in Box 1 of 3
Part
# Description
Qty.
16985-04 Sub frame 1
16985-12 Lateral compression arms 2
16985NB Hardware bag 1
Parts contained in Box 2 of 3
Part
# Description Qty.
HDDIFF-01 DS differential relocation bracket 1
16985-23 PS differential relocation bracket 1
TBD99-01 Torsion bar relocation brackets 2
16985-10 Rear carrier bearing relocation bracket 1
16985-11 Lateral compression mounts 2
22SW Square washers 8
BL402 4” rear lifted blocks 2
5U-9296S 5/8” x 2 3/4” x 14” square u-bolts 4
58NW Hardware bag 1
16985PL Hardware bag 1
16985SL Hardware bag 1
9802 Axle spacers 2
16985INST Instruction manual 2
MIRRORHANGER
Rear view mirror hanger 1
WARNINGDECAL Warning decal 1
Parts contained in Box 3 of 3
Part
# Description Qty.
16985-01M DS knuckle 1
16985-02M PS knuckle 1
16985NB6 Hardware bag 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.
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.
Please see the end of the installation manual for a picture of the hard parts that are included in this suspension system.
Installation manual
6” suspension system
2001 -- 2010
Chevy or GMC Silverado 2500HD
Part # 16985
sj03062012rev.05
Important customer information:
Tuff Country EZ-Ride Suspension highly recommends
that a qualified or a certified mechanic performs this
installation.
It is the responsibility of the customer/installer 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. If you
have any questions or concerns, please contact our
technical department @ (801) 280-2777. Also, the 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.
If you desire to return your vehicle to stock, it is the
customers responsibility to save all stock hardware
and components.
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 # 16985 but a larger sized tire and the stock
wheels will not work in conjunction with part # 16985.
Once part # 16985 has been installed with larger tires,
new wheels with a 4.5” back spacing or less is
required. Tuff Country recommends a 35x12.50 tire
package. If larger than a 35x12.50 tire is installed on
your vehicle in conjunction with part # 16985; Tuff
Country assumes no liability and the warranty will be
VOID.
Before installation begins, Tuff Country EZ-Ride
Suspension highly recommends that the installer
performs a test drive on the vehicle. During the test
drive, check to see if there are any uncommon sounds
or vibrations. If uncommon sounds or vibrations occur
on the test drive, uncommon sounds or vibrations will
be enhanced once the suspension system has been
installed. Tuff Country EZ-Ride Suspension highly
recommends notifying the customer prior to
installation to inform the customer of these issues if
they exist.
After installation, some vehicles may encounter a front
drive line vibration. If this is the case on the vehicle
that you are working on, the stock front drive line may
need to be rebalanced. If the stock front drive line is
rebalanced and the vibration still occurs, a new front
drive line may be needed.
New longer front and rear shocks are needed after this
suspension system has been installed and the front
and rear shocks need to be ordered as a separate part
#. If you have not already ordered your front and rear
shocks, please feel free to contact Tuff Country or
your local Tuff Country dealer and order your front and
rear shocks. Tuff Country recommends installing a 23”
fully extended nitrogen gas shock in the front and a
30” fully extended nitrogen gas shock in the rear.
Tuff Country EZ-Ride Suspension packages (2) sets of
instruction sheets with this box kit. (1) is for the
installer and (1) is for the customer. The (1) for the
customer has some post installation procedure
literature and it is the installers responsibility to make
sure that the customer receives a copy of the
installation manual along with the literature.
Torque settings:
5/16” 15—18 ft lbs.
3/8” 28—32 ft lbs.
7/16” 30—35 ft lbs.
1/2” 65—85 ft lbs.
9/16” 85—120 ft lbs.
5/8” 95—130 ft lbs.
3/4” 100—140 ft lbs.
Hardware bag 16985SL includes:
Description Quantity
S10007 (.500” x .380” x 1.700”) 2
S10058 (.875” x .500” x 2.080”) 4
S10067 (.500” x .380” x 2.610”) 2
S10073 (.687” x .563” x 1.320”) 2
S10074 (.687” x .558” x 1.500”) 4
S10082 (.875” x .563” x 2.080”) 1
S10120 (.750” x .510” x 1.000”) 1
Hardware bag 16985PL includes:
Description
Quantity
PB6199 (short bump stop) 4
PB6052 (tall bump stop) 2
PB2408 (poly bushing) 10
MO2220 (poly bushing) 4
PB8016 (sway bar end link bushing) 8
S10049 (sway bar end link washer) 8
LUBE (poly lube pack) 2
SHOCKTIE (zip tie) 10
Hardware bag 16985NB includes:
Bag # 1
Description
Quantity
3/8” x 7” bolts 2
3/8” x 3 1/2” bolts 2
3/8” x 1 1/2” self threading bolts 2
3/8” unitorque nuts 10
5/16” USS flat washers 12
10 mm x 35 mm bolts 12
10 mm x 60 mm bolts 4
10 mm lock washers 17
1/4” x 1” self threading bolt 1
Bag # 2
Description
Quantity
7/16” x 3” bolt 1
7/16” x 1 1/2” bolts 10
7/16” unitorque nuts 11
3/8” USS flat washers 22
Bag # 3
Description
Quantity
1/2” x 2” bolts 4
1/2” x 3 1/2” bolts 4
1/2” unitorque nuts 8
7/16” USS flat washers 16
Bag # 4
Description
Quantity
9/16” x 1 3/4” bolts 2
9/16” unitorque nuts 2
1/2” USS flat washers 4
Bag # 5
Description Quantity
5/8” x 4 1/2” bolts 2
5/8” x 5 1/2” bolts 2
5/8” unitorque nuts 4
9/16” USS flat washers 8
Hardware bag 58NW includes:
Description
Quantity
5/8” u-bolt high nuts 8
5/8” u-bolt harden washers 8
Hardware bag 16985NB6 includes:
Description
Quantity
BLR11 (brake line bracket) 2
1/4” x 3/4” bolt 4
1/4” flat washer 6
1/4” unitorque nut 2
1/4” lock washer 2
Special post installation procedure: Tuff Country EZRide Suspension highly recommends adding a
minimum of 1 pint, but no more that 1 1/2 pints, of
proper front differential fluid into the front differential.
To achieve this, you may have to fill the differential
with it on its side or you may have to insert the fluid
through the vent tube opening. On occasion, the
customer may find burping of fluid coming out of the
front vent tube.
Recommended tools selection:
Torsion bar puller
(Part # 7822A / LSP code: 769 006 21)
Cut off wheel
Sawzall
Torque wrench
Standard socket set
Standard wrench set
Metric socket set
Metric wrench set
Tape measure
Hydraulic floor jacks
Special note: Some of the pictures in this installation
manual are used from a 1/2 ton vehicle. The concept of
the installation is the same on the 1/2 tons as the 3/4
ton vehicles.
Please follow instructions carefully:
Before installation begins, measure from the center of
the hub, to the bottom of the fender well, and record
measurements below.
Pre-installation measurements:
Driver side front:_______________________________
Passenger side front:___________________________
Driver side rear:________________________________
Passenger side rear:____________________________
At the end of the installation take the same
measurements and compare to the pre-installation
measurements.
Post installation measurements:
Driver side front:______________________________
Passenger side front:__________________________
Driver side rear:_______________________________
Passenger side rear:___________________________
Front end installation:
1. To begin installation, block the rear tires of the vehicle so
that the vehicle is stable and can’t roll backwards. Safely lift
the front of the vehicle and support the frame with a pair of
jack stands. Place a jack stand on both the driver and the
passenger side. Next, remove the front wheels and tires
from both sides.
2. Working on the driver side, attach the torsion bar
removing tool to the 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 stock
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.
3. Mark both torsion bars before removal so that they can
be re-installed back into the same location. Example:
Driver vs. Passenger and front vs. rear. Tap the torsion
bars forward until the torsion bar cross member can be
removed. Once you tap the torsion bar out of the torsion
bar cross member, the torsion bar key will fall out. Set the
torsion bar key aside for later re-installation. Repeat procedure on the passenger side.
4. Working on the driver side, remove the hardware that
connects the torsion bar cross member to the mounting
point. Set the stock hardware aside for later re-installation.
Special note: The stock mounting point is on the inside
of the frame rail. Repeat procedure on the passenger
side. Remove the torsion bar cross member and set aside
for later re-installation.
5. Working on the driver side, slide the torsion bar out of the
rear lower control arm and set aside for later re-installation.
Repeat procedure on passenger side.
6. Remove the stock lower skid plate and discard the stock
lower skid plate and the stock hardware.
7. Remove the upper skid plate. Save the skid plate and
the upper hardware. The lower hardware may be discarded.
8. Working on the driver side, remove the hardware on the
top of the shock. The upper hardware may be discarded.
Remove the hardware on the lower shock mount and save
the hardware for later re-installation. The shock may be discarded. Special note: New longer front shocks are
needed, if you have not already ordered shocks, please
contact Tuff Country or your local Tuff Country dealer
and order the proper shocks. Tuff Country recommends using a 23” fully extended nitrogen gas shock.
Repeat procedure on the passenger side.
9. Working on the driver side, remove the sway bar end link
from the sway bar and lower control arm. The end link and
hardware may be discarded. Repeat procedure on the passenger side. Special note: At this time, invert the sway
bar.
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 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 pas-
senger side.
11. Working on the driver side, remove the brake line
bracket that connects to the steering knuckle and discard
the hardware. Next, remove the brake line mounting point
that connects to the upper control arm. Save the hardware
for later re-installation. Also, remove any other brake line
mounting points on the steering knuckle and upper control
and save the hardware for later re-installation. Repeat procedure on the passenger side.
12. Working on the driver side, locate the ABS line quick
disconnect located above the upper control arm.
Disconnect the ABS lines from each other. Also, disconnect
the ABS line from any other mounting points on the frame
rail. Repeat procedure on the passenger side.
13. 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 brake line. Repeat procedure on the passenger side.
14. Working on the driver side, remove the rotor and set
aside for later re-installation. Repeat procedure on the passenger side.
15. Working on the driver side, remove the cap right in the
middle of the hub assembly. Set the cap aside for later reinstallation. Repeat procedure on the passenger side.
16. Working on the driver side, remove the hardware that
connects the axle to the hub assembly. Save the hardware
for later re-installation. Repeat procedure on the passenger
side.
17. Working on the driver side, scribe a mark on the CV
plate and another directly across to the differential. This will
allow you to re-install the CV back into the OE location.
Repeat procedure on the passenger side.
18. Working on the driver side, remove the (6) bolts holding
the inner CV axle to the front differential. Discard the hardware. Carefully remove the CV axle from the vehicle and
set the CV axle aside for later re-installation. Special note:
During the removal of the CV axle, take special care not
to damage the threads of the CV axle or the CV axle
dust boot. Repeat procedure on the passenger side.
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 stock 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 taper for now. Repeat procedure on the
passenger side.
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