Tuff Country 16987 User Manual
PART NUMBER : 16987 / WITH OUT SHOCKS
PART NUMBER : 16988 / WITH SHOCKS
2001—CURR. CHEVY HEAVY DUTY 2500
6” SUSPENSION SYSTEM WITH FRONT SPINDLES
Part # Description Qty.
16985-01 Passenger Side Spindle 1
16985-02 Driver Side Spindle 1
16985-04 6” One Piece Sub Frame 1
16985-08 Rear Cross Member Support Bracket 1
16985-09 Transfer Case Drop Shims 8
16985-10 Rear Carrier Bearing Drop Bracket 1
16985-11 Rear Lateral Compression Arm Bracket 2
16985-12 Lateral Compression Arms 2
C4I1SN-21 Torsion Bar Drop Brackets 2
BL402 Rear 4” Lifted Blocks 2
5U-9296S 5/8” x 2 3/4” x 13 5/8” Square U-bolts 4
58NW 5/8” U-bolt High Nuts & Washers 1
16985NB Hardware Box 1
16985SL Sleeve & Poly Bag 1
16987INST Instruction Sheet 1
SHOCKTIE Shock Ties 10
Special Note: Tuff Country EZ-Ride Suspension
recommends the use of an 8” wheel once part #
16987 & 16988 has been installed on a vehicle.
Special Options: Tuff Country EZ-Ride Suspension
offers a front brush plate. If you would like a new
brush plate, please contact Tuff Country or your
local Tuff Country dealer and order part # 90008.
Congratulations
on your selection to purchase a Tuff
Country EZ-Ride Suspension System. We at Tuff
Country are proud to offer a high quality product at the
industries most competitive pricing. Thank you for your
confidence in us, and our product.
Before installation begins, it is the customers/installers
responsibility to make sure that all parts are on hand. If
any parts are missing, please feel free to call one of our
customer service representative @ (800) 288-2190.
Make sure to use locktite on all new and stock hardware
associated with this installation.
INSTALLATION MANUAL
6” I.F.S. SUSPENSION 2001 - CURR.
CHEVY HEAVY DUTY 2500 2WD
PART # 16987 / WITH OUT SHOCKS
PART # 16988 / WITH SHOCKS
SJ031502
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.
IMPORTANT CUSTOMER INFORMATION
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
check every 6 months to ensure proper tracking,
proper wear on tires and front end components. Tuff
Country EZ-Ride Suspension take 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.
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.
LIMITED LIFETIME WARRENTY
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
Special Note: After the installation is complete, a
front end alignment is required.
Special Note: After completion of the installation and
the new tires and wheels have been installed,
trimming of the plastic valance may be needed.
Slight trimming may be needed when installing a 33 x
12.50. When installing a 35 x 12.50 trimming is
mandatory.
For a list of all parts, please refer to the Parts
Description Page, at the end of the Installation
Manual.
Please Follow Instruction Carefully
Before installation begins, drive and check to make
sure there are no uncommon sounds and or frame
damage. Also at this time 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 wheels and
tires from both sides.
2. Remove the stock front upper and lower skid plates.
The stock front upper, lower skid plate and stock
hardware may be discarded.
3. Working on the driver side, remove the stock hardware
on the top of the stock shock. The upper stock hardware
may be discarded. Remove the stock hardware on the
lower shock mount and save hardware for later re-
installation. The stock 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.
4. Measure exposed threads on the 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
5. Working on the driver side, attach the torsion bar
removing tool to the stock torsion bar cross member,
making sure that the unloading bolt in the center of the
torsion bar removing tool is in the small divot of the stock
torsion bar key. Adjust the torsion bar key up high
enough so that the stock small metal adjusting block and
bolt can be removed. Set the stock torsion bar block and
hardware a side for later re-installation. Repeat
procedure on passenger side.
See Illustration # 2
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.
Tap the stock
torsion bars forward until the stock torsion bar cross
member can be removed.
7. Working on the driver side, remove the stock bolt that
connects the stock torsion bar cross member to the stock
mounting point. Save the stock hardware for later reinstallation. 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.
8. 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.
9. Working on the driver side, remove the stock sway bar
end link from the stock location and discard the stock end
link and all the stock hardware. Repeat procedure on the
passenger side. Special Note: At this time, invert the
stock sway bar.
10. Working on the driver side, remove the stock brake
line bracket that connects to the stock steering knuckle
and discard the stock hardware. Also remove any other
brake line mounting points on the stock steering knuckle
and stock upper control arm. Repeat procedure on the
passenger side.
11. Working on the driver side, remove the (2) stock bolts
that connect the stock brake caliper to the stock hub
assembly. Save the stock hardware for later reinstallation. 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.
12. Working on the driver side, remove the stock rotor
and set a side for later re-installation.
13. 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.
14. 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.
15. 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.
16. 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.
17. 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 all
(3) nuts and washers for later re-installation.
18. Carefully remove the stock hub assembly and the
stock steering knuckle form the stock location.
19. Working on the driver side stock hub assembly,
remove the stock cup located on the inner part of the
stock hub assembly, save for later re-installation. Next,
remove the (4) 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.
Also, carefully remove the stock rubber “O” ring located in
the stock steering knuckle and save for later reinstallation. A new steering knuckle is used, the stock
steering knuckle can be discarded.
20. Locate the new driver side steering knuckle. Using
the stock rubber “O” ring that was removed in step # 19,
carefully re-install the stock rubber “O” ring into the new
driver side knuckle. Using the stock hardware that was
removed from step # 19, secure the new driver side
steering knuckle to the stock hub assembly. Install the
stock cup back into the stock location, on the stock hub
assembly. Torque to 92 ft lbs. Special Note: Make sure
locker or lock tite.
21. Set the new driver side steering knuckle and hub
assembly a side for later re-installation.
22. Working on the driver side, remove the stock front
and rear hardware that connects the stock lower control
arm to the stock location. Save the stock hardware for
later re-installation. Set the stock lower control arm a side
for later re-installation.
23. Repeat step’s 10 - 22 on the passenger side.
24. Working on the driver side, remove the (2) stock bolts
that connect the stock rear cross member to the stock
driver side rear lower control arm mounting point and
save stock hardware for later re-installation. Repeat
procedure on the passenger side.
See Illustration # 3
25. Locate the new one piece sub frame and the stock
lower control arm mounting hardware that was removed
from step # 22. 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 and
secure 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 # 4 / Front Location
See Illustration # 5 / Rear Location
26. Locate (2) 6199 poly bump stops, “Special Note:
There are (6) poly bump stops located in the poly and
sleeve bag, (4) are the same size and (2) are taller,
locate (2) of the shorter poly bump stops” (2) 3/8”
unitorque nuts, (2) 3/8” flat washers and (2) 3/8” lock
washers. Working on the driver side rear portion of the
newly installed one piece sub frame, secure the new poly
bump stop using the new 3/8” hardware. Torque to 28 ft
Repeat procedure on the passenger side.
lbs.
sure to use thread locker or lock tite.
Make
See Illustration # 6
27. 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. Also locate the stock lower control arms
that were removed from step # 22. Working on the driver
side, install the stock lower control 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 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.
See Illustration # 7 / Front Location
See Illustration # 8 / Rear Location
28. Locate the new driver side steering knuckle and stock
hub assembly, 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 # 17. 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 tite. Repeat procedure on
the passenger side using the passenger side steering
knuckle.
See Illustration # 9
29. 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.
30. Working on the driver side, reconnect the stock ABS
lines back together. Repeat procedure on the passenger
side.
31. Locate the new rear cross member support bracket,
(2) 1/2” x 1 1/4” bolts, (4) 1/2” flat washers, (2) 1/2”
unitorque nut, (2) 1/2” lock washers and the stock
hardware that was removed from step # 24. Working on
the rear portion of the newly installed sub frame, secure
the new rear cross member support bracket to the new
one piece sub frame using the new 1/2” x 1 1/4” bolts and
hardware. Do not tighten at this point. Make sure to
use thread locker or lock tite.
Next, secure the other
end of the new support bracket to the passenger side
stock rear cross member location using the stock
hardware. Torque the stock and new 1/2” hardware to 85
ft lbs.
See Illustration # 10
32. Locate the stock brake caliper hardware that was
removed in step # 11. Working on the driver side, reinstall the stock brake caliper to the stock hub assembly
and secure using the stock hardware. Torque to 76 ft.
Repeat procedure on the passenger side. Special
lbs.
Note: make sure to re-install the stock rotor.
33. Locate (10) shock ties. Working on the driver side,
secure the stock brake line bracket to the stock upper
control arm using the stock hardware that was removed
from step # 11. Next, shock tie the stock ABS line and
the stock brake line to the newly installed spindle. Also,
shock tie together the stock ABS line and the stock brake
lines together. Repeat procedure on the passenger side.
See Illustration # 11
34. Working on the front portion of the new one piece sub
frame, using the one piece sub frame as a guide, drill (2)
7/16” holes into the bottom of the stock frame. Locate (2)
7/16” x 1 1/4” bolts, (4) 7/16” flat washers, (2) 7/16”
unitorque nuts and (2) 7/16” flat washers. Secure the
front portion of the new one piece sub frame to the stock
frame using the new 7/16” x 1 1/4” bolt and hardware.
Torque to
42 ft lbs.
35. On the driver side of the stock frame rail, scribe a
mark in the center of the (2) stock lower holes where the
stock torsion bar bracket was located.
See Illustration # 12
36. Locate (2) new torsion bar drop brackets, (4) 4902
poly bushings and (2) 9/16” x 1 1/4” anti crush sleeve.
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 front
lateral compression arms. This will increase the life
of the bushing as well as prevent squeaking.
37. Working on the driver side, hold the new torsion bar
drop bracket to the bottom of the stock frame rail. Line up
the mark that was scribe in step # 35 with the center of
the new torsion bar drop bracket. Scribe a mark on the
bottom of the stock frame rail where the new torsion bar
bracket should go. Carefully drill a 1/2” hole in the bottom
of the stock frame rail. 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.
38. Locate (4) 1/2” x 1 1/2” bolts, (8) 1/2” flat washers, (4)
1/2” unitorque nuts and (4) 1/2” lock washers. Working on
the driver side, secure the new driver side torsion bar
drop bracket to the bottom side of the stock frame rail
using the new 1/2” x 1 1/2” bolt and hardware.
Make
sure to use thread locker or lock tite. Torque to 76 ft
lbs. Repeat procedure on the passenger side.
See Illustration # 13
39. Locate the stock torsion bars that were removed from
step # 8. Refer to the marks that were made in step # 6.
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 reinstalled. Repeat procedure on the passenger side.
40. Locate the stock torsion bar cross member and stock
hardware that was removed from step # 7. Install the
stock torsion bar cross member to the newly installed
torsion bar drop brackets and secure using the stock
hardware.
Make sure to use thread locker or lock tite.
Torque to 90 ft lbs.
See Illustration # 14
41. Locate the stock torsion bar keys that were removed
from step # 5. 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 torsion bar key. Repeat
procedure on the passenger side.
42. Locate the torsion bar adjusting blocks and hardware
that was removed from step # 5. 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 # 4 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.
43. Locate (2) 3/8” x 7” bolts, (2) 3/8” unitorque nuts, (2)
new sway bar end links and the new stock sway bar end
link bushings and washers. Special Note: If you did not
invert the stock sway bar in step # 10, invert the
stock sway bar now.
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 # 15
44. Locate (2) front lateral compression arms, (8) 2408
poly bushings and (4) 916218SLWOH and 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.
45. Locate (2) 1/2” x 3 1/2” bolts, (4) 1/2” flat washers, (2)
1/2” unitorque nuts and (4) 1/2” lock washers. 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 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.
Repeat procedure on the passenger side.
46. Working on the driver side, measure from the new
lateral compression arm mount located on the previously
installed one piece sub frame back to the center of the
stock transfer case cross member. Special Note: Chevy
has a variation on the placement of the stock transfer
case cross member. Your measurement should either
be 31” or 32” long. Remember the measurement, this
measurement is needed in step # 47.
47. Locate (2) 1/2” x 3 1/2” bolts, (4) 1/2” flat washers, (2)
1/2” unitorque nuts and (4) 1/2” lock washers. Also locate
(2) rear lateral compression mounts. Working on the
driver side, if the measurement that you had in step # 46
was 31”, secure the new lateral compression arm to the
new rear lateral compression arm mount rear hole using
the new 1/2” x 3 1/2” bolt and hardware.
at this point. Special Note: Refer to Illustration # 16
for proper placement. If the measurement that you had
in step # 46 was 32”, secure the new lateral compression
arm to the new rear lateral compression arm mount front
hole using the new 1/2” x 3 1/2” bolt and hardware. Do
not tighten at this point. Special Note: Refer to
Illustration # 16 for proper placement. Hold the new
lateral compression arm and mount up to the stock
transfer case cross member and scribe a mark on the
transfer case cross member where the new mount will
go. Repeat procedure on the passenger side.
See Illustration # 16
48. Working on the driver side, carefully drill a 5/16” hole
in the bottom of the stock transfer case cross member.
Refer to the mark that was scribe in step # 46. Repeat
procedure on the passenger side.
49. Working on the driver side lateral compression arm,
remove the new lateral compression arm mount from the
new lateral compression arm and save hardware for later
re-installation. Repeat procedure on the passenger side.
50. Locate (2) 3/8” x 1 1/4” self threading bolts, (2) 3/8”
flat washers and the new rear lateral compression arm
mounts that were removed from step # 49. Working on
the driver side, secure the new rear lateral compression
arm mount to the previously drilled hole in the stock
transfer case cross member. Use the new 3/8” x 1 1/4”
self threading bolt and washer. Torque to 28 ft lbs.
Repeat procedure on the passenger side.
make sure that the longer leg of the new lateral
compression arm is towards the rear of the vehicle.
Refer to illustration # ? for proper placement.
See Illustration # 17
51. 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 # 18 / Front Location
See Illustration # 19 / Rear Location
52. Locate the new front shocks. Special Note: New
longer front shocks are needed, if you have not
already ordered shocks, please contact Tuff Country
or your local Tuff Country dealer and order the
proper shocks. Tuff Country recommends using a
23” fully extended nitrogen gas shock.
driver side, install the new shock into the stock location
using the stock hardware on the bottom mount and the
new hardware on the top mount. Repeat procedure on
the passenger side.
53. Re-install the tires and wheels and carefully lower the
vehicle to the ground.
Do not tighten
Special Note:
Working on the
54. 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.
Front end Installation Complete
!
Rear End Installation:
55. 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.
56. Working on the driver side, remove the stock shock
from the stock upper and lower mounting points and save
hardware for later re-installation. The stock shocks may
be discarded. Special Note: New longer rear 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 30” fully extended
nitrogen gas shock. Repeat procedure on the
passenger side.
57. Place a pair of hydraulic floor jack under the rear
differential and raise up on both hydraulic floor jacks at
the same time until they come into contact with the rear
differential.
58. Working on the driver side, remove the stock U-bolts
from the stock location and discard the stock U-bolts and
hardware. Set the stock upper and lower U-bolt plates a
side for later re-installation. Repeat procedure on
passenger side.
59. Carefully lower down both hydraulic floor jacks at the
same time approximately 5”. Special Note: Take special
care not to over extend any brake lines and/or hoses.
Working on the driver side, if so equipped, remove and
discard the stock rear block. Repeat procedure on the
passenger side.
60. Locate (2) new 4” lifted blocks. Working on the driver
side, install the new 4” lifted block into the stock location.
Special Note: The new 4” lifted block has a taper to it,
make sure that smaller end of the new block is
pointing towards the front of the vehicle.
procedure on the passenger side.
See Illustration # 20
61. Carefully raise up on both hydraulic floor jacks at the
same time until the stock spring assembly sits flush with
the newly installed 4” lifted block.
62. Locate (4) 5/8” x 2 3/4” x 13 5/8” square U-bolts, (8)
5/8” U-bolt high nuts, (8) U-bolt washers and the stock
Repeat
upper and lower U-bolt plates that were removed from
step # 58. Working on the driver side, install the new Ubolts into the stock location and secure using the new
high nuts and washers. Special Note: Make sure to re-
install the stock upper and lower U-bolt plates.
Torque to
side.
63. Working on the driver side, install the new shock into
the stock location and secure using the stock hardware
that was removed in step # 56. Special Note: New
longer rear 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
30” fully extended nitrogen gas shock.
procedure on the passenger side.
64. Carefully remove the (2) hydraulic floor jack from
under the rear differential.
65. Locate (2) 6199 poly bump stops, (2) 6052 poly bump
stop, (4) 3/8” unitorque nuts and (4) 3/8” flat washers.
Working on the driver side of the stock rear spring
assembly. Remove the (2) stock teflon insert located on
the stock over load in the stock spring assembly. Discard
the stock teflon inserts. Install (1) 6052 (taller poly bump
stop) in front location on the stock spring assembly.
Secure using the new 3/8” hardware. Torque to 28 ft lbs.
Install (1) 6199 (shorter poly bump stop) in the rear
location on the stock spring assembly. Secure using the
new 3/8” hardware. Torque to
procedure on the passenger side.
66. Carefully place a hydraulic floor jack under the rear
driveline near the stock carrier bearing mounting location.
Raise up on the hydraulic floor jack until it comes into
contact with the rear driveline. Remove the stock
hardware that connects the stock carrier bearing to the
stock location and discard the stock hardware.
67. Locate the new rear carrier bearing drop, (2) 1 3/4”
crush sleeves, (2) 3/8” x 3 1/2” bolt, (4) 3/8” flat washers
and (2) 3/8” unitorque nuts. Install the new carrier bearing
drop bracket between the stock carrier bearing and the
stock mounting point. Secure using the new 3/8” x 3 1/2”
bolt, crush sleeves and hardware. Torque to 28 ft lbs.
Remove the hydraulic floor jack from under the rear drive
line.
has slotted holes, make sure that when you torque
the new 3/8” hardware that the new carrier bearing is
pushed as far forward as possible.
68. Install the tires and wheels and carefully lower the
vehicle to the ground.
135 ft lbs.
See Illustration # 21 / Front Location
See Illustration # 22 / Rear location
Special Note: The stock carrier bearing mount
Repeat procedure on passenger
See Illustration # 20
28 ft lbs.
See Illustration # 23
Repeat
Repeat
Congratulations installation complete. Check
and double check to make sure that all steps
were performed properly. Check torque settings
to make sure that all stock and new hardware
has been torque to proper torque specifications
Take vehicle directly to an alignment shop for
proper alignment.
Special Note: After the vehicle has been aligned,
drive to see if there is any drive line vibrations. If
drive live vibrations occur, please follow step #
69 & 70
69. Place a pair of hydraulic floor jacks under the stock
transfer case cross member. Carefully raise up on both
hydraulic floor jacks at the same time until the hydraulic
floor jacks come into contact with the stock transfer case
cross member. Working on the driver side, remove the
(2) stock bolts and hardware that connects the stock
transfer case cross member to the bottom sides of the
stock frame rail. On the side of the stock frame rail
remove the stock transfer case support bracket and
hardware. The stock transfer case support bracket and
stock hardware may be discarded. Repeat procedure on
the passenger side.
See Illustration # 24
70. Carefully lower down on both hydraulic floor jacks at
the same time about 3/4”. Locate (8) transfer case
lowering shims, (4) 1/2” x 2” bolt, (8) 1/2” flat washers, (4)
1/2” unitorque nuts and (4) 1/2” lock washers. Working on
the driver side, install (4) shims, (2) in the forward hole
and (2) in the rearward hole, between the stock transfer
case cross member and the stock frame rail. Secure
using the new 1/2” x 2” bolt and hardware. Torque to
ft lbs. Repeat procedure on the passenger side. Remove
both hydraulic floor jacks.
See Illustration # 25
85
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.
Also refer to the Vehicle owners manual for proper
torque specifications on any stock hardware.
If you have any question and/or concerns about the
installation, please feel free to contact Tuff Country
or your local Tuff Country dealer.
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