Tuff Country 34100 User Manual
Part # 34100
2009 - 2011 Dodge Ram 1500 4WD
4” Suspension kit
Parts contained in Box 1 of 3
Part
# Description
Qty.
34100-12 Skid plate 1
34100-13 DS rear LCA frame bracket 1
34100-14 PS rear LCA frame bracket 1
34100-15 PS track bar relocation frame bracket 1
34100-16 Rear sway bar brake hose bracket 2
34100-CL01 Rear coil springs 2
Parts contained in Box 2 of 3
Part # Description Qty
.
34100-03 DS front forward differential bracket 1
34100-04 PS front forward differential bracket 1
34100-05 DS front differential pinion mount 1
34100-06 Front cross member 1
34100-07 Rear cross member 1
34100-08 PS front brake hose bracket 1
34100-09 DS front brake hose bracket 1
34100-10 Sway bar endlink extension 2
34100-11 Front drive shaft spacer 1
34100NB1 Hardware bag 1
34100NB2 Hardware bag 1
34100NB3 Hardware bag 1
34100NB4 Hardware bag 1
34100-17 PS rear track bar relocation support bracket 1
34100NB5 Hardware bag 1
34100-18 Upper strut spacer 2
34100-19 DS rear bump stop extension 1
34100-20 PS rear bump stop extension 1
34100NB6 Hardware bag 1
34100INST Instruction manual 2
MIRRORHANGER Rear view mirror hanger 1
WARNINGDECAL Warning decal 1
Parts contained in Box 3 of 3
Part # Description Qty.
34100-01 DS knuckle (RED) 1
34100-02 PS knuckle (YELLOW) 1
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.
If you desire to return your vehicle to stock, it is the
customers responsibility to save all stock hardware.
Installation manual
2009 - 2011
Dodge Ram 1500 4WD
4” Suspension Kit
Part # 34100
sj02102011rev.01
Important customer information:
Tuff Country EZ-Ride Suspension highly recommends
that a qualified and/or certified mechanic performs
this installation.
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.
It is the responsibility of the customer or the mechanic to wear safety glasses at all times when performing
this installation.
It is the customers/installers responsibility to read and
understand all steps before installation begins. OEM
manual should be used as a reference guide.
Make sure to use loctite on all new and stock hardware
associated with this installation.
The Tuff Country EZ-Ride Suspension product safety
label that is included in your kit box must be installed
inside the cab in plain view of all occupants.
Before installation begins, it is the
customers/installers responsibility to make sure that
all parts are on hand. If any parts are missing, please
feel free to call one of our customer service representatives @ (801) 280-2777.
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:
If the vehicle that you are working on is equipped with
the factory TRX package, different front strut spacers
will need to be ordered. Please contact Tuff Country or
your local Tuff Country dealer and order (2) of part #
34100-21. If the strut spacers that are included in this
box kit are installed on a vehicle equipped with the
TRX package, the vehicle will be sitting 1” higher in the
front than in the rear.
The stock tires and wheels will not work in conjunction
with part # 34100. 18” wheels or larger will need to be
installed once the suspension kit has been installed.
Tuff Country recommends an 18” diameter x 9” wide
(maximum width) wheel with a maximum backspacing
of 5” or less or a 20” diameter x 9” (maximum width)
wheel with a maximum backspacing of 5 1/2” or less.
Tuff Country recommends a 35x12.50 tire package. If
larger than a 35x12.50 tire is installed on your vehicle
in conjunction with part # 34100; Tuff Country
assumes no liability and the warranty will be VOID.
Before installation begins, Tuff Country EZ-Ride
Suspension highly recommends that the installer
performs a test drive on the vehicle. During the test
drive, check to see if there are any uncommon sounds
or vibrations. If uncommon sounds or vibrations occur
on the test drive, uncommon sounds or vibrations will
be enhanced once the suspension system has been
installed. Tuff Country EZ-Ride Suspension highly
recommends notifying the customer prior to
installation to inform the customer of these issues if
they exist.
New longer rear shocks are needed after this suspension system has been installed and the rear shocks
need to be ordered as a separate part #. If you have not
already ordered your rear shocks, please feel free to
contact Tuff Country or your local Tuff Country dealer
and order your rear shocks. Tuff Country recommends
installing 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.
Hardware bag 34100NB1 includes:
Description Quantity
516716TUBE (Vacuum line) 1
HC-01 (Hose coupler) 1
34100NB8 (Hardware bag) 1
Hardware bag 34100NB2 includes:
Description
Quantity
M18NLN (18 mm nylock nut) 4
M18150B (18 mm x 150 mm bolt) 4
S10225 (1.265” x .800” x 3.590” sleeve) 4
1122WA (1 1/2” x 2” washer) 4
34SAE (3/4” SAE washer) 8
TL271 (Thread locker 271) 1
Hardware bag 34100NB3 includes:
Description
Quantity
SHOCKTIE (shock tie) 2
M1250B (12 mm x 50 mm bolt) 4
14NLN (1/4” nyloc nut) 2
1434B (1/4” x 3/4” bolt) 2
38FLN (3/8” flange lock nut) 2
381B (3/8” x 1” bolt) 2
716FFN (7/16” fine flange nut) 6
716SAE (7/16” SAE washer) 12
Hardware bag 34100NB4 includes:
Description
Quantity
38FLN (3/8” flange lock nut) 6
381CSB (3/8” x 1” counter sunk bolt) 6
Hardware bag 34100NB5 includes:
Description
Quantity
S10226 (1.265” x .800” x 2.400” sleeve) 2
S10227 (1.140” x .680” x 1.440” sleeve) 1
S10228 (nut bracket) 2
34100NB8 (Hardware bag) 1
Hardware bag 34100NB6 includes:
Description
Quantity
38NLN (3/8” nyloc nut) 4
38SAE (3/8” SAE washer) 4
381B (3/8” x 1” bolt) 4
Hardware bag 34100NB8 includes:
Description Quantity
12UN (1/2” unitorque nut) 2
M12WA (12 mm flat washer) 14
M12UN (12 mm unitorque nut) 2
M12LWA (12 mm lock washer) 5
M1240B (12 mm x 40 mm bolt) 5
M1260B (12 mm x 60 mm bolt) 2
12SAE (1/2” SAE washer) 4
12234B (1/2” x 2 3/4” bolt) 2
Hardware bag 34100NB9 includes:
Description
Quantity
12114B (1/2” x 1 1/4” bolt) 2
516NLN (5/16” nyloc nut) 2
516SAE (5/16” SAE washer) 4
5161B (5/16” x 1” bolt) 2
58UN (5/8” unitorque nut) 4
58SAE (5/8” SAE washer) 8
58412B (5/8” x 4 1/2” bolts) 2
584B (5/8” x 4” bolt) 2
716NLN (7/16” nyloc nut) 4
716SAE (7/16” SAE washer) 8
716114B (7/16” x 1 1/4” bolt) 2
7161B (7/16” x 1” bolt) 2
916NLN (9/16” nyloc nut) 1
916SAE (9/16” SAE washer) 2
916312B (9/16” x 3 1/2” bolt) 1
Special note: Before installation begins, it is the
customers/installers responsibility to make sure that
all parts are on hand. If any parts are missing, please
feel free to call one of our customer service
representatives @ (801) 280-2777.
Recommended tools selection:
Cut off wheel
Sawzall
Torque wrench
Standard socket set
Standard wrench set
Metric socket set
Metric wrench set
Tape measure
Hydraulic floor jacks
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.
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:___________________________
Before front installation begins and the vehicle is lifted
in the air, perform these steps on the rear end. Failure
to do so could cause damage to rear end parts.
Disconnect the upper end of the track bar. Loosen but
do not remove, the track bar at the driver side side axle
mount. On both the driver and passenger side, disconnect the upper ends of the anti-sway bar links where
they attach to the frame. Disconnect the brake line
mount and wheel speed sensor. These are both located on the frame, right behind the coil springs upper
mount. Working on the driver side, remove the bolt
securing the wire hanger bracket for the parking brake
cables located on the lower control arm. Save the
stock hardware.
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. If equipped, remove the front differential skid plate and
discard.
3. Disconnect the front drive shaft from the front differential.
Save the stock hardware. Also at this time, tie the front
drive shaft up and out of the way.
4. Working on the driver side, remove the stock sway bar
endlink from the sway bar. Save the hardware. Leave the
sway bar end link attached to the lower control arm. Repeat
procedure on the passenger side.
5. Working on the driver side, remove the Wheel Speed
Sensor wire from the rubber brake hose, the rear leg of the
upper control arm and the engine compartment side of the
inner fender well. Special note: This attaching point is
just above the rear leg of the upper control arm. Also,
pulling the plastic inner fender outboard slightly. Also
at this time, disconnect the Wheel speed sensor at the
quick disconnect location. Take special care not to
damage the quick disconnect.
6. Working on the driver side, remove the brake caliper
from the stock location. Save the stock hardware.
Carefully tie the brake caliper up out of the way in the
fender well.
7. Working on the driver side, remove the rotor and set
aside.
8. Working on the driver side, remove the retaining nut from
the center of the bearing hub. Set retaining nut aside.
9. Working on the driver side, loosen but do not remove the
upper control arm bolts.
10. Working on the driver side, carefully remove the stock
knuckle from the upper control arm, lower control arm and
outer tie rod. Save the stock hardware. Set the knuckle
along with the wheel speed sensor wire aside for now.
11. Working on the driver side, loosen but do not remove
the lower control arm bolts.
12. Working on the driver side, remove the stock lower strut
hardware that connects the strut to the lower control arm.
Save the hardware.
13. Working on the driver side, remove the (3) nuts holding
the stock strut into the upper location. Save the stock nuts
and carefully remove the strut from the vehicle.
14. Working on the driver side, remove the stock lower control arm cam bolts and lower control arm from the stock
location and set aside for later re-installation. Special note:
Before removal of the lower control arm, scribe a DS on the
control arm so that you make sure the control arm is reinstalled on the driver side of the vehicle.
Repeat step # 4 - 14 on the passenger side.
15. Working on the driver side, remove the stock rear lower
control arm cross member from the stock location. The
hardware and cross member may be discarded.
16. Disconnect all electrical and vacuum lines from the
front differential. Support the front differential with a differential jack stand. Remove all mounting points for the front
differential and remove the front differential from the vehicle completely.
17. Working on the driver side and measuring from the rear
Loading...