Tuff Country 35920 User Manual

Installation manual

4.5” Suspension system

1994 — 2002 Dodge Ram 2500 / 3500

Old part # D52B

New part # 35920

Sj052206rev.03

Old part # D52B
New part # 35920
Dodge Ram 2500 / 3500 4.5” Suspension system
Parts list:

Part # Description Qty.

D5I-001 4.5” Upper coil spring spacer 2
D5I-002 Upper control arm 2
D3I-003 Lower control arm 2
D5I-004 Front driver side track bar bracket 1
DODDSSWAY-01 Driver side sway bar drop bracket 1
DODPSSWAY-01 Passenger side sway bar drop bracket 1
D5I-010 Track bar kicker support bracket 1
TCI-R23D Rear add-a-leaf 2
BL5503 Rear block 2
5U-2514S 9/16” x 3” x 14 5/8” square u-bolt 4
916NW Hardware bag 1
35920NB Hardware bag 1
CB12 Hardware bag 1
35920NB1 Hardware bag 1
D3IPL Poly bushing bag 1
D3ISL Sleeve bag 1
D5ISL Sleeve bag 1
35920INST Instruction sheet (customer copy) 1
35920INST instruction sheet (installer copy) 1
MIRRORHANGER Rear view mirror hanger 1
WARNINGDECAL Warning decal 1
DECAL Window sticker 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.

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.

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.

Important customer information
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 suspensi on system after the first 100 mile s
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 Suspe nsion takes no responsi bility
for abuse, improper installation or improper
suspension maintenance.

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:

If the vehicle that you are working on was
manufactured between November of 1993 and
February 1994 this suspension system will not work.
Unfortunately, Tuff Country EZ-Ride suspension
does not offer a suspension system that will fit on
vehicles manufactured between these dates. If the
vehicle that you are working on was manufactured
between these dates, STOP and return this box kit to
the company that you purchased it from (with a
receipt) for a full refund.

Special note: Dodge comes with two different size
pitman arms. Part # 70500 will work on the 1/2 ton
and 3/4 ton vehicles that were manufactured from
1994—2000. Also, part # 70500 will work on the 1/2
ton that was manuf actured in 2001. Part # 70501 w ill
work on the 3/4 ton that was manufactured in 2001
and all 3/4 vehicles that were manufactu red in 2002.
The pitman arm is not included with this suspension
system and needs to be ordered as a separate part
number. If you have not already done so, please
contact Tuff Country or your local Tuff Country
dealer and order the proper pitman arm. Also, the
new pitman arm looks identical to the stock pitman
arm. The new pitman arm has a reverse taper w here
the stock tie rod connects to it.

Some Dodge Ram 2500/3500 vehicle come from the
factory with a 2 piece rear drive line. After the
suspension system is installed a vibration may occur
at initial take off. If this is the case on the vehicle that
you are working on, the stock carrier bearing drop
bracket needs to be lowered. Please contact Tuff
Country or your local Tuff Country dealer and order
part # 20824.

If the vehicle that you are working on has a stock
steering stabilizer, the stock steering stabilizer is not
going to be re-installed once the 5” suspension
system has been installed.

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 EZ­Ride Suspension highly recommends notifying the
customer prior to installation to inform the customer of
these issues if they exist.

If the 3/4 ton or 1 ton that you are work ing on has a stock
contact over load, the u-bolts that are included in this kit
box will not be long enough, longer u-bolt s are going to be
needed. If you have not already done so, please contact
Tuff Country or your local Tuff Country dealer and order
part # 37755

Hardware bag 916NW includes:
Description Quantity
9/16” u-bolt high nuts 8

9/16” u-bolt harden washers 8
Poly bushing bag D3IPL includes:
Description Quantity
PB2408 (poly bushings) 16
Sleeve bag D3ISL includes:
Description Quantity
S10029 (.875" X .500" X 2.250") 4

S10030 (.875” X .560” X 2.625”) 4
Sleeve bag D5ISL includes:
Description Quantity
S10042 (.875" X .563" X 2.250") 4

S10043 (.875" X .693" X 2.760") 4
Hardware bag 35920NB includes:
Description Quantity

1/4” x 1” bolts 2
1/4” flat washers 4
1/4” unitorque nuts 2
3/8” x 1” bolts 2
3/8” x 1 1/2” bolts 4
5/16” USS flat washers 14
3/8” nylon insert nuts 8
7/16” x 1 1/2” bolts 4
3/8” USS flat washers 16
7/16” unitorque nuts 8
1/2” x 2 1/2” bolt 1
7/16” USS flat washers 2
1/2” unitorque nut 1
18 mm x 75 mm bolt 1
18 mm castle nut 1
3/4” USS flat washer 2
Cotter pin — 3/32” x 1 1/4” 1
Cotter pin — 1/8” x 1 3/4” 1
Sert fittings 8
7/16” x 3” bolts 4

Hardware bag 35910NB1 includes:
Description Quantity

S10078 (track bar sleeve) 1
916WAMD (9/16” modified washer 1
LUBE (poly lube pack) 2
PB8297 (Front upper shock bushings)4
S10107 (Front upper shock washers) 4
D5I-011 (Rear sway bar drop tube) 2

Hardware bag CB12 includes:
Description Quantity
1/2” x 6” centering bolt 2

1/2” 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].

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 passenger side. Next, remove the tires and
wheels from both sides.

2. Position a pair of hydraulic floor jacks under the front
axle. Place one jack stand on the driver side and one on
the passenger side. Carefully raise up on both hydraulic
floor jacks at the same time until they make contact with
the front axle.

3. Working on the driver side, un-bolt the stock sway bar
at the frame location and save the stock hardware for
later re-installation. Repea t pr oced ure on pass eng er sid e.

Let the stock sway bar hang.

4. Working on the driver side lower control arm axle
mount, scribe a mark on the stock alignment cams and
reinforcement bracket. This mark will be used as a

reference when installing the new front lower control
arms. Repeat procedure on the passenger side.

Illustration # 1

5. Working on the driver side, remove the stock castle nut
and cotter pin from the stock track bar at the stock track
bar location. Save the stock castle nut for later re­installation. The stock cotter pin may be discarded, a new
cotter pin is provided.

Illustration # 2

6. If the vehicle that you are working on is equipp ed with
a stock steering stabilizer, remove the stock steering
stabilizer from the stock location and discard the stock
steering stabilizer and the stock hardware. If the vehicle
that you are working on is not equipped with a stock
steering stabilizer, please discard step # 6.

7. Working on the driver side, remove the stock castle nut
and cotter pin from the stock tie rod end that connects to
the stock pitman arm. Save the stock castle nut and
stock cotter pin for later re-installation. Special note: The

new pitman arm looks identical to the stock pitman
arm but the new pitman arm has a reverse taper on it
where the stock tie rod connects to it. At this point,

rotate the stock tie rod 18 0 de grees.

8. Working on the stock steering box, remove the stock
nut and the stock lock washer from the sector shaft on
the stock steering box. Save the stock nut and the stock
lock washer for later re-installation. Using a pitman arm
puller, carefully remove the stock pitman arm from the
stock location. The stock pitman arm may be discarded.

9. Working on the driver side, scribe a mark on the stock
coil spring and another directly across on the stock lower
coil spring pocket. Special no te: sc ribe the mark on the

bottom of the stock coil spring and one directly
across on the lower coil spring pocket. This will allow
you to re-install the stock coil spring back into the
stock location at a later step. Repeat procedure on

passenger side.

10. Working on the driver side, locate the top of the stock
shock absorber stud in the engine compartm en t. Remove
the stock nut, retainer washer and grommet. The stock
upper shock nut, retainer washer and grommets may be
discarded. Repeat procedure on passenger side.

Illustration # 3

11. Working on the driver side, remove the stock (3) nuts
from the stock upper shock tower and discard the stock
nuts. Set the stock upper shock tower a side for later re­installation. Repeat procedure on the passenger side.

Illustration # 4

12. Working on the driver side, remove the stock lower
shock bolt that connects the stock shock to the stock
lower mounting location. Save the stock hardware for
later re-installation. Remove the stock shock by lifting the

stock shock up through the engine compartment. The
stock shock may be discard. Special note: New longer

front shocks are needed once this suspension
system has been installed and the front shocks need
to be ordered as a separate part #. If you have not
already ordered your new front shocks, please feel
free to contact Tuff Country or your local Tuff
Country dealer and order your new front shocks. Tuff
Country recommends installing a 30” fully extended
nitrogen gas shock in the front. Repeat procedure on

the passenger side.

13. Working on the driver side, remove the stock upper
control arm from the stock frame location and the stock
axle location. Save the s tock hardware. The stoc k upper
control arm may be discarded. Repeat procedure on the
passenger side.

14. Working on the driver side, remove the stock lower
control arm from the stock frame location and the stock
axle location. Save the stock hardware. The stock lower
control arm may be discarded. Repeat procedure on the
passenger side.

15. Working on the driver side, remove the stock brake
line bracket that is located between the stock upper and
lower control arm mounting point that is located on the
stock front axle. The stock hardware may be discarded.
Let the stock brake line bracket hang. Repeat procedure
on the passenger side.

16. Carefully lower down on both hydraulic floor jacks at
the same time approximately 6”. Working on the driver
side, remove the stock coil spring from the stock location
and set aside for later re-installation. Next, remove the
stock rubber isolation pad and s tock shock ring from the
stock upper shock pocket. Set the stock rubber isolation
pad aside for later re-installation. The stock shock ring
may be discarded. Repeat procedure on passenger side.

Special note: Before removal of the stock coil spring,
make sure that you scribed a mark on the stock coil
spring and the stock coil spring pocket in step # 9.

17. Locate (2) 1/4” x 1” bolts, (4) 1/4” flat washers and (2)
1/4” unitorque nuts from hardware bag 35910NB.
Working on the driver side, move the stock brake line
bracket to the top of the stock upper control arm axle
mount bracket and secure using the new 1/4” x 1” bolt
and hardware. Make sure to use thread lo cker or lock
tite. Torque to 12 ft lbs. Repeat procedure on the
passenger side. Special note: If the stock upper

control arm axle mount bracket does not have a hole,
carefully drill a 1/4” hole into the top of the stock
upper control arm axle mount bracket.

Special note: If the vehicle that you are working on
was manufactured before 09/01/01 please follow
steps # 18 — 26.

Special note: If the vehicle that you are working on
was manufactured after 09/01/ 01 please follow steps
# 27 — 31.

18. Locate the new lower control arms that are included
in this suspension system. Special note: The new lower

control arms are the longer arms that are included in
this suspension system. Also, locate (8) PB2408 poly

bushings from poly bag D3IPL. Insert the new poly
bushings into each end of the new lower control arms.

Special note: Make sure to use a lithium or moly base
grease prior to inserting the new bushings into the
new lower control arms. This will increase the life of
the bushing as well as prevent squeaking.

19. Locate (4) new S10030 crush sleeves from sleeve
bag D3ISL. Insert the new S10030 crush sleeves into the
previously installed poly bushings in the new lower
control arms.

20. Locate (4) sert fitting from hardware bag 35910NB.
Carefully install the sert fittings into each end of the new
lower control arms. Special note: Take special care not
to damage the sert fittings during installation.

21. Locate the stock lower control mounting hardware
that was removed in step # 14. Working on the driver
side, install the new lower control arm into the stock
frame mount location and secure using the stock
hardware. Make sure to use thread locker or lo ck tite.
Do not fully tighten at this point. On the stock front bolt
that connects the new lower control arm to the stock front
bracket, refer to the reference marks that were made in
step # 4 and re-install into the same location. Make sure

to use thread locker or lock tite. Do not fully tighten
at this point. Special note: Raising the axle to ride
height and moving the axle up and down will help
make installation of the new lower control arm a little
easier. Slight prying of the stock control arm bracket
also may be needed to make installation easier.

Repeat procedure on passenger side.

Illustration # 5

22. Locate the new upper control arms that are included
in this suspension system. Special note: The new

upper control arms are the shorter arms that are
included in this suspension system. Also, locate (8)

PB2408 poly bushings from poly bag D3IPL. Insert the
new poly bushings into each end of the new upper
control arms. Special Note: Make sure to use a lithium

or moly base grease prior to inserting the new
bushings into the new upper control arms. This will
increase the life of the bushing as well as prevent
squeaking.

23. Locate (4) new S10029 crush sleeves from sleeve
bag D3ISL. Insert the new S10029 crush sleeves into the
previously installed poly bushings in the new upper
control arms.

24. Locate (4) sert fitting from hardware bag 35910NB.
Carefully install the sert fittings into each end of the new
lower control arms. Special note: Take special care not
to damage the sert fittings during installation.

25. Locate the stock upper control mounting hardware
that was removed in step # 13. Working on the driver
side, install the new upper control arm into the stock
frame mount location and the axle mount location and
secure using the stock hardware. Make sure to use

thread locker or lock tite. Do not fully tighten at this
point. Special note: Raising the axle to ride height
and moving the axle up and down will help make
installation of the new upper control arm a little
easier. Slight prying of the stock control arm bracket
also may be needed to make installation easier.

Repeat procedure on passenger side.

Illustration # 6

26. Move back to the stock upper and lower control arm
hardware and torque to 85 ft lbs. Special note: On the

stock axle mount hardware on the new lower control
arms make sure that the alignment marks that were
made in step # 4 are still lined up.

If the vehicle that you are working on was
manufactured before 09/01/99 skip to step # 36

If the vehicle that you are working on was
manufactured after 09/01/099 follow step # 27 — 35

27. Locate the new lower control arms that are included
in this suspension system. Special note: The new lower

control arms are the longer arms that are included in
this suspension system. Also, locate (8) PB2408 poly

bushings from poly bag D3IPL. Insert the new poly
bushings into each end of the new lower control arms.

Special note: Make sure to use a lithi um o r moly base
grease prior to inserting the new bushings into the
new lower control arms. This will increase the life of
the bushing as well as prevent squeaking.

28. Locate (4) new S10043 crush sleeves from sleeve
bag D5ISL. Insert the new S10043 crus h sleeves into t he
previously installed poly bushings in the new lower
control arms.

29. Locate (4) sert fitting from hardware bag 35910NB.
Carefully install the sert fittings into each end of the new
lower control arms. Special note: Take special care not
to damage the sert fittings during installation.

30. Locate the stock lower control mounting hardware
that was removed in step # 14. Working on the driver
side, install the new lower control arm into the stock
frame mount location and secure using the stock
hardware. Make sure to use thread locker or lock tite.
Do not fully tighten at this point. On the stock front bolt
that connects the new lower control arm to the stock front