Tuff Country 36011 User Manual
Part # 36011
July 2007 and newer Dodge Ram 2500 / 3500
6” suspension system
Part
# Description
Qty.
36000-02 Upper control arms 2
36000-03 Lower control arms 2
36008-01 Track bar relocation bracket 1
DODDSSWAY-01 DS upper sway bar relocation bracket 1
DODPSSWAY-01 PS upper sway bar relocation bracket 1
34000-10 Pitman arm 1
34008NB Hardware bag 1
36005SL Hardware bag 1
34000PL Hardware bag 1
BL404 4” rear lifted blocks 2
LUBE Poly lube packs 2
36011INST Instruction manual (customer copy) 1
36011INST Instruction manual (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 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 representatives @ (801)
280-2777.
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.
Installation manual
6” suspension system
July 2007 and newer
Dodge Ram 2500 / 3500
Part # 36011
sj111507rev.01
Important customer information:
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.
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/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. OEM
manual should be used as a reference guide.
Make sure to use lock tite 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.
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 front coil springs for part # 36011 are not included
in this box kit. The front coil springs need to be
ordered as a separate part #. If you have not already
ordered your new front coil springs, please contact
Tuff Country or your local Tuff Country dealer and
order part # 36006.
The rear end u-bolts for part # 36011 are not included
in this box kit. The rear end u-bolt kit needs to be
ordered as a separate part #.
If the vehicle that you are working on is a Dodge Ram
2500 that does not have the 24 valve high output rear
end, and you have not already ordered the rear end
u-bolt kit, please contact Tuff Country or your local
Tuff Country dealer and order part # 36001.
If the vehicle that you are working on is a Dodge Ram
2500 that has the 24 valve high output rear end or a
Dodge Ram 3500, and you have not already ordered
the rear end u-bolt kit, please contact Tuff Country or
your local Tuff Country dealer and order part # 36002.
It is mandatory that a 17” or taller wheel is installed
once part # 36011 has been installed. Tuff Country
recommends a 36x12.50 tire package. If larger than a
36x12.50 tire is installed on your vehicle in
conjunction with part # 36011; Tuff Country assumes
no liability and the warranty will be VOID.
Some of the new 2003 — 2008 Dodge Rams 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.
Due to the different stock coil spring spring rates that
are offered from Dodge, once the new coil springs
have been installed, the vehicle that you are working
on may be sitting low in the rear end. If this is the case
of the vehicle that you are working on, a rear add-aleaf may need to be installed. Please contact Tuff
Country or your local Tuff dealer and order part #
82450. Part # 82450 is a 1 1/2” rear add-a-leaf that will
help level the rear end of your vehicle with the front.
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.
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 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 30” fully
extended nitrogen gas shock in the front and a 33” fully
extended nitrogen gas shock in the rear.
After completion of the installation, Tuff Country EZRide Suspension highly recommends that the installer
informs the customer that whenever they have their
vehicle lifted in the air by the frame rail, the front sway
bar end links need to be disconnected from the stock
sway bar. If this is not done, damage will occur to the
stock front end links.
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
Hardware bag 34008NB includes:
Description Quantity
9166B (9/16”x 6” bolt) 1
916512B (9/16” x 5 1/2” bolt) 1
9164B (9/16” x 4” bolt) 2
12WA (1/2” USS flat washer) 6
SUW-916 (9/16” u-bolt harden washer) 2
916UN (9/16” unitorque nut) 3
124B (1/2” x 4” bolt) 1
716WA (7/16” USS flat washer) 2
12UN (1/2” unitorque nut) 1
716112B (7/16” x 1 1/2” bolt) 4
38WA (3/8” USS flat washer) 8
716UN (7/16” unitorque nut) 4
S10107 (fender washer) 4
38112B (3/8” x 1 1/2” bolt) 6
516WA (5/16” USS flat washer) 12
38NLN (3/8” Nylock nut) 6
M1680B (16 mm x 80 mm bolt) 2
M16WA (16 mm flat washer) 4
M16UN (16 mm unitorque nut) 2
M16LWA (16 mm lock washer) 2
Hardware bag 36005SL includes:
Description
Quantity
S10059 (.875” x .550” x 2.370”) 4
S10060 (.875” x .640” x 2.630”) 4
S10061 (1.130” x .610” x 2.270”) 1
S10062 (1.130” x .610” x 1.330”) 1
34000-07 (nut bracket) 1
Hardware bag 34000PL includes:
Description
Quantity
MO2617 (control arm bushing) 16
MO3509 (front upper shock bushing) 2
M03510 (front upper shock bushing) 2
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:___________________________
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:__________________________
Front end installation:
1. Working on the driver side, remove the stock sway bar
from the stock sway bar end link. Save the stock sway bar
end link hardware for later re-installation. Repeat the
procedure on the passenger side. Now remove the stock
sway from the stock end links and let the stock sway bar
hang.
Photo # 1
Special note: Step # 1 needs to be performed with
weight of the vehicle on the ground. If this step is not
performed with the weight of the vehicle on the ground,
damage will occur to the stock sway bar end links.
2. 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.
3. Place a pair of hydraulic floor jacks under the front axle.
Place one on the driver side and one on the passenger side.
Carefully raise up on both hydraulic floor jacks at the same
time until the hydraulic floor jacks come into contact with the
front axle.
4. Working on the driver side, remove the stock nut that connects the stock tie rod end to the stock pitman arm. Save the
stock nut for later re-installation. Using a hammer, carefully
break the taper on the stock tie rod that connects to the stock
pitman arm. Special note: Take special care not to rip or
tear the stock outer tie rod boot. The new pitman arm
has a reverse taper on it, after the new pitman arm has
been installed, the stock outer tie rod needs to be rotated 180 degrees.
Photo # 2
5. Next, remove the stock nut and lock washer from the
sector shaft on the stock steering box. Save the stock hardware for later re-installation. Using a pitman arm puller,
carefully remove the stock pitman arm from the stock sector
shaft. The stock pitman arm may be discarded.
Photo # 3 / Photo # 4
6. Open the hood of your vehicle. Working on the driver side,
locate and remove the upper stock shock nut. Also, remove
the upper stock shock retainer washer and grommet. The
stock nut, retainer washer and grommet may be discarded.
Repeat procedure on the passenger side.
Photo # 5
7. Working on the driver side, remove the (3) stock nuts that
hold the upper stock shock tower to the stock location. Save
the stock nuts for later re-installation. Set the upper stock
shock tower aside for later re-installation. Repeat procedure
on the passenger side.
Photo # 6
8. Working on the driver side, remove the stock lower shock
bolt from the stock mounting location and save the stock
hardware for later re-installation. Carefully lower down on
the hydraulic floor jack holding the driver side axle about 2”.
Remove the stock shock and the stock coil spring from the
stock location. Save the stock upper coil mounting ring and
the stock isolator for later re-installation. The stock shock
and the stock coil spring may be discarded. Special note:
Shocks are not included with this kit box and the shocks
need to be ordered as a separate part number. Tuff
Country EZ-Ride Suspension recommends using a 30”
fully extended nitrogen gas shock. Also, the new front
coil springs are not included with this kit box and they
need to be ordered as a separate part #. If you have not
already ordered your shocks or your new front coil
springs, please contact Tuff Country or your local Tuff
Country dealer and order these part #’s for the new coil
springs and the new front shocks. Repeat procedure on
the passenger side.
Photo # 7 / Photo # 8
9. Working on the driver side, remove the stock hardware
that connects the stock track bar to the stock location. the
stock hardware may be discarded.
Photo # 9
10. Working on the driver side, remove the stock brake line
bracket that connects the stock brake line between the stock
upper and lower control arm mounts on the axle. Save the
stock hardware for later re-installation. Repeat procedure on
the passenger side.
Photo # 10
11. Working on the driver side lower control arm mounting
bracket that is located on the stock front axle, scribe a mark
on the stock alignment cams and another directly across on
the reinforcement bracket. This will give you a good
alignment reference until you get the vehicle to an alignment
shop for a proper front end alignment. Repeat procedure on
the passenger side.
Photo # 11
12. Working on the driver side, remove the stock lower con-
trol arm from the stock frame rail and axle location. Save the
stock hardware for later re-installation. Remove the stock
lower control arm and discard. Repeat procedure on the
passenger side.
Photo # 12 / Photo # 13
13. Working on the driver side, remove the stock upper
control arm from the stock frame mount and axle location.
The stock hardware may be discarded. Remove the stock
upper control arm and discard. Repeat procedure on the
passenger side. Special note: Due to clearance issues
with the stock exhaust, the passenger side upper
control arm frame mounting hardware will need to be
cut off. Carefully cut the stock bolt and discard the stock
hardware. New hardware is provided for the new upper
control arms. Carefully pushing the stock exhaust over
to the driver side will help make clearance to perform
this step on the passenger side.
Photo # 14
Special note: The front coil springs for part # 36005 are
not included in this box kit. The front coil springs need
to be ordered as a separate part #. If you have not
already ordered your new front coil springs, please contact Tuff Country or your local Tuff Country dealer and
order part # 36006.
14. Locate the new front coil springs. Also, locate the stock
upper coil mounting rings and the stock isolator. Carefully
lower down on both hydraulic floor jacks holding the front
differential enough so that the new coil springs can be
installed. Working on the driver side, install the new coil
spring into the stock lower and upper pocket. Make sure to
install the stock isolator and the stock upper coil mounting ring. Raise up on the hydraulic floor jack holding the
driver side of the stock front differential until the new coil
springs seats properly into the stock location. Repeat procedure on the passenger side.
15. Locate the new upper control arms. Locate (8) control
arm bushings from hardware bag 34000PL. Also, locate (4)
S10059, upper control arm sleeves from hardware bag
36005SL. Special note: The new upper control arms are
the shorter of the 2 arms. 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. Next, install the new upper control
arm sleeves into the previously installed poly bushings.
16. Locate (1) 9/16” x 6” bolts, (1) 9/16” x 5 1/2”, (2) 9/16” x
4” bolts, (6) 1/2” USS flat washers, (2) 9/16” u-bolt harden
washers and (3) 9/16” unitorque nuts from hardware bag
36000NB1. Also, locate (1) 34000-07 (nut bracket) from
hardware bag 36005SL. Working on the driver side, install
the new upper control arm to the stock frame mount location
and secure using the new 9/16” x 6” bolt, hardware and 9/16”
u-bolt harden washer. Special note: the new 9/16” special
washers needs to be installed on the inner part of the
stock frame rail. Do not tighten at this point. Next, install
the new upper control arm to the stock mounting location on
the stock front axle. Secure using the new 9/16” x 4” bolt and
hardware. Do not tighten at this point. Special note:
Raising the axle to ride height and moving the axle up
and down will make for easier upper control arm installation. Slight prying of the stock control arm bracket
also may be needed to make installation easier. Working
on the passenger side, install the new upper control arm to
the stock upper frame mount and secure using the new 9/16”
x 5 1/2” bolt, 1/2” USS flat washer (on the outside of the
stock frame rail), 9/16” u-bolt harden washer (on the inside
of the stock frame rail) and the new nut bracket. Next, install
the new upper control arm to the stock mounting location on
the stock front axle. Secure using the new 9/16” x 4” bolt and
hardware. Do not tighten at this point. Special note:
Carefully pushing the stock exhaust over to the driver
side will help make clearance to perform this step on the
passenger side.
Photo # 15 / passenger side upper mount
Photo # 16 / driver side axle mount
17. Locate the new lower control arms. Locate (8) control
arm bushings from hardware bag 34000PL. Also, locate (4)
S10060 lower control arm sleeves from hardware bag
36005SL. Special note: The new lower control arms are
the longer of the 2 arms. 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. Next, install the new lower control arm
sleeves into the previously installed poly bushings.
18. Locate the stock lower control arm mounting hardware.
Working on the driver side, install the new lower control arm
to the stock frame mount location and secure using the stock
hardware. Do not tighten at this point. Next, install the new
lower control arm to the stock mounting location on the stock
front axle. Secure using the stock hardware. Special note:
Raising the axle to ride height and moving the axle up
and down will make for easier lower control arm installation. Slight prying of the stock control arm bracket
also may be needed to make installation easier. Add
some thread locker or lock tite to the stock lower axle
mounting hardware and refer back to the marks that were
scribed in step # 11 and torque the stock hardware to 85 ft
lbs.
Photo # 17 / driver side frame mount
Photo # 18 / passenger side axle mount
19. Locate the new front 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 30” fully
extended nitrogen gas shock. If you have not already
ordered your shocks, please contact Tuff Country or
your local Tuff Country dealer and order the proper front
shocks. Install the new poly bushings and proper crush
sleeve into the bottom part of the new shock. Special note:
Make sure to use a lithium or moly base grease prior to
inserting the new bushings and sleeves into the new
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