Tuff Country 52904 User Manual
Part #: 52904
1995 - 2004 Toyota Tacoma
4 x 4 & PreRunner
3” suspension system
Parts list:
Part #
Description Qty.
52904-01 Rear brake proportioning valve bracket 1
52907-02 Front pre load spacer 2
52904-03 Front strut spacer 2
BL301 3” Rear lifted block 2
5U-243S 9/16” x 2 1/2” x 10 5/8” square u-bolts 4
52904BL Rear extended brake line 1
52904NB Hardware bag 1
52904NB1 Hardware bag 1
52904INST Instruction manual (customer copy) 1
52904INST Instruction manual (installer copy) 1
MIRRORHANGER Rear view mirror hanger 1
WARNINGDECAL
Warning decal 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 loctite 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.
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.
Installation manual
3” suspension system
1995 - 2004 Toyota Tacoma
4 x 4 & PreRunner
Part # 52904
sj05292012rev.03
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 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.
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.
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:
Tuff Country recommends a 32x10.50 tire package. If a larger size tire is installed on your vehicle in conjunction with
part # 52904; 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 EZ-Ride Suspension recommends installing a
26” fully extended hydraulic shock once the suspension
system has been installed.
Tuff Country EZ-Ride Suspension recommends a wall
mounted strut compressor be used when performing the
steps that talk about installing the strut spacer into the strut.
If you do not have a wall mounted strut compressor, please
have these steps performed by your local Toyota Dealership.
Hardware bag 52904NB includes:
Description
Quantity
SUW-916 (9/16” U-bolt high nut) 8
M830B (8 mm x 30 mm bolt) 2
M840B (8 mm x 40 mm bolt) 2
51634B (5/16” x 3 /4” bolt) 2
14WA (1/4” USS flat washer) 6
516UN (5/16” unitorque nut) 2
128B (1/2” x 8” bolt) 2
12UN (1/2” unitorque nut) 2
Hardware bag 52904NB1 includes:
Description
Quantity
ECLIP (Brake line clip) 1
BU3000 (10 mm studs) 1
SB34 (3/4” shock bushing) 4
S10021 (.500” x .380” x .620” sleeve) 2
S10051 (1.750” x .510” x .950”) 2
BLR01 (rear emergency brake cable extension) 1
5161B (5/16” x 1” bolt) 1
14WA (1/4” USS flat washers) 2
516UN (5/16” unitorque nut) 1
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.
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:__________________________
Please follow instructions carefully:
Front end Installation:
1. To begin installation, safely lift the front and rear of the
vehicle and support the vehicle with jack stands on each
corner of the vehicle. Next, remove the wheels and tires
from both the front and rear of the vehicle.
2. Working on the driver side, remove the sway bar hardware from the frame location. Save the hardware for later
re-installation. Repeat procedure on the passenger side.
Special note: Tie the sway bar up and out of the way
during installation.
3. Working on the driver side, remove the (3) upper nuts
that connect the strut into the OE location. The nuts may be
discarded. Repeat procedure on the passenger side.
4. Working on the drivers side, remove and save the cotter
pin that is located in the ball joint connected to the upper
control arm. Now, loosen but do not remove the castle nut.
Using a hammer, carefully break the taper on the upper
control arm ball joint. Special note: Take special care not
to damage the upper control arm, the ball joint or the
ball joint dust boot. Repeat procedure on the passenger
side.
5. Working on the driver side, remove the lower bolt that
connects the strut to the lower mounting location and save
the hardware for later re-installation. Special note: During
removal of the bolt, take special care not to damage the
CV boot. Also, make a mental note on which way the
bolt is removed, it needs to be re-installed the same
way that it was removed. Remove the strut assembly
from the vehicle and set aside. Repeat procedure on the
passenger side.
Tuff Country EZ-Ride Suspension recommends a wall
mounted strut compressor be used when performing
the steps that talk about installing the pre-load spacer
into the strut. If you do not have a wall mounted strut
compressor, please have these steps performed by
your local Toyota Dealership.
6. Working on the driver side strut, scribe a line down the
entire strut from the top of the strut to the bottom. Special
note: If this step is not performed properly re-installing
the strut back into the vehicle will be difficult.
7. Using a wall mounted strut compressor, carefully compress the strut until the upper bearing plate can be
removed. Remove the nut and hardware from the top of the
strut assembly and save the hardware for later re-installation.
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