Tuff Country 55900 User Manual
Part # 55900
1999 - 2004 Toyota Tundra 4WD & 2WD
4.5” Suspension Lift Kit
Part
# Description
Qty.
T5I-02 Upper ball joint spacers 2
T5I-03 Upper strut spacer 2
TOYSUB-01 Sub frame 1
T5I-15 DS Knuckle support bracket 1
T5I-16 PS Knuckle support bracket 1
TOYBRAKE-01 Rear proportioning valve bracket 1
TOYDSDIFF-01 DS differential bracket 1
TOYPSDIFF-01 PS differential bracket 1
TOYDSSWAY-01 DS sway bar bracket 1
TOYPSSWAY-01 PS sway bar bracket 1
TOYSTEER-01 Steering shaft extension 1
TOYRACK-01 PS rack and pinion bracket 1
TOYRACK-02 Center rack and pinion bracket 1
55900NB1 Hardware bag 1
55900NB2 Hardware bag 1
BL301 Rear block 2
5U-247S 9/16” x 2 9/16” x 9 5/8” square u-bolt 4
916NW Hardware bag 1
55900INST Instruction manual 1
MIRRORHANGER
Rear view mirror hanger 1
WARNINGDECAL Warning decal 1
INSTFILLER Instruction filler 1
NAMETAG Name tag 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.
If you desire to return your vehicle to stock, it is the
customers responsibility to save all stock hardware
and components.
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.
Installation manual
4.5” Suspension Lift Kit
1999 - 2004 Toyota
Tundra / 4WD & 2WD
Part # 55900
sj10142013rev.03
Important customer information:
Tuff Country EZ-Ride Suspension highly recommends
that a qualified or a certified mechanic performs this
installation.
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. If you
have any questions or concerns, please contact our
technical department @ (801) 280-2777. Also, the 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.
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.
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 wheel with a back spacing
of 4.75” or less once this Suspension Kit has been
installed. If more back spacing is used, contact will
occur and may cause damage to the vehicle. If more
back spacing than 4.75” is installed, Tuff Country
assumes no liability and the warranty will be VOID!
Tuff Country recommends installing a 33” x 12.50” tire
once this Suspension Kit has been installed. If taller
than a 33” tire is installed, Tuff Country assumes no liability and the warranty will be VOID!
Once this Suspension kit is installed, new longer rear
shocks will be needed. Rear shocks are sold seperately. If you have not already ordered your new rear
shocks, please contact Tuff Country or your local Tuff
Country dealer and order the rear shocks. Tuff Country
recommends installing a 26” fully extended shock.
This Suspension Kit comes with (1) installation manual
and some post installation procedure literature and it is
the installers responsibility to make sure that the customer receives the post installation procedure literature. If a customer would like a copy of the installation
manual, please have them visit our website at www.tuffcountry.com. Have them go to the customer care section to download these instructions. If you have any
questions, please feel free to call us at (801) 280-2777.
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.
Make sure to use loctite on all new and stock hardware
associated with the installation of this suspension system.
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:
Torque wrench
Standard socket set
Standard wrench set
Metric socket set
Metric wrench set
Tape measure
Hydraulic floor jacks
Hardware bag 55900NB1 includes:
Description
Quantity
M12FN (M12 fine nut) 1
M12LWA ( 12 mm lock washer) 1
51634B (5/16” x 3/4” bolt) 2
5161B (5/16” x 1” bolt) 5
516114B (5/16” x 1 1/4” bolt) 1
14WA (1/4” USS flat washer) 16
516UN (5/16” unitorque nut) 8
381B (3/8” x 1” bolt) 4
38112 (3/8” x 1 1/2” bolt) 2
516WA (5/16” USS flat washer ) 14
38UN (3/8” unitorque nut) 10
716112B (7/16” x 1 1/2” bolt) 4
716LWA (7/16” lock washer) 4
12114B (1/2” x 1 1/4” bolt) 2
12112B (1/2” x 1 1/2” bolt) 2
716WA (7/16” USS flat washer ) 8
12UN (1/2” unitorque nut) 4
916214B (9/16” x 2 1/4” bolt) 1
916212B (9/16” x 2 1/2” bolt) 1
12WA (1/2” USS flat washer) 7
916LWA (9/16” lock washer) 1
34412B (3/4” x 4 1/2” bolt) 2
34512B (3/4” x 5 1/2” bolt) 2
34WA (3/4” USS flat washer) 8
34UN (3/4” unitorque nut) 4
Hardware bag 55900NB2 includes:
Description
Quantity
PB2408 (poly bushing) 4
S10082 (.875” x .563” x 2.080” sleeve) 2
MO2382 (poly bushing) 2
S10076 (.750” x .629” x 2.875 sleeve) 1
MO3354 (poly bushing) 2
S10075 (.750” x .625” x 1.275 sleeve) 1
S10140 (fender washer) 2
BLR09 (brakeline bracket) 2
BLR01 (brakeline bracket) 2
T5I-12L (knuckle washer) 2
5U-5161316R (5/16” x 1 3/16” x 2” round u-bolt) 4
516FN (5/16” flange nut) 8
ZIPTIE (zip tie) 2
SB34 (shock bushing) 2
Hardware bag 916NW includes:
Description
Quantity
SUW-916 (9/16” u-bolt washer) 8
916HN (9/16” harden washer) 8
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 front wheels and tires from
both sides.
2. Remove the front skid plate. Save the skid plate and hardware.
3. Working on the driver side, remove the brake line bracket
that connects to the side of the frame rail. Save the hardware. Repeat procedure on the passenger side.
4. Working on the driver side, remove the hardware from the
sway bar end link and save the hardware for later re-installation. Repeat procedure on passenger side.
5. Working on the driver side, remove the sway bar from the
OE location and save the hardware for later re-installation.
Repeat procedure on passenger side. Set the sway bar a
side for later re-installation.
6. Using a pair of hydraulic floor jacks, support the front axle
on the driver and passenger side.
7. Working on the driver side, scribe a mark on the strut indicating driver side. This will allow you to re-install the driver
side strut back into the OE location at a later step. Repeat
procedure on passenger side.
8. Working on the driver side, remove the (3) upper nuts that
hold the strut assembly into the upper pocket. Save the hardware for later re-installation. Special note: DO NOT remove
the upper center nut that holds the shock to the bearing
plate. If the nut is removed, a coil spring compressor is
going to be needed to put the strut assembly back
together. Repeat procedure on passenger side.
9. Working on the driver side, remove the lower bolt that
holds the strut into the OE location and save the hardware
for later re-installation. Repeat procedure on passenger side.
Set the driver and passenger side strut’s aside for later reinstallation.
10. Working on the driver side, remove the cotter pin and
castle nut the secures the ball joint to the upper control arm.
The cotter pin and castle nut may be discarded. Carefully
separate the taper on the ball joint and the upper control
arm. Repeat procedure on the passenger side.
11. Working on the driver side, remove the upper control arm
from the OE location and set aside for later re-installation.
Save the hardware. Repeat procedure on passenger side.
12. Working on the driver side, carefully remove the ball joint
from the knuckle and discard. Special Note: A ball joint
puller may be needed to help make removal easier.
When removing the ball joint take special care not to
damage the knuckle. Repeat procedure on passenger side.
13. Working on the passenger side, remove the two bolts
that hold the rack and pinion hi pressure and return lines to
the inside of the frame rail. Save the hardware for later reinstallation.
14. Working on the driver side, carefully tie the rack and pinion to the sway bar mount. Repeat procedure on the passenger side.
15. Working on the driver side, remove the hardware that
connects the rack and pinion to the steering shaft. Save the
hardware.
16. Working on the driver side, remove the hardware that
connects the rack and pinion to the rear cross member. Save
the hardware.
Loading...