Tuff Country 56900 User Manual
Part # 56900
2005 - 2010 Toyota Tacoma
6” suspension system
Parts contained in Box 1 of 2
Part
# Description
Qty.
56900-03 Front cross member 1
56900-04 Rear cross member 1
56900-05 Driver side differential relocation bracket 1
56900-06 PS differential relocation bracket 1
56900-07 Front lower skid plate 1
56900-08 Front coil spring spacers 2
56900-09 Front bump stop spacers 2
56900-10 Front sway bar relocation brackets 2
56900NB Hardware Bag 1
56900NB1 Hardware Bag 1
TCI-R38 Rear add-a-leaf 2
CB38 Hardware Bag 1
BL301 3” Rear lifted blocks 2
5U-247S 9/16” x 2 1/2” x 9 5/8” Square U-bolts 4
916NW Hardware Bag 1
56900INST Instruction Sheet 2
Mirrorhanger Rear view mirror hanger 1
Warningdecal Warning Decal 1
Decal Window sticker 1
Parts contained in Box 2 of 2
Part # Description Qty.
56900-02 Driver side Knuckle 1
56900-01 Passenger side Knuckle 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 parts, please refer to the back of the installation manual for photos of parts that are included in
this suspension system.
Installation manual
6” suspension system
2005 - 2010
Toyota Tacoma
Part # 56900
sj07012010rev.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.
If you desire to return your vehicle to stock, it is the
customers responsibility to save all stock hardware.
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 stock wheels will not work in conjunction with this
suspension system. New 17” wheels or larger with a
4.5” back spacing or less is required. Tuff Country recommends a 33x12.50 tire package. If larger than a
33x12.50 tire is installed on your vehicle in conjunction with part # 56900; Tuff Country assumes no liability and the warranty will be VOID.
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 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.
This suspension system will only work on vehicles
that are equipped with ABS braking systems.
This suspension system will not work on vehicles
equipped with VSC (Vehicle Stability Control)
Make sure to use thread locker or loctite on all new
and stock hardware associated with the installation of
this suspension system.
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.
Hardware bag 56900NB includes:
Bag # 1
Description
Quantity
M10WA (10 mm flat washer) 2
M10LWA (10 mm lock washer) 2
M1050HEXB (10 mm x 50mm hex screw ) 2
34WA (3/4” Flat washer) 4
34UN (3/4” unitorque nut) 2
345B (3/4” x 5” bolt) 2
M8WA (8mm flat washer) 2
M8LWA (8mm Lock washer) 2
M1030BSOC (8mm x 30mm socket head screw) 4
M850HEXB (8mm x 50mm hex cap screw) 2
SUW-916 (9/16” hardened u-bolt washer) 5
916LWA (9/16” lock washer) 5
Bag # 2
Description
Quantity
12UN (1/2” unitorque nut) 5
12312B (1/2” x 3 1/2” bolt) 3
12512B (1/2” x 5 1/2” bolt) 2
14WA (1/4” USS flat washer) 15
38UN (3/8” unitorque nut) 10
38WA (3/8” USS flat washer) 12
516UN (5/16” unitorque nut) 7
516WA (5/16” USS flat washer) 10
5161B (5/16” x 1” bolt) 4
51634B (5/16” x 3/4” bolt) 3
716UN (7/16” unitorque nut) 6
716WA (7/16” USS flat washer) 10
716114B (7/16” x 1 1/4” bolt) 6
Hardware bag 56900NB1 includes:
Description Quantity
S10105 (1.000" OD X 0.325" ID X 1.300") 2
S10162 (1.500" X .525" X .750") 2
S10175 (.6875" X .565" X 1.600") 2
56900-12 (upper driver side diff hose bracket) 1
56900-13 (front brake line bracket) 2
56900-14 (front, rear E brake cable bracket) 2
56900-15 (front, front E brake cable bracket) 2
56900-16 (rear over-size laser cut washer) 4
56900-17 (front over-size laser cut washer) 4
PB2408 (Poly Bushing) 6
S10058 (.875" X .500" X 2.080") 3
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
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 the
passenger side. Next, remove the front wheels and tires
from both sides.
2.Working on the front of the vehicle, remove the upper skid
plate and save all hardware for later re-installation
3. Working on the driver side, remove the stock outer tie rod
cotter pin from the castle nut. Save the cotter pin. Loosen but
do not remove the stock castle nut completely. Repeat procedure on the passenger side.
4. Working on the driver side and using a hammer, carefully
break the stock outer tie rod from the stock knuckle. Special
note: Take special care not to damage the stock outer tie
rod or tie rod boot. Once the taper has been broken,
remove the stock nut and save. Repeat procedure on the
passenger side.
5. Working on the driver side, remove the sway bar end link
from the neck of the steering knuckle, save stock hardware
and repeat on passenger side.
6. Working on the driver side, remove ABS and brake line
brackets from the upper control arm and the steering knuckle. Save stock hardware and repeat on passenger side.
7.Working on the driver side, remove the bolt that connects
the brake line bracket to the frame rail. Save hardware and
repeat on passenger side.
8. Working on the driver side, un-bolt the ABS sensor from
the steering knuckle and move ABS wire harness aside and
out of the way. Repeat on passenger side. Special note: Be
careful not to put ABS sensor and wire harness anywhere that it can be damaged during install.
9. Working on the driver side, un-bolt the brake caliper from
the steering knuckle, save the stock bolts for re-install. Now
remove brake caliper and carefully tie it up out of the way
during install. Repeat on passenger side. Special note:
when removing brake caliper, take special care not to
bend or kink the hard brake line.
10. Working on the driver side, remove the brake rotor from
the hub and set aside for later re-install. Repeat on passenger side.
11. Working on the driver side, remove the cap in the center
of the hub assembly, then remove cotter pin and retaining
nut, now remove the large axle nut and save all stock hardware for later re-install. Repeat on passenger side.
12. Using a rubber mallet or anything similar, tap the CV axle
loose from the knuckle in the hub assembly. Special note:
take special care not to damage the threads on the end
of the axle shaft.
13. Working on the driver side, remove the cotter pin from
the upper ball joint nut, then loosen but don’t remove the nut
completely. Repeat on passenger side.
14. Working on the driver side, loosen but don’t remove the
upper control arm mounting bolts, this is done so that the
upper control arm can easily be swiveled up and down.
Repeat procedure on the passenger side.
15. Working on the driver side, using a hammer or proper
ball joint tool, carefully sperate the upper ball joint from the
steering knuckle. Remove nut and save. Special note: Take
special care not to damage the ball joints rubber boot.
Repeat on passenger side.
16. Working on the driver side, remove bolts that attach the
lower steering arm/ball joint to the steering knuckle. Save
stock hardware for later re-install. Now remove steering
knuckle from vehicle. Repeat on passenger side.
17. Working on the driver side, remove the (3) nuts that
attach the strut assembly to the upper mount of the vehicle,
now remove the lower shock mounting bolt and save all
hardware. Special note: DO NOT remove the upper CEN-
TER nut that holds the shock to the upper strut plate, if
this nut is removed, a coil spring compressor will be
needed to put the assembly back together. Now remove
entire strut assembly from the vehicle and set aside. Repeat
on passenger side.
18. Working on the driver side, remove the lower control arm
bump stop. This part un-threads from its location and can
easily be done with large channel lock pliers. Save the stock
bump stop for later re-install. Repeat on passenger side.
19. Working on the driver side, remove the front and rear
cam bolts that hold the lower control to the vehicle, now
remove the lower control arm and set aside. Save stock cam
bolts and sleeves. Repeat on passenger side.
20. Working on the driver side rear cross member, measure
4 1/4” from the CENTER of the slotted cam bolt hole over
towards the center of the vehicle and make a mark. Do the
same on the passenger side. Now place a jack underneath
the front differential housing to support it while the cut is
being made. Carefully cut completely through the rear cross
member using your mark as a reference. Special note: Tuff
Country does not recommend using a torch to make this
cut, Tuff Country recommends using a Sawzall or die
grinder to make
this cut. Also, be
careful not to
damage any surrounding parts.
Below: passenger side.
21. After the 2 cuts have been made through the rear cross
member, remove the allen headed nut on the rear differential mount. Save the stock nut. Now remove the section of
rear cross member that has been cut and discard.
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