Tuff Country 52925 Toyota Tundra 1999 - 2006 2.5" Lift Kit Instructions
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INSTALLATION MANUAL
2 1/2” SUSPENSION 2000 - 200
6
TOYOTA TUNDRA
PART # 52925
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PART NUMBER : 52925
2000 - 200 6 TOYOTA TUNDRA
2 1/2” SUSPENSION SYSTEM
PARTS LIST:
#
52925-01
52925-02
52925-03
52925-04
M121.5B
5U-247S
916NW
S10051
Rear Brake Proportioning Bracket
Front Strut Spacer
Front Strut Pre-Load Spacer
Rear lifted block
M10 x 1.5” Strut Stud Bolts 6
9/16” x 2 1/2” x 9 1/2” Square U-bolts 4
9/16” u-bolt high nuts & washers 1
Front differential drop sleeves 2
1
2
2
2
52925INST Instruction 1 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.
Special Note: A strut compressor is going to be needed to perform this installation. If you do not have a strut compressor you may rent one from your local
Auto Parts store.
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
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
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 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.
Torque Settings
15—18
3/8”
30—35
1/2”
9/16”
95—130
3/4”
LIMITED LIFETIME WARRENTY IMPORTANT INFORMATION THAT NEEDS TO BE
READ BEFORE INSTALLATION BEGINS:
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.
For a list of all parts, please refer to the Parts
Description Page, at the end of the Installation
Manual.
Before installation begins, Tuff Country EZ-Ride
Do not install a body lift in conjunction with a suspension system. If a body lift is used in
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 conjunction with any Tuff Country EZ-Ride
Suspension product, your Tuff Country EZ-Ride vibrations occur on the test drive, uncommon sounds or vibrations will be enhanced once the
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 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.
Hardware bag 52925NB includes: 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
Description
1/2” x 8” bolts unitorque nuts
2
2
M8-1.25 x 35 mm bolts
8 washer
2
2
8 mm x 15 mm bolt
8 mm unitorque nut
Hardware bag 916NW includes:
1
1
Quantity 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
9/16” u-bolt high nuts
9/16” u-bolt harden washers
8
8
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 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
Before installation begins, measure from the center returned for warranty claim must be returned through the dealer of the distributor from whom it was feel free to call one of our customer service representatives @ (801) 280-2777.
Please Follow Instructions Carefully: of the hub, to the bottom of the fender well, and record measurements below.
Pre-Installation Measurements: purchased. Tuff Country reserves the right to examine all parts returned to it for warranty claim to
Driver Side Front:______________________________ 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.
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: tires from both sides. installation. Special note: During removal of the stock
Auto Parts store. bottom. will be difficult.
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 wheels and
2. Working on the driver side, remove the stock sway bar hardware from the stock frame location and save the stock hardware for later re-installation. Repeat procedure on the passenger side. Special Note: Tie the stock sway bar up and out of the way during installation.
3. Working on the driver side, remove the (3) upper stock nuts that connect the stock strut into the stock location.
Save the stock nuts for later re-installation. Repeat procedure on the passenger side.
4. Working on the driver side, remove the stock lower bolt that connects the stock strut to the stock lower mounting location and save the stock hardware for later rebolt, take special care not to damage the stock 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 remove.
Remove the stock strut assembly from the stock location and set a side for further instructions. Repeat procedure on the passenger side.
Special Note: A strut compressor is going to be needed to perform this installation. If you do not have a strut compressor you may rent one from your local
5. Locate the driver side stock strut that was removed in step # 4. Working on the driver side strut, scribe a line down the entire strut from the top of the strut to the
Special note: If this step is not performed properly re-installing the strut back into the vehicle driver side stock strut until the upper stock strut bracket can be removed. Remove the stock nut and hardware from the top of the stock strut assembly and save the stock hardware for later re-installation. Set the driver side strut and strut compressor a side for further instructions.
7. Working on the driver side stock strut, remove the
6. Using a strut compressor, carefully compress the stock upper strut bracket from the stock strut assembly.
Remove the stock rubber isolator from the stock upper strut bracket and set the stock upper strut bracket a side for further instructions. The stock rubber isolator may be discarded.
8. Locate (3) new 10 mm x 1 1/2” strut stud bolts.
Working on the driver side stock upper strut bracket, carefully remove the stock studs located in the stock upper strut bracket and discard. Special note: The use of a hammer will make the removal of the stock studs easier. Carefully install the new 10 mm x 1 1/2” strut stud bolts into the stock upper strut bracket. Set the stock upper strut bracket a side for further instructions.
9. Locate (1) new strut spacer, the driver side stock strut, the newly modified stock upper strut bracket and the stock upper strut hardware that was removed in step # 6.
Carefully compress the stock strut enough so that the new strut spacer can be installed. Install the new strut spacer into the stock strut and secure the stock upper bracket to stock strut assembly using the stock upper strut hardware. Make sure to use thread locker or lock tite. Torque to 65 ft lbs.
10. Locate (1) new upper strut isolator spacer and the stock upper hardware that was removed from step # 3.
Working on the driver side, install the new upper strut isolator spacer on top of the new strut assembly and install into the stock strut upper location. Secure the top of the new strut assembly using the stock hardware.
Torque to the stock hardware to hardware.
42 ft lbs.
Illustration # 1
11. Locate the stock lower strut bolt and hardware that was removed from step # 4. Secure the stock strut assembly into the stock lower location using the stock
Make sure to use thread locker or lock tite.
Torque to 75 ft lbs. Special Note: When installing the stock lower bolt, make sure that the bolt is installed the way it was removed. Facing towards the front of the vehicle. Also, take special care not to damage the stock CV boot when re-installing the stock hardware.
12. Repeat steps 3 - 11 on the passenger side strut assembly.
13. Re-install the stock sway bar into the stock location and secure using the stock hardware that was removed from step # 2.
14. Re-install the tires and wheels and torque to 75 ft lbs. Carefully lower the vehicle to the ground.
15. Working on the front of the vehicle, carefully remove the stock skid plate fro the stock location and save the stock hardware.
16. Place a pair of hydraulic floor jacks under the front differential. Place one on the driver side and one on the
passenger side. Carefully lift up on both hydraulic floor jacks until they make contact with the front differential.
17. Working on the driver side, carefully remove the stock bolt that connects the stock front differential to the stock front cross member. Save the stock oversize washer. The stock bolt and nut may be discarded. Repeat procedure on the passenger side. to the new extension bracket using the new 8 mm x 15 mm bolt and hardware, into the top position and the remaining stock bolt in the middle position. Special note:
Make sure to use thread locker or lock tite. Torque the stock and new hardware to 20 ft lbs.
23. Position a pair of hydraulic floor jacks under the rear differential. Place one jack stand on the driver side and one on the passenger side. Raise up on both hydraulic
18. Locate (2) new S10051, front differential spacer sleeves. Locate (2) 1/2” x 8” bolts and (2) 1/2” unitorque nuts from hardware bag 52925NB. Also, locate the stock oversize washers that where removed in step # 17.
Carefully lower down on both hydraulic floor jacks allowing enough room for the new front differential floor jacks at the same time until they make contact with the rear differential. Working on the driver side, remove the stock rear u-bolts. The stock rear u-bolts and hardware may be discarded. Place the stock u-bolt plate and the stock bump stop a side for later re-installation.
Repeat procedure on the passenger side. spacers to be installed. Working on the driver side, install the new front differential spacer between the front differential and the stock front cross member and secure using the new 1/2” x 8’ bolt, 1/2” unitorque nut and the
24. Carefully lower down on both hydraulic floor jacks at the same time until the stock rear spring assembly separates from the stock rear axle approximately 2”. This stock over size washer. Make sure to use thread locker or lock tite. Do not tighten at this point. Repeat will allow enough room for the new rear blocks to be installed. procedure on the passenger side. Torque the new 1/2” hardware to 80 ft lbs. Carefully remove both hydraulic floor jacks front under the front differential.
19. Locate the stock front skid plate and the stock hardware that was removed in step # 15. Also, locate (2) new 8 mm x 35 mm bolts from hardware bag 52925NB.
Install the stock front skid plate into the stock location and secure using the stock hardware in the front holes and the new 8 mm bolt in the rear. thread locker or lock tite.
Make sure to use
Do not tighten at this point.
25. Locate (2) new rear lifted blocks. Working on the driver side, install the new rear lifted block between that axle and the stock spring assembly. Special note: The new rear lifted block has a slight taper to it, make sure that the taper of the block is facing towards the front of the vehicle. Repeat procedure on the passenger side.
26. Locate (4) 9/16” x 2 1/2” x 9 1/2” square u-bolts.
Locate (8) new 9/16” u-bolt high nuts and (8) new 9/16” u-bolt washers from hardware bag 916NW. Also, locate
Front End Installation Complete:
Rear End Installation:
20. To begin installation, block the front tires of the vehicle so that the vehicle is stable and can’t roll forward.
Safely lift the rear of the vehicle and support the frame with a pair of jack stands. Place the jacks stands on both the driver and the passenger side. Make sure that the parking brake is not set. Next, remove the tires and wheels from both sides.
21. Working on the driver side, remove the stock shock from the stock lower location and save the stock hardware for later re-installation. Special note: Do not remove the stock shock from the upper location.
Repeat procedure on the passenger side.
22. Locate the new rear brake proportioning valve extending bracket. Also, locate (1) 8 mm x 15 mm bolt and (1) 8 mm unitorque nut from hardware bag 52925NB. the stock u-bolt plates and the stock bump stops that were removed from step # 23. Working on the driver side, re-install the stock u-bolt plate and bump stop into the stock location. Secure the stock spring assembly to the stock axle using the new u-bolts, u-bolt high nuts and the new u-bolt washers. Torque to procedure on the passenger side. cut off the excess threads on the new u-bolts about an 1” below the new high nuts. lbs.
If needed, carefully
Illustration # 2
85 ft lbs.
Carefully lower the vehicle to the ground.
Repeat
27. Locate the stock lower shock hardware that was removed in step # 21. Working on the driver side, install the stock shock into the stock lower location and secure using the stock hardware. Torque to 65 ft lbs. Repeat procedure on the passenger side.
28. Re-install the tires and wheels and torque to 75 ft
Check and double check to make sure that all steps were
Remove the stock rear brake proportioning valve arm where it attaches to the rear differential housing. Save the stock hardware. Secure the new rear brake proportioning valve extending bracket to the stock rear differential housing using (1) of the stock bolts (in the lower position). Next, secure the proportioning valve arm performed properly. Once installation is complete take vehicle directly to an alignment center for proper front end alignment.
If you have any questions and or concerns about the installation, please feel free to contact one of our customer services representatives @ Tuff Country EZ-Ride suspension
FRONT STRUT
PRE-LOAD
SPACER
FRONT STRUT
SPACER
STOCK
STRUT ASSEMBLY
NEW M10 X 1.5”
STRUT STUD BOLTS
AND STOCK NUTS
NEW 1 1/2” LIFTED BLOCK
ILLUSTRATION # 1
NEW 9/16” X 2 1/2” X 9 1/2” SQUARE
U-BOLTS & HARDWARE
ILLUSTRATION # 2
REAR BRAKE PROPORTIONING
VALVE BRACKET
52925-01 / QTY 1
FRONT STRUT SPACER
52925-02 / QTY 2
FRONT STRUT PRE-LOAD
SPACER
52925-03 / QTY 2
1 1/2” LIFT BLOCK
52925-04 / QTY 2
REAR U-BOLTS
5U-247S / QTY 4

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