Chevy Tahoe X-Pak Install - Four Wheeler Magazine

One of the first mods we make to our rigs very often involves a suspension lift and a set of larger, more aggressive tires. This combination gives us more ground clearance, better approach and departure angles, and improved traction. And, of course, the result makes our rigs look better.

This is the complete X-Pak as delivered. Four Mickey Thompson tires and six-lug wheels, a complete RCD 6-inch suspension system and four Bilstein 5100 Series shock absorbers.
This is the complete X-Pak as delivered. Four Mickey Thompson tires and six-lug wheels, a
Before
After

RCD Suspension and Mickey Thompson Performance Tires have announced a new cross-promotion that they call the Extreme Makeover for Trucks, which features kits called X-Paks. Each X-Pak offers packaged wheels, tires and suspension components to consumers and dealers. The benefits of this deal are twofold: Simplicity in ordering and substantial dollar savings.

We wanted to experience the X-Pak for ourselves so we ordered a kit for our '99 Chevy Tahoe. With the included RCD 6-inch suspension system, we had our choice of either 33- or 35-inch Mickey Thompson Baja Radial MTX or Baja Claw tires. Wheel choices included either M/T Classic II or M/T Classic Lock wheels. We chose the 35-inch MTX radials and M/T Classic Lock wheels. It was as easy as that. Street price of the kit is $2,929. Purchased separately, the lift, tires and wheels would have cost $3,130, for a savings on this kit of $201.

We had all of the components shipped to Attitude Performance in Arlington Heights, Illinois, and then we hung out while the crew at Attitude transformed our Tahoe from a boring stocker to a more capable attention-getter. RCD recommends that a professional mechanic install this kit. Special tools are required for the safe removal and installation of the ball joints, tie rods and torsion bars. What follows will give you an overview of some of the parts and steps that went in to our Tahoe's 10-hour makeover.

After disassembling the front suspension, we disconnected the front driveshaft from the differential yoke and secured it out of the way. We then disconnected the electrical connector and vent hose from the differential assembly. Using a cutting tool (not a cutting torch), we removed the rear lower-differential mount bracket, plus an additional inch of the frame supporting the bracket. This is done to provide clearance for the lower control-arm frame mount.
After disassembling the front suspension, we disconnected the front driveshaft from the di
Support the front differential assembly, remove the upper mounting hardware and passenger-side axle hardware, and then slowly remove the differential from the vehicle.
Support the front differential assembly, remove the upper mounting hardware and passenger-
With the differential out of the vehicle, we welded a new frame cap in where we cut out the rear lower differential-mount bracket. We filed all sharp edges smooth and then painted the cap black to match the frame.
With the differential out of the vehicle, we welded a new frame cap in where we cut out th

The upper mount on the differential housing needs to be cut off to provide room for the new RCD bracketry.
The upper mount on the differential housing needs to be cut off to provide room for the ne
The first step in reassembly is to install the bushings into the differential support bracket and attach the differential support bracket to the front differential (support bracket shown on right). RCD notes that differential housings may vary, and it may be necessary to grind the outside edge of the bracket to fit. Install the differential drop bracket to the differential axle (drop bracket shown on left).
The first step in reassembly is to install the bushings into the differential support brac
The new front crossmember installs into the existing front lower control-arm mounting pockets using the factory hardware.
The new front crossmember installs into the existing front lower control-arm mounting pock

The Lowdown on the Lift Kit
When RCD Suspension introduced this 6-inch suspension system in October 2001, it was unique in that it was the first subframe-and-spindle system on the market for the "old-body-style" six-lug Chevy/GMC pickup, Suburban and four-door Tahoes and Yukons. The benefits of this system include fewer frame modifications and utilization of the factory steering system components. The kit comes with a new lower subframe, CNC-machined replacement steering knuckles, front differential relocation brackets, billet steel antiroll-bar links, extended stainless-steel braided front brake lines, Bilstein 5100 Series shocks, rear lift blocks and all required hardware.