Tried to get a set of Green Keys installed today on my '07 Classic crew cab with the GL bars. Got the old keys out no problem, but when trying to load the new keys, we needed to go about another 1/2" - 3/4" of an inch to get the piece the bolt threads into back in. With the GM unload tool, she just didn't want to go any further. Everything on the front end is still stock. What am I missing? More grunting?! :( Truck was on a lift...

Thanks!

Sounds like you had then indexed wrong. basically you had them on the bars but clocked too much...try repositioning them with a different start point.

I had the same prob ended up finding someone to do it for 75$ call around

When I did keys on my burb I had to use a 3Ft long breaker bar to get the levrage I needed so I could get the bolt bracket in (the little half moon thingie) I was using a 5 ton puller NOT the GM tool (that's at your own risk) I also undid the shocks because they would not let it droop enough.

I did not think of the shocks that could have been my problem, wait now that I think of it my bump stops were resting on the frame stops. but I also used the 5 ton gear puller but gave up after it slipped about half way, still can't get the stain out.

I did not think of the shocks that could have been my problem, wait now that I think of it my bump stops were resting on the frame stops. but I also used the 5 ton gear puller but gave up after it slipped about half way, still can't get the stain out.

I've had that too. A few years back, I put a set of 2500hd t-bars in my Z-71 to plow with (and get a better stance). The puller slipped on me too. Not a good idea. I had a buddie shortly after try to one up me on the bars. His dumb a** put one ton bars in his (or tried to). He snapped the GM tool and broke his wrist. The last time I did a set, I wore my long weld gloves and wrapped the puller with a towel just in case.

Thanks for the replies, I'm sure the indexing was right. I imagine a big breaker bar would've done the trick, I'll have to check if undoing the shocks would help at all.

What contributes to the fact that some folks seem to get them in pretty easy and others have a real tough go of it? Anyone with a big problem try putting in blue or orange keys instead? Seems they would still be an improvement over purple keys but not as indexed as the green...

I had a ***** of a time getting mine on also. I broke 3 5-ton gear pullers doing it. The pullers would start getting off center and then they would snap sideways and come off breaking (or severely bending) the bolt. They would not push straight up. I tried over and over and they kept wanting to go to the side. So....I got the puller started straight, put a ratcheting tow strap around it and tied the other end to the step bar to hold it straight while I turned the bolt. I was using an impact wrench so I didn't have to crank on them by hand. It also helps if you grease the tip of the bolt so it can turn easier on the key.