Installation Instructions
Contents
1. sandwich between the bumper and frame bracket Insert the bracket so cutout is at the top and install using supplied 10mm x 40mm bolts and washers The center bolts will require the additional nuts and washers Reconnect the trailer and license plate light harnesses and re install the license plate Re install spare tire Check all hardware for proper torque Post Installation Warnings 1 Check all fasteners for proper torque Check to ensure for adequate clearance between all rotating mobile fixed and heated members Verify clearance between exhaust and brake lines fuel lines fuel tank floor boards and wiring harness Check steering gear for clearance Test and inspect brake system 2 Perform steering sweep to ensure front brake hoses have adequate slack and do not contact any rotating mobile or heated members Inspect rear brake hoses at full extension for adequate slack Failure to perform hose check re placement may result in component failure Longer replacement hoses if needed can be purchased from a local parts supplier 3 Perform head light check and adjustment 4 Re torque all fasteners after 100 miles Always inspect fasten ers and components during routine servicing D9150 Installation pg 132. D9150 Installation Instructions 09 Dodge 1500 1 5 Body Lift OFFROAD PRODUCTS Read and understand all instructions and warnings prior to installation of product and operation of vehicle Zone Offroad Products recommends this system be installed by a professional technician In addition to these instructions profes sional knowledge of disassembly reassembly procedures and post installation checks must be known Minimum tool requirements include the following Assorted metric and standard wrenches hammer hydraulic floor jack and a set of jack stands See the Special Tools Required section for additional tools needed to complete this installation properly and safely Propuct SAFETY WARNING Certain Zone Suspension Products are intended to improve off road performance Modifying your vehicle for off road use may result in the vehicle handling differently than a factory equipped vehicle Extreme care must be used to prevent loss of control or vehicle rollover Failure to drive your modified vehicle safely may result in serious injury or death Zone Offroad Products does not recom mend the combined use of suspension lifts body lifts or other lifting devices You should never operate your modified vehicle under the influence of alcohol or drugs Always drive your modified vehicle at reduced speeds to ensure your ability to control your vehicle under all driving conditions Always wear your seat belt Difficulty Level TECHNICAL SUPPORT ea
3. Place the front bumper brack ets over the front of the frame horn Mark the center of the holes to be drilled Drill holes to 4 Figure 13 D9150 Installation pg 23 24 25 26 27 Figure 13 Reinstall the front bumper by attaching the two lower studs into the drilled holes directly against the frame rail Place the thick washer over the top stud of the bumper Install the relocation brackets Tighten assembly with factory nuts Figure 14 Figure 14 Tighten the upper bumper cover support 2 per side Reinstall upper bumper cover Reinstall headlights grill and upper radiator cover Install the ground strap extension in the driver s side inner fenderwell Use serrated edge washer between the strap and wire Use serrated edge washer between the strap and frame Attach with 4 nylock nut Figure 15 D9150 Installation pg 9 D9150 Installation pg 10 Figure 15 28 Adjust bumper to be even side to side Tighten bumper bolts to 65 ft lbs 29 Recheck all hardware for proper torque gt gt Rear Bumper amp Spare Tire WINCH INSTALLATION 30 Disconnect the trailer harness and 2 license plate lights 31 Remove the license plate to reveal the 2 center bumper bolts 32 Remove the bumper by removing the 6 bumper bracket bolts 2 on each side and 2 in the center Figure 16 Figure 16 33 The alignment pins at each bumper mount location will need to be removed Using a cut off wheel cut the hea
4. ds of the studs off behind the mount as shown Figure 17 Figure 17 34 Drill the holes where the studs where located to 1 2 35 Remove the two bolts that hold the spare tire winch to the frame Locate the provided 1 5 spacers and supplied 8mm x 60mm bolts and washers Install the spacers between the spare tire winch and frame and tighten bolts to 18 ft lbs Figure 18 Figure 18 36 Remove the factory U Nuts from the center bracket and install them in the large holes of the center relocation bracket Install the center relocation bracket using the 1 2 flat head bolts and serrated edge nuts Figure 19 D9150 Installation pg 11 D9150 Installation pg 12 Figure 19 37 Install the provided bumper step spacer with the 10mm x 40mm bolts nuts and washers through the existing holes in the bumper mount 38 The bottom of the bumper will have to be slightly trimmed Measure over 3 4 and cut out the sections as shown in Figure 20a amp 20b Figure 20a Figure 20b 39 40 41 42 43 44 There is a slot and hole between the factory mounting holes on the bumper Drill out the factory hole to 1 2 and do the same in the center of the slot using a drill or rotary grinder Figures 21a amp 21b Figure 21b Install bumper back on the vehicle by letting it rest on the new step spacer Loosely fasten the center bracket with the factory hardware Locate the provided side bumper brackets These will
5. radiator shroud cover it will not be reinstalled Models with electric fans will not require the removal or modification of the factory shroud Figure 2 Figure 2 5 Remove the upper radiator cover Figure 3 D9150 Installation pg 3 D9150 Installation pg 4 Figure 3 6 Remove the grill disconnect the 4 bolts that attach the grill to the body Figure 4 Pull the lower portion of the grill straight out and slightly up Figure 4 7 Remove the 2 bolts that attach the headlights to the body Figure 5 Figure 5 8 Lower the flap inside the wheel well to access the headlights Raise the plastic retaining clip up to allow the headlight to be removed Pull out on the headlight to dislodge it Figure 6a 6b Disconnect the wiring harness and set headlights aside Remove the bolt that attaches the inner fenderwell to the front bumper Figure 7a Sport models need to have additional bolts removed Figure 7b Figure 7b 10 Remove the top cover bolt that is run from the inside of the fender Figure 8 Figure 8 D9150 Installation pg 6 11 Sport models these steps are not required skip to step 13 Remove the upper bumper cover from the vehicle 12 Loosen the 4 bolts 2 per each side that attach the upper cover support bracket to allow it to move out of the way for removal of the bumper Figure 9 Figure 9 13 Remove the 6 nuts 3 per side that attach the bumper to the frame Remove the b
6. roducts recommends rear alterations first 7 Due to payload options and initial ride height variances the amount of lift is a base figure Final ride height dimensions may vary in accordance to original vehicle attitude Always measure the attitude prior to beginning installation Important Verify you have all of the kit components before beginning installation Kit Contents Part 3 OD x 1 5 x 9 16 ID blocks 1 5 square crush tube 1 2 washer 0 11 0 14 thick Ground strap extension Front bumper bracket Ribbed shank rivet plastic Body mount bolt pack 8 12mm 1 75 x 150mm bolt 6 12mm 1 75 x 75mm bolt 8 12mm flat washer 2 1 4 external tooth serrated edge washer 1 4 20 nylock nut D9150 Installation pg 2 Qty 1 1 2 2 1 1 Part Rear bumper step spacer Rear bumper center bracket Rear bumper outside bracket Spare tire spacer sleeve Loctite Rear bolt pack 2 8mm 1 25 x 65mm bolt 2 8mm flat washer 8 10mm 1 50 x 40mm bolt 12 10mm flat washer 4 10mm 1 50 prevailing torque nut 1 2 13 x 1 1 4 flat head allen bolt 1 2 13 serrated edge flange nut Installation Instructions gt gt Front DISASSEMBLY 1 Park vehicle on clean flat and level surface Block the wheels to prevent the vehicle from rolling 2 Disconnect the battery 3 Disconnect the ground strap from the inside of the driver s side wheel well Figure 1 Figure 1 4 Engine mounted cooling fans Remove the lower
7. sy 1 O 3 4 5 difficult Live Chat provides instant communication with Zone tech support Anyone can access live Estimated installation 3 5 hours Special Tools Required chat through a link on www zoneoffroad com www zoneoffroad com may have additional information about this product including the lat est instructions videos photos etc Send an e mail to tech zoneoffroad com detailing your issue for a quick response 888 998 ZONE Call to speak directly with Zone tech support PreE INSTALLATION NOTES 1 Special literature required OE Service Manual for model year of vehicle Refer to manual for proper disassembly reassembly procedures of OE and related components 2 Adhere to recommendations when replacement fasteners retainers and keepers are called out in the OE manual 3 Larger rim and tire combinations may increase leverage on suspension steering and related components When selecting combi nations larger than OE consider the additional stress you could be inducing on the OE and related components 4 Post suspension system vehicles may experience drive line vibrations Angles may require tuning slider on shaft may require replacement shafts may need to be lengthened or trued and U joints may need to be replaced 5 Secure and properly block vehicle prior to installation of Zone Offroad Products Always wear safety glasses when using power tools 6 If installation is to be performed without a hoist Zone Offroad P
8. umper from the vehicle Figure 10 Figure 10 gt gt Cas AND Bep Lirt PROCEDURE 14 Remove the cab mounting bolts 4 per side from the passenger s side only Loosen the bolts on the driver s side 15 Remove the washers from the factory bolts Figure 11 D9150 Installation pg 7 Figure 11 16 Raise the passenger s side of the cab and install the body lift blocks Apply loctite and install the 12mm x 150mm bolts with the factory washers The rear Step 16 Note cab mount will get the large factory block with a new 12mm washer Do not Body mount hardware is located in tighten bolts at this time bolt pack 279 17 Repeat installation on driver s side Tighten all body mount bolts to 65 ft lbs 18 Locate the spare tire removal tool from under the passenger side seat and lower the spare tire and remove See owner s manual 19 Remove the 3 passenger s side bed bolts Loosen the driver s side bed bolts 20 Lift the passenger s side of the bed and install the lift blocks Apply loctite to the 12mm x 75mm bolts and install them at the bed mounts with the provided wash ers Do not tighten Remove the rubber bed supports Transfer them to the new bed spacer blocks Install them with the plastic push tree pins Figure 12 Figure 12 21 Repeat block installation on driver s side Tighten all hardware to 65 ft lbs gt gt Front Bumper INSTALLATION 22 Bend the factory tab back flush with the bracket
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