Zone Offroad Products D1200 User manual

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 oor jack and a set of jack stands. See the "Special
Tools Required" section for additional tools needed to complete this installation properly and safely.
Pr o d u c t Sa f e t y Wa r n i n g»
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 modied 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 modied vehicle under the inuence of alcohol or drugs. Always drive your modied vehicle at re-
duced speeds to ensure your ability to control your vehicle under all driving conditions. Always wear your seat belt.
te c h n i c a l Su P P o r t»
Live Chat provides instant communication with Zone tech support. Anyone can access live
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 [email protected] detailing your issue for a quick response.
888.998.ZONE Call to speak directly with Zone tech support.
Pr e -in S t a l l a t i o n no t e S»
Special literature required: OE Service Manual for model/year of vehicle. Refer to 1.
manual for proper disassembly/reassembly procedures of OE and related components.
Adhere to recommendations when replacement fasteners, retainers and keepers are called out in the OE manual.2.
Larger rim and tire combinations may increase leverage on suspension, steering, and related components. When selecting combina-3.
tions larger than OE, consider the additional stress you could be inducing on the OE and related components.
Post suspension system vehicles may experience drive line vibrations. Angles may require tuning, slider on shaft may require re-4.
placement, shafts may need to be lengthened or trued, and U-joints may need to be replaced.
Secure and properly block vehicle prior to installation of Zone Offroad Products. Always wear safety glasses when using power tools.5.
If installation is to be performed without a hoist, Zone Offroad Products recommends rear alterations rst.6.
Due to payload options and initial ride height variances, the amount of lift is a base gure. Final ride height dimensions may vary in 7.
accordance to original vehicle attitude. Always measure the attitude prior to beginning installation.
Zone Oroad Products • 3 Grahl Dr., Coldwater, MI 49036 • »888.998.ZONE • www.zoneoroad.c o m
rev030410
#D1200 Installation Instructions
2002-2005 Dodge 1500 4wd
2" Torsion Key Lift
Diculty Level
easy 1 2 3 4 5 difcult
Estimated installation: 1 hours
Special Tools Required
Torsion bar unloading tool
Tire/Wheel Fitment
33x12.5 w/ factory backspace
wheel

D1200 Installation - pg. 2
INSTALLATION INSTRUCTIONS
Park vehicle on clean, at and level surface. Block the rear wheels for safety.1.
Measure the ride height of the vehicle and record.2.
Raise the front of the vehicle with a hydraulic jack. Support the frame rails with 3.
jackstands.
Measure the length of the torsion bar adjuster bolts (top of the adjuster bolt head 4.
to adjuster)
Remove the adjuster bolts, keep driver's and pass side bolts separate.5.
Use the appropriate torsion bar removal tool to remove the threaded adjuster as-6.
sembly. Release the pressure from torsion bar with the unloading tool.
Caution:
There is an extreme amount of energy stored in the torsion bars. Use extreme
care with the proper tools to avoid serious injury or death.
Pull the torsion bars rearward out of the lower control arms to allow the keys to7.
be removed. It may be necessary to use an air hammer on the factory keys to get
them free from the end of the bars.
Apply a small amount of grease to the hex on each end of the torsion bar. Install 8.
the new torsion keys.
Install the torsion bar adjuster assembly with torsion bar tool.9.
Set the overall length of the exposed thread and bolt head to the original mea-10.
surement. The minimum recommended exposed length is 3/4". This may need
to be adjusted if heavy accessories are added to the front of the vehicle.
Lower the front end to the ground, bounce the front end to settle the suspension11.
and roll the vehicle forward and back several feet to allow the vehicle to set at
the nal ride height.
Check the nal ride height measurement. This should not be more than 25". If 12.
it is greater than this, the adjusters need to be lowered. Excessive ride height
will reduce ride quality and increase wear on suspension, steering and drive axle
components.
A front end alignment must now be performed.13.
Torsion Key
Torsion Bar
Adjuster Bolt
Kit Contents
Qty Part
2 Dodge Torsion Keys
Important—measure
before starting!
Measure from the center of the
wheel up to the bottom edge of the
wheel opening
LF__________ RF__________
LR__________ RR__________
Important—measure
before starting!
Measure from the exposed length
of the torsion bar adjusters before
starting:
Drv_________ Pass__________
Caution: There is an extreme
amount of energy stored in the tor-
sion bars. Use extreme care with
the proper tools to avoid serious
injury or death.