Zone Offroad Products D1201 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.
»Product 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 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
reduced speeds to ensure your ability to control your vehicle under all driving conditions.
Always wear your seat belt.
»technical SuPPort
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.
»Pre-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 combinations 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 Products recommends rear alterations rst.
7. Due to payload options and initial ride height variances, the amount of lift is a base gure. Final ride height dimensions may vary
in accordance to original vehicle attitude. Always measure the attitude prior to beginning installation.
Diculty Level
easy 1 2 3 4 5 difcult
Estimated installation: hours
Special Tools Required
General Tools
Tie Rod Separator (recommended)
Tire/Wheel Fitment
35x12.50 w/ 5.5" of Backspacing
»Zone Oroad Products • 491 W. Gareld Ave., Coldwater, MI 49036 • 888.998.ZONE • www.zoneoroad.com
rev091318
D1201 Installation Instructions
2013 Dodge Ram 3500 4WD
2014 Dodge Ram 2500 4WD
Leveling Kit D1201

pg. 2 - D1201 Installation -
INSTALLATION INSTRUCTIONS
1. Park vehicle on clean, at, and level surface. Block the rear wheels for safety
2. Remove the front trackbar hardware from the frame. Keep the bolt and nut tab for
reinstallation later. (Fig 1)
Figure 1
3. Raise the front of the vehicle and support frame rails with jack stands. Support the
front axle with a hydraulic jack, and remove the front wheels.
4. Disconnect the sway bar links from the sway bar, and allow the sway bar to swing
up. (Fig 2)
Figure 2
*Important* Verify you have all of the kit components before beginning installation.
D1201 Kit Contents
Qty Part
2 Dodge 3500 Spacers
1 605 Bolt Pack
2 7/16" x 1-1/4" Bolts
4 7/16" Washers
2 7/16" Nuts

D1201 Installation - pg. 3
5. Disconnect the brake line brackets from the top of the radius arm mount on the
front axle. (Fig 3)
Figure 3
6. Disconnect the drag link from the pitman arm, use correct puller to avoid damag-
ing the tie rod end boot. (Fig 4)
Figure 4
7. Disconnect the front shocks from the axle, keep the lower mounting bolt and nut
tab. (Fig 5)
Figure 5

pg. 4 - D1201 Installation -
8. Lower the front axle and remove the coil springs. Check for slack in ABS wires,
brake lines, and differential breather hose. Keep the coils separated, do not mix
sides.
9. Install new spacers with 7/16” hardware through the factory hole. Tighten to 35
ft-lbs. The orientation of the parts will be so that the weld seam is facing away
from the center of the vehicle. There is an extra hole in the bracket, only one hole
will be used per side. (Fig 6a, 6b)
Figure 6A
Figure 6B
10. Reinstall the factory upper isolator and coil springs. The tab on the isolator will go
directly below the bolt. Coil orientation is critical to keep the factory coils from
bowing an excessive amount.
11. Raise front axle and attach shocks. Tighten upper bushings until they begin to
swell if installing new shocks. Tighten lower shock bolt to 70 ft-lbs.
12. Reattach sway bar links to the sway bar with factory hardware. Tighten to 40
ft-lbs.
13. Reattach the drag link to the pitman arm with factory hardware. Tighten to 65
ft-lbs.
14. Reattach the factory brake line brackets to the axle with factory hardware. Tighten
to 12 ft-lbs.
15. Install wheels, if installing aftermarket wheels remove the retaining clips on the lug
studs before installing new wheels. Tighten to factory specications.
Fig 9 Note:
Hardware for spacer is located in
Bolt Pack 605

D1201 Installation - pg. 5
16. Lower vehicle to the ground.
17. Turn the steering wheel and reattach the track bar with factory hardware. Tighten
to 180 ft-lbs.
18. Perform a steering sweep and check for adequate clearance. Recheck all hardware
for proper torque.
19. Adjust steering wheel to center by adjusting the collar on the drag link, do not
drive the vehicle with the steering wheel crooked or traction control problems may
arise.
20. Have an alignment performed. Recheck all hardware after 500 miles.
OPTIONAL REAR SHOCK INSTALLATION:
»2500 modelS only
21. Rear Shock Installation: Grease and install bushings and sleeves into new shocks.
Install new shocks with new stem bushings and washers, the same as the factory
shock setup. Fox shocks only: Fox shocks will require an oset stem eliminator
bracket. e eye of the shock will need to be oset to the REAR of the vehicle to
give the shock body clearance to the frame rail hole. Locate the OE frame hole
towards the rear of the vehicle from the original stem mounting hole. Enlarge
this hole using a 3/8” drill bit to t to the tab on the oset bracket. Verify shock
clearance to the frame opening, in may be necessary to slightly enlarge the
opening due to variances in trucks, however this is highly unlikely. (Fig. 7)
Figure 7
»3500 modelS only
22. Rear Shock Installation: Grease and install bushings and sleeves into new shocks.
Install new shocks the same as the factory shock setup.
Post-Installation
Warnings
1. Check all fasteners for proper
torque. Check to ensure for
adequate clearance between all
rotating, mobile, xed, and heated
members. Verify clearance between
exhaust and brake lines, fuel lines,
fuel tank, oor boards and wiring
harness. Check steering gear for
clearance. Test and inspect brake
system.
2. Perform steering sweep to
ensure front brake hoses have ad-
equate slack and do not contact any
rotating, mobile or heated members.
Inspect rear brake hoses at full ex-
tension for adequate slack. Failure
to perform hose check/ replacement
may result in component failure.
3. Perform head light check and
adjustment.
4. Re-torque all fasteners after 500
miles. Always inspect fasteners and
components during routine servic-
ing.
Fig 21 Note:
Hardware for the stem eliminator
is in the shock box and is Bolt
Pack 946