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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.

 

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Certain Zone Suspension Products are intended to improve off-road performance. Modi

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fying 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 recommend 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.

 

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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.

Secure and properly block vehicle prior to installation of Zone Offroad Products. Always wear safety glasses when using

power tools.

5.

Zone Offroad Products body lifts are designed to be used on vehicles in good operating condition. It is not recommended that

body lifts be used on vehicles in poor physical shape. This includes rusted body mounts, damaged or worn frame-to-body

mounting brackets, and poor mechanical condition. Perform a visual inspection of the vehicle before beginning installation.

#C9154 Installation Instructions
1999-2002 Chevy/GM 1500 2/4wd
1.5" Body Lift Kit

Difficulty Level

easy  1  2  3  4  5  difficult
Estimated installation: 4 hours

Special Tools Required

Reciprocating saw or equivalent

Содержание C9154

Страница 1: ...ve your modified vehicle at reduced speeds to ensure your ability to control your vehicle under all driving conditions Always wear your seat belt Pre Installation Notes 1 Special literature required O...

Страница 2: ...t Pack Body Mount 273 1 Bolt Pack Front Bumper etc 272 16 3 Dia x 1 5 Tall Body Block 2 2 Dia x 1 5 Tall Bumper Spacer 1 Front Bumper Bracket drv 1 Front Bumper Bracket pass 4 1 5 Steel Bed Spacer 2 U...

Страница 3: ...ove the cover from the vehicle Save clips and cover Figure 1 3 Remove the grill Four Phillips head fasteners are located at the four corners of the grill face that require a quarter turn to release Fi...

Страница 4: ...clip that is attached to the middle of the air intake tube Remove the intake tube from the vehicle 7 Remove the bolts 2 or 4 depending on vehicle mounting the top of the fan shroud to the core support...

Страница 5: ...e the bolt that connects the upper steering column to the lower steering shaft Figure 7 Make a mark on each half for alignment dur ing installation Remove the bolt and separate the shafts by sliding t...

Страница 6: ...ssed from above the bumper Figure 9 While supporting the bumper remove the four bolts and separate the bumper from the vehicle Save bumper mounting bolts Figure 9 14 Locate the wire loom running along...

Страница 7: ...p Figure 11 Check for any other lines hoses or wires in this area that may not have enough slack to compensate for 1 5 of lift Mark these lines hoses or wires and disconnect Figure 11 Parking Brake Ca...

Страница 8: ...the driver s side door There is a small indent in the connector that must be removed to allow the cable to be pulled free Figure 13 Remove the indent with a punch small rotary grinder or drill Figure...

Страница 9: ...to see that it is properly aligned on the frame and the bed Remove each body bolt one at a time and apply Loctite to the threads Torque all body mount bolts to 65 ft lbs Bed Lift 25 Loosen but do not...

Страница 10: ...rackets so the studs point toward the engine compartment Torque hardware to 10 ft lbs Figure 16 32 Mount the fan shroud on the relocation bracket studs and fasten with the provided 1 4 nuts and washer...

Страница 11: ...past the thickness of the core support material The radiator is located just above 35 With the holes drilled reposition the lower shroud brackets and fasten with the provided 1 4 x 3 4 self tapping b...

Страница 12: ...stic retaining clip at the bottom of the core support Check that the cooler lines are not rubbing on anything It may be necessary to slightly bend them to properly clear the core support and or the fa...

Страница 13: ...C9154 Installation pg 13 Figure 19 Figure 20A 44 Cut the inside of the frame brackets off along the cut line with a reciprocating saw Figure 20B Figure 20B...

Страница 14: ...econd bracket mounting hole to be drilled Drill 1 2 hole at mark Figure 21 Figure 21 Pass Side Shown 47 Attach the new brackets to the frame with the provided 7 16 x 1 1 4 bolts nuts and washers Align...

Страница 15: ...e original outside bumper support bracket mount holes on each front body mount Measure straight up from the center of the holes 1 1 2 and mark Drill 7 16 holes at the marks 4 total Figure 23 The brack...

Страница 16: ...1 2 x 1 1 4 bolts nuts and washers Leave hardware loose Figure 24 51 Loosely fasten the original outer support bracket to the new holes in the front body mounts with the factory bolts along with the 1...

Страница 17: ...Install the grill on the vehicle in the reverse of how it was removed 56 Install the plastic core support cover on the top of the core support and fasten with the original plastic retaining clips Par...

Страница 18: ...nings 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 fu...

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