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Zone C9154 Installation Instructions Manual

1999-2002 chevy/gm 1500 2/4wd 1.5" body lift kit

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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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S
roduct
afety
Certain Zone Suspension Products are intended to improve off-road performance. Modi-
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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nStallation
Special literature required: OE Service Manual for model/year of vehicle. Refer to manual for proper disassembly/reassembly
1.
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
3.
combinations larger than OE, consider the additional stress you could be inducing on the OE and related components.
Secure and properly block vehicle prior to installation of Zone Offroad Products. Always wear safety glasses when using
4.
power tools.
Zone Offroad Products body lifts are designed to be used on vehicles in good operating condition. It is not recommended that
5.
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.
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arning
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#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

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Summary of Contents for Zone C9154

  • Page 1 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...
  • Page 2: Kit Contents

    3" Dia x 1.5" Tall Body Block 2" Dia x 1.5" Tall Bumper Spacer Front Bumper Bracket - drv Front Bumper Bracket - pass 1.5" Steel Bed Spacer Upper Fan Shroud Bracket Lower Fan Shroud Bracket C9154 Installation - pg. 2...
  • Page 3: Installation Instructions

    Remove the 4 bolts mounting the transmission cooler to the core support Not all models were equipped with . Pull the cooler forward, free from the core support mount. Save bolts. Figure 3 transmission coolers. C9154 Installation - pg. 3...
  • Page 4 Pull up on the fan shroud to remove it from the bottom retaining clips. On some models, oil lines must be removed from retaining clips on the driver’s side of the lower fan shroud. Disconnect the ground strap from the driver’s side firewall . Save nut. Figure 6 C9154 Installation - pg. 4...
  • Page 5 . Make a mark on each half for alignment dur- ing installation. Remove the bolt and separate the shafts by sliding the steering column up off the lower shaft. Save mounting hardware. Figure 7 C9154 Installation - pg. 5...
  • Page 6 If the vehicle is equipped with a front skid plate, removing the skid plate will aid in accessing the clips. C9154 Installation - pg. 6...
  • Page 7 » arking rake aBle Pull down on the parking brake cable that runs down the driver’s side frame rail. Clamp the cable where it runs through the front body mount so it stays slack Figure 12 C9154 Installation - pg. 7...
  • Page 8 Figure 13 indent with a punch, small rotary grinder or drill. Figure 13 Figure 14 Compress the retaining clip at the body mount and pull the parking brake cable out the front of the body mount. C9154 Installation - pg. 8...
  • Page 9 Figure 15 body spacers at these locations. Attach the spacers to the frame with tap the holes before installing the 5/16" x 3/4” self-tapping bolts. Tighten hardware to 10 ft-lbs. spacer. C9154 Installation - pg. 9...
  • Page 10 The lower horizontal shroud lip should rest #272 just below the core support and the shroud pulled tight forward. Use the brack- ets to mark the position of the holes to be drilled. C9154 Installation - pg. 10...
  • Page 11 With the holes drilled, reposition the lower shroud brackets and fasten with the factory front plastic splash guard provided 1/4" x 3/4" self-tapping bolts. Tighten bolts to 10 ft-lbs. Figure 18 in order to get a better angle for drilling. C9154 Installation - pg. 11...
  • Page 12: Front Bumper

    The factory front bumper frame mounts need to be modified. Draw a cut line in hardware pack #272. that starts on the inside edge of the upper mount tab and runs down along the Figure 20A inside surface of the frame rail. C9154 Installation - pg. 12...
  • Page 13 Figure 19 Figure 20A Cut the inside of the frame brackets off along the cut line with a reciprocating Figure 20B saw. Figure 20B C9154 Installation - pg. 13...
  • Page 14 Torque tow hook bolts to 55 ft-lbs. with tow hooks from the factory, use the second set of 7/16" x 1-1/4" bolts, nuts and washers provided in hardware pack #272 for the lower mounting hole. C9154 Installation - pg. 14...
  • Page 15 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 brackets will be attached after the bumper is in place. Figure 23 C9154 Installation - pg. 15...
  • Page 16 Leave all hardware loose. Figure 25 Adjust the bumper to the proper location and torque all mounting hardware. Tighten the outer support bolts (6 total) to 45 ft-lbs and upper/lower main frame mount bolts to 60 ft-lbs. C9154 Installation - pg. 16...
  • Page 17 Bend the tab up flat against the mount to gain slack Figure 26A runs through it. Figure 26B for the cable. Run the cable back through the mount into its original Figure 26C location. Figure 26A Figure 26B C9154 Installation - pg. 17...
  • Page 18 Figure 26C Pull slack on the parking brake cable and clamp it off like it was during disas- sembly. Reconnect the front cable to the rear cable and remove the clamp. » anUal HiFt ranSFer Check the fuel lines near the transfer case shift linkage. They are the on the driver's side of the transfer case.