Dee Zee DZ500215 - Manual (Page 2)

GRILLE GUARD
94-01 1500 DODGE RAM
94-02 2500-3500 DODGE RAM
Page 1 of 3 4/16/12 (DP)
PARTS LIST:
1 Grille Guard 2 10-1.5mm x 40mm Hex Bolts
2 Top Clamp Brackets 2 10-1.5mm x 30mm Hex Bolts
2 Bottom Brackets 4 10mm x 30mm OD x 2.5mm Large Flat Washers
2 Spacer Plates 4 10mm x 20mm OD x 2mm STD Flat Washers
2 12-1.75mm x 120mm Hex Bolts 4 10mm Lock Washers
2 12mm Lock Washers 4 10mm Hex Nuts
2 12mm x 37mm OD x 3mm Flat Washers
PROCEDURE:
1. REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT. READ INSTRUCTIONS
CAREFULLY BEFORE STARTING INSTALLATION. ASSISTANCE IS RECOMMENDED. DRILLING IS
REQUIRED.
2. Open the front hood. Measure to locate the approximate top-center of the front bumper, (Figure 1). Use a
small piece of removable tape to mark the center of the bumper, (masking tape for example). Measure
outward from the center 22-3/4" along the top edge in both directions, (toward driver and passenger side).
Cover these spots on the bumper with removable tape for protection and place a mark on each side at 22-
3/4" (Figure 1).
3. Select the (2) Top Clamp Brackets. Slide the smaller slot on the bottom of the Clamp over the edge of the
steel bumper. Slide the plastic cover into the middle slot in the Clamp. Line up the center of each Top
Clamp on the marks in Step 2, (Figure 2-inset).
4. Next, from under the front of the vehicle, remove the driver side factory body bolt. Select (1) Bottom
Mounting Bracket and Spacer. Insert (1) 12mm x 120mm Hex Bolt, (1) 12mm Lock Washer and (1) 12mm
Flat Washer through the Bottom Mounting Bracket and Spacer and into the bottom of the body mount,
(Figure 2). Snug but do not fully tighten the hardware at this time.
5. Repeat Step 4 for passenger side Bottom Bracket and Spacer installation.
6. With assistance, lift the Grille Guard up to the vehicle and line up the (2) Top mounting tabs on the Grille
Guard with the (2) Top Clamp Brackets. NOTE: The Grille Guard is shipped with (2) Edge Covers to
protect the front bumper from damage. These are installed at the factory but may come loose in shipping,
(Figure 2). Please reinstall before continuing with installation.
7. Bolt the Grille Guard to the Top Clamp Brackets with (2) 10mm x 40mm Hex Bolts, (4) 10mm x 20mm STD
Flat Washers, (2) 10mm Lock Washers and (2) 10mm Hex Nuts. Snug both Hex Bolts evenly but do not
fully tighten hardware at this time.
8. Carefully slide the Grille Guard side to side to center on the vehicle. Loosen Top Clamp hardware if
necessary. Once the Grille Guard is properly centered, make sure that the bottom tabs on the grille guard
are against the lower bumper cover. Mark the location of the (2) mounting holes in the tabs onto the
bumper cover. IMPORTANT: Before drilling, verify that the Bottom Brackets line up with the back of the air
dam and the lower tabs on the grille guard.
9. Temporarily remove the Grille Guard. Drill (2) 7/16" holes through the cover in line with the bottom
mounting tabs. Reinstall the Grille Guard as described in Steps 5 & 6.
10. Line up the Bottom Mounting Brackets with the tabs on the Grille Guard and the 7/16" holes drilled in Step
9. Bolt the Grille Guard to the Bottom Brackets with (2) 10mm x 30mm Hex Bolts, (4) 10mm x 30mm Large
Flat Washers, (2) 10mm Lock Washers and (2) 10mm Hex Nuts, (Figure 2). Snug both Hex Bolts but do
not fully tighten hardware at this time.
11. IMPORTANT: Slowly close the hood to check for clearance and fit of the Grille Guard and brackets. Adjust
as necessary then snug but do not tighten all of the hardware.
12. Stand back from the vehicle and check to see that the Grille Guard is centered and level on the vehicle and
adjust as necessary. Once properly aligned, tighten all hardware. NOTE: Tighten the (4) 10mm Hex Bolts
evenly to pull the Grill Guard straight and flat against the front bumper. Remove any protective tape used
during installation.
13. Do periodic inspections of the installation to make sure that all hardware is secure and tight.