Dee Zee DZ500797 - Manual (Page 2)

3” BULL BAR
01-06, 07 "CLASSIC" 1500HD CHEVY SILVERADO/GMC SIERRA
99-06, 07 "CLASSIC" 2500LD CHEVY SILVERADO/GMC SIERRA
99-06, 07 "CLASSIC" 2500LD CHEVY SILVERADO/GMC SIERRA
00-06 2500SUBURBAN
00-06 2500 TAHOE/YUKON, YUKON XL
Page 1 of 3 11/28/11 REV1(DP)
PARTS LIST:
1 Bull Bar 4 10mm Lock Washers
1 Driver/Left Side Mounting Bracket 4 10-1.5mm Nuts
1 Passenger/Right Side Mounting Bracket 4 12-1.75mm x 40mm Hex Bolts
2 Spacer Plates 4 12mm x 44mm OD x 4mm Flat Washers
4 10-1.5mm x 35mm Hex Bolts 4 12mm Lock Washers
8 10mm x 30mm OD x 2.5mm Flat Washers
PROCEDURE:
1. REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT. READ INSTRUCTIONS
CAREFULLY BEFORE STARTING INSTALLATION. PLASTIC BUMPER COVER MAY REQUIRE
CUTTING FOR INSTALLATION.
2. NOTE: It may be necessary to remove/relocate front license plate and license plate bracket. It is not
required, but strongly recommended. If local/state law requires a license plate, license plate relocation
kit is available.
3. Starting at the passenger/right side, remove the two factory bolts and the tow hook if equipped. NOTE:
This Bull Bar is not compatible with factory tow hooks and they cannot be reinstalled.
a. NOTE: Vehicles without tow hooks. Temporarily remove the lower bumper cover and place it
on a clean, stable work surface, (Figure 1).
4. Select the passenger/right side Frame Bracket. Slide the Frame Bracket into the open end of the frame
channel accessible through the opening in the bumper cover for the tow hook, if equipped, (Figure 2).
5. Line up the (2) welded nuts on the Frame Bracket with the (2) factory holes in the bottom of the frame
channel. Insert (1) 12mm x 40mm Hex Bolt, (1) Spacer Plate, (1) 12mm Flat Washer and (1) 12mm
Lock Washer through the large hole in the bottom of the frame channel and into the threaded nut on the
Frame Bracket. Insert (1) 12mm x 40mm Hex Bolt, (1) 12mm Flat Washer and (1) 12mm Lock Washer
into the remaining factory hole in the frame channel. IMPORTANT: Use the (2) Spacer Plates to cover
the large holes in the bottom of the frame channel, (Figure 2). Do not tighten hardware at this time.
6. Repeat Steps 3 - 5 for driver/left side Frame Bracket installation.
7. With assistance, position the Bull Bar up to the inside of the Frame Brackets. Bolt the Bull Bar to the
Frame Brackets using the included (4) 10mm x 35mm Hex Bolts, (4) 10mm Lock Washers, (8) 10mm
Flat Washers and (4) 10mm Hex Nuts, (Figure 2). NOTE: Each mounting tab on the Bull Bar has (3)
slots. Determine the correct mounting position for the Bull Bar.
a. 99-02 Vehicles: Push the Bull Bar in toward the vehicle and bolt the Bull Bar to the Brackets
using the forward and center slots only. Do not tighten hardware at this time.
b. 03-06, 07 "Classic" Model Vehicles: Pull the Bull Bar away from the vehicle and bolt the Bull
Bar to the Brackets using the center and rear slots only. Do not tighten hardware at this time.
8. Level, center and adjust the Bull Bar.
a. Vehicles equipped with tow hooks: Tighten all hardware at this time.
b. Vehicles without tow hooks: Tighten the 12mm hardware bolting the Brackets to the frame
channel only. Temporarily remove the Bull Bar. Hold the lower bumper cover up to the (2)
Frame Brackets. Mark the location of the Brackets onto the back of the plastic bumper cover.
Carefully cut out the indented fill panel in the plastic bumper to clear the (2) Brackets, (Figure
1). For a clean installation, remove as little material as necessary to clear the Brackets. Once
properly cut, reinstall the plastic cover with the factory hardware. Reinstall the Bull Bar and
tighten all hardware, (Figure 2).
9. Do periodic inspections to the installation to make sure that all hardware is secure and tight.