Ramsey 295929 User Manual

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INSTALLATION INSTRUCTIONS

FOR SIERRA WRAP AROUND KIT # 295929

ON 2002-2006 DODGE RAM 1500

Notice

Ramsey kits are designed for use with Ramsey Winches only.

Use or sale of kits for other winches or applications voids warranty.

Warning

Ramsey offers mounting kits and winches for various vehicles. In crash tests on a limited number of automotive manufacturer’s vehicles, winches/mounting kits, which have been properly mounted, have not interfered with air bag operation.

The user/customer, or their installer, must verify that the mounting kit does not interfere with the factory air bag sensors, which must not be relocated or modified in any way.

The user/customer should follow the vehicle manufacturer’s recommendations and those of a qualified mechanic to determine if the winching/mounting kit might interfere with the air bag operation. The user/customer should then determine the suitability of a winch/mounting kit on a particular vehicle.

PLEASE BE ADVISED THAT THE VEHICLE’S AIR BAG SYSTEM MAY NOT OPERATE PROPERLY IF THE WINCH/MOUNTING KIT IS NOT MOUNTED IN COMPLIANCE WITH THE VEHICLE MANUFACTURER’S RECOMMENDATIONS.

DO NOT ATTACH TOW HOOK TO ANY PART OF MOUNTING KIT UNLESS INSTRUCTED TO DO SO.

DO NOT SUBSTITUTE ATTACHING HARDWARE ITEMS (BOLTS, NUTS, OR WASHERS).

READ AND UNDERSTAND WINCH OWNER’S MANUAL BEFORE INSTALLATION AND OPERATION OF THE WINCH. SEE WARNINGS AND CAUTIONS IN WINCH OWNER’S MANUAL.

IMPORTANT NOTES!

1. RIGHT AND LEFT HAND DIRECTIONS AS IF SEATED BEHIND STEERING WHEEL.

2. ALL FASTENING HARDWARE MUST BE LOOSELY ASSEMBLED UNTIL DIRECTED TO TIGHTEN.

RAMSEY WINCH COMPANY

P.O. BOX 581510

TULSA, OKLAHOMA 74158

PHONE: (918) 438-2760 • FAX: (918) 438-6888

http://www.ramsey.com

913367-0307-E

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Note: It is not necessary to remove the airdam in order to modify it or install the kit. The following pictures show the airdam removed for clarity only.

1. Cut notches in air dam for the Lower Mounting Brackets to fit through. Cut 1/2” wide notches from the bottom of the top lip of the air dam, cutting through the bottom lip of the air dam. As shown below, the spacing of the notches is 16 3/16” from center to outside of notch. The best way to measure the center of the air dam is to measure from the License Plate mounting bolt holes. Find the center between the holes, and mark it as your center of the air dam.

The 1/2” width of the notch does not allow any clearance of the bracket that fits through it. You may need to trim it slightly after you have the bracket installed, but you will want the fit as tight as possible.

2. Remove factory bolt assembly and discard.

1 2

Air dam

License Plate

Mounting Holes

Cut Notch

Here

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3. Use (2) 7/16” x 5” capscrews (Item #14) and (2) locknuts (Item #19) and (4) flat washers (Item #23) to install lower mounting brackets (Item #8). Use the lower bracket gasket (Item #28). They should be installed in the order shown below.

To mount the Upper Mounting Bracket (Item #10), remove the nut from the Bumper Bracket bolt of the vehicle. Slide the Upper Mounting Bracket and gasket (item #29) onto the Bumper Bracket bolt and tighten the nut back on.

It is a good idea to install the mounting bracket assembly entirely on one side, then start on the other. Install bolts

loosely—do not tighten until told to do so.

4. Install (1) 1/2” x 7 1/2” capscrews (Item #16), (1) lower mount backing plate (Item #25), (2) flat washers (Item #24), and (1) locknut (Item #20) to frame and lower mounting bracket (Item #8).

5. Repeat steps 2 through 4 for right side.

Bumper

Upper Mounting

Bracket

Lower Mounting

Bracket

Frame

Bolt

Locknut

Gasket

Lower Mounting Bracket

Washers

Bumper Bracket

(under Bumper)

Frame

Capscrew

Spacer

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Note: The following steps may require assistance from another person. Install all bolts loosely until instructed to tighten.

6. Install Winch Channel (Item #1) into Center Unit (Item #6) using (4) 3/8” X 1” capscrews (Item #13), (4) 3/8” locknuts (Item #18), (8) 3/8” flat washers, and (2) channel gaskets (Item #27).

7. Lift Center Unit (Item #6) into place next to Upper Mounting Brackets (Item #9 and #10) and install (1 each per side) 3/8” x 1” bolt (Item #13) through Center Section Assembly and Upper Mounting Bracket. Tighten with (1 per side) 3/8” lock nut (Item #18) and (2 per side) 3/8” flat washers (Item #22) loosely. Rotate Center Section Assembly down so that (3 each per side) 1/2” x 1-1/2” capscrews (Item #15) can be installed through Center Section Assembly and Lower Mounting Bracket. Fasten with (3 per side) 1/2” locknuts (Item #20) and (6 per side) 3/8” flat washers (Item #24).

8. Once Center Unit is bolted to Lower Mounting Bracket, remove

3/8” capscrew that attaches Channel Assembly to Upper Mounting Bracket so that Light Tubes can be installed.

Forks of Center Section Assembly should fit snuggly through notches in air dam from step 5.

9. Install Wrap Around Right and Left units (Items #2 and #3) to

side plates of Center Unit using (2 per side) 1/4” x 1” capscrews (Item #12) and lock nuts (Item #17) with gaskets (Item #26) and washers (Item #21). Re-install cap screw and locknut through Upper Mounting Bracket, side plate of Center Section Assembly, and Wrap Around units.

10. Install Headlight Grille Right and Left units (Item #4 and #5) to Wrap Around units and

side plates of Center unit using (2) 1/4” x 1-1/4” capscrews (Item #11), and lock nuts (Item #17) with washers (Item #21). Far end of Headlight Grille units will snap into Wrap Around units.

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11. If needed, install License Plate Bracket (Item #29) to

underside of Winch Channel (Item #1) using (2) 1/4” x 1” capscrews (Item # 11) and (2) locknuts (Item #17).

12. Align and tighten all bolts to proper torque before installing

winch. See Torque Value Chart below.

13. Install the fairlead using hardware furnished with the

winch. Note that the top holes in the Channel Assembly align with the bottom holes on the roller fairlead.

14. Install the winch in the Winch Channel (Item #1) accord-

ing to mounting instructions in the Winch owner’s manual, using supplied hardware.

15. Refer to Winch owner’s manual for instructions on electri-

cal connections. Be sure battery cables are not drawn taut across any surfaces which could possibly damage them.

16. Push battery cable into loom (Item #31) and slide loom

up cables as close as possible to mounting frame assembly. Secure using cable ties (item #32) at each end of loom. To improve appearance, wrap ends of loom with electrical tape.

17. Plug remote switch into receptacle on top of solenoid.

Run winch forward and reverse to check connections. Snap appropriate “IN” and “OUT” disk into proper thumb cavity, after determining winch operating direction. Do not leave switch plugged in when not in use.

18. Place end of wire rope through fairlead and attach clevis

hook. Use clevis pin and cotter pin (furnished with winch).

19. Tighten remaining capscrews to proper torque values (see

Torque Value chart below).

Upper

Mounting

Bracket

Winch

Channel

Vehicle

Bumper

Center

Unit

Bolt Torque, Torque, Size ft-lbs. Nm

1/4-20 5 ft-lbs 7 Nm

3/8-16 34 ft-lbs 46 Nm

7/16 31-35 ft-lbs. 42-48 Nm

1/2-13 87 ft-lbs 118 Nm

Torque Value Chart

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Item

No. Part No. Qty. Description

1 R-CHANNEL32 1 WINCH CHANNEL 32” 2 R-W929R 1 WRAP AROUND RIGHT 3 R-W929L 1 WRAP AROUND LEFT 4 R-G929R 1 HEADLIGHT GRILLE RIGHT 5 R-G929L 1 HEADLIGHT GRILLE LEFT 6 R-P929 1 CENTER UNIT 7 R-LM929R 1 LOWER MOUNT RIGHT 8 R-LM929L 1 LOWER MOUNT LEFT

9 R-US899R 1 UPPER SUPPORT RIGHT 10 R-US899L 1 UPPER SUPPORT LEFT 11 HCS1/4-20X1 6 HEX CAP SCREW 1/4” X 1” 12 HCS1/420X1.25 4 HEX CAP SCREW 1/4” X 1-1/4” 13 HCS3/8X1.25 6 HEX CAP SCREW 3/8” X 1” 14 HCS7/16X5 4 HEX CAP SCREW 7/16” X 5” 15 HCS1/2X1.5 6 HEX CAP SCREW 1/2” X 1-1/2” 16 HCS1/2X7.5 2 HEX CAP SCREW 1/2” X 7-1/2” 17 LNUT1/4-20 8 1/4-20 LOCKNUT 18 LNUT3/8-16 6 3/8-16 LOCKNUT 19 LNUT7/16 4 7/16 LOCKNUT

Item

No. Part No. Qty. Description

20 LNUT1/2-13 8 1/2-13 LOCKNUT 21 WASHFLTPL1/4 8 1/4” PLASTIC WASHER 22 WASHFLAT3/8 12 3/8” FLAT WASHER 23 WASHFLAT7/16 8 7/16” FLAT WASHER 24 WASHFLAT1/2 16 1/2” FLAT WASHER 25 BP278 2 LOWER MOUNT BACKING PLATE 26 R-GASKET929W 2 WRAP GASKET (FIVE HOLES)* 27 R-GASKETCHAN 2 CHANNEL GASKET (2 HOLES) 28 R-GASKET929L 2 LOWER PLASTIC GASKET

(3 HOLES)*

29 GASKETUS 2 UPPER BRKT PLASTIC GASKET

(1 HOLE) 30 408127 1 LICENSE PLATE BKT 31 R-LOOM 24” LOOM 32 R-CABLETIE 12 CABLE TIES

* Not pictured

Parts List for Kit #295929

1215

1416