Ramsey 295930 User Manual

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INSTALLATION INSTRUCTIONS

FOR SIERRA GRILLE GUARD KIT # 295930

ON 2002-2005 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) 438-6688

http://www.ramsey.com

913368-0105-D

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Note: It is not necessary to remove the airdam in order

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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.

License Plate

Mounting Holes

2. Remove factory bolt assembly and discard.

Air dam

Cut Notch

Here

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3. Use (2) 7/16 x 5” capscrews (Item #9), (2) locknuts (Item #14) and (4) flat washers (Item #17) to install lower mounting bracket (Item #3). Use lower bracket gasket (Item #21). They should be installed in the order shown below.

To mount the Upper Mounting Bracket (Item #5), remove the nut from the Bumper Bracket bolt of the vehicle. Slide the Upper Mounting Bracket and gasket (item #22) 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.

Gasket

Frame

Locknut

Bumper Bracket

(under Bumper)

Upper Mounting

Bracket

Bumper

Lower Mounting

Bracket

Bolt

Washers

Lower Mounting Bracket

4. Install (1) 1/2 x 7-1/2” capscrew (Item #11), (1) lower mount backing plate (Item #19), (2) flat washers (Item #18), and (1) locknut (Item #15) to frame and lower mounting bracket (Item #4).

5. Repeat steps 2 through 4 for right side.

Frame

Capscrew

Backing Plate

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

6. Install Winch Channel (Item #1) into Center Unit (Item #2) using (4) 3/8” x 1” capscrews (Item #8), (4) 3/8” locknuts (Item #13), (8) 3/8” flat washers (Item #16), and (2) channel gaskets (Item #20).

7. Lift Center Unit (Item #2) into place next to Upper Mounting Bracket (Items #5 and #6) and install (1 per side) 3/8” x 1” bolt (Item #8). Tighten with 3/8” lock nut (Item #13) and (2 per side) 3/8” flat washers (Item #16).

8. Rotate Center Unit down so that (3 each per side) 1/2” x 1-1/2” bolts (Item #10) can be installed through Center Unit and Lower Mounting Bracket. Fasten with (3 per side) 1/2” lock nuts (Item #15) and (6 per side) 1/2” flat washers (Item #18)

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

Upper

Mounting

Bracket

Center

Unit

9. If needed, install License Plate Bracket (Item #23) to underside of Winch Channel (Item #1) using (2) 1/4” x 1” capscrews (Item #7) and locknuts (Item #12). Attach License Plate to License Plate Bracket using (2) 1/4” x 1” capscrews.

10. Align and tighten all capscrews to proper torque

before installing winch. See Torque Value Chart below.

11. 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.

12. Install the winch in the Channel Assembly according

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

13. Refer to Winch owner’s manual for instructions on

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

14. Push battery cable into loom (Item #24) and slide

loom up cables as close as possible to mounting frame assembly. Secure using cable ties (Item #25) at each end of loom. To improve appearance, wrap ends of loom with electrical tape.

Vehicle

Bumper

15. 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.

16. Place end of wire rope through fairlead and attach clevis hook. Use clevis pin and cotter pin (furnished with winch).

17. Tighten all remaining capcrews to proper torque values (see Torque Value chart below).

Torque Value Chart

Bolt Torque, Torque, Size

1/4 5 ft-lbs 7 Nm 3/8 34 ft-lbs 46 Nm 7/16 31-35 f 1/2 87 ft-lbs 118 Nm

ft-lbs. Nm

Winch

Channel

t-lbs 42-48 Nm

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Parts List for Kit # 295930

Item

No. Part No. Qty. Description

R-CHANNEL32 1 WINCH CHANNEL 32”

1 2 R-P-929 1 CENTER UNIT

R-LM-929-R 1 LOWER MOUNT RIGHT

3 4 R-LM-929-L 1 LOWER MOUNT LEFT

R-US-899-R 1 UPPER SUPPORT RIGHT

UPPER SUPPOR

R-US-899-L

S1/4-20X1

S3/8X1.25

S7/16X5

S1/2X1.5 6 HEX CAP SCREW 1/2” X 1-1/2”

HCS1/2X7.5 2 HEX CAP SCREW 1/2” X 7-1/2”

LNUT1/4-20 2 1/4-20 LOCKNUT

12 13 LNUT3/8-16 6 3/8-16 LOCKNUT 14 LNUT7/16 4 7/16 LOCKNUT

1 2 HEX CAP SCREW 1/4” X 1” 6 HEX CAP SCREW 3/8” X 1” 4 HEX CAP SCREW 7/16” X 5”

T LEFT

Item

No. Part No. Qty. Description

LNUT1/2-13 8 1/2-13 LOCKNUT

15 16 WASHFLAT3/8 12 3/8” FLAT WASHER

WASHFLAT7/16 8 7/16” FLAT WASHER

17 18 WASHFLAT1/2 16 1/2” FLAT WASHER

BP278 2 LOWER MOUNT BACKING PLATE

CHANNEL GASKET (2 HOLES)

R-GASKETCHAN

R-GASKET929L

LOWER PLASTIC GASKET

(3 HOLES) * UPPER BRKT PLASTIC GASKET

GASKETUS

(1 HOLE)

R-LICENSE 1 LICENSE PLATE BKT

R-LOOM 24” LOOM

24 25 R-CABLETIE 12 CABLE TIES

* Not Pictured