INSTALLATION INSTRUCTIONS
FOR SIERRA GRILLE GUARD KIT # 295939
AND WRAPAROUND KIT #295938
ON 2003-2007 DODGE RAM HD 2500/3500
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
913380-0607-E
Note: If the vehicle is equipped with a
diesel engine, raise hood and remove (2)
bolts on the oil cooler. It will be necessary to
lift cooler to allow access to frame and bumper
bolts in the next steps.
If vehicle is not diesel, proceed to step #1.
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
3
1
2
1
2
1
2
16
3
16
16
3
16
Air dam
License Plate
Mounting Holes
Cut Notch
Here
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.
2. Loosen and remove factory bolt assembly nuts. Figure at
right is view from under vehicle looking up at frame. The
bolt assembly points away from vehicle frame.
3. If vehicle is diesel, push oil cooler up to access factory
bolt assembly. Remove factory bolt assembly and reinstall with lower mounting brackets (Item #8). Figure at
right is view from under vehicle looking up.
Lower mounting brackets should fit snuggly through
notches in airdam.
3
Bumper
Bumper
Bracket Bolt
Bumper
Oil Cooler
Lower Mounting
Bracket
Factory Bolt
Assembly
4. To mount the Upper Mounting Bracket (Item #10),
remove the nut from the upper factory Bumper
Bracket bolt. Attach the Upper Mounting Bracket to
the Bumper Bracket bolt and tighten the nut back
on. Figure at left is view from above vehicle looking
down.
5. Install Winch Channel (Item #1) into Center Unit (Item #6)
using (4) 3/8” X 1” capscrews (Item #12), (4) 3/8” locknuts (Item #15), and (2) channel gaskets (Item #20).
Note: The following steps may require assistance from
another person. Install all bolts loosely until instructed
to tighten.
6. Lift Center Unit (item #6) into place and align
with Lower Mounting Brackets and attach with
(3) 1/2” x 1-1/2” capscrews (item #13), (1)
gasket (item #21), and (3) locknuts (item #16)
on each side.
7. Attach Upper Mounting Bracket to Center Unit
using (1) 3/8” x 1” capscrew (item #12), (1)
gasket (item #22), and (1) locknut (item #15) on
each side.
4
Lower Mounting
Bracket
Center Unit
Center Unit
Upper
Mounting
Bracket
If installing Grille Guard only, skip steps 8-10.
8. Remove 3/8” bolt that attaches Center Unit to Upper Mounting
Bracket.
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 #11) and lock nuts (Item #14) with gaskets
(Item #19) and washers (Item #18). Re-install 3/8” capscrew
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 #14) with
washers (Item #18). Far end of Headlight Grille units will snap
into Wrap Around units.
5
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 #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.
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 bolts to proper torque values (see
Torque Value chart below).
6
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
7
Item
No. Part No. Qty. Description
1 R-CHANNEL321 1 WINCH CHANNEL 32”
2 R-W929R 1 WRAP AROUND RIGHT
2
3 R-W929L 1 WRAP AROUND LEFT
2
4 R-G929R 1 HEADLIGHT GRILLE RIGHT
2
5 R-G929L 1 HEADLIGHT GRILLE LEFT
2
6 R-P295929 1 CENTER UNIT
7 R-LM929R 1 LOWER MOUNT RIGHT
8 R-LM929L 1 LOWER MOUNT LEFT
9 R-US929R 1 UPPER SUPPORT RIGHT
10 R-US929L 1 UPPER SUPPORT LEFT
11 HCS1/4-20X1 2 HEX CAP SCREW 1/4” X 1”
3
HCS1/4-20X1 8 HEX CAP SCREW 1/4” X 1”
2
12 HCS3/8X1 6 HEX CAP SCREW 3/8” X 1”
13 HCS1/2X1.5 6 HEX CAP SCREW 1/2” X 1-1/2”
14 LNUT1/4-20 8 1/4-20 LOCKNUT
2
15 LNUT3/8-16 6 3/8-16 LOCKNUT
16 LNUT1/2-13 8 1/2-13 LOCKNUT
Item
No. Part No. Qty. Description
18 WASHFLTPL1/4 16 1/4” PLASTIC WASHER
2
19 R-GASKET929W 2 WRAP GASKET (FIVE HOLES)
1 2
20 R-GASKETCHAN 2 CHANNEL GASKET (2 HOLES)
21 R-GASKET929L 2 LOWER GASKET (3 HOLES)
1
22 GASKETUS 2 UPPER BRKT PLASTIC GASKET
(1 HOLE)
23 R-408127 1 LICENSE PLATE BKT
24 R-LOOM 24” LOOM
25 R-CABLETIE 12 CABLE TIES
1
Not pictured
2
Used with Wraparound Kit #295938 only
3
Used with License Tag Bracket
8
Parts List
6
3
5
1
2
4
9
10
7
8
25
11
13
12
15
14
16
22
18
23
24
20
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