Ramsey 295940, 295941 User Manual

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INSTALLATION INSTRUCTIONS FOR SIERRA

GRILLE GUARD KIT # 295940 AND WRAPAROUND KIT #295941

ON 2001-2004 FORD F250/F350/F450/F550 SUPERDUTY

AND 2002-2004 FORD EXCURSION

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

913383-0204-C

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1. Remove vehicle bumper in order to access tow hooks and frame.

2. Remove tow hooks by removing (3) 12mm factory bolts.

3. Remove the three nuts on the underside of the blocker bar as

shown at lower right. Remove blocker bar.

On some models, to remove the blocker bar, remove the four bolts that hold the blocker bar to the bracket as shown below.

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4. While bumper is still removed from vehicle, fasten upper support brackets (item #5 & #6) to vehicle bumper bracket as shown at right using factory hardware.

The outside edges of the upper support brackets should be 32 1/4” or less apart (see figure below).

Tighten bumper bracket hardware to proper torque before re-installing bumper to vehicle. Refer to Torque Value Chart for proper torque.

Note: The outer edges of the upper brackets should be 32 1/4” or slightly less apart and the inner edges of the lower brackets should be 32 7/8” or slightly more apart in order to attach the center unit to them. Because the mounting hardware for these brackets need to be tightened prior to attaching the center unit to them, make sure the spacing is correct before you tighten the mounting hardware. Once the bumper is re-installed, it will not be possible to adjust the mounting hardware for these brackets.

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5. Install lower mounting brackets (Item #3 & #4) to frame

rails at tow hook holes. Use (3) 12mm x 40 mm capscrews (item #9), (3) 1/2” lockwashers (item #15), per side. Tighten hardware before bumper is re-installed. Refer to Torque Value Chart for proper torque.

6. Re-install bumper. Bumper should slip over lower mounting

brackets.

7. Re-install blocker bar.

8. Install winch channel to center unit using (2) 3/8” x 1 cap-

screws (item #8), (2) 3/8” locknuts (item #12), and channel gasket (item #16) on each side. Attach loosely.

9. Install center unit to upper brackets using (1) 3/8” X 1 cap-

screw (item #8), (1) 3/8” locknut (item #12), and upper mounting bracket gasket (item #18) on each side. Attach loosely.

10. Install center unit to lower brackets using (2) 1/2” x 1-1/2

capscrews (item #10), (2) 1/2” locknuts (item #14), and lower mounting bracket gasket (item #17) on each side. Attach loosely.

HOLES FOR WRAPAROUND UNIT

HOLES FOR LITE TUBES

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If installing Grille Guard only, skip steps 11-

13.

11. Remove 3/8” capscrew that attaches Center Unit to

Upper Mounting Bracket.

12. Install Wrap Around Right and Left units (Items #22

and #23) to side plates of center unit using (2 per side) 1/4” capscrews (Item #27) and lock nuts (Item #28) with wraparound gasket (Item #26) and (2 per hole) washers (Item #29). See previous page for location of mounting holes. Re-install 3/8” capscrew and locknut through Upper Mounting Bracket, side plate of Center Section Assembly, and Wrap Around units.

13. Install Headlight Grille Right and Left units (Item #24

and #25) to Wrap Around units and side plates of Center unit using (2) 1/4” x 1-1/4” capscrews (Item #27), and lock nuts (Item #28) with washers (Item #29). Far end of Headlight Grille units will snap into Wrap Around units.

14. Install tow hooks to tapped holes in lower mounting

brackets using (3) 12mm x 50 mm capscrews (item #11) and (3) 12mm hex nuts (item #13) on each side.

15. If needed, install License Plate Bracket (Item #21) to

underside of Winch Channel (Item #1) using (2) 1/4” capscrews (Item # 7).

16. Align and tighten all bolts to proper torque before

installing winch. See Torque Value Chart below.

17. 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.

18. Install the winch in the Winch Channel according to

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

19. 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.

20. Push battery cable into loom (Item #19) and slide loom up cables as close as possible to mounting frame assembly. Secure using cable ties (item #20) at each end of loom. To improve appearance, wrap ends of loom with electrical tape.

21. 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.

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

Bolt Torque, Torque, Size ft-lbs. Nm

1/4-20 5 ft-lbs 7 Nm

3/8-16 34 ft-lbs 46 Nm

1/2-13 87 ft-lbs 118 Nm

12mm 60 ft-lbs 90 Nm

Torque Value Chart

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Parts List

ITEM NO. PART NO. QTY DESCRIPTI ON

1 R-CHANNEL321 1 WINCH CHANNEL 32" 2 R-P295940 1 CENTER UNIT 3 R-LM940R 1 LOWER MOUNT RIGHT 4 R-LM940L 1 LOWER MOUNT LE FT 5 R-US293R 1 UPPER SUPPORT RIGHT 6 R-US293L 1 UPPER SUPPORT LEFT 7 HCS1/4-20X1 2 HEX CAPS CREW 1/ 4 X 1 8 HCS3/ 8X1 6 HEX CAPSCREW 3/8 X 1

9 HCS12MMX40MM 6 HEX CAPSCREW 12mm X 40mm 10 HCS1/2X1.5 4 HEX CAPS CREW 1/ 2 X 1-1/2 11 HCS12MMX50 6 HEX CAPS CREW 12mm X 50 mm COARSE 12 LNUT3/8-16 6 3/8-16 LOCKNUT 13 HEXNUT12MM 6 12mm HEXNUT 14 LNUT1/2-13 4 1/2-13 LOCKNUT 15 LOCKWASHER1/2 6 1/2 SPLIT LOCKWASHER 16 R-GASKETCHAN 2 CHANNEL GASKET (2 HOLES) 17 R-GASKET940LM 2 LOWER BRACKET GASKET (2 HOLES) 18 GASKETUS 2 UPPER BRACKET GASKET (1 HOLE) 19 R-LOOM 1 LOOM 20 R-CABLETIE 1 CABLE TIE 21 R-408127 1 LICENSE P LATE ASSEMBLY

22 R-W941R 1 W RAPAROUND RIGHT 23 R-W941L 1 WRAPAROUND LEFT 24 R-G293R 1 HEADLIGHT GRILL RIGHT 25 R-G293L 1 HEADLIGHT GRILL LEFT 26 R-GASKET294W 2 W RAP S HIM 27 HCS1/4X1 10 HEX CAPS CREW 1/ 4-20 X 1 28 LNUT1/4 10 1/4-20 LOCKNUT 29 WASHFLAT1/4 20 1/4 FLAT WASHERS

ADDITIONAL P ARTS F OR WRAPAROUND KIT #295941