Zone Offroad D1201 Leveling Kit

1. Introduction

This manual provides essential information for the proper installation, use, and maintenance of your Zone Offroad D1201 Leveling Kit. This kit is designed to provide a front lift to level the stance of your vehicle, accommodating larger tires and improving aesthetic appeal. Please read this manual thoroughly before beginning installation to ensure safe and correct procedures.

For optimal performance and safety, it is highly recommended that installation be performed by a certified professional technician.

2. Safety Information

Always prioritize safety during installation and operation. Failure to follow these guidelines may result in serious injury or damage to your vehicle.

• Professional Installation Recommended: Due to the complexity and safety-critical nature of suspension modifications, professional installation is strongly advised.
• Vehicle Support: Always use appropriate jack stands and wheel chocks to securely support the vehicle before working underneath it. Never rely solely on a jack.
• Personal Protective Equipment: Wear safety glasses, gloves, and other appropriate personal protective equipment (PPE) during installation.
• Tool Safety: Use tools correctly and ensure they are in good working condition.
• Torque Specifications: Adhere strictly to all specified torque values for fasteners. Overtightening or undertightening can lead to component failure.
• Post-Installation Checks: After installation, perform a thorough inspection of all components and re-torque fasteners after the first 500 miles of driving.
• Alignment: A professional wheel alignment is mandatory immediately after installation to prevent premature tire wear and ensure proper vehicle handling.

3. Package Contents

Please verify that all components are present and undamaged before beginning installation. If any parts are missing or damaged, contact Zone Offroad customer support immediately.

Image 3.1: Components of the Zone Offroad D1201 Leveling Kit. Shown are two black, powder-coated steel leveling spacers, along with a set of zinc-plated bolts, flat washers, and nuts required for installation.

• (2) Front Leveling Spacers (Black, Powder-Coated Steel)
• (4) High-Strength Bolts
• (4) Flat Washers
• (4) Lock Nuts
• (1) Instruction Sheet (this document)

4. Setup and Installation

This section provides a general overview of the installation process. Refer to the detailed instruction sheet included with your kit for vehicle-specific steps and torque specifications.

4.1. Pre-Installation Steps

1. Park the vehicle on a flat, level surface.
2. Engage the parking brake and chock the rear wheels.
3. Loosen the front wheel lug nuts.
4. Lift the front of the vehicle using a suitable jack and support it securely with jack stands under the frame rails.
5. Remove the front wheels.

4.2. Installation Procedure (General)

1. Carefully disconnect necessary suspension components (e.g., sway bar links, brake line brackets) to allow the lower control arm to drop sufficiently.
2. Remove the factory strut assembly from the vehicle.
3. Install the Zone Offroad leveling spacer on top of the factory strut assembly, aligning the bolt holes.
4. Reinstall the strut assembly with the attached spacer into the vehicle, ensuring all bolts are properly aligned.
5. Reconnect all previously disconnected suspension components.
6. Torque all fasteners to the manufacturer's specified values. Refer to your vehicle's service manual or the detailed kit instructions for specific torque settings.
7. Repeat the process for the other side of the vehicle.

4.3. Post-Installation

1. Reinstall the front wheels and torque lug nuts to factory specifications.
2. Lower the vehicle completely.
3. Bounce the front of the vehicle several times to settle the suspension.
4. Mandatory Wheel Alignment: Drive the vehicle to a professional alignment shop immediately for a full wheel alignment. This is crucial for proper handling and tire longevity.

5. Usage Considerations

After installing the leveling kit, be aware of potential changes to your vehicle's dynamics.

• Ride Quality: While designed to maintain factory ride quality, minor changes may be perceived depending on the vehicle and existing suspension condition.
• Tire Clearance: The primary benefit is increased front tire clearance. Ensure any new, larger tires clear all suspension and body components throughout the full range of steering and suspension travel.
• Headlight Aim: The front lift may alter headlight aim. Adjust headlights as necessary to avoid blinding oncoming traffic.

6. Maintenance

Regular inspection and maintenance will ensure the longevity and safe operation of your leveling kit.

• Initial Re-torque: Re-torque all fasteners associated with the leveling kit and suspension components after the first 500 miles of driving.
• Periodic Inspection: Inspect all components of the leveling kit and surrounding suspension parts every 5,000 to 10,000 miles, or during routine vehicle maintenance. Check for signs of wear, damage, or loose fasteners.
• Cleaning: Keep the components clean from excessive dirt and debris, especially after off-road use.

7. Troubleshooting

If you encounter issues after installation, consider the following common troubleshooting steps:

If issues persist, contact Zone Offroad customer support or a qualified automotive technician.

8. Specifications

9. Warranty Information

Zone Offroad products are backed by a manufacturer's warranty against defects in material and workmanship. Specific warranty terms and conditions may vary. Please refer to the official Zone Offroad website or contact their customer service for detailed warranty information and registration procedures.

10. Support

For technical assistance, installation questions, or to report missing/damaged parts, please contact Zone Offroad customer support directly. Have your product model number (D1201) and purchase information ready when contacting support.

Zone Offroad Official Website: www.zoneoffroad.com (Example link, actual link may vary)