Zone Offroad T1209 2-Inch Rear Lift Block and U-Bolt Kit

1. Introduction

This manual provides detailed instructions for the proper installation, operation, and maintenance of the Zone Offroad T1209 2-Inch Rear Lift Block and U-Bolt Kit. This kit is designed to provide a 2-inch rear lift for 2005-2020 Toyota Tacoma vehicles, allowing for a slightly tail-high stance and accommodating larger tires. Please read all instructions thoroughly before beginning installation.

2. Safety Information

• Professional installation is highly recommended. If you are not experienced with vehicle suspension work, consult a qualified technician.
• Always wear appropriate personal protective equipment, including safety glasses, gloves, and sturdy footwear.
• Ensure the vehicle is parked on a level, stable surface. Use wheel chocks on the front wheels to prevent movement.
• Never work under a vehicle supported only by a jack. Always use appropriately rated jack stands to support the vehicle securely.
• Do not modify any components of this kit. Unauthorized modifications can compromise safety and performance.
• Keep hands and clothing clear of moving parts and pinch points.
• Refer to your vehicle's service manual for specific torque specifications and procedures not covered here.

3. Package Contents

Verify that all components listed below are present and undamaged before beginning installation:

• 2x 2-Inch Rear Lift Blocks (High Carbon Steel)
• 4x U-Bolts
• 8x U-Bolt Nuts
• 8x U-Bolt Washers

This image displays the complete Zone Offroad 2-inch Rear Lift Block and U-Bolt Kit. It includes two black rectangular lift blocks, designed to be placed between the vehicle's axle and leaf springs, and four black U-shaped U-bolts with accompanying nuts and washers, used to secure the assembly. These components are made from high carbon steel and are essential for achieving a 2-inch rear lift.

4. Tools Required

The following tools are typically required for installation:

• Hydraulic Jack
• Jack Stands (appropriately rated)
• Wheel Chocks
• Torque Wrench
• Socket Set (various sizes, including those for U-bolt nuts)
• Wrench Set
• Penetrating Oil (optional, for rusted fasteners)
• Safety Glasses

5. Setup / Installation

Follow these steps carefully for proper installation:

1. Vehicle Preparation: Park the vehicle on a firm, level surface. Engage the parking brake and place wheel chocks securely on the front wheels.
2. Lift Rear of Vehicle: Using a hydraulic jack, carefully lift the rear of the vehicle by the frame until the rear wheels are off the ground. Place appropriately rated jack stands under the frame rails, just forward of the leaf spring mounts, ensuring the vehicle is stable. Slowly lower the vehicle onto the jack stands.
3. Support Rear Axle: Place the hydraulic jack under the center of the rear axle to provide support. Do not lift the vehicle further with the axle jack.
4. Remove Factory U-Bolts: Loosen and remove the nuts from the factory U-bolts on one side of the vehicle. Carefully remove the factory U-bolts and any associated plates.
5. Lower Axle: Slowly and carefully lower the hydraulic jack supporting the axle just enough to create a gap between the leaf spring and the axle perch. Ensure brake lines and ABS wires are not stretched or damaged.
6. Install Lift Block: Place one 2-inch lift block between the leaf spring and the axle perch. Ensure the block is correctly seated and aligned with the locating pins on both the axle perch and the leaf spring.
7. Raise Axle: Slowly raise the hydraulic jack to bring the axle back up, ensuring the leaf spring seats properly onto the new lift block.
8. Install New U-Bolts: Position two new U-bolts over the leaf spring and around the axle/block assembly. Install the provided washers and nuts onto the U-bolt threads.
9. Tighten U-Bolts: Hand-tighten the U-bolt nuts evenly. Then, using a torque wrench, tighten the U-bolt nuts in a crisscross pattern to the vehicle manufacturer's specified torque for U-bolts. (Refer to your vehicle's service manual for exact torque specifications. A common range for U-bolts is 90-120 ft-lbs, but this can vary significantly by vehicle.)
10. Repeat for Other Side: Repeat steps 4 through 9 for the other side of the vehicle.
11. Final Lowering: Once both sides are complete and U-bolts are torqued, carefully remove the jack stands and slowly lower the vehicle completely to the ground.

6. Operating (Post-Installation Checks)

• Alignment: After installation, it is highly recommended to have a professional wheel alignment performed. Lifting the rear of the vehicle can alter suspension geometry.
• Test Drive: Perform a short, cautious test drive to ensure proper handling and no unusual noises.
• Re-torque U-Bolts: After the first 50-100 miles of driving, re-torque all U-bolt nuts to the manufacturer's specifications. This is crucial as components can settle. Check U-bolt torque periodically thereafter.

7. Maintenance

• Regularly inspect all suspension components, including the lift blocks and U-bolts, for any signs of wear, damage, or corrosion.
• Periodically check the torque of the U-bolt nuts, especially after off-road use or heavy loads.
• Keep components clean to prevent buildup of dirt and debris.

8. Troubleshooting

• Unusual Noises (Clunking, Squeaking): Re-check all U-bolt nuts for proper torque. Inspect for any loose components or contact between parts. Ensure lift blocks are seated correctly.
• Uneven Ride Height: Verify that the correct lift blocks were installed on both sides and are properly seated. Ensure U-bolts are tightened evenly.
• Poor Handling: A professional wheel alignment is critical after any suspension modification. If handling issues persist, consult a qualified suspension specialist.

9. Specifications

• Brand: ZONE OFFROAD
• Model: T1209 (Manufacturer Part Number: ZONT1209)
• Lift Height: 2 Inches (Rear)
• Auto Part Position: Rear
• Material: High Carbon Steel
• Included Components: 2" Lift Blocks, U-Bolts
• Compatibility: 2005-2020 Toyota Tacoma
• Item Weight: Approximately 16.8 pounds
• Product Dimensions: Approximately 14.5 x 6.3 x 6.1 inches
• UPC: 711745601710

10. Warranty and Support

For warranty information and technical support, please refer to the official Zone Offroad website or contact their customer service directly. Warranty terms and conditions are subject to the manufacturer's policies.

Zone Offroad Contact Information: Please visit www.zoneoffroad.com for the most current support and contact details.