How to Install a Roadmaster Active Suspension with a Winch Plate
If you're adding a Roadmaster Active Suspension (RAS) kit to a vehicle that's also equipped with a winch, the winch plate changes how the installation goes. Understanding what's involved — and what variables shape the outcome — helps you approach the job with realistic expectations.
What a Roadmaster Active Suspension System Does
A Roadmaster Active Suspension is an aftermarket leaf spring enhancement system. It adds a set of pre-loaded bars that connect to the axle and frame, redistributing load forces across the existing leaf spring pack. The result is reduced axle wrap, improved load control, and a more level ride — especially when towing or hauling.
It's a passive system with no electronics, fluid, or moving parts in the traditional sense. That simplicity makes it DIY-friendly compared to airbag or coilover upgrades, but installation still involves working under the vehicle with brackets, U-bolts, and mounting points that vary by make and model.
Where the Winch Plate Complicates Things
On trucks and SUVs with a front-mounted winch, a steel winch plate or winch mounting plate is typically bolted to the frame or integrated into the bumper receiver. This structure can physically conflict with Roadmaster's front mounting points depending on:
- How far forward the winch plate extends
- Whether the plate uses the same frame holes Roadmaster targets
- What clearance exists between the plate and the axle/spring perch area
For rear RAS installations, a rear-mounted winch or spare tire winch carrier can create similar conflicts around the rear axle brackets. Either way, the winch hardware becomes an obstacle that has to be worked around — or temporarily removed — before the Roadmaster components can seat correctly.
General Installation Steps for RAS with a Winch Plate Present
While exact steps depend on your specific vehicle and RAS kit, the general sequence looks like this:
1. Assess Mounting Conflicts Before Ordering
Not all Roadmaster kits fit every chassis. Before purchasing, identify your vehicle's year, make, model, and trim, confirm which axle configuration you have, and determine exactly where the winch plate's mounting hardware sits relative to the frame rail. Roadmaster publishes vehicle-specific fitment guides, and the company has a reputation for responsive technical support.
2. Remove or Reposition the Winch Plate Temporarily
In many cases, the winch plate needs to come off to allow clean access to the frame mounting positions. This isn't a minor step — some winch plates are heavily loaded with hardware and may require disconnecting the winch drum, fairlead, and power leads. Label every connection before disassembly.
If the winch plate is integrated into a full front bumper assembly, you may need to remove the entire bumper to access the Roadmaster mounting points cleanly.
3. Install the Roadmaster Mounting Brackets
Roadmaster kits use frame-mounted brackets and axle clamps that sandwich onto the leaf spring perch. These are installed with the vehicle on a level surface, ideally on jack stands with the suspension at normal ride height. Torque specs matter here — under-torqued U-bolts can allow the bracket to shift under load.
4. Reinstall the Winch Plate
Once the Roadmaster hardware is in place, the winch plate goes back on. At this point, check for clearance conflicts — the Roadmaster bars, brackets, or connecting hardware shouldn't press against the winch plate under full suspension compression or articulation.
If there's contact, spacers or repositioning may be needed. Some installations require drilling new holes or using provided adjustment slots to shift the Roadmaster components slightly.
5. Verify Suspension Travel and Component Clearance
🔧 Before calling the job done, cycle the suspension manually (and later through a test drive) to confirm nothing binds, rubs, or contacts the winch plate, wiring, or hydraulic lines at any point in the suspension's range of motion.
Variables That Affect How This Job Goes
| Variable | Why It Matters |
|---|---|
| Vehicle make/model/year | Determines which RAS kit applies and where brackets mount |
| Winch plate design | Integrated bumper vs. bolt-on plate affects disassembly scope |
| Winch size and weight | Heavier winches mean more disconnection work |
| Frame condition | Rust or prior damage can complicate bracket installation |
| Leaf spring configuration | Single-stage vs. multi-stage packs affect clamp fit |
| DIY vs. shop install | Access to a lift and torque equipment matters significantly |
DIY vs. Professional Installation
This is a job many truck owners do themselves, but it's not a quick afternoon project. You need:
- A floor jack and stable jack stands rated for your vehicle's weight
- Basic hand tools plus a torque wrench
- Confidence working under a loaded vehicle
- Enough space to stage the winch hardware you remove
Labor costs at a shop vary widely depending on region and the complexity of the winch plate removal. Some shops that handle suspension work regularly will have seen this combination before; others won't.
What the Instructions Won't Fully Cover
🛠️ Roadmaster's installation guides are vehicle-specific, but they're written for stock configurations. A winch plate is an aftermarket addition, and no kit documentation accounts for every possible combination of hardware already on the vehicle. That gap — between the generic instructions and your actual truck — is where most of the real problem-solving happens.
Whether that's a minor adjustment or a significant rework depends entirely on what's already bolted to your frame.