Installation Manual 2 Box Contents 1 3 2 4 5 6 7 (Images not shown to scale) 1.) Bumper 2.) Side Bumper Brackets 3.) Vertical Bumper Plate 4.) Lower Bumper Weldment 5.) Side Bumper Weldments 6.) Side Strap Brackets 7.) Hat Brackets
Installation Manual 3 Hardware ITEM NO. DESCRIPTION MATERIAL QTY. IMAGE 1 5/16-1 SERRATED FLANGE NUT STEEL, ZINC 4 2 3/4" WEDGE WASHER IRON, GALVANIZED 3 4 5 3/-16 X 1 1/4 HHCS (FULLY THREADED) 3/ LOCK WASHER (.35/.6/.094) 3/ SAE FLAT WASHER (.406/.13/.055-.00) 16 6 1/2-13 HEX NUT 7 1/2 SAE FLAT WASHER (.532/1.063/.074-.121) 5/16-1 HEX NUT 4 9 1/2 LOCK WASHER (.512/.69/.125min) 10 11 12 13 14 15 16 5/16 SAE FLAT WASHER (.344/.6/.055-.00) 5/16 LOCK WASHER, HD SPRING LOCK (.322/.53/.07 min) 1/2 USS FLAT WASHER (.563/1.375/.097-.121) 12 4 5/16-1 X 1 1/4 HHCS (FULLY THREADED) 4 5/16-1 X 1 HHCS 4 1/2-13 X 1 3/4 HHCS (FULLY THREADED) 3/-16 SERRATED FLANGE NUT 17 3/-16 X 1 HHCS (FULLY THREADED) (Images not shown to scale)
Installation Manual 4 Installation Steps 1.) Remove the front bumper fascia and pull it away from the vehicle: a. Remove the front license plate holder by drilling out the plastic rivets with a drillbit. b. Remove all external bolts and clips that hold the front bumper fascia to the vehicle. c. Using a 10mm extended socket & impact gun, remove the 3 hidden driver and passenger side inside wheel well bolts that hold the bumper fascia to the vehicle. i. Use impact for top 2 bolts, and a hand wrench for the last bottom bolt. d. Pull the fascia away from the vehicle and set it to the side on a soft surface. 2.) Cut the driver and passenger side bumper mounting holes in the front bumper fascia: a. From the inside of the bumper fascia, with a white paint marker, mark the following lines on both the driver and passenger side fog light covers: i. Mark area vertically from the inner lower edge of the fog light cover to the bottom edge of the fog light cover with a line roughly measuring 3 1/ long. ii. Continue a horizontal line from each edge of the first vertical line for roughly 1 3/4 towards the outside edge of the bumper.
Installation Manual 5 iii. Mark the final line connecting the two horizontal lines to form a skewed rectangle and repeat on the other side as seen in the example image. b. Drill a hole in each corner of the marked cutting area to prepare for cutting on both the driver and passenger sides of the bumper fascia, as shown below: c. With an air saw, using the 4 holes you previously drilled as a helpful guide, cut along the drawn lines to create the rectangular openings on the driver and passenger side. 3.) Cut away the lower bumper fascia grill to allow for lower weldment mounting: a. Using a pair of snips, cut away the following grill pieces to make way for the lower weldment to match the example below:
Installation Manual 6 4.) Attach the driver and passenger side bumper brackets: a. Remove and save the factory bumper bolts on both the driver and passenger sides of the vehicle bumper. b. Using the factory bolts, install the driver and passenger side bumper brackets onto the vehicle bumper. Each side bumper bracket is marked with a D or P to designate the side in which to install. 5.) Attach the vertical bumper plate to the bumper using the driver and passenger side hat brackets: 1 2 3 4 5 6 7 a. Slide the vertical bumper plate down from the top, behind the vehicle bumper and in front of the radiator, until the upper lip of the plate sits on the top of the bumper.
Installation Manual 7 b. Center the plate by measuring 13-13/16 from the passenger side edge of the first factory bumper angle to the edge of the plate. c. Insert the top (4) 3/-16 X 1 HHCS along with (4) 3/ SAE Flat Washer and (4) 3/-16 Serrated Flange Nut from the back of the plate, pushing out towards the front of the vehicle. d. Place both the driver and passenger side hat brackets onto the factory bumper by lining up the top of the brackets with the top 4 bolts (some force may be required due to vehicle manufacturing variations). e. Once brackets are in place, hand-tighten the top 4 bolts. f. Insert the bottom (4) 3/-16 X 1 HHCS along with (4) 3/ SAE Flat Washers and (4) 3/- 16 Serrated Flange Nuts from the back, through the hat bracket and hand-tighten. g. Double check measurement from the passenger side edge of the factory bumper to the vertical plate to ensure that it still measures 13-13/16 and adjust as needed. h. Use a 9/16 socket and impact gun to tighten all () 3/-16 X 1 HHCS connecting the hat brackets to the vertical bumper plate to complete installation of the vertical plate. 6.) Attach both the driver and passenger side strap bracket to the top of the vertical plate by hand tightening (4) 5/16-1 X 1 1/4 HHCS () 5/16 SAE Flat Washers (4) 5/16 Lock Washers, HD Spring Lock (4) 5/16-1 Hex Nuts 1 2 3 4
Installation Manual 7.) Remove the factory splash guard: a. Remove the 3 factory mm bolts holding the splash guard in place and save them. b. Set the guard to the side as it will be reinstalled..) Re-attach fascia to vehicle: a. With the help of a second installer, re-attach the font bumper fascia to the vehicle taking care to allow the fascia to slide over and through the driver and passenger side strap brackets. b. Using a 10mm extended socket and impact gun, replace the 3-10mm bolts on both the driver and passenger wheel wells 9.) Attach the driver and passenger side bumper weldments: LEFT RIGHT
Installation Manual 9 a. Slide the driver and passenger side bumper weldments through the precut front bumper fascia holes. b. Using a 9/16 socket and impact gun, hand tighten the driver and passenger side bumper weldments to the side bumper brackets using (4) 3/-16 X 1 1/4 HHCS, (4) 3/ SAE Flat Washers, and (4) 3/ Lock Washers, and then fully tighten with an impact gun. 10.) Attach the lower weldment to the vertical bumper plate: a. Insert (4) 3/-16 x 1 1/4 HHCS, (4) 3/ SAE Flat Washers, and (4) 3/ Lock Washers through the lower mounting holes of the vertical bumper plate from the back towards the front of the vehicle on each side. b. Slide the lower weldment though the precut holes in the bumper fascia grill. c. Attach the lower weldment to the vertical bumper plate by hand tightening the 4 bolts. d. Secure all 4 HHCS with a 9/16 th wrench.
Installation Manual 10 11.) Replace the factory splash guard: a. Place the factory splash guard in place under the vehicle. b. Using an mm socket and impact gun, replace the splash guard with the 3 factory mm bolts. 12.) Attach the front protective bumper to the vehicle: a. With the help of a second installer, team lift the front protective bumper and place it onto the front of the vehicle aligning as follows: i. Driver and passenger side strap brackets below the top bumper lip. ii. Lower weldment below the bottom bumper edge iii. Driver and passenger side bumper weldments on the top of the bottom bumper edge. b. With a 1/2" wrench, attach the front protective bumper to the driver and passenger side strap brackets using (4) 5/16-1 X 1 HHCS, (4) 5/16 SAE Flat Washers, and (4) 5/16-1 Serrated Flange Nuts.
Installation Manual 11 c. Using a 3/4" wrench, attach the front protective bumper to the lower weldment using (4) HCCS assemblies that contain the following: 1/2-13 HEX NUT 1/2 LOCK WASHER 1/2 USS FLAT WASHER 3/4 WEDGE WASHER (Short side faces away from front of vehicle) 1/2 SAE FLAT WASHER 1/2-13 X 1 3/4 HCCS d. Attach the front protective bumper to the driver and passenger side weldments using 4 of the HHCS assemblies shown above with a 3/4" wrench. 1/2-13 HEX NUT 1/2 LOCK WASHER 1/2 USS FLAT WASHER 3/4 WEDGE WASHER (Short side faces away from front of vehicle) 1/2 SAE FLAT WASHER 1/2-13 X 1 3/4 HCCS 13.) Go back and tighten all bolts to ensure that the bumper is securely attached. 14.) Finish attaching the front fascia to the vehicle by inserting all remaining clips and bolts.
Installation Manual 12 Installation Complete