Expedition Front Bumper Instructions QTY 3D PN. FCS PART NUMBER DESCRIPTION 1 691256 A 8 E X D - 1 7 B 635-AAPLN FRONT BUMPER REPLACEMENT HARDWARE SUPPLIED 10 SELF TAPING SCREWS -10 for Front Bumper PLASTIC CLIPS NOTE: IF VEHICLE IS EQUIPPED WITH FACTORY INSTALLED RUNNING BOARDS NON-POWER OR POWER RUNNING BOARDS YOU HAVE THE OPTION OF REMOVING THEM AND INSTALLING THE 3DCARBON SIDE SKIRTS. IF YOU CHOOSE TO NOT REMOVE YOUR RUNNING BOARDS, PLEASE SKIP THE SIDE SKIRT SECTION OF THESE INSTRUCTIONS. TOOLS & MATERIALS REQUIRED - Philips Edge Screw Driver - Phillips Screw Tip - 90 Degree Angle Screw Gun (if possible) - Clean Wiping Cloths - Air or Electric Drill Motor 1/8 Drill Bit - Lacquer Thinner - Grease Pencil - Grinder For Exhaust Extension installation only CAUTION!!!! IF A HEATED SPRAY BOOTH IS USED FOR BAKING THE PRIMER OR PAINT, DO NOT BAKE OR CURE GREATER THAN 120 F DEGREES FARENHEIT. THE PARTS CAN BE DISTORTED AND PERMANENTLY DAMAGED.
PREPPING THE KIT PRIOR TO PAINT The first step is to inspect the parts to make sure you have the correct parts. Refer to the part numbers on the back of the parts to confirm the Year Make Model. Parts that are prepped and painted cannot be returned or exchanged. Using lacquer thinner and a clean cloth clean the tape flange surface on the back of each part where the double sided tape will be applied. Using 1 masking tape, apply the tape 1/8 below the top edge of the part. This will protect the tape flange from getting contaminated during the prepping and painting process. Refer to Prepping and Painting Instructions for Step by Step procedures. APPLYING THE 3M TAPE TO THE KIT After the kit has been prepped and painted, the double face tape should be applied to the parts. The tape is not preinstalled on parts prior to shipping because the tape can be contaminated during the sanding/ priming and painting process. The first step is to clean the tape flange on the back of the parts where the tape will be applied. Make sure the complete tape flange is clean and free of all primer and paint. Using lacquer thinner on a clean rag, thoroughly clean the tape flanges on all parts of the kit. Using the adhesion promoter bottle with felt tip supplied, apply it to the tape flanges be careful not press too hard causing too much to be applied. The adhesion promoter will leave a thin clear polymer primer film that will increase the bonding strength of the double face tape. IMAGE #1 The tape should be applied 1/8 down from the top edge of the part so that it cannot be seen after the kit is installed. The tape should be applied to the flange of each part. Press the tape firmly to the surface to insure good adhesion of the double faced tape. (See Images #1-2) IMAGE #2 Repeat the cleaning and adhesion promoter steps on all parts of the kit.
INSTALLING THE FRONT AIR DAM HARDWARE SUPPLIED 10 SELF TAPING SCREWS PLASTIC CLIPS IMAGE #3 Step 1) Locate and remove all factory clips. There are (12) black plastic clips located on the plastic cover. (See Images #3-4) IMAGE #4 Step 2) After removing the clips, remove the plastic cover. Locate and remove the (4) T30 screws that secure the factory grille to the vehicle. (See Images #5-6) IMAGE #5 Step 3) Locate and remove the black plastic clip on the sides of the factory grille. (See Image #7) IMAGE #6 IMAGE #7
Step 4) Locate and remove the (2) 10mm bolts that secure the front bumper to the fender. (See Image #8) IMAGE #8 Step 5) Locate and remove the (2) 7mm screws that secure the front bumper to the inner fender well. (See Images #9-10) IMAGE #9 Step 6) Locate and unplug and unbolt the factory fog lights from the factory front bumper. DO NOT DISCARD These will be re-installed on the new 3dCarbon bumper. IMAGE #10 Step 7) Locate the (2) factory brackets that secure the bottom of the bumper to the reinforcement and remove the clip. (See Image #11) IMAGE #11 Step 8) Remove the bumper from the vehicle and place it on a clean, soft working surface. Step 9) Remove the black impact absorber from the bumper. Do not discard. This will be re-installed on the new 3dCarbon front bumper. (See Image #12) IMAGE #12
Step 10) Remove the factory front grille. Locate and remove the metal clips that secures the front grille to the factory bumper. Do not discard these clips. They will be re-installed on the new 3dCarbon front bumper. (See Images #13-14) IMAGE #13 Step 11) Locate the (2) brackets on either end of the bumper and remove by drilling out the existing pop rivet. DO NOT DISCARD These will be reinstalled on the new 3dCarbon bumper. (See Image #15) IMAGE #14 IMAGE #15 Step 12) Locate and remove the fender flare extensions on the factory bumper. DO NOT DISCARD These will be re-installed on the new 3dCarbon bumper (See Image #16) IMAGE #16 Step 13) Take the impact absorber removed in Step 9 and place it in the new 3dCarbon front bumper. Secure it to the bumper using the clips supplied. (See Images #17-18) IMAGE #17
IMAGE #18 Step 14) Install the aluminum mesh grille. Place aluminum mesh grille on the new 3Carbon grille bumper (See Image #19). Note: The grille fits between the bumper and the black impact absorber. (See Image #20) IMAGE #19 IMAGE #20 Step 15) Secure the aluminum mesh grille to the bumper using the supplied coarse plastic screws and washers. (See Images #21-22). IMAGE #21 IMAGE #22 Step 16) Place the bumper right side up and place the clips through the bumper and into the plastic impact absorber. When placing the plastic clips through the bumper, be sure to align the mesh and the plastic absorber so that the pre-drilled holes line up.(see Image #23 & 24) IMAGE #23
IMAGE #24 Step 17) Correct installation of the mesh grille is shown below. (See Image #25 & 26) IMAGE #25 IMAGE #26 Step 18) Install the factory fog lights onto the 3dCarbon bumper. (See Image #27) IMAGE #27 Step 19) Re-install the upper grille onto the new 3dCarbon bumper by sliding it in through the tabs on the lower grille. (See Images #28) After the grille has been properly installed, re-install the locking clips removed in step 10 onto the locking tabs in the same location as previously removed. (See Image #29) IMAGE #28 IMAGE #29
Step 20) Reinstall the fender end brackets previously removed in step 11. Secure these to the new 3dCarbon bumper with the supplied pop rivet and washer as seen in image #30 & 31. IMAGE #30 IMAGE #31 Step 21) Reinstall the factory fender flare extensions previously removed in step 12. First, place the fender flare onto the 3dCarbon bumper and check the fit and align the flare.(see Image #32). Once properly aligned, place the plastic washers onto the mounting points and secure using the factory nuts. (See Image #33-34) Do not over tighten because this may cause them to strip. IMAGE #32 IMAGE #33 IMAGE #34
Step 22) Once the fender flare extensions are installed, use the supplied ¾ washer and slide it in between the fender flare and the bumper as seen in image #35. Proper installation is shown in image #36. IMAGE #35 IMAGE #36 Step 23) Locate the bumper reinforcement ends on the vehicle. Using the supplied trim-lock rubber, install the rubber on the ends of the reinforcement. (See Images #37-38) IMAGE #37 IMAGE #38 Step 24) Re-install the 3dCarbon bumper back onto the vehicle as previously removed. Check to ensure that all clips removed in the original factory bumper removal are properly re-installed. Step 25) Locate the factory bolt and place the supplied bracket onto the underside of the bumper. Tighten the bracket but be sure not to over tighten as it may distort the bracket. (See Image #39) IMAGE #39 Step 26) Install the supplied clips on the bottom of the bumper. Push the clips through the bumper and into the brackets. (See Image #40). IMAGE #40 3DCARBON BODY KITS CAR BODY KITS