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105968A0

I N S T A L L A T I O N I N S T R U C T I O N S

Figure 13

Figure 12

Figure 14

10. Route the factory wiring harness to new bumper.

NOTE:

Be sure that the wiring harness will not interfere with

winch operation. It may be necessary to extend portions

of the wiring harness.

11. Install sensors into the correct sensor carriage in the new

bumper.

NOTE: Be sure sensors match the orientation of

the stock bumper.

12. Secure the front mounting brackets (A4 and A5) to the

new bumper by installing six bolts (B5) with six washers

(B3) into the mounting hole and secure with six washers

(B3) and nuts (B4) and (

each bracket

NOTE: Ensure that

the bolts are at the top of the slots in the bumper in order

to move the brackets as high as possible relative to the

bumper.

13. Line up crossmember (A3) with brackets.

14. Using a 19mm socket and wrench, loosely mount the

crossmember to the mounting brackets and bumper

by installing 8 bolts (B5) with 8 washers (B3) into the

mounting hole and securing with 8 washers (B3) and

nuts (B4).

CAUTION

Always use assistance when moving or lifting heavy parts.

NOTE: For the next step we recommend getting assistance

from one or two more people.

15. With assistance, line up the bumper/crossmember

assembly to the vehicle bumper mounting holes.

NOTE:

The tabs on the back of the crossmember should slide

over the vehicle frame pad.

16. Using a 19mm socket and wrench, secure the bumper

& crossmember assembly to the vehicle by installing six

bolts (B5) with six washers (B3) into the mounting holes

and secure with six washers (B3) and nuts (B4) and (

each

side

17. Insert one spacer (A2) between the crossmember’s

corner tab and the vehicle frame (each side).

18. Insert one bolt (B6) up through crossmember’s tab, the

spacer and the vehicle’s mounting hole. Repeat for other

side.

19. Tighten

all

bumper hardware now, refer to torque

specifications on page 3.

B5, B4, B3

Tab

B5, B3, B4

Spacer

B5, B4, B3

Figure 11

Содержание 103638

Страница 1: ...your winch and its operations Never work under vehicle before properly securing vehicle Always use appropriate and adequate care in lifting components into place Never work under vehicle before properly securing vehicle Always use appropriate and adequate care in lifting components into place Never use a jack to support the vehicle Always use jack stands in pairs to support the vehicle Always use ...

Страница 2: ...ve these instructions could lead to minor or moderate injury Part edges may be sharp Always use proper posture lifting technique or get lifting assistance while handling and installing product Read installation and operating instructions thoroughly This product may interfere with driver assist systems such as adaptive cruise control and parking as sist systems that have sensors or cameras installe...

Страница 3: ...L I S T T O R Q U E S P E C I F I C A T I O N S Item PN Description Qty A1 102453 BUMPER 1 A2 103691 SPACER 2 A3 103636 CROSSMEMBER WELDMENT 1 A4 95648 RH MOUNTING BRACKET 1 A5 95643 LH MOUNTING BRACKET 1 A6 100903 LH LIGHT BRACKET 1 A7 100904 RH LIGHT BRACKET 1 A8 94889 LH LIGHT PORT 1 A9 94888 RH LIGHT PORT 1 Item PN Description Qty B1 100661 9 16 LOCKING PLUG 6 B2 102248 1 3 32 PLUG 6 B3 93106 ...

Страница 4: ...move fender liner Using an 8mm socket remove the three screws in fender well Repeat for other side b Remove the two remaining lower screws to release fender liner Repeat for other side c Slide fender line down and out 2 If equipped unplug the wiring harness located in the front left corner of the bumper Figure 1 Fender well bolt Figure 2 Figure 3 ...

Страница 5: ... bumper Repeat for other side CAUTION Always use assistance when moving or lifting heavy parts 4 Carefully remove bumper and set on a clean and stable surface 5 If equipped remove the active air dam a Unplug the motor and remove the four retaining nuts with a 12mm socket see Figure 5 and 6 NOTE The air dam will not be reinstalled with the new bumper Remove nuts Unplug Remove nuts Figure 4 Figure 5...

Страница 6: ...k the location and orientation of each sensor plug TIP Numbering each sensor with tape and marking the top with a paint pen works well 7 Remove the carriages from stock bumper a Squeeze in the two tabs on the side of the carriages and push each carriage out the front of the bumper 8 Release the plastic clips holding the wire harness in place and remove completely 9 From the front of the bumper car...

Страница 7: ...a 19mm socket and wrench loosely mount the crossmember to the mounting brackets and bumper by installing 8 bolts B5 with 8 washers B3 into the mounting hole and securing with 8 washers B3 and nuts B4 CAUTION Always use assistance when moving or lifting heavy parts NOTE For the next step we recommend getting assistance from one or two more people 15 With assistance line up the bumper crossmember as...

Страница 8: ...oded view on page 3 24 The remaining hardware B1 and B2 are to used to install license plate to new bumper 25 Tighten ALL hardware now refer to torque specifications on page 3 26 If not installing a Baja Bar insert plugs B1 into the holes in the top of the bumper CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE READ AND UNDER STAND ALL SAFETY PRECAUTIONS AND OPE...

Страница 9: ...PRODUCT M A I N T E N A N C E C A R E 1 Inspect all parts on the winch winch mount and related hardware prior to each use Replace all hardware that appears rusted or deformed 2 Inspect all nuts and bolts on the winch winch mount and related hardware prior to each use Tighten all nuts that appear to be loose Stripped fractured or bent bolts or nuts need to be replaced 3 Check all cables prior to us...

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