March 2008

Before installation check to make sure you have all the hardware.

Read all Instructions thoroughly before installation.

Required tools:

A shop press, large vice, or good-sized hammer.
A decent socket set.
Open and closed end wrenches.

IMPORTANT INSTALL NOTES:

If you are installing a winch, it is best to do it after the bumper is put on.
If you are also installing an Expedition One Rubi Skidä, install the winch before you install the Rubi Skidä

Hardware List:

Eight ½”x 2” all thread button head allen bolts
Eight ½” nuts
Twelve ½” flat washers
Two ½” lock washers
Two ½”x1-½” (or 12mm x 40mm equivalent bolts) with nuts

Install:

1. Remove stock bumper – First thing to do if you have not already done it is to remove the obnoxious plastic air dam that sits below the stock bumper. This will allow easy access to the bumper bolts. If your vehicle is equipped with the factory fogs, it is easiest to let them remain in the bumper. Undo the wiring plugs on the back of each light. After that, all you need to do is remove the 8 bolts, 2 on the inside and 2 on the outside of each frame rail respectively. Your bumper should be free at this point. You will also want to remove the plastic trim piece that sits under the bumper and grill. It is held on with plastic retaining screws so you have 2 options: 1) Be very careful and slowly with little downward pressure undo the screws and back them out. If that doesn’t work go with the next option, which is usually faster. 2) Get a good grip on the trim piece and yank it off. You should be good now and ready to install your BASIC bumper.

2. Removing the factory recovery hook bolts – If you are following the “standard” install and using the stock tow hooks, you must first remove the big ugly press fit bolts in the hooks. There are a few ways to do this. The recommended way is to get a large vice or press and using a tubular metal piece (a large socket works well), press bolts through. The other, more brutal option is to beat them out with a miniature sledge type hammer (watch your fingers on this one). The first options are going to be the easiest and most effective, but if you need it, a good hammer will work. These bolts can be discarded after removal. They are NOT reused in the installation.

3. Installing the Bumper - Once the bolts are removed you are ready to put your bumper on. Using the eight allen head bolts and nuts, put the tow hooks in between the frame and inside face of the Basic bumper. To make life easier we recommend putting the bumper in place with a few bolts so you don’t have to hold it up the whole time. Easiest method we’ve found is to put 2 bolts in the top holes of the bumper on the inside first, holding them loosely with nuts. On the bottom of the stock tow hooks you will notice they taper in about 1/8”. Use 8 of the ½” flat washers, 2 on each bottom bolt, as shims between the bumper and recovery hooks. Once the bolts on the front face of the bumper are on and roughly tightened, you may now put in the two rear winchmount bolts. The bolt and nut placement should be somewhat obvious. Using a ½” washer on the nut side install the bolts in the winchmount, this will probably require both a socket wrench and regular wrench. Once all bolts are in place you can tighten them to snug. If you are planning on utilizing the stock tow hooks there is no drilling required. Yea! J If you are not, you will have to drill the 2 rear holes.

Still have questions or having trouble with your install? Email info@expeditionone.biz being sure to indicate in your subject that you need install help and we’ll get back to you asap.