Expedition One
JK WRANGLER FRONT BUMPER INSTALLATION INSTRUCTIONS
December 2007
Before installation check to make sure you have all the hardware.
Read through all of the instructions before you begin installation.
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 Skid, you’ll want to install the winch before you install the Rubi Skidä
Tools: Drill and 1/2" bit metric & standard socket set, & wrenches are all that are needed though ratchet wrenches can help make the job easier.
Parts list
1 Expedition One Trail Series Front Winch Bumper
4 mounting plates w/ 4 nuts welded in each
2 ½" nuts welded to extension rod
Hardware:
10 ½" washers
10 ½" x 1" bolts
Pre-installation Notes
- If you are installing a winch you must install the fairlead before installing the winch.
- If you are installing auxiliary lights for underneath the hoop, you will want to install them before you install the winch.
- The fairlead holes in the bumper may be too small for some fairlead bolts. We recommend swapping out the bolts for a grade 8, 3/8" bolt, or you may choose to drill the holes out for the bigger size if so desired.
Installation
- Remove stock outer bumper and plastic shrouding: 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 will also want to unclip the plastic retainer pieces on the frame that hold the stock light wiring harness on if your vehicle is so equipped. You should be ready now to install your bumper.
- Bumper Test fit- with the stock bumper off you can now test fit your bumper. Before doing so we recommend taping the front face of the fender flairs with masking tape to protect them from bumper contact.
When Putting the bumper on it must be set down on the frame and then slid forward.
1. 
2. 
3. 
Once it’s on you can bolt up a few bolts on each side, making so it is mostly flush against the front mounting plates of the frame. You then want to mark the area in which to drill the holes for the rear mounting of the bumper. It is likely that you will see a small mounting hole originally used for a plastic retainer clip. That matches up with the hole in the bumper. In most cases you can use these as pilot holes. It’s easiest to remove the bumper for drilling, but not a necessity…
Using a ½" bit, drill a hole through the 1st layer or sheet metal. Do not continue into the frame rail.
- Installing the bumper- Once the holes are drilled you can install the bumper. Use 1 washer per bolt on the bolt side. Put all mounting bolts on but DO NOT TIGHTEN until all are on. The nut with the rod extension is used for the rear bolts of the bumper. You can approach it from the top side as shown in the picture below or you may approach from underneath.
If you haven’t already, now is a good time to install the lights. Follow the install instructions that come with the lights.
Installing a Winch
Install the fairlead first!!!
When installing the winch you may note that there is more than 1 set of hole patterns for mounting. Most winches will use the forward most holes that are directly centered with the fairlead opening and fairlead mounting holes. The other pattern(s) are good for hydraulic winch fitments and the Warn Duel Force Power Plant Winch specifically.
:::NOTE::: You may want to come back and check all the bolts in a few weeks or after a nice off road trip. The bolts can loosen a bit.
Still have questions or having trouble with your install? Email us at info@expeditionone.biz being sure to indicate in your subject that you need install help and we’ll get back to you asap.