Fab Fours Off Road Bumpers Installation Instructions

Installation Instructions
Chevy Replacement Bumper
Product Number: S2750
Application: ’11 Chevy 2500-3500 HD
SAFETY
Your safety and the safety of others is very important.

In order to help you make informed decisions about safety, we have provided installation
instructions and other information.
 These instructions alert you to potential hazards that could hurt you or others.
 Please do a job safety analysis (JSA) before each task to identify potential hazards for
your situation and remove/protect against them.
 You must use your own good judgment, and take your time.
Read and understand all safety precautions and instructions before installing this product.
THIS PRODUCT IS FOR OFFROAD USE ONLY. ALL LIABILITY FOR INSTALLATION
AND USE RESTS WITH THE OWNER.
CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY
OR EQUIPMENT DAMAGE.
Injury hazard
Failure to observe these instructions could lead to severe injury or death.
 Always remove jewelry and wear eye protection.
 Always use extreme caution when jacking up a vehicle for work. Set emergency
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brake and use tire blocks. Locate and use the vehicle manufacturers designated
lifting points. Use jack stands.
Always use appropriate and adequate care in lifting components into place.
Always insure components will remain secure during installation and operation.
Always wear safety glasses when installing this kit. A drilling operation will
cause flying metal chips. Flying chips can cause serious eye injury.
Always use extreme caution when drilling on a vehicle. Thoroughly inspect the
area to be drilled (on both sides of material) prior to drilling, and relocate any
objects that may be damaged.
Always use extreme caution when cutting and trimming during fitting.
Always tighten all nuts and bolts securely per installation instructions.
Always route electrical cables carefully. Avoid moving parts, components that
become hot and rough or sharp edges.
Always insulate and protect all exposed wiring and electrical terminals.
Always perform regular inspections and maintenance on mounts and related
hardware.
Copyright 2010 Fab Fours, Inc.
Page 1 of 10
Installation Instructions
Chevy Replacement Bumper
Product Number: S2750
Application: ’11 Chevy 2500-3500 HD
I. Overview
Congratulations on your purchase of the industries’ best and most stylish Chevy
Replacement Bumper! This bumper has been engineered for strength while keeping
the weight down.
Your bumper was designed in 3-D from digitized data, CNC laser cut, fabricated,
and powder coated… all in the U.S.A.
Enjoy the fit and finish of a quality Chevy Replacement Bumper from Fab Fours Inc!
Copyright 2010 Fab Fours, Inc.
Page 2 of 10
Installation Instructions
Chevy Replacement Bumper
Product Number: S2750
Application: ’11 Chevy 2500-3500 HD
II. Tools Required
 Socket Wrench With
Extensions
 10mm Socket
 15mm Socket
 18mm Socket
 21mm Deep Socket
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

7/32” Socket
3/4” Socket
18mm Open End Wrench
3/4” Open End Wrench
Phillips Screwdriver
Hammer
III. Vehicle Preparation
1. Detach the splash mat from the body by removing the 3 plastic push clips
from the center splash guard and outer cooling supports.
CLIP
LOCATIONS
Figure 1 – Clip Locations
2. Remove the two screws per side (10mm) connecting the plastic inner fender to
the bumper.
Copyright 2010 Fab Fours, Inc.
Page 3 of 10
Installation Instructions
Chevy Replacement Bumper
Product Number: S2750
Application: ’11 Chevy 2500-3500 HD
Figure 2 - Screw Locations
3. Disconnect the wiring harness from both fog lights.
4. Remove the two screws connecting the outer bumper support bar to the body
mount bracket (15mm). Loosen the screw connecting the outer bumper
support bar to the bumper (15mm), allowing it to rotate downward
Figure 3 – Outer Bumper Support Screws
Copyright 2010 Fab Fours, Inc.
Page 4 of 10
Installation Instructions
Chevy Replacement Bumper
Product Number: S2750
Application: ’11 Chevy 2500-3500 HD
5. Remove the two fasteners per tow hook (18mm) and pull tow hook out from
the front of the truck.
6. Remove the two main bumper bracket nuts per side. DO NOT REMOVE
THE BOLT STRIPS WITHOUT SUPPORTING THE BUMPER.
MAIN
BRACKET
NUTS
TOW HOOK
HARDWARE
Figure 4 - Tow Hook and Main Bracket Hardware
7. With the weight of the bumper supported, remove the stud plates and pull the
bumper forward away from the truck. Save stud plates and nuts for reuse.
Copyright 2010 Fab Fours, Inc.
Page 5 of 10
Installation Instructions
Chevy Replacement Bumper
Product Number: S2750
Application: ’11 Chevy 2500-3500 HD
IV. Bumper Installation
NOTE: The Following Installation steps apply to the installation of the Bumper
to the vehicle. PLEASE READ THE ENTIRE MANUAL BEFORE
ATTEMPTING INSTALLATION! Ignoring these steps will increase your
probability of scratching the vehicle during product Installation!
1. Remove the Bumper from the shipping carton. Lay all items out on a blanket
to prevent damage to the powder coating. Install lower guard (IF
INSTALLING A WINCH SEE WINCH TRAY INSTALLATION
INSTRUCTIONS) by rotating it into position from the bottom of the bumper
as shown below. Install three ½” fasteners (Provided in hardware bag labeled
20260-HW) per side with bolt heads facing the inside of the bumper.
Figure 5 - Lower Guard Installation
2. OPTIONAL: If you wish to retain the stock fog lamps, remove the lights
from the stock bumper and reinstall using OEM hardware in the provided
brackets behind the protective mesh. It may be necessary to remove the
adjuster screw prior to installation. With the fog light clipped in the bracket,
reinstall the adjuster screw to clamp the light in place.
Copyright 2010 Fab Fours, Inc.
Page 6 of 10
Installation Instructions
Chevy Replacement Bumper
Product Number: S2750
Application: ’11 Chevy 2500-3500 HD
3. OPTIONAL: If installing your bumper with D-ring shackle mounts, they
should be placed inside the bumper mounting brackets before final
installation. Insert the shackle mounts from the front of the bumper as shown
below.
Figure 6 - Shackle Bracket Installation
4. OPTIONAL: If installing the 2” receiver hitch accessory, attach it to the
bumper with the provided ½” hardware
Figure 7 - Hitch Installation
Copyright 2010 Fab Fours, Inc.
Page 7 of 10
Installation Instructions
Chevy Replacement Bumper
Product Number: S2750
Application: ’11 Chevy 2500-3500 HD
5. Install intermediate brackets in the orientation shown below (larger offset to
the outside of the truck) using the OEM mount locations. Stud plates should
point toward the inside of the truck for ease of tightening. Install supplied ½”
bolts in the tow hook mounting holes. DO NOT TIGHTEN UNTIL BUMPER
ASSEMBLY HAS BEEN INSTALLED AND ALIGNED.
Figure 8 - Intermediate Bracket Orientation
6. Lift bumper and align mounting slots with the mating slots on the intermediate
mounts. Install ½” mounting bolts but do not tighten fully. Repeat for other
side. It may be helpful to support bumper with a floor jack(s) during install.
7. Adjust the bumper to achieve good visual alignment. Adjust and up/down and
left/right alignment with the mount-to-bumper bolts. Adjust in/out alignment
with mount to frame bolts.
8. Tighten all fasteners; beginning with frame mounts. Then tighten all mountto-bumper fasteners.
9. Trim inner-fender liners to match bumper if desired.
Copyright 2010 Fab Fours, Inc.
Page 8 of 10
Installation Instructions
Chevy Replacement Bumper
Product Number: S2750
Application: ’11 Chevy 2500-3500 HD
Install the Supplied Tow Hooks in the orientation shown below (Open to the inside and
on the outside of the brace) using the supplied ½”-13 bolts, washers, and nuts.
Copyright 2010 Fab Fours, Inc.
Page 9 of 10
Installation Instructions
Chevy Replacement Bumper
Product Number: S2750
Application: ’11 Chevy 2500-3500 HD
V. Maintenance/Care
 Periodically check and tighten all fasteners.
 Stripped, fractured, or bent bolts or nuts need to be replaced.
More than expected… Better than expected
Copyright 2010 Fab Fours, Inc.
Page 10 of 10