Owners manual

ManualsBrandsFab Fours ManualsAutomotiveFS11-A2652-1 Premium Heavy Duty Winch Front Bumper

Installation Instructions

Ford Winch Bumper

Product Number: A2550-A2652

Application: ’11-Current Ford Super Duty

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

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.

Summary of content (12 pages)

PAGE 1
Installation Instructions Ford Winch Bumper Product Number: A2550-A2652 Application: ’11-Current Ford Super Duty 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.
PAGE 2
Installation Instructions Ford Winch Bumper Product Number: A2550-A2652 Application: ’11-Current Ford Super Duty I. Overview Congratulations on your purchase of the industries’ best and most stylish Ford Winch Bumper! This bumper has been engineered for strength while keeping the weight down. It can accept the Warn 16.5 winch… and look cool doing it. This product has also been engineered to allow alignment in three directions plus “castor” so you will end up with a very professional fit.
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Installation Instructions Ford Winch Bumper Product Number: A2550-A2652 Application: ’11-Current Ford Super Duty II. Tools Required  Test Light or Multi-Meter  Socket Wrench With Extension  5/32” Allen Wrench  1/8” Allen Wrench  18mm Socket  15mm Socket        13mm Socket 3/4” Socket 3/4” Open End Wrench 7/16” Open End Wrench 3/8” Open End Wrench 7/32” Socket Phillips Screwdriver III. Vehicle Preparation 1.
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Installation Instructions Ford Winch Bumper Product Number: A2550-A2652 Application: ’11-Current Ford Super Duty 5. Remove OEM bumper assembly and set aside. 6. (If Equipped) Remove the under-run guards from both frame rails with an 18mm Socket. Save this hardware for later use. SAVE THIS HARDWARE FOR REUSE Figure 2 - Under-run Hardware 7. Remove the bumper mount / tow hook assembly from both frame rails using a 15mm socket. Save this hardware for later use.
PAGE 5
Installation Instructions Ford Winch Bumper Product Number: A2550-A2652 Application: ’11-Current Ford Super Duty IV. Lights and Wiring Installation 1. Remove headlights following procedure in owners manual. On each side, tap into the three turn indicator wires using supplied tap connectors (reference the wiring diagram). 2. Connect supplied turn indicator wiring harnesses to factory wires using supplied tap connectors; See below for wire color guide. 3. Replace headlights in reverse order of removal. 4.
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Installation Instructions Ford Winch Bumper Product Number: A2550-A2652 Application: ’11-Current Ford Super Duty 8. Install the light inserts with turn indicators into the cutout in the bumper. Use the ¾” length ¼” stainless steel button head, ¼” washers and hex nuts to fasten the insert through the holes shown below: Figure 5 – Light Insert Installation 9. Install the Fab Fours fog lights onto the mounting brackets as shown below using the #8 button head screws, washers, and nylock hex nuts.
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Installation Instructions Ford Winch Bumper Product Number: A2550-A2652 Application: ’11-Current Ford Super Duty 10. Install the fog light and bracket into the bumper using the remaining two holes available in the light insert. Use the 1-1/2” length ¼” stainless steel button heads with ¼” washers and nylock nuts: Figure 7 - Fog Light Installation 11. Repeat steps 7-10 for other side.  Do not connect wiring harnesses to lights until bumper is installed.
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Installation Instructions Ford Winch Bumper Product Number: A2550-A2652 Application: ’11-Current Ford Super Duty V. Bumper Installation  Optional: If installing winch and roller fairlead into bumper, do it at this time. Follow the winch manufacturer’s instructions for installation. If you are installing a winch with a pulling capacity of 12,000 lbs. or greater, the front face mounting holes must be used.
PAGE 9
Installation Instructions Ford Winch Bumper Product Number: A2550-A2652 Application: ’11-Current Ford Super Duty 2. Insert the provided stud plate assemblies through the back of the bumper mount face as shown below. Figure 9 – Stud Plate Orientation 3. Lift the bumper and carefully inert the studs into the slots on the mounting brackets. With the bumper supported, install four nuts, washers, and lock washers per side onto the studs. DO NOT FULLY TIGHTEN Copyright 2011 Fab Fours, Inc.
PAGE 10
Installation Instructions Ford Winch Bumper Product Number: A2550-A2652 Application: ’11-Current Ford Super Duty Figure 10 – Bumper Installation 4. Adjust the bumper to achieve good visual alignment as follows: 1. Adjust in/out bumper alignment with mounting bracket to frame hardware. 2. Adjust up/down and left/right alignment with bumper to mounting bracket hardware 5. Tighten all fasteners fully; beginning with frame mounts. Then tighten all mount-to-bumper fasteners. 6.
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Installation Instructions Ford Winch Bumper Product Number: A2550-A2652 Application: ’11-Current Ford Super Duty Copyright 2011 Fab Fours, Inc.
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Installation Instructions Ford Winch Bumper Product Number: A2550-A2652 Application: ’11-Current Ford Super Duty VI. Maintenance/Care  Periodically check and tighten all fasteners.  Stripped, fractured, or bent bolts or nuts need to be replaced. VII. Contact Information Fab Fours Inc. 1312 Camp Creek Rd. Lancaster, SC 29720 Phone Fax Email (866)-385-1905 (866)-574-1424 Support@fabfours.com More than expected… Better than expected Copyright 2011 Fab Fours, Inc.