CALI RAISED Toyota Tacoma Stealth Bumper Installation Guide

CALI RAISED Toyota Tacoma Stealth Bumper

Product Information

This product is a winch installation kit that allows you to install a winch onto your bumper. The kit comes with all the necessary hardware to install the winch and fairlead. It is compatible with two winch models, Smittybilt and Warns.

Product Usage Instructions

1. Prepare the winch for installation. If you have a Smittybilt winch, it is ready for installation. If you have a Warn winch, remove the controller by removing the 4 allen bolts on the side of the winch that holds the top plate and controller in place. Be careful not to pull it apart. With the top plate removed, flip it over and take out the 4 smaller allen bolts that hold the controller to the top plate. Also, disconnect the wires from the back of the winch, leaving them connected to the controller. Re-install the top plate back on the winch.
2. Install the fairlead using the hardware that comes with the winch and fairlead. Depending on your hardware and fairlead, you may need to install the bolt from the back, to keep this clear, and move the taller nut and washers to the front. Tighten the fairlead hardware in place.
3. Prepare the bumper by putting the winch in place. If the winch line is already installed, ensure it is pushed through the fairlead before tightening in place.
4. Bolt the winch to the bumper using the hardware provided with the winch. For Smittybilt and Warn winches, slide the square nuts into the winch body. Make sure your bumper is on a surface where you can tilt it forward to install the hardware. Push the bolts through the bumper and into the winch. Tighten everything down in place.
5. If you want to install LED mounts inside the bumper, install them first by grabbing a 3/8 bolt, installing a washer, pushing through the bumper and mount, and installing another washer and lock nut. Leave hand tight. Then, install your LED to the mounts. Tighten everything in place.
6. To prep your truck, remove the grill by removing the two bolts on top and the two plastic clips on top. If you have the Safety Sense radar, unplug it and remove the ware clip from the grill. If you have a front license plate, remove it and the mount as well.
7. Remove the black center plastic trim by removing the plastic holders on the far left and right side. Push in the center lever and pull out the pin. After removing the pin, push the center down and pull the trim away, start in one spot and slowly move your way from clip to clip pulling outward slightly on the trim so it doesn’t clip back in place.

HARDWARE

2016+ TACOMA FRONT STEALTH BUMPER HARDWARE

Quantity| Type| Thread| Length| Mat/Type| Finish
Sea| Hex Bolt| 5/16-18| 3/4| Grade 5| Zinc
Sea| Lock Nut| 5/16-18| N/A| Grade 5| Zinc
lOea| Washer| 5/16| N/A| Grade 5| Zinc
3ea| Socket Cap Bollt| M6-1mm| 16mm| Grade 5| Zinc
3ea| Washer| M6| Oversized| Grade 5| Zinc
3ea| Lock Washer| M6| N/A| Grade S| Zinc
2ea| Hex Bolt| 3/8-76| 1| Grade S| Zinc
2ea| Lock Nut| 3/8-76| N/A| Grade S| Zinc
4ea| Washer| 3/8| N/A| Grade S| Zinc
lea| Winch Controller Mount| Powder
2ea| lower LED Bracket (lea Right,lea Left)| Powder
3ea| Power Steering Rellocation Bracket| Powder
Optional lower Grill LED Mount
4ea| Socket Cap Bolt| l/4-20| 1| Grade 5| Zinc
4ea| Lock Nut| l/4-20| N/A| Grade 5| Zinc
Sea| Washer| 1/4| N/A| Grade 5| Zinc
2ea| Socket Cap Bollt| M6-1mm| 16mm| Grade 5| Zinc
2ea| Washer| M6| Oversized| Grade 5| Zinc
2ea| Lock Washer| M6| N/A| Grade S| Zinc

TOOLS

 | 2016+ TACOMA FRONT STEALTH| BUMPER| TOOLS|
---|---|---|---|---
Quantity| Type| Size| Notes
lea| Ratchet| N| I/A| And extensions
2ea| Wrench| l/2|
lea| Wrench| 9/16|
lea| Allen| 3/16|
lea| Allen| Sm,m|
lea| Socket| 10mm|
lea| Socket| 9/16|
lea| Socket| 72mm|
lea| Socket| 14mm| Deep socket
lea| Socket| 77mm|
lea| Pick| N| I /A| Or small flat screw driver
lea| Cutoff| N| I /A| Orsimilar tools to cut pl| lastic bumper
Various wrenches or sockets depending on winch brands and models

Installations Steps

1. Winch prep – First we need to prep our winch for installation. We sell two winches for this bumper. If you have a Smittybilt, it will come ready for installation. If you went with a Warn, you need to remove the controller.

2. Start by removing the 4 allen bolts on the side of the winch that hold the top plate and controller in place. This will allow the winch to split apart, be careful to not pull it apart.

3. With the top plate removed, flip it over and take out the 4 smaller allen bolts that hold the controller to the top plate. Also disconnect the wires from the back of the winch, leave them connected to the controller.

4. Re-install the top plate back on the winch.

5. Now we need to install the fairlead.

6. We recommend using the hardware that comes with the winch and fairlead, in most cases it is a bolt, washer and lock washer or nut.

7. IMPORTANT NOTE – The winch is tight to the bumper. De-pending on your hardware and fairlead, you may need to install the bolt from the back, to keep this clear, and move the taller nut and washers to the front.

8. Tighten the fairlead hardware in place.

9. Next we will prep the bumper. Grab your winch and put it in place. If the winch line is already installed, ensure it is pushed through the fairlead before tightening in place.

10. Bolt the winch to the bumper using the hardware provided with the winch. For the Smitty and Warn winches, you will slide the square nuts into the winch body.

11. Make sure your bumper is on a surface where you can tilt it forward to install the hardware.

12. Push the bolts through the bumper and into the winch. Tighten everything down in place.

13. Optional – LED Mounts inside the bumper. If you are installing an LED in the bumper, we first need to install the mounts. They are adjustable to fit multiple lights. Orient the mount so that it is pointing forward, and the L-Tab is pointing inward.
    Grab a 3/8 bolt, install a washer, push through the bumper and mount, and install another washer and lock nut. Leave hand tight.

14. Next install your LED to the mounts. Tighten hand tight.

15. Position the LED front to back and side to side to your de-sired location.

16. Tighten the LED to the mount.
    Tighten the mount to the bumper. Your bumper is now ready for install.

17. Truck Prep – Now we can prep your truck. Start by removing the grill. There are two bolts on top, there are also two plastic clips on top. If you have the Safety Sense radar, don’t forget to unplug that and remove the ware clip from the grill.

18. With the hardware removed, pull the grill forward and re-move.

19. Truck Prep – Now we can prep your truck. Start by removing the grill. There are two bolts on top, there are also two plastic clips on top. If you have the Safety Sense radar, don’t forget to unplug that and remove the ware clip from the grill.

20. If you have a front license plate, remove it. The screws for the plate mount are behind the plate itself, remove the mount as well.

21. Now we need to remove the black center plastic trim. On the far left and right side are plastic holders that need to be removed first. They have a lever that gets pushed in the center, then pull the pin out. After removing the pin, there are multiple little clips built into the trim. Push the center down and pull the trim away, start in one spot and slowly move your way from clip to clip pulling outward slightly on the trim so it doesn’t clip back in place.

22. Truck Prep – Now we can prep your truck. Start by removing the grill. There are two bolts on top, there are also two plastic clips on top. If you have the Safety Sense radar, don’t forget to unplug that and remove the ware clip from the grill.

23. Now we will remove 4 bolts that hold the aluminum crash bar to the bumper. There are two in the center, and one on the passenger and drivers side.

24. Now we can remove the crash bar. Start with the nuts that hold the long bar in place. There are 3 on each side. Remove the nuts. Then there are 3 more nuts on each side that hold the bar to the frame. Remove those nuts as well.

25. See location of the bolts.

26. Truck Prep – Now we can prep your truck. Start by removing the grill. There are two bolts on top, there are also two plastic clips on top. If you have the Safety Sense radar, don’t forget to unplug that and remove the ware clip from the grill.

27. Then with the extra space, you can slide the crash bar to one side, pop it out, then fish the rest out and remove.

28. Now it is time to cut. You will see a lip that followed the old trim part in place. We want to cut the center out so that there is a 1/2 to 5/8 lip remaining. Mark with a sharpie. Also you do not need to cut the center of the top, go only to the 2nd clip hole as shown above.
    Mark both sides.

29. Using a cutoff wheel, Dremel, sharp knife or another cutting tool, trim away the plastic.

30. Now use a file, sand paper or other tool to smooth out where you just trimmed.

31. The next step is to relocate the power steering cooler rear-ward. Start by removing the two bolts in the front that attach it to the frame.

32. There is also one additional bolt that holds the power steer-ing line in place. Remove the bolts to the line can move freely. You can access this on the passenger side right behind the front mud guard.

33. Next install the relocation bracket. Place a washer on the 5/16 bolt and push it through the power steering line bracket, then through the hole of the provided bracket. Then put the factory bolt back into the slot on the bracket. Leave loose for now.

34. We will now do this for the cooler itself. Follow the same step of putting the bolt through the bracket and into the bracket on the cooler.

35. Put the relocation bracket on the bottom and push the bolt up though the mount,

36. Install the washer and nut, do this for both positions. Then like the line, install the factory bolt through the slot in the relocation bracket. Push the cooler towards the radiator, then tighten the cooler in place. With the cooler in place, now tighten the line bracket in place.

37. Lastly, we need to remove the factory tow point.

38. Optional – If you also purchased the top / hidden LED mount, we need to get it prepped and in place before we install the bumper. If not, you will not be able to get the LED in place. Start by bolting the mount to the LED. Making sure the mount is pointing forward towards the front of the LED

39. Grab some zip ties or string or something to help hold the LED up and in place.

40. Put the LED in place behind the lower grill, and with your zip ties or string, wrap them around the factory grill support and tighten them so the LED stays up and in position. With the LED up and out of the way, we can now install the bumper.

41. Now we can install the bumper. We highly recommend you use the help of a friend or two. Get the bumper into position and push it into the truck.

42. Slowing pushing the bumper into the truck and into posi-tion, slide the bumper over the 6 studs on the frame. With it pushed into position, install at least one nut on each side to hold it in place and from falling.

43. Now put on the remaining nuts. Start with the nut that is on the inside of the frame. Tighten them up allowing the bumper to pull up and into position on the truck. Tighten inner bolt on each side until it is snug.

44. Now tighten all the nuts to the frame, 3 on each side.

45. Optional – If you have the hidden upper LED, cut the zip ties or string. Then maneuver the brackets in place. They both go on the inside of the vertical bumper brackets. With them inside, put a washer on a 1/4 bolt, push the bolt through the bumper, then the LED mount. Then put on a washer and nut. Do this for all 4 positions. With the mounts in place, push the LED forward. Tighten the LED to the mounts, then the mounts to the bumper.

46. With the bumper installed, we can now install the winch con-troller and mount. In this image we see the placement of the mount. The wires to the winch will need to exit the left side of the mount to reach the winch.

47. First we need to install the controller to the mount. This mount is designed specifically for the Smittybilt and Warn winches we list. It may work for others. Line up the mounting holes and ensure the wires are pointed the correct direction, then install the bolts included with your winch.

48. Place the mount in the truck. The top mount lines up with the threaded hole in the core support.

49. Take your M6 bolt and install a lock washer and flat washer, then push the bolt through the mount and thread into the core support.v

50. Now that the winch controller is installed, you will need to run the wires. Following the instructions for Smittybilt, install the wires from the winch controller to the winch in the order called out. For Warn, the wires and studs are color coded. Connect green to green, blue to blue, yellow to yellow. For both, you will also have a positive and negative that go to your vehicle battery. Route the wires and install. Test winch functionality after wiring.

51. Then bellow are two bolt opportunities. You only need to install one. put a washer on your 5/16 bolt, push through the mount and core support. Then install the washer and lock nut.

52. Lastly, re-install the grill. Push it into place, then put the two plastic clips and two bolts in place. If you have safety sense, plug it back in.

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