ALUMINESS 210546 Front Winch Bumper Instruction Manual

Front Bumper
Installation Instructions
P/N 210546, 210546.1: 2020+ Ford Transit Front Bumper

Before you begin

• Stainless steel hardware may bind together when tightening — apply an anti-seize assembly lubricant to the threads of each bolt before assembly (not grade 8 bolts)
• This bumper is NOT compatible with vans prepared with a motorhome prep package. The large intercooler behind the factory steel bumper will interfere with the Aluminess bumper.
• This installation requires two or more people
• Be sure to use all appropriate PPE while installing.

Required Tools

• Standard and metric wrench set
• Standard and metric socket set
• Flat head screwdriver
• Cut-off wheel
• Prybar
• Hammer
• Safety Glasses

Included Hardware

Additional Parts

Stock Bumper Removal

1. Open and secure the hood.

2. Remove the five (5) plastic rivets and four (4) 10mm bolts on the top of the grille (Figure 1).

3. Remove the two (2) torx screws attaching each headlight. Once the bolts are removed, slide the headlight straight away from the vehicle, unclip wiring connectors, and remove the headlight (Figure 2).

4. Remove the two (2) torx bolts holding the front fascia to the vehicle sides and the one (1) 10mm screw holding the top of the factory bumper located in the back corner underneath the headlight (Figure 3). Remove the plastic backing plate (Figure 3).

5. Remove the four (4) torx bolts inside the inner wheel well along the fender flare (Figure 4).
   PRO TIP: Access to the bolts is made much easier by turning the vehicle’s wheels.

6. Gently pull each fender flare away from the vehicle starting closest to the door. Once you reach the bumper, there are three (3) plastic catches that need to be released (Figure 5 & 6).

7. Pull the inner wheel well down and away from the bumper to gain access behind the plastic. Remove the 10mm bolt from inside the wheel well (Figure 7). NOTE: the two (2) torx bolts now visible on the bumper do not need to be removed.

8. Remove the eight (8) 10mm bolts connecting the factory bumper to the under-carriage plastic (Figure 8).

9. Remove the front license plate (if applicable). Remove the bolts or drill out the two or three (2-3) rivets attaching the license plate holder onto the factory bumper using a ¼” drill bit.

10. Remove the now exposed bolt caps as applicable and remove the final two (2) 13mm  bolts holding on the stock bumper (Figure 9).

11. Release the four (4) large plastic catches holding the grille onto the front of the vehicle (Figure 10 & 11). Note: it may be helpful to do in combination with the next step. NOTE: The middle two catches are underneath the top plastic cover of the grille as shown in Figure 10.

12. Remove stock front bumper and grille by pulling directly away from vehicle, slowly working from the edges closest to the doors toward the center (Figure 12).

13. Be sure to disconnect any sensors that are attached to the bumper during removal (Figure 13).

14. Separate the factory plastic bumper from the grille by use a plastic pry tool or a flat head screwdriver covered in masking tape. Release the bumper catches holding the bumper onto the front body panels underneath the headlight area (Figure 14).

15. Remove all parking sensors from back of the plastic factory bumper (Figure 15).

16. Remove the inner plastic radiator air deflectors (Figure 16 & 17) by removing all plastic push pins. Cut air deflectors to as shown (Figure 17). (Passenger Side Shown without Air Deflector)

17. Remove any and all sensors from the factory steel bumper:
    a. Temperature sensor (Figure 18). b. Collision prevention / adaptive cruise control sensor – unclip from sensor and remove all clips from steel (Figure 19). c. Remove entire adaptive cruise control system from steel bumper (2X – 8 mm bolts and 1X – torx bolt) (Figure 20).

18. Remove two (2) 10mm bolts holding on the plastic under-carriage and pull down to remove (Figure 21).

19. Remove the eight (8) 13mm bolts from the backside of the steel bumper (Figure 22).

20. Remove the 4 spot welds (2 per side) holding on the bumper to the frame (Figure 23). To remove, there are a couple of options:
    d. Drill out each spot weld
    e. Gently pry the bumper away from the frame and use a Sawzall to cut weld
    f. Use an angle grinder to grind the spot welds down enough to use prybar/hammer to remove.

21. Remove eight (8) 13mm bolts to remove the lower factory scuff guard (black steel member; Figure 24).

22. Separate any remaining wiring from the front of the frame and touch up any exposed metal surfaces with appropriate paint (Figure 25).

23. Cut the front radar bracket as shown in Figure 26 using a cut off wheel. Front Bumper Installation:

24. Install the factory radar bracket onto the front sensor bracket using the provided ¼”-20 hardware (Figure 27). Ensure the bottom bolt is pointed down to minimize the profile for the best fitment with a winch.

25. Install the now assembled radar sensor into the aluminum bumper behind the sensor window (Figure 28).

26. Install the winch tray onto the frame using ½”13 hardware through the top four (4) frame holes and 3/8”-16 bolts on the bottom four (4) scuff guard extension holes (Figure 29). Loosely install all 16 bolts through the frame/scuff guard and center the winch tray onto the vehicle before tightening. Once located, tighten the 1/2”-13 bolts to 80 ft-lbs and tighten the 3/8”-16 bolts to 20 ft-lbs.

27. Install winch onto winch tray per the manufacturer’s instructions if desired (Figure 30).

28. Install the plastic radiator air deflectors after being cut by reusing the top push pin (reference Figure 17 & 30).

29. Install the outer support brackets onto the corresponding driver and passenger sides using ½”-13 hardware (Figure 31 and 32).
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30. If applicable, install the parking sensors into Aluminosis front bumper using the Parking Sensor Upgrade Kit (P/N 210560) and by following the separately included instructions.

31. Install the aluminum bumper onto the winch plate and loosely fasten them together using the remaining 1/2”-13 hardware. There are four (4) holes on each side of the bumper and winch mount to bolt through (Figure 33).

32. Position bumper into desired location and install ¼”-20 hardware through the outer support gussets.

33. Tighten ½”-13 hardware to 80 ft-lbs.

34. Use ¼”-20 bolts to attach the plastic wheel well liner to the side of the bumper (Figure 34) through one of the two provided holes.

35. Reconnect all wiring harnesses back into sensors as applicable.

36. Measure and cut fender flares at the desired position against bumper, either just above, or just below the top surface of the bumper (Figure 35).

37. Re-install fender flares into position.

38. Your bumper is now installed! Verify all sensors are working correctly and adjust as needed.
    Check all hardware after the first 100 miles and periodically thereafter.

Aluminosis Products, Inc. (Aluminosis) Warranty

1. Lifetime Warranty. Aluminosis provides a lifetime warranty of its products to the original retail purchaser provided such products are installed correctly according to the official Aluminosis installation instructions. Any modification to the original product design, function or use of any Aluminosis products will void the Aluminosis warranty. Aluminosis will have sole discretion to determine warranty eligibility for any and all Aluminosis products sold to any purchaser.

2. Limited Remedies. Subject to any limitations and exclusions described herein, and subject to Aluminess’ determination of warranty eligibility, Aluminess will remedy defects in product materials and/or workmanship of any product by repairing or replacing such defective product, which shall be within Aluminess’ sole discretion, without charge for parts or labor. Aluminess may elect in its sole discretion not to replace a defective product and issue the purchaser a refund equal to the purchase price of  any defective product or purchaser may elect to receive a credit (equal to such refund) toward the purchase of new Aluminess products. Repair or replacement of a defective product or providing a refund or credit to purchaser will be purchaser’s exclusive  remedy under this warranty. Damage to a purchaser’s vehicle, cargo and/or any other person or property is expressly excluded from the Aluminess warranty.

3. Modification. Aluminess products are designed to be mounted to factory equipped vehicles. Aftermarket additions to such vehicle may or may not require modification of an Aluminess product. The Aluminess warranty does not extend to any Aluminess
   products that are modified to fit around other otherwise accommodate or be compatible with any aftermarket vehicle accessories or alterations. Aluminosis does not guarantee fitment with any other aftermarket accessories or modified vehicle, and it is up to purchaser to determine fitment prior to purchasing any Aluminosis product.

4. Damage. Damage to Aluminosis products due to normal wear and tear, including, but not limited to, cosmetic issues and superficial scratches, or structural damage to an Aluminosis product in connection with any vehicle collisions or other structural
   degradation in connection with the use of such vehicle (on road or off road) will not be covered by the Aluminess warranty.
   Additionally, any product user’s misuse, neglect, overloading, improper maintenance or improper installation or repair of any Aluminess products are not covered under the Aluminess warranty.

5. Use of the Products. Aluminess products are designed for off road vehicle use. Installing Aluminess products on a vehicle may exceed the factory designed capabilities of such vehicle and could potentially lead to vehicle damage. Aluminess will not be
   responsible for any damage caused to a purchaser or user’s vehicle or any vehicle accessories caused by the use of any Aluminess products. It is to the sole responsibility of purchaser to inspect and ensure that the intended vehicle and Aluminess products  are suitable and compatible for travel on road and off road. No seller nor any manufacturer of Aluminess products will be liable for any loss, damage or injury directly or indirectly arising from the use of any Aluminess products. Before using any Aluminess products, the purchaser or user will determine the suitability of the product(s) for their intended use(s) and the purchaser or user shall assume all responsibility and risk in connection therewith.

6. DISCLAIMER. THE ALUMINESS WARRANTY IS EXPRESSLY MADE IN LIEU OF ANY AND ALL OTHER WARRANTIES, AND EXCEPT FOR THE ALUMINESS WARRANTY SET FORTH HEREIN, ALUMINESS MAKES NO WARRANTY WHATSOEVER WITH RESPECT TO ANY ALUMINESS PRODUCT, INCLUDING ANY WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WHETHER EXPRESS OR IMPLIED BY LAW, COURSE OF DEALING, COURSE OF PERFORMANCE, USAGE OF TRADE, OR OTHERWISE. EXCEPT FOR PURCHASER’S LIMITED REMEDIES SET FORTH HEREIN, IN NO EVENT WILL ALUMINESS BE LIABLE FOR ANY LOST PROFITS, LOST SALES, OR FOR ANY CONSEQUENTIAL, DIRECT, INDIRECT, INCIDENTAL, SPECIAL, EXEMPLARY OR PUNITIVE DAMAGES OR FOR ANY OTHER DAMAGES OF ANY KIND OR NATURE.

7. Compliance. Aluminosis cannot guarantee that its products comply with all Federal, State, and/or local laws. Purchaser is advised to review local vehicle codes for compatibility prior to purchase to ensure that the installation and use of any Aluminosis
   products does not violate any applicable laws.

8. Warranty Claim Submission. Purchaser will responsible for returning any defective product to Aluminosis for warranty consideration and purchaser may be responsible for all costs associated with shipping the product to and from Aluminosis. Prior to returning any product for warranty, purchaser must contact Aluminosis Products Inc. for proper authorization.

info@aluminess
619-449-9930

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