ADD OFFROAD F238100010103 PRO Bolt-On Front Bumper Instruction Manual

: June 13, 2024
: ADD OFFROAD

Table of Contents

Preparation:
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

ADD OFFROAD F238100010103 PRO Bolt-On Front Bumper Instruction Manual

Preparation:

Disconnect the negative battery terminal. Park the vehicle on level ground and set the emergency brake.
We recommend reading through the installation instructions in whole before performing the work.
When button head bolts are being used, install the supplied washer on the nut side. Then, hold the bolt stationary and only turn the nut to tighten. Do not turn the bolt to tighten hardware assembly, unless otherwise noted.
Estimated Installation Time: 2 Hours for OEM Removal/Bumper Installation

1 Additional Hour to Wire Top Hoop Lights
1 Additional Hour to Wire Center Light

This installation requires 2 people for best results
Labor Rates are based on a vehicle with no pre-existing damage. Wiring labor is based on a standard wiring procedure with light switches installed in an easily accessible location. Custom light triggering or switch mounting location will result in a greater labor charge.

You will need the following tools:

Ratchet
11mm Socket
Long Ratchet Extension
5/32″ Allen Set
13mm Socket
T40 Torx Socket & Wrench
7/32″ Allen Set
15mm Socket
Flat Head Screw Driver
9/16″ Socket & Wrench
18mm Socket
Needle Nose
5/16″ Allen Socket
19mm Socket & Wrench

Included in Kit:

4 – Black Nylon Lock Nut (1/
4”- 20) 4 – Black Nylon Lock Nut (1/2”- 13)
4 – Black Flat Washers (1/4”)
4 – Black Button Head Bolts (1/2”- 13 x 1 1/2″)
4 – Black Button Head Bolts (1/4”- 20 x 3/4″)
4 – Black Flat Washer (1/2”)
2 – Intercooler Brackets
1 – Bottom Mount Spacer
2 – Sensor Tabs
1 – Light mount Kit

Plastic Bumper Removal (Steps 2-7) Steel Bumper Removal (Steps 8-14)

Remove the 6 skid plate bolts (15mm) shown in (Fig A).

Plastic Bumper Removal:
Pull off the cover on each side of the bumper and unplug the sensors by spreading the sensor bezel tabs apart, which will release the tension and allow you to easily push back the sensors. (Fig B) Make sure to keep track of the position/orientation of the parking sensors so that you can install them in the same position/ orientation on your new bumper.
After the sensor have been removed squeeze the black sensor bezel tabs together, which will allow them to pull forward off the bumper. Keep track of the position/orientation of each sensor bezel so that you can installthem in the same position/orientation on your new bumper. (Fig C)
Disconnect the main wiring harness located on the driver side of the Bronco (Found next to the headlight, up in the corner). (Fig D)
Remove plastic over then unbolt the 3 (15mm) bolts that hold the OEM bumper in place. (Fig E)
There is a metal plate held in place by 8 bolts, 4 on each side. This plate needs to be removed to access the wiring harness for removal. (Fig F)
Remove wiring harness from the OEM bumper by disconnecting the fog light, than pulling out all the tabs that secure the harness in place. ( Fig G)
There are 4 plastic clips on each side of the bumper that need to be removed to take off the plastic plate. (Fig H)
After the plastic cover has been removed from both sides, the tow hooks will be visible. There are 3 bolts that hold the tow hooks on each side for a total of 6 bolts size 15mm. (Fig I)
Disconnect the main wiring harness which is located next to the headlight, After the harness has been disconnected the bumper can be removed. (Fig J)
Remove the plastic intercooler shroud, no tools are required. It is clipped in place to remove just unclip and pull out. (Fig K)
After the bumper has been removed, disassemble the metal plate that holds the sensors/wiring harness. To remove the metal plate, there are 4 bolts on each side size 13mm for a total of 8.Then there are 3 Torx-40 button heads that located on the top of bumper on each side for a total of 6 T-40 bolts that need to be removed for disassembly. (Fig L)
After the metal plate has been removed from both sides, disconnect the wiring harness and unplug the sensors from the bumper. (Fig M)
After the harness has been pulled then remove the sensor bezels by squeezing them together then pulling out of the bumper. (Fig N)
Install the ADD Adaptive Cruise Control relocation bracket now if your vehicle has it.
Install the ADD Adaptive Cruise Control relocation bracket now if your vehicle has it. There are 4 bolts that hold the intercooler guard in place, take out the 4 bolts which will give you access to the backside then disconnect the cruise control line. (Fig O)
Use a pair pf needle nose pliers to spread open the tabs on each side to pop out the fin that is attached to the shutter motor.(Fig P)
Use a flat head screw driver and pry out the fin from the plastic side piece that holds it in place. Then pull it directly out from the shutter motor. (Fig Q)
Use a flat head screw driver and press into the tabs that hold the shutter motor into place. There are 3 spots that need to be pressed down with the flat head to break it loose. Start with the top then pry the bottom out last. After the shutter motor has been released disconnect the plug and pull the wiring through the opening.(Fig S)
After the shutter motor has been taken out from the plastic guard, find a spot in the bronco to zip tie it in place. (Fig S)
Remove the 2 bolts that hold the bracket in place to install the new intercooler bracket. (Fig T) (Support intercooler while installing ADD intercooler brackets)
Install the ADD intercooler bracket using the OEM hardware. (Fig U) (Remember, only do one side at a time as the brackets are the only thing that hold the intercooler in place)
Install the sensor tabs on the bumper using the supplied 1/4″ black button head bolts, washers, and lock nuts. (Fig V) (Make sure the Black button head is inside the bumper, while the lock nut is faced outside next to the sensor as shown below)
Transfer over the wiring harness to the ADD bumper. Install the 4 sensor bezels rings into the ADD bumper. When the bezels have been installed, Outer sensors and sensor bezels will be installed in the same poision/orientation. The Inner sensor bezels need to be installed on oppoiste sides (FIR goes where FIL would). Place the sensor plugs in the bezels following the way they are shown in the picture below. (Fig W)

Light Hoop Install:
Slide light hoop in place then install the provided (4x) Black 3/8″ Hardware. (Fig X)
Fit the bumper in place and use the provided 1/2″ black button heads (x2) per side, Leave loose. (Fig Y ) (Leave loose to get skid plate bolts in place)
Once the top bolts have been started, using the OEM hardware install the skid plate then full tighten them. There is a spacer you will install between the frame and skid plate. (Fig Z) (After they have been fully tightened, you can adjust the height of the bumper from the top)
Adjust the hieght of the bumper then torque down to 70 foot pounds
Stand back and enjoy your new ADD Pro Bolt-on™ Front Bumper.
Check and re-tighten, if needed, all mounting bolts after 100 miles and periodically thereafter.