HAVOC HFB-05-020 HD Hinge Casting User Manual
- June 13, 2024
- HAVOC
Table of Contents
HAVOC HFB-05-020 HD Hinge Casting
Product Information
- Part Number: HFB-05-020
- Product Name: HD Hinge Casting, Bronco
Components and Hardware:
- HD Hinge Casting
Tools for Installation:
- No. 2 Phillips driver
- 10mm socket
- Small flat head screwdriver
- Pry tool
- T-45 Torx driver
- Grease pencil or painters tape
Product Usage Instructions
-
Remove the spare tire from the tailgate. Have a table or cart nearby to place the OE tire carrier on after removing it.
-
Remove the 2 torx bolts next to the camera. Then, remove the 8 bolts securing the OE tire carrier to the tailgate.
-
Place the tire carrier onto a nearby table. Remove the 4 screws holding the OE 3rd brake light to the tire carrier.
-
Remove the insulation from behind the camera in the tire carrier. Gently remove the stud plate and camera assembly from the tire carrier. Disconnect the camera from the wire harness. Let the 3rd brake light and wire harness hang below the tailgate. Set the OE tire carrier aside.
-
Open the tailgate. Using a No. 2 Phillips driver, remove the four plastic rivets next to the tailgate hinge.
-
Using a 10mm socket, remove the two fasteners near the tailgate hinge. Remove the plastic hinge cover from the vehicle to expose the OE tailgate hinge.
-
The tailgate strut is located on the bottom of the tailgate.
Using a small flat head screwdriver, lift the retainer clip on the tailgate strut. Gently pull the strut away from the ball bracket on the tailgate. -
Starting near where the wire harness sleeve goes into the side trim panel, lightly pry the trim panel open.
-
With the trim panel lifted, the wire harness plug should be visible. There is a plastic retainer holding the plug to the vehicle. Gently slide a pry tool between the plug and metal bodywork. Then lift the plug away from the bodywork.
-
Pull the plug toward you. Press down on the plug release and pull to disconnect it from the vehicle.
-
Using a grease pencil or painters tape, mark the position on the vehicle where the upper and lower tailgate hinges are mounted.
Note: Have a second person help in the process of removing and remounting the tailgate. The OE tailgate is large but not heavy. -
Using a 13mm socket, remove the 4 bolts securing the tailgate hinges to the vehicle. Place the OE tailgate on a table with the outer panel facing up.
-
Using a T-45 Torx driver, remove the 4 bolts securing the upper and lower hinges from the tailgate.
-
Using the supplied M8 x 40mm button head (#6) bolt and M8 washer (#7), loosely attach the hinge casting to the tailgate.
-
Using the marks created in step 11, align the tailgate and cast hinge assembly to the vehicle. Reusing OE hardware, attach the tailgate to the vehicle. Ensure the hinge is in the same location as the OE hinge before tightening.
-
While gently holding up the tailgate, slowly close the tailgate. To compensate for the added weight of the spare tire, we suggest adjusting the tailgate upward until the latch housing is making contact with the striker. Also, check the gaps between the tailgate and body panels.
Note: You will most likely need to make multiple small adjustments to get everything to align.
Part # HFB-05-020
Components and Hardware
- Hinge Casting ……………………………………………………………………….(1)
- Mesh ……………………………………………………………………………………(1)
- Antenna Bracket …………………………………………………………………..(1)
- Upper Spacer ………………………………………………………………………..(1)
- Lower Spacer ……………………………………………………………………….(1)
- M8 x 40mm Button Head Bolt ………………………………………………..(4)
- M8 Washer …………………………………………………………………………..(6)
- M6 x 8mm Button Head Bolt ………………………………………………….(4)
- M6 Washer …………………………………………………………………………..(4)
- M8 x 15mm Button Head Bolt ………………………………………………..(2)
Tools for Installation
- 13mm socket
- T-30 torx socket
- T-45 Torx Driver
- 3/8” and 1/2” socket driver
- No. 2 Phillips Head Screw Driver
- 10mm socket
- Plastic Rivet Pry Tool
- Grease Pencil
- Allen Wrench
- Small Flat Head Screwdriver
HD Hinge Casting, Bronco
-
Remove the spare tire from the tailgate.
Note: Have a table or cart close to the tailgate to place the OE tire carrier on after removing it. -
Remove the 2 torx bolts next to the camera. Then, remove the 8 bolts securing the OE tire carrier to the tailgate.
-
Place Tire carrier onto nearby table. Remove the 4 screws holding the OE 3rd brake light to tire carrier.
-
Remove the insulation from behind the camera in the tire carrier. Gently, remove the stud plate and camera assembly from the tire carrier. Disconnect the camera from the wire harness. Let 3rd Brake light and wire harness hang below the tailgate. Set OE tire carrier to the side.
-
Open the tailgate. Using a No. 2 Phillips driver, remove the four plastic rivets next to the tailgate hinge.
-
Using a 10mm socket, remove the two fasteners near the tailgate hinge. Remove the plastic hinge cover from the vehicle to expose the OE tailgate hinge.
-
The tailgate strut is located on the bottom of the tailgate.
Using a small flat head screw driver, lift retainer clip on tailgate strut. Gently pull strut away from ball bracket on tailgate. -
Starting near where the wire harness sleeve goes into the side trim panel, lightly pry trim panel open.
-
With the trim panel lifted, the wire harness plug should be visible. There is a plastic retainer holding the plug to the vehicle. Gently slide a pry tool between the plug and metal body work. Then lift the plug away from the body work.
-
Pull the plug toward you. Press down on the plug release and pull to diconnect it from the vehicle.
-
Using a grease pencil or painters tape, mark the position on the vehicle where the upper and lower tailgate hinges are mounted.
Warning: Have a second person help in the process of removing and remounting the tailgate. The OE tailgate is large but not heavy. -
Using a 13mm socket, remove the 4 bolts securing the tailgate hinges to the vehicle. Place OE tailgate on table with the outer panel facing up.
-
Using a T-45 Torx driver, remove the 4 bolts securing the upper and lower hinges from the tailgate.
-
Using supplied M8 x 40mm button head(#6) bolt and M8 washer(#7), loosely attach hinge casting to tailgate.
-
Using the marks created in step 11, align tailgate and cast hinge assembly to vehicle. Reusing OE hardware, attach tailgate to vehicle. Ensure the hinge is in the same location as the OE hinge before tightening.
-
While gently holding up the tailgate, slowly close the tailgate. To compensate for added weight of the spare tire, we suggest adjusting the tailgate upward until the latch housing is making contact with the striker. Also, check the gaps between the tailgate and body panels.
Note: You will most likely need to make multiple small adjustments to get everything to align. -
Fully tighten M8 hardware installed in step 14.
-
Using M6 button head bolt(#8) and washer(#9), attach logo mesh to hinge casting.
-
Using M8 x 15mm button head bolt(#10) and M8 washer(#7), attach antenna bracket to hinge casting.
Note: The large hole in the bracket is for CB antennas, while the smaller hole can be used to mount a pod light.
Notice: Use instruction sheet provided with Havoc Wheel Mount, HFB-05-021, if mounting it at this time. Step 21-23 are for remounting the OE tire carrier. -
Reconnect the camera to the wire harness. Align the OE camera assembly to the metal bracket and insulation bracket. Reattach camera assembly to the OE tire carrier.
-
Reattach the 3rd brake light to the OE tire carrier. Reconnect plug inside cargo area, tailgate strut, and reattach plastic panels.
-
Align the OE tire carrier to the tailgate. Using only the passenger side mounting holes (1), loosely attach the tire carrier reusing OE hardware.
Gently slide the upper and lower spacers between the tail-gate and OE tire carrier (2). Install the remaining OE hard-ware to the tailgate (3). Tighten all hardware to secure tire carrier to the tailgate. Remount spare tire.
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