BODY ARMOR TC-19341 Pro Series Front Winch Bumper Instruction Manual

BODY ARMOR TC-19341 Pro Series Front Winch Bumper

Product Information

The 2005-2015 Toyota Tacoma Pro Series Front Winch Bumper (Part #TC-19341) is a heavy-duty bumper designed for Toyota Tacoma trucks. It includes various parts and hardware for installation, such as bumper assemblies, reinforcement brackets, grille support brackets, LED L brackets, license plate accessories, bolts, washers, nuts, trim, and a hex wrench.

Product Usage Instructions

1. Remove the skid plate from below the bumper (if equipped).
2. Open the hood and remove the plastic cover from the top of the grille and radiator. Carefully remove the plastic grille.
3. Remove the plastic covers between the top of the factory bumper and the bottom of the headlights.
4. Remove the factory hardware attaching the front bumper to the driver/left wheel opening. Move along the bottom of the bumper and remove the hardware attaching the bottom of the bumper. Continue to the passenger/right wheel opening and remove the hardware to release the bumper cover.
5. Remove the hardware attaching the top of the bumper to the vehicle. Carefully remove the plastic bumper cover.
6. Remove the impact crossbar and brackets from the end of the frame.
7. Determine if LED an LED-style light will be installed (light not included).
   • Select the driver/left LED L Bracket. Attach the Bracket to the back of the bumper with (1) 8mm x 25mm Hex Bolt, (2) 8mm Flat Washers, (1) 8mm Lock Washer, and (1) 8mm Hex Nut. Repeat this Step to attach the remaining passenger/right L Bracket.
   • Attach the light to the L Brackets with the included (2) 8mm x 16mm Hex Bolts, (2) 8mm Lock Washers, and (2) 8mm Flat Washers.
8. Push the included Edge Trim onto the top edge of the Bumper. Cut the Edge Trim to fit.
9. For 2005-2011 models ONLY: Locate and remove 4 bolts securing factory core support. Remove core support and set aside for later. Use pliers to slightly bend the sheet metal core support mounting tab upward for clearance and installation ease.

PARTS LIST

Bolts
1| Driver/Left Grille Support Bracket| 12| 10mm x 20mm OD x 2mm Flat Washers
1| Passenger/Right Grille Support Bracket| 6| 10mm Nylon Lock Nuts
1| Driver/Left LED “L” Bracket| 4| 8mm x 25mm Hex Bolts
1| Passenger/Right LED “L” Bracket| 2| 8mm x 16mm Hex Bolts
2| License Plate Plugs| 8| 8mm x 24mm OD x 2mm Flat Washers
1| License plate bracket| 4| 8mm Lock Washers
2| 12-1.75mm x 120mm Hex Bolts| 2| 8mm Flange Hex Nuts
2| 12-1.75mm x 40mm Hex Bolts| 2| 8mm Hex nut
4| 12mm x 44mm x 4mm Spacer Flat Washers| 1| 6mm Hex Wrench

PROCEDURE

REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT. READ INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION. BUMPER IS HEAVY, ASSISTANCE IS RECOMMENDED TO AVOID POSSIBLE INJURY OR DAMAGE TO THE VEHICLE.

1. Remove the skid plate from below the bumper if equipped, (Figure 1).

2. Open the hood and remove the plastic cover from the top of the grille and radiator. Carefully remove the plastic grille, (Figure 2).

3. Remove the plastic covers between the top of the factory bumper and bottom of the headlights, (Figure 3).

4. Remove the factory hardware attaching the front bumper to the driver/left wheel opening, (Figure 4). Move along the bottom of the bumper and remove the hardware attaching the bottom of the bumper, (Figure 5). Continue to the passenger/right wheel opening and remove the hardware to release the bumper cover.

5. Remove the hardware attaching the top of the bumper to the vehicle, (Figure 6). Carefully remove the plastic bumper cover.

6. Remove the impact crossbar and brackets from the end of the frame, (Figures 7 & 8).

7. Determine if LED an LED-style light will be installed (light not included).

8. Select the driver/left LED “L” Bracket. Attach the Bracket to the back of the bumper with (1) 8mm x 25mm Hex Bolt, (2) 8mm Flat Washers, (1) 8mm Lock Washer, and (1) 8mm Hex Nut, (Figure 9). Repeat this Step to attach the remaining passenger/right “L” Bracket.

9. Attach the light to the “L” Brackets with the included (2) 8mm x 16mm Hex Bolts, (2) 8mm Lock Washers, and (2) 8mm Flat Washers.

10. Determine if a winch will be installed (winch not included)

11. Attach cable guide to the front of the bumper. For models with front license plate, select the License Plate Bracket. Attach the Bracket to the front of the bumper between the cable guide and the bumper.

12. For models without cable guide, attach the License Plate Bracket to the front of the Bumper with the included (2) 10mm x 25mm Button Head Bolts, (4) 10mm Flat Washers, and (2) 10mm Nylon Lock Nuts, (Figure 10).

13. Insert the (2) License Plate Plugs into the Bracket to attach the License Plate, (Figure 10).

14. Follow the manufacturer’s instructions to attach the winch to the Winch Tray.

15. Push the included Edge Trim onto the top edge of the Bumper. Cut the Edge Trim to fit, (Figure 11). use thin edge trim material for 2005-2011 models.

16. 2005-2011 models ONLY: Locate and remove 4 bolts securing factory core support. Remove core support and set aside for later.
    – The core Support mount slightly interferes with the angle mount on the bumper leading to the frame.
    For clearance and installation ease, use a pair of pliers to slightly bend the sheet metal core support mounting tab upward to prevent rubbing.

17. With assistance, reuse the (6) factory hex nuts to attach the Bumper to the end of the frame, (Figures 12 & 13). Leave hardware loose at this time.

18. Attach the lower mounting tab on the back of the driver/left side of the bumper to the bottom of the crossmember with the included (1) 12mm x 40mm Hex Bolt, (2) 12mm STD Flat Washers, (1) 12mm Lock Washer and (1) 12mm Hex Nut, (Figure 14). Repeat to attach the passenger/right side of the bumper to the crossmember. Snug but do not fully tighten the hardware at this time.

19. Select the driver/left outer Support Bracket. Slide the slots on the outer Support Bracket under the outer (2) factory hex nuts attaching the Bumper to the frame, (Figure 15). Attach the Bracket to the side of the frame with (2) 10mm x 90mm hex Bolts and (2) 10mm Flat Washers, (Figure 16A). Hold the Inner Support Bracket up to the back of the frame. Secure the inner Bracket to the side of the frame with (2) 10mm Flat Washers and (2) 10mm Nylon Lock Nuts, (Figure 16A & B). Do not fully tighten the hardware at this time.

20. Select (1) 12mm x 120mm Hex Bolt and (1) 12mm x 32mm STD Flat Washer. Insert the Bolt and Washer in from the front of the mounting plate on the bumper, through the crossmember, and out the Outer Support Bracket, (Figure 17). Slide (1) 12mm x 44mm Flat Spacer Washer onto the Hex Bolt. Secure the Bracket to the crossmember with (1) 12mm Lock Washer and (1) 12mm Hex Nut, (Figure 18). Do not tighten the hardware at this time.

21. Repeat Steps 12 & 13 to attach the passenger/right Outer and Inner Support Brackets to the frame.

22. Level and adjust the Bumper and tighten all hardware. IMPORTANT: To adjust the Bumper down slightly, loosen the mounting hardware and slide the included (2) 12mm x 44mm Flat Spacer Washers (use 1 per side), between the lower mounting tab and the bottom of the crossmember, (see Step11Figure 14). Once level and adjusted, fully tighten all hardware.

23. Next, select the driver/left Grille Support Bracket. Attach the Bracket to the bottom outer mounting screw on the back of the grille, (Figure 19). Repeat this Step to attach the passenger/right Support Bracket.

24. Reinstall the Grille. Attach the driver/left Grille Support Bracket to the top of the sheet metal panel with (1) 8mm x 25mm Hex Bolt, (1) 8mm Flat Washer and (1) 8mm Flange Nut, (Figures 20 & 21). Repeat this Step to attach the passenger/right Grille Support Bracket. Reinstall the plastic cover.

25. Reinstall the skid plate, if equipped. Do periodic inspections to the installation to make sure that all hardware is secure and tight.
    To protect your investment, Do not use any type of polish or wax that may contain abrasives that could damage the finish. Mild soap may be used to clean the Bumper assembly

INSTALLATION INSTRUCTIONS

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