Fab Fours F5251 Ford Bronco Premium Front Instruction Manual

Fab Fours F5251 Ford Bronco Premium Front

IMPORTANT SAFETY GUIDE

Your safety and the safety of others is very important. In order to help you make informed decisions about safety, we have provided the following warnings, safety precautions, installation instructions, and other important information to alert you to potential hazards that could hurt you or others. Please do a job safety analysis before each task to identify potential hazards for your situation and remove/protect against them. Use your own good judgment and take your time. Check packaged materials immediately upon arrival to ensure all listed parts are included and undamaged. Read and understand all warnings, safety precautions, and instructions before installing this product. THE SENSOR FIELD OF VIEW MAY BE ALTERED WITH THE USE OF THE REPLACEMENT BUMPER.

WARNINGS

• Failure to observe the following warnings and instructions provided in this manual could lead to severe injury and/or death.
• For professional installation only. Careless installation and/or operation can result in serious injury, death, and/or equipment damage. All liability for installation and use rests with the user or consumer.
• Fab Fours, Inc. only approves installing this product according to these written instructions with the hardware provided.
• Failure to install according to these instructions will invalidate the warranty. This includes, but is not limited to, using alternative installation methods, hardware, or materials.
• This product is for off-road use only.

SAFETY PRECAUTIONS

• Always remove jewellery and wear eye protection.
• Always use extreme caution when jacking up a vehicle for work. Set the emergency brake and use tire blocks. Locate and use the vehicle manufacturer-designated lifting points. Use jack stands.
• Always use appropriate and adequate care in lifting components into place.
• Always ensure components will remain secure during installation and operation.
• Always wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause serious eye injury.
• Always use extreme caution when drilling a vehicle. Always disconnect the power before welding.
• Thoroughly inspect the area to be drilled (on both sides of the material when possible) prior to drilling, and relocate any objects that may be damaged.
• Always use extreme caution when welding a vehicle. Thoroughly inspect the area to be welded (on both sides of the material when possible) prior to welding, and relocate any objects that may be a fire hazard.
• When welding in a cab, make sure the interior surfaces are covered (e.g., welding blanket) and a fire extinguisher is at hand.
• Always use extreme caution when cutting and trimming during fitting.
• Always tighten all nuts and bolts securely per installation instructions.
• Always route electrical cables carefully. Avoid moving parts, components that become hot, and rough or sharp edges.
• Always insulate and protect all exposed wiring and electrical terminals.
• Perform regular inspections and maintenance on mounts and hardware.

A message from the owner
Fab Fours’ was born out of a passion for customizing vehicles and a love of the outdoors. Our engineering team uses the latest 3D design software to turn new product ideas into reality. In our factory, designs come to life with the combination of cutting-edge technology for metal cutting and forming and an American workforce that puts its’ heart and pride into every product. From design and manufacturing to quality and delivery, Fab Fours’ mission is to be the market leader for steel truck and jeep accessories. We make sure a quality product is delivered on time, more than expected, and better than expected to our customers. Enjoy your new Fab Fours product. Welcome to the family!

Greg Higgs
Founder, Fab Fours

Getting started

Before you begin the installation process of your new Fab Fours product, we suggest laying out all materials and parts on a pad or protective surface. Failure to fully account for all components before beginning installation may leave vehicle immobile until the part is acquired. Refer to the next pages as an inventory check.

Provided materials

TOOLS REQUIRED

• Body Pry Tool
• 3/8 Drill Bit
• 10mm Wrench
• 9/16 wrench
• 13mm Wrench
• 7/32 wrench
• 15mm Wrench
• 1/2 wrench
• 18mm Wrench

assistance

We recommend two people perform the installation as items are heavy and may need to be held in place while installing.

Organization
Disassemble the vehicle so that you can catalogue and store everything. We suggest labelling and bagging all the OEM bolts when removing them from the vehicle. Failure to keep track of parts could lead to an inability to properly reinstall components.

assistance
This manual shows the six-sensor configuration for illustration purposes but your specific installation may vary.

Hardware kit

1. Open the hood and remove all the push pins holding the plastic radiator cover on. Figure 1.

2. Use a 10mm socket to remove the four (4) bolts holding the top of the grill to the radiator frame. Figure 2.

3. Remove the OEM grill by carefully pulling the clips free at the base and sides of the grill.

4. Using the panel pry tool remove the eight (8) push pins attaching the two (2) tow hook cover plates to the bumper. Figure 3.

5. Using the 15mm socket wrench remove the six (6) bolts that attach the factory bumper to the frame. Figure 4.

6. Unplug the wiring harness and remove the OEM bumper from the Bronco.

7. Remove the OEM electrical harness from the bumper by removing the push pins. (Figure 5-6)
   NOTE: Document the location of each sensor housing for reference when reinstalling into your bumper.

8. Remove the sensor from the sensor housing by expanding both sides of the sensor housing and lifting. (Figure 7-8

9. Remove the sensor housing from the bumper by depressing the four (4) tabs while pulling outward from the outside of the bumper. (Figure 9-10)

10. Remove the intercooler shroud from the vehicle by depressing the tabs around the perimeter of the shroud and then separating the shroud from the intercooler. Figure 11.

11. Using the 15mm socket wrench, remove the two bolts at the front of the OEM skid plate and then loosen the two bolts at the rear of the OEM skid plate to remove it from the vehicle.

12. Using the 15mm socket wrench, remove the front bolt and loosen the rear bolt that attaches the skid plate mounting brackets to the frame letting the two brackets hang down.

13. Remove the adaptive cruise control (ACC) sensor shroud from the vehicle using a panel pry tool to release the plastic clips. Using an 8mm socket wrench remove the ACC sensor with bracket from the intercooler. Figure 12.

14. Install the sensor housings into their respective locations in the bumper base and use the provided epoxy to fasten them in. Figure 13.

15. Plug the Sensors harness into the sensors and run the harness through the bumper using zip ties to fasten it in place. Make sure to keep the harness plug on the driver’s side of the bumper when installing. Figure 14.

16. If your Bronco does not use sensors install the provided rubber grummets and plugs to fill the sensor holes. Figure 15.

17. Install your Warn VR EVO 10 Winch at this time using the manufacturer’s instructions and hardware.

18. With assistance, hold the bumper up to the frame and use the provided M14 flange bolts with 7/16” flat washers to fasten it in place. Hold the bumper as high as it can go before tightening the hardware. (It is suggested to test fit the grill at this time to ensure proper fitment, the bumper may need to be adjusted to ensure the grill sits properly). Figure 16.

19. Place the winch cover plate (22591) on the bumper and use the provided 3/8” yellow zinc hardware to fasten it in place. Figure 17-18.

20. With assistance, hold the grille up to the bumper and vehicle and use the provided 3/8” zinc hardware to loosely fasten it to the bumper. while installing the grille make sure to plug the camera into the hardness as you will not have access after the grille is installed—figure 26.

21. Reinstall OEM or Fab Fours skid plate at this time using the OEM hardware along with the provided 7/16” zinc washers.

22. Plug in all sensors and wiring harnesses and make sure all mounting hardware is fully tightened.

Contact information
Fab Fours Inc.
2213 Industrial Park Road Lancaster, SC 29720
Phone: 866-385-1905
Fax: 970-385-1914
Email: support@fabfours.com fabfours.com

“If you’re looking for more of the same, Then you’ve come to the wrong place.” – Greg Higgs

References

• Fab Fours

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