Fab Fours X535X Front Bumper Instruction Manual

: June 13, 2024
: Fab Fours

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Fab Fours X535X Front Bumper Instruction Manual
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Fab Fours X535X Front Bumper Instruction Manual

X535X

Installation manual
Front Bumper
Product number: X535X
Application: 2021 Ford raptor

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 own good judgment and take your time.

Check packaged materials immediately upon arrival to ensure that all listed parts are included and undamaged.

Read and understand all warnings, safety precautions, and instructions before installing this product.

SENSORS FIELD OF VIEW MAY BE ALTERED WITH 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 jewelry and wear eye protection.
Always use extreme caution when jacking up a vehicle for work. Set emergency brake and use tire blocks. Locate and use the vehicle manufacturers 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 power before welding. Thoroughly inspect the area to be drilled (on both sides of 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 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

X535X

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, better than expected to our customers.

Enjoy your new Fab Fours product. Welcome to the family!

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 part is acquired. Refer to the next pages as an inventory check.

Provided materials

Hardware kit | D535X

Hardware kit

TOOLS REQUIRED

10mm Socket Wrench
13mm Socket Wrench
15mm Socket Wrench
21mm Socket Wrench
T27 Star Head
Body Pry Tool
Cutting Tool
7/16” Socket Wrench
1/2” Socket Wrench
3/4” Socket 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 where you can catalog and store everything. We suggest labeling and bagging all the OEM bolts when removing 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.

Unplug the wiring harness located on the passenger side frame behind the front bumper.
Use a 13mm socket wrench to remove the 6 bolts holding the skid plate on and remove the skid plate from the truck. Figure 1.
Use a 21mm socket to remove the 6 (3 per side) nuts holding the front bumper to the frame rails. Figure 2.
Use a 15mm socket wrench to remove the two bolts holding the tow hooks to the frame. Remove the tow hooks from the truck and set aside the bolts and nut strips for later use. Figure 3.
Use an 8mm socket wrench to remove the four bolts holding the louver system between the frame horns. Unplug and remove the system from the trucks. Figure 4.
Remove the front air skirt from the louver system by unclipping it from the assembly. Trim the louver system as shown in Figure 6. Figure 5-6
Reattach the louvers to the truck using the provided brackets (21614 and 21615) along with the OEM bolts and (6) 1/4” yellow zinc hex bolt, flat washer, lock washers and nuts (50296-HW). Figure 7-8.
Carefully remove the sensors from the OEM bumper by pulling the sensors out of the housings and then pushing the housings out of the bumper. Be careful not to damage the sensors or the housings during removal. Note the location of each housing so it can be places in the correct location in your new bumper. Figure 9.
Place the housings into the new bumper and use the provided epoxy packets to fast them in place. Note orientation of the housings and make sure they are turned in the correct direction for the sensors and harness to fit. Figure 10.
Use a 13mm socket to remove the 5 bolts holding the driver side mounting plate onto the OEM bumper. Figure 11.
On the inside of the driver side mounting plate, you will find the Adaptive Cruise Control (ACC) Sensor. Use a 10mm socket to remove the 3 bolts holding the ACC sensor to the mounts. Figure 12.
Cut the provided plastic sheet to the dimensions shown in Figure 13. Once cut hold the plastic sheet in the bumper over the ACC sensor cut out and use a sharpie to mark the bolts hole locations. Use a 5/16” drill bit to drill the marked mounting holes. Figure 13
Use the provided #10 Black bolts, flat/lock washers, and nuts to fasten the plastic sheet into the bumper. Figure 14.
Use the provided 1/4” yellow zinc bolts, flat/lock washers, and nuts to install the ACC sensor to the ACC bracket (22532). Use the provided 5/16” yellow zinc bolts, flat/lock washers, and nuts to attach the sensor and bracket to the bumper. Figure 15.
If installing a 30” Single row light bar: Do so now using the provided L-brackets (21871) along with (2) 1/4” yellow zinc hex bolts, flats/lock washers and nuts to attach the light bar to the mounting structure (50296-HW). Figure 16.
Run the OEM wiring harness through the bumper and plug in the parking sensors and ACC sensor. Make sure that the harness plug is located on the passenger side of the bumper. Figure 17.
Place the frame gussets (22530 and 22531) into the driver and passenger side frames respectively. Place the tow hook nut plate on the frame gusset before putting them into the frame. Figure 18.
Install your winch into the winch tray (22529) using the manufacturer’s hardware and instructions.
With assistance, hold the winch tray up to the bumper and use the provided 1/2” yellow zinc bolts, flat and lock washers, and nuts to install it. Start by loosely attaching the tray to the frame rail using two of the 1/2” bolts (1). Next, use the OEM tow hook bolts along with 1/2” flat washers to loosely bolt through the frame to the frame gussets installed in step 17 (2). Lastly, install and fully tighten the front two 1/2” bolts through the winch tray to the frame gusset (3). Fully tighten bolts (1) and (3) respectively. Figure 19
Once all mounting hardware on the tray is tightened, remove the front two bolts (2) from the frame gussets. Figure 20.
With assistance, hold the bumper up to the winch tray and use the provided 1/2” bolts with flat/lock washers to attach it. Position the bumper as desired and fully tighten all mounting hardware. Figure 21.
Install the light boxes into the bumper by sliding the tabs into the upper slots and using the provided 5/16” yellow zinc bolts with fender washers and lock washers to fasten them in place. Figure 22.
Plug the wiring harness in and enjoy the fit and finish of your Fab Fours Matrix!