GO RHINO 24132T BR6 Bumper Replacement Instruction Manual

INSTALLATION INSTRUCTIONS
REV 3 05/13/2016

24132T BR6 Bumper Replacement

PART NO.
● 24132T| PRODUCT DESCRIPTION:
● BR6 BUMPER REPLACEMENT| APPLICATION:
● RAM 1500
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PRODUCT SAFETY & LEGAL DISCLAIMER

• IMPORTANT READ ALL INSTRUCTIONS CAREFULLY BEFORE INSTALLING, FAILURE TO DO SO MAY CAUSE PERSONAL INJURY OR DAMAGE TO PRODUCT AND/OR PROPERTY.
• Review the product package and contents prior to beginning the installation. Take care when opening the packaging and removing items. If a return is needed you will want to return the product in its original packaging if possible.
• This instruction guide is provided as a GENERAL installation guide, some vehicles vary dimensionally and may require additional steps.
• Test fit the product on the vehicle prior to any third party modifications and or finishing. The manufacturer and/or distributors do not accept responsibility for third party charges, labor and or third part replacement modifications. Some modifications may void the factory warranty.
• Exercise due-diligence when installing this product. The manufacturer and distributors of this product do not accept any responsibility for vehicle damage or personal injury resulting from the installation of this product. Careless installation and operation can result in serious injury or equipment damage.
• This product is for general off-road use. All liability for installation and use rests with the owner/operator.
• INSTALLER: Once installation is complete, please return this guide along with other documentation included in this product back to the consumer for future reference. The manufacturer/distributors of this product do not guarantee this particular version will be available at a later date.

INJURY HAZARD

Please complete a shop and tool inspection prior to beginning the installation.

• Always make sure you have a clean, dry and well lit work area.
• Always remove jewelry, loose fitting clothing and wear protective gloves and eye protection.
• Always use extreme caution when jacking or raising a vehicle for work. Set the emergency brake and use tire/wheel blocks and jack stands. Refer to the vehicle manufacturer hand book. Utilize the vehicle manufacturers designated lifting points.
• Always use appropriate and adequate care in lifting parts during disassembly and installation. Seek help in lifting heavy or large items into place. Utilize jacks and or lifting devices when available.
• Always insure products are secure during disassembly and installation.
• Always wear eye protection and take steps to protect any exposed skin during the installations. Drilling, cutting and grinding plastic and metal may create flying particles that can cause injury.
• Always use extreme caution when drilling, cutting and or grinding on a vehicle. Thoroughly inspect the area to be drilled, on both sides of material, prior to modification and relocate any objects that may become damaged.
• Always assemble and tighten all fasteners per the installation instructions.
• Always route electrical cables carefully. Avoid moving parts, parts that may become hot and rough or sharp edges.
• Always insulate and protect all exposed wiring and electrical connections.

MAINTENANCE AND CARE

• Always perform regular inspections and maintenance on mounts and related fasteners.

• Periodically check and tighten all fasteners.

• Stripped, fractured, or bent fasteners must be replaced.

• After washing the vehicle make sure to fully dry all surfaces.

• In areas with cold temperatures make sure to wash the product often to remove harmful materials used on road ways.

• Never use abrasive cleaners or polish compounds. Clean with a gentle soap and water. If you use wax use a non-abrasive automotive wax such as pure carnauba wax.
  WARNING
  Some products have been designed to work together with factory rear sensor systems, factory forward facing sensor systems and factory air bags.

• Installation of some of these products may alter the factory sensor system performance.

• Factory sensors may read shackles or hooks protruding from the fairlead and or tow hooks.

• All sensor testing is completed by Go Rhino Products and or third party testing labs on modified vehicles.

• Sensor sensitivity, factory sensor housing, orientation, and operating conditions are all variables that will influence functionality of the sensors.

• Installation of some product may effect the factory air bag systems.

• Some products allow the use of third party products such as winches, shackles, hooks, etc. Follow the respective manufacturers operating instructions for use with our products.

• Make sure to fully understand the product, it’s intended use and operation prior to use.

• Above all… be safe!

PARTS INCLUDED IN THIS LIST:

Go Rhino recommends you, the installer, read this installation instruction manual from front to back before installing the product. You may also click here to view an installation video or visit http://www.gorhino.com/Installation-Videos.

TOOLS NEEDED FOR INSTALLATION:

• 3/4” Socket & Wrench
• 9/16” Socket & Wrench
• 8, 10, 12 & 18mm Socket
• Ratchet & Extension

ESTIMATED TIME FOR INSTALLATION: 1.5 Hour

If you need installation service for your new product, call the authorized distributor from whom you purchased the product or an authorized installation service company which can be found by calling toll free 1-888-427-4466

OEM Bumper Removal
Step-1 Open the hoof and disconnect the vehicle battery. From under the vehicle, on the driver side, disconnect the bumper wiring harness from the vehicle wiring harness (FIGURE 1).

Step-2 Locate on each side of the vehicle, using a 8mm socket, remove the (5) screws securing the fender liner, (FIGURE 2).

Step-3 From underneath on each side of the vehicle, using a 18mm socket remove (3) nuts securing the OEM bumper , (FIGURE 3). Remove the OEM bumper from vehicle.
Note: If equipped, unplug the connector on the back side of the air dam motor and remove (4) nuts attaching the air dam from the vehicle. The air dam will not be reinstalled.

Step-4 If equipped, on each side of the vehicle using a 18mm socket remove the (2) bolts securing the tow hook, then remove the hook pushing out the rubber ring from the rear part of the hook (FIGURE 4). Note: The tow hooks will not be reinstalled.

BR5.5 Bumper Installation
Step-1 Install the driver side auxiliary bracket by positioning the bracket underneath the frame member, secure using the bolts previously removed. Leave the rear bolt loose to install the lateral bracket sliding on the bolt. NOTE: Leave the bolt´s rubber spacer between the brackets. Leave the bolts loose for final adjustment. Figure 1.

Step-2 Install the driver side frame bracket by positioning the bracket up to the end of the frame member plate and the auxiliary bracket, align the holes and secure using (5) ½” x 1 ½” Carriage bolts, (5) ½” Flat washers, (5) ½” Lock washers and (5) ½” Hex nuts. Leave the nuts loose for final adjustment. Figure 2.

Step-3 Position the winch tray on top of the frame brackets. Align the holes and secure the winch tray to the side of each bracket using (1) ½ x 1 ½” hex bolt, (1) ½” flat washers, (1) ½” lock washers and to the bottom of each bracket using (3) ½ x 1 ½” carriage bolt, (3) ½” flat washers, (3) ½” lock washers and (3) ½” hex nuts. Figure 3. Leave the bolts and nuts loose for final adjustment.

Note: If you are installing a winch, place the winch in the winch tray and refer to the winch manufacturer’s instructions for installation. Do not install the fairlead at this time.
If your vehicle is not equipped with front Park Assist, move ahead to page 9 of the BR6 Bumper Installation instructions. If your vehicle is equipped with front Park Assist, continue with the following steps. Note: The Park Assist sensors and sensor bezels have to be installed in the BR6 bumper replacement in the same position as removed from the OEM bumper.
Step-4 Disconnect the parking sensors from the OEM bumper wiring harness and remove the wiring harness from the OEM bumper.
Step-5 Remove each parking sensor from the plastic bezel by gently spreading the bezel tabs and pulling out on the back of the sensor. Note: Do not push on the front of the sensor as this may damage it.
Step-6 Remove the parking sensor bezels from the OEM bumper by depressing the tabs around the base and pushing the bezel out through the front of the bumper.
Step-7 Remove the (4) plastic plugs from the sensor bezel plates that are preinstalled in the BR6bumper.
Step-8 Aline the protrusions on each sensor bezel with the profile in the matching bezel plate, then from the front of the BR6 bumper push the bezel through the profile in the plate until the tabs around the base lock in position. Note: The Park Assist sensors and bezels have to be installed in the BR6 bumper replacement in the same position as removed from the OEM bumper.
Step-9 Install the parking sensors in the sensor bezels and transfer the OEM bumper wiring harness to the BR6 bumper and re-connect to the parking sensors, (Fig 4).

Step-10 The pre-installed Mesh Vent Covers need to be removed from each side of the bumper using hand tools to slowly remove the bolts, (Fig 5). Note: Using an air assisted impact or ratchet will damage the bolt threads and rubber rivet-nut assembly.

Step-11 With assistance lift the bumper shell up to the vehicle, align the holes in the bumper shell brackets with the holes in the frame brackets, and weld nuts on the winch tray. Secure the bumper shell bracket to each side of the winch tray using (3) ½” x 1 1/2” hex bolts, (3) ½” lock washers and (3) ½” flat washers, (Fig 6). Leave the bolts loose for final adjustment.

Step-12 Attach the opposite end of each support bracket to the bumper shell bracket using (1) 1/2” x 1 1/2” hex bolt, (2) 1/2” flat washers, (1) 1/2” lock washer and (1) 1/2” hex nut, (Fig 7).

Step-13 With assistance, adjust and hold the bumper shell visual alignment position, then tighten all factory and supplied nuts and bolts securing the brackets, winch tray and bumper shell.
Step-14 If installing a winch, install the roller fairlead to the bumper shell at this time. Refer to the winch manufacturer’s instructions for installation. If installing an BR6 bumper replacement optional light bar, install the light bar to the bumper replacement at this time. Refer to the light bar instructions for installation.
Step-15 Reinstall the passenger and driver side front vent covers to the bumper shell using the ¼” x 1” button head bolts, ¼” plastic flat washers and ¼” rubber rivet-nuts removed in step 10.
Step-19 If your state law requires a front license plate, attach the license plate bracket to the holes in the face of the bumper shell, using the supplied 3/8” bolts, washers and nuts. Attach the license plate to the holes in the license plate bracket. If installing a winch, attach the license plate directly to the holes in the hitch cover, (Fig 9).

LIMITED WARRANTY

Go Rhino warrants to Buyer that for a period of five (5) years from the date of shipment of the product(s) (“Warranty Period”) for black finishes and chrome finishes, that such products will materially conform to the specifications set forth in Go Rhino’s specifications in effect as of the date of shipment(s) and will be free from material defects in material workmanship.
Go Rhino warrants to Buyer that for the life of the product(s) from the date of shipment of the product(s) (“Warranty Period”) for polished stainless steel finished products purchased after April 2004, that such products will materially conform to the specifications set forth in Go Rhino’s specifications in effect as of the date of shipments and will be free from material defects in material workmanship.
Warranty claims must be accompanied with the original invoice and photos of the product. It is the customer’s responsibility to clean regularly and protect finish with regular applications of a nonabrasive polish that is compatible with the product’s finish.
This warranty covers the cost of the product only and does not include the cost of removal, installation, third party modifications or shipping of the product. In no event shall Go Rhino be liable to buyer or any third party for any damage or harm caused by the product or use thereof, regardless of whether such damages were foreseeable and whether or not Go Rhino has been advised of the possibility of such damages, not withstanding the failure of any agreed or other remedy of its essential purpose. This warranty is void if the product shows signs of alteration, misuse, mishandling, improper care, neglect, improper application and/or damage due to improper installation.
With respect to any such product(s) during the limited warranty period, Go Rhino shall, in its sole discretion, either: (i) provide a one-time repair or replacement of such products (or the defective part) or (ii) credit or refund the price of such products at the pro rata contract rate provided that, if Go Rhino so requests, Buyer shall, at Go Rhino’s expense, return such product(s) to Go Rhino. The remedies shall be the Buyer’s sole and exclusive remedy and Go Rhino’s entire liability for any breach of the limited warrant(ies).
Go Rhino disclaims all other warranties except to the extent that any such warranty cannot be validly disclaimed under applicable law.

Finish Limited Warranty:
Limited lifetime on stainless steel products (after April 2004)
5 year warranty on black powder coat products
5 year warranty on chrome products
This warranty does not cover exposed welds

Finish warranty covers peeling, flaking, or cracking. Washing all finishes regularly with car wash soap and rinsing well with water is the best method for maintaining the finish on your products. You must also protect the finish with nonabrasive automotive wax on a regular basis. The use of any compound which contains abrasives becomes a self-defeating exercise as the compound scratches the finish and opens it to corrosion. The use of harsh chemicals used to remove bugs and tar may also cause the finish to fail and should be avoided.
If you are unsatisfied with your purchase please contact the establishment you purchased the product from.
If you need to place a warranty claim or need assistance, the Go Rhino customer service team will answer any questions you may have. Please contact the Go Rhino customer service team at 1-888-427-4466 during normal business hours Monday thru Friday 7 am to 5 pm PST. You may also email [email protected]. In order to better serve you please provide a copy of the original invoice / receipt, a photo of the issue you are experiencing and a photo of the vehicle the product is installed on.
All warranty returns must have an approved RGA number. The RGA number must be clearly marked on the exterior of the return package. All approved warranty returns must be shipped to Go Rhino Products, 810 Nafta Blvd Laredo, TX 78045

PRODUCT REGISTRATION

Please remember to register your new purchase. You may register your product at www.gorhino.com. Registering your product may help speed any future warranty or customer service inquiries.

Thank you again for purchasing from Go Rhino Products
Please take a few minutes to view additional products for your vehicle and more at GORHINO.com
These installation instructions are available on the Go Rhino web site along with installation videos for many of our products.

www.gorhino.com
www.bigcountryauto.com
www.gorhinopd.com

REV.01
© 2016 Go Rhino Products. All rights reserved

References

• Big Country Truck Accessories | RealTruck
• Big Country Truck Accessories | RealTruck
• Gorhinopd.com

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