Installation Instructions

HANSON RUBICON SERIES FRONT BUMPER FOR JEEP TJ/YJ/LJ

Thank you for purchasing a Hanson Bumper!

Installation time should be approximately 30 to 60 minutes.

Tools needed are a T-55 Torx socket, 7/16” through 5/8” sockets along with the appropriate ratchet and combination wrenches.

REMEMBER! ALWAYS TEST FIT ANY BOLT-ON PRODUCT BEFORE PAINTING OR MODIFYING IT IN ANY WAY TO BE SURE IT FITS. MODIFIED PARTS CANNOT BE RETURNED AND WE WILL NOT REIMBURSE YOU FOR ANY FINISHING COSTS.

The front bumper installation is straightforward for the Wranglers. It uses the original bumper holes in the frame and comes with all needed hardware. The factory plastic anti-swaybar cover can be retained if desired, but a slight trimming may be required.

1. Remove the six Torx type bolts holding the stock bumper in place, along with the tow hooks, if present.

On TJ/LJ models the upper frame holes line up with the two forward-most inline holes in our bumper bracket. On YJ models the wider spaced front and rear upper holes are utilized. Bottom holes are the same on all three models.

IF NOT INSTALLING A WINCH OR OTHER ACCESSORIES SKIP STEPS 2 AND 3.

2. The winch must be mounted to the bumper prior to installing the bumper. However, you must test fit the bumper first to determine if any adjustments need to be made. Trial fitting the bumper before mounting the winch or other accessories assures a correct fit without having to lift the added weight of a winch.

3. Bolt the fairlead to the supplied fairlead mount. Place the bumper on a solid working surface. Place the fairlead assembly over the pre-drilled holes in the winch-deck with the fairlead facing forward. Run winch cable through fairlead assembly. Place winch on top of fairlead assembly, sandwiching the fairlead mount between winch and the bumper. Line up the holes on the bumper, fairlead mount and winch. Using the four 3/8 x 2” bolts supplied with the bumper, go from the inside of the bumper through fairlead mount into the winch. After all 4 bolts are inserted, tighten them according to winch manufacturer's recommendations.

4. Now you can install your bumper. For safety, we recommend a helper when installing a bumper and winch combination. Slide the bumper over frame ends and insert the supplied hex bolts with flat washers. Before tightening bolts, check alignment on bumper. Tighten bolts securely. Recheck bolts for tightness after 2 weeks of use.

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Tuesday 09 March, 2010