Removable Front Bumper End Caps - Raptor - Removing and Installing the Front Bumper End Caps

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Removing and Installing the Front Bumper End Caps

WARNING: Do not store the bumper end-caps in the vehicle. Unsecured end-caps could become a projectile in a sudden stop or crash.

Note: Front bumper end caps are not rated for rock crawl use or off-road conditions where ground contact is likely to occur. We recommend removing the end caps before use on roads under these conditions to avoid damage.

Removing the Front Bumper End Cap

Park your vehicle on level ground and make sure the transmission is in park (P) and the engine is off.

Locate the 17 reusable pushpins on the center front bumper cover.

Use a suitable tool, such as a flat blade screwdriver in the 0.10 in (2.5 mm) space between the head of the pushpin and the body of the pushpin to pry out the head away from the body to release the locking mechanism.

Pull the head of the pushpin out so space between the head and body of the pushpin is about 0.626 in (15.9 mm).

Note: The pushpin should now be loose in the bumper cover.

Pull the pushpin out from the bumper cover.

Note: Complete removal of the pushpin head is not necessary to remove the pushpin. The head and stem of the pushpin may come apart from the body of the pushpin during removal. The pushpin is not broken. The head can be reinserted into the body later during installation. Make sure to remove the body of the pushpin from the bumper cover to allow removal of the bumper cover.

Repeat Steps 2-4 to remove the rest of the pushpins.

Remove the center front bumper cover.

Note: Avoid setting the front bumper cover down on hard or sharp surfaces to prevent damage.

From behind the front bumper end cap, disengage the lamp electrical connector by pressing and holding down on the release tab on the vehicle-side connector while pulling the connectors apart.

Note: The lamp connector is attached to the lamp housing and you do not need to remove it from the lamp to perform this step.

Locate the tool pouch and use the hex tool to remove the bolt at the top center of the lamp.

Store the lamp bolt in the pocket of the tool pouch.

Loosen the top rear bolt of the bumper end cap.

Note: Make sure the bolt does not touch the end cap.

Note: You do not need to remove the bolt. Removal could cause damage to body panel above the bolt. The end cap at this location has a slot to allow removal in the next step.

Remove the three bolts from the bumper end cap lower attachment and one bolt from the front top attachment.

Slide the end cap with the lamp assembly straight out to the side of the vehicle.

Note: Avoid setting the end cap down on hard or sharp surfaces to prevent damage to the end cap and lamp housing.

Note: Store the end cap out of the elements to prevent damage to the bumper end cap and lamp electrical connector.

Using the hex tool, install and tighten the four bolts removed in Step 12.

Tighten the bolt loosened in Step 11.

Note: We recommend that you use a torque wrench to make sure that you tighten all the bolts to 16 lb.ft (22 Nm).

Locate the docking plug and cover on the back of the front bumper.

Disengage the docking plug protective cover by pressing down and holding the release tab while pulling the docking plug protective cover apart from the docking plug.

Note: You do not need to remove the docking plug that is attached to the bumper to perform this step.

Store the protective docking cover in the pocket of the tool pouch.

Insert the vehicle-side lamp connector into the docking plug attached to the bumper. Push in until you feel it click together.

Note: Installation of the vehicle-side lamp connector into the docking plug is important to prevent damage to the vehicle wiring, lighting system, or fuses.

Note: Make sure you do not press the release tab on the lamp connector when pushing the connectors together, this way you can feel them click together.

To remove additional front bumper end caps, repeat Steps 2-19 on the opposite side.

Reinstall the center front bumper cover in the original location.

Install the 17 pushpins removed in Steps 2-6. Do not press the pushpin heads in until all pushpins are in place.

Lock the pushpins in place by pushing the head in until it stops.

Note: There should be a gap of about 0.10 in (2.5 mm) between the head and body of the pushpin.

Return the hex tool to the tool pouch with the docking plug protective caps and lamp bolts, and then secure the tool pouch in the vehicle.

Installing the Front Bumper End Cap

Park your vehicle on level ground and make sure to place the transmission in park (P) and that you switch the engine off.

Locate the 17 reusable pushpins on the center front bumper cover.

Use a suitable tool, such as a flat blade screwdriver in the 0.10 in (2.5 mm) space between the head of the pushpin and the body of the pushpin to pry out the head away from the body to release the locking mechanism.

Pull the head of the pushpin out so space between the head and body of the pushpin is about 0.626 in (15.9 mm).

Note: The pushpin should now be loose in the bumper cover.

Pull the pushpin out from the bumper cover.

Note: Complete removal of the pushpin head is not necessary to remove the pushpin. The head and stem of the pushpin may come apart from the body of the pushpin during removal. The pushpin is not broken. You can reinsert the head into the body later during installation. Make sure to remove the body of the pushpin from the bumper cover to allow removal of the bumper cover.

Repeat Steps 2-4 to remove the rest of the pushpins.

Remove the center front bumper cover.

Note: Avoid setting the front bumper cover down on hard or sharp surfaces to prevent damage.

From behind the front bumper, disengage the lamp electrical connector from the docking plug by pressing and holding down on the release tab on the vehicle-side connector when pulling the connectors apart from the docking plug.

Note: The docking plug is attached to the bumper and you do not need to remove it from the vehicle to perform this step.

Locate the tool pouch and remove the docking plug protective caps stored in the pouch during bumper end cap removal.

Insert the docking plug protective cap onto the docking plug attached to the bumper and push together until you feel them click together.

Note: It is important to reinstall the docking plug protective cover on the docking plug to prevent damage to the vehicle lamp connector the next time you use the docking plug.

Note: Make sure you do not press the release tab on the lamp connector when pushing the connectors together, this way you can feel them click together.

Use the hex tool to remove the three bolts from the bumper end cap lower attachment and one bolt from the front top attachment.

Loosen the top rear bolt of the bumper end cap.

Note: Make sure the bolt does not touch the end cap

Note: You do not need to remove the bolt. Removal could cause damage to the body panel above the bolt. The end cap at this location has a slot to allow removal in the next step.

Slide the end cap with the lamp assembly straight in from the side of the vehicle.

Note: Make sure the front bumper end cap slot is under the top rear bolt head on the bumper.

Align the holes in the end cap and bumper at the front lower attachment.

Hand start the three bolts at the front bumper end cap lower attachment and the one bolt from the front top attachment.

Note: Do not tighten or torque the bolts.

Locate the lamp bolt stored in the tool pouch during the front bumper end cap removal.

From behind the bumper, hand start the lamp bolt at the top center of the lamp housing.

Note: Do not tighten or torque the bolt.

Using the hex tool, tighten the four bolts installed in Step 15. Then tighten the bolt loosened in Step 12. Lastly, tighten the bolt installed in Step 17.

Note: We recommend that you use a torque wrench to make sure that you tighten all the bolts to 16 lb.ft (22 Nm).

Insert the vehicle-side lamp wiring connector onto the lamp plug attached to the lamp housing and push together until you feel it click together.

Note: Make sure you do not press the release tab on the lamp connector when pushing the connectors together, this way you can feel them click together.

Note: The lamp-side wiring connector is attached to the lamp housing and does not need to be removed to perform this step.

To install the additional front bumper cap, repeat Steps 8-19 on the opposite side.

Reinstall the center front bumper cover in the original location.

Install the 17 pushpins removed in Steps 2-6. Do not press the pushpin heads in until all pushpins are in place.

Lock the pushpins in place by pushing the head in until it stops.

Note: There should be a gap of about0.10 in (2.5 mm) between the head and body of the pushpin.

Return the hex tool to the tool pouch with the docking plug protective caps and lamp bolts, and then secure the tool pouch in the vehicle.

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