IRONBISON IB-CCS1-03 Front Bumper Installation Guide

Torque & Tools

90-180 min

Cutting Not Required

Drilling Not Required

Fastener Size	Tightening Torque (ft-lbs)	Wrench Required		Allen Wrench Required
6mm	7-8.5		10mm		4mm
8mm	18-20		13mm		5mm
10mm	35-40		16mm		6mm
12mm	60-70		18mm		8mm
BEFORE INSTALLATION REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT DEPEND ON THE PARTS LIST. READ INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION. ASSISTANCE IS HIGHLY RECOMMENDED TO AVOID POSSIBLE INJURY OR DAMAGE TO THE VEHICLE.

Use to attach theFrame Bracket tothe frame：	x8 12mm x 37mm x 3mm Flat Washer   x8 12mm Nylon x4 Lock Nut x410mm x 30mm x 2.5mm Flat Washer x4 10mm Nylon Lock Nut
Use to attach Bumper to the Frame Bracket:	x6 12mm x 40mm Hex Bolt x6 12mm Lock Washer x6 12mm x 37mm x 3mm Flat Washer
Use to attach Center Mesh Fill Panel or LED Light Bar to the Bumper:	x4 8mm x 25mm Hex Bolt x8 8mm x 24mm x 2mm Flat Washer x4 8mm Lock Washer
Use to attach theWings to the Bumper:	8mm x 20mm Hex Bolt 8mm x 16mm Flat Washe 8mm Flange Nut 6mm x 20mm Combo Bolt 6mm Flange Nut
Use to attach the LED Cube Light Brackets and Outer Mesh Fill Panels to the Bumper:	6mm x 20mm Combo Bolt 6mm Flange Nut
Use to attach License Plate Bracket to the Bumper:	x2 6mm x 20mm Button Head Bolt x4 6mm x 18mm x 1.6mm Flat Washer x2 6mm Nylon Lock Nut x1 4mm Allen Wrench
Use to attachhjihjuuihyu8hu8hyu8yu8hy8y8y8y7gy7y7y76y766 theParking Sensors onthe Bumper：	x2 Sensor Cap x2 Foam Spacer x2 Foam Seal Wire Harness Extension x2 Sensor Hole Plastic Plug (Use on the models without Front Sensor) x6 Sensor Cover (Cover the sensor when it fails)

STEP 1Open the hood and remove the plastic cover from the top of the grille and radiator, (Fig 1).

Remove cover and screws attaching grille
Models with grille mounted camera, unplug camera. Next, remove the screws attaching the grille to the radiator core support. Once all hardware has been removed, firmly pull the grille straight out from the vehicle to release the grille from the clips, (Fig 2).

STEP 2
Remove the license plate and bracket. On models with factory fog lights and/or bumper sensors, unplug the wiring harness leading to the bumper, (Fig 3).

Through the passenger/right fender liner, unplug wiring harness leading to front bumper (arrow)
NOTE: Wiring harness connector is located up and behind the passenger/right side of the bumper. Release clips attaching passenger/right fender liner to access plug for harness. Move harness away from bumper.
STEP 3
From behind the driver/left side of the bumper, remove the hardware attaching the outer bumper support to the side of the outer end of the bumper, (Fig 4).

Remove the hardware attaching the outer support bracket to the bumper (arrow)
STEP 4
Locate and remove the hex bolts attaching the bottom of the bumper to the bumper bracket attached to the end of the frame, (Fig 5).

Remove lower bumper supports (arrow) 

STEP 5
Repeat Steps 3 & 4 to remove the hardware attaching the bumper to the passenger/right bumper support and lower bumper bracket.

STEP 6
Move back to the top of the bumper. Pull back the end of the rubber cover between the bumper and the radiator to expose the bolts attaching the top of the bumper bracket to the frame bracket, (Fig 6).

Pull back cover to locate top bumper bolts
STEP 7
Place blocks or jack stands under the front bumper to support it during mounting bolt removal. Once the bumper has been safely supported, from above, remove the bumper bolts attaching the bumper assembly to the top of the bumper bracket, (Fig 6).
WARNING! Assistance is required to hold the bumper in place during bolt removal to prevent the bumper from falling. Carefully slide the bumper assembly with brackets off of the ends of the frame.
WARNING! Do not crawl under bumper unless it is properly supported on blocks or stands or the bumper may fall.

STEP 8
Remove both tow hooks from the end of the frame if equipped, (Fig 7)

Remove tow hooks if equipped
STEP 9
Select the driver/left Frame Bracket, (Fig 8).

Use (1) Left Offset and (1) Right Offset Triple Bolt Plates to attach the driver/left Frame Bracket to the frame
Slide the Bracket over the end of the frame. Insert (1) Left Offset Triple Bolt Plate into the end of the frame and out through the holes in the side of the frame and Mounting Bracket.

NOTE: Each Mounting Bracket will require (1) Left Offset and (1) Right Offset Bolt Plate for installation.

STEP 10
Attach the Bracket to the Left Offset Bolt Plate with the included (2) 12mm Flat Washers, (2) 12mm Nylon Lock Nuts, (1) 10mm Flat Washer and (1) 10mm Nylon Lock Nut, (Fig 8). Repeat to install (1) Right Offset Bolt Plate in the remining holes in the other side of the Frame Bracket, (Fig 9).

Driver/left Frame Bracket installed
(Fig 8) Use (1) Left Offset and (1) Right Offset Triple Bolt Plates to attach the driver/left Frame Bracket to the frame
(Fig 9) Driver/left Frame Bracket installed

STEP 11
Repeat Steps 9 & 10 to attach the passenger/right Frame Mounting Bracket.

STEP 12
Remove the air dam. Disassemble the factory bumper to remove the lower bumper fill panel, (Fig 10).

Disassemble front bumper assembly to remove lower bumper insert (arrow)
NOTE: Air dam and fill panel will not be reinstalled.

STEP 13
Determine if bumper is equipped with front parking sensors.

Models without sensors:

a. Push the included (2) Sensor Hole Plastic Plugs into the holes for sensors, (Fig 11). Skip to Step 14. Models with parking sensors.
a. Unplug and remove the (2) center sensors from the factory bumper.
b. Select (1) sensor. Remove the silicone seal from the end of the sensor. Slide the included larger Foam Seal over front of sensor, (Fig 12).
c. Insert sensor with Seal into sensor mount on the hoop on the Bumper, (Fig 13).
d. Place Foam Spacer onto the end of sensor. Push Sensor Cap and snap onto the sensor mount, (Fig 13).

Models without sensors, insert Plastic Plugs into sensor mounts on Bumper Hoop

(Fig 12) Remove original silicone seal from sensor. Slide included Foam Seal over end of sensor

(Fig 13) Push Sensor Cap into mounting sleeve

STEP 14
Reassemble the factory bumper. On models equipped with sensors, select (1) Wire Harness Extension. Push the Harness Extension through the sensor mount hole in the center of the factory bumper and plug into the inner factory harness. Repeat to insert the remaining Harness Extension.

STEP 15

Determine if factory fog lights, (if equipped), LED Cube lights, (not included), or if no lights will be installed with the Bumper.

Models equipped with and reusing factory fog lights:

a. Leave fog lights attached to plastic mount son back of factory bumper, (Fig 14).
b. Reinstall the factory bumper. Cube style LED light installation (not included):
a. Remove factory fog lights, (if equipped), from mounts on back of factory bumper, (Fig 15).
b. Select the driver/left LED Cube Light Bracket, (Fig 16). Attach the Bracket to the back of the Bumper with the included (5) 6mm x 20mm Combo Bolts and (5) 6mm Flange Nuts.
c. Attach Cube Light (Not Included) to tab on top of Mounting Bracket.
d. Repeat previous Steps to install the passenger/right cube light Bracket and light.
e. NOTE: If lights will not be installed, attach the included (2) Mesh Fill Panels to the Cube Light Brackets with (4) 6mm x 20mm Combo Bolts and (4) 6mm Flange Nuts, (Fig 17).

STEP 16
Determine if a center 20” LED light bar, (not included), or Mesh Fill Panel will be installed. Center 20” LED light bar installation (light not included).

a. Select the (2) “L” LED Brackets, (Fig 18). Attach the Brackets to the (2) mounting tabs on the back of the bumper with the included (2) 8mm x 25mm Hex Bolts, (4) 8mm x 24mm Flat Washers, (2) 8mm Lock Washers and (2) 8mm Hex Nuts. Leave loose at this time.
b. Attach the LED light to the “L” LED Brackets with the hardware included with the light or the included (2) 8mm x 16mm Hex Bolts, (2) 8mm Lock Washers and (2) 8mm x 24mm Flat Washers, (Fig 18). Do not fully tighten hardware at this time.
c. Follow light manufacturer’s instructions to properly wire the light.

Center Mesh Fill Panel Installation (do not  install Fill Panel with light).

a. Repeat the previous Step to install the (2) “L” LED Brackets.
b. Attach the Center Mesh Fill Panel to the “L” LED Brackets with the included (2) 8mm x 25mm Hex Bolts, (4) 8mm x 24mm Flat Washers, (2) 8mm Lock Washers and (2) 8mm Hex Nuts, (Fig 19).
c. Push Fill Panel up against the back of the Bumper and fully tighten hardware.

(Fig 18) Attach “L” LED Brackets if installing LED center light (not included) or Center Mesh Fill Panel.
Attach License Plate Bracket to BumperSTEP 18
If front license plate is required, attach the License Plate Bracket to the holes in the Bumper with the included (2) 6mm x 20mm Button Head Screws, (4) 6mm Flat Washers and (2) 6mm Nylon Lock Nuts. Insert (2) Square Plastic Plugs into the square holes in the Bracket, (Fig 21). Reuse the factory screws to attach the license plate to the Square Plastic Plugs.

STEP 20
Reinstall the plastic grille, camera if equipped and cover removed in Step 1, (Fig1).

STEP 21
Place the Bumper face down in front of the vehicle. Models with sensors, plug the Wire Harness Extensions into the (2) sensors in the Bumper, (Fig 22).

(Fig 22) Models with sensors, plug Wire Harness Extensions (see Step 14) on factory bumper into the sensors installed on the Bumper.

WARNING! Do not crawl under bumper unless it is properly supported on blocks or stands or the bumper may fall.

STEP 23
Line up the (3) slots in the driver/left side mounting plate on the back of the Bumper with the Frame Bracket. Insert (1) “T” Nut Plate into the back of the Frame Bracket, (Fig 23). Attach the Bumper to the Frame Bracket and “T” Nut Plate with the included (3) 12mm Hex Bolts, (3) 12mm Lock Washers and (3) 12mm Flat Washers, (Fig 24). Repeat to attach the passenger/right side.

(Fig 24) Driver/left side of Bumper attached to Frame Bracket (Note cube light installation)

STEP 25
Select the driver/left Lower Wing. Attach the Wing to the end of the Bumper with (1) 8mm x 20mm Hex Bolt, (1) 8mm x 16mm Small Flat Washer and (1) 8mm Flange Nut, (Figs 25 & 26). Attach the top of the Wing to the bottom of the factory bumper with the included (2) 6mm Button Head Combo Bolts and (2) 6mm Flange Nuts, (Fig 26). Repeat this Step to attach the passenger/right Lower Wing to the Bumper.

(Fig 26) Attach driver/left Lower Bumper “Wing” to end of Bumper and bottom of factory bumper. Installation illustrated from behind bumper

(Fig 27) Complete installation (20” Double Row Light Bar and two LED Cube Lights are not included)

STEP 26
Do periodic inspections to the installation to make sure that all hardware is secure and tight.

IRONBISON IB-CCS1-03 Front Bumper Installation Guide

Torque & Tools

Part List

STEP 1
Open the hood and remove the plastic cover from the top of the grille and radiator, (Fig 1). Models with grille mounted camera, unplug camera. Next, remove the screws attaching the grille to the radiator core support. Once all hardware has been removed, firmly pull the grille straight out from the vehicle to release the grille from the clips, (Fig 2). Place grille on a clean, soft surface.
(Fig 1) Remove cover and screws attaching grille
(Fig 2) Firmly pull grille straight out from vehicle

STEP 2
Remove the license plate and bracket. On models with factory fog lights and/or bumper sensors, unplug the wiring harness leading to the bumper, (Fig 3).
NOTE: Wiring harness connector is located up and behind the passenger/right side of the bumper. Release clips attaching passenger/right fender liner to access plug for harness. Move harness away from bumper.
(Fig 3) Through the passenger/right fender liner, unplug wiring harness leading to front bumper (arrow)

STEP 3
From behind the driver/left side of the bumper, remove the hardware attaching the outer bumper support to the side of the outer end of the bumper, (Fig 4).
(Fig 4) Remove the hardware attaching the outer support bracket to the bumper (arrow)

STEP 4
Locate and remove the hex bolts attaching the bottom of the bumper to the bumper bracket attached to the end of the frame, (Fig 5).
(Fig 5) Remove lower bumper supports (arrow) 

STEP 5
Repeat Steps 3 & 4 to remove the hardware attaching the bumper to the passenger/right bumper support and lower bumper bracket.

STEP 6
Move back to the top of the bumper. Pull back the end of the rubber cover between the bumper and the radiator to expose the bolts attaching the top of the bumper bracket to the frame bracket, (Fig 6).
(Fig 6) Pull back cover to locate top bumper bolts

STEP 7
Place blocks or jack stands under the front bumper to support it during mounting bolt removal. Once the bumper has been safely supported, from above, remove the bumper bolts attaching the bumper assembly to the top of the bumper bracket, (Fig 6).

WARNING! Assistance is required to hold the bumper in place during bolt removal to prevent the bumper from falling. Carefully slide the bumper assembly with brackets off of the ends of the frame.

WARNING! Do not crawl under bumper unless it is properly supported on blocks or stands or the bumper may fall.

STEP 8
Remove both tow hooks from the end of the frame if equipped, (Fig 7)
(Fig 7) Remove tow hooks if equipped 

STEP 9
Select the driver/left Frame Bracket, (Fig 8). Slide the Bracket over the end of the frame. Insert (1) Left Offset Triple Bolt Plate into the end of the frame and out through the holes in the side of the frame and Mounting Bracket.

NOTE: Each Mounting Bracket will require (1) Left Offset and (1) Right Offset Bolt Plate for installation.

STEP 10
Attach the Bracket to the Left Offset Bolt Plate with the included (2) 12mm Flat Washers, (2) 12mm Nylon Lock Nuts, (1) 10mm Flat Washer and (1) 10mm Nylon Lock Nut, (Fig 8). Repeat to install (1) Right Offset Bolt Plate in the remining holes in the other side of the Frame Bracket, (Fig 9).

(Fig 8) Use (1) Left Offset and (1) Right Offset Triple Bolt Plates to attach the driver/left Frame Bracket to the frame
(Fig 9) Driver/left Frame Bracket installed

STEP 11
Repeat Steps 9 & 10 to attach the passenger/right Frame Mounting Bracket.

STEP 12
Remove the air dam. Disassemble the factory bumper to remove the lower bumper fill panel, (Fig 10).

NOTE: Air dam and fill panel will not be reinstalled.

STEP 13
Determine if bumper is equipped with front parking sensors.

Models without sensors:

a. Push the included (2) Sensor Hole Plastic Plugs into the holes for sensors, (Fig 11).

Disassemble front bumper assembly to remove lower bumper insert (arrow)
Skip to Step 14. Models with parking sensors.
a. Unplug and remove the (2) center sensors from the factory bumper.
b. Select (1) sensor. Remove the silicone seal from the end of the sensor. Slide the included larger Foam Seal over front of sensor, (Fig 12).

Remove original silicone seal from sensor. Slide included Foam Seal over end of sensor
c. Insert sensor with Seal into sensor mount on the hoop on the Bumper, (Fig 13).
d. Place Foam Spacer onto the end of sensor. Push Sensor Cap and snap onto the sensor mount, (Fig 13)
Push Sensor Cap into mounting sleeve

STEP 14
Reassemble the factory bumper. On models equipped with sensors, select (1) Wire Harness Extension. Push the Harness Extension through the sensor mount hole in the center of the factory bumper and plug into the inner factory harness. Repeat to insert the remaining Harness Extension.

STEP 15
Determine if factory fog lights, (if equipped), LED Cube lights, (not included), or if no lights will be installed with the Bumper.

Models equipped with and reusing factory fog lights:

a. Leave fog lights attached to plastic mount son back of factory bumper, (Fig 14).

Reassemble bumper without lower bumper insert. Back of driver/left side of model with fog light pictured
b. Reinstall the factory bumper. Cube style LED light installation (not included):
a. Remove factory fog lights, (if equipped), from mounts on back of factory bumper, (Fig 15).

Remove factory fog light if installing LED cube style lights or Mesh Fill Panels
b. Select the driver/left LED Cube Light Bracket, (Fig 16).

Install driver/left LED cube light Bracket
Attach the Bracket to the back of the Bumper with the included (5) 6mm x 20mm Combo Bolts and (5) 6mm Flange Nuts.
c. Attach Cube Light (Not Included) to tab on top of Mounting Bracket.
d. Repeat previous Steps to install the passenger/right cube light Bracket and light.
e. NOTE: If lights will not be installed, attach the included (2) Mesh Fill Panels to the Cube Light Brackets with (4) 6mm x 20mm Combo Bolts and (4) 6mm Flange Nuts, (Fig 17).

 Attach Fill Panel to Light Bracket if no light will be installed
STEP 16
Determine if a center 20” LED light bar, (not included), or Mesh Fill Panel will be installed. Center 20” LED light bar installation (light not included).

a. Select the (2) “L” LED Brackets, (Fig 18).

Attach “L” LED Brackets if installing LED center light (not included) or Center Mesh Fill Panel.
Attach the Brackets to the (2) mounting tabs on the back of the bumper with the included (2) 8mm x 25mm Hex Bolts, (4) 8mm x 24mm Flat Washers, (2) 8mm Lock Washers and (2) 8mm Hex Nuts. Leave loose at this time.
b. Attach the LED light to the “L” LED Brackets with the hardware included with the light or the included (2) 8mm x 16mm Hex Bolts, (2) 8mm Lock Washers and (2) 8mm x 24mm Flat Washers, (Fig 18). Do not fully tighten hardware at this time.
c. Follow light manufacturer’s instructions to properly wire the light.

Center Mesh Fill Panel Installation (do not  install Fill Panel with light).

a. Repeat the previous Step to install the (2) “L” LED Brackets.
b. Attach the Center Mesh Fill Panel to the “L” LED Brackets with the included (2) 8mm x 25mm Hex Bolts, (4) 8mm x 24mm Flat Washers, (2) 8mm Lock Washers and (2) 8mm Hex Nuts, (Fig 19).

Attach Center Mesh Fill Panel to “L” LED Brackets (Do not install Fill Panel with LED light)
c. Push Fill Panel up against the back of the Bumper and fully tighten hardware.

STEP 17
Attach the included Edge Trim to the top edge of the Bumper, (Fig 20).

Apply Rubber Trim to edge of Bumper

STEP 18
If front license plate is required, attach the License Plate Bracket to the holes in the Bumper with the included (2) 6mm x 20mm Button Head Screws, (4) 6mm Flat Washers and (2) 6mm Nylon Lock Nuts. Insert (2) Square Plastic Plugs into the square holes in the Bracket, (Fig 21). Reuse the factory screws to attach the license plate to the Square Plastic Plugs.

Attach License Plate Bracket to Bumper

STEP 20
Reinstall the plastic grille, camera if equipped and cover removed in Step 1, (Fig1).

STEP 21
Place the Bumper face down in front of the vehicle. Models with sensors, plug the Wire Harness Extensions into the (2) sensors in the Bumper, (Fig 22).

Models with sensors, plug Wire Harness Extensions (see Step 14) on factory bumper into the sensors installed on the Bumper.

WARNING: To avoid possible injury or damage to the vehicle, do not proceed until the Bumper is fully and safely supported.
WARNING! Do not crawl under bumper unless it is properly supported on blocks or stands or the bumper may fall.

STEP 23
Line up the (3) slots in the driver/left side mounting plate on the back of the Bumper with the Frame Bracket. Insert (1) “T” Nut Plate into the back of the Frame Bracket, (Fig 23). Attach the Bumper to the Frame Bracket and “T” Nut Plate with the included (3) 12mm Hex Bolts, (3) 12mm Lock Washers and (3) 12mm Flat Washers, (Fig 24).

Driver/left side of Bumper attached to Frame Bracket (Note cube light installation)
Repeat to attach the passenger/right side.

STEP 25
Select the driver/left Lower Wing. Attach the Wing to the end of the Bumper with (1) 8mm x 20mm Hex Bolt, (1) 8mm x 16mm Small Flat Washer and (1) 8mm Flange Nut, (Figs 25 & 26). Attach the top of the Wing to the bottom of the factory bumper with the included (2) 6mm Button Head Combo Bolts and (2) 6mm Flange Nuts, (Fig 26). Repeat this Step to attach the passenger/right Lower Wing to the Bumper.
c
(Fig 25) Attach driver/left Lower Bumper “Wing” to end of Bumper and bottom of factory bumper (arrows)

(Fig 26) Attach driver/left Lower Bumper “Wing” to end of Bumper and bottom of factory bumper. Installation illustrated from behind bumper

(Fig 27) Complete installation (20” Double Row Light Bar and two LED Cube Lights are not included)

STEP 26
Do periodic inspections to the installation to make sure that all hardware is secure and tight.

www.ironbisonauto.com Page 10 of 10 Rev. 6/27/23 (JH)

Documents / Resources

IRONBISON IB-CCS1-03 Front Bumper [pdf] Installation Guide IB-CCS1-03, IB-CCS1-03 Front Bumper, Front Bumper, Bumper

References

• User Manual