Fab Fours
Instruction Manual for Fab Four models including: n545x, 2022 TOYOTA tundra, 2022 TOYOTA Tundra Hidden Winch Mount, 2022, TOYOTA Tundra Hidden Winch Mount, Tundra Hidden Winch Mount, Hidden Winch Mount, Winch Mount, Mount
File Info : application/pdf, 23 Pages, 10.36MB
DocumentDocumentInstallation manual TOYOTA TUNDRA Hidden winch mount part number: n545x Application: 2022 TOYOTA tundra 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. Table of contents 2 SAFETY / DISCLAIMER 3 TABLE OF CONTENTS 4 A MESSAGE FROM THE OWNER 5 GETTING STARTED 6 PROVIDED MATERIALS 7 HARDWARE KIT 8 INSTALLATION 12 CONTACT A message from the owner 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! Greg Higgs 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. 5 Provided materials 22635 - HIDDEN WINCH MOUNT TOOLS REQUIRED · 10mm socket wrench · 14mm socket wrench · 15mm socket wrench · 17mm combination wrench · 5/8" combination wrench · 7/16" socket wrench · 1/2" socket wrench · 11/16" socket wrench · 3/4" combination wrench · Phillips Head Screw Driver · Body Pry Tool · Cutting Tool 22610 AIR DAM RELOCATION BRACKET 22643 SMALL LIGHT BAR L-BRACKETS QTY:2 assistance We recommend two people perform the installation as items are heavy and may need to be held in place while installing. 22636 DS MOUNT 22637 - PS MOUNT 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. 21871 - SIDE VALANCE L-BRACKETS QTY:2 20296 - 1/2" BOLT STRIP QTY:2 221859 7/16 WELD NUT BRACKET QTY:2 N545X-IM INSTRUCTION MANUAL 50322-HW HARDWARE KIT Hardware kit | N545X-IM Fab Fours Component QTY Identification Description 50322-HW Black Plastic Winch Tray Plugs 4 50322-HW 1/2", SAE, Yellow-zinc, Grade 8, Lock washer 8 50322-HW 1/2"-13 Yellow Zinc Hex Nut, Grade 8 4 50322-HW 1/2" Yellow Zinc Flat Washer, Grade 8 4 50322-HW 1/2" Yellow Zinc Lock Washer, Grade 8 4 50322-HW 1/4"-20 Yellow Zinc Hex Head Bolt, Grade 8 10 50322-HW 1/4"-20 Yellow Zinc Hex Nut, Grade 8 10 50322-HW 1/4" Yellow Zinc Flat Washer, Grade 8 18 50322-HW 1/4" Yellow Zinc Lock Washer, Grade 8 10 50322-HW 1/4" Stainless Steel Fender Washer 2 50322-HW 7/16"-14 Yellow Zinc Hex Head Bolt, Grade 8 6 50322-HW 7/16"-14 Yellow Zinc Hex Nut, Grade 8 4 50322-HW 7/16" Yellow Zinc Flat Washer, Grade 8 14 50322-HW 7/16" Yellow Zinc Lock Washer, Grade 8 6 7 installation 1. Use a 10mm socket to remove the 4x bolts holding the top of the grille to the radiator frame (Figure 1.). Use a body pry tool to remove the 2x push pins on the sides of the top grill and unplug the wiring harness (Figure 2.). Figure 1 Figure 2 2. Use a 10mm socket to remove the 4x bolts holding the bottom of the bumper to the frame structure. Figure 3. Figure 3 3. Use a 10mm socket to remove the 5x bolts on the front of the wheel wells to access the valance body clips. Figure 4. Figure 4 4. Carefully use a body pry tool to disengage the panel clips holding the fender flare onto the truck. Pull the flare away from the body to access the valance clips. Note: Do NOT fully remove fender flare. Figure 5. Figure 5 9 5. Remove the grill and bumper assembly from the truck by carefully disengaging the lower grille panel clips. Set the grill assembly aside for disassembly. 6. Use a 17mm socket to remove the 8x bolts (2x on top 2x on bottom) holding the crash bar to the frame rails. Figure 6-7. Figure 6 Figure 7 7. Use a Phillips head screwdriver to remove the bolts on the air dam housing. Figure 8. Figure 8 8. Use a 10mm socket and a Phillips head to remove the 2x hex head bolts and 1x screw respectively. Remove the motor assembly from the housing. Remove the motor assembly from the aluminum crash bar using a 10mm socket to remove the 4x bolts. Figure 9. Figure 9 11 9. Remove the white plastic gear from the motor assembly by pulling it off. Figure 10. Figure 10 10. Use a Phillips head to remove the 3x bolts holding the gear and shaft in place. Remove the gear and shaft from the assembly. Figure 11-12. Figure 11 Figure 12 11. Remove the E-clip from the linkage pin. Set the gear shaft linkage aside for later assembly. Figure 13. Figure 13 12. Use a cutting too to remove the access gusset material on the air dam motor housing. Figure 14-18. Figure 14 Figure 15 Figures continued on next page 13 Figure 16 Figure 17 Figure 18 13. Reverse steps 6-10 to put the motor assembly back together. Include the shaft linkage removed in step 10. 14. Use a 1/4" drill bit to drill 2x holes in the motor assembly to attach it to the provided mounting bracket (22610). Use the provided ¼" yellow zinc bolts with washers and nuts. Figure 19. Figure 19 15. Use a 12mm and 10mm socket to relocate the passenger side horn to the 10mm bolt. This will allow room for the air dam relocation. Figure 20-21. Figure 20 Figure 21 15 16. Use the provided ¼" yellow zinc bolts with washers and nuts to attach the air dam relocation bracket to the grill mounts. Plug in the air dam motor to its harness. Figure 22. Figure 22 17. Use a body pry tool to unclip and remove the lower center section of the bumper. Figure 23. Figure 23 18. Use a body pry tool to remove the wire harness clips from the lower center before cutting. Figure 24-25. Figure 24 Figure 25 19. Draw a line along the border of the center section as shown in Figure 26-27. Figure 26 Figure 27 17 20. Use a cutting tool to cut out the center section. 21. Place the provided 7/16" weld nut bracket into the driver and passenger side frames over the lower frame hole. Figure 28. Figure 28 22. Place the mounting supports (22636 and 22637) on the driver and passenger side frames. Use the provided 7/16" yellow zinc hex head bolts with flat and lock washers to fasten the mount supports to the frame and weld nut placed in step 20. Leave loosely bolted. Figure 29-30. Figure 29 Figure 30 23. If installing a 30" light bar, do so now using the provided ¼" bolts with short L-brackets (22643). Position the light bar as desired and fully tighten mounting hardware. Figure 31. Figure 31 24. Install your winch at this time using the manufacturing hardware. 25. With assistance, hold the bumper up to the mounting brackets and use the provided 7/16" yellow zinc bolts, washers and nuts along with the 1/2" bolt strips washers and nuts to attach it. Use two of the OEM bolts removed in step 5 to attach the bumper directly to the frame. Leave all mounting hardware loose at this time. Figure 32. Figure 32 19 26. Place the front grill and facia back on the truck by reversing steps 1-4. Figure 33. Figure 33 27. Position the bumper and fully tighten all mounting hardware. Figure 34. Figure 34 28. Use the provided large L-brackets (21870) with the 1/4" yellow zinc bolts washers and nuts to fasten the lower facia to the bumper. Use the 1/4" stainless steel fender washer on top of the plastic mount. Note: Do not over tighten or the plastic will break. Figure 35. Figure 35 29. Cover the winch bolting holes with the provided plastic plugs. Figure 36. Figure 36 21 Contact information Fab Fours Inc. 2213 Industrial Park Road Lancaster, SC 29720 Phone: (866) 385-1905 Fax: 970-385-1914 Email: support@fabfours.com fabfours.com "If you're looking for more of the same, Then you've come to the wrong place." - Greg Higgs