Front Bumper Skid Plate User Manual

Introduction

Thank you for purchasing the FRONT BUMPER SKID PLATE. Please read this manual carefully and keep it properly for future reference. For support, contact us with your product model number and order number.

WARNING

⚠️ This product is designed primarily to enhance vehicle appearance. Do not rely on it for protection against injury or death in accidents. Read all safety messages and understand all instructions before installation or use.

CAUTION

❗ Properly torque and recheck fasteners and step tread security after 250 miles and inspect frequently. Do not use if damaged.

Required Tools

• Socket
• Ratchet
• Wrench
• Allen Wrench
• Safety Glasses

Parts Information

Note: Spare parts such as N19, B37, B70, W27, W25, B20, N22, W19, W16, B15, S04, N29, S13, B32, W23, W22 are provided with 1PCS each (included in the number of parts details).

Installation Variations

There are THREE different installations based on the factory bumper and engine size on the Bronco: one for the plastic bumper (top picture), one for the steel bumper (bottom picture), and one for the necessary V6 steps. Follow the steps for the particular bumper on your vehicle. Both types of installs involve replacing your factory front plastic gravel guard or metal skid plate. If you have the Rough Country front fabricated modular bumper installed, follow the steps for the plastic bumper installation. The V6 steps will be located in the back of this booklet.

Section 1: Winch Tray and Skid Plate Installation for Plastic or RC Fabricated Bumper

1. Park your vehicle on a clean flat surface, engage the parking brake and block the rear tires.
2. Save all hardware removed from the vehicle unless otherwise noted.
3. Open the hood and disconnect the negative terminal on the battery.
4. Remove the gravel guard from the vehicle using a 15mm socket in 6 locations. The two rearmost bolts only need to be loosened to slide the gravel guard off. Once removed, tighten the rearmost bolts back down. Photo 1: Shows the gravel guard hardware being removed.

5. On the front of the frame, locate extensions that need to be removed to install the winch. Use a suitable cutting tool (Sawzall shown) and remove these even with the frame rail as shown. You will have 4 sides on each extension to cut through. Do not cut through electrical or brake lines. Photo 2: Illustrates cutting off frame extensions.

6. Remove the frame extensions. Photo 3: Shows the frame extensions removed.
7. Sand any burs and sharp edges smooth. Paint the exposed metal with a quality rust preventative paint. Photo 4: Depicts sanding and painting exposed metal surfaces.
8. Locate the winch tray and the driver and passenger side mounts. Photo 5: Shows the winch tray mounts and tray.
9. Install the mounts to the tray using the provided 12mm bolts, washers, and flange nuts as shown, using an 18 and 19mm wrench. Photo 6: Illustrates installing the mounts to the tray.
10. Install the winch to the winch tray using the hardware provided with the winch. It is easier to place the winch upside down and then install the tray to the winch. This kit was specifically designed around the RC 9500 and 12000 lb winch with synthetic rope and Hawes fairlead. Photo 7 & 8: Show the winch being installed onto the tray.
11. If stock tow rings are installed, remove the tow ring filler panel by pulling out and away from the tow rings. Photo 9: Depicts removing filler panels.
12. Remove the factory tow rings using a 15mm socket. The intercooler is held in place with these as well, and you will need to support it as you remove the tow rings. If you have the Rough Country tow hook brackets installed, remove them the same way. Photo 10: Shows removing tow hook mount hardware.
13. Remove the intercooler rubber isolator by twisting and pulling down away from the intercooler. Install the intercooler washer onto the top of the isolator. Reinstall the rubber isolator onto the intercooler. Photo 11: Illustrates installing the intercooler spacer.
14. Use of an assistant, floor jack, or other jack is recommended. Raise the assembled winch tray up to the frame rails of the vehicle while holding the intercooler out of the way. Photo 12: Shows using a jack to install the winch tray.
15. Install the provided nut tab through the frame opening until the nut lines up with the round hole in the frame and winch tray. Photo 13: Depicts inserting the nut tab through the frame opening.
16. Install provided 7/16" bolt and washers. Leave loose at this time. Photo 14: Shows installing the 7/16" hardware.
17. If you are installing the factory tow rings back to the vehicle, reuse the factory hardware to sandwich the winch tray to the frame rail while lining up the intercooler mounts. Only snug this hardware up at this time. Photo 15: Illustrates installation with factory tow rings.
18. If you are installing the Rough Country tow hook brackets, do the same as above with the factory hardware. Once you have both sides in place, torque the back two bolts above the lower control arm cam bolts to 35 ft-lbs, pull the tow hooks as far forward in their slots as possible and torque to 45 ft-lbs. Shown with the Rough Country Bull Bar option brackets from the bull bar kit. Photo 16: Shows installation with RC tow hook brackets.
19. Install the provided electrical control box extension to the side of the winch control box. Photo 17: Depicts installing the control box extension.
20. Route the electrical cables for the winch up through the engine bay to the battery. Cable tie to the battery tray mount and along their route to keep out of harm's way from moving components. Photo 18: Shows routing all electrical cables to the battery.
21. Install the bumper filler panel to the winch skid plate using the provided 6mm button head bolts and locking nuts. Photo 19: Illustrates installing the bumper filler panel.
22. Install the Hawes Fairlead to the skid plate using the provided 12mm black button head bolts. Photo 20: Shows installing the Fairlead.
23. Install the winch skid plate to the frame and the factory tow ring brackets using the factory hardware. Torque all to 35 ft-lbs. If you have the Rough Country tow hook brackets, you will need to use the provided 10mm nuts and washers from the tow hook bracket kit and the factory bolts. Slide the nut and washer through the opening in the tow hook bracket. Photo 21: Depicts installing hardware from the tow hook bracket kit.
24. Under the hood, reconnect the battery negative terminal to the battery. Connect the winch positive and negative cables directly to the connections of the battery. Photo 22: Shows connecting battery terminals.
25. Find a suitable place to install the winch control extension to the vehicle. It is recommended to notch the core support filler panel and screw in place using the provided screws as shown. Photo 23: Illustrates notching the core support plastic.
26. Use a drill and small bit to make a pilot hole. These screws will "self-tap" into the plastic. Photo 24 & 25: Show drilling a pilot hole and installing the cable extension.

Section 2: Winch Tray and Skid Plate Installation for Factory Modular Steel Bumper

1. Park your vehicle on a clean flat surface, engage the parking brake and block the rear tires.
2. Save all hardware removed from the vehicle unless otherwise noted.
3. Open the hood and disconnect the negative terminal on the battery.
4. Remove the factory skid plate by loosening the rearmost bolts and completely removing the forward most bolts using a 15mm socket. Photo 1: Shows the skid plate being removed.
5. Slide the skid plate off the rearmost bolts and set aside. Tighten the rearmost bolts back down. Photo 2: Depicts removing the skid plate.
6. Remove the plastic rivets holding the plastic cover in place. Use a pair of pliers or other suitable tool to pull out the middle of the plastic rivet. Remove the rivet body. Photo 3: Illustrates removing plastic rivets.
7. Remove the plastic cover and set aside. Photo 4: Shows removing the plastic cover.
8. If you have proximity sensors in your bumper, disconnect their harness. Behind the plastic cover you will find the main bumper mounting hardware. Have an assistant help hold the bumper and remove the 6 mounting bolts using a 15mm socket. Photo 5: Depicts removing bumper mounting hardware.

9. On the front of the frame, locate extensions that need to be removed to install the winch. Use a suitable cutting tool (Sawzall shown) and remove these even with the frame rail as shown. You will have 4 sides on each extension to cut through. Do not cut through electrical or brake lines. Photo 6: Shows cutting off frame extensions.

10. Sand any burs and sharp edges smooth. Paint the exposed metal with a quality rust preventative paint. Photo 7: Depicts sanding and painting exposed metal.
11. Remove the factory intercooler mounts using a 15mm socket. Let the intercooler hang out of the way. Photo 8: Shows removing the intercooler mounts.
12. Locate the winch tray and the driver and passenger side mounts. Photo 9: Depicts locating the winch tray mounts and tray.
13. Install the mounts to the tray using the provided 12mm bolts, washers, and flange nuts as shown, using an 18 and 19mm wrench. Photo 10: Illustrates installing the mounts to the tray.
14. Install the winch to the winch tray using the hardware provided with the winch. It is easier to place the winch upside down and then install the tray to the winch. This kit was specifically designed around the RC 9500 and 12000 lb winch with synthetic rope and Hawes fairlead. Photo 11 & 12: Show the winch being installed onto the tray.
15. Remove the intercooler rubber isolator by twisting and pulling down away from the intercooler. Install the intercooler washer onto the top of the isolator. Reinstall the rubber isolator onto the intercooler. Photo 11: Illustrates installing the intercooler spacer.
16. Use of an assistant, floor jack, or other jack is recommended. Raise the assembled winch tray up to the frame rails of the vehicle while holding the intercooler out of the way. Photo 12: Shows using a jack to install the winch tray.
17. Install the provided nut tab through the frame opening until the nut lines up with the round hole in the frame and winch tray. Photo 13: Depicts inserting the nut tab through the frame opening.
18. Install provided 7/16" bolt and washers. Leave loose at this time. Photo 14: Shows installing the 7/16" hardware.
19. Install the intercooler mounts by reusing the factory hardware to sandwich the winch tray to the frame rail while lining up the intercooler mounts. Snug this hardware up. Torque the 7/16" hardware to 35 ft-lbs and then the intercooler hardware to 45 ft-lbs. Photo 15: Illustrates installing the intercooler mount.
20. Install the provided electrical control box extension to the side of the winch control box. Photo 16: Depicts installing the control box extension.
21. Route the electrical cables for the winch up through the engine bay to the battery. Cable tie to the battery tray mount and along their route to keep out of harm's way from moving components.
22. Use an assistant to help install the bumper to the frame rails using a 15mm socket. Adjust until the bumper is level and centered on the frame. Torque the hardware to 45 ft-lbs. Photo 23: Shows reinstalling the bumper.
23. Reinstall the plastic bumper covers using the previously removed plastic rivets by inserting the body into the hole and then the head into the body. Push the head in until it seats. Photo 18: Depicts reinstalling the plastic covers.
24. Install the winch hook. Photo 19: Shows installing the winch hook.
25. Under the hood, reconnect the battery negative terminal to the battery. Connect the winch positive and negative cables directly to the connections of the battery. Photo 20: Shows connecting battery terminals.
26. Find a suitable place to install the winch control extension to the vehicle. It is recommended to notch the core support filler panel and screw in place using the provided screws as shown. Photo 21: Illustrates notching the core support plastic.
27. Use a drill and small drill bit to drill a pilot hole. These screws will "self-tap" into the plastic. Photo 22: Shows drilling a pilot hole and installing the cable extension.

Section 3: V6 Model Instructions

1. Under the hood, disconnect the driver side charge tube next to the battery by releasing the spring clip. Photo 1: Shows locating the charge tube clip.
2. Pull spring clip back towards the battery until you get the ears to lock into their notches. Photo 2: Depicts releasing the spring clip.
3. Gently push down on the charge tube until it is fully disconnected from the upper plenum. Photo 3: Shows disconnecting the charge tube.
4. Move to under the vehicle and locate the transmission cooler and hoses on the front crossmember. You will be removing the coolant pump, coolant hoses, and oil cooler. Photo 4: Illustrates locating the oil cooler components.
5. Disconnect the coolant boost pump electrical connection. Photo 5: Shows disconnecting the pump electrical connector.
6. Remove the coolant boost pump from the frame above the lower control arm mount using a 10mm wrench. Once the bracket is removed from the frame, remove the clip nut from its hole using a pry tool. Photo 6: Depicts removing the pump bracket.
7. With the boost pump out of the way, disconnect the charge pipe lower connection in the same fashion as the upper mount. Push towards the engine and then rotate the pipe to remove it from the vehicle. Once removed, unlock the spring clips so that they pop back into place in their mounts. This will allow a positive connection when reinstalled. Photo 7 & 8: Show removing the charge pipe.
8. Locate both of the feed and return coolant lines and use a pair of locking pliers to pinch off the coolant flow. Do not damage the lines. Clamp the passenger line up above the factory tie clamp so that the piers are out of the way for future installation instructions. Photo 9: Illustrates using locking pliers to pinch off the lines.
9. Place a container under the cooler to catch lost coolant. Use a pair of pliers to depress the locking clip under the quick connect of the coolant lines. Photo 10: Shows releasing the quick connect fittings.
10. Pull the coolant line off the fittings. Photo 11: Depicts removing the coolant hoses.
11. Use a pair of pliers to compress the hose clamp on the boost pump. Remove the boost pump from the hose. Photo 12: Shows removing the boost pump from the hose.
12. Remove the remaining coolant line from the boost pump. Photo 13: Depicts removing the coolant line.
13. Remove the boost pump from the factory bracket using an 8mm socket. Photo 14: Shows removing the factory bracket.
14. Install the boost pump to the Rough Country bracket as shown using the provided 6mm button head bolts and nuts. Photo 15: Illustrates installing the boost pump to the RC bracket.
15. On top of the oil cooler, remove the wire harness mount using an 8mm socket. Photo 16: Shows removing the electrical harness mount.
16. Remove the two oil cooler mounts on the top of the frame using a 10mm wrench. Photo 17: Depicts removing the upper oil cooler hardware.
17. Remove the two oil cooler mounts on the front of the frame using a 10mm wrench. Photo 18: Shows removing the lower oil cooler hardware.
18. Let the oil cooler hang out of the way. Photo 19: Depicts letting the oil cooler hang out of the way.
19. On the front of the frame, locate extensions that need to be removed to install the winch. Use a suitable cutting tool (Sawzall shown) and remove these even with the frame rail as shown. You will have 4 sides on each extension to cut through. Do not cut through electrical or brake lines. Photo 20: Shows cutting off the frame extensions.
20. Repeat the process for both frame extensions. Photo 21: Depicts cutting off the frame extensions.
21. Sand any burs and sharp edges smooth. Paint the exposed metal with a quality rust preventative paint. Photo 22: Shows sanding smooth and painting exposed metal.
22. Use a flat head pry tool to open up the clamp holding the hard brake line to the frame. Photo 23: Illustrates prying open the brake line mount.
23. Remove the plastic mount from the metal bracket. Relocate the metal brake line into the rearmost recess on the plastic mount. Close the mount until it locks. Photo 24: Shows installing the brake line bracket.
24. Remove the brake line metal bracket using a 10mm wrench. Save the bracket as you will reuse it later. Photo 25: Depicts removing the brake line bracket.
25. Install the assembled boost pump and bracket to the frame in the place of the brake line bracket using the factory hardware. Set the assembly straight up and tighten the hardware. Photo 26: Shows installing the boost pump and bracket.
26. Install the brake line plastic mount to the boost pump bracket. Photo 27: Depicts installing the brake line bracket.
27. Connect the boost pump electrical connector. Photo 28: Shows connecting the pump electrical connection.
28. Make a mark on the core support 9" from the driver side frame rail. Photo 29: Illustrates marking the core support.
29. In the center of the made mark, drill out a hole in the core support using a 1/4" drill bit in preparation for a self-threading bolt. Photo 30: Shows drilling out the mark with a 1/4" bit.
30. Locate the 5/16" self-threading bolt in your hardware bag and use an impact driver to drive this bolt into the core support. Do not overtighten and strip the core support out. Remove the bolt after you have completed the threading process. Paint the exposed metal. Photo 31: Depicts using an impact driver to thread the hole.
31. Install the provided rubber isolated clamp to the passenger side coolant hose. You will need this clamp to sit above the core support when installed correctly. Photo 32: Shows installing the clamp to the passenger hose.
32. Install the previously removed brake line bracket to the clamp using the provided 6mm button head bolt and nut as shown. Make sure to use the small hole at the clamp, leaving the large hole open. Photo 33: Illustrates installing the clamp to the bracket.
33. Install the bracket to the core support using the self-threading 5/16" bolt from the previous step. Look up into the engine bay following this coolant line. Make sure that it is not sitting on any moving components of the engine. Adjust the hose in the clamp as necessary to keep it clear of all components. Photo 34: Shows installing the bracket to the core support.
34. Pull the driver side coolant line down to the boost pump and make a mark even with the lowest position of the nipple. Photo 35: Depicts marking the driver coolant line.
35. Use a suitable cutting tool to cut the hose at the mark. Cut back the plastic anti-wear sleeve to expose the rubber line. Use a lighter or micro torch to singe the sleeve to keep it from unraveling. Install the coolant line to the boost pump using the provided hose clamp. Photo 36: Shows cutting and installing the coolant line.
36. Mark a line on the passenger side coolant line 7.5" from the end of the crimp connection closest to the 90 degree fitting. Cut the line at the mark and do the same as before with the anti-wear sleeve. Photo 37: Depicts marking the hose 7.5" from the end of the crimp.
37. Place the cut off hose into a vice and use a suitable cutting tool (cut off disc shown) to cut through the crimp fitting. Make sure to not cut into the plastic fitting. Do this on two sides of the fitting. Pry the crimp fitting off the hose and pull the 90 degree fitting out of the hose. Photo 38: Shows cutting through the crimp fitting and removing it.
38. Install the 90 degree fitting into the cut hose using the provided hose clamp facing as shown. Photo 39: Illustrates installing the 90 degree fitting.
39. Rotate the oil cooler 180 degrees to get to the back mounts. You will be removing these from the cooler. Photo 40: Shows flipping the oil cooler around.
40. Use a suitable cutting tool (air body saw shown) to cut off both the upper mounts from the cooler. Do not cut into the cooler body. Sand any burrs smooth. Photo 41: Depicts cutting off the upper mounts.
41. Flip the cooler back around. Connect the passenger coolant line back to its original location while making sure to route the hose under the transmission line. Photo 42: Shows installing the cooler hose.
42. Install the original driver side coolant hose to the cooler. Photo 43: Depicts installing the coolant hose.
43. On the remaining cooler mounts, remove the metal crush sleeve and flip to the opposite side. Install the Rough Country oil cooler bracket to the cooler using the provided 8mm x 35mm bolts, washer, and flange nut. Photo 44: Shows installing the oil cooler to bracket.
44. Install the Rough Country oil cooler bracket to the frame rail using the provided 8mm x 25mm black bolts and washers. Photo 45: Depicts installing the bracket to the frame.
45. Once the oil cooler is in position, route the remaining hose to the boost pump and mark it. Cut at the mark and remove the remaining anti-wear sleeving. Photo 46: Shows marking and cutting the remaining hose.
46. Install the hose to the boost pump using the provided hose clamp. Remove the locking pliers from the coolant hoses. Top off the coolant reservoir. Start the vehicle and check for leaks and for all hose clearances. Photo 47: Illustrates installing the coolant hose to the pump.
47. Install the charge pipe back to the intake and intercooler. Make sure the spring clips lock into place. Photo 48: Shows reinstalling the charge tube.
48. Locate the winch tray and the driver and passenger side mounts. Photo 49: Depicts locating the winch tray mounts and tray.
49. Install the mounts to the tray using the provided 12mm bolts, washers, and flange nuts as shown, using an 18 and 19mm wrench. Photo 50: Illustrates installing the mounts to the tray.
50. Install the winch to the winch tray using the hardware provided with the winch. Leave the mounting hardware loose so that you can adjust later. It is easier to place the winch upside down and then install the tray to the winch. This kit was specifically designed around the RC 9500 and 12000 lb winch with synthetic rope and Hawes fairlead. Photo 51 & 52: Show installing the winch to the tray.
51. Flip the assembled winch tray over. The winch controller box needs to be relocated. Use a 2mm hex wrench to remove the set screws for the cross bar cover at the front of the winch. Photo 53: Depicts removing the cross bar cover.
52. Once the cover is removed, slide the controller box forward to release the mounting brackets from the cross bars. Photo 54: Shows sliding the controller box forward.
53. Flip the controller box over and remove the mounting brackets using a 10mm socket. Photo 55: Depicts removing the mounting brackets.
54. Reinstall the cross bar cover. Photo 56: Shows reinstalling the cross bar cover.
55. Install the winch controller to the Rough Country bracket as shown using the previously removed hardware. Photo 57: Illustrates installing the controller to the bracket.
56. Install the assembled controller and bracket to the winch tray using the provided 10mm bolts, washers, and flange nuts. Leave loose so that you can adjust at a later step. Photo 58: Shows installing the bracket to the winch tray.
57. Install the winch controller extension to the control box. Photo 59: Depicts installing the controller extension.
58. When installing the winch tray, pay close attention to the control box and winch handle when raising into place. Adjust the winch and the controller box bracket in their slotted holes to clear the oil cooler if needed. Fully tighten the hardware. Photo 60: Shows adjusting the winch and controller.

Final Assembly

Plastic bumper and Rough country fabricated bumper: Skip back to page 5, step 11 to finish your installation.

Factory Modular bumper: Skip back to page 10, step 15.

The skid plate is assembled.