INSTALL INSTRUCTIONS
FOR 76-2012
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BEFORE YOU START

• Please read the entire product guide before proceeding.
• Ensure all parts are present.
• If you are missing any of the components, call our customer support at 909-947-0015.
• Kit may not fit with certain parts and accessories. Modification may be required to ensure fit.
• See Steps 17b & 36 for installation pictures to determine if your accessories will interfere with the mounting positions.
• Do not work on your vehicle while the engine is hot.
• Make sure the engine is turned off and the vehicle is in Park or the Parking Brake is set.

REQUIRED TOOLS

• 2.5, 4, & 5mm Hex Key
• 6, 10, & 13mm Wrench or Socket
• 5/16” Nut Driver or Flathead Screwdriver
• Heavy Duty Wire Cutter
• Flush Cutter
• Utility Knife or Scissor
• #3 Phillips Screwdriver

STEP 1
Slide the drivers seat all the way forward by pulling up on the seat adjuster found under the front of the seat.STEP 2
Remove the center console cover by lifting up on the back and sliding the front tab out from its slot. Make sure the rear mounting grommets did not pull out with the cover. STEP 3
Remove the the stock air duct from the air box by squeezing the top and bottom of the air duct and pulling it into the cab. STEP 4
Remove the foam seal from the stock air duct, using your fingers between the two to carefully separate the factory adhesive holding them together. Be careful not to tear the foam. STEP 5
Remove the air box lid by rotating the handle counter clockwise. The air box lid can be accessed from the driver’s side rear wheel well. STEP 6
Slide the air filter out of the air box. STEP 7
Insert the Air Box Coupler (L) into the air box opening from inside the cab.STEP 8
Make sure the groove on the coupler is fully seated, and the coupler flange seals on the inside of the air box. STEP 9
Reinstall the air filter in the air box. STEP 10
Reinstall the air box lid by rotating the handle clockwise. STEP 11
Install the stock foam seal, removed in Step 4, into the gap around the Air Box Coupler, ensuring the semi circle bead is on the bottom. Push the entire foam seal into the gap until it is flush with the gap opening. STEP 12
Insert the Intake Tube (M) and Hose Clamp (O) into the Air Box Coupler with the S&B logo facing straight ahead towards the front of the vehicle. Tighten the hose clamp. STEP 14
Install the L Brackets (F) onto the Adapters with the Screws (K) and Washers (I), selecting the proper angle and orientation based on the desired location for the Particle Separator. Apply Thread Locker to the screws before installing, then tighten. STEP 15
Slide the Straps (H) over roll cage. Wrapping a small parts bag around the roll cage will make sliding the strap over the roll cage easier and help protect the roll cage from scratches. STEP 16
Install the Pivot Bodies (G) with the Screws (J), Washers (I), and Locknuts (E). Snug the straps up, but do not fully tighten, leave the straps loose enough so they can be slid side to side and rotated. STEP 17A
Install the L Brackets onto the Pivot Bodies using the Screws (K) and Washers (I). Apply a small amount of Thread Locker (W) to the screw before installing, then tighten. STEP 17B
If you have the optional roof, you can use the 3″ Spacers (Y) and Screws (Z) and Washers (I) to mount the particle separator behind the roof tail. STEP 18
Once you are satisfied with the position of the Particle Separator, tighten the Straps, double check that all mounting screws and nuts are tight and that they are securely mounting the Particle Separator on the roll cage. STEP 19A
19A: Install the End Cuff (X) and Hose Clamp (O) onto one side of the Flex Duct (N) and slide it onto the Intake Tube (M) as shown. Tighten the Hose Clamp. STEP 19B
19B: Bring the other end of the Flex Duct (N) towards the outlet of the Particle Separator (A). Note the length needed to reach the plenum and add an extra 3″, this is where you will cut the Flex Duct.STEP 20
Using a Utility Knife pierce the Flex Duct centered between the two reinforcement wires. Cut all the way around the Flex Duct keeping the blade centered between the wires. Use diagonal cutters to cut through the reinforcement wire.STEP 21
Install the End Cuff (X) and a Hose Clamp (O) onto the Flex Duct (N) and slide it onto the plenum of the Particle Separator (A) as shown. Tighten the Hose Clamp.STEP 22
Familiarize yourself with the Wire Harness (U). It has a red Power Wire with fuse, a black Ground Wire, a red Accessory Wire, and a Fan Connector. The Power and Ground Wires go to the battery, the Accessory Wire goes to the Posi-Tap and a keyed/switched power source, and the Fan Connector goes to the Particle Separator.STEP 23
Install the Power and Ground wires onto the battery terminal posts. The red Power Wire goes to the positive (+) terminal first and then the black Ground Wire goes to the negative (-) terminal.STEP 24
Remove the fuse box from the back panel between the seats by depressing the locking tab and sliding the fuse box up.STEP 25
Install the Posi-Tap (V) onto one of the brown wires coming from the bottom of the fuse box that is connected to the HEAD (15A Fuse). STEP 26
Unscrew the large end cap from the Posi-Tap body and slide the brown wire in-between the legs of the cap.STEP 27
Then reinstall the Posi-Tap body onto the large end cap and tighten.STEP 28
Strip about 3/8” off the end of the red Accessory wire.STEP 29
Unscrew the small end cap from the Posi-Tap and insert the red Accessory wire. STEP 30
Insert the small end cap and wire into the Posi-Tap body making sure the strands of the wire go around the metal core inside the body.While holding the wire in place, screw the cap back on until it is tight and the wire is secure.STEP 31
Route the Find Fan Connector along the Flex Duct up to the Particle Separator, plug it in and secure the wire to the duct with Velcro (Q).STEP 32
Secure the Flex Duct to the roll cage with Velcro.STEP 33
Reinstall the fuse box onto the back panel and secure any excess wire with Cable Ties (P) near the battery in thcenter console area.STEP 34
Install Prongs (T) onto the Center Console (R) using the Screws (S) and Thread locker.STEP 35
Install the Center Console by sliding the front tab in its slot then and pressing down on the rear of the cover.STEP 36
Double check to make sure all connectors are plugged in and secured. Turn the ignition on and make sure air is blowing out the exhaust port of the Particle Separator. If the exhaust fan does not turn on, double check your electrical wiring. Your installation is now complete. Enjoy your new product!

Documents / Resources

SandB 76-2012 Particle Separator [pdf] Installation Guide 76-2012, 76-2012 Particle Separator, 76-2012 Separator, Particle Separator, Separator

References

• User Manual