Step by step on how to install the EVO Rear Bumper on the 5th Gen 4Runner! Questions or Support: Phone: 269-353-1184 Email: info@victory4x4.com
Included Parts: (1x) Mount 1 | (L&R) Mount 2 | (L&R) Mount 3 | (1x) Bumper Shell Center | (L&R) Bumper Shell Wing | (2x) Bezel Plate | (2x) Spacer | (1x) Nut Strip 1 | (1x) Nut Strip 2 | (2x) D-Ring
Included Hardware:
Prior to installing the bumper, the factory plastic bumper will need to be trimmed.
Begin by removing the mudlfaps. This can be done by removing the two bolts circled in red, the two clips circled in blue and the third bolt going up through the bottom, not shown in the image above.
To begin marking the cut lines, place a strip of tape so that the bottom edge is 5" below the horizontal body line above it. Carry that line all the way around the corner below the tail light and stop it just past the vertical body line found there near the hatch opening. Make sure the line stays parallel to the initial body line all the way throughout.
To check that the cut line remains straight around the corner, measure up from the seam shown. The bottom edge of the tape should sit 2-1/4" above.
Measure 1/4" off the radius as shown, and place the edge of a strip of tape along that line, matching the radius and maintaining that 1/4" all the way across. Using a fine line tape can be helpful for this.
Where the radius ends, carry that line straight up to the other tape placed previously.
Cut along the lines laid out with whatever tool you have access to. This can be done with the plastic on or off of the vehicle depending on preferance. If leaving the pastic on the vehicle, make sure to only do shallow cuts as there is a risk of cutting into sheet metal if the blade goes too deep.
With the bumper cut, remove the two bolts securing it from underneath and pull it off the vehicle.
This is what the cut should look like after it is finished. At htis time, the tape can be pulled off and the cut edge can be cleaned up with sandpaper or flap disk or something similar.
If the vehicle is equipped with a factory hitch, remove it using a 17mm socket on the four bolts in the rear of the frame as well as the two foing up through the bottom.
Remove the factory tow hooks from the bottom of the frame using the same 17mm socket.
If installing cube lights, do so now. They will be accessible after the bumper is installed, however, it is easier to do prior. If installing a carrier, this would be a good time to install the pin track onto the respective wing as well.
Drill the holes circled in the image above out to 17/32 to accept 3/8" rivet nuts. The rivet nuts can then be installed.
Install part 2 onto the corner of the frame using two of the provided M12 bolts and washers underneath with the spacer sandwiched between the mount and the bottom of the frame.
Install two of the 3/8" X 1-1/2" bolts and 5/16" USS washers into the rivet nuts. Tighten them all into place making sure that the top face of the mount is parallel to the top face of the frame and then mark the top hole on the back face to be drilled.
Prior to installing the rivnuts, a tool will need to be created using provided hardware. A 3/8"-16 partially threaded bolt, 5/16 washer and 7/16" flange nut will be needed to create the tool.
The tool should look as shown when finished. Make sure the serrations on the flaneg nut are towards the rivnut. The threads of the 7/16" nut will need to be drilled out slighlty in order for the 3/8" bolt to pass through it freely.
Remove the mount, drill a 17/32" hole at the marked location and install a 3/8" rivnut. Repeat this on both sides of the vehicle. The hole should be 1-5/8" above the one previously drilled.
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