Demello-Offroad Rear Bumper Install Instructions - pics

[sbechtold]

Demello-Offroad Rear Bumper - Installation Steps

I finished my bumper installation and thought I would post up some instructions with pictures. Please use these a a guide and not gospel. If you have a suggestion please post it.

Tools:

3/8” ratchet and extension
10mm, 12mm, 17mm sockets
19mm box end wrench
Flat head screw driver
Pliers
Electric drill
1/2” drill bit
Painters tape
Box knife (or a tool that will cut plastic)
Semi-gloss black paint (optional)
Assorted towels/tarps

Installation notes:

During the installation of the Demello Offroad high clearance FJ Cruiser bumper you will be required to perform the following tasks. If you are not comfortable performing these tasks we suggest you seek the help of a professional installation shop.

• Cutting of the OEM plastic bumper
• Bending of a metal bracket on the rear cargo area
• Drilling of additional holes in the frame
• Electrical wiring (optional with backup lights)

OEM Bumper Removal:

1.) Use a 10mm socket to remove all the bolts from the top and bottom of the OEM bumper.



2.) Using a flat head screw driver remove the plastic push pop rivet on right side.



3.) Using fingers pull outer plastic bumper cover away from the side of the vehicle. There are snap along the top and one snap rivet in the middle. A reasonable amount of force is required to get the plastic to release.





4.) Stand behind your vehicle and pull the bumper rearward while supporting the plastic bumper. The entire bumper unit will slide of the vehicle. Be careful not to bump the doors while you pull the bumper off.



Note:

Set the bumper down on the ground. You may want to place something protective like a towel or drop cloth on the ground to prevent scratching of the bumper plastic.

5.) Remove the Styrofoam support and discard.

6.) Use a 17mm socket to remove the 6 bolts in the factory tow hitch mount and remove the tow hitch. (Optional step can be skipped if no hitch)



7.) Remove the backup sensors from the OEM bumper by carefully sliding the retainer clip off the back of the sensor. Be careful with the clips as they can break easily. Slide the sensor out of the OEM bumper and set aside the sensor and clip as they will be used in a later step. Remove both sensors.



8.) Remove the rear plastic bumper wings by removing the 5 white plastic retainer clips from the back side of the bumper. A flat head screw may be helpful in removing the clips.



9.) Turn the OEM bumper over and pull the plastic bumper wings off the bumper.



10.) Use a 10mm socket to remove the 4 brackets from underneath the rear cargo area. Remove the brackets and rubber gasket and discard.



11.) Use a 12mm socket to remove the outermost bumper brackets from the rear cargo opening. There are two brackets one located on each side. Remove and discard.



12.) Use a pair of pliers to bend the center bracket downward as seen in the picture below.






Cutting the OEM rear bumper to fit:

In this portion of the installation you be required to cut portions of the plastic bumper. We recommend applying blue painters tape to your OEM bumper to protect it from scratching. Please use caution and wear appropriate safety wear when handling cutting tools.

1.) Cut the outer piece of the bumper as depicted in the picture below. Note the silver line in the pictures below. These are the approximate location of where you need to trim the rear plastic bumper. A box knife or similar tool can be used to trim the bumper.

Rear view:



Bottom view:



Side view:




2.) Once you have completed the trimming process you will have two side pieces. Reinstall the side pieces on your vehicle. Use a 10mm bolt to fasten the bottom of the plastic side piece to the bottom bracket on your vehicle.

Note:
The painters tape will help prevent scratching of the plastic bumper.




Install backup lights in bumper (optional step):

1.) Install lights into the bumper with appropriate hardware.



Note:
This install guide does not cover the wiring aspects of the backup light installation.

Installation of backup sensors:

Trimming of the backup sensors is required to make them fit into the openings in the Demello rear bumper. Below is a picture of an original untrimmed sensor and the same sensor post trimming. The “U” shaped piece of plastic needs to be removed in order to fit the sensors into the bumper. Please use caution when trimming so that you don’t damage or break the sensor.

1.) Trim off the “U” shaped piece of plastic and the small side pieces that look like and “L”. Use a knife or sander to trim the plastic.



Here is the sensor after trimming.



2.) Insert the sensor into the sensor hole in the rear bumper so that the “L” shaped end will end up facing towards the top of the bumper as you push the sensor into the bumper.

Note:
You may need to wiggle the sensor to get it through the hole. Be careful not to force the sensor into the opening as this could result in breaking the sensor.



3.) Once the sensor is completely in the bumper rotate the connector end towards the outside ends of the bumper. Be careful to rotate the sensor too much as it could break.



Note:
The factory sensor retainer clips are not need to hold the sensor in place.

------- CONTINUED IN NEXT POST ---------

[sbechtold]

Demello-Offroad Rear Bumper - Install Steps (Continued)

Installation of the rear bumper:

1.) Carefully place the Demello Offroad high clearance rear bumper on the rear section of the frame and slowly slide the bumper into place.

2.) Using a 10mm bolt that you removed during the bumper removal process. Install a 10mm bolt through the center hole at the top of the bumper and into the bracket that you bent downward in an early step.



3.) Align the 4 bolts holes in the rear of the bumper with the 4 bolts holes in the frame.



3.) Install 4 of the shorter grade 8 bolts and washers into the rear of the bumper. Install 2 more of the bolts and washers into the holes on the bottom of the frame.

Note:
Tighten the bolts slowly and tighten them evenly. Use tightening pattern similar to when tightening wheel lug nuts. Tighten one side a little and then move to the other side. This will help align the bumper on the rear of the vehicle.



4.) The two lower outer most bumper brackets require a new hole be drilled in the bottom of the frame cross member. With the bumper installed use a pen to mark the opening of the brackets on the frame. Do this on both sides of the bumper.



5.) Remove all the bolts from the bumper and remove the bumper from the vehicle and set it out of the way.

6.) Using a power drill and a ½” drill bit drill a hole through the bottom of the frame cross member. Do this on both side where you marked the frame. There is a hole in the top of the cross member already, so you are only required to drill a new hole on the bottom of each side.



7.) Reinstall the rear bumper and connect the backup sensor wires by following the above installation steps. To connect the backup sensor wires leave a gap between the bumper and the frame so you can reach up behind the bumper and connect the sensor wires. After both sensor wires are connected install remaining bolts, but hand tighten only.



8.) After the bumper has been mounted and all bolts installed install the 5” long side bolts into the bottom brackets and through the holes that you drilled.



9.) Install a washer and lock nut on top of the bolt by reaching up behind the bumper.



10.) Use a 19mm socket to tighten down the 4 bolts on the rear face of the bumper. Then tighten down the 2 bolts directly under the 4 bolts. Lastly, use a 19mm box end wrench to hold the lock nut on the backside of the frame and tighten the long 5” bolts on the sides.

Note:
As you tighten the bumper make sure that it remains centered on the back of the vehicle. Tightening the bolts in crisscross pattern will help keep the bumper straight.

Rear bumper Installation complete:






Painting rear cargo area (optional step):

When I first installed the bumper I could see the silver paint under the door. In order to make this blend in a little better I decided to paint the lower portion of the cargo opening. You can see the silver paint under the door in the picture below.



1.) Remove belt molding from the lower portion of the rear cargo opening. Use painters tape and plastic to prevent over spray from getting on the rear cargo area and back door.

2.) Use 12mm socket to remove door hinge bracket.

3.) Clean area appropriately and paint.



4.) Remove tape and plastic, reinstall door hinge. Below you can now see that the silver does not show and the semi-gloss black blends in better.

[FJ #8]

I'm drooling. GRREAT write up and install

[razr]

Thats a big tire!

[FJ #8]

Did you place the demello bumper up to the oem bumper to determine where to make your lines to cut the plastic?

[Layonnn]

Terrific write up Sol.

[Chatsworth 818 FJ]

Great looking FJ.

[Mtbcoach]

Thanks for taking the extra time to document your install. I will be following your advise and I really like the touch up with the black paint. Good call, something many of us might have missed but won't now...

[MissFJ]

Guess I missed the license plate announcement

[Savvyav]

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