Dissent off-road no cut rear bumper installation instructions

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Important!!! For the aluminum bumpers please refer to page 11 prior to installation.

Alright guys, I’m going to attempt some instructions for the new rear bumper.
These will be added to as I install more accessories. Hopefully these will get you guys by until I can get some proper instructions.
I apologize for the grammar errors in advance!


#1
Remove existing bumper, clean off any excess welding spatter from the frame, check and clean threads as needed.

#2
Drill out holes on each side of frame to fit a 1/2” bolt. (Note that this is not required on some of the early versions of the bumpers.) mark the frame as seen in the pic.
There is a hole on the inside of the frame that will need enlarged so that a through bolt can be installed.

Once the frame is drilled and clean it is recommended to put a fresh coat of paint on the frame. At this time you will also need to cut the lower pinch weld seam at about a 45° angle as marked out in the pic below. This is the corner at the wheel arch. Once cut make sure to touch up the paint on the fresh cut.

#3
Now you will install the wing stiffener plate loosely to the frame.
If you do not have the stiffener that looks like this you will skip this step for now.

#4
Using masking tape, tape on one of the 1/4” hitch spacers to the frame.
(Note, on some 03 and up models equipped with the integrated towing cross member these spacers will not be used.

Now install the wings into place and loosely install the 3 lower m14 bolts.
(If swing out are being installed you will want to install the ball studs into the bumper before hand)

 

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Once the wings are in place you can now move them around for proper alignment.
Once the desired alignment is achieved go ahead and snug the lower m14 bolts while holding the center of the bumper tight to the frame.

#5
Now it’s time to install the hitch.
First, slide the hitch into place, install the top m12 bolts loosely,

install the lower hitch bolts loosely.

 

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Next, the back 1/4” spacer and back plate can be installed along with the 4” through bolts.

Install all hitch bolts loosely.

#6
Now we will begin to tighten the bumper.
After confirming everything is still aligned start with tightening the lower hitch bolts

Then the through bolts.

And lastly the top bolts

 

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#7
Now we will move on to the wing stiffener.
Loosely install the three 1/2” bolts on both sides with nuts and washers.

Once installed you can tighten up all bolts. All 1/2”, m14 and m12 bolts should be tightened to roughly 95fp.
At this point if you will not be installing the swing outs you can finish off the bumper by installing the logo badge, trailer plug, backup lights, latch plate blank off bolts and hinge blank off bolts.
It is important to check and clean all captive and tapped holes to ensure they are not clogged with powder coating. If the are it may be necessary to clean the threads with a tap.
Also note that it is recommended to use anti seize on all tapped and captive bolts as well as all stainless!

(Side note)
The first batch of bumpers that shipped will have a different wing stiffener. These will be installed on the bottom of the wing. They may require slight bending of the exhaust. This can be easily done with 4’ extension inserted into the tail pipe and pull towards the drivers side or push it with your foot.

That should be it on the base bumper.
Now we can move on to the optional accessories if applicable.

 

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Swing arm installation.

We will start by assembling the swing arm.
First install the nylon liners into the handle along with nylon washers top and bottom.

Install the 5/16 stainless bolt from the bottom of the swing arm up. (Nut will be on top) use anti seize on threads!
Making sure the latch is straight tighten the bolt until there is no slip in the latch but it still moves freely.
Next install the striker, there are extra washers included as alignment shims if needed but a good start is 2 washers.
Now install the uhmw pad and spring bracket. The pad will come with 3 stainless steel shims however we will start with 2.

Should look like this when done.
Now install the bearings, seals, grease fittings and bearing spacers.

Next loosely install the proper hinge bracket.
(Note that there will be no washer on the bottom, also note that the Nut will be installed on the bottom, it is a good idea to pack the bearings with grease prior to installation. Also grease the shaft before assembling. The final assembly should look like this.

 

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Next you will install the uncoated stainless striker pads with the 1/4x20x3/8 stainless button head bolts.

Now set the swing arm into place with and let it latch closed.

Install the 2 outer 7/16 bolts with the swing arm closed, while paying close attention to the uhmw pad, tighten the outer bolts, once tight you can tighten the main hinge bolt, this bolt should be tighten to where you feel the preload on the bearings.
Once tight swing open the swing arm, install and tighten the inner 7/16 bolts.
Now check everything is aligned and working properly. Add or remove shims as needed. (Note that you will want the aluminum washer on the striker to set in between the bumper and striker pad like in the photo above. Add or remove washers as needed.
Now is a good time to grease the bearings via the grease fittings if you didn’t pre pack them.

Now install the gas strut as pictured

Once the swing arm is aligned torque the 4 7/16 bolts to 52 foot lbs.
(DO NOT OVER TORQUE!)

 

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Once the gas strut is in place install the 1” bump stops on the inside of the swing arm and the smaller bump stop on the outside.

Once installed check that the swing arm is not over extending the gas strut, install supplied spacers as needed.
The inside bump stop set a preload on the latch. Make sure there is a proper preload on the latch to prevent rattling while driving. Add or remove washers as needed.

Once the swing arm is installed, aligned and greased we can move onto the tire carrier. This will get pre assembled on a work bench prior to installation on bumper. First lay out all the parts.

Next install the table leg to the back plate as pictured.

 

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Next install the back plate on the front plate as pictured. (Note the orientation of the bolts and duplicate the photo)

Next, install the table bracket loosely. (DO NOT TIGHTEN UNTIL FINAL TABLE ALIGNMENT!)

Next install the table latch with nylon washers and one 10mm nylon spacer. As pictured. Tighten until you have a fair bit of drag but are still easily able to spin the latch by hand.

Then cut and install the supplied foam on both sides of the table legs and over the bolts that contact the table.

Next tighten up all moving parts to the table where they are snug but still move freely while maintaining proper alignment and center at the latch.

 

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Install swash plate,

Install tire carrier clamps

Loosely install tire mount

Install internal reinforcement plates

Tighten all bolts and install table/tire assembly onto swing arm. Adjust tire to desired height and angle and tighten bolts.
( Note the tire mount can be flipped 180 degrees from the photo to gain an additional 1” in height if desired.)

 

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License plate light wire routing.

 

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Note on the aluminum rear bumpers there are 4 nut plates that will need to be installed prior to the bumper being installed. It is important to torque these to 100fp as you will not be able to after the bumper is in place. These will install on both hinge bracket corners. See pics.

 

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[ibrahim83]

Wonderful work Ben! I'm starting to think i might have to order a swingout or two.

And to think all this came from one person's mind. Amazing.

 

[Cola]

Happen to put together any directions for the Latching Jerry Can Basket? Have no idea which bolts and washers go where

 

[BillZ260]

Put my bumper together in about 1 full day, haven't done any of the wiring. The only issue I ran into was my rear frame was tweaked a tad and made using the two top frame bolts impossible to start, because of the way the frame rotated. Everything else went fine. I'll drill them through, and add two more bolts like the bottom, should work out fine.

 

[Dparo]

Do the stiffener plates just use one through bolt each and then use the factory hole with another bolt? I am trying to layout the hardware and this makes sense but I wasn’t positive.

 

[BillZ260]

Correct. Get the bumper bolts started first!

 

[phatdragon]

Gonna go ahead and put a pin in this thread. Dig the bumper.

 

[Kabanstva]

Anybody know what this threaded hole is for in the spare tire assembly? I was thinking of putting my MMS CB antenna mount there.