DV8 FBGX-02 User manual

6400 SYCAMORE CANYON BLVD.
RIVERSIDE, CALIFORNIA 92507
855-680-9595
WWW.DV8OFFROAD.COM
855-680-9595
NEED HELP?
PRODUCT
INSTALLATION MANUAL
FBGX-02
2003-2009 + Lexus GX470
Front Bumper
TOOLS REQUIRED SKILL LEVEL TIME REQUIRED
- 10,13,14,21,22mm
- Push Pin Removal Tool
- Grinder or Similar Cutting Tool
- #5 Allen head
Before you install this kit — Read and understand all
instructions, warnings, cautions, and notes contained in
this installation instruction guide. Consult your vehicle
owner’s manual for proper disconnection of electrical and
lifting of vehicle if required for installation of this product.
This install may require some technical skills and
knowledge of basic mechanical work. If you do not feel that
you are capable of performing this install please take this
product to a trained professional.
After reading this guide please contact us with any
questions or concerns before installing product.
Customer Service: 855-680-9595
DV8 Offroad is not responsible for any bodily injury or harm to you
or your vehicle as a result of an improper install.
Proper installation of this kit required knowledge of the factory
recommended procedures for removal and installation of original
equipment components. We recommend that the factory shop manual
and any special tools needed to service your vehicle be on hand during
the installation. Installation of this kit without proper knowledge of the
factory recommended procedures may affect the performance of these
components and the safety of the vehicle
• Always wear eye protection when operating power tools
Inspect all contents of this package to make sure product is not damaged
and all installation hardware has been included. If parts are missing from
kit, please be prepared to provide the following information
1. Name of purchase location
2. Bar Code on side of box
3. Date above bar code
4. Date inside box cover
- 3.5 out of 5
- 2 persons
Moderate Skill Required.
- 3 Hours
Time to install this should only
take approximately 3 Hours
WARNINGS/CAUTIONS BEFORE STARTING INSTALLATION

INSTALLATION MANUAL
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STEP 1
STEP 3
Begin by unpacking all items and
inspecting for missing pieces or
damage. If you have any concerns,
please contact the company the
product was purchased from.
Under each front wheel well, remove
the two 10mm bolts using a socket.
STEP 2
Begin by removing the front bumper
of the GX. Open the hood to access
the front push pin clips. Using a push
pin removal tool, remove all pins
holding the top of the bumper.
(6) M10x30mm Bolts
(6) M10 Flat Washers
(12) M8x35 Bolts
(12) M8 Nuts
(12) M8 Split Washers
(24) M8 Flat Washers
(4) M6x20mm Bolts
(4) M6 Locking Nuts
(4) M6 Flat Washers
Hardware Included:

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STEP 4
STEP 6
On the bottom corner of the bumper,
remove the three 10mm bolts on each
side.
Unplug the fog lights from the factory
wire harness.
STEP 5
Remove the air damn between the
bumper and skid plate and the two
center bolts on the bumper using a
10mm.

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STEP 7
To release the bumper from the
vehicle, pull the side of the bumper
away from the fender rmly.

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STEP 8
Once released, move down to where
the bumper, headlight, and fender
connect and pull bumper forward to
release front clip.

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STEP 9
Remove the foam piece from the
crash bay by simply pulling it off.

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STEP 10
Using a 14mm socket, loosen the four
bolts on the front of the crash bar.
Note: This must be done before removing
the crash bar to prevent damaged to the
crash bar studs.

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STEP 11
Remove the four nuts on each side
of the crash bar using your 14mm
socket. Remove the crash bar and set
off to the side since this will not be
reused.

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STEP 12
You can either reinstall the front
bumper or you can leave it off during
the cutting phase. Using a cutoff
wheel or another similar tool to cut
the bumper. Note: We recommend
cutting leaving 1/2”-3/4” more
bumper than our measurements
and trimming as needed since every
vehicle is slightly different.
6-3/8”
4-1/8”

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STEP 13
With the bumper trimmed, ensure
the edge is clean and without burrs to
prevent damage to the bumper.
Note: We added a ¼” edge trimming
available at most local auto parts stores.
STEP 14
Begin with assembly of the DV8
bumper. Install the provided foam
onto the wings.

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STEP 15
Using the M14 hardware, loosely
attached the wings to the center
section of the bumper. Make sure the
hole on the very top face of the wing,
goes over the corresponding hole
on the center section. Repeat for the
other side.

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STEP 16
Use the M8 allen head bolts and
loosely attached the top of the wing
and center section.
STEP 17
Align the wings with the center
section of the bumper and secure
the wings using a 22mm socket and
21mm wrench.
STEP 18
Install lights into the wings using the
hardware provided with the lights.
(Lights not included)
Note: We are using two 3” DV8elite pod
lights.

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STEP 19
If running a light bar behind the
screen, use the two provided “L”
brackets and hardware and secure
to the bumper. Mount light with
brackets onto “L” brackets and
secure.

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STEP 20
If running a winch, place winch into
the bumper and secure utilizing
hardware provided with the winch.
STEP 21
Using assistance, light bumper and
loosely install onto the factory crash
bar mounts. Thread the factory nuts
on loosely to allow for adjustment.

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STEP 22
If you need to gain more adjustment
upwards, bend the tabs on the skid
plate down slightly using a wrench
and a rag to prevent damage to the
coating.
STEP 23
Once bumper is adjusted, secure
factory bumper nuts to 60ft lbs.

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STEP 24
Using factory hardware, install the
two 10mm bolts on the bottom of the
skid plates.

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STEP 25
Using the remaining M8 hardware,
install the wing support brackets
between the center section and each
wing of the bumper.
STEP 26
Double check that all hardware is
secure and wire the winch and lights
to your preference.