DV8 FS-15 Series User manual

6400 SYCAMORE CANYON BLVD.
RIVERSIDE, CALIFORNIA 92507
855-680-9595
WWW.DV8OFFROAD.COM
855-680-9595
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PRODUCT
INSTALLATION MANUAL
FS-15 Series Front Bumper
2021 FORD BRONCO
FBBR-02
TOOLS REQUIRED SKILL LEVEL TIME REQUIRED
- #3 Allen
- Zip Ties
- 18mm &21mm Socket
- 21mm Wrench
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
- Novice/Intermediate
- 2 to 3 people
Intermediate skill level required.
Additional help will be needed
when removing factory bumper.
- Approximately 2.5 Hours
Time to install this should
take about 2.5 hours
WARNINGS/CAUTIONS BEFORE STARTING INSTALLATION

INSTALLATION MANUAL
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STEP 1
REMOVAL OF FACTORY STEEL BUMPER
STEP 2
Begin by removing the front plastic
d-ring guards. Using a screwdriver or
push pin remover, remove the (2) pins
on the bottom and (2) near the top of
the d-ring mount.
Using a 15mm socket, loosen the (3)
bolts on each side.
Note: When you do this, the bumper can
become free from the vehicle and can fall.
Ensure you have another person holding
it, or the bumper secure to prevent falling
and injury.
Pull the top half away from the Bronco
and set to the side. Repeat for the
other side.

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STEP 3
Once all bolts are loose, remove the
plug for the fog lights and front sensors
if equipped. This is located at the back
end of the grill on the driver side.
STEP 4
Once unplugged, remove all (6)
bumper bolts and d-rings mounts.
Set bumper face down off to the side.

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STEP 5
STEP 7
Remove the rubber/plastic shroud
under the grill by pulling the tabs
on the shroud away (up/down) from
vehicle while pulling the shroud from
the vehicle.
Reach behind each bumper mount on
the frame rail and remove the factory
nut plate.
STEP 6
If you do not have adaptive cruise
control, remove the plastic cover by
pushing the clip on the top down
while pulling away from Bronco, and
set off to the side.
Note: If you have adaptive cruise control,
you will need to relocate the module using
our ABBR-01 to retain the functionality
(Adaptive Cruise Control Relocation
Bracket).

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STEP 8
If equipped with sensors, remove
the main bumper brackets from
the backside of the bumper using
a 13mm socket, remove the (4) hex
head bolts.
STEP 9
Next, using a T40 torx bit, remove the
(6) bolts securing the mount in place.
Once removed, gently separate mount
from bumper, and set off to the side.

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STEP 10
STEP 12
To remove the wire harness, using a at
head screwdriver or pin puller, remove
all the retaining clips securing the
harness to the bumper.
Lastly, gently squeeze the same two
tabs on the sensor bezel and push the
backside of the sensor to remove the
bezel. Continue the same steps on the
remaining sensors.
STEP 11
To remove the sensors, spread the two
tabs on the sensor bezel and gently
pull up on the sensor. Make sure that
the rubber ring around the sensor
head remains on the sensor.

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STEP 1
STEP 3
If vehicle is equipped with factory
sensors, lay out the harness over the
bumper and begin to feed the harness
into the bumper cavities so that the
sensors lay near their corresponding
holes.
Note: The large plug on the harness needs
to be on the driver side of the bumper.
Note: If your vehicle is not equipped with
sensors, use provided sensor plugs and
skip to step 6.
STEP 2
Place the bumper face down on a soft
surface to prevent any damage to the
coating.
INSTALLATION OF DV8 BUMPER
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.
(6) M12x50mm Bolts
(6) M12 Split Washers
(12) M12 Flat Washers
(4) M6x20mm Bolts
(4) M6 Lock Nuts
(8) M6 Flat Washers
Hardware Included:

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STEP 4
STEP 6
Lean the bumper back and t the
sensor bezels into place.
Note: Our bumpers are designed to accept
both factory metal bumper and plastic
bumper sensor bezels. All cutouts are cut
differently to ensure each bezel is placed
into the correct hole. They should easily
pop into place.
Using the welded in zip tie tabs,
secure the wiring harness to the
bumper.
While holding the front of the sensor
bezel, push the sensor into the bezel,
until the sensor clicks into place.
Repeat steps for all sensors.
STEP 5

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STEP 7
STEP 9
If you will be installing a winch,
you will want to install that now.
Using the hardware provided with
your winch, secure the winch
into place according to the winch
manufacturers specications. Secure
the wiring up and away from the back
of the bumper. Do not run the wiring
yet as it will make installing the
bumper more difcult.
Install the mount using the provided
(4) M6 allen head bolts and nuts.
Note: Our mount has an offset. Depending
on the light being used, you can either
have the lights offset forward or slightly
backward. Check prior to installation (for
reference we offset ours forward for our
20” dual row).
STEP 8
Our FBBR-02 light mount is designed
to hold (1) 20” dual row light, or (6) 3”
pod lights.

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STEP 10
Install light onto mount using
hardware provided with light and
secure wiring using zip tie tabs onto
the bumper.
STEP 11
Reinstall the factory nut plates on
the backside of the frame mounting
plates.

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STEP 12
STEP 14
With assistance, hold the bumper up
to the frame plates and install using
the provided M12 hardware using a
18mm socket.
If running a winch, run the wiring
through the rear access holes of the
bumper. Plug in the factory wiring
harness into the driver side plug.
STEP 13
As you tighten the hardware, level the
bumper to your preference and secure
the bolts to 70ft lbs.

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STEP 15
If you are going to be adding the
FBBR-02W full width wings to the
bumper, then lay them out on a soft
surface to install the foam padding.
STEP 16
Using the supplied M12 hardware,
install the wings onto the bumper.
Align with the bumper and the grill,
and secure.
STEP 17
Double check all hardware and
connect lights and winch to power
supplies.
You are now done with the install of your
new DV8 FS-15 Series Front Bumper.