Fab Fours H2340 User manual

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 1 of 21 H234X_REV_A-Rev.A
SAFETY
Your safety and the safety of others is very important.
In order to help you make informed decisions about safety, we have provided installation
instructions and other information.
These instructions alert you to potential hazards that could hurt you or others.
Please do a job safety analysis (JSA) before each task to identify potential hazards for
your situation and remove/protect against them.
You must use your own good judgment, and take your time.
Read and understand all safety precautions and instructions before installing this product.
THIS PRODUCT IS FOR OFFROAD USE ONLY. ALL LIABILITY FOR INSTALLATION
AND USE RESTS WITH THE OWNER.
CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY
OR EQUIPMENT DAMAGE.
Injury hazard
Failure to observe these instructions could lead to severe injury or death.

Always remove jewelry and wear eye protection.

Always use extreme caution when jacking up a vehicle for work. Set emergency
brake and use tire blocks. Locate and use the vehicle manufacturers designated
lifting points. Use jack stands.

Always use appropriate and adequate care in lifting components into place.

Always insure components will remain secure during installation and operation.

Always wear safety glasses when installing this kit. A drilling operation will
cause flying metal chips. Flying chips can cause serious eye injury.

Always use extreme caution when drilling on a vehicle. Thoroughly inspect the
area to be drilled (on both sides of material) prior to drilling, and relocate any
objects that may be damaged.

Always use extreme caution when cutting and trimming during fitting.

Always tighten all nuts and bolts securely per installation instructions.

Always route electrical cables carefully. Avoid moving parts, components that
become hot and rough or sharp edges.

Always insulate and protect all exposed wiring and electrical terminals.

Always perform regular inspections and maintenance on mounts and related
hardware.

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 2 of 21 H234X_REV_A-Rev.A
I. Overview
Congratulations on your purchase of the industries’ best and most stylish GMC
Yukon XL Winch Bumper! This bumper has been engineered for strength while
keeping the weight down. It can accept the Warn 12K winch… and look cool doing
it.
This product has also been engineered to allow alignment in three directions so
you will end up with a very professional fit.
Your bumper was designed in 3-D, fabricated, and powder coated… all in the
U.S.A.
Enjoy the fit and finish of a quality GMC Yukon XL Winch Bumper from Fab
Fours Inc!

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 3 of 21 H234X_REV_A-Rev.A
II. Tools Required

 Multi meter or circuit test
light

 Socket Wrench With
Extensions

 5/32” and 1/8” Allen
Wrenches

 3/4”, 7/32”, 7mm, 10mm,
and 19mm Socket, 22mm
deep socket

 Needle Nose Pliers

 19mm, 3/4", and 3/8” Open
End Wrench

 Phillips Screwdriver

 #3 Square driver

 Drill with 3/8" bit

 Air saw or Rotary tool
III. Package Contents
QTY
DESCRIPTION
FAB FOURS PART
NUMBER
x 1
GMC Yukon XL Front Bumper
H235X-B
x 1
Yukon XL Driver Mounting Bracket
20244
x 1
Yukon XL Passenger Mounting Bracket
20245
x 1
Grille Remounting Bracket
20371
x 1
Driver Fog Light Mounting Bracket
20318-08
x 1
Passenger Fog Light Mounting Bracket
20318-09
x 2
Fab Fours Fog Light
61349
x 2
Fab Fours Running light, Turn indicator
61350
x 4
Stud Plate
20296
x 1
HDLA Hardware Kit
HDLA-HW
x 1
H235X Hardware Kit
H235X-HW
x 1
H235X Instruction Manual
H235X-IM

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 4 of 21 H234X_REV_A-Rev.A
Bumper Hardware HDLA Hardware
2 x
4 x
20 x
4 x
16 x
6 x
6 x
12 x
6 x
20 x
14 x
12 x
6 x
20 x
2 x
4 x
2 x
14 x
6 x
½” – 13 x 1.5
½” – 13
#10-32 x 1.0
½”
½”
#10-32
#10
½” – 13 x 5.5
1/4” – 20 x 0.75
1/4” – 20
1/4”
1/4
”
1/4” – 20 x .75 Stainless
#8” – 32 x .75
#6 Thread forming Screw
1/4”-20
#8-32
#8
1/4” – 20 x 1.25 Stainless
1/2” -13 x 5.5
1/2” -13 x 1.5
1/2” -13
1/2”
1/2”
2 x
4 x
14 x
20 x
14 x
#10
#10-32
#10 –32 x 1.0
6 x
12 x
6 x
6 x
16 x
4 x
20 x
20 x
6 x
12 x
6 x
2 x
4 x
2 x

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 5 of 21 H234X_REV_A-Rev.A
Vehicle Preparation
1
1. . Remove two (2) plastic push clips with a small screwdriver or plastic rivet
removal tool, and two (2) screw fasteners with a 7mm socket and ratchet from
the front of each wheel well as shown below:
Figure 1 - WHEEL WELL FASTENER LOCATIONS
2
2. . Remove the two screw fasteners attaching the plastic bumper cover to the
truck from underneath with a 10mm socket. Repeat for other side. See image
below for location:
Figure 2 –LOWER FASTENER LOCATION –VIEW FROM BELOW

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 6 of 21 H234X_REV_A-Rev.A
3
3. . Open the hood and remove the six (6) fasteners attaching the bumper and
grille to the radiator core support with a 10mm socket :
Figure 3 - GRILLE FASTENER REMOVAL
4
4. . Reaching behind the bumper cover at the outer corner, firmly pull the cover
outward to release it from the fastening clips. Repeat for other side
Figure 4 - CORNER CLIP RELEASE

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 7 of 21 H234X_REV_A-Rev.A
5
5. . Pull forward on the bumper cover to remove it from the truck.
Figure 5 –BUMPER COVER REMOVAL
6
6. . If your vehicle is equipped with fog lights, the wiring harness must be
disconnected from both lights before the bumper cover can be set aside.
7
7. . Set the bumper cover aside. This part will later be modified to re-fit the grille
with your new Fab Fours heavy duty bumper.
8
8. . Remove the bumper cover clipping brackets from the bottom of the fenders
with a 10mm socket:
Figure 6 - CLIPPING BRACKET REMOVAL
Headlight

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 8 of 21 H234X_REV_A-Rev.A
9
9. . With a 22mm socket and breaker bar, loosen the two main push bar mounting
screws. Pull the push bar forward away from the truck:
Figure 7 - PUSH BAR MOUNTING SCREWS
1
10 0. . Use a ratchet, 19mm socket, and 19mm wrench to remove the tow hooks from
inside the frame ends:
Figure 8 - TOW HOOK REMOVAL

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 9 of 21 H234X_REV_A-Rev.A
1
11 1. . Use a ratchet and 10mm socket to remove the headlight to access the turn
indicator wiring; Remove the two top fasteners and loosen the outer fastener.
Repeat for both sides.
Figure 9 –HEADLIGHT REMOVAL
1
12 2. . The disassembly of the vehicle is now complete. Proceed to the Grille
Modification section of this instruction manual to prepare the OEM grille to
fit with your Fab Fours bumper.

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 10 of 21 H234X_REV_A-Rev.A
IV. Grille Modification
NOTE: Reinstalling the OEM grille section with your Fab Fours bumper requires you to
cut the bumper cover and grille surround into separate pieces. READ THIS ENTIRE
SECTION CARFULLY BEFORE PROCEDING. Failing to do so may affect the quality
of the final installation of your bumper.
1
1. . Remove the grille insert by careful pressing the plastic tabs inwards, allowing them to
be pulled from the bumper. Using a small flat blade screwdriver or similar tool can be
useful when loosening the tabs.
Figure 10 –GRILLE PANEL TAB REMOVAL

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 11 of 21 H234X_REV_A-Rev.A
2
2. . Remove the foam core support from the bumper cover by unscrewing the six (6) self-
tapping plastic screws with a #3 square drive bit.
Figure 111 - FOAM FASTENER REMOVAL
3
3. . Attach the Fab Fours provided grille mounting bracket to two center foam mounting
holes as shown below. Use the ¼” hardware with nyloc nuts and fender washers
Figure 122 - BRACKET ATTACHMENT –VIEW FROM REAR, ABOVE
4
4. . Drill through the bumper face at the outer mounting holes with a 3/8” drill bit to
allow the remaining 1/4” hardware to be fitted:
Figure 133 - DRILLING LOCATIONS –VIEW FROM INSIDE

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 12 of 21 H234X_REV_A-Rev.A
5
5. . Fasten the grille bracket at the drilled holes at the outside of the bracket with ¼”
screws, fender washers, and nyloc nuts.
6
6. . With a body saw or rotary tool, cut the bumper section off of the grille, following the
existing body line (See Bold line on image below). Be very careful when trimming
not to damage the paint on the grille. The bumper section will not be reused.
Figure 144 - TRIM LINE -VIEW FROM REAR, BELOW
Figure 155 –TRIMMED GRILLE
7
7. . The grille surround is now ready for the installation process with your new Fab Fours
bumper. Do not reattach the grille insert to the surround at this time. Proceed to the
Lights and Wiring section to complete the electrical installation of your Fab Fours
bumper components.

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 13 of 21 H234X_REV_A-Rev.A
V. Lights and Wiring Installation
1. With the headlights removed, tap into the turn indicator wiring with the
supplied tap connectors.
2. The turn indicator wiring harness may be installed at this time. To do so,
remove the wiring harness and bulb socket from the lens housing. See below
for wire color guide.
WIRE COLORS:
WIRE
OEM COLOR
FAB FOURS COLOR
Running
Brown
White
Turn
White/Blue (Pass)
Red
Ground
Power
Black
Purple
Green
Red
Ground
Black
Green
3. Tuck the Fab Fours provided wiring and bulb out of the way until the
installation of the Fab Fours bumper is complete.
4. Replace headlights in reverse order of removal. Be sure to route newly
installed Fab Fours wiring away from sharp edges down to the bumper area.
5. Tap into OEM fog light harnesses on each side of the vehicle using two
supplied tap connectors.
6. Connect the supplied fog lamp wiring harnesses to tap connectors following
wire color guide above.
7. Tuck OEM fog light harness and Fab Fours supplied wiring out of the way
until completion of the bumper installation.
TURN SIGNALS
FOG LIGHT

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 14 of 21 H234X_REV_A-Rev.A
8. Install turn indicators into the plastic light insert using three self- tapping
screws as shown below:
Figure 166 –Turn Signal Installation
9. Install the light inserts with turn indicators into the cutout in the bumper. Use
the ¾” length ¼” stainless steel button head, ¼” washers and hex nuts to
fasten the insert through the holes shown below. Do not use the two holes
closest to the center of the bumper at this time. Use washers only on the nut
side (inside the bumper). Use needle nose pliers to tighten nuts with limited
access.
Figure 177 –Light Insert Installation

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 15 of 21 H234X_REV_A-Rev.A
10. Install the Fab Fours fog lights onto the mounting brackets as shown below
using the #8 button head screws, washers, and nylock hex nuts.
Figure 188 - Fog Light to Bracket Installation
11. Install the fog light and bracket into the bumper using the remaining two holes
available in the light insert. Use the 1-1/2” length ¼” stainless steel button
heads with ¼” washers and nylock nuts:
Figure 19 - Fog Light Installation
12. Repeat steps 7-10 for other side.

 Do not connect wiring harnesses to lights until
bumper is installed.

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 16 of 21 H234X_REV_A-Rev.A
VI. Bumper Installation
Optional: If installing winch and roller fairlead into bumper, do it at this
time. Follow the winch manufacturer’s instructions for installation. If you are
installing a winch with a pulling capacity of 12,000 lbs., the front face
mounting holes must be used.
If not installing a winch, a license plate may be installed onto the front face of
the bumper (Hardware not included).
1. Install intermediate mount onto the frame rail using bolts, washers, lock
washers and nuts provided in the hardware kit. Use the 5.5” bolts in the OEM
push bar mounting location (shown in the top view) and the 1.5” bolts in the
tow hook mounting holes (Shown in bottom view). The offset portion of the
bracket should face the outside of the truck. DO NOT FULLY TIGHTEN,
repeat for other side.
Figure 20 –INTERMEDIATE BRACKET INSTALLATION –TOP VIEW

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 17 of 21 H234X_REV_A-Rev.A
Figure 191 - INTERMEDIATE BRACKET INSTALLATION - BOTTOM VIEW
2. Refit the modified grille surround to the bumper, locating the Fab Fours
provided grille mounting bracket onto the top of the foam core support shell
housing. Reattach it at the top corners with the OEM screws and align the
outside edges with the surface of the headlight. Drill though the support shell
with a 3/8” bit to mount the lower mounting bracket as shown below. Attach
with provided 1/4” bolts, fender washers, and nyloc nuts.
Figure 202 - DRILLING LOCATIONS

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 18 of 21 H234X_REV_A-Rev.A
3. Insert the studs into the slots on the mounting brackets from the back side as
shown below:
Figure 213 –STUD PLATE ORIENTATION
4. With the help of others or a lifting device, lift and align the bumper mounts
with the frame mounts. With the bumper fully supported supported, install
four nuts, washers, and lock washers per side onto the studs from underneath
the vehicle. DO NOT FULLY TIGHTEN

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 19 of 21 H234X_REV_A-Rev.A
Figure 224 –BUMPER ATTACHMENT –VIEW FROM BOTTOM
5. Adjust the bumper to achieve good visual alignment as follows:
1. Adjust in/out bumper alignment with mounting bracket to frame
hardware.
2. Adjust up/down and left/right alignment with bumper to
mounting bracket hardware
NOTE: Fab Fours recommends a MINIMUM gap of 3/8” at the outer fenders and
headlights to prevent paint damage in normal operation.
6. Tighten all fasteners fully; beginning with frame mounts. Then tighten all
mount-to-bumper fasteners.
7. OPTIONAL: Trim the inner fender liners to match the higher clearance of
your Fab Fours bumper. This can be done with a body saw, rotary tool, or
sharp utility knife (New blade strongly recommended). USE CAUTION
WHEN PERFORMING ANY CUTTING OPERATION TO PREVENT
VEHICLE DAMAGE OR PERSONAL INJURY.
8. OPTIONAL: Hardware and mounting provisions are provided to reattach the
inner fender liner to you Fab Fours bumper if desired. It is recommended that
vehicles that perform in severe duty environments or spend a significant
amount of time off-highway that the inner fender liner NOT be attached to the
Fab Fours bumper, as it may cause damage to the inner fender liner mounting
due to chassis flex.

Installation Instructions
Yukon XL 1500 Winch Bumper
Product Number: H2340-H2342
Application: ’07-’12 GMC Yukon XL 1500
Copyright 2012 Fab Fours, Inc. Page 20 of 21 H234X_REV_A-Rev.A
9. Connect wiring harnesses to lights as shown in wiring diagram.
10. Verify proper operation of lights. Note: Turn indicators should be dim during
“running” condition and flash bright for turn.
VII. Maintenance/Care

 Periodically check and tighten all fasteners.

 Stripped, fractured, or bent bolts or nuts need to be replaced.

 Keep all surfaces free of dirt, road grime, and standing water to ensure
finish longevity.