TrailFX B1603S User manual

Page 1of 5
PARTS LIST:
Qty
Part Description
Qty
Part Description
1
3.5in Oval Bull Bar Assembly
4
12mm Plastic Retainers
1
Driver/left Frame Bracket
4
12mm x 32mm OD x 3mm Flat Washer
1
Passenger/Right Frame Bracket
4
12-1.75mm Nylon Lock Nut
1
Driver/left Bull Bar Mounting Bracket
8
10-1.5mm x 30mm Hex Bolt
1
Passenger/right Bull Bar Mounting Bracket
16
10mm x 27mm OD x 3mm Flat Washer
4
12-1.75mm x 35mm Bolt Plates
8
10-1.5mm Nylon Locknut
`
3.5" Oval Bull Bar
Part No. B1603S/B
Fits: 2011-2016 Chevrolet Silverado/GMC Sierra 2500/3500
Passenger/right Side
Frame Bracket
Driver/left Side
Frame Bracket
Passenger/right Side
Bull Bar Bracket
Driver/left Side
Bull Bar Bracket
(4) 12mm Bolt Plates
with Plastic Retainer
ASSISTANCE IS RECOMMENDED.
REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT.
READ INSTRUCTIONS CAREFULLY BEFORE STARTING INSTALLATION.
DO NOT OVER TORQUE.STANDARD OPERATING LOAD FOR TIGHTEN
BODY MOUNT NUTS & BOLTS VARIES FROM
45
TO
65
FOOT POUND.
60-180 min
Drilling Not
Required
Cutting
Required

Page 2of 5
INSTALLATION PROCEDURE:
CUTTING MAY BE REQUIRED. INSTALLATION MAY INTERFERE WITH BUMPER MOUNTED
PARKING SENSORS. ASSISTANCE IS RECOMMENDED.
NOTE: It may be necessary to remove/relocate front license plate and license plate bracket. It is not
required, but strongly recommended. If local/state law requires a front license plate, license plate relocation
kit is available.
1. Starting at the driver side, remove the factory tow hook if equipped, (Figures 1A & 1B). NOTE: This Bull
Bar is not compatible with the factory tow hooks and they cannot be reinstalled. IMPORTANT: On some
model years, with and without tow hooks, the pocket in the plastic bumper may need to be trimmed or
completely cut out, (Figure 1A). Use a sharp knife or hacksaw blade and carefully cut out the pocket to
clear the Bull Bar Brackets. Only cut enough to clear the Brackets.
2. Insert (1) 12mm Bolt Plate, (Figure 3), into the end of the frame channel, (Figure 4), and out through
the hole in the bottom of the frame. Insert a second Bolt Plate into and out the hole in the outer side of
the frame, (factory hole for tow hook bolt), (Figures 4 & 5). Thread 12mm Plastic Retainers onto the Bolt
Plates to help hold them in place as needed. NOTE: Plastic Retainers are not required for installation
and use is optional.
Front
Fig 1B) Remove the tow hook and hardware,
(Driver/left tow hook pictured from below bumper)
(Fig 3) 12mm Bolt Plate with hardware
(Fig 4) Driver/left side tow hook opening pictured
(2) 12mm Bolt Plates
Remove the factory tow
hook and hardware. Tow
hook will not be reinstalled
Fig 1A

Page 3of 5
3. Select the driver side Frame Bracket, (Figure 5). Position the Frame Bracket onto the outside of the
frame channel and over the (2) Bolt Plates, (Figure 6). Secure the Bracket to the frame and Bolt Plates
with (2) 12mm Flat Washers and (2) 12mm Nylon Lock Nuts. Leave hardware loose at this time.
4. Next, select the driver side Bull Bar Mounting Bracket, (Figure 7). Attach the Bull Bar Bracket to the
inside of the Frame Bracket with the included (2) 10mm x 30mm Hex Bolts, (4) 10mm Flat Washers and
(2) 10mm Nylon Lock Nuts, (Figure 7). Leave hardware loose at this time. NOTE: On some models, it
may be possible or simpler to bolt the Frame and Mounting Brackets together first and install as one
piece.
(Fig 5) Attach driver/left Frame Bracket
to 12mm Bolt Plates in end of frame
(2) 12mm Flat Washers
(2) 12mm Nylon Lock
Nuts
(2) 12mm Bolt Plates
(2) 12mm Plastic
Retainers (use is
optional)
(Fig 5) Attach driver/left Frame Bracket
to 12mm Bolt Plates in end of frame
(2) 12mm Flat Washers
(2) 12mm Nylon Lock Nuts
(2) 12mm Bolt Plates
(2) 12mm Plastic
Retainers (use is
optional)
(2) 12mm Flat Washers
(2) 12mm Nylon Lock Nuts
Front
(Fig 6) Driver/left Frame Bracket pictured

Page 4of 5
5. Starting at the bottom of the frame, tighten the lower 12mm Frame Bracket mounting hardware first then move to
the side of the frame. Fully tighten Frame Bracket to 12mm Bolt Plate hardware only at this time. Do not tighten the
10mm Bull Bar Bracket hardware.
6. Repeat Steps 1—5for passenger side Frame and Mounting Bracket installation.
7. With assistance, position the Bull Bar assembly up to the inside of the Mounting Brackets. Attach the Bull Bar to
the Brackets with the included (4) 10mm x 30mm Hex Bolts, (8) 10mm Flat Washers and (4) 10mm Nylon Lock
Nuts, (Figure 8). Do not fully tighten hardware at this time.
8. Level and adjust the Bull Bar and fully tighten all remaining hardware.
9. Do periodic inspections to the installation to make sure that all hardware is secure and tight.
(2) 10mm x 30mm Hex Bolts
(4) 10mm Flat Washers
(2) 10mm Nylon Lock Nuts
(Fig 7) Attach driver/left Bull Bar
Bracket to inside of Frame Bracket
(Fig 8) Attach Bull Bar to inside of Mounting Brackets
(2) 10mm x 30mm Hex Bolts
(4) 10mm Flat Washers
(2) 10mm Nylon Lock Nuts

Page 5of 5
FAQ’s
1. Hardware’s are not of correct size.
In GMC / Chevrolet truck model 2006 & up, customer needs to reuse the factory body bolts to install the bracket. If your vehicle is not
GMC / Chevrolet 2006 & up, ensure that holes are not partially covered with any plastic grommet or rust? If it is, remove the plastic
grommet & rust from the thread holes & re-try the installation.
2. Mounting Bracket are not getting Installed properly.
In some cases Illustration images shown in Installation manual may not be the exactly same as per actual vehicle images ,also if Driver /
Passenger side mounting brackets are very identical in the design, suggest referring Parts Identification guide to avoid fitment issue.
3. Products are thumping / rattling after installation.
Ensure that all required mounting brackets / hardware’s are installed & tighten correctly. Suggest using white lithium / regular grease
between the metal to metal contact surfaces.
4. Side Bar is not aligning with vehicle / Step Pads are not aligning with vehicle doors.
Side bar may be interchanged or mounting brackets are not installed at the correct position in the vehicle. Refer Parts identification guide.
5. Missing / Excess Hardware.
Recheck hardware count as per the part list.
6. Product not installing properly.
Ensure make model year, cab length and bed size of your vehicle is listed in the application. All installation steps are followed correctly.
Check out these other TrailFX Products!!
PRODUCT CARE
Periodically check the product to ensure all fasteners are tight and components are intact.
Regular waxing is recommended to protect the finish of the product.
Use ONLY Non-Abrasive automotive wax. Use of any soap, polish or wax that contains an abrasive is detrimental and can scratch the
finish leading to corrosion.
Aluminum polish may be used to polish small scratches and scuffs for Stainless Steel finish.
Mild soap may be used to clean the product for both Stainless Steel and Black finish.
Keystone Automotive Operations Inc. (KAO) warrants this product to be free of defects in material and workmanship at the time of purchase by the
original retail consumer. KAO disclaims any other warranties, express or implied, including the warranty of fitness for a particular purpose or an
intended use. If the product is found to be defective, KAO may replace or repair the product at our option, when the product is returned prepaid,
with proof of purchase. Alteration to, improper installation, or misuse of this product voids the warranty. KAO’s liability is limited to repair or
replacement of products found to be defective, and specifically excludes liability for any incidental or consequential loss or damage.