Westin SPORTSMAN 40-1665 User manual

STEP 1.
STEP 2.
STEP 3.
STEP 4.
STEP 5.
STEP 6.
STEP 7.
STEP 8.
Remove the contents from box and check for damage. Verify all parts are present. Read instructions com-
pletely before beginning.
Attach light guard assemblies as shown.
Open hood and attach support braces as shown . Use rubber bumpers to keep
mount braces off of bumper.
From underneath vehicle, remove the 4 lower nuts holding the bumper frame to the main frame and the 2
body mount bolts, then attach top brackets as shown. Torque nuts and bolts to 65 FT.LBS.
Attach bottom brackets using 1/2” fasteners as shown. Leave loose.
Lift Sportsman up towards vehicle and attach as shown to both lower brackets and support braces. Center and
level Sportsman. Torque 3/8” and 10mm support brace fasteners to 35 FT.LBS and 1/2” fasteners to 65
FT.LBS.
lower hood and check for clearance between sportsman and hood and mount braces and hood.
Reposition sportsman if neccessary.
For chrome assemblies. If light glare is being experienced off the wings of the Sportsman, anti-reflective tape
has been supplied to reduce glare. With headlighs on, note where the reflection is concentrated on the wing.
Clean the wing well with a non-abrasive cleaner (rubbing alcohol works the best.) Trim the anti-reflective tape
to the appropriate size where the glare was located and apply tape.
SEE FIGURE 1.
SEE FIGURES 2 NOTE:
SEE FIGURE 2 .
SEE FIGURE 2 .
SEE FIGURE 1.
Slowly
INSTALLATION INSTRUCTIONS
APPLICATION: 2005-UP DODGE DAKOTA 2/4 WHEEL DRIVE
SPORTSMAN
ASSEMBLY
40-1665
43-1660
75-0504 Revision B 6/12/06
142076WO:
AUTOMOTIVE PRODUCTS, INC.
TOOLS REQUIRED
3/4” SOCKET 3/4” WRENCH 9/16” SOCKET 9/16” WRENCH 7/16” WRENCH
5/32” HEX WRENCH 18MM SOCKET 18MM WRENCH 19MM SOCKET 13MM SOCKET
RATCHET SOCKET EXTENSION TORQUE WRENCH
PARTS KIT CONTENTS
ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION
SPORTSMAN ASSEMBLY
LIGHT GUARD ASSEMBLY, PASSENGER(2) & DRIVER(3)
TOP BRACKET, PASSENGER(4) & DRIVER(5)
BOTTOM BRACKET, PASSENGER(6) & DRIVER(7)
SUPPORT BRACE, PASSENGER(8) & DRIVER(9)
1/2-13 X 1.25” HEX HEAD BOLT
1/2” FLAT WASHER
1/2” LOCK WASHER
1/2-13 HEX NUT
3/8-16 X 1.25” HEX HEAD BOLT
3/8” FLAT WASHER
3/8” LOCK WASHER
3/8-16 HEX NUT
3/8-16 X 1.25” BUTTON HEAD BOLT
RUBBER BUMPER
ANTI-REFLECTIVE TAPE
(FOR CHROME ASSEMBLIES ONLY.)
NOTE: NOT ALL FASTENERS WILL BE USED.
4
2
4
8
4
4
2
14
15
16
17
18
19
20
1
2,3
4,5
6,7
8,9
10
11
12
13
1
2
2
2
2
8
16
8
8
3
2
15
4
7
6
9
8

Finish protection - Westin products have a high quality finish that must be cared for like any other
exposed finish on the vehicle. Protect the finish with a non-abrasive automotive wax (pure carnauba,
for example) on a regular basis. The use of cleaner wax or any compound which contains an abrasive is
detrimental, as the compounds scratch the finish and open it to corrosion.
Westin Automotive Products, Inc.
5200 N. Irwindale Ave. Suite 220
Irwindale, Ca. 91706
Thank You for choosing Westin products
For aditional installation assistance please call
Customer service [phone] or [phone]
INSTALLATION VIEW OF PASSENGER SIDE,
DRIVER SIDE IS OPPOSITE
FIGURE 2
EXISTING BOLT
EXISTING FLANGE NUTS
EXISTING FRAME
BOLT AND WASHER
UPPER SUPPORT FRAME
10
10
11
11
13
15
1
18
12
16
15
11
6
4
17
FIGURE 1
LIGHT GUARD INSTALLATION
ITEM QTY. DESCRIPTION
1 8 1/4-20 X 1.00” BUTTON HEAD BOLT
2 8 1/4” FLAT WASHER
3 4 1/4” INTERNAL TOOTH LOCK WASHER
4 4 1/4-20 NYLON NUT
5 8 RUBBER WASHER
NOTE: ALL FASTENERS MAY NOT BE USED.
1
2
2
5
5
2
4
4
1
APPLY TAPE HERE
**ON BOTH WINGS**
APPLY TAPE HERE
**ON BOTH WINGS**
20
3
1
2
13
8
13
12
11