Westin SPORTSMAN 40-1665 Installation Instructions

AUTOMOTIVE PRODUCTS, INC.
SPORTSMAN
ASSEMBLY
40-1665
43-1660
ITEM QTY DESCRIPTION
1 1
SPORTSMAN ASSEMBLY
2,3 2
LIGHT GUARD ASSEMBLY, PASSENGER(2) & DRIVER(3)
4,5 2
TOP BRACKET, PASSENGER(4) & DRIVER(5)
6,7 2
BOTTOM BRACKET, PASSENGER(6) & DRIVER(7)
8,9 2
SUPPORT BRACE, PASSENGER(8) & DRIVER(9)
10 8
1/2-13 X 1.25" HEX HEAD BOLT
11 16
1/2" FLAT WASHER
12 8
1/2" LOCK WASHER
13 8
1/2-13 HEX NUT
3/4" SOCKET 3/4" WRENCH
5/32" HEX WRENCH 18MM SOCKET
RATCHET SOCKET EXTENSION
STEP 1.
Remove the contents from box and check for damage. Verify all parts are present. Read instructions com-
pletely before beginning.
STEP 2.
Attach light guard assemblies as shown.
STEP 3.
Open hood and attach support braces as shown
mount braces off of bumper.
STEP 4.
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.
STEP 5.
Attach bottom brackets using 1/2" fasteners as shown.
STEP 6.
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.
Slowly
STEP 7.
lower hood and check for clearance between sportsman and hood and mount braces and hood.
Reposition sportsman if neccessary.
STEP 8.
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.
I N S TA L L AT I O N I N S T R U C T I O N S
APPLICATION: 2005-UP DODGE DAKOTA 2/4 WHEEL DRIVE
2
1

PARTS KIT CONTENTS

TOOLS REQUIRED

9/16" SOCKET
18MM WRENCH 19MM SOCKET
TORQUE WRENCH
3
ITEM QTY
14 4
15 2
16 4
17 8
18 4
19 4
20 2
9/16" WRENCH
SEE FIGURE 1.
SEE FIGURES 2 NOTE:
SEE FIGURE 2 .
SEE FIGURE 2 .
4 6
5 7
DESCRIPTION
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.
7/16" WRENCH
13MM SOCKET
. Use rubber bumpers to keep
Torque nuts and bolts to 65 FT.LBS.
Leave loose.
SEE FIGURE 1.
WO: 142076 75-0504 Revision B 6/12/06
8
9