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Expedition One RANGEMAX EXP262 Install Manual

Front bumper 2022+ toyota tundra
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FRONT
BUMPER
2022+ TOYOTA TUNDRA
I N S T A L L G U I D E
E X P 2 6 2
P L E A S E R E A D E N T I R E G U I D E B E F O R E I N S T A L L A T I O N
Recommended that you read this entire install guide before installation. Check that all hardware is
present before staring or scheduling an install. This guide is supplemental to mechanical knowledge and
ability. Anyone not familiar with automotive installation should seek professional installation.
LAST UPDATE 5/24/23 v1

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Summary of Contents for Expedition One RANGEMAX EXP262

  • Page 1 FRONT BUMPER 2022+ TOYOTA TUNDRA I N S T A L L G U I D E E X P 2 6 2 P L E A S E R E A D E N T I R E G U I D E B E F O R E I N S T A L L A T I O N Recommended that you read this entire install guide before installation.

  • Page 2: Install Guide

    Expedition One does not guarantee fitment with other aftermarket products, or reinstallation of take off OEM parts. Expedition One is NOT RESPONSIBLE for damage to paint or powder coating, items assembled in error during installation or costs associated with install OEM manufacture model refreshes/updates, factory build location and suppliers may cause variations in fitment or installation and can not be verified, vehicle to vehicle .
  • Page 3 INSTALL GUIDE IMPORTANT INFO/FAQ I N S T A L L G U I D E A L L LIGHTPORTS To give you a wide range of options from various brands and designs, the light ports were designed to be as universal as possible.

  • Page 4: Hardware Info

    INSTALL GUIDE HARDWARE INFO I N S T A L L G U I D E A L L HARDWARE Please review for details and installation. Figures or data may vary. Leave all accessible hardware loose for installation and tighten all hardware after everything is installed on the vehicle. Check and retighten all hardware after the first 100 miles and/or after off roading.

  • Page 5: Hardware Guide

    INSTALL GUIDE HARDWARE GUIDE I N S T A L L G U I D E E X P 2 6 2 WINCH & FRAME MOUNTS A Winch Mount B Winch Mount Brackets C Front Reinforcement Brackets D Frame Spacer BUMPER MOUNTS E Bumper Mount Bracket F Mount Shim Thick...
  • Page 6 INSTALL GUIDE HARDWARE GUIDE E X P 2 6 2 GRILLE SHUTTER RELOCATION H Motor Bracket Top I Motor Bracket Bottom J Motor Lever K Motor Gear WINCH & FRAME MOUNT HARDWARE 3/8”-16 X 1 1/4” Hex Cap Bolt 3/8”-16 Nyloc Nut 3/8”...
  • Page 7 NOTE - Extra hardware may need to be removed due to model or option specific items that were not be present for the models and year specific vehicles used in our install. Check for extra connections before removing hardware. 1 - REMOVE OEM BUMPER HARDWARE Remove the front bumper OEM hardware from the front wheel wells on each side of the vehicle.

  • Page 8: Wiring Connections

    2 – WIRING CONNECTIONS Disconnect all wiring at the top of the grille,, grille shutter and main harness connect point. The OEM lights and sensors should remain attached to the bumper as part of the harness. 3 – BUMPER REMOVAL Check for any remaining hardware connecting the bumper.
  • Page 9 5 – CROSS MEMBER REMOVAL Unbolt and remove the cross member as shown below. Save OEM hardware to be reused in mounting. Remove the lower grace brace and remaining fixtures from the area of the cross member.
  • Page 10 6 – GRILLE SHUTTER REMOVAL Unbolt grill shutter assembly from the grille and disconnect from the wiring harness. The center section will need to be pried open to gain access to mounting hardware and the motor once removed. NOTE – The grille shutters may remain in place if no winch is mounted or if a compact option with a solenoid relocation is used.
  • Page 11 6 – CONTINUED Remove the motor and harness once from the grille shutter housing. This will be reinstalled later. 7 – WIRE LOOM REMOVAL Unclip the wiring loom from the grille. Disconnect the parking sensors from the bezels. Be care to not break any clips or parts of the bezel as they will be reused in the new bumper.
  • Page 12 8 – GRILLE TRIM REMOVAL Undo the clips and pull off the lower front fascia panel. Remove the OEM lights and the remaining lower grill side trim. Save hardware as some parts will be reinstalled after trimming.
  • Page 13 8 – CONTINUED The bumper as shown removed of trim and ready for cutting.
  • Page 14 9 – BUMPER TRIMMING (RANGEMAX ULTRA ONLY) Trim the bumper as shown. Measure 1” above transition face on the side of the bumper and cut towards the center of the OEM light area. Cut horizontally across the grill following the transition edge of the grill line Cut as needed..
  • Page 15 9 – CONTINUED...
  • Page 16 10– FRAME MODIFICATION (IF APPPLICABLE) NOTE The OEM frame tops may be bent or have undersized holes. This may require one of the options below 1 – Bend them back to level 2 – Drill holes to fit 1/2“ hardware (recoat surface) 3 –...
  • Page 17 12 – REINFORCEMENT BRACKET INSTALLATION Attach the reinforcement bracket next to the frame as shown. Mount using the provided 3/4” hardware. Leave all hardware loose for adjustment. 3/4”- 10 X 4 1/4” Hex Cap Bolt 3/4”- 10 Nyloc Nut 3/4“ USS Washer...
  • Page 18 13 – REINFORCEMENT BRACKET INSTALLATION Attach the bumper mount bracket next to the frame and reinforcement bracket as shown. Mount using the provided 3/8” & 1/2” hardware and OEM bolts Leave all hardware loose for adjustment.
  • Page 19 13 – HARDWARE DIAGRAM OEM HARDWARE 3/8”- 16 X 1 1/4” Hex Cap Bolt 3/8”- 16 Nyloc Nut 3/8“ USS Washer 1/2” – 13 x 1 1/2” HEX CAP BOLT 1/2” – 13 NYLOC NUT 1/2” USS WASHER 1/2” – 13 x 1 1/2” HEX CAP BOLT 1/2”...
  • Page 20 14 – WINCH MOUNT BRACKET INSTALLATION Attach the winch mount bracket next to the bumper mount and reinforcement bracket as shown. Use the provided 1/2” hardware Leave all hardware loose for adjustment.

  • Page 21: Hardware Diagram

    14 – HARDWARE DIAGRAM 1/2” – 13 x 1 1/2” HEX CAP BOLT 1/2” – 13 NYLOC NUT 1/2” USS WASHER 1/2” – 13 x 1 1/2” HEX CAP BOLT 1/2” – 13 NYLOC NUT 1/2” USS WASHER MOUNT IN A TRIANGLE PATTERN...
  • Page 22 15 – WINCH MOUNT INSTALLATION Place the winch mount onto the winch mount bracket as shown. Mount with the provided 1/2” hardware Leave all hardware loose for adjustment. 1/2” – 13 x 1 1/2” HEX CAP BOLT 1/2” – 13 NYLOC NUT 1/2”...

  • Page 23: Winch Installation

    16 – TIGHTEN HARDWARE Adjust the winch mount to its desired location and TIGHTEN HARDWARE. Check that all hardware is tightened including all brackets and mounting locations 17 – WINCH INSTALLATION Mount the winch at this time using the winch manufacture provided hardware. This will mount directly to the winch mount.
  • Page 24 18 – SPOILER MOTOR RELOCATION (IF APPLICABLE) Unbolt and relocate the horn as shown. Before for reinstalling the spoiler motor, bend the tab back from the old horn location. Next the motors housing will need to be trim of tabs or gussets for clearance and weight.
  • Page 25 19 – OEM BUMPER REINSTALLATION Loosely reinstall the wiring harness in the grille area matching the positions of sensors and plug locations from before, this will position the harness once the bumper is installed. Make sure wiring or other items including the winch rope are clear of pinch points for installation.. Reinstall the OEM bumper. Mask off the area around the grill and cut lines for installation of the bumper.
  • Page 26 20 – HARDWARE DIAGRAM 1/2” – 13 x 1 1/2” HEX CAP BOLT 1/2” – 13 NYLOC NUT 1/2” USS WASHER Use the provided spacers if necessary to shim the bumper. The OEM plastic and frame will vary in Relation to each other and the bumper. Adjust and use as need when mounting.

  • Page 27: Wiring Harness

    21– WIRING HARNESS Reconnect the wiring harness into the new bumper. Place all wiring out of the way of mounting points and hardware locations. Check that the wiring loom connectors match there original points of connection per each side of the vehicle and ACC sensor. Install the new bezels and connect the sensors. When using the provided replacement rubber bezels use WD40 and align the fat edge directional to the pointed surface when fitting.
  • Page 28 22 – CONTINUED Secure the motor top over the motor and bottom. Mount the gear to the top using the provided screw. Bend the flanges over to secure in place. Connect the motor to the wiring harness and Mount on a level surface away from the engine, fan, cooling wires etc.
  • Page 29 23 – TIGHTEN HARDWARE Adjust the bumper to its desired location and TIGHTEN HARDWARE. Check that all hardware is tightened including all brackets and mounting locations. Reconnect the parking sensor wiring harness and other connections to the vehicles electronics and secure all loose wiring. Check that everything is working and adjust if needed before driving on the road.

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