Expedition One ULTRA EXP261 Install Manual

Front bumper 2022+ toyota tundra

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ULTRA

FRONT

BUMPER

2022+ TOYOTA TUNDRA

I N S T A L L G U I D E

E X P 2 6 1

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 ULTRA EXP261

Page 1 ULTRA FRONT BUMPER 2022+ TOYOTA TUNDRA I N S T A L L G U I D E E X P 2 6 1 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 1 WINCH & FRAME MOUNTS A Winch Mount B Winch Mount Brackets C Front Reinforcement Brackets D Frame Spacer BUMPER MOUNTS E Bumper Mount Bracket F light Port...
Page 6 INSTALL GUIDE HARDWARE GUIDE E X P 2 6 1 BUMPER SPECIFIC HARDWARE K Grille Brace L Grille Brace Brackets GRILLE SHUTTER RELOCATION M Motor Bracket Top N Motor Bracket Bottom O Motor Lever P Motor Gear WINCH & FRAME MOUNT HARDWARE BUMPER HARDWARE 3/8”-16 X 1 1/4”...
Page 7: Wiring Connections
1 - REMOVE OEM BUMPER HARDWARE Remove the front bumper OEM hardware from the front wheel wells on each side of the vehicle. Extra locations may need to be unbolted to flex the fender trim (or completely remove the trim) for bumper removal, access and installation.
Page 8: Bumper Removal
3 – BUMPER REMOVAL Check for any remaining hardware connecting the bumper. Remove the bumper by pulling it away from the corner near the wheel wells. 4 – FRONT SPOILER REMOVAL With the bumper removed, disconnect the wiring for the front spoiler motor. Unbolt all hardware and remove the motor and associated spoiler .The motor will be separated and remounted later to avoid setting a check engine code.
Page 9 5 – CONTINUED Remove the lower grace brace and remaining fixtures from the area of the cross member. 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 –...
Page 10 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 11 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 12 8 – CONTINUED The bumper as shown removed of trim and ready for cutting. 9 – BUMPER TRIMMING Trim the bumper as shown. Start 1” from the bottom edge of the side feature and cut horizontally across to the grill. Follow the bottom edge of the grill line and cut straight across the bottom edge. Cut as needed..
Page 13 1 ”...
Page 14 9– CONTINUED 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 15 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 16 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 17 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 18 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 19: 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 20 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 21: Winch Installation
17 – WINCH INSTALLATION Mount the winch at this time using the winch manufacture provided hardware. This will mount directly to the winch mount. Adjust as needed, and see winch section for details 18 – SPOILER MOTOR RELOCATION (IF APPLICABLE) Unbolt and relocate the horn as shown.
Page 22 19 – CONTINUED 20 – GRILLE BRACE Attach the grace brace brackets to the crossmember above the winch location using the OEM bolts. Leave loose for adjustment once on the vehicle and the bumper is mounted.
Page 23 20 – CONTINUED Attach the grace brace to the original sensor location of the grille using the OEM bolts. Leave loose for adjustment once on the vehicle and the bumper is mounted. 21 – 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.
Page 24: Clevis Installation
22 – CLEVIS INSTALLATION Mount the clevis mounts to the bumper as shown. Use the provided 5/8” hardware 5/8” – 11 x 2” HEX CAP BOLT 5/8” – 11 NYLOC NUT 5/8” USS WASHER...
Page 25 23 – LIGHT PORT INSTALLATION Attach the provided 3/8” clip nuts to the bumpers light port frame. Finish mounting the light port with 3/8” hardware. Attach any aftermarket lights to the light ports at this time. Use the provided spacers if required, see light port section for details.
Page 26 24 – OEM LIGHTS INSTALLATION Mount the OEM lights to the brackets as shown using the provided 1/4” hardware . Attach the bracket using 5/16” hardware. Adjust as needed once on the vehicle.
Page 27 25 – SENSOR BRACKET INSTALLATION Mount the ACC Sensor to the bracket as shown using the provided 1/4” hardware . Place the sensor cover in the bumper and secure in place by attaching the bracket using 5/16” hardware. Adjust as needed once on the vehicle.
Page 28 26 – BUMPER MOUNTING Mount the bumper as shown using the provided 1/2“ hardware. Center the bumper with the vehicle and align gaps between the body and bumper to your preference before mounting. Mount the front bumper using the OEM hardware as shown below. Leave all hardware loose for adjustment. 1/2”...
Page 29: Wiring Harness
27– 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. 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 30 29– 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.

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