Service Procedure

1. Raise the vehicle on an appropriate hoist.

2. Support the fuel tank with an OTC Fuel Tank Jack or equivalent.





3. Remove the four (4) fuel tank-to-rear bumper fascia clips (Figure 1).





4. Loosen, but do not remove, the bolts for the two (2) rear brush guard-to-frame support brackets (Figure 2).





5. Loosen, but do not remove, the bolts for the front brush guard-to-frame support bracket (Figure 3).

6. Disconnect the electrical harness clip from the left side of the brush guard.





7. Remove the three (3) forward-most LEFT SIDE brush guard/trailer hitch (if equipped) mounting bolts (Figure 4). Do NOT remove the rear left brush guard/trailer hitch mounting bolt.

8. Loosen, but do not remove, the remaining four (4) brush guard bolts (one left side and three right side).

9. For vehicles equipped with a trailer hitch, loosen but do not remove, the two (2) rear-most trailer hitch bolts.

10. Using a large pry bar, reposition the fuel tank/brush guard assembly as far to the right side of the vehicle (passenger side) as possible.

11. With an assistant holding the tank assembly in the right-most position, and using a 12 inch extension, tighten the three right and the rear-most left, brush guard bolts to 65 ft-lbs (88 N.m).

12. For vehicles equipped with a trailer hitch, tighten the two (2) rear-most trailer hitch bolts to 65 ft-lbs (88 N.m).





13. Install the fuel tank blocker bracket adjacent to the left side of the fuel tank brush guard (Figure 5).

IMPORTANT:
For vehicles equipped with a trailer hitch, install the supplied spacer between the blocker bracket and the brush guard at the forward-most bolt hole location.

14. Position the blocker bracket as far to the right as possible (next to the brush guard) and then install the fuel tank brush guard/trailer hitch mounting bolts (Figure 5). Using a 12 inch extension, tighten the bolts to 65 ft-lbs (88 N.m).

IMPORTANT:
Tighten the forward-most blocker bracket bolt first.

15. Secure the electrical harness to the blocker bracket with the harness clip. If the clip was damaged during removal, use a new clip (PN 04688451).

16. Tighten the front brush guard-to-frame support bracket bolts (Figure 3).

17. Tighten the bolts for the two (2) rear brush guard-to frame support brackets (Figure 2).

18. In stall the four (4) rear fascia-to-fuel tank push pins (Figure 1)

19. Remove the fuel tank support.

20. Lower the vehicle.