1996 4R ARB bumper install questions
 

I'm trying to help my 17 yr old and his buddies install an ARB bullbar on his 96 4runner LTD and I'm doing it BY PHONE (he lives with his mom).
We got him the Tacoma bumper and mounting kit and I'm not really sure what differences (if any) might exist at the frame.

He is saying he thinks he needs to grind off something near or at the "crush boxes" .

I'm at a loss not being able to see ...anybody have any insight for me?
For you guys who have them, was there anything not covered by Taco instructions??

Thanks in advance

I'm not positive, but I'm pretty sure that the '99-02 4runners had a fat-lip bumper which had a different mounting plate than the '96-98 4runners. It's possible that he bought the wrong bumper?

theres a flange at the end of the frame rails. there are some rail-ends that are bolted on and have to be removed. the flange on the frame rails is what needed to be ground down, so the mounting bracket fits over it.

after that...its just nuts n bolts. having an extra pair of hands or a hi-lift helps line it up properly before cranking the bolts down.

Thanks he finally emailed me a pic and the flange on the frame horn is the issue. Looks like I'll be making a road trip with my grinder.

Hello, i just recently did this so let me see if i can help.

1) of coarse remove all of old bumper assembly. Dis-connect the lights, throw the old bumper away!
At the end of the frame rails there is a wedge shaped piece with a bolt in the center. Take that piece off. Now you have to grind the lip flush around each frame rail. It is like a quarter inch of steel hanging over the lip. Once the lip is flush with the frame, the mounting brackets should just slide on.
With my application i had to drill a couple holes but nothing major.
I left all the bolts loose until i got the bumper on the brackets, then got it lined up and bolted it down. You want about a quarter inch gap between the bumper and the body mostly because the frame flexes on bumpy roads, if there is no gap it will rattle and drive the owner crazy. Then, after it is all bolted up do the turn signal wires, and your set. Its pretty easy once you get past the grinding and drilling.

patrick

When installing a TJM-15 on my '96 4runner I had rail-ends that were bolted on and had to be removed. I just unbolted and a quick tap with a hammer and they were off. After that the TJM bumper brackts were able to be installed. There wasn't a lip that needed to be grinded down. The bumper bracket was flush after the unbolting and removal of the rail-ends. Hope this helps.
Reminder to leave a gap between the bumper and the front fenders. I didn't leave a big enough gap while installing. I had to go back and readjust. Not a big deal but more work than necessary. I'm just glad someone reminded me, otherwise my new bumper would've damaged my fenders.