I hadn't seen one of these so, as my new grill arrived, I thought I'd document the process for all to enjoy.
Look! The new grill! It's very brown and square;
Out of the box, this is a thin lip M4
Here's my truck before I started
As soon as you open the hood you'll notice these two clips on either ends of the grill.
Simply use a small flat-head screwdriver and slide it under the smaller of the two heads - It should pop right open. If it's stubborn you may need to slightly twist.
Open - Now simply, and carefully pull the entire plastic faster directly up and out.
Next, undo the two 10mm bolts. Careful, they are just threaded into plastic. When it's time to put thing back together be VERY careful not to over-tighten these.
At this point, the grill will be feel like it wants to come out, but there are two more fasteners - down on the actual headlight body.
Deliberate but careful force will release them. They hook into the headlight. My right one came out immediately, the left one took some negotiation.
The old grill will lift up and out of the truck - leaving you with this view. You'll notice the bare aluminum sides to the radiator/cooler as well as those unsightly horns.
Most people will want to relocate the horns. This too is quite simple. Start by removing the plastic radiator cover. It uses the exact same clips used by the grill.
Unplug and remove the two horns using a 12mm socket and set them aside. The cable is routed underneath the radiator sub-frame. The cable's held in place with these black clips.
Simply squeeze them and they will release;
You'll also need to free this little sensor.
Works exactly the same way as the other clips;
The horn wiring should now free for you to relocate it
I went around through one of the small ports near the bottom of the left headlight. This gives you lots of extra cable to work with.
You can almost see the port I used.
I ran the cable along the lower brace of the radiator sub-frame. there is a suitable existing hole for the sensor clip to snap back into right next to the right radiator lower mount (the black thingie in the corner of the photo).
To reattach the horns, you'll need some nice giant fender washers and some lock-nuts. I just happened to have these on hand.
I chose the two center most oval holes and placed the horn towards the center. You can see my fender washer on the back side of the radiator sub-frame.
This places the horns immediately behind the lower grill. (only one horn fit here).
Another image of the new horn placement. I used a couple of long zip-ties to fasten the horn wires to the lower radiator sub-frame.
Now time to paint. I cleaned up the aluminum bits and sprayed them with some satin black heat paint. Not overly concerned as it's mostly to obscure stuff. It doesn't need to look perfect.
You insert the new grill from the top down and gently press the clips into the headlight (the HomerTashi grill comes with new clips - no need to remove them from your old grill).
Because nobody seems to mention. I chose the thin lip, M4.
From the right now...
The end result