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C4 FAB 3rd gen rear bumper with BSM support, installation instructions.

Discussion in 'C4 Fabrication' started by C4 Fabrication, Dec 10, 2016.

  1. Dec 10, 2016 at 1:44 PM
    #1
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

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    Caleb
    South Dakota
    Vehicle:
    07 DCLB Sport
    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    Here are the install instructions for our direct replacement rear bumper with BSM support.

    Tools needed:
    -Flat and Philips head screwdrivers
    -10mm wrench/socket
    -12mm wrench/socket
    -17mm wrench/socket
    -19mm wrench/socket
    -7/16" wrench/socket
    -Side cutters/wire snips
    Visit this link to see the original rear bumper and hitch removal process:
    https://www.tacomaworld.com/threads...stallation-instructions.445366/#post-13288835

    We recommend thoroughly reading through all of the instructions and pictures before starting the process so you are familiar with all of the components.

    If your rear bumper is equipped with BSM and park sensors, there will be extra wiring harnesses that need to be disconnected from the park sensors and the BSM sensors during removal.
    Remove these clips first when taking the plastic covers off the rear bumper components-
    DSCN3854.jpg

    Next remove these plastic clips
    DSCN3844.jpg DSCN3842.jpg DSCN3840.jpg DSCN3841.jpg

    Then pull the cover away from the bumper frame work.
    DSCN3847.jpg

    Now remove the park sensors (small round sensors) then remove the BSM sensors (large square plastic box)
    DSCN3849.jpg DSCN3848.jpg DSCN3850.jpg DSCN3852.jpg DSCN3851.jpg DSCN3853.jpg


    Label the BSM sensors with a marker so that you know which side is which and also which end is the top of the sensor.

    Finish removing the rest of the bumper components and the receiver hitch according to the instructions in the link at the top.
     
    Last edited: Dec 10, 2016
    DrFunker likes this.
  2. Dec 10, 2016 at 1:57 PM
    #2
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

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    Caleb
    South Dakota
    Vehicle:
    07 DCLB Sport
    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    Now you can begin assembly of the new bumper.

    Install the trailer wiring plug into the cutout provided.
    DSCN4199.jpg DSCN4201.jpg

    Next install your Baja Designs backup lights if you ordered the bumper with that option.
    The lights go in from the outside face of the bumper so that the flush mount bezel is on the outside of the bumper.
    DSCN4248.jpg
    Here is a view of what the light looks like from the inside of the bumper.
    DSCN4216.jpg


    If your bumper does not have the park sensors or BSM sensors, you can now lift your bumper up into place on the truck and bolt it into position.

    If you have park sensors, install those now. The sensors go in from the outside of the bumper. push firmly on the sensors to clip them into the bumper. Make sure the portion of the sensor that goes on the inside of the bumper points in the same direction as the notch in the cutout of the bumper.
    DSCN4189.jpg DSCN4191.jpg DSCN4192.jpg DSCN4193.jpg DSCN4194.jpg
    Here is what the sensor should look like from the inside of the bumper.
    DSCN4195.jpg
     
    DrFunker and qxrtz4321 like this.
  3. Dec 10, 2016 at 2:56 PM
    #3
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

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    Vehicle:
    07 DCLB Sport
    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    Now the plastic cover and BSM sensors need to be installed if you ordered your bumper to be BSM compatible.
    The BSM sensors will not function behind any material other than plastic. So in order to retain the function of the sensors, we designed the corner of the bumper with a large cutout in the steel which gets covered with plastic.
    You will need to paint your plastic cover to match the color choice of your steel bumper.
    Install the plastic from the inside of the bumper.
    In the bottom corners of the bumper you will see a flat piece of steel that creates a groove to capture the plastic piece.
    Fit the plastic cover into the corner so that it sits down into the groove at the bottom corner of the bumper.
    DSCN4171.jpg DSCN4172.jpg DSCN4174.jpg DSCN4180.jpg
    DSCN4175.jpg DSCN4176.jpg

    Now install the angle bracket that holds the plastic in place. Install the bracket on the bottom side of the slotted hole. Loosely install the provided 5/16"x1" bolt to hold the bracket onto the bumper.
    DSCN4177.jpg DSCN4178.jpg DSCN4179.jpg DSCN4181.jpg

    Push the angle bracket up tight against the plastic panel to pinch it in place against the bumper. Then tighten the bolt to hold it in place.
    DSCN4182.jpg

    The cover panel should look like this from the outside.
    DSCN4183.jpg
     
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  4. Dec 10, 2016 at 3:11 PM
    #4
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

    Joined:
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    Caleb
    South Dakota
    Vehicle:
    07 DCLB Sport
    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    Now install the BSM sensors into the corners of the bumper.
    There are brackets welded into each corner of the bumper that have nutserts installed into them. The BSM sensors bolt into those brackets with the supplied 1/4-20 bolts and washers.
    Make sure you install the correctly marked sensor into each corner.
    DSCN4185.jpg DSCN4187.jpg DSCN4186.jpg DSCN4188.jpg

    Tighten the bolts and the sensor install is done.

    You should now be ready to install the bumper onto the truck.

    Have a friend help you lift the bumper into position on the truck and install the bolts that were used to hold the original bumper and hitch to the truck.

    Let the bumper hang loose so that you have room to run the wiring harness and plug in all of the sensors.

    DSCN4208.jpg

    Route the wires up over the frame rail where the bumper attaches so that the wires can reach the sensors.
    DSCN4209.jpg
    DSCN4211.jpg
    DSCN4210.jpg

    Route the wires into the appropriate locations so that they can be plugged into the sensors.
    DSCN4213.jpg DSCN4216.jpg DSCN4217.jpg

    Now the bumper can be adjusted as necessary and all of the bolts can be tightened.
    DSCN4218.jpg
     
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  5. Dec 10, 2016 at 3:34 PM
    #5
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

    Joined:
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    Caleb
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    07 DCLB Sport
    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    Lastly you will need to attach the harness for the trailer plug in. The harness is barely long enough to reach the plug, so you will most likely need to cut a couple of the plastic clips holding the harness in place farther up the frame rail so that it can be stretched to reach.
    Also it helps to take the grey plastic cover off the back of the plug in on the harness. This allows the wires to straighten out a bit and add some length.
    Here is what it looks like all plugged in.
    DSCN4219.jpg

    One final thing that needs to be added is the license plate led light strip. Make sure you clean the bottom side of the tail gate very well so the strip sticks properly. Then attach the strip to the center bottom side of the tailgate. The wire can be ran through the opening in the frame where the wire harness for the backup camera goes through. Splice the wire into one of the original license plate light wires.
    DSCN4207.jpg DSCN4206.jpg

    The only thing left to do is to wire up your Baja Designs reverse lights and install the license plate.

    Your rear bumper install is now done!
     
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  6. Dec 10, 2016 at 3:36 PM
    #6
    DrFunker

    DrFunker Zookeeper, Referee, Policymaker, Juggler, Janitor

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    ChadsPride likes this.
    Impressive. Well thought out.
    What a PITA!
    Bravo to you. :bowdown:
     
  7. Dec 10, 2016 at 3:36 PM
    #7
    Ossaris

    Ossaris The square root of rope is string.

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    Awesome guide mate! I bet you're gonna make a lot of the guys on here quite happy!
     
  8. Dec 10, 2016 at 3:37 PM
    #8
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

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    07 DCLB Sport
    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    Haha, PITA creating the instructions or PITA designing the bumper?
     
  9. Dec 10, 2016 at 3:38 PM
    #9
    DrFunker

    DrFunker Zookeeper, Referee, Policymaker, Juggler, Janitor

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    ChadsPride likes this.
    :laugh: Both actually.
    But designing that bumper......Wow! Nice work.
     
  10. Dec 10, 2016 at 3:38 PM
    #10
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

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    07 DCLB Sport
    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    Thank you!
     
    Ossaris likes this.
  11. Dec 10, 2016 at 3:39 PM
    #11
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

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    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    LOL i agree! Both were a PITA! im not sure which one was less fun, designing the bumper or creating instructions! haha
    And thank you for the nice comments, i really appreciate it!
     
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  12. Dec 10, 2016 at 3:42 PM
    #12
    DrFunker

    DrFunker Zookeeper, Referee, Policymaker, Juggler, Janitor

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    ChadsPride likes this.
    I need to have something C4 on my truck. Your attention to detail really makes me giddy. :oops:
     
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  13. Dec 10, 2016 at 3:42 PM
    #13
    Ossaris

    Ossaris The square root of rope is string.

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    Agreed! Hopefully sometime soon!
     
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  14. Dec 10, 2016 at 3:43 PM
    #14
    DrFunker

    DrFunker Zookeeper, Referee, Policymaker, Juggler, Janitor

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    ChadsPride likes this.
    I am thinking rear bumpah (with beer opener of course). :anonymous:
     
  15. Dec 10, 2016 at 3:44 PM
    #15
    Ossaris

    Ossaris The square root of rope is string.

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    YA. The new one is sweet! I'm digging the function and look. It's not as extreme or high-profile as some of the other ones out there.
     
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  16. Dec 10, 2016 at 3:53 PM
    #16
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

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    07 DCLB Sport
    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    DrFunker and Ossaris like this.
  17. Dec 10, 2016 at 4:02 PM
    #17
    Ossaris

    Ossaris The square root of rope is string.

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    @C4 Fabrication soon my friend, soon! I dig your product and your builds. It's nice seeing so much love on the 3rd gens! Keep it up!
     
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  18. Dec 10, 2016 at 5:42 PM
    #18
    Kennedyusmc

    Kennedyusmc Well-Known Member

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    Still waiting for it
    Summer project there...
    Is there a ridgid light option?
     
  19. Dec 10, 2016 at 5:55 PM
    #19
    Ossaris

    Ossaris The square root of rope is string.

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    I'm sure there is. Caleb makes the bumper with fairly standard dimensions. I'd bet the lights are fairly interchangeable, provided you got ones that fit.
     
  20. Dec 11, 2016 at 9:46 AM
    #20
    C4 Fabrication

    C4 Fabrication [OP] Well-Known Member Vendor

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    07 DCLB Sport
    2" lift, 285/70/17 BFG TA KO2's, baja bumper, bedrack with swing out, CVT RTT, Leather interior, heated seats, JBL, remote start, K&N intake, Hood Scoop LED lightbar mod.
    We currently do not offer an option for a Rigid flush mount. We are a dealer for Baja Designs and also feel that their product is superior to Rigid, so we like to stick with one company and work with them directly.

    There may be a Rigid flush mount that will fit the same hole, but we have never tried one out.
     
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