Navajo Rear Bumper Inspection and Repair Procedures
Figure II:
INSPECTION OF CUSTOMER'S VEHICLES
For dealership stock vehicles proceed directly to modification kit installation.
1. Inspect lower area of left and right bumper reinforcement below inner arm brackets for a crack as shown in Figure II.
2. If a crack exists and extends past the lower inner arm attaching hole (1-3/8") replace the bumper assembly (see procedure below and Figure II). The inner arm brackets may have to be removed to determine the length of the crack.
3. If there is no crack or the crack does not extend beyond the lower inner arm bracket attaching hole, proceed with installation of the modification kit.
Figure IV:
REAR BUMPER ASSEMBLY REPLACEMENT
1. Remove the license plate lamps from the rear bumper.
2. Remove the inner arm bracket to frame attaching stud plates (2 nuts from each side) and remove the complete bumper assembly from the vehicle.
3. Install the modification kit to the new bumper assembly as described in this bulletin below.
4. Loosely install the bumper assembly to the vehicl.e by inserting 4 new 14 mm bolts (J) through the new cuter arm bracket and frame and attach with 4 new nuts (K) as shown in Figure IV.
5. Center the bumper on the vehicle while maintaining a 25 mm margin vertically to the "D" pillar and fore and aft to the body side moulding. The brackets provide the required adjustment.
6. Install recall label to driver's door.
Figure III:
Figure IV:
MODIFICATION KIT INSTALLATION
1. Remove license plate lamps from the rear bumper.
2. Remove the bumper assembly from the vehicle by removing 4
nuts (B) and stud plates (A) as shown in Figure III from
both sides of the bumper.
3. Remove (4) hitch plate to bumper carriage bolts (C) and nuts
(D) as shown in Figure III. Discard the hitch plate, bolts, and nuts.
4. Position new hitch plate from kit to bumper. Secure using
(2) new carriage bolts (E) and 2 new nut and washer
assemblies (F). Tighten to 108-122 N-m (80-90 ft.lb.) as
shown in Figure IV.
5. Loosely install the new outer arm bracket (L) to the new
hitch plate using (4) four 12 mm torx bolts (G) and (4) four
12 mm flange nuts (H) as shown in Figure IV.
NOTE: Do not fully tighten at this time.
6. Loosely install the bumper assembly to the vehicle by
inserting 4 new 14 mm bolts (J) through the new outer arm
bracket and frame and attach with 4 new 14 mm nuts (K) as
shown in Figure IV.
7. Secure 12 mm torx bolts (G) to 108-122 N-m (80-90 ft.lb.).
8. Align the bumper to the vehicle body maintaining a 25 mm
margin vertically to the "D" pillar and fore and aft to the body side moulding.
9. Tighten bolts (J) with nuts (K) to 100-136 N-m (74-100 ft.lb.) as shown in Figure IV.
10. Install recall label to driver's door.