5
Lit. No. 63617
September 13, 2002
THRUST ARMS
1. Position driver side thrust arm to vehicle frame and
crossmember on driver side. Align hole in angle
with hole in mount frame. Fasten with 1/2" x 1-1/2"
bolt and lock nut. (Place lock nut toward outside of
vehicle.)
2. Position thrust arm tightly into corner of vehicle
frame and crossmember. Clamp in place. Using
hole in thrust frame as a template, drill 1/2" hole
into both bottom of frame and lower hole in front
face of crossmember. Fasten with 1/2" x 1-1/4" bolt
with top flange lock nut on inside of frame and
U-bolt placed through top hole in crossmember.
(Assembly tip: Tape lock nut to box end wrench
and assemble through front of frame. Use rubber
band provided to hold U-bolt in place when
attaching 1/2" locking nuts.)
3. Repeat steps 1 and 2 for passenger side.
LINK ARMS
Assemble a link arm (chamfered side of holes towards
center of vehicle) between each pair of link arm lugs
with a 3/4" x 3-1/4" Grade 5 rivet and cotter pin.
BUMPER
1. Remove brackets from bumper and lengthen slots
1/4" to inside as shown on page 4. Reinstall
brackets to bumper, positioning each bracket 1/4"
closer together.
2. Position bumper on vehicle aligning brackets and
frame brackets. Center bumper on vehicle. Mark
location of link arm lugs and spreader frame sides
on air dam. Remove bumper and notch air dam for
clearance. Lug arm clearance should be 3" wide by
5" deep per side. Spreader side clearance should
be 1" wide by 3" deep per side when viewed from
the bottom of the bumper.
3. Reinstall bumper and corner brackets to vehicle
with existing hardware.
MOUNT INSTALLATION
4. Reinstall fan air deflector behind radiator. It may be
necessary to cut away a portion from the right
angle area forward on the passenger side only.
5. Reattach fog lamp wire harness plug if so
equipped.
Tighten all bolts to corresponding torque chart
values.
NOTE: During electrical installation, THE LONG
BATTERY GROUND CABLE (no stripe) MUST BE
GROUNDED TO THE NEGATIVE BATTERY
TERMINAL.
HARNESS KIT SELECTION
All model years require the use of 61185 Park/Turn
Harness Kit in parklamp circuit. (Furnished in the Mount
Box.)
DRL equiped vehicles require the installation of a 61584
DRL Kit. (Not included in any kits.)
For Dual replaceable bulb type HB-5
• 2001 Vehicle Model Year
Without DRL’s:
Box No. 61540-1 Headlamp Kit 9-pin
and 63412 Harness Kit HB-5 9-pin -G
With DRL’s:
Box No. 61540-1 Headlamp Kit 9-pin
and 63412 Harness Kit HB-5 9-pin -G
• 2000 Vehicle Model year
Without DRL’s:
Box No. 61540-1 Headlamp Kit 9-pin
and 63396 Harness Kit HB-5/HB-1 9-pin -F
With DRL’s:
Box No. 61550-1 Headlamp Kit 12-pin
and 63404 Harness Kit HB-5/HB-1 12-pin -F
NOTE: After 5 to 10 hours of snowplow usage,
retorque all mount assembly fasteners.
