Toyota Tacoma (1995–2004) Front Bumper Removal

Here's how to remove the front bumper cover.

1. From underneath the truck, unplug the connector on the back side of your fog lights.
2. Using a 17mm and a 12mm Socket, remove your skid plate mounting bolts (x6), then remove the skid plate. (Fig A)
    
    
   
    
    
3. Using a 10mm Socket, remove the lower Bumper Bolts (x6). (Fig B)
    
    
   
    
    
4. If your vehicle has fender flares, use a 10mm Socket to remove the fender flare bolts along the inside of your wheel well (6 per side). (Fig C)
    
    
   
    
    
5. Release enough of the plastic clips holding your fender flare on to be able to pull it back and out of your way. You may remove this flare completely if you desire, but it is not necessary. (Fig D)
    
    
   
    
    
6. Measure and cut your OEM bumper.

• Follow the bodyline just above your fog light. Measure from the bottom of the radius of this body line downwards 2 7/8". (Fig E)
   
   
  
   
   
• Find the union between the fender and the bumper. (Fig F)
   
   
  
   
   
• Follow the body line at the top of the fog light pocket. (Fig G)
   
   
  
   
   
• Join these three points together to form a line. (Fig H)
   
   
  
   
   
• When you cut this line, leave about 1/8"-1/4" of material to ensure you do not cut off too much material. (Fig I)
   
   
  
   
   
• Repeat Step 6 on the other side of the vehicle. Then, pull the OEM bumper off the vehicle. Release the series of plastic clips holding the black plastic inset onto the grille as you pull the bumper off so that it will come off with the bumper. (Fig J)
   
   
  
   
   
• Remove the black plastic impact damper by releasing its plastic clips and pulling it off the vehicle. (Fig K)
   
   
  
   
   
• Using a 14mm Socket, remove the Aluminum Bumper mounting bolts (x6), then remove the Aluminum Bumper. (Fig L)
   
   
  
   
   
• Using a 14mm Socket, remove the Bumper Mount nuts (x6). Then, remove both the Bumper Mounts. (Fig M) **SAVE THESE NUTS FOR REUSE
   
   
  
   
   
• Using a 17mm Socket, remove the passenger side tow hook mounting bolts (x2). Then, remove the tow hook. (Fig N)
   
   
  
   
   
• Using a cutoff wheel, cut the driver side tow hook off flush with front cross member. Be sure to paint over any raw metal. (Fig O)
   
   
  
   
   
• Using a 17mm Socket, remove the lower cross member mounting bolts (x4). Then, remove these crossmembers. (Fig P) **SAVE TWO OF THESE BOLTS FOR REUSE
   
   
  
   
   
• Using a 17mm Socket, remove the frame extension mounting bolts (1 per side). Then, remove the frame extensions. (Fig Q)
   
   
  
   
   
• If you do not have a winch bumper, move on to Step 17. Using a 14mm Socket, remove the driver side bolt for the power steering cooler. (Fig R)
   
   
  
   
   
• Install the supplied power steering cooler bracket.

• Bolt the bracket to the stock cooler location using the OEM bolt. (Fig S)
   
   
  
   
   
• Bolt the cooler to the supplied bracket using the supplied 3/8" Bolt, Washer, and Nut. (Fig T)
   
   
  
   
   
• Using a utility knife or a cutoff wheel, cut your inner fender liner as shown in Fig U.