I bought a new Hanson 60" Prerunner model front bumper and finally got around to installing it this weekend. It didn't come with any instructions so to help the next person that wants to buy one or install one, i hope this helps.
I decided on the 60" because I wanted the protection for my fenders in the daily driving enviorment on Long Island with all the "special people" we have driving here.
The bumper arrived well packed in a heavy cardboard box with sprayed in foam padding all around it. The Hanson Bumper is a heavy well made unit, the shipping label on the box stated 87lbs and the box and padding was about 15lbs at most. All the welds are clean and straight, and the break forms in the steel are perfect. The bars are perfectly rounded and the attachment points for the D-rings are through and welded all the way around on both sides. I was very impressed with the quality of the metal work, and the paint finish on this bumper. But I guess you can say for $650+ it better be top quality.
Despite the padding, the two mounting tabs on the bottom of the bumper were bent upwards and required a bit of adjustment with a prybar to open them up to slide over the chassis rails.
The before Jeep with a push bar on the stock bumper
The old bumper comes off after removing the four T-55 torx bolts on the top and a couple more underneath. The bumper slides off leaving the chassis rail ends and the cross member between them. the next step is to remove the cover over the sway bar. This is two bolts on each side and the plastic cover comes up and off.
The Hanson fit is perfect. After the two lower bolt tabs were opened up a bit the bumper slides over the end of the chassis rails and is held in place by two 3/4" bolts through the top and a single on the bttom on each side for a total of six 3/4" bolts holding it to the chassis rails. The bolts and washers are also included. The included bolts by the way, are grade 5 and will probably be switched out for grade 8 when the winch goes on next week.
The four bumper mounting bolts on the top are actually under the top plate of the bumper and require some manuvering with a wrench to get to. The foward bolt on each side is tucked way inside and the top deck prevents using a large 1/2" drive ratchet to crank down on it. I found a ratcheting box wrench to work quite well for these foward bolts. With a box wrench and some pulling you can snug down the foward top bolts with plenty of torque. The rear top bolts can be cranked down with a 3/8" drive ratchet and a shallow socket. The bottom bolts have no obstructions and any ratchet/wrench can be used.
The after Jeep, also note the black painted headlight rings
Next weekend the Warn M8000 goes on. The Hanson bumper requires you mount the winch before the bumper goes on the Jeep due to the front winch bolts being right above and behind the front cross member. This adds a bit of security for the winch as its almost impossible to get at two of the winch bolts with any good size wrench.
More pics to follow after the Warn is installed.
I was a little skeptic of a $650+ bumper really being worth it, but I have to say I have no regrets about paying that much for this bumper.