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How To: Rear bumper removal and rustproofing

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Old 08-18-2009, 08:22 AM
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How To: Rear bumper removal and rustproofing

This wasn't an easy one, but I'm glad I did it. These bumpers will be rusting out in time (like everything else).

The rear bumper is held on with six flat, torx-head, bolts (on top) and two 13mm bolts (underneath).
The hard part is removing the plastic bumper cover.

First remove the plate lights and spare tire lock.

Now the hard part...
This is held in place by 16 molded-in plastic fingers that push into slots on the bumper. This is what they look like. A pair of 6" slip-joint pliers works perfectly to squeeze them as you push up, (start at one end).
Be patient, and try not to break 'em....a new bumper cover is $142.


Now with that removed, you can get at the top bolts.


Here's some pics of the rusty back:



I used my grinder and wire wheels to clean it up...


Prior to removing the plastic cover, I marked where it covers the bumper, so I could paint under it. I did this with POR-15.




While I was at it I removed the rear, plastic rocker covers.
The dirt was held in there.


I also masked and painted under these areas, (Rustoleum Hammered Silver).


And lastly, while the bumper was off, I POR-15'd the bumper support/tow hitch.

Thanks for looking, and good luck with your project!

Last edited by mjb1032; 08-18-2009 at 08:27 AM.
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Old 05-09-2010, 04:13 PM
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Do you recall what size torx bolts those were?
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Old 05-09-2010, 04:41 PM
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im willing to bet they are the sme size as the ones on my 98.. and that would be 47 torx bit
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Old 05-09-2010, 10:58 PM
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OK thanks
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Old 05-10-2010, 07:23 AM
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Quote:
Originally Posted by illness95 View Post
im willing to bet they are the sme size as the ones on my 98.. and that would be 47 torx bit
I have my 98 apart right now, - factory bumper, not rusty on the inside, -that much anyway. There's 4 18mm 10.9 Stainless or Galvanized bolts holding her on. Same with the hitch except there's 8 bolts for that.
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Old 05-10-2010, 01:46 PM
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Quote:
Originally Posted by jbrew View Post
I have my 98 apart right now, - factory bumper, not rusty on the inside, -that much anyway. There's 4 18mm 10.9 Stainless or Galvanized bolts holding her on. Same with the hitch except there's 8 bolts for that.
i have 4 21 mm bolts that hold the reinforcement to the frame.. i took the skin off the reinforcement using basically the same technique the OP used getting his bumper off.. Because for some odd reason the bolts just spun on the reinforcement .. its an odd setup
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Old 05-11-2010, 08:38 AM
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Oh okay, I got confused I guess :o , I thought you guys were talking about the bolts holding the bumper to the truck frame. I didn't lift the plastic from the bumper like the OP.

I do know that POR-15 is good stuff

My back bumper still shines like new. The front bumper is starting to go to hell tho. Has two tiny rust holes on each side now

Another part that needs replacing...
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Old 05-11-2010, 08:54 AM
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i know the feeling .. the paint has chipped on my front bumper too causing it to rust as well .. luckily its just some minor surface rust ill be able to clean up and paint over...
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Old 05-11-2010, 09:20 AM
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where did you get the paint from?
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Old 05-11-2010, 09:29 AM
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Originally Posted by illness95 View Post
i know the feeling .. the paint has chipped on my front bumper too causing it to rust as well .. luckily its just some minor surface rust ill be able to clean up and paint over...
Yea, when they start to go it doesn't seem like it takes long. I had to cut above the body line down both sides of the bed and replace the panels. Rockers and maybe cab corners (depends) are next. Drivers side rocker is just about completely gone.

What a bunch work it has been this year. Damn truck runs so good , I can't get rid of it lol. Welding in new parts so it should be good for another 10 years or so.

My luck, I'll get her done and someone will plow into me
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Old 05-11-2010, 09:33 AM
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Originally Posted by MUD DIGGER View Post
where did you get the paint from?
Not sure where he purchased his DIGGER, I get it from here -

http://www.tptools.com/dg/187_POR15-....html?page=all
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Old 05-11-2010, 09:04 PM
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Originally Posted by jbrew View Post
Yea, when they start to go it doesn't seem like it takes long. I had to cut above the body line down both sides of the bed and replace the panels. Rockers and maybe cab corners (depends) are next. Drivers side rocker is just about completely gone.

What a bunch work it has been this year. Damn truck runs so good , I can't get rid of it lol. Welding in new parts so it should be good for another 10 years or so.

My luck, I'll get her done and someone will plow into me
i hear ya on that.. my corners are starting to show the most insignificant signs of rust.. and the bottom edge of the doors.. not enjoying the thouhgt of those but meh oh well.. fiberglass bed sides FTW..lol
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Old 07-05-2010, 01:53 PM
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Well I spent 2 days this weekend trying to get the damn step pad off and I give up! Tasca has them for $96, going to order one and rip the old one off. I have a ding in my bumper and found a nice used one for $50. I tried getting it off using small channel locks and even a pair of small needle nose vice grips to no avail. Figured my time is worth more than all the time it takes to get the damn thing off without destroying it. It will be worth it to just rip the damn thing off plus a new one sure would look nicer than the 5 year old thing thats on there now.


UPDATE
Called my local dealer and asked for price for new step pad= $160 I told them that Tasca had it for $96.48 + $10 shipping , they said that they would match that price. Total cost $103.71 with tax. Had the old bumper off and new one one in less than 1/2 hr, took longer getting new pad on, used a rubber mallet to set the square plastic hooks.

Last edited by mkinttrim; 07-05-2010 at 04:46 PM.
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Old 08-25-2010, 02:58 PM
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I have to remove mine

Quote:
Originally Posted by jbrew View Post
I have my 98 apart right now, - factory bumper, not rusty on the inside, -that much anyway. There's 4 18mm 10.9 Stainless or Galvanized bolts holding her on. Same with the hitch except there's 8 bolts for that.
Was that the four bolts that are 2 on each side?, and the whole bumper and steel frame come off? Correct? I need to get at the body for rust on the rear right and left ends and the bumper is in the way..what size where the nuts?
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Old 09-10-2010, 09:45 PM
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i just got a new truck and havent had to deal with any rust yet. My bumpers are chrome so im looking to get some STX bumpers. But do the STX bumpers rust or are they just plastic?
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