AEV JK Wrangler Front Bumper Install – Part 2

Remove the old stuff

Start by removing the factory plastic skid plate then bumper followed by the plastic closeout on top of the frame. TIP: Be sure to disconnect the fog lights and detach the wiring harness from the inside of the bumper.

TIP: Removing the plastic “scrivet” fasteners can be very difficult. Honestly they can be near impossible. We used a thin flat chisel and hammer to cut them off since they will not be reused.

With the bumper removed remove the fog lights from the back of the stock bumper and install them in the new brackets.

Fog Light Wiring Modification

In the directions it is indicated how to modify the fog light wiring harness since the lights are placed outside the frame rails on the AEV bumper. The directions state not to cut the wires but we could not make it work so we needed to cut and lengthen the drivers side.

Fog Light Wiring Modification

In the directions it is indicated how to modify the fog light wiring harness since the lights are placed outside the frame rails on the AEV bumper. The directions state not to cut the wires but we could not make it work so we needed to cut and lengthen the drivers side.

If you decide you need to lengthen the wiring be sure to use quality connectors and proper gauge wire. We used a new piece of wiremold on the extension all the way to the light.

Frame Preparation

There are several holes that need to be enlarged to accommodate the larger bolts. For some reason it is even necessary to enlarge holes on the AEV supplied components, why?

Time for some cutting

TIP: Be sure to apply paint or rust inhibitor to all drilled out or exposed metal surfaces.

Remove the inner steel bumper from the outer plastic shell. Since the AEV bumper uses the factory crush cans they must be cut out from the factory bumper. The cleanest and easiest method is to use a cut off wheel in an angle grinder. Carefully cut out the cans making sure to leave plenty of extra material.


cutting the crush can

crush can trimmed for install

After cutting out both cans use the supplied template to trace a pattern on the back of the cans. Trim the cans to match the template. We used the cut off wheel, bench grinder, and die grinder to obtain the proper shape.

Instructions Inconsistency ??
In the directions it indicates precise cutting of the crush can to obtain a proper fit but the above image from the AEV instructions shows the cans not trimmed and drilled to be bolted in using the can cover bolts. You decide which method to use.

Part 3 – Installation