FITTING INSTRUCTIONS - TJM Productscatalogue.tjmproducts.com/infos/070SB15F46Z.pdf · ·...

FITTING INSTRUCTIONS

Product: T15 / T17 Frontal Protection Bar Vehicle: Ford Ranger / Mazda BT50

Part No. 070SB15F46Z 070AP15F46Z 074SB17N46Z

For further information contact T.J.M. Head Office on (07) 3865 9999. Distributors Australia wide.

File: 82280.DOC of 13 24/07/2008

Australian Standards Relating to Installing Vehicle Frontal Protection Systems (VFPS): AS 4876.1-2002 a) Do not attach V.F.P.S. to vehicle using anchorages not intended for this purpose (e.g. engine mounting bolts), other than those

specified by the V.F.P.S. manufacturer in this instruction. b) Do not use this product for any vehicle make or model other than those specified by the V.F.P.S. manufacturer (as above). c) Do not remove any plaques or labels from the V.F.P.S. d) Do not modify the structure of the V.F.P.S. in any way.

Warranty 1. If any product or part of a product manufactured by TJM is found to be defective during a period of three (3) years after the date of

purchase, TJM shall repair (at TJM’s discretion) the defective product or part. 2. Any defect in a product distributed by TJM, but not manufactured by TJM, shall be dealt with in accordance with, and to the extent of, the

warranty offered by the manufacturer of that product. 3. TJM does not warranty that the products manufactured by it comply with the laws of the place where those product are purchased or

used. It is the sole responsibility of the purchaser to ascertain whether products being purchased, or the affixation of those products to any other object, comply with local laws.

4. Except to the extent described in this warranty, TJM shall not be liable for any other claims, including claims arising from incorrect fitment, product or vehicle modification, faulty design, the use of the product on any indirect special or consequential damage or injury to any person, company or other entity.

5. Modification or alteration to any product manufactured by TJM to enable fitment in conjunction with other vehicle accessories or modifications (e.g. lift kits) will void any warranty claims.

BOLT KIT:- FIT KIT :- FACTORY FITTED:-

Bolt tensions Dia. (mm) Nm ft.lbs Dia. (inch) Nm ft.lbs 5 5 4 1/4” 9 7 6 9 7 5/16” 22 15 8 22 16 3/8” 33 27

10 44 32 7/16” 55 43

All bolt tensions are as follows

unless otherwise specified.

12 77 57 1/2” 86 66

ALLOY QTY Part Number Description STEEL QTY. 2 K0688 M5 x 0.8 x 20mm Pan XR Metal 2 2 K0604 M5 x 0.8 Nyloc Hex Nut 2 2 K2913 3/16” x 3/4" x 16G Flat Washer 2 8 K0550 M6x1.0x20mm Hex Bolt 8 8 K0605 M6 x 1.0 Nyloc Hex Nut 8 16 K0626 1/4 x 5/8 x 18G Flat Washer 16 10 K0570 M12 x 1.25 x 35mm Hex Head Screw 4 2 K0576 M12x1.5x35mm Hex Bolt 2 12 K0581 M12 x 1.25 Hex Nut 6 14 K0617 1/2" x 5/32” x 1/8” Medium Spring Washer 8 24 K0638 1/2” x 1-1/4” x 4.0mm Flat Washer 12 6 K0419 Scotchlocks 6 – T15 ONLY 2 K1412 76 – 127mm Stainless Steel Hose Clamp 2 2 K2898 Polyurethane Mount Blocks 2 2 86526 M12x1.25x35mm Bolt on 300mm Wire Assy 2

1 428IND-PKCLR Indicator / Park Light Assy 1 – T15 ONLY 3 K2942 Air Vent 0 1 82187 Chassis / Winch Frame Assembly 0 1 FUG-MZ154 Front Underbody Guard 1 1 MTST-F221 Right Hand Angle Bracket 1 1 MTST-F232 Left Hand Angle Bracket 1

3 metres 93152 Pinchweld (no-bubble) 3 metres

1 HC0057 Airbag Compliance Sticker 1

1 K3241 TJM Sticker 1





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1. Remove the bumper. To do this, remove the two screws and the six push clips from the top of the grill, remove the two screws at each end of the bumper at the wheel arch and the two M6 bolts from the bottom corners, remove the two push clips from the centre. Remove the bumper.

2. Remove the crossmember. To do this, remove the two bolts from inside the engine bay that are securing the top of the cross member to the top of the chassis rails, retain the bolts. Remove the two bolts securing the front of the crossmember to the chassis. Discard these bolts and the crossmember. Remove and discard the bottom support bracket for the bumper and the grill from the front of the intercooler (refer diagram 1). For automatics only, remove and discard the guard off the cooler also.

DIAGRAM 1

3. Remove and discard the tie down lug and bolts from the right hand side chassis rail.

4. On the left hand side, remove the tow hook and the tie down lug, retain the bolts. Separate the tow hook and the tie down lug (which are welded together). Discard the tie down lug and retain the tow hook.





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5. ON THE FORD RANGER ONLY: - Remove the plastic bumper support bracket from the vehicle and modify to suit. Refit the support bracket, refer Diagram 2.

DIAGRAM 2

6. FOR ALLOY BARS ONLY:- Fit the winch frame assembly to the vehicle using the bolts retained in section 2. Secure the mounts through the rear holes in the top of the chassis and maneuver the M12x1.25x35mm bolts on wire through the holes in the outside of the chassis rail and position them through the front holes in the mounts. Secure using M12 nuts, flat and spring washers. Finger tighten only (refer diagram 3).

7. If a winch is to be fitted it is to be done at this stage. Fit the winch into the winch

frame with the control box mounted to the motor end of the winch using hose clamps and polyurethane blocks supplied. Remove the micro-jointed section from the lower centre of the bar. Ensure any sharp edges and removed and treat all raw surfaces. Refer to the winch fitting instructions.

NOTE:- If fitting an OX winch 8000lb, 9000lb or 10000lb, rotate the gear box so that the handle is facing forward of the vehicle. To do this, follow these steps :-





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Remove the gear box end from the winch.

Remove the 10 allen key bolts from the gear box.





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Rotate the gear box plate forward to allow fitment to the bar. Re-fit the allen key bolts previously removed and re-attach the gear box end to the winch.

Note the position of the lever





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8. FOR ALLOY BARS ONLY:- Using two people carefully lift and place the bar into position on the winch frame assembly. Secure the bar in place using M12x1.25x35mm bolts, nuts, flat and spring washers.

9. FOR STEEL BARS ONLY:- Using two people carefully lift and place the bar in

position, using the bolts retained in section 2. Secure the mounts through the rear holes in the top of the chassis and maneuver the M12x1.25x35mm bolts on wire through the holes in the outside of the chassis rail and position them through the front holes in the mounts. Secure using M12 nuts, flat and spring washers. Finger tighten only (refer diagram 3).

DIAGRAM 3

10. On the bottom of the right hand side of the chassis, use the right hand angle bracket

(F221) and align with the mount and the chassis. Use M12x1.5x35mm bolts, flat and spring washers into chassis and M12x1.25x35mm bolts, nuts, flat and spring washers through the bracket and the mount.





File: 82280.DOC of 13 24/07/2008

11. On the left hand side of the chassis, position the left hand angle bracket (F232) between the chassis and the tow hook and align with the mount. Using the bolts retained in section 4, bolt through these and into the chassis and reaffix the front bolts in the tow hook. Using M12x1.25x35mm bolts, nuts, flat and spring washers, bolt the bracket and the mount together. Finger tighten only.

12. Align the bar with the vehicle and tighten all fixings.

13. For the cutting details of the bumper on the Ford Ranger, refer diagram 4.

DIAGRAM 4 - RANGER

Part A

Part B





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For the cutting details of the bumper on the Mazda BT50, refer Diagram 5.

DIAGRAM 5 – BT50

Part A

Part B





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BT50

Part C

14. ON THE FORD RANGER: - Before removing the grill from the bumper you must mark the position of the grill on the bumper, refer diagram 6. Using the dimensions in diagram 4, cut the bumper section and re-fit it to the vehicle. It will be necessary to re-trim the bumper sections to gain a true and even 10mm to 12mm gap between the bar and the bumper. Once this has been done, fit the pinchweld. Remove the four tags from the bottom of the grill, refer diagram 7. Mark and drill two 6mm holes both sides of the grill (refer Diagram 8), place the grill on the bumper cut section. Align the holes on the top and the marks on the front. Then, using the holes previously drilled in the grill as a guide, drill the bumper section, refer diagram 9. Bolt together using M6x1.0x25mm bolts, nyloc nuts and flat washers. Re-fit to the vehicle and tighten all fixings.

DIAGRAM 6 - RANGER

MARK ON BUMPER

GRILL





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DIAGRAM 7 - RANGER

REMOVE 4 TAGS

DIAGRAM 8 - RANGER

DRILL TWO x 6mm HOLES BOTH SIDES





File: 82280.DOC of 13 24/07/2008

DIAGRAM 9 - RANGER

15. ON THE MAZDA BT50:- Remove the grill and flare ends from the bumper. Using the dimensions in diagram 5, cut the bumper, discard the lower sections and refit it to the vehicle. It will be necessary to re-trim the bumper section to gain a true and even 10mm to 12mm gap between the bar and the bumper. Once this has been done, trim the flare end to suit.

16. ON THE MAZDA BT50:- Mark the position of the flare on the bumper as shown

in diagram 10. DIAGRAM 10 – BT50

BUMPER

FLARE MARK POSITION OF FLARE





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17. ON THE MAZDA BT50:- Once marked, remove the fixings from inside the bumper and then the flare. Place a pencil mark approximately 5mm back as shown in diagram 11.

DIAGRAM 11 – BT50

18. ON THE MAZDA BT50:- Cut a small section away (as shown in diagram 12) to allow the pinchweld to pass through the bumper and onto the flare. Refit to the vehicle or bumper.

DIAGRAM 12 – BT50

ALLOWANCE FOR PINCHWELD





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19. ON THE MAZDA BT50:- Fit the pinchweld into position and re-fit the bumper to the vehicle. Refer diagram 13. Tighten all fixings.

DIAGRAM 13 – BT50

20. BOTH:- Fit the grill back into the bumper and tighten all fixings. Connect the parker/indicators into the vehicle wiring loom (if applicable). Fit the number plate to the bar using screws, washers and nyloc nuts supplied. Fit the underbody guard to the mounts using M6x1.0x25mm bolts, flat washers and nyloc nuts.

21. Ensure that no vehicle components are crushed or chaffed as a result of fitting the

bar.

FITTING INSTRUCTIONS - TJM Productscatalogue.tjmproducts.com/infos/070SB15F46Z.pdf · ·...

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