Ironman4x4 BBC110 Bedienungsanleitung

Document Number: BBR074/070323

INSTALLATION

INSTRUCTIONS

BBC / BBCD / BBP110

BULL BARS TO SUIT FORD RANGER

Next-Gen 2022+

This product has been tested for airbag compatibility

and therefore the mounting system MUST NOT be modified

Document Number: BB110/241123

Bumper Cut

Required

SAFETY WARNING

Ironman 4X4 requires you read and understand the safety and pre-install

directions on page 2 and 3 before commencing installation of this product.

5 Hours

Approximately

Bar Weight: 97Kgs (BBC /BBP) & 103Kgs (BBCD)

Page 2 of 25

BBC / BBCD / BBP110 Installation Guide

Document Number: BB110/241123

Pre-Installation Procedures

SAFETY WARNING

• It is always good practice to disconnect the battery while working on 12 Volt systems.

- Please check the owner’s manual for vehicle-specific requirements as some models may need

battery backup.

• Auto electrical work should be carried out by a competent person. Vehicle wire colours are listed as a

guide only and may vary on some makes and models.

• The function of each wire should be checked before any connections are made.

All wires tapped into should be soldered and then insulated with electrical tape or heat shrink.

• Grounding/Earth points must always be connected to the factory grounding points, not to the battery

negative terminal. See owner’s manual.

• Using only a LED test light, test all electrical components of the vehicle before and after wiring.

This is to ensure everything works correctly.

• Ironman 4x4 does not recommend the installation of large or light-coloured antennas or aerials to the

front of a bull bar as this may cause the lane departure system to malfunction.

NOTE

• Only a competent person should perform accessory installations. It is the responsibility of this person

to ensure correct fitment.

• Whilst working on this vehicle, always use appropriate safety equipment.

• Read and understand instructions fully before commencing fitment.

• Check the hardware supplied against the contents list on the following pages.

• Do not use this product for any vehicle make or model other than specified in these instructions.

• This product and or hardware must not be modified in any way. Do not remove labels from this product.

• Recording the batch number on the customer’s job card is good practice for future reference,

or complete the information below and file with customer job card.

CARE INSTRUCTIONS

• To maintain the finish of the product, wash regularly using a PH neutral car wash, hose off and

chamois dry.

• Do not use acidic or alkaline cleaners.

• Plastic components can be maintained with a silicone spray or similar (non-acidic or alkaline based).

CUSTOMER INFORMATION

Customer Name: Date:

Contact:

Part Number: Batch Number:

(Located on label behind bull bar wing)

Page 3 of 25

BBC / BBCD / BBP110Installation Guide

Document Number: BB110/241123

• Ironman 4x4 recovery points are FEA tested during design and destruction tested during development

to establish the Working Load Limits (WLL).

• Ironman 4x4 recovery points have been designed as a matching pair, supplied as right and left sides

for vehicle-specific fitment.

• Ironman 4x4 includes specific mounting hardware to ensure correct fitment to your 4WD.

The correct fitment of these components is critical for your safety.

• Do not use this recovery point for any other vehicle make or model other than the one intended and

specified by Ironman 4x4.

• Do not alter or modify the recovery point in any way. Doing so may compromise the strength and

integrity of the recovery point.

• Ensure all bolts are tightened to the specified torque.

• Do not remove warning labels from recovery points. (Some recovery points require the warning labels

to be installed, these are supplied and must be installed).

• It is advised to use an equalising or bridle strap. Failure to do so correctly can result in recovery point

fatigue or bending and void your warranty.

• Never use a single recovery point combined with a side load pull.

• Recovery Points are designed for a straight-line pull, by pulling on an angle or sideways pull may

result in a reduction of the WLL.

NOTE

• This product has been tested for airbag compatibility; therefore, the mounting system MUST NOT

be modified.

• Fitting instructions are correct at the time of publication date and Ironman 4x4 cannot be held

responsible for any vehicle changes from the manufacturer. It is the responsibility of the installer

to ensure correct fitment.

Page 3 of 25

Installation Guide

Warning

Page 4 of 25

BBC / BBCD / BBP110 Installation Guide

Document Number: BB110/241123

No. Part Description Qty

1. Bull bar assembly 1

2. Number plate ﬂip bracket 1

3. Underbody protection plate 1

4. Side wing protection plate - LHS 1

5. Side wing protection plate - RHS 1

6. Winch cradle 1

7.* Rear chassis bracket spacer - LHS 1

8.* Rear chassis bracket spacer - RHS 1

No. Part Description Qty

10. Front chassis bracket spacer - RHS 2

11. Air trap plate 1

12. Recovery point - LHS 1

13. Recovery point - RHS 1

14. Support Mounting Bracket - LHS 1

15. Support Mounting Bracket - RHS 1

16. Side wing protection plate bracket 1 - LHS 1

17. Side wing protection plate bracket 1 - RHS 1

18. Side wing protection plate bracket 2 - LHS 1

No. Part Description Qty

19. Side wing protection plate bracket 2 - RHS 1

20. Horn Mounting Bracket 2

21. Sensor holders 6

22. Wired crush tube 2

23. Wired spring clip 2

24. Logo badge 1

25. Pinch weld 1

26. Recovery point warning sticker 2

27. Zip ties 8

Parts List (Item)

Any damage or losses caused by improper installation and application, goes beyond our quality warranty.

2222

1111

1010

1313

1919

1717

2020

2121

1515

1414

2121

1818

1616

1212

22 22

12 16

10 11 10

18 17

* May be required on overseas models only

Page 5 of 25

BBC / BBCD / BBP110Installation Guide

Document Number: BB110/241123

Parts List (Item)

Any damage or losses caused by improper installation and application, goes beyond our quality warranty.

22 23 24

25 26 27

28 29 30

31 32 33

34 35 36

37 38 39

40 41 42

43 44 45

No. Part Description Qty

28.

Dome Hex Head Bolt M10 (30 x1.5mm)

Flat Washer M10 (29.5 x 10.5 x 3.0mm)

Nyloc Nut M10

29.

Dome Hex Head Bolt M8 (30 x1.25mm)

Flat Washer M8 (16 x 8.5 x 2.5mm) x 2

Flat Washer M8 (16 x 8.5 x 2.5mm)

Nyloc Nut M8

30.

Flange Hex Head Bolt M10 (30 x 1.25mm) (H17)

Flat Washer M10 (29.5 x 10.5 x 3.0mm)

Spring Washer M10

Hex Nut M10 (H17)

31.

Hex Head Bolt M12 (110 x 1.75mm) (H19)

Flat Washer M12 (36.5 x 14 x 4.0mm)

Spring Washer M12

Hex Nut M12 (H19)

32.

NOT USED

Hex Head Bolt M12 (50 x 1.75mm) (H19)

Spring Washer M12

Flat Washer M12 (36.5 x 14 x 4.0mm)

33.

Hex Head Bolt M12 (40 x 1.75mm) (H19)

Spring Washer M12

Flat Washer M12 (36.5 x 14 x 4.0mm)

34.

Hex Head Bolt M12 (40 x 1.25mm) (H19)

Flat Washer M12 (36.5 x 14 x 4.0mm) x 2

Spring Washer M12

Hex Nut M12 (H19)

35.

Hex Head Bolt M10 (40 x 1.5mm) (H17)

Spring Washer M10

Flat Washer M10 (29.5 x 10.5 x 3.0mm)

36.

Hex Head Bolt M10 (30 x 1.5mm) (H17)

Spring Washer M10

Flat Washer M10 (50 x 12 x 3.0mm)

37.

Hex Head Bolt M8 (50 x 1.25mm) (H13)

Spring Washer M8

Flat Washer M8 (26 x 8.5 x 2.5mm)

38.

NOT USED

Hex Head Bolt M8 (50 x 1.25mm) (H13)

Flat Washer M8 (26 x 8.5 x 2.5mm)

Flat Washer M8 (22.5 x 8.5 x 2.5mm)

Spring Washer M8

Hex Nut M8 (H13)

39.

Hex Head Bolt M8 (30 x 1.25mm) (H13)

Flat Washer M8 (26 x 8.5 x 2.5mm)

Flat Washer M8 (22.5 x 8.5 x 2.5mm)

Spring Washer M8

Hex Nut M8 (H13)

40.

Hex Head Bolt M8 (20 x 1.25mm) (H13)

Spring Washer M8

Flat Washer M8 (22.5 x 8.5 x 2.5mm)

41.

Hex Head Bolt M6 (25 x 1.0mm) (H10)

Flat Washer M6 (22.5 x 6.5 x 2.5mm) x 2

Spring Washer M6

Hex Nut M6 (H10)

42.

Hex Head Bolt M6 (20 x 1.0mm) (H10)

Spring Washer M6

Flat Washer M6 (22.5 x 6.5 x 2.5mm)

43. Cage Nut M6 (1.0mm) 2

44. 3M Primer 1

45. Logo Badge 1

Page 6 of 25

BBC / BBCD / BBP110 Installation Guide

Document Number: BB110/241123

PROPERTY

CLASS TORQUE ma

NOMINAL DIAMETER - COARSE THREAD

M6 x 1 M8 x 1.25 M10 x 1.25 M12 x 1.25

8.8

Nm 10.5 25 49 88

ft/lb 7.7 18 36 64

Tools Required

Bolt Tension Guide

MANDATORY

To meet some State Regulations, the bull bar plug-and-play wiring harness (parker/indicator/fog lights) is

required to be fitted - IBBPL110

This must be ordered separately.

OPTIONAL

If installing driving lights or lightbar, you will require a suitable wiring harness to access the IPL connector

(High Beam Trigger). These are sold separately.

• Lightbar patch loom - ILBWL001

• Scope 7” driving lights - IDLWL001

• Scope 9” driving lights - IDLWL002

If fitting a winch, a winch extension cable is not required given the proximity of the winch to the plug fitting

hole in the bull bar unless positioning in an alternative location.

• Winch extension cable - WWB030

• Hidden control box mount kit - WWBCP110

NOTE

Please refer to specific wiring loom instructions for correct installation.

Accessories

Metric Spanner Set Screwdriver Set Metric Socket Set Air Hacksaw Tape Measure Drill and Drill Bits

Page 7 of 25

BBC / BBCD / BBP110Installation Guide

Document Number: BB110/241123

1. Before installation, unwrap the hardware.

Unwrap the bull bar, taking care not to

damage or scratch in the process. Inspect bar

for any damage.

Ensure bull bar application is compatible with

the vehicle and you have the correct cutting

template.

TIP

It is good practice to lay out all hardware to

cross-reference against the parts list and to

record the Batch Number.

2. Remove and retain the number plate if fitted,

to be reinstalled later. Remove the factory

number plate holder.

Disconnect the negative battery terminal if

applicable.

NOTE

Check manufacturer’s handbook for any

recommendations.

Remove and retain the top plenum cover,

ensuring to keep all plastic clips.

Once the cover is removed, disconnect

front camera wiring, washer nozzle hose (if

applicable) and grey bumper harness (1).

TIP

It’s advised to apply masking tape across the

front of the bumper and under the headlights,

to protect painted surfaces from possible

damage.

Remove two (2) upper grille bolts and starting

on the outside headlight section.

Once unclipped, depress the lower grill clips

and gently remove the grill.

Store front grille in a safe place for later

reinstall.

Generic image used as reference only.

Page 8 of 25

BBC / BBCD / BBP110 Installation Guide

Document Number: BB110/241123

4. Remove all factory flare clips from around the

vehicle wheel arch. Retain clips for later use.

Remove the lower retaining bolt.

Repeat procedure on opposite side.

5. Unclip the flare starting at the front lower

section and making your way back along the

guard.

NOTE

If the vehicle has blind spot sensors, this will

need to be disconnected before commencing

to unclip the flare.

Repeat procedure on opposite side.

6. Remove the three (3) clips and two (2) bolts

from the factory bumper to the radiator

support.

Page 9 of 25

BBC / BBCD / BBP110Installation Guide

Document Number: BB110/241123

Clip

7. Under the inner guard there are inspection

ports. Remove the three (3) clips and twist the

guard out of the way to access the bolts and

clips behind securing the factory bumper to

the guard.

Remove the three (3) bolts and place aside for

later use.

Repeat procedure on opposite side.

8. Remove the bolts from the factory bumper on

the underside. There are two (2) located on

each side.

Repeat procedure on opposite side.

9. To remove the factory bumper, depress

the inner clip and firmly, but gently pull

downwards.

Repeat procedure on opposite side.

TIP

We suggest using a 10mm socket to ‘pop’ the

clip out.

Page 10 of 25

BBC / BBCD / BBP110 Installation Guide

Document Number: BB110/241123

11. Unplug horn and remove horn bracket. Retain

for later use.

12. Remove and discard the left-hand and right-

hand lower bar brackets.

13. Support intercooler with workshop stands and

remove outer tie down points / intercooler

support brackets.

Retain the bolts for later use.

10. Remove the factory bumper and bar foam.

Unbolt the three (3) bolts on each side

securing the bar reinforcement and place

aside for later use.

If vehicle is fitted with a radar, unclip the

cover, disconnect the plug and remove the

two (2) side bolts. There is another bolt

located behind, remove this too.

Carefully remove the radar.

WARNING

Ensure you do not drop the radar.

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