Ironman Bullbar Ranger Install

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INSTALLATION

GUIDE
BB038
TO SUIT FORD RANGER 9/2011-7/2015
(MY12 TO MY15)

• Ironman 4x4 BBA/BBT/BBC/BBCD038 Bull Bars fit to a Ford Ranger. (MY12 to MY15)
• It will take about 4 hours to install.
BB038/111220

NOTE: This product has been tested for air bag compatibility and therefore
the mounting system MUST NOT be modified

IMPORTANT: Bull Bar installations should only be done by a qualified


person and it is the responsibility of this person to ensure correct fitment.
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Installation Guide BB038

Bull Bar Parts List


1. Bull Bar 2. Mounting Bracket

QTY-1 QTY-1

3. Steel Skid Plate 4. Steel Skid Plate L-R

QTY-1 QTY-2

5. Support Bracket 1 L-R 6. Support Bracket 7. License Plate Bracket 8. Skid Plate Bracket 9. Bolt M12x1.25x90mm

QTY-2 QTY-2 QTY-2 QTY-2 QTY-4

10. Bolt M10x1.25x40mm 11. Bolt M12x1.25x40mm 12. Bolt M6x1.0x25mm 13. Bolt M8x1.25x25mm 14. Bolt M8x1.25x25mm

QTY-14 QTY-7 QTY-2 QTY-17 QTY-2

15. Logo 16. STL Bottle Opener

QTY-1 QTY-1

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©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Installation Guide BB038
1. Before installation confirm bull bar application
is compatible with your vehicle make, model and year.

2. Unwrap bull bar. Check over riders and light


assemblies have been fitted correctly and are
tight in bull bar before installation.

3. Remove grill, bumper bar, bumper bar


reinforcement and bumper support brackets.

NOTE:

Retain bolts from bumper reinforcement.

Remove the following items:

• Grill
• Bumper bar
• Bumper reinforcement
• Bumper support bracket

4. Mask lower edges of mudguard and paint satin


black as shown.

5. Measure 100mm from point on bumper bar as


shown, and mask down bumper bar from this
point.

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©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Installation Guide BB038
6. Mask a line along ridge of bumper bar as shown.
Using an air hacksaw or similar, cut along lines
previously marked to remove the lower section of #
the bumper bar.

7. Temporarily refit top section of bumper bar (Cut


in previous step) to vehicle. Using end of bumper
bar as a guide, mark cut lines onto plastic MARK HERE

bumper support brackets.


Remove from vehicle and cut as shown.

CUT HERE

DISGARD THIS SECTION REFIT THIS SECTION

8. Refit previously modified section of plastic


support bracket and top section of bumper bar to
vehicle, using the original mounting hardware.

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©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Installation Guide BB038
9. Install chassis bracket as shown using hardware
provided.

10. Using chassis bracket as a guide, drill a


12.5mm hole through chassis and install bolts,
flatwashers, spring washers and nuts as shown,

11. If winch is being installed, refer to winch


installation instructions, Pages 7 - 8.

12. Fit bull bar to chassis brackets using M12x25mm


bolts, flat washers, spring washers and nuts
provided.

13. Align bull bar with vehicle leaving enough gap


between bullbar wing and mudguard. Tighten all
bolts.

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©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Installation Guide BB038
14. Once bar is aligned with vehicle and tightened
drill through pinning holes between bull bar and
chassis bracket and secure with bolts, washers
and nuts provided.

15. Connect park lights, indicators, fog lights and


DRL if applicable as per wiring diagrams at the
back of fitting instruction manual.

16. Refit grill.

17. Fit protection plates to underneath of bull bar


using M8 bolts, spring washers and flat washers
provided.

18. Trim guard liners using protection plates as a


guide. Attach to protection plates using clips
provided.

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©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Installation Guide BB038

Winch Installation
1. Bolt winch to cradle with gearbox to the left hand
side of vehicle and cable spooling from bottom of
the cable drum using bolts and washers provided.

2. Bolt fairlead to recess in front of bull bar using


bolts, washers and nuts provided.

3. Fit bull bar to vehicle referring to steps 12 - 17 of


bull bar fitting instructions.

4. Mount control box in desired location.

5. Connect three colour coded cables to the


corresponding poles on winch motor.

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©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Installation Guide BB038
6. Connect the thin black earth wire and negative
battery cable to the earth connection on the
opposite side of winch motor.

7. Run the positive and negative battery cables into


the engine bay taking care to secure cables away
from any sharp or moving objects.

8. Connect positive and negative battery cables


main battery of vehicle (Not Auxilliary Battery).

9. Attach breather hose to barb fitting on winch


motor. Run hose to the highest available point
in engine bay and cable tie in position. Cable tie
hose away from any sharp, hot or moving objects.

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©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Installation Guide BB038

Wiring Diagrams
PARK LIGHT & INDICATOR

Red
Daytime Running Light
Brown
Park Light
Yellow
Indicator Light

White

Ground
If vehicle is not fitted with DRL, leave red wire disconnected

FOG LIGHTS

Ground Red
Red Lamp
Fuse
85 30

Connector
87
86 87a Relay

Black
Blue
Battery Lamp

Parklight Switch
SPST
Ground

White
Ground

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©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd

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