Blue Ox BX2198 User manual

BX2198
2006-10 Ford Explorer/Mercury Mountaineer
2007-10 Ford Explorer Sport Trac
Installation Instructions
292-2993 Rev. E Page 1 of 9 10/19/09
Please read BOTH these Installation Instructions and the General
Instructions before attempting to install or operate this equipment.
1. Blue Ox®towing products and accessories are
intended to be installed by Blue Ox® Dealers
who are familiar with our products and have the
necessary equipment and knowledge to do “t
work”. When necessary Blue Ox®Dealers can be
found at www.blueox.com or by contacting our
Customer Care Department at [phone] or
toll free at [phone].
2. Many Blue Ox®baseplates are designed to
use existing holes and hardware to mount the
baseplate to the towed vehicle. Even though
bolts are there, do not assume they are adequate
for baseplate mounting. Always use hardware
supplied in the hardware kit and existing
hardware specied in the Baseplate Installation
Instructions.
Conrm the towability and pre-towing
procedures for your vehicle with
the owner’s manual or contact the
vehicle’s manufacturer for specic
towing procedures.
Attachment Tab Height: 24”
Attachment Tab Width: 20”
Bolt Size Grade 5 Grade 8
1/4” 10 14
5/16” 19 29
3/8” 33 47
7/16” 54 78
1/2” 78 119
5/8” 154 230
Bolt Torque Specications
Torque in Foot-Pounds for Inch Bolts
Bolt Torque Specications
Torque in Foot-Pounds for Metric Bolts
Bolt Size Grade 8.8 Grade 10.9
6MM 6 8
8MM 16 22
10MM 31 40
12MM 54 70
14MM 89 117
Serial Number
!
Failure to read and follow these instructions
could result in separation of the towed vehicle
from the tow bar, causing property damage,
loss of towed vehicle, personal injury or death.
WARNING

BX2198
2006-10 Ford Explorer/Mercury Mountaineer
2007-10 Ford Explorer Sport Trac
Installation Instructions
292-2993 Rev. E Page 2 of 9 10/19/09
Parts List
Ref. No. Qty. Part # Description
1 1 61-6464 WLDM’T, BASEPLATE, BX2198
2 8 61-4029 WELDMENT, 1/2 NUT WIRE COMMON
3 8 201-0068 1/2-13 X 1 3/4 HEX BOLT GRD.5, ZP
4 8 203-0012 1/2 LOCK WASHER, ZP
5 1 201-0654 #10-16 X 1 SELF DRILLING SCREW
6 2 201-0979 #12-14 X 1” Self Drilling Screw, ZP
7 2 201-0192 10-32 X 1/2 SLOT, RD. HD. SCREW
8 2 203-0054 #10 LOCK WASHER
9 2 202-0047 #10-32 HEX NUT
10 2 101-5822 ADAPTER, 4 WAY CONNECTOR
11 2 62-3468 ATT TAB ASSY, REM, SF/SB, 1 HOLE
2 290-0437 RECEIVER, CAP PLUG (BLK) (NOT SHOWN)
2 226-0046 BASEPLATE SAFETY CABLE, 36” CL III (NO SH)
2 229-0359 QUICKLINK, 3/8, ZP (NOT SHOWN)
Important:
Use only genuine factory replacement parts on your baseplate. Do NOT substitute homemade or non-typical parts. If a bolt is lost or in need of
replacement, for your safety and the preservation of your baseplate, be sure to use a replacement bolt of the same grade. In most cases it will be
Grade 5. Please reference the parts list above. Replacement parts may be ordered through your nearest Blue Ox® dealer or distributor, or call our
Customer Care Team at [phone] or toll free [phone].
Tools Required
10MM Socket Vise Grips
13MM Socket Utility Knife
15MM Socket Reciprocating Saw
3/4” Socket Flat Screwdriver
17/32” Drill Bit Phillips Screwdriver
5/16” Nut Driver Loctite Red

BX2198
2006-10 Ford Explorer/Mercury Mountaineer
2007-10 Ford Explorer Sport Trac
Installation Instructions
292-2993 Rev. E Page 3 of 9 10/19/09
Attachment Tabs
Motorhome mount tow bars are recommended for
use with this baseplate. Due to the design of the
removable tabs, the RangeFinderII, Adventurer, and
Ambassador tow bars can not be used. The Acclaim
tow bar may be used, but will not fold and store on the
front of the vehicle. Adapters, except the BX8833 and
BX88151, can not be used with this baseplate.
Instructions
The front fascia, metal bumper and air dams are
removed for the baseplate installation. Drilling is
required. Trimming of the air dam and metal bumper
is required. Trimming of the fascia may be necessary.
The dimensional variations between otherwise
identical vehicles can be considerable. Although
the baseplate was designed for easy installation,
it may be necessary to tailor the baseplate slightly
to compensate for auto manufacturer’s tolerances.
These minor adjustments may include ling a hole
slightly, bending electrical rods, and/ or bending end
plates.
The BX8869, Bulb and Socket Wiring Kit is
recommended for this vehicle.
2. Remove the four (4) pushpins from upper
fascia opening just behind the license
plate bracket. Do this to both sides of
the vehicle. Set pushpins aside to be
reinstalled later.
2
1. Using a Phillips screwdriver, remove three
(3) pushpins from the black plastic cover
on the top side of the fascia. Do this to
both sides of the vehicle. Set pushpins
aside to be reinstalled later.
1
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Installation Instructions
Possible Location for the BX8869
Bulb and Socket Wiring Kit.
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BX2198
2006-10 Ford Explorer/Mercury Mountaineer
2007-10 Ford Explorer Sport Trac
Installation Instructions
292-2993 Rev. E Page 4 of 9 10/19/09
4. Using a 10MM socket, remove the two (2)
metric bolts from lower tabs on the bottom
edge of the fascia. Set the bolts aside to
be reinstalled later.
4
5
5. Just forward of the front tire on the
fascia’s corner, remove the two (2)
screws with a Phillips screwdriver. Do this
on both sides of the vehicle. Pull fascia
corners down, then forward to release.
Disconnect electrical connections. Set the
fascia and screws aside to be reinstalled
later.
3. Just forward of the front tire on the
fascia’s lower edge, remove one (1)
Christmas tree pushpin. Do this to both
sides of the vehicle. Set pushpins aside to
reinstall later.
3
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6
6. Using the 15MM socket, remove the
two (2) metric bolts from the front of the
metal bumper. Do this to both sides of the
vehicle. Push down hard and out then pull
the bumper forward. Set the bumper and
metric bolts aside to be reinstalled later.
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BX2198
2006-10 Ford Explorer/Mercury Mountaineer
2007-10 Ford Explorer Sport Trac
Installation Instructions
292-2993 Rev. E Page 5 of 9 10/19/09
7. Remove the Christmas tree pushpin from
the frame rail. Remove the air dam. Air
dam will NOT be reinstalled. Do this to
both sides of the vehicle.
78
8. Using the 13MM socket, remove the
metric bolt from the lower coolant line
on the passenger’s side, as indicated
by the white arrow in the photo above.
Some models may have a Block Heater
cord bracket in this area to remove, as
indicated by the grey arrow in the photo
above.
9
9. Slide baseplate between frame rails. Then
slide baseplate forward just behind weld
of the bumper bracket. Using vise grips,
clamp in place to the bottom of the frame
rail. Do this to both sides of the vehicle.
Using the baseplate as a template, drill
the two (2) bottom holes into the frame
rail with the 17/32” drill bit. Do this on both
sides of the vehicle.
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10
10. Insert the 1/2”-13 whiz nuts through
the frame rail opening and align with
the drilled holes. Insert the 1/2”-13 x
1-3/4” hex bolts and 1/2” lock washers
and tighten. Do this to both sides of the
vehicle.
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BX2198
2006-10 Ford Explorer/Mercury Mountaineer
2007-10 Ford Explorer Sport Trac
Installation Instructions
292-2993 Rev. E Page 6 of 9 10/19/09
12
13
11
11. Using the baseplate as a template, drill
the two (2) holes in the side of the frame
rail with the 17/32” drill bit. Do this to both
sides of the vehicle. Protect coolant pipe
line when drilling (note the section of pipe
on the drill bit).
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13. Insert the bent end of coolant bracket
into the smaller front hole provided in
baseplate on the passenger’s side. Drill
the self drilling screw in bracket hole
provided in baseplate and into frame.
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12. Insert the 1/2”-13 whiz nuts to align with
the drilled holes inside the frame rail and
tighten the 1/2”-13 x 1-3/4” hex bolts and
1/2” lock washers. Do this to both sides of
the vehicle. Cut nut plate wires to make
them ush with the end of the frame rail.
This prepares the area for the metal
bumper reinstallation.
BE SURE TO USE LOCTITE® RED ON ALL BOLTS
BEFORE TIGHTENING. TIGHTEN ALL BOLTS
ACCORDING TO THE TORQUE CHART.
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BX2198
2006-10 Ford Explorer/Mercury Mountaineer
2007-10 Ford Explorer Sport Trac
Installation Instructions
292-2993 Rev. E Page 7 of 9 10/19/09
14. Align the metal bumper as close to it’s original position as possible, mark area to be cut on
the top and bottom of the side bumper. The top portion is to be removed, mark 5/8” wide
and approximately 2-1/2” toward the weld on the front edge of the bumper on both sides, to
alleviate the area for the upper baseplate end plate. Mark the lower portion to be removed 1”
wide and approximately 1-1/4” toward the front of bumper on both sides (to alleviate the area
for front lower baseplate bolt head).
14-A
15-A
15. Secure the metal bumper to a work bench with the vise grips and cut designated areas from
the previous step with the reciprocating saw. After cutting, clamp vise grip to the cut portion
to be removed and move vise grip back and forth until cut portion breaks. Reinstall metal
bumper to verify enough of metal bumper is removed. Trim as needed and reinstall bumper
with existing hardware.
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15-B
14-B

BX2198
2006-10 Ford Explorer/Mercury Mountaineer
2007-10 Ford Explorer Sport Trac
Installation Instructions
292-2993 Rev. E Page 8 of 9 10/19/09
17. Mark the top side of the lower air dam, 1” from the outside edge of the hard plastic in toward
the center of the air dam and 3” from the front edge of the air dam hard plastic to the back
of the air dam. Do this to both sides of the vehicle. Then reinstall the air dam to its original
position.
17-A 17-B
18. Reinstall the bumper and fascia, inserting all screws, pushpins, and bolts. Trim the bumper if
necessary for the attachment tabs to come through. The installation of the baseplate is now
complete.
Install the tow bar and safety cables according the instructions when demonstrating this to the
customer. Be sure the safety cables do not rub against any hoses or moving parts.
Do NOT substitute other devices if the tow bar pin and clip are lost or misplaced.
16-A 16-B
16. Using a utility knife, cut the fascia horizontal bar starting at the outer vertical bar and 3-1/2” out
toward the edge. Do this on both sides of the fascia.
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BX2198
2006-10 Ford Explorer/Mercury Mountaineer
2007-10 Ford Explorer Sport Trac
Installation Instructions
292-2993 Rev. E Page 9 of 9 10/19/09
© 2007, 08, 09 Blue Ox
One Mill Road, Industrial Park
Pender, Nebraska 68047
Phone: [phone]
Fax: [phone]
www.blueox.com
CUSTOMER SERVICE COMMITMENT
Blue Ox is committed to providing you with
exceptional customer care throughout your
lifetime with our products. Our team is here
to assist you with any questions you may have
regarding the performance of your product.
Simply call 1-800-228-9289 and you can speak
with our customer care team.
Additionally, please visit our website to see
which rallies our Destination America team will
be attending. For a nominal fee, our service
technician will service your towing system to
ensure it’s in proper working condition. Also as
a commitment to our customers, should you visit
our factory you can stay at our full service Blue
Ox campground at no charge along with enjoying
a factory tour.
Again thank you for being our customer and
for the condence you have shown in the
performance of our products. It is because of
customers like you we enjoy the success we
have today.
DEALER or INSTALLER:
Be certain the user receives the
instruction sheets for their products.
2008 With removable tabs installed.
‘08 Without removable tabs installed.
2009 With removable tabs installed.