Blue Ox BX2635 User manual

BX2635
2009-14 Ford F150 (No Raptor/King Ranch)
2015-16 Ford Expedition
2015-17 Ford F150
2015-16 Lincoln Navigator
(Includes EcoBoost & ACC)
Installation Instructions
405-0253 Rev D Page 1 of 10 10/25/2016
Please visit www.blueox.com for the latest version of these installation instructions.
Attachment Tab Height: 20”
Attachment Tab Width: 35”
Serial Number
If the front of your vehicle looks different than this, please contact us at [phone].
2009-14 F-150
2009-14 F-150
Expedition
Expedition
2015-16 F-150
2015-16 F-150
Reference your vehicle owner’s manual for manufacturer’s towing specifications.
Navigator
Navigator
Please read BOTH these Installation Instructions and the General Information sheet prior to
installing or operating this equipment.

BX2635
2009-14 Ford F150 (No Raptor/King Ranch) (Includes EcoBoost)
2015-16 Ford Expedition, Lincoln Navigator (Includes EcoBoost & ACC)
2015-17 Ford F150
Installation Instructions
405-0253 Rev D Page 2 of 10 10/25/2016
!
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
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
3/4” 257 380
Bolt Torque Specifications
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
16MM 161 230
18MM 222 318
Bolt Torque Specifications
Torque in Foot-Pounds for Inch Bolts
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 equipment and knowledge necessary to do “fit work”. If needed,
Blue Ox®Dealers can be found at www.blueox.com or by contacting our Technical Service Department 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 the hardware supplied in the hardware kit and existing hardware as specified in the installation
instructions.

BX2635
2009-14 Ford F150 (No Raptor/King Ranch) (Includes EcoBoost)
2015-16 Ford Expedition, Lincoln Navigator (Includes EcoBoost & ACC)
2015-17 Ford F150
Installation Instructions
405-0253 Rev D Page 3 of 10 10/25/2016
Drill a hole according to the tail light wiring kit instructions.
NOTICE
• Handling of some cosmetic parts when installing this product may require the use of protective
covers, rags, specialty tools, etc. to prevent damage.
• When using power drills be aware of the dangers of torque and drill bit length.
• When using a reciprocating saw be aware of objects behind the cutting surface.
• Use a good quality paint to spray cut edges of frame to prevent rusting.
• Be sure that ALL electrical connections are plugged in and accessories are functioning properly
before reinstalling the fascia.
• The baseplate is computer tested to your vehicle’s GVWR, exceeding this weight will void the
manufacturer’s warranty.
• Be sure to use a sufficient amount of Loctite®Red on all bolt threads before tightening. Tighten all
bolts according to the torque chart provided.
• Dealer or installer be certain the user receives these instruction sheets.
• If the baseplate is in an accident, it must be replaced. DO NOT use it again! An accident can
cause unseen damage and using it again could result in more damage or serious injury. DO NOT
use the baseplate if it is damaged or missing parts.
F-150
F-150
Expedition
Expedition
Instruction Notes: The bumper is removed and reinstalled for the baseplate installation. Some
drilling and trimming is required. Tow hooks are removed and not reinstalled.
Place all components that are removed on a flat, sturdy surface. All items will be reinstalled unless
otherwise noted after the baseplate is installed.
The dimensional variations between otherwise identical vehicles can be considerable. While the
baseplate was designed for easy installation, it may be necessary to tailor the baseplate slightly to
compensate for vehicle manufacturer’s tolerances.
The BX8869 Tail Light Wiring Kit is recommended for non-LED equippedvehicle applications.
The BX8848 Diode Wiring Kit is recommended for LED equipped vehicle applications.

BX2635
2009-14 Ford F150 (No Raptor/King Ranch) (Includes EcoBoost)
2015-16 Ford Expedition, Lincoln Navigator (Includes EcoBoost & ACC)
2015-17 Ford F150
Installation Instructions
405-0253 Rev D Page 4 of 10 10/25/2016
SWITCH
1
4
CONNECTOR
SAFETY CABLES (2)
ATTACHMENT LOCATION
8
14
CONNECTOR
4 PIN
6 PIN
3
11
9
7
FOR PERMANENT BASE PLATE
13
11
2
10
12
6
15 5
BREAKAWAY
Tools Required
Torque Wrench
Drill
Tape Measure
Loctite®RED
17/32” Drill Bit
8MM Socket
10MM Socket
15MM Socket
21MM Socket
7/16” Socket
7/16” Wrench
3/4” Socket
3/4” Wrench
T30 Torx
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. Failing to follow and/
or altering these installation instructions in either installation or required equipment will void the manufacturer’s warranty. Towing behind a non-motorized
vehicle will void the warranty.
Item No. Part No. Description Qty.
1.................................61-4029...........................1/2”-13 Nut Plate with 10” Wire............................................ 4
2.................................61-6996...........................BX2635 Passenger Side Baseplate..................................... 1
3.................................61-7008...........................BX2635 Driver Side Baseplate ............................................ 1
4.................................62-3468...........................Attachment Tab with Hole.................................................... 2
5.................................101-6135.........................90° Electrical Bracket........................................................... 1
6.................................201-0050.........................1/4”-20 x 3/4” Hex Head Bolt, Grade 5, ZP.......................... 5
7.................................201-0068.........................1/2”-13 x 1-3/4” Hex Head Bolt, Grade 5, ZP....................... 8
8.................................201-0192.........................#10-32 1/2” Round Slotted Head Screw.............................. 2
9.................................202-0047.........................#10-32 Hex Nut.................................................................... 2
10...............................202-0094.........................1/2”-13 Hex Lock Nut with Nylon Insert ............................... 4
11...............................202-0102.........................1/4”-20 Hex Nut with Nylon Insert........................................ 5
12...............................203-0001.........................1/4” Flat Washer, ZP............................................................ 4
13...............................203-0005.........................1/2” Flat Washer, ZP............................................................ 4
14...............................203-0012.........................1/2” Lock Washer, ZP........................................................... 8
15...............................203-0054.........................#10 Lock Washer................................................................. 2
16...............................226-0049 (not shown).....36” Class IV Safety Cables.................................................. 2
17...............................229-0512 (not shown).....1/2” Quicklink, ZP.................................................................4
18...............................290-0437 (not shown).....Black Receiver Cap ............................................................. 2
19...............................293-1339 (not provided)..Breakaway Switch................................................................ 1
20...............................294-0805 (not provided)..4 Pin Connector................................................................... 1
21...............................294-0902 (not provided)..6 Pin Connector................................................................... 1

BX2635
2009-14 Ford F150 (No Raptor/King Ranch) (Includes EcoBoost)
2015-16 Ford Expedition, Lincoln Navigator (Includes EcoBoost & ACC)
2015-17 Ford F150
Installation Instructions
405-0253 Rev D Page 5 of 10 10/25/2016
1. Using a 15MM socket, remove the nut in
front of the lower valance. Do this on both
sides of the vehicle.
2009-14 F-150 Bumper Removal
3. Unclip the cable from the clamp on the passenger side (left). Using a 8MM socket, remove the
two (2) bolts from the middle of the bumper (right-white). Then using a 10MM socket, remove
the center bolt from the middle of the bumper (right-gray). Remove the bumper from the
vehicle disconnecting any electrical connections and set aside.
2. Using a 21MM socket, remove the two (2)
nuts from the backside of the bumper. Do
this on both sides of the vehicle.
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continue to page 9 for baseplate installation

BX2635
2009-14 Ford F150 (No Raptor/King Ranch) (Includes EcoBoost)
2015-16 Ford Expedition, Lincoln Navigator (Includes EcoBoost & ACC)
2015-17 Ford F150
Installation Instructions
405-0253 Rev D Page 6 of 10 10/25/2016
1. Using a Phillips screwdriver, remove the
twelve (12) push pins from the top edge of
the fascia cover. There are six (6) on each
side. Set the cover aside.
2. Using a T30 Torx, remove the four (4)
screws from the top edge of the grille.
There are two (2) on each side.
3. Using a 7MM socket, remove the three (3)
screws from the edge of the wheel well.
Do this on both sides of the vehicle.
4. Using a 10MM socket, remove the two
(2) screws from inside edge of the fascia/
fender joint. Do this on both sides of the
vehicle.
Pull the corners of the fascia away from
the vehicle disconnecting any electrical
connections and set the fascia aside.
Expedition Fascia Removal
continue to page 9 for baseplate installation
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BX2635
2009-14 Ford F150 (No Raptor/King Ranch) (Includes EcoBoost)
2015-16 Ford Expedition, Lincoln Navigator (Includes EcoBoost & ACC)
2015-17 Ford F150
Installation Instructions
405-0253 Rev D Page 7 of 10 10/25/2016
1. Unsnap the plastic cover from the face of
the bumper. Do this on both sides of the
vehicle.
2. If equipped with Adaptive Cruise, using a
11MM socket, remove the three (3) nuts
from the ACC sensor. Unsnap the sensor,
disconnect the electrical connection and
set aside.
3. On the backside of the bumper, using
a 21MM socket, remove the nut on the
outside of the frame. Do this on both sides
of the vehicle.
Directly center of the bumper, remove the
push pin at the bumper/lower valance joint
(inset).
4. Using a 21MM socket, remove the two (2)
nuts from the face of the bumper. Do this
on both sides of the vehicle.
Disconnect any electrical connections and
set the bumper aside.
Remove the plastic shields from around
the tow hooks (inset).
2015 F-150 Bumper Removal
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continue to page 9 for baseplate installation

BX2635
2009-14 Ford F150 (No Raptor/King Ranch) (Includes EcoBoost)
2015-16 Ford Expedition, Lincoln Navigator (Includes EcoBoost & ACC)
2015-17 Ford F150
Installation Instructions
405-0253 Rev D Page 8 of 10 10/25/2016
1. Using a Phillips screwdriver, remove the
twelve (12) push pins from the top edge of
the fascia cover. There are six (6) on each
side. Set the cover aside.
2. Using a T30 Torx, remove the four (4)
screws from the top edge of the grille
(gray). There are two (2) on each side.
Using a 10MM socket, remove the outer
fascia screw (white). Do this on both sides
of the vehicle. On the passenger side only,
remove the two (2) hood latch screws.
3. Using a 10MM socket, remove the three
(3) screws from the edge of the wheel
well. Along with the two (2) screws up
inside the wheel well along the fascia joint.
Do this on both sides of the vehicle.
4. On the underside of the fascia towards the
middle, remove the two (2) push pins.
Pull the corners of the fascia away from
the vehicle disconnecting any electrical
connections and set the fascia aside.
Navigator Fascia Removal
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continue to page 9 for baseplate installation

BX2635
2009-14 Ford F150 (No Raptor/King Ranch) (Includes EcoBoost)
2015-16 Ford Expedition, Lincoln Navigator (Includes EcoBoost & ACC)
2015-17 Ford F150
Installation Instructions
405-0253 Rev D Page 9 of 10 10/25/2016
1. Using a 15MM socket, remove the two (2)
bolts from the tow hook. Do this on both
sides of the vehicle. Do not discard the
existing hardware.
3. Using a 17/32” drill bit, drill the existing
holes thru the frame. Install 1/2”-13 x
1-3/4” bolts with lock washers into the
holes with 1/2”-13 nut plates on the inside
of the frame. Do this on both sides of the
vehicle. Fully tighten all hardware.
2. Install the baseplate to the frame with the
existing hardware. Do this on both sides
of the vehicle. Fully tighten all fasteners.
(Note: If tow hooks are not present, use the
supplied hardware for baseplate installation.)
4. Attach the permanent baseplate safety
cables to the provided convenience link on
the baseplate. The photo above shows the
recommended installation of the cables to frame
of vehicle. Additional options may interfere with
suggested mounting; in this case, secure the
cables to a solid piece of the frame as described
in the instructions included with the permanent
baseplate safety cables. Be sure the safety
cables do not rub against any hoses or moving
parts. Do this on BOTH sides of the vehicle.
** Use Loctite®Red on all bolt threads and tighten all bolts to the
appropriate torque.
** Use Loctite®Red on all bolt threads and tighten all bolts to the
appropriate torque.
Baseplate Installation
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BX2635
2009-14 Ford F150 (No Raptor/King Ranch) (Includes EcoBoost)
2015-16 Ford Expedition, Lincoln Navigator (Includes EcoBoost & ACC)
2015-17 Ford F150
Installation Instructions
405-0253 Rev D Page 10 of 10 10/25/2016
5. Reinstall the ACC sensor if removed.
Reinstall the bumper or fascia/fascia
cover.
© 2015 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 [phone] and you can speak with our technical
service team.
Additionally, please visit our website to see which rallies our DestinationAmerica 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 confidence you have shown in the performance
of our products. It is because of customers like you we enjoy the success we have today.