Dobinsons BU19-3542 User manual

Bullbar Installation Guide
ENSURE PAGE SCALING IS TURNED TO
NONE OR OFF WHEN PRINTING
Part Number: BU19-3542, BU19-3708, BU19-3709
Fits:
Ford Ranger PX MK 2 Facelift models (Without Radar Collision System)
This Bullbar will take approximately 3.5 hours to install
Tools required are
•Spanners and socket set.
•Pneumatic hacksaw
•Screwdrivers
•Pliers and side cutters
Dobinsons BULLBARS should be installed by a qualified installer and it is
the installer responsibility to ensure correct fitment.
Fully read and understand the instructions before beginning the installation
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Dobinsons Springs and Suspension www.dobinsonsprings.com

Dobinsons Springs and Suspension www.dobinsonsprings.com

Dobinsons Springs and Suspension www.dobinsonsprings.com

Fitting Guide
1. Remove the number plate.
2. Remove the screws and bolts from the top of
the radiator to grill cover and remove the
cover.
3. Remove the bolts and fixings at the top of the
grill attaching the top of the grill to the
vehicle.
4. From in behind the grill remove the fixing
bolts and from the front remove the lower
outer fasteners.
5. Remove the fasteners along the inside edges
of the wheel arches on both sides.
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6. Remove all the fasteners securing the bottom
edge of the bumper to the vehicle.
7. With help from another person, start from
each wheel arch edge of the of the bumper
and gently unclip the bumper - look for any
fasteners at the bottom of the grill you may
have missed as you unclip the bumper and
grill.
8. Carefully remove the bumper & grill from the
vehicle.
9. Remove the inner air dam grill.
10. Remove the lower bash plate and put aside
for re-fitment later keeping the bolts.
11. Remove the lower plastic air deflector.
12. Remove the cross beam and discard, but keep
bolts.
13. Remove the inner and outer “L” shaped
bumper support brackets, 4 in total.
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14. The plastic black bumper supports that fit
under the outer edges of the headlight that
the bumper clips to, need to be removed and
the outer lower sections trimmed as seen in
the picture below, then refitted.
15. Ensure that page scaling was turned off when
printing this guide, cut out both parts of the
template at the end of this guide and measure
the scale line. It should be within 1mm.
(sample picture only shown below)
16. Check the template on the bumper checking
that it fits correctly with the bottom of the
headlight edge and follows the contour of the
bumper join. Shown in the picture below is
how the template aligns to the bumper with it
following the guard join contour and the
under headlight edge. The outer and lower
edges are the cut lines.
17. Apply masking tape to the bumper where the
cut edges are for the template - this is so you
can mark the template and when cutting it
does not scratch the visible part of the
bumper.
18. Align the template on the vehicle bumper as
per instructions on the template and mark the
cut lines. The last 3 steps can then be
repeated for the other side of the vehicle by
flipping the template over.
19. Measure down 330mm from the top of the
grill and using masking tape mark a line
straight across the bumper as shown below
then downward 90 degrees at each end to
meet the cuts from the previous step.
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20. Once cut, remove the burrs from the edges
and re-install the bumper to the vehicle.
21. Reinstall the bumper and grill fasteners as
well as the grill cover and fasteners.
22. Install the LH and RH triangular bracket
supports first on the outside of each chassis
rails as per page 4 diagram. The LH bracket
can also be bolted at the back.
23. Install the bullbar mounting bracket. Bolt the
small flat brackets (item 14) from the inner
part of the main bracket to the radiator plastic
deflector. Use the original cross beam bolts on
the main bracket and drill through the plastic
and use the bolts nuts and washers item 10
supplied for the plastic section.
24. Ensure the bracket is central to the vehicle
and tighten all nuts and bolts.
25. Install the lower original bash plate supports
(item 13) ready for fitment to the o.e. bash
plate later.
26. Carefully un-wrap the bulbar taking care not
to scratch it especially on the top loops.
Reinstall the number plate to the bullbar as it
is easier now. If installing driving lights to the
bullbar it is easiest to install now.
27. If not installing a winch skip to step 35
28. See the Installation section of your Dobinsons
4x4 Winch manual for specific detailed fitting
instructions. For a brief overview see the
following steps.
29. Test fit your winch to the mounting bracket
and do up loosely with the clutch handle on
the left hand side of the vehicle.
30. This may require the clutch handle and gear-
box housing to be rotated forward one or 2
bolt holes to allow easy access through the
bulbar holes. See instructions in winch user
manual.
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31. Determine where the winch control box will
be located and mount the control box. See
instructions in winch user manual for control
box mounting options. If mounting to the top
of the bullbar using the supplied bracket,
check clearance of control box to grill and also
check where the wires will route as if the
wires are passing through the holes in the top
of the bullbar the control box may not be able
to be wired until the bullbar has been fitted as
below.
32. Wire the winch up as per the winch
instruction manual and bolt the winch to the
mounting bracket, ensure the mounting bolts
are not too long and tighten correctly. Route
the wires and connect to battery and also
route the breather hose.
33. Unwind some cable from the winch, and pass
the cable through the fairlead hole in the
bullbar and through the roller fairlead. This
may require removing a circlip from the
fairlead and re installing once the cable is
passed through.
34. Install the roller fairlead into the bulbar.
35. Check the poly bulbar over riders, fog light
and top loop bolts are tight (Do not over
tighten the stainless steel loop mounting
bolts. Do not over tighten the poly bullbar
over riders as they will pull the over riders out
of shape).
36. Wire up the lights. NOTE: When wiring up the
LED indicator and parker lights it may cause
the dash indicator lamp to flash faster than
normal due to a load being applied to the
circuit. In most cases this is no problem
however if the customer requires this to be
rectified, LED load resistors may need to be
fitted to the power wire for each LED light or
consult an auto electrician for other methods.
37. Using a multimeter or test light first locate the
earth wire, parker positive and indicator
positive wires from the wiring on the back of
the original vehicle lights on each side.
38. Unclip the wiring from the indicator/parker
lights. Check that the wiring will be long
enough to reach the new bullbar
indicator/parker lights and extend if required.
Using the diagram at the end of this manual,
join the corresponding wires to original
vehicle wires located in the previous step. The
wires can be joined by either using good
quality snap lock crimp connectors or by
soldering. Ensure the connection is secure and
is sufficiently insulated.
39. If fitting a bullbar with fog lights, the fog lights
can be connected using the original vehicle
fog light wires if fitted. If required, cut the old
fog light wiring plugs off and cut the new fog
light wiring plugs and join. If the vehicle is not
fitted with OEM fog lights the wiring loom
supplied can be used. Follow the wiring
diagram at the end of this manual. NOTE: It is
extremely important that all earth wires are
attached to the body end of the battery earth
cable or to the vehicle chassis NOT the
negative terminal of the battery as this can
affect the vehicle charging system.
40. With help, fit the bulbar into position and
install nuts and bolts supplied.
41. Align the bar, leaving a gap of about 10 -
15mm at the rear wing tips to the body to
allow movement.
42. Once you are happy with the alignment
tighten the nuts and bolts on each side.
43. Once happy with the alignment of the bullbar
drill 2 x 8mm pinning holes on each side of the
bullbar drilling through both the mounting
bracket mounting plate and bullbar mounting
plate. Fix with 8mm bolts and nyloc nuts to
keep the bullbar in its position. This may be
easiest performed by drilling with a small
bodied drill from the inside or a right angle
drill chuck from the outside.
44. Plug the wires into the indicator, parker light
plug and fog lights. Test all lights and adjust
the position of the fog lights if required.
45. Fit the under bar protection kit now with the
bolts supplied. The rear of the centre bash
plate will be bolted to the original bash plate
as well as to the brackets item number 13
installed earlier.
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46. Install the side plates and tighten all nuts and
bolts in all under protection plates.
47. Check over all items removed during
installation.
48. Trim the wheel arch splash guards level with
the bottom of the under protection plates and
secure.
49. IMPORTANT NOTES: It is important to inform
the customer that headlight adjustment may
also be required due to the change in ride
height. It is also important to inform the
customer that there will be a change in
vehicle handling characteristics. It is also
important to note that due to their nature fog
lights are required to provide a yellow light to
allow clear fog vision. For this reason
Dobinsons bullbars utilise a Halogen bulb.
Halogen bulbs generate a considerable
amount of heat to achieve the yellow colour
and this causes the air inside the fog light lens
to expand and contract. For this reason the
fog light assembly cannot be sealed and has a
small breather on the back. In some cases this
may cause condensation to form inside the
fog light. The customer may choose to seal
the lens of the fog light but must not seal the
rear breather.
In some vehicles there is a possibility of noise
interference with the radio in some
conditions. If this is experienced then it is
recommend to fit the genuine FORD antenna
interceptor wiring kit part number
EB3T18812SAA. This part is used with genuine
FORD bullbars that experience the same issue,
a
n
d
f
itting instructions for the part are available
through FORD.
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BOTTOM
OF HEADLIGHT
BU19-3542, BU19-3708, BU19-3709 ENSURE ENSURE PAGE SCALING IS TURNED TO NONE OR OFF BEFORE PRINTING. MEASURE SCALE LINE BELOW TO ENSURE IT IS PRINTED TO THE CORRECT SIZE. CAREFULLY CUT OUT THE TEMPLATE AND PLACE ONTO THE BUMPER (THIS SIDE OUT LEFT HAND SIDE) AND MARK THE SECTION TO CUT. FLIP OVER AND THEN MARK THE RIGHT HAND SIDE SECTION TO CUT.
150MM
ALIGN WITH BUMPER
TO QUARTER PANEL JOIN

Customer Copy: Bullbar Care Instructions
To ensure the surface finish quality it is recommended that the
bullbar be washed and cleaned regularly to prevent build up of
dirt and contaminants which when exposed to the elements can
degrade the surface finish. It is also recommended that the mounting fasteners on the bullbar be checked after
1000km’s. Winch servicing and care should also be carried out as per the winch instruction manual.
Stainless Loop Deluxe Bullbar Loop Care and Maintenance
(Customers with Stainless Loop Deluxe Models Only)
The top loops on your Dobinsons Stainless Loop Deluxe steel bullbar are manufactured from high quality 304 grade
stainless steel. Once formed and welded it is highly polished to provide a high gloss finish. Whilst the material is a
high quality stainless steel, like any other exterior polished surface, care and some maintenance is required to
ensure the surface finish quality.
It is recommended that the stainless loops be kept as clean as possible and is thoroughly washed and dried regularly
to prevent build up of dust and contaminants. This is especially important in coastal and high dust areas. The loops
can simply be cleaned with most regular car cleaning items like a soft sponge, car wash and a chamois, avoid strong
cleaning chemicals. Like many other highly polished exterior metals, over extended periods of time and heavy
weathering can cause some staining of the surface may occur. If this occurs the surface can be simply polished using
the following methods to remove the stains and restore the high gloss surface using simple tools and cheap readily
available polishing items.
Tools Required:
•Electric buffer or Electric drill (an electric/cordless drill is generally more convenient).
•Polishing compound – This can be supplied by Dobinsons Spring and Suspension. Please contact head office
on the details below for polish, as a specific type is used.
•Soft finishing type buffing wheel – The buffing wheel should be a soft, finishing type/Calico loose leaf style to
allow the surface to be polished to a high gloss without further marking the surface. The 2 types of discs
shown below are readily available from most hardware stores (Australian customers – Bunnings etc). The
brand below is Josco, and if purchasing a twin pack ensure that only the finishing buff is used and not the
cutting buff. DO NOT USE METAL OR HARSH BUFFING PADS.

Method
1. The stainless loops may be removed from the bullbar if this makes it easier to work on, however if using a
cordless drill this is not a necessity. If removing the loops, do not over tighten the loop retaining bolts when
re fitting.
2. Ensure the loops are first completely clean and dry.
3. Fit the polishing buff wheel to the drill or buffing tool –take note of the maximum wheel speed and rotation
direction.
4. It is recommended to follow specific instructions on the packaging of the buffing wheel for best results.
However if no instructions are provided the following guidelines can be used:
A). Carefully dress the buff wheel with the compound across the rotating wheel for a few seconds, taking
care not o apply too much compound, it is better to apply a little compound more frequently than to
overdress the buff.
B). Gently buff the work area with the buffing wheel and with light pressure move back and forth across the
job.
C). After polishing use a soft, clean, dry rag to clean the surface and inspect in the light for an even finish.
D). Once complete clean thoroughly again with a sponge and warm water.
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