Ironman4x4 BBCD115 User manual

Document Number: BBR074/070323
INSTALLATION
INSTRUCTIONS
BBCD115
BULL BARS TO SUIT FORD EVEREST
Next-Gen 2022+
This product has been tested for airbag compatibility
and therefore the mounting system MUST NOT be modified
©Copyright 2023 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Document Number: BBCD115/140623
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
NOTE
This bull bar should not impede the operation of the
Intercooler Active Aero.
Bar Weight: 103Kg (83Kg additional weight after OE removal)

Page 2 of 25
BBCD115 Installation Guide
©Copyright 2023 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Document Number: BBCD115/140623
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
BBCD115Installation Guide
©Copyright 2023 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Document Number: BBCD115/140623
• 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.
• This bull bar should not impede the operation of the Intercooler Active Aero.
• 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
BBCD115 Installation Guide
©Copyright 2023 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Document Number: BBCD115/140623
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
4b. Side wing protection plate joiner - LHS 1
5. Side wing protection plate - RHS 1
5b. Side wing protection plate joiner - RHS 1
6. Winch cradle 1
7. Rear chassis bracket spacer - LHS 1
8. Rear chassis bracket spacer - RHS 1
No. Part Description Qty
9. Front chassis bracket spacer - LHS 2
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. Camera bracket 1
24. Wired spring clip 2
25. Pinch weld 1
26. Recovery point warning sticker 2
27. Zip ties -
Parts List (Item)
Any damage or losses caused by improper installation and application, goes beyond our quality warranty.
2222
2222
22
2222
2222
2222
11
2222
33
55
1111
1010
1010
99
99
66
1313
1919
1717
2020
2121
1515
88
77
1414
2121
1818
1616
1212
44
33
33
22 22
14
7
12 16
6
10 11 10
9
4
4b
21
21
2
1
21
21
5
5b
9
21
3
18 17
19
20
13
8
15
21

Page 5 of 25
BBCD115Installation Guide
©Copyright 2023 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Document Number: BBCD115/140623
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
2
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
2
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)
4
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)
2
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)
4
33.
Hex Head Bolt M12 (40 x 1.75mm) (H19)
Spring Washer M12
Flat Washer M12 (36.5 x 14 x 4.0mm)
2
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)
6
35.
Hex Head Bolt M10 (40 x 1.5mm) (H17)
Spring Washer M10
Flat Washer M10 (29.5 x 10.5 x 3.0mm)
4
36.
Hex Head Bolt M10 (30 x 1.5mm) (H17)
Spring Washer M10
Flat Washer M10 (50 x 12 x 3.0mm)
2
37.
Hex Head Bolt M8 (50 x 1.25mm) (H13)
Spring Washer M8
Flat Washer M8 (26 x 8.5 x 2.5mm)
4
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)
12
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)
4
40.
Hex Head Bolt M8 (20 x 1.25mm) (H13)
Spring Washer M8
Flat Washer M8 (22.5 x 8.5 x 2.5mm)
15
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)
3
42.
Hex Head Bolt M6 (20 x 1.0mm) (H10)
Spring Washer M6
Flat Washer M6 (22.5 x 6.5 x 2.5mm)
11
43. Cage Nut M6 (1.0mm) 2
44. 3M Primer 1
45. Logo Badge 1

Page 6 of 25
BBCD115 Installation Guide
©Copyright 2023 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Document Number: BBCD115/140623
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
BBCD115Installation Guide
©Copyright 2023 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Document Number: BBCD115/140623
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).
3.
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.
1.

Page 8 of 25
BBCD115 Installation Guide
©Copyright 2023 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Document Number: BBCD115/140623
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
BBCD115Installation Guide
©Copyright 2023 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Document Number: BBCD115/140623
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
BBCD115 Installation Guide
©Copyright 2023 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Document Number: BBCD115/140623
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.