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Ironman4x4 BBCD115 Installation Instructions Manual
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Ironman4x4 BBCD115 Installation Instructions Manual

Bull bars to suit ford everest
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Bar Weight: 103Kg (83Kg additional weight after OE removal)
NOTE
This bull bar should not impede the operation of the
Intercooler Active Aero.
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.
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
INSTALLATION
INSTRUCTIONS
BULL BARS TO SUIT FORD EVEREST
Bumper Cut
Document Number: BBR074/070323
BBCD115
Next-Gen 2022+
5 Hours
Required
Approximately
Document Number: BBCD115/140623

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Summary of Contents for Ironman4x4 BBCD115

  • Page 1 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. Document Number: BBCD115/140623 This product has been tested for airbag compatibility Document Number: BBR074/070323 and therefore the mounting system MUST NOT be modified...

  • Page 2: Pre-Installation Procedures

    (Located on label behind bull bar wing) Page 2 of 25 Document Number: BBCD115/140623 ©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...
  • Page 3 Page 3 of 25 Page 3 of 25 Document Number: BBCD115/140623 ©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...
  • Page 4 Any damage or losses caused by improper installation and application, goes beyond our quality warranty. Page 4 of 25 Document Number: BBCD115/140623 ©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...
  • Page 5 Any damage or losses caused by improper installation and application, goes beyond our quality warranty. Page 5 of 25 Document Number: BBCD115/140623 ©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...

  • Page 6: Tools Required

    M10 x 1.25 M12 x 1.25 10.5 ft/lb Page 6 of 25 Document Number: BBCD115/140623 ©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...
  • Page 7 Store front grille in a safe place for later reinstall. Page 7 of 25 Document Number: BBCD115/140623 ©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...
  • Page 8 Page 8 of 25 Document Number: BBCD115/140623 ©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...
  • Page 9 We suggest using a 10mm socket to ‘pop’ the Clip clip out. Page 9 of 25 Document Number: BBCD115/140623 ©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...
  • Page 10 Retain the bolts for later use. Page 10 of 25 Document Number: BBCD115/140623 ©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...
  • Page 11 Remove the cradle and trim the intercooler shroud where previously marked as shown. Page 11 of 25 Document Number: BBCD115/140623 ©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...
  • Page 12 Item: 12, 33 and 35 LHS. Item: 13, 33 and 35 RHS. Page 12 of 25 Document Number: BBCD115/140623 ©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...
  • Page 13 Reconnect horn plug. Item: 20 and 42. Page 13 of 25 Document Number: BBCD115/140623 ©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...
  • Page 14 24. Install the winch to the cradle. Page 14 of 25 Document Number: BBCD115/140623 ©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...
  • Page 15 Repeat procedure on opposite side. Item: 25. Page 15 of 25 Document Number: BBCD115/140623 ©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...
  • Page 16 Item: 21. Page 16 of 25 Document Number: BBCD115/140623 ©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...
  • Page 17 Item: 44. Page 17 of 25 Document Number: BBCD115/140623 ©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...
  • Page 18 Item: 23. Page 18 of 25 Document Number: BBCD115/140623 ©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...
  • Page 19 Mark the cover and cut. Page 19 of 25 Document Number: BBCD115/140623 ©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...
  • Page 20 45. Refit the grille into place, securing loosely before preparing to fit bull bar. Page 20 of 25 Document Number: BBCD115/140623 ©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...
  • Page 21 Repeat procedure on opposite side. Item: 30. Page 21 of 25 Document Number: BBCD115/140623 ©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...
  • Page 22 Trim guard liners. Repeat procedure on opposite side. Page 22 of 25 Document Number: BBCD115/140623 ©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...
  • Page 23 If the calibration is not completed or RBA not available/ warning is still shown, repeat the driving procedure. Page 23 of 25 Document Number: BBCD115/140623 ©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...

  • Page 24: Wiring Diagrams

    Positive power supply at connector to factory fog light Page 24 of 25 Document Number: BBCD115/140623 ©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...
  • Page 25 Stand back, stop pissing and moaning about no instructions, grab a beer and admire your work. Page 25 of 25 Document Number: BBCD115/140623 ©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...