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Ironman4x4 BBR085E, Installation Manual

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Ironman4x4 BBR085E Installation Manual Download Page 1

RAID BULL BAR TO SUIT RAM DT

INSTALLATION

GUIDE

• Ironman 4x4 BBR085E Raid Bull Bar to suit Ram DT. 
• It will take approximately 2.5 hours to install.

IMPORTANT:

 Bull bar installations should only be done by a qualified person  

and it’s the responsibility of this person to ensure correct fitment.

NOTE: This product has been tested for air bag compatibility 

and therefore the mounting system MUST NOT be modified

 BBR085E/070622

BBR085E

©Copyright 2022 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd

Summary of Contents for BBR085E

Page 1: ...y be done by a qualified person and it s the responsibility of this person to ensure correct fitment NOTE This product has been tested for air bag compatibility and therefore the mounting system MUST NOT be modified BBR085E 070622 BBR085E Copyright 2022 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 2: ... commencing fitment Do not remove labels from this bull bar It is good practice to record the bull bar batch number on the customer s job card for future reference BULL BAR CARE INSTRUCTIONS To maintain 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 silicon spray or similar...

Page 3: ...an the one intended and specified by Ironman 4x4 Do not alter or modify the recovery point in any way Doing so may compromise the points strength and integrity Ensure that bolts are tightened to specified torque Don t remove warning labels from the recovery point Some recovery points require the warning labels to be installed these must be installed It is advised to use an equalizing or bridle str...

Page 4: ...HS QTY 1 13 Side Bash Plate Holding Bracket LHS QTY 1 14 Side Bash Plate Holding Bracket RHS QTY 1 15 Light Bar Mounting Bracket LHS QTY 1 16 Light Bar Mounting Bracket RHS QTY 1 17 Winch Control Box Mount QTY 1 18 Number Plate Hinge Mount Bracket QTY 1 19 M10 Hex Nyloc Nut QTY 2 20 M8 Hex Nyloc Nut QTY 4 21 Flat Washer M8 QTY 8 22 Flange Nut M6 QTY 6 23 Flange Nut M8 QTY 4 24 Combo kit Hex bolt f...

Page 5: ...8 QTY 2 40 Flat Washer M10 QTY 4 41 Flat Washer M12 QTY 38 42 Hex Head Bolt M10 40 QTY 4 43 Hex Head Bolt M12 40 QTY 8 44 Hex Head Bolt M12 45 QTY 6 45 Hex Head Bolt M12 50 QTY 8 46 Hex Head Bolt M8 30 QTY 2 47 Parking Sensor Extension Harness QTY 3 48 3M Adhesion Promoter QTY 1 49 Pinch Weld 1200mm QTY 1 50 Recovery Point Warning Sticker QTY 2 51 Zip tape QTY 10 52 Parking Sensor Holder QTY 6 53 ...

Page 6: ...NAL 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 Parts List Tools Required Page 4 of 14 Copyright 2022 Ironman 4x4 Pty Ltd No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd QTY QTY QTY QTY QTY Parts List Tools Required Metric spanner set Metric socket set Air hacksaw Tape mea...

Page 7: ...f fitted to be reinstalled later Disconnect negative battery terminal Please check owner s manual to see vehicle specific requirements as some models may need battery backup 2 Remove and retain number plate if fitted to be reinstalled later 3 Remove all factory bumper bar retaining clips and bolts including splash tray clips Unbolt and remove factory stone tray bash plate 4 Disconnect factory fog ...

Page 8: ...e aero dame 7 Unbolt and remove factory chrome recovery points 2 x 18mm and 2 x 21mm NOTE the 21mm bolt is a body mount bolt keep this bolt for reinstallation later Also retain the 2x factory 18mm bolts 8 Unbolt all factory bumper bar reinforcement 6x 18mm bolts and remove 9 Remove factory bumper 5 If the vehicle is fitted with factory aero Unplug aero harness off the motor and remove 4 x 13mm nut...

Page 9: ... and 1Xm12x40mm 11 Unwrap winch cradle bar brackets 12 Fit bar outer brackets to the front of vehicle Do not tighten the bolts at this stage as adjustment will be required once bull bar is installed M12X40mm x 6 Repeat step for opposite side 13 Mount recovery points using the factory OEM hardware Also use 1XM12x50mm to mount the front point NOTE don t mount the side point mount as this will mount ...

Page 10: ...dle holes and side brackets 17 If winch is being installed refer to winch installation instructions and follow steps 18 to 20 18 If installing a winch use the provide winch control box mounting plate NOTE it is advised to mount the bracket to the control box first 19 Install winch control box mounting bracket to winch control box using N 37 4 x M5x 08x16mm nut washer spring washer and flange nut N...

Page 11: ...ore removing sensors from original bumper bar note the location and orientation of each sensor so when they are fitted back into the Raid bar this can be replicated 21 Remove the parking sensor wiring and parking sensors from the factory bumper taking note of the direction and position of each sensor Remove grommets from the sensor holes in Raid bumper 22 Fit sensor with factory silicone sleeve to...

Page 12: ...ep is important to ensure sensor holders adhere properly to the bull bar 25 Remove protective film from one side of double sided tape and apply to mounting surface of sensor holder 26 Remove protective film from double sided tape and apply sensor holder sensor to Raid bar making sure sensors are in the same positions as they were in the original bumper and in the same orientation 27 Plug the parki...

Page 13: ...asher nut N 28 2x M6X1X20mm bolt washer spring washer nut NOTE Optional centre light bar ILBDR002B 29 Assemble and install Ironman 4x4 cube lights to light pod The brackets provide some adjustment to ensure centralized positing and vertical aim of the light The Cube Light cable can be secured to the inside edge of bull bar using cable ties 30 If you are not fitting the optional light bar There is ...

Page 14: ... when lifting the bumper into position to avoid injury or damage to the vehicle and components NOTE bar will need to be feed between the recovery points to align The mounting holes are at the rear of the bracket in behind the crush box 33 Tension all fasteners and mounting hardware and recovery points refer to page 6 N 32 6X M10x1 5x30mm 34 Drill and pin bar into position using M10 Taptite bolts w...

Page 15: ...ount is the aero mounting pedestal using the inner chassis rail as shown Repeat on the other side 38 Install centre protection plate with black M8 bolts provided N 29 4X M8x1x25mm and 2 x N 36 M12x1 5x45mm bolt washer nut Bolt the UBP through the lower cradle mount and then to chassis 35 Note This bar has been supplied with Taptite Bolts These don t require a washer or nut to mount Installation Th...

Page 16: ...may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd 42 Connect negative battery terminal if removed 41 Tuck guard liners in place behind side wing protection plates drill 2 holes as shown and bolt into place 40 Bolt number plate to the vehicle with M6 hardware supplied ...

Page 17: ...r written consent of Ironman 4x4 Pty Ltd Wiring Diagrams Parklight Blue Relay Connector Ground Fuse Red 30 85 86 87 87a Red Lamp Black Lamp Battery Ground Ground White Switch SPST Positive power supply at connector to factory fog light Blue Relay Connector Ground Fuse Red 30 85 86 87 87a Red Lamp Black Lamp Battery FOG LIGHTS WITHOUT FACTORY FOG LIGHTS ...

Page 18: ...y or every 10k kms Visually inspect the Raid bar and hardware retention the bar hardware or when needed Check the operation of the blinkers park lights fog lights and winch if installed and ensure that they are all functioning correctly Make sure all electrical wiring is clear of sharp edges and is secured correctly If vehicle is fitted with parking sensors radars and or front cameras check they a...

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