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TJM T13, Fitting Instructions Manual

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TJM T13 Fitting Instructions Manual Download Page 3

 

FITTING INSTRUCTIONS 

Product: 

T13 Outback Frontal Protection System 

Vehicle: 

Ford Ranger PXIII 

Part No.  

  070SB13N21W 

 

 

 

 

For product warranty please refer to our website www.tjm.com.au 

 F-27198.docx 

Page 3 of  27 

04/11/2021 

 

ITEM NO. 

Description 

Qty  Part Number 

PARTS LIST 

1 

T13 Outback FPS 

1 

F-26213 

2 

Chassis Mount / Winch Frame 

1 

F-10773 

3 

Center Guard 

1 

F-10991 

4 

Wing Guard LH 

1 

F-26368L 

5 

Wing Guard RH 

1 

F-26368R 

 

 

 

 

FITTING KIT 

6 

Chassis Brace LH 

1 

F-1072L 

7 

Chassis Brace RH 

1 

F-1072R 

8 

Inner Chassis Nut-Plate LH 

1 

F-1075L 

9 

Inner Chassis Nut-Plate RH 

1 

F-1075R 

10 

Bend Angle LH 

1 

F-10861L 

11 

Bend Angle RH 

1 

F-10861R 

12 

Bending Washer Plate 

2 

F-8052 

13 

Sliding Washer Plate 

2 

F-10874 

14 

Number Plate Mount 

1 

F-27293 

15 

Fairlead Cover Plate 

1 

F-11096 

16 

Spacer 2mm 

2 

F-8918 

17 

Spacer 4mm 

2 

F-8921 

18 

LED Parker/Indicator 

2 

92600 

19 

Winch Slot Cover Insert 

1 

92106 

20 

Winch Frame Washer Plate 

2 

F-11003 

21 

Wing Guard Bracket 

2 

F-11004 

22 

Parking Sensor Housing  Kit 

6 

F-5417 

23 

Fusebox Vent Bracket 

1 

F-9896 

24 

Radar Grille 

1 

F-26352 

25 

Radar Top Mount 

1 

F-26429 

26 

Panel Backing LH 

1 

F-27303L 

27 

Panel Backing RH 

1 

F-27303R 

28 

Radar Cover Panel 

1 

F-26351 

29 

Grille (Folding) LH 

1 

F-9971L 

30 

Grille (Folding) RH 

1 

F-9971R 

31 

Hinge Bush 

6 

K1292 

32 

Grille Latch 

2 

F-9969 

33 

Fog Light Washer Plate 

4 

88057 

34 

Fog Light Blanking Cover 

2 

92091 

N/A 

Bumper Trim Template 

1 

F-11766-T 

N/A 

12.7mm Plastic Plug 

4 

K0765 

N/A 

Nylon Plug 

4 

K0665 

N/A 

Recovery Point Use Guide 

1 

F-1768 

N/A 

Pinch-Weld (400mm Long) 

1 

93154 

N/A 

Rubber Grommet 

1 

92645 

N/A 

Christmas Tree Plug 

1 

K0666 

N/A 

Vent Hose (530mm) 

1 

K3075 

N/A 

Cable Tie (300mm) 

8 

K1148 

N/A 

Foam Tape (750mm) 

1 

K1361 

N/A 

TJM LOGO Sticker 

1 

K3183 

N/A 

Rated Recovery Point Label 

1 

HC0064 

N/A 

Airbag Compatibility Label 

1 

HC0057 

 

ITEM 

NO. 

Description 

Qty 

Part 

Number 

BOLT KIT

 

N/A 

R-Clip 

1 

91130 

 

 

 

 

N/A 

M5 x 0.8 x 20mm Pan Head Screw 

6 

K0688 

N/A 

M5 x Ø10mm Flat Washer 

6 

K0417 

N/A 

M5 x 0.8 Nyloc Nut 

6 

K0604 

 

 

 

 

N/A 

M6 x 1.0 x 20mm S/S Button Head Bolt 

20 

K3218 

N/A 

M6 x 1.0 x 20mm Hex Head Bolt 

12 

K0550 

N/A 

M6 x 1.0 x 30mm Hex Head Bolt 

2 

K3220 

N/A 

M6 x 1.0 Flange Nut 

10 

K3033 

N/A 

M6 x 1.0 Cage Nut Type B 

10 

K1550 

N/A 

M6 x 1.0 Nyloc Nut 

2 

K0605 

N/A 

M6 x 1.0 S/S Nyloc Nut 

8 

K1549 

N/A 

M6 Spring Washer 

2 

K0915 

N/A 

M6 S/S Spring Washer 

12 

K1552 

N/A 

M6 x Ø12.5mm Flat Washer 

10 

K0897 

N/A 

M6 x Ø12.5mm S/S Flat Washer 

16 

K1551 

N/A 

M6 x Ø18mm x 1.6mm  Flat Washer 

5 

K2905 

N/A 

M6 x Ø18mm S/S Flat washer 

8 

K1554 

 

 

 

 

N/A 

M8 x 1.25 x 20mm Hex Head Bolt 

2 

K0552 

N/A 

M8 x 1.25 x 25mm S/S Button head bolt 

2 

K2084 

N/A 

M8 x 1.25 x 35mm Hex Bolt 

2 

K0555 

N/A 

M8 x Ø24mm Flat Washer 

4 

- 

N/A 

M8 x Ø17mm S/S Flat Washer 

2 

K0923 

N/A 

M8 x Ø19mm Flat Washer 

4 

K0628 

N/A 

M8 S/S Spring Washer 

2 

K0924 

N/A 

M8 x 1.25 Nyloc Nut 

4 

K0606 

N/A 

M8 Cage Nut 

2 

K1560 

 

 

 

 

N/A 

M10 x 1.25 x 20mm Hex Bolt 

2 

K0938 

N/A 

M10 x 1.5 x 25mm Button Head Bolt 

2 

K2690 

N/A 

M10 x 1.25 x 30mm Hex Bolt 

8 

K0564 

N/A 

M10 x 1.25 Nyloc Nut 

8 

K3099 

N/A 

M10 x 1.5 Nyloc Nut 

2 

K0607 

N/A 

M10 x 1.25 Flange Nut 

2 

K3036 

N/A 

M10 x Ø30mm Flat Washer 

16 

WSST-W13 

N/A 

M10 x Ø20mm Flat Washer 

6 

- 

 

 

 

 

N/A 

M12 x 1.25 x 35mm Hex Bolt 

6 

K0570 

N/A 

M12 x 1.25 x 40mm Hex Head Screw 

14 

K0571 

N/A 

M12 x 1.25 x 50mm Hex Bolt 

4 

K0572 

N/A 

M12 x 1.25 x 90mm Hex Bolt 

2 

K0976 

N/A 

M12 x 1.25 Nyloc Nut 

20 

K1200 

N/A 

M12 Spring Washer 

6 

K0977 

N/A 

1/2" x Ø1-

1/4” Flat Washer

 

46 

K0623 

 

 

Summary of Contents for T13

Page 1: ...e you are familiar with and adhere to the usage instructions specified by the manufacturer in the owner s manual or other official documentation For vehicles with active park assist ensure you read and understand the OE manufacturer s guidelines limitations warnings for parking aids The driver of the vehicle is ultimately responsible for its operation Left hand and Right hand components are determ...

Page 2: ...G INSTRUCTIONS Product T13 Outback Frontal Protection System Vehicle Ford Ranger PXIII Part No 070SB13N21W For product warranty please refer to our website www tjm com au F 27198 docx Page 2 of 27 04 11 2021 ...

Page 3: ...66 N A Vent Hose 530mm 1 K3075 N A Cable Tie 300mm 8 K1148 N A Foam Tape 750mm 1 K1361 N A TJM LOGO Sticker 1 K3183 N A Rated Recovery Point Label 1 HC0064 N A Airbag Compatibility Label 1 HC0057 ITEM NO Description Qty Part Number BOLT KIT N A R Clip 1 91130 N A M5 x 0 8 x 20mm Pan Head Screw 6 K0688 N A M5 x Ø10mm Flat Washer 6 K0417 N A M5 x 0 8 Nyloc Nut 6 K0604 N A M6 x 1 0 x 20mm S S Button ...

Page 4: ...plate 2 Cut out templates and attach to bumper 3 Remove retain the number plate discarding the fastener 4 Using the top of the number plate holes as reference mark a horizontal cut line along the bumper 10mm down frome the feature edge 4 1 Trim the bumper along the trim line marked 5 350mm from the bumper centreline mark a rectangle 85mm wide by 35mm high as shown Repeat both sides RHS SHOWN FEATU...

Page 5: ...m com au F 27198 docx Page 5 of 27 04 11 2021 6 Remove and retain the 5 clips securing the grille radiator apron in addition to the 2 bolts securing the air intake 7 Releasing the grille radiator apron clips from behind the grille as shown remove and retain the grille radiator apron 8 Remove and retain the 2 bolts securing the top of the grille to the vehicle as shown ...

Page 6: ...sides of the grille to the vehicle 10 From both sides of the vehicle remove and discard the plastic clips and screws that secure the lower bumper skirting in place 11 Remove and discard the lower bumper skirting 12 On both sides of the vehicle release the plastic inner guard from the bumper discarding all of the fasteners 13 Remove bumper to fender screw both sides and retain 14 Disconnect any wir...

Page 7: ...upport brackets at lower air dam position 18 Remove the bumper and grille assembly from the vehicle 19 Remove and discard the clips 2 securing the foam to the intrusion beam 20 Remove and discard foam IF THE VEHICLE IS EQUIPPED WITH RADAR FOLLOW THE BELOW STEPS TO REMOVE IT USE EXTREME CAUTION IN HANDLING THE RADAR DAMAGE CAUSED BY MISHANDLING IS NOT WARRANTABLE 21 Unplug harness from the rear of ...

Page 8: ...n the front intrusion beam fasteners 4 from the indicated locations 24 Mark the air guide as per following process 24 1 Mark a line on as per contour shown below 24 2 Trim rubber portion and plastic accordingly 25 Mark the left hand air guide and cut CAUTION REMOVE TEMPERATURE SENSOR ON LHS PRIOR TO CUTTING THEN REPLACE 25 1 Mark the coutour line on with the same dimension to the RHS 25 2 Caution ...

Page 9: ...d to cut RHS side for clearance to winch control box 27 Cut the side of the air guide to allow clearance to winch frame bracket side view looking from the arrow 28 Trim lower air deflector to allow clearance to winch frame 28 1 Mark the contour of the cut line below 28 2 Trim the part repeat on the RHS side RHS SHOWN STEP 26 1 Follow the corner profile 50 mm 30 mm Extend the cut line horizontally ...

Page 10: ... holes in the vehicle body with a rust preventative Repeat on RHS 32 Trim bumper support as shown de burr and clean edges then refit to guard Repeat on LHS 33 Loosely secure the bumper support plastics to the vehicle body through the previously drilled hole using an M6 x 1 0 x 30mm bolt 1 M6 x Ø18mm washers 2 and M6 Nyloc nut 1 Repeat on LHS Fit the indicator park light wiring harness to the vehic...

Page 11: ...198 docx Page 11 of 27 04 11 2021 34 On both sides of the vehicle feed the wiring loom through the gap below the headlights 35 Remove discard the inner guard lower bumper mount Retain fasteners 36 Unclip the wire harness body clip from the vehicle 37 Loosen the bolt securing the FM box and rotate it towards the center of the car Retighten bolt 38 LHS SHOWN RHS SHOWN Loosen Rotate ...

Page 12: ...and trim 40 Deburr all edges 41 Using a supplied M6 x Ø18mm flat washer 1 and Christmas tree plug secure the upper corner of the aerial to the vehicle body as shown 42 Move wiring clip from radiator support panel to the edge of the antenna where shown connect aerial 43 Insert the supplied grommet through the antenna hole at the location shown Secure to the vehicle with an OE fastener retained from...

Page 13: ...nut plate with the holes in the chassis rail 49 Position the outer chassis support on the outer face of the chassis rail as shown aligning the respective holes with the inner chassis nut plate then loosely secure it in place using M12 x 1 25 x 40mm hex screws 3 M12 spring washers 3 and 1 2 x Ø1 1 4 flat washers 3 50 Repeat steps 47 to 49 for the opposite side of the vehicle 51 Position the chassis...

Page 14: ...the relevant torque settings listed on page 2 54 Using spacers 4mm and 2mm supplied align faces between chassis chassis mount and chassis support bracket assemble loosely 54 1 Using M12 x 1 25 x 90mm hex bolts 1 M12 nyloc nuts 1 1 2 x Ø1 1 4 flat washers 2 fasten loosely in place 54 2 Using M12 x 1 25 x 50mm hex bolts 2 M12 nyloc nuts 2 1 2 x Ø1 1 4 flat washers 4 fasten loosely in place REPEAT ON...

Page 15: ... 54 and 55 to the relevant torque settings listed on Page 2 57 Fit clamp Angle bracket to inboard face of winch frame and washer plate to front using M12 x 1 25 x 35mm bolts 3 1 2 x Ø1 1 4 Flat Washers 6 M12 nyloc nuts 3 IMPORTANT FIT M12 BOLT ASSEMBLY WITH BOLT HEAD ON FRONT FACE 58 Align plate with existing holes and tighten to specified torque Check holes and slots align after tightening to all...

Page 16: ...indicator park light as shown 63 Separate the indicator park light body from the backing plate 64 Secure the backing plate to the FPS using the screws provided with the light assemblies 65 Supporting the backing plate refit clip each indicator park light body ensuring that an adequate seal is achieved Ensure that the park light is towards the outside of the vehicle 66 Repeat steps 62 to 65 for the...

Page 17: ...Looking at the lower bumper section from the rear record each parking sensor s position and orientation 72 Remove the parking sensors and the associated wiring harness from the bumper 73 Feed the parking sensor loom through the FPS channel securing with cable ties IF PARKING SENSORS ARE NOT FITTED TO THE VEHICLE PROCEED TO STEP 77 IF ONLY 4 PARKING SENSORS ARE FITTED TO THE FRONT OF THE VEHICLE PR...

Page 18: ... 77 Secure the parking sensor retaining plate to the parking sensor housing using the supplied 8g x 25mm pan head screws 78 Apply the supplied 1 2mm thicker double sided sticker to the front face of the parking sensor housing 79 Clean mountings surfaces so they are free of oils residues then affix the parking sensor housings to the rear side of the FPS IF PARKING SENSORS ARE FITTED ENSURE THEY ARE...

Page 19: ...utton head bolts 2 M10 x Ø20mm Flat Washers 4 and M10 x 1 5 Nyloc nuts 2 82 Fit the LH RH grilles using hinge bush item 18 4 M5 x 0 8 x 20mm pan head screw 4 M5 x Ø10mm flat washers 4 M5 nyloc nut 4 M5 x Ø10mm flat washers to be used on nyloc nut side only 83 Fit the spring latch to the FPS as shown using a M6 x 1 x 20mm S S Button head bolt M6 x Ø12 5mm S S Flat washers 2 M6 S S Nyloc Nut 84 Adju...

Page 20: ...ng is aligned with wheel arch 87 Tighten all of the fasteners to the relevant torque settings listed on Page 2 88 Re connect the indicator park lights to the corresponding wiring harness 89 Check the operation of the indicators park lights and any fog lights winches etc to ensure that they are functioning correctly 90 Use the indicated hole in the sliding washer plate as a guide and drill an Ø8mm ...

Page 21: ...EAT ON LHS 96 Insert M6 cage nuts 4 into the wing guard so the nut is situated on the top face of the wing guard 97 Apply the supplied foam tape to the underside of the wing guard as shown below 98 Position the wing guard as shown and secure it in place using M6 x 1 0 x 20mm SS button head bolts 4 M6 S S spring washers 4 M6 x Ø18mm S S flat washers 4 99 Secure the wing guard at the indicated posit...

Page 22: ...guide mark a trim line on the inner guard 102 Using an air hacksaw or similar tool cut along the previously marked trim line It may be necessary to remove the wing guard REPEAT ON LHS STEP 103 APPLIES ONLY IF A WINCH HAS BEEN INSTALLED 103 Install and torque the rear winch fasteners 104 Position the centre guard as shown secure it in place at the front locations using M6 x 1 0 x 20mm hex bolts 2 M...

Page 23: ...and torque the front winch fasteners through the indicated holes in the centre guard STEP 107 APPLIES WHERE NO WINCH IS PRESENT 107 Secure the centre guard through the two indicated holes using M10 x 20mm bolts 2 M10 x Ø20mm flat washers 2 and M10 flange nuts 2 placing the flange nuts on the top side of the winch frame 108 Clean the back face of the radar grille of any residues or oils methylated ...

Page 24: ...w it from the front and adhere the radar cover panel to the exposed sections of double sided tape ENSURE THE LEATHERGRAIN FACE OF THE PANEL IS VISIBLE STEPS 111 to 120 APPLY ONLY WHERE THE VEHICLE IS EQUIPPED WITH A RADAR OTHERWISE PROCEED TO STEP 121 111 WITH GREAT CARE separate the radar from its mounting bracket at the ball and socket joints 112 Remove the indicated clip from both sides of the ...

Page 25: ...u F 27198 docx Page 25 of 27 04 11 2021 113 WITH GREAT CARE remove the indicated plastic sockets from the radar 114 As shown opposite fit 2 M6 cage nuts to the radar upper mount 115 Fit the radar upper mount to the radar using M8 x 1 25 x 20mm hex head bolts 2 M8 x Ø19mm flat washers 4 and M8 Nyloc nuts 2 through the holes vacated by the plastic sockets in step 113 as shown ...

Page 26: ... 0 x 20mm S S button head bolts 2 M6 x Ø12 5mm S S flat washers 4 and M6 S S Nyloc nuts 2 Place the head of the bolt to the inside 117 118 Secure the radar top mount to the radar grille using M6 x 1 0 x 20mm S S button head bolts 2 M6 S S Spring Washers and M6 x Ø12 5mm S S flat washers 2 119 Run a straight edge across the back of the radar and ensure it is parallel to the front face of the radar ...

Page 27: ...ed number plate mount to top holes using hinge bush item 18 2 M5 x 0 8 x 20mm pan head screw 2 M5 x Ø10mm flat washers 4 M5 nyloc nut 2 Pan Heads to face outside M5 x Ø10mm flat washers to be used on nyloc nut side only Lock the number plate mount to the FPS using the supplied R Clip through the lower holes 125 Using M6 x 1 0 x 20mm SS button head bolts 2 M6 SS spring washers 2 M6 x Ø12 5mm SS fla...

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