STEP 1.
STEP 2.
STEP 3.
STEP 4.
STEP 5.
STEP 6.
Remove the contents from box and check for damage. Verify all parts are present. Read instructions completely before
beginning.
Attach light guard assemblies as shown.
From underneath the vehicle on the drivers side, locate two bumper attaching bolts on the inside of the frame rail. Remove nuts
and install top bracket with existing fasteners. Leave loose. Place one spacer plate between bracket and frame rail. Line up hole
in spacer plate with hole in bracket. Place another spacer plate on outside of frame rail over existing hole. Insert 5.50” bolt with
flat and lock washer through frame and bracket. Leave loose.
Attach driver bottom bracket to top bracket with 1/2” yellow fasteners.
On vehicles with tow hooks it may be
necessary to loosen and move tow hook to gain proper adjustment on brackets. Repeat steps 3 and 4 for passenger side.
Determine passenger and driver bottom stiffeners. From the front of the vehicle, insert bottom driver side stiffener through the
top outside slot of lower grille.
Repeat for passenger side. From underneath vehicle, fasten bottom stiffener
to top bracket using the 3/8” yellow zinc fasteners.
Remove factory cover plate by removing eight plastic screws and the eight plastic push pins. Bolt top inner braces to radiator
support using an extruded u-nut, M8-1.25 x 30mm hex head bolt, 5/16” lock washer and 5/16” flat washer as shown.
Some vehicles come factory equipped with a bolted down bracket in the location. If this is the case, remove
SEE FIGURE 1.
SEE FIGURE 6.
SEE FIGURE 6.
SEE FIGURE 5.
SEE FIGURE 6.
SEE FIG-
URE 2. NOTE:
I N S TA L L AT I O N I N S T R U C T I O N S
APPLICATION: 2003-UP FORD EXPEDITION 2/4 WHEEL DRIVE
SPORTSMAN
ASSEMBLY
40-1125
75-0815 REVISION 3/28/07
WO:
AUTOMOTIVE PRODUCTS, INC.
TOOLS REQUIRED
7/16” SOCKET
13MM WRENCH
15MM SOCKET
FLAT SCREWDRIVER
3/4” SOCKET
3/4” WRENCH
9/16” SOCKET
9/16” WRENCH
PHILLIPS SCREWDRIVER
7/16” WRENCH
5/32” HEX WRENCH
21MM SOCKET
RATCHET
TORQUE WRENCH
PARTS KIT CONTENTS
ITEM QTY
DESCRIPTION
ITEM QTY
DESCRIPTION
SPORTSMAN ASSEMBLY
LIGHT GUARD ASSEMBLY, PASSENGER (2) AND DRIVER (3)
TOP BRACE
SPACER PLATE
3/8-16 X 1.25” HEX HEAD BOLT, STAINLESS STEEL BLACK ZINC
3/8” FLAT WASHER
3/8” LOCK WASHER
3/8-16 HEX NUT
, INNER
TOP BRACE, OUTER
MOUNT TOP STIFFENER
BOTTOM STIFFENER, PASSENGER (7) AND DRIVER (8)
TOP BRACKET, PASSENGER (9) AND DRIVER (10)
BOTTOM BRACKET, PASSENGER (11) AND DRIVER (12)
1/2-13 X 1.25” HEX HEAD BOLT, STAINLESS STEEL BLACK ZINC
1/2” FLAT WASHER, STAINLESS STEEL BLACK ZINC
1/2” LOCK WASHER, STAINLESS STEEL BLACK ZINC (2 NOT USED)
1/2-13 HEX NUT, STAINLESS STEEL BLACK ZINC
, STAINLESS STEEL BLACK ZINC
, STAINLESS STEEL BLACK ZINC
, STAINLESS STEEL BLACK ZINC
1/4-20 X 1.00” HEX HEAD BOLT, STAINLESS STEEL BLACK ZINC
1/4” FLAT WASHER, STAINLESS STEEL BLACK ZINC
1/4” LOCK WASHER, STAINLESS STEEL BLACK ZINC
1/4-20 HEX NUT, STAINLESS STEEL BLACK ZINC
1/2-13 X 5.50” HEX HEAD BOLT, YELLOW ZINC
1/2-13 X 1.25” HEX HEAD BOLT, YELLOW ZINC
1/2” FLAT WASHER, YELLOW ZINC
1/2” LOCK WASHER, YELLOW ZINC
1/2-13 HEX NUT, YELLOW ZINC
3/8-16 X 1.25” HEX HEAD BOLT, YELLOW ZINC
3/8” FLAT WASHER, YELLOW ZINC
3/8” LOCK WASHER, YELLOW ZINC
3/8-16 HEX NUT, YELLOW ZINC
M8-1.25 X 30MM HEX HEAD BOLT, YELLOW ZINC
5/16” FLAT WASHER, YELLOW ZINC
5/16” LOCK WASHER, YELLOW ZINC
M8-1.25 EXTRUDED U-NUT
1/4-20 X 1.00” HEX HEAD BOLT, YELLOW ZINC
1/4-20 X 1.25” HEX HEAD BOLT, YELLOW ZINC
1/4” FLAT WASHER, YELLOW ZINC
1/4” LOCK WASHER, YELLOW ZINC
1/4-20 HEX NUT, YELLOW ZINC
3/8-16 X 1.25” BUTTON HEAD CAP SCREW (NOT
USED)
NOT ALL FASTENERS WILL BE USED.
NOTE:
2
4
12
6
6
2
4
2
2
3
3
3
3
3
1
8
4
4
2
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
1
2,3
4
5
6
7,8
9,10
11,12
13
14
15
16
17
18
19
20
21
22
23
24
25
1
2
2
2
1
2
2
2
4
6
12
8
6
2
4
2
2
2
4
2
2
13
4
5
7
8
9
10
11
12
2
3
1
6
