T.J.M. 070SB13N20A Fitting Instructions Manual

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 1 of 27 03/01/2019 Australian Standards Relating to Installing Vehicle Frontal Protection Systems (VFPS): AS 4876.1-2002 a) Do not attach V.F.P.S. to vehicle using anchorages not intended for this purpose (e.g. engine mounting bolts), other than those specified by the V.F.P.S. manufacturer in this instruction. b) Do not use this product for any vehicle make or model other than those specified by the V.F.P.S. manufacturer (as above). c) Do not remove any plaques or labels from the V.F.P.S. d) Do not modify the structure of the V.F.P.S. in any way. • Read instructions fully before commencing fitment. • Estimated Fitting Time: 4hrs • 076SKITB20A and 946TQEXT500 supplementary kits may also be required for vehicles fitted with a radar. (Not compatible with centrally mount radar) • 076PSHOUSE supplementary kit may be required for vehicles fitted with 6 front parking sensors. • The fitment of TJM products does not nullify the OE manufacturer's operating guidelines and/or warnings. Ensure you are familiar with and adhere to the usage instructions specified by the manufacturer in the owner's manual or other official documentation. • Left hand and Right hand components are determined as seated in the vehicle. • Check for (and remove) any build up in all captive nuts fitted to the FPS. • Be aware that a number of government / fleet departments require that the tow points be painted red. • Ensure that the “Rated Recovery Point Label” is affixed alongside the compliance label, in the driver’s side doorjamb. • When fitting accessories to TJM products (ie. driving lights and aerials), ensure suitable washer plates are used under the mounting surface that allow the accessory to be secured in a way that prevents it from damaging the product. • When removing protective coatings, ensure all new edges are deburred, clean any swarf from the area and apply rust preventative to exposed surfaces. Bolt tensions Dia. (mm) Nm ft.lbs Dia. (inch) Nm ft.lbs All bolt tensions are as follows unless otherwise specified. 5 5 4 1/4” 9 7 6 9 7 5/16” 22 15 8 22 16 3/8” 33 27 10 44 32 7/16” 55 43 12 77 57 1/2” 86 66

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 2 of 27 03/01/2019

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 3 of 27 03/01/2019 ITEM NO. Description Qty Part Number PARTS LIST 1 T13 Outback FPS 1 F-11172 2 Chassis Mount / Winch Frame 1 F-10773 3 Center Guard 1 F-10991 4 Wing Guard LH 1 F-10569L 5 Wing Guard RH 1 F-10569R 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 Fairlead Cover 1 F-11350 15 Spacer 2mm 2 F-8918 16 Spacer 4mm 2 F-8921 17 LED Parker/Indicator 2 92600 18 Winch Slot Cover Insert 1 92106 19 Winch Frame Washer Plate 2 F-11003 20 Wing Guard Bracket 2 F-11004 21 Parking Sensor Housing Kit 4 F-5417 22 Fusebox Vent Bracket 1 F-9896 23 LED Fog-Light and Mount Kit 1 92675 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 Rated Recovery Point Label 1 HC0064 N/A Recovery Point Use Guide 1 F-1768 N/A Pinch-Weld (750mm Long) 1 93154 N/A TJM LOGO Sticker 1 K3550 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 ITEM NO. Description Qty Part Number BOLT KIT N/A M6 x 1.0 x 20mm Hex Head Bolt 16 K0550 N/A M6 x 1.0 x 30mm Hex Head Bolt 2 K3220 N/A M6 x 1.0 Flange Nut 2 K3033 N/A M6 x 1.0 Cage Nut Type B 6 K1550 N/A M6 x 1.0 Nyloc Nut 2 K0605 N/A M6 Spring Washer 14 K0915 N/A M6 x Ø12.5mm Flat Washer 8 K0897 N/A M6 x Ø18mm x 1.6mm Flat Washer 11 K2905 N/A M8 x 1.25 x 35mm Hex Bolt 4 K0555 N/A M8 x Ø24mm Flat Washer 6 - N/A M8 Spring Washer 2 K0620 N/A M8 x 1.25 Nyloc Nut 2 K0606 N/A M8 Cage Nut 2 K1560 N/A M10 x 1.25 x 20mm Hex Bolt 2 K0938 N/A M10 x 1.25 x 30mm Hex Bolt 8 K0564 N/A M10 x 1.25 Nyloc Nut 8 K3099 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 2 - 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

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 4 of 27 03/01/2019 FOR PXII Bumper and Grille cut refer steps 1-23 below: 1. Cut out templates and attach to bumper. 2. Mark trim line 10mm below feature edge. 3. Remove and retain the number plate, discarding the fasteners. 4. Remove and retain the plastic clips (5) that secure the top of the grille/radiator shroud. 5. Raise shroud at grille, release and remove clips underneath. 6. Inside lower grille area behind air dam, locate and remove grille and bumper retaining screws. Note : Grille will need to be removed to expose center retaining clips. LHS SHOWN LHS SHOWN TEMPLATE MARK TRIM LINE 10mm BELOW FEATURE EDGE LOCATION LHS SHOWN FEATURE EDGE

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 5 of 27 03/01/2019 7. Gently disengage the clips (2) along each side of the grille before releasing lower clips (8). Take care as the clips which connect the grille to the bumper are a molded part of the grille & the clips can break easily if proper care is not taken. 8. Remove the grille from vehicle & set it aside. 9. Remove and discard the newly exposed upper bumper clips indicated (4). 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. RHS SHOWN SKIRTING RHS SHOWN

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 6 of 27 03/01/2019 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 wiring harnesses secured to the bumper. 15. Carefully remove the bumper leaving the templates in place for marking at step 19. 16. Remove and retain the OE front underbody guard and associated fasteners. 17. Remove center lower bumper support brackets at lower air dam position. 18. Remove and discard the front intrusion beam using the following steps: 18.1. If radar is fitted, remove and retain mount bracket with radar in place for later installation. 18.2. Remove and retain the front intrusion beam fasteners (4) from the indicated locations. 18.3. Remove and discard the clips on the lower plastic air guides. RHS SHOWN STEP 18.1 STEP 18.2

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 7 of 27 03/01/2019 19. Mark a trim line along the grille recess as shown. The trim line is to be marked 15mm from the “front” edge of hole located in recessed face on each side. 20. Trim the bumper along all trim lines marked and those shown on templates. Deburr all new edges. Caution should be used with handling grille not to damage finish. 21. Apply paper tape to grille and mark a horizontal cut line 10mm down from the feature edge crease. 22. Trim the grille removing lower section. 23. On both sides of the grille centerline mark 85mm wide by 40mm high cutouts, 350mm from centerline as shown. Trim the bumber behind the grille to match and deburr all new edges. HORIZONTAL CUT LINE 10mm down TRIM LINE ALIGNMENT HOLES 350mm OUT FROM CENTRE LINE 40mm 85mm BOTH SIDES REAR VIEW TRIMMING CONNECT CUT LINES AT CORNER 15mm

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 8 of 27 03/01/2019 For PXIII 2018 bumper cut refer steps 24-27 belows. 24. Cut out templates and attach to bumper. 25. Remove & retain the number-plate, discarding the fastener. 26. Using the top if the number plate holes as reference, mark a horizontal cut line along the bumper. 10mm down frome the feature edge. 26.1. Trim the bumper along the trim line marked. 27. Trim the bumper from grille centerline mark 85mm wide by 35mm high cuts, 350mm from centerline as shown. Repeat both sides RHS SHOWN 350 mm OUT FROM CENTRE LINE 35 mm 85 mm 10 mm down FROM FEATURE EDGE STEP 26.1

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 9 of 27 03/01/2019 28. Drill a 6mm hole through the bumper support plastics and vehicle body in the location shown. 29. Remove the outer bumper support plastics from the front guards. 30. Deburr and treat the new holes in the vehicle body with a rust preventative. Repeat on RHS. 31. Trim bumper support as shown, de-burr and clean edges then refit to guard. Repeat on LHS. 32. 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. DRILL 6mm HOLE LHS SHOWN RHS SHOWN ALIGN CUT LINE TO CORNER RHS SHOWN

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 10 of 27 03/01/2019 PXII Air guide cut refer steps 33-40 33. Mark the left hand lower air guide following the below process: 33.1. Mark a horizontal line on the front face 10mm above the top of the circle mount. 33.2. Mark a vertical line on the side face, 20mm from the flat front face. 33.3. Join the two lines previously created with a horizontal line on the side face. 34. Repeat step 0 for the RHS then trim the lower air guides along the marked lines. 35. Deburr the edges and clean any swarf from the area. 36. Mark the left hand upper air guide as shown, on the lower foam edge face. CAUTION: REMOVE TEMPERATURE SENSOR ON LHS PRIOR TO CUTTING, THEN REPLACE. 37. Repeat step 36 for the RHS then trim marked lines and deburr the edges. LHS SHOWN STEP 33.2 STEP 33.3 STEP 33.1 LHS SHOWN Temperature sensor hole 20mm 100mm 85mm AIR GUIDE AS TRIMED CIRCLE MOUNT

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 11 of 27 03/01/2019 38. Mark the left hand upper air guide as shown, following the below process: 38.1. Mark a line on the top face from mounting tab corner to a point 40mm forward of rear edge. 38.2. Mark 2nd line from previous line down to a point 110mm front rear edge. 38.3. On the horizontal lower face, mark a line along the edge 95 mm from the front. 38.4. Join the previously marked trim lines as shown. 39. Repeat step 38 for the RHS then trim the upper air guides to shape as shown. 40. Deburr the edges and clean any swarf from the area. Fit the indicator/park light wiring harness to the vehicle loom as per instructions. Temporarily plug in supplied indicator / park light and fog lights. Check the operation then disconnect the light assemblies. PXIII Air guide and Air deflector cut refer steps 41-46 41. Remove the 2 clips and discard instrusion beam foam and remove instrusion beam. LHS SHOWN 95mm STEP 38.4 110mm STEP 38.1 LHS SHOWN 40mm STEP 38.2 STEP 38.3 STEP 41

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 12 of 27 03/01/2019 42. Mark the air guide as per following process. 42.1. Mark a line on as per contour shown below. 42.2. Trim rubber portion and plastic accordingly. 43. Mark the left hand air guide and cut CAUTION: REMOVE TEMPERATURE SENSOR ON LHS PRIOR TO CUTTING, THEN REPLACE. 43.1. Mark the coutour line on with the same dimension to the RHS. 43.2. Caution not to cut temperature sensor hole. 44. Trim air guide rib for winch installation only 44.1. Align cut line to corner and mark the line as per opposite photo. Only required to cut RHS side for clearance to winch control box. 45. Cut the side of the air guide to allow clearance to winch frame bracket (side view looking from the arrow) STEP 42 STEP 44 STEP 42 RHS SHOWN 45mm 80mm 40mm STEP 43 LHS SHOWN STEP 38.3 Temperature sensor hole RHS SHOWN STEP 38.3.1 Follow the corner profile 50 mm 30 mm Extend the cut line horizontally and vertically to meet the open edge. Side view Show opposite

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 13 of 27 03/01/2019 46. Trim lower air deflector to allow clearance to winch frame 46.1. Mark the contour of the cut line below 46.2. Trim the part, repeat on the RHS side. 47. On both sides of the vehicle, feed the wiring loom through the gap below the headlights. 48. With the nuts towards the center of the vehicle, insert the inner chassis nut-plate into the large opening in the front of the chassis rail, ensuring the thin “leg” is positioned towards the rear of the vehicle & touching the bottom inside face of the chassis rail. 49. Align the holes in the inner chassis nut-plate with the holes in the chassis rail. RHS SHOWN THESE TWO HOLES ALIGN LHS SHOWN Lower Air deflector STEP 46.1 Mark the horizontal line along the front face Extend the line 30mm

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 14 of 27 03/01/2019 50. 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). 51. Repeat steps 48 to 50 for the opposite side of the vehicle. 52. Trim a section of the air guide as shown to provide clearance to the winch frame washer plate 53. Position the chassis mount / winch frame and winch frame washer plate on the vehicle chassis rail ends then loosely secure it in place using the fasteners retained in step 18.2. THE CHASSIS MOUNT / WINCH FRAME SHOULD FIT AROUND THE PREVIOUSLY TRIMMED AIR GUIDES. RHS SHOWN WASHER PLATE CHASSIS RAIL END RHS SHOWN

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 15 of 27 03/01/2019 54. Centralize the chassis mount / winch frame to the vehicle by measuring diagonally from mount tip to headlamp corner as shown, equalize sizes as close as practical. 55. Tension the fasteners from step 53 to the relevant torque settings listed on page 2. 56. Using spacers (4mm) and (2mm) supplied, align faces between chassis, chassis mount and chassis support bracket, assemble loosely. 56.1. 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. 56.2. 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 LHS. If necessary, use any combination of the supplied 2mm shims on the relevant side (or sides) of the chassis mount to assist in centering the chassis mount / winch frame to the vehicle. = = RHS SHOWN SPACERS STEP 56.2 STEP 56.1

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 16 of 27 03/01/2019 57. Secure chassis mount / winch frame to the vehicle through the holes shown using M10 x 1.25 x 30mm hex screws (8), M10 x Ø30mm flat washers (16) & M10 nyloc nuts (8) 58. Tighten all fasteners installed in steps 56 and 57 to the relevant torque settings listed on Page 2. 59. 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. 60. Align plate with existing holes and tighten to specified torque. Check holes and slots align after tightening to allow easy bolt fitment/clearance. REPEAT ON LHS. 61. Remove & discard the inner guard lower bumper mount. Retain fasteners. NUTS TO INSIDE! RHS SHOWN Holes must align RHS SHOWN

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 17 of 27 03/01/2019 STEPS 62 TO 66 RHS ONLY 62. Mark and trim area around aerial: 62.1. Measure 5 mm up from aerial top edge 60 mm in from outside edge. 62.2. Measure 5 mm out from aerial side edge and 100 mm up from bottom edge. 62.3. Join the two marked lines and trim 63. Deburr all edges. 64. 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. 65. Move wiring clip from radiator support panel to the edge of the antenna where shown, connect aerial 66. Insert the supplied grommet through the antenna hole at the location shown. Secure to the vehicle with an OE fastener retained from step 61. RHS ONLY STEP 62.2 STEP 62.1 60mm 5mm 15mm 100mm STEP 65 STEP 64 65 RHS ONLY STEP 66

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 18 of 27 03/01/2019 67. Mark and trim clearance relief cut on inner guard aligning to features shown. Steps 68 to 71 only apply if a winch is to be fitted. Otherwise please proceed to step 72 68. Refer to the winch fitting instructions to fit the winch to the chassis mount / winch frame. DO NOT INSTALL WINCH FASTENERS AT THIS TIME. 69. When winch is fitted, further grill trimming is required. 69.1. On the RHS only, increase 85mm cut made in step 23 inboard to 300mm. 300 mm RHS SHOWN AS TRIMMED ALONG TOP OF SLOT ALONG EDGE

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 19 of 27 03/01/2019 Steps 70 to 71 only apply for vehicles fitted with radar, otherwise proceed to step 72. 70. If radar was removed at step 18.1 install mount bracket from kit 076SKITB20A as per supplied instructions. 71. Fit winch control extension kit 946TQEXT500 as per supplied instruction. A number of positions exist for mounting the winch control extension bracket 72. Refit bumper to vehicle, using OE fasteners retained. 73. Tighten the fasteners installed in step 32. 74. Refit grille using OE fasteners retained and fit pinch weld to lower cut edge of the outer grill panel as shown. STEP 74

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 20 of 27 03/01/2019 75. Insert the nylon plugs supplied, into the square cut-outs for the indicator / park light (as shown). 76. Separate the indicator / park light body from the backing plate. 77. Secure the backing plate to the FPS, using the screws provided with the light assemblies. 78. 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. 79. Repeat steps 75 to 78 for the opposite side of the vehicle. 80. Refer to the fitting instructions provided in the fog-light kit to install fog-lights to the FPS. IF NO FRONT PARKING SENSORS ARE FITTED TO THE VEHICLE, PROCEED TO STEP 89. 81. Looking at the lower bumper section from the rear, record each parking sensor’s position and orientation. 82. Remove the parking sensors and the associated wiring harness from the bumper. 83. Feed the parking sensor loom through the FPS channel, securing with cable ties. RHS SHOWN RECORD ORIENTATION OF CONNECTOR

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 21 of 27 03/01/2019 IF ONLY 4 PARKING SENSORS ARE FITTED TO THE FRONT OF THE VEHICLE, PROCEED TO STEP 87. SUPPLEMENTARY KIT 076PSHOUSE MAY BE REQUIRED FOR ADDITIONAL SENSOR HOUSINGS 84. Using the adjacent image as a reference, drill a 28mm hole in the lower outside face of each wing. 85. Deburr any edges and treat with a rust preventative. 86. For the 2 outermost (longer) parking sensors, install an isolating ring (supplied in the fitting kit) over the top of the factory installed clear rubber, with the flanged end towards the painted surface of the parking sensor. COMPLETE ALL REMAINING STEPS AS PER A 4 PARKING SENSOR SYSTEM 87. Remove the OE rubber isolating ring from the parking sensors and replace with the isolating rings supplied in the fitting kit. 88. Press out the blanking from the front of the parking sensor housing and insert the parking sensor. 89. Secure the parking sensor retaining plate to the parking sensor housing using the supplied 8g x 25mm pan head screws. 90. Apply the supplied 1.2mm (thicker) double sided sticker to the front face of the parking sensor housing. RHS SHOWN

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 22 of 27 03/01/2019 91. 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 POSITIONED AND ORIENTED ACCORDING TO THE NOTES MADE IN STEP 81 AND CONNECT TO THE SENSOR LOOM. STEP 92 APPLIES ONLY IF A WINCH IS FITTED 92. Install the fairlead supplied with the winch to the front of the FPS as shown. PROCEED TO STEP 94 93. Position the fairlead opening cover as shown & secure it in place, using M6 x 1.0 x 20mm hex screws (4), M6 x Ø12.5mm flat washers (4) & M6 spring washers (4). FAIRLEAD FAIRLEAD COVER

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 23 of 27 03/01/2019 94. With the assistance of another person, carefully lift the FPS into position on the chassis mount, then loosely secure it in place, using supplied “ Sliding washer plate” and M12 x 1.25 x 40mm hex bolts (4), 1/2" x Ø1- 1/4" flat washers (8) & M12 nyloc nuts (4) at the indicated locations. IMPORTANT: SLIDING WASHER PLATE MUST BE ORIENTATED CORRECTLY AS SHOWN! REPEAT ON LHS. FOR VEHICLES FITTED WITH A RADAR, IT MAY ASSIST TO REMOVE THE RADAR BRACKET FASTENERS AND SLIDE THE WINCH AND RADAR TO GAIN ACCESS THROUGH THE FRONT WINCH ACCESS PRESSING. 95. Align the FPS to the vehicle so that the guard clearance is 20 to 25mm, and wing is aligned with wheel arch. 96. Tighten all of the fasteners to the relevant torque settings listed on Page 2. 97. Re-connect the indicator / park lights & fog- lights to the corresponding wiring harness. 98. Check the operation of the indicators, park lights, fog-lights, winches, etc to ensure that they are functioning correctly. RHS SHOWN CHAMFER TO TOP

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 24 of 27 03/01/2019 99. Use the indicated hole in the sliding washer plate as a guide and drill an Ø8mm hole through the mounts in both sides of the vehicle. Keep the drill square to align with holes in winch frame. 100. De-burr all new edges, clean any swarf from the areas and apply rust preventative to exposed surfaces. 101. Secure through the holes drilled in step 99 using M8 x 1.25 x 35mm hex screws (2), M8 x Ø24 flat washers (4) & M8 x 1.25 nyloc nuts (2). 102. Tension the fasteners to the specified torque settings listed on page 1. 103. Loosely secure the wing guard bracket to the winch frame washer plate using a M6 x 1.0 x 20mm hex bolt (1) and M6 flange nut (1). 104. Insert an M8 cage nut (1) into the wing guard bracket so the nut is situated on top of the bracket. REPEAT ON LHS. RHS SHOWN RHS SHOWN

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 25 of 27 03/01/2019 105. Insert cage nuts (3) into the wing guard so the nut is situated on the top face of the wing guard. 106. Apply the supplied foam tape to the underside of the wing guard as shown below. 107. Position the wing guard as shown, and secure it in place using M6 x 1.0 x 20mm hex bolts (3), M6 spring washers (3) & M6 x Ø18mm flat washers (3). 108. Secure the wing guard at the indicated position using M8 x 1.25 x 35mm hex bolts (1), M8 spring washers (1) & M8 x Ø24mm flat washers (1). 109. Fix the wing guard bracket in place by tightening the fastener installed in step 103 to its appropriate torque setting. 110. Using the wing guard as a guide, mark a trim-line on the inner guard. 111. 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. RHS SHOWN STEP 108

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 26 of 27 03/01/2019 STEP 112 APPLIES ONLY IF A WINCH HAS BEEN INSTALLED. 112. Install and torque the rear winch fasteners. 113. Position the centre guard as shown & secure it in place at the front locations using M6 x 1.0 x 20mm hex bolts (2), M6 spring washers (2) & M6 x Ø12.5mm flat washers (2). 114. Re-fit the OE underbody guard using the OE fasteners removed in step 16 ensuring center guard sits between the underbody guard and the vehicle

Vehicle: Ford Ranger PXII, PXIII (Non-Tech pack), Everest (UA model only) Part No. 070SB13N20A For product warranty please refer to our website www.tjm.com.au F-12114 Page 27 of 27 03/01/2019 STEP 115 APPLIES ONLY IF A WINCH HAS BEEN FITTED 115. Install and torque the front winch fasteners through the indicated holes in the centre guard. STEP 116 APPLIES WHERE NO WINCH IS PRESENT 116. 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. 117. Using M6 x 1.0 x 20mm hex bolts (2), M6 spring washers (2) & M6 x Ø12.5mm flat washers (2), secure the number-plate in place, to the front of the FPS. 118. Clip the winch slot cover in place in the winch viewing slot. 119. Ensure that all of the fasteners are fully tightened to the appropriate torque settings & that, as a results of fitting the product, no vehicle components are crushed or will chafe. STEP 117 STEP 118