R O A D M A S T E R, I N C.

Transcription

1 R O A D M A S T E R, I N C. BASEPLATE KIT Item Qty Description Part No /2" x 8" BOLT /2" LOCK WASHER /2" NUT /2" x 3 1/2" BOLT /2" CLIPPED FLAT WASHER... A mm x 1.25 x 50MM BOLT mm LOCK WASHER " SAFETY CABLE QUICK LINK ZIP TIES /4" x 2" x 2" BACKING PLATE... A DRIVER SIDE BACKING PLATE W/ ROD...C PASSENGER SIDE BACKING PLATE W/ROD...C MAIN RECEIVER...C DRIVER SIDE REAR BRACE...C PASSENGER SIDE REAR BRACE...C DRIVER SIDE ARM...C PASSENGER SIDE ARM...C FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN DEATH, PERSONAL INJURY OR PROPERTY DAMAGE

2 This is one of our EZ series brackets, which allows the visible front portion of the bracket be easily removed from the front of the vehicle (Fig.A and Fig.B). The bracket kit consists of a main receiver brace, two lower braces and two removable front bracket arms and a hardware pack. The main receiver brace mounts behind the front bumper fascia the botm of the bumper core and the front of the frame. The removable front brackets install in the main receiver braces. Before starting the installation, lay out the kit components in order, as they will be used. This will give you a visual idea of how the components work, and will also confirm that everything is present and accounted for. Fig.A Fig.B IMPORTANT: All brackets must be assembled with all the bolts left loose for final adjustment and positioning (before tightening) unless otherwise instructed. All bolts must be rqued for proper strength. If more than one bolt is used per fastening point, the diagram may only show one. Use flat washers over all slotted holes Use lock washers on all fasteners ROADMASTER Limited Warranty, including One-Year Conditional Warranty Text and Product Registration Card, in Carn. Failure follow these instructions can result in property damage, WARNING personal injury or even death. Installation of most mounting brackets requires moderate mechanical aptitude and skills. We strongly recommend professional installation by an experienced installer. The installer must read the instructions and use all bolts and parts supplied. Failure When the securely do instructions so could fasten result require the in bracket loss the of reuse could the wed of result facry vehicle. in loss bolts, of Use the thread wed Loctite lock vehicle. and/or Red lock on all washers bolts used must for also mounting be used. this Failure bracket. securely fasten the bracket could result in loss of the wed vehicle. Do not use this document for cusm fabrication, as it may not show Do all parts not use or structural this document components. for cusm Cusm fabrication, fabrication as or it may an attempt not show all copy parts this or bracket structural design components. could result Cusm in loss fabrication of the wed or an vehicle. attempt copy this The owner bracket must design inspect could all mounts result loss of and brackets the wed vehicle. Every 3,000 miles, the owner must inspect the fasteners before for each proper use Every rque, for cracks 3,000 according miles, other the signs bolt owner of rque fatigue. must requirements inspect Also, inspect the chart fasteners the on fasteners the for last proper page for rque, of proper these according rque, instructions. according the The bolt owner rque the bolt must requirements rque also requirements inspect chart all on mounts the chart last on page and the of brackets last these page. instructions. for Failure cracks do The or so other owner could signs result must of in also fatigue loss inspect of the every wed all 3,000 mounts vehicle. miles. and brackets Failure The owner for do must so cracks could or check result other the vehicle in loss signs of of manufacturer's the fatigue wed vehicle. every 3,000 miles. instructions for Failure the proper do so could procedure(s) result in loss of prepare the wed vehicle. The owner must check the vehicle manufacturer's the vehicle for instructions wing. Some for The the vehicles proper owner must must procedure(s) be equipped check the with vehicle prepare a transmission manufacturer's the vehicle lube for pump, instructions wing. an axle Some disconnect, proper must driveline procedure(s) be equipped disconnect with or prepare a free-wheeling transmission the vehicle hubs lube pump, before wing. an they axle can Some dis- be vehicles connect, wed. Failure must driveline be equipped properly disconnect equip with or free-wheeling the transmission vehicle will hubs lube cause before pump, severe they an axle damage can dis- be connect, wed. the transmission. Failure driveline properly disconnect equip or free-wheeling the vehicle will hubs cause before severe they damage can be wed. Failure properly equip the vehicle will cause severe damage for vehicles the If running the transmission. changes were made by the vehicle manufacturer after this bracket the transmission. If running was changes designed, were some made bolts by or the other vehicle fasteners manufacturer in the hardware after this If bracket pack running may was no changes designed, longer be were some the made correct bolts by size. or the other vehicle It is fasteners the manufacturer installer s the responsi- hardware after this bracket pack bility may was verify no designed, longer that the be bracket some the correct bolts is securely size. or other It is fastened fasteners the installer s the the vehicle responsibility pack fitted may with verify no the longer correct that the be hardware bracket the correct is securely account size. It for is fastened these installer s changes. the vehicle responsi- Failure and bility fitted securely with verify fasten the correct that the the bracket hardware bracket could is account securely result in for fastened loss these of the changes. wed the vehicle Failure vehicle. and fitted securely with fasten the correct the bracket hardware could account result in for loss these of the changes. wed Failure vehicle. hardware and securely fasten the bracket could result in loss of the wed vehicle. If the wed vehicle has been in an accident, it must be properly re- If paired the wed before vehicle attaching has the been bracket. in an Do accident, not install it must the be bracket properly if any repaired structural before frame attaching damage the is bracket. found. Do Failure not install repair the bracket damage if could any structural structural result in the frame frame loss damage damage of the wed is is found. found. vehicle. Failure Failure repair repair the the damage damage could could result result Some in in morhome the the loss loss of of chassis the the wed wed have vehicle. vehicle. such a tight turning radius that you can Some Some damage morhome morhome your morhome, chassis chassis wed have have such such vehicle, a tight tight w turning turning bar or bracket radius radius that that while you you turning can can damage damage sharply. your your Before morhome, morhome, getting on wed wed the vehicle, vehicle, road, test w w your bar bar or or turning bracket bracket radius while while turning turning an sharply. sharply. empty parking Before Before getting getting lot. Turning on on the the o road, road, sharply test test could your your result turning turning radius radius non-warranty in in an an empty empty damage parking parking wing lot. lot. system, Turning Turning morhome o o sharply sharply and/or could could wed result result vehicle. in in non-warranty non-warranty damage Do not back wing up with system, the morhome wed vehicle and/or attached wed vehicle. or non-warranty Do Do damage not not back back will occur up up with with your the the wed wed wing vehicle vehicle system, attached attached morhome or or and/or non-warranty non-warranty wed damage damage vehicle. will will occur occur your your wing wing system, system, morhome morhome and/or and/or wed wed vehicle. The safety cables must connect the wing vehicle the wed The The vehicle safety safety frame cables cables frame, must must with connect connect the cables the the wing wing crossed, vehicle vehicle with enough the the wed wed slack vehicle vehicle for sharp frame frame turns. frame, frame, Refer with with the the the cables cables instructions crossed, crossed, with with for proper enough enough routing. slack slack for for Failure sharp sharp leave turns. turns. enough Refer Refer slack the the in cable cable the safety instructions instructions cables, for for failure proper proper routing. routing. connect Failure Failure the safety leave leave cables enough enough frame slack slack frame, in in the the will safety safety result cables, cables, in the or or loss failure failure of the connect connect wed the the vehicle. safety safety cables cables frame frame frame, frame, will will result result in in the the loss loss of of the the wed wed vehicle. This bracket is designed for use with ROADMASTER w bars and This This ROADMASTER bracket bracket is is designed designed adaprs only. for for use use Using with with this ROADMASTER ROADMASTER bracket with other w w bars bars brands, ROADMASTER ROADMASTER without an approved adaprs adaprs ROADMASTER only. only. Using Using this this adapr, bracket bracket may with with result other other brands, brands, in non- without without warranty an an damage approved approved or injury. ROADMASTER ROADMASTER adapr, adapr, may may result result in in nonwarranty Upon final damage installation, or injury. the installer must inspect the bracket en- Upon non- Upon sure adequate final final installation, installation, clearance, the the particularly installer installer must must around inspect inspect hoses, the the air bracket bracket conditioner ensure ensure lines, adequate adequate radiars, clearance, clearance, etc., or non-warranty particularly particularly around around damage hoses, hoses, the air air wed conditioner conditioner vehicle lines, lines, will result. radiars, radiars, etc., etc., or or non-warranty non-warranty damage damage the the wed wed vehicle vehicle will This result. bracket is only warranteed for the original installation. Installing This This a used bracket bracket bracket is is only only another warranteed warranteed vehicle for for is the the not original original recommended installation. installation. and Installing Installing will void a the used used warranty. bracket bracket on on another another vehicle vehicle is is not not recommended recommended and and will will void void the the warranty. warranty.

3 BASEPLATE KIT Fig.C Passenger side Fig.E Radiar cover Fig.D Battery cover 1. Important: please use all supplied bolts and parts and read all instructions carefully before beginning this installation. The majority of questions you may have can be answered within the text, and proper installation will ensure safe and secure travel. Now, begin the installation. Start by removing five plastic fasteners attaching the radiar cover the fascia and the core support (Fig.C). 2. Remove the plastic battery cover, (driver side), and the radiar cover by pulling upward on them (Fig.D, E). Fig.F Fig.G Fig.H 3. Next, remove the two plastic fasteners attaching the p of the fascia the core support (Fig.F). 4. Bend and unlock the two metal locking tabs attaching the p of the fascia the core support (Fig.G). 5. On both sides, remove two plastic fasteners attaching the fender liner the fascia (Fig.H). Fig.J Fig.I Fig.K Fig.I 6. On both sides, remove three 10mm (head) bolts and one plastic fastener attaching the fascia the splash shield (Fig.I). 7. Unplug the fog lights, if your vehicle is so equipped (Fig.J). 8. Pull back the fender liner and remove one Phillips head screw attaching the corner of the fascia the fender (Fig.K). ROADMASTER, INC. reserves the right make changes at any time without notice in material, specification and models or discontinue models.

4 Fig.L Fig.M Fig.N 9. Now, remove the two plastic fasteners attaching the botm of the fascia the plastic shock absorption pad (Fig.L). 10. Pull out and forward on both corners of the fascia remove it (Fig.M). 11. Next, remove the plastic shock absorption pad by compressing the eight plastic tabs (Fig.N), then pull forward on the pad remove it. Fig.O Fig.P Fig.Q Ambient temperature sensor 12. Remove the ambient temperature sensor (Fig.O). 13. Temporarily remove the air bag sensor by removing two T27 Torx screws (Fig.P). Note: do not unplug the air bag sensor. 14. On both sides, locate the large existing holes in the front of the frame. Using each hole as a template for drilling, drill a ½" hole through the frame (Fig.Q). Note: be sure drill straight on. 15. Remove the lower plastic air deflecr by removing the five 10mm bolts (Fig.O). 16. Remove four plastic fasteners across the front of the lower splash shield gain access the subframe mount bolts (Fig.R). Fig.R

5 Fig.S Fig.T Fig.U 17. Position the main receiver brace over the front of the frame, so that the pre-drilled holes in the main receiver brace align the holes you drilled in step 14. Bolt the main receiver brace in place using two ½" x 7½" bolts, two 3" x 3" backing plates, lock washers and nuts, one set per side (Fig.S, T). Tighten both of the bolts. Note: position each backing plate on the back side of the frame (Fig.U). 18. Then, again using the receiver brace as a template for drilling, drill two ½" holes through the botm of the bumper core (Fig.V). 19. Remove the front inside 17mm (head) bolt from the subframe mount on each side (Fig.W). Fig.V Fig.W Fig.X 20. Hold the lower brace over the mounting hole and bolt in place with a 12mm x 1.25 x 60mm bolt, lock washer and flat washer (Fig.X). Repeat for the other side. 21. Insert one of the threaded backing plates in the bumper core, over the hole you drilled in step 18 (Fig.Y). Then, bolt through the p of the lower brace, the receiver brace, the botm of the bumper core and in the backing plate with the ½ x 3½ bolt, lock washer and nut (Fig.Z). Repeat for the other side. Fig.Y Fig.Z ROADMASTER, INC. reserves the right make changes at any time without notice in material, specification and models or discontinue models.

6 Fig.AA Fig.BB Fig.CC 22. Torque all the bolts the rque specifications listed at the end of these instructions (Fig.AA). Then, zip tie the ambient air temperature sensor the receiver brace cross bar (Fig.BB). 23. Place the lower splash shield against the lower support and mark for trimming on both sides. Refer the yellow marker line in Figure CC for correct trimming. Fig.DD Fig.EE Fig.FF 24. Hold the lower air dam against the lower supports and mark for trimming on both sides. Refer the yellow marker line in Figure DD for correct trimming. 25. Hold the plastic shock absorption pad against the bumper core and mark for trimming on both sides, allow clearance for the pipe spacers. 26. Now, hold the fascia in place over the receivers and mark for trimming on both sides (Fig.EE backside, Fig.FF front side). Note: the center chrome pieces in the grilles can be reattached with contact adhesive. 27. Insert the removable front bracket arms in the front receiver braces, and rotate 90 degrees lock. 28. Install the w bar the mounting bracket according the manufacturer's instructions. 29. Attach the 8" safety cables with the cable connecrs (Q-Links) the front of the receiver braces (Fig.GG). Fig.GG 30. Attach the ends of the safety cables the w vehicle's safety cables and w bar. ROADMASTER, INC. reserves the right make changes at any time without notice in material, specification and models or discontinue models.

7 BOLT TORQUE REQUIREMENTS Note: The rque values represented below are intended as general guidelines. Torque requirements for specific applications may vary. Roadmaster does not warrant this information be accurate for all applications and disclaims all liability for any claims or damages which may result from its use. STANDARD BOLTS Thread Size Grade Torque 5/ ft./lb. 3/ ft./lb. 7/ ft./lb. 1/ ft./lb. 5/ ft./lb. METRIC BOLTS Thread Size Grade Plated / Unplated 8mm ft./lb. 18 ft./lb. 8mm ft./lb. 18 ft./lb. 10mm ft./lb. 36 ft./lb. 10mm ft./lb. 35 ft./lb. METRIC BOLTS Thread Size Grade Plated / Unplated 12mm ft./lb. 65 ft./lb. 12mm ft./lb. 61 ft./lb. 12mm ft./lb. 60 ft./lb. 14mm ft./lb. 97 ft./lb. ROADMASTER, INC. reserves the right make changes at any time without notice in material, specification and models or discontinue models.