1300 BE TUFF TUFF BY NAME * TUFF BY NATURE

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1 TUFF BULLBARS AUSTRALIA, Ph: 1300 BE TUFF ( ) 6 Tews CT, (P.O. Box 1977) Fax: Torrington, sales@tuffbullbars.com.au Toowoomba, admin@tuffbullbars.com.au Queensland 4350, feedback@tuffbullbars.com.au AUSTRALIA TOYOTA PRADO 150 SERIES MY14 BULLBAR BOLT & BRACKET KIT 2 x BULLBAR BRACKETS 2 x 25X25 RHS STABILSER BARS 1 x WIRING KIT (X 2 LED LIGHTS; WIRE EXTENSIONS & WIRE TAPS) 4 x 130MM X 12 BOLTS 2 x 40MM X 12 FINE THREAD BOLTS 4 x 50MM X 10 BOLTS 14 x 12MM FLAT WASHERS 8 x 10MM FLAT WASHERS 2 x 3/16X1 BOLTS & NUTS (FOR NUMBER PLATE) 8 x TECK SCREWS & WASHERS 8 x 12MM NYLOCK NUTS 4 x 10MM NYLOCK NUTS 8 x ¼ X ¼ MUD GUARD 2 x 12MM SPRING WASHERS BE TUFF TUFF BY NAME * TUFF BY NATURE AUSTRALIA S LEADING BULLBAR MANUFACTURER Page 1

2 Remove Grill and Bumper (*See Bumper cut section for preparing the bumper to cut) Connect wiring kit to wiring harness using wire taps or solder Wiring goes under and behind headlights TIP: Try out LED lights before you fit bulbar YELLOW = INDICATOR WHITE = EARTH BLACK = PARK Page 2

3 Fit TUFF Crash box. Mark and Drill 13mm wholes as shown Enlarge existing holes to 12.5mm or 13mm to accommodate 12mm bolts Page 3

4 Attach Bullbar brackets using the x 12mm bolts and nuts and 1 12mm fine bolt with flat spring washers Left and right brackets on vehicle Plates face inwards Place rectangular, two holed, rubber washers onto the bullbar mounting bolts (They may be already fitted) Page 4

5 Place Bullbar onto the brackets. Bolt it up loosely with washers and 12 mm nuts. Align the bullbar left and right and make sure that the wings follow the line of the vehicle. Tighten all bolts TIP: TIGHTENING THE BOTTOM BOLTS MOVES THE WING OF THE BULLBAR UP. TIGHTENING THE TOP BOLT MOVES THE WING DOWN - MAKE SURE BOLTS ARE TIGHT! Place indicator lights into bullbar Page 5

6 Cut bumper Place cut bumper back in, along with Grille and other pieces Position bumper to meet bullbar - Side of bumper sit above the bulbar while the middle area around the Grille should go under. Trim bumper so that there is a gap of 15mm between bumper and top of bullbar Page 6

7 Position Grill Bolt to mud flap Page 7

8 CUTTING THE BUMPER THE TOP HALF OF YOUR ORIGINAL BUMPER HAS TO BE CUT AND RE-FITTED TO THE VEHICLE Mark six points along the bumper (3 on each side) ready to tape up Position 1: Top of bulbar to where the bumper meets the mudguard Position 2: Outside high point of headlight where the head light meets the mudguard Position 3: Inner point of head light ALL measurements must be taken from bulbar up on both sides of the vehicle Run a tape along the six marked position to highlight a cutting line Page 8

9 Cut along the line with a jigsaw or a similar tool. Clean up the cutting edge. Once the top bumper is ready it will look like this. Try it on the vehicle. You may need to trim it if it is not fitting evenly. There should be a +/- 20mm gap Fit top half of the bumper to the vehicle. Teck screw plastic mud flaps to the bullbar or support. Use large washers supplied, trim flap if necessary Page 9

10 Connect 25 x 25 RHS Stabiliser Rod between the bullbar and the bracket as shown Holes in RHS will have to be marked and drilled. Use two 10 x 50 Bolts, Nuts & Washers each side. Fit number plate and indicator/park lights connect lights into wiring harness Use 3mm Bolts and Nuts supplied Page 10

11 PLEASE DON T HESITATE TO CALL US ON 1300 BE TUFF ( ) IF YOU HAVE ANY PROBLEMS WITH FITTING BEST REGARDS THE TUFF TEAM! Page 11

12 PRADO AND 200 SERIES Parking Sensors 1. Unplug Sensors and remove from Bumper 2. Trim plastic clips from sides of sensors so that the spacers supplied will fit around the sensors SPACER GLUE TO BULLBAR GLUE SENSOR TO SPACER PLUG IN SENSOR 3. Using Sikaflex-252 or similar type glue, glue the Spacer to the sensor. Let it dry. Apply the glue to the opposite side of the spacer and push it into the hole drilled in the channel of the Bullbar. Make sure that the sensors are positioned so the wire plugs can be re-attached. Let the glue set. Push in the wiring plugs and tie the wiring up. Step Lights Fit step lights before you fit the rails to the vehicle. Remove lights from your genuine steps. Fit lights to your new step below the Tuff cut out using 3/16 bolts & nuts supplied. Make sure the lights face upwards. Exclude middle sensors on 200 SERIES Front View 18.5mm holes for sensors. Centre Centre NUMBER PLATE 30mm 30mm Page 12