TUFF BULLBARS AUSTRALIA sales@tuffbullbars.com.au 6 Tews Ct, (PO Box 1977) marketing@tuffbullbars.com.au TOOWOOMBA QLD 4350 feedback@tuffbullbars.com.au Phone: 1300 BE TUFF www.tuffbullbars.com.au (1300 23 8833) Fax: (07) 4633 1236 BULLBAR Fitting instructions to fit TUFF Range Bullbars (2-3 Post, and Aerostyle) to NISSAN NP300 NAVARA Estimated fit time: 3 hours Call 1300 BE TUFF (1300 23 8833) for assistance
Read Fitting instructions carefully before fitting product to vehicle When installed in accordance with these instructions, the front protection bar does not affect operation of the SRS airbag. This product has been tested for Air Bag Compatibility and therefore the mounting system MUST NOT be modified This product must be installed exactly as per these instructions using only the parts supplied In the event of damage to any bullbar component, contact the tuff team ASAP Do not use this product for any vehicle make or model, other than those specified by tuff Do not remove any labels from the bullbar and/or brush rails & steps Bullbar installations should be done by a qualified person and it is the responsibility of this person to ensure correct fitment Tools suggested for fitment Phillips Screw Driver Flat Blade Screw Driver 10mm Socket or spanner 17mm socket with extension 19mm Socket 18mm Spanner Tork bits (T20) Ratchet Jigsaw or other cutting tool (Bumper cut) Linersher or other filling tool (To neaten Bumper cut) Bolt and Bracket kit for fitment Items sent 4 16mm Nylock nuts 4 16mm Flat washers 4 10mm x 50mm bolts 6 Tech screws 6 ¼ x 1 ¼ mudguard washers 2 3/16 bolts and nuts 4 90mm x 10mm bolts 8 10mm Nylock nuts 16 10mm Flat washers 2 Bullbar brackets 2 Indicators (Brytec) 2 Indicator leads 6 Wire tap connectors 2 7 Rubbers 2 Inner guard brackets Items received (your check list) 2 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Read through the fitting instructions and pictures below or visit https://youtu.be/v3ehn520228 for a fitting instruction video Prepare the vehicle ready for fitment: First remove the clips from the top of the grill using a flat blade screw driver (4x across the top) In the grill, turn the clips in the grill to pop out (2x per side) Remove the clips along the bottom of the grill (connecting to the bumper). Lift and pull out the grill (6x clips) 3 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Cont. Prepare the vehicle ready for fitment: Remove the clips from the bumper (under the grill area) using a phillips screw driver Keep aside all clips for use later Using a Tork bits (T20), remove all the screws from the inner bumper guard (both sides) Using a ratchet or spanner, 10mm socket or spanner, pull the inner guard back to reveal the 10mm screw to be removed (keep aside for later use) Underneath the front of the vehicle, remove the middle plastic pannel using a 10mm socket or spanner. Remove the 10mm bolts (4x bolts) from the underside of the bumper Bumper is now ready to be removed 4 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Cont. Prepare the vehicle ready for fitment: Remove all the plastic panneling from from the front of the vehicle using a flat blade screw driver Remove the orginal crash box using a socket, extension and ratchet. Place aside for later Remove the bumper brackets with a 10mm socket and ratchet, to enable the TUFFbrackets to slide over the top of the chassis Place the TUFFbrackets on using the 110x12mm bolts, placing the bolts to go through the side of the chassis 5 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Cont. Prepare the vehicle ready for fitment: Using the original crash box, place the crash box back in place using a 17mm socket with extension for a handle Nip the bolts up so the brackets are sitting flush with the chassis but not fully tightened, using a 19mm socket, ratchet and 18mm spanner (both sides and the same for the front) TUFFbracket and original crash box in position Now you can tighten all bolts, starting with the ones at the front, then both sides INDICATOR LIGHTS Installing the indicator lights: Remove the indicator plug by removing the headlight. To remove the headlight, undo the clips (2x at the top, 1x on the side and 1x at th bottom). 6 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Installing the indicator lights cont: Unplug the indicator to expose the wiring Turn the lights on and test the connections to identify which wires should connect with which Connect the wiring kit to the wiring harness using wire taps or solder TIP: Try out the LED indicator lights before you install the bullbar YELLOW: INDICATOR WHITE: EARTH BLACK: PARK Once completed, position wiring under and behind the headlights 7 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
PREPARING THE BULLBAR Preparing the bullbar: Place rectangular (two wholed) rubber washers onto the bullbar mounting bolts Please note: this may have already been fitted for you Ready to install the TUFF bullbar Installing the TUFF bullbar: Place the bullbar onto the brackets. Please note: for safety reasons, this is a two person job Secure the bullbar in place and loosely position the bolts ready to align and tighten, using the 16mm flat washers and 16mm Nylock nuts 8 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Installing the TUFF bullbar: Align the bullbar with the square (Gap should be approx. 63mm with a 5mm tolerance either way) Make sure that the wings follow the line of the vehicle. Once alighed, tighten all bolts TIP: tightening the bottom bolts moves the wing of the bullbar up. Tighten the top bolt moves the wing down. Please make sure all bolts are tight! CUTTING THE BUMPER THE TOP HALF OF THE ORIGINAL BUMPER HAS TO BE PREPARED TO BE CUT AND RE-FITTED TO THE VEHICLE THERE WILL BE A 5/10MM GAP BETWEEN THE BULLBAR AND THE BUMPER WE DO THIS BY MEASURING SIX MEASUREMENTS FROM THE BULLBAR TO THE CAR BODY POSITIONS THREE EACH SIDE (SUBRACT 20MM FROM THESE MEASUREMENTS) Preparing to cut the bumper: Ist measurement: Measure the verticle distance beteen the bullbar and the end of the flare arch 9 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Preparing to cut the bumper: 2nd measurement: Measure the verticle distance just outside the of the headlight to the bullbar Preparing to cut the bumper: 3rd measurement: Measure the verticle distance just under the inside of the headlight to the bullbar TIP: write these measurements on a piece of masking tape and stick onto the bumper, ready to measure the bumper for cutting 10 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Preparing to cut the bumper: Mark all six measurments (1 st, 2 nd and 3 rd from above on each side) on the bumper (less a maxiumn of 20mm with a minumn of 10mm, to accommodate a gap between the bumper and bullbar) Ist measurement from above place masking tape to measure the bumper Using making tape and your measurements, run the tap (less a maxiumn of 20mm with a minumn of 10mm, to accommodate a gap between the bumper and bullbar) along the bumper ready to cut Cut along the masking tape with a Jigsaw or other cutting tool Bumper has been cut and is now ready to be trimmed and neatened Try fitting the bumper back in and mark with masking tape the areas needed to be trimmed and neated Using your gap (maxiumn of 20mm with a minumn of 10mm) trim the bumper up with a Linisher or other sanding tool to neaten the bumper cut. Please make sure the end bumper looks neat 11 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Preparing to cut the bumper: Once the bumper is ready, try fitting it back to the vehicle. You may need to trim it if it s not fitting evenly Once the bumper is in, place the grill back onto the vehicle (don t forget the bottom clips at the bumper area) TIP: Place clips into grill sides to position back onto the vehcile Secure original clips back on and tighten the original nuts at the top of the grill Secure the guard to the bumper/vehicle 12 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
PREPARING THE STABILISERS Preparing the stabilisers: Teck screw plastic mud flaps to the bullbar or support using large washers supplied. Trim flap if necessary Connect 25 x 25 RHS Stabiliser rod between the bullbar and the bracket Mark out the wholes in the RHS Stabiliers to be drilled Using two 10x50mm bolts, nuts and washers each side Last step; fit the number plate using the 3mm bolts and nuts supplied and position and fit the indicator/park lights into the bullabr 13 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E
Job compeleted! PLEASE DON T HESITATE TO CALL US ON 1300 BE TUFF (1300 23 88 33) IF YOU HAVE ANY PROBLEMS WITH FITTING BEST REGARDS THE TUFF TEAM! 14 P a g e T U F F B Y N A M E, T U F F B Y N A T U R E