INSTALLATION

GUIDE

INSTALLATION GUIDE

BOCAR WINCH BULLBAR - BPEPWBRAN15

Suits: FORD RANGER 2015+ (PXII & PXIII)

http://www.bocar.com.au/products/Bullbars/BPEPWBRAN15

4/1/2020 Page 2 of 13

Important Notes:

• Read instructions completely before commencing fitment.

• Additional fitting kits may be required for vehicles fitted with parking sensors, Radar, winch etc. Consult

website or retailer.

• (a) Do not attach VFPS to the vehicle using anchorages not intended for this purpose (e.g. engine mountings

bolts).

• (b) Do not use this product for any vehicle make or model, other than those specified by the VFPS manufac-

turer.

• (c) Do not remove the plaque or label from the VFPS.

• (d) Do not modify the structure of the VFPS in any way.

Bolt tensions Dia. (mm) Nm

All bolt tensions are as follows unless otherwise specified.

5 5

6 9

8 22

10 44 12 77

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ITEM PART NAME QTY PART NO.

1 BOCAR RANGER15 BUMPER 1 BOCB0012

2 BOCAR RANGER15 BAR MOUNT 1 BOCB0019

3 CLAMPING ANGLE RH 1 BOCB0022

4 MIRROR_CLAMPING ANGLE RH 1

5 CHASSIS BRACE PLATE 2 BOCB0023

6 SPACER PLATE 4 BOCB0024

7 CHASSIS MOUNT PLATE RH 1 BOCB0021

8 MIRROR_CHASSIS MOUNT PLATE RH

1

9 BOCAR_PX2 CENTER GUARD 1 BOCB0025

10 BOCAR_PX2 WING GUARD 1 BOCB0026

11 MIRROR_BOCAR_PX2 WING GUARD 1

*12 BOCAR LOGO STICKER 1

13 BOCAR INDICATOR 2

14 INDICATOR AND FOG 2 BOCG0002

15 ISO 4762 - M5 X 20MM - 20N - SOCKET HEAD CAP SCREW

20

16 M5 FLANGE NUT 20

17 M5 SPRING WASHER 20

*18 WARNING LABEL 1

ITEM PART NAME QTY PART NO.

19 M6 CAGE NUT 12

20 M6 SPRING WASHER 12

21 M6 X Ø12.5MM FLAT WASHER 12

22 M6 X 1.0 X 20MM HEX HEAD BOLT 12

23 M8 X 1.25 X 30MM HEX BOLT 2

24 M8 X 1.25 NYLOC NUT 2

25 M8 X Ø19 MM FLAT WASHER 4

26 M10 X 1.25 X 35MM HEX HEAD SCREW

16

27 M10 X 1.25 NYLOC NUT 16

28 M10 X Ø30MM FLAT WASHER 32

29 M12 X 1.25 X 40MM HEX HEAD SCREW

4

30 M12 SPRING WASHER 4

31 M12 X 1.25 X 30MM HEX BOLT 8

32 M12 X 1.25 NYLOC NUT 12

33 M12 FLAT WASHER 28

34 M12 X 1.25 X 25MM HEX BOLT 4

*35 PARKING SENSOR HOLE PLUGE 6 BOCG0015

36 BOCAR RANGER BUMPER TRIM 1

Note : *** Item 12, 18 & 35 are fitted by factory. ***

ITEM IMAGES

1

2

3, 4

5

6

7, 8

9

ITEM IMAGES

10,

11

*12 1 x BOCAR LOGO STICKER

13

14

15 20 x ISO 4762 - M5 X 20MM

SOCKET HEAD CAP SCREW

16 20 x M5 FLANGE NUT

17 20 x M5 SPRING WASHER

*18 1 x WARNING LABEL

19 12 x M6 CAGE NUT

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ITEM IMAGES

20 12 x M6 SPRING WASHER

21 12 x M6 X Ø12.5MM FLAT WASH-

ER

22 12 x M6 X 1.0 X 20MM HEX HEAD

BOLT

23 2 x M8 X 1.25 X 30MM HEX BOLT

24 2 x M8 X 1.25 NYLOC NUT

25 4 x M8 X Ø19 MM FLAT WASHER

26 16 x M10 X 1.25 X 35MM HEX

HEADSCREW

27 16 x M10 X 1.25 NYLOC NUT

28

32 x M10 X Ø30MM FLAT WASHER

29 4 x M12 X 1.25 X 40MM HEX

HEAD SCREW

30

4 x M12 SPRING WASHER

31

8 x M12 X 1.25 X 30MM HEX BOLT

ITEM IMAGES

32 12 x M12 X 1.25 NYLOC NUT

33

28 x M12 FLAT WASHER

34

4 x M12 X 1.25 X 25MM HEX BOLT

*35

6 x PARKING SENSOR

HOLE PLUGE

36

BOCAR RANGER BUMPER TRIM

Note : *** Item 12, 18 & 35 are fitted by factory. ***

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ADDITIONAL PART OPTIONS (Purchased separately)

No. ITEM NAME PART NUMBER IMAGES

1 LED Foglamp Set (BOCAR)

BPEPLEDFOG

(4280300024)

2 RADAR MOUNT KIT PXII

:Required on PX2 model with Radar fitted

BPEPKITRAD2

(42803000028)

3 RADAR MOUNT KIT PXIII

:Required on PX3 with Radar fitted

BPEPKITRAD3

(42803000029)

4 NUMBER PLATE MOUNT HINGED

:Required on PX3 with Radar and winch

:Optional when winch fitted. Increased airflow.

BPEPKITLP01

(42803000030)

5 Parking sensor mount kit

:Required on vehicles with front sensors. Match vehicle. Purchase both kits if 6 needed.

BPESENKIT4

BPESENKIT2

Contains 4 sensor housings

Contains 2 sensor housings

6 WIRE HARNESS KIT

:Required if vehicle not pre fitted with foglights

BPEPLEDFOGWIRE

(4280300025)

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1. Disconnect any bumper lights. Remove and retain factory bumper bar, grill assembly, intrusion beam, outer bumper mounting plastics and factory protection plate from un-der radiator.

2. Remove parking sensors and wiring from bumper if fitted. Take notes of position and plug orientation of all sensors.

3. Trim bumper mounting plastic as shown, de-burr and clean edges then refit to vehicle.

TRIM LINE

REFIT THIS TO VEHICLE

LHS SHOWN

4. Cut out templates supplied and attach to

bumper.

5. Mark trim line as shown, then cut bumper

and de-burr edges. PXII will require cutting

of center grille across same feature line.

MARK TRIM LINE ON FEATURE

EDGE LOCATION

TEMPLATE

6. Refit trimmed bumper with grill to vehicle as

shown. Grille may be fitted later on PX3 to

improve access to bar fastening bolts if

winch and or radar is installed.

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7. 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 with nuts on inside.

THESE TWO HOLES ALIGN

RHS SHOWN

8. Align the holes in the inner chassis nut-plate with the holes in the chassis rail.

10. 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 bolts (2) • M12 spring washers (2) • 1/2” x Ø1-1/4” flat washers (2)

Repeat steps 7 to 10 for the opposite side of the vehicle.

RHS SHOWN

9. Spacer washers fit between chassis and outer chassis support.

RHS SHOWN

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11. Install chassis mount (Winch frame) on the vehicle chassis rail ends, centralize, then tighten it in place, using original bolts from intrusion beam in original position as well as:

• M10 x 1.25 x 35mm hex bolts (8) • M10 x Ø30mm Flat Washers (16) • M10 x 1.25 Nyloc Nuts (8)

13. Fit clamping angle bracket to inboard face of the chassis mount with using :

• M12 x 1.25 x 25mm hex bolts (2) • 1/2 ” x Ø1-1/4 ” flat washers (4) • M12 x 1.25 Nyloc Nuts (2) Align slots before tightening.

RHS SHOWN

RHS SHOWN 12. Secure the chassis support bracket to the chassis mount with using :

• M10 x 1.25 x 35mm hex bolts (3) • M10 x Ø30mm Flat Washers (6) • M10 x 1.25 Nyloc Nuts (3)

Repeat steps 12 to 13 for the opposite side of the vehicle.

14. If winch is being installed, refer to winch installation instructions.

For parking sensor, radar and fog-lamp please refer to supplied instructions.

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15. Fit bull bar to bar mount, then loosely se-cure it in place with using :

• M12 x 1.25 x 30mm hex bolts (4) • 1/2 ” x Ø1-1/4 ” flat washers (8) • M12 x 1.25 Nyloc Nuts (4)

RHS SHOWN

RHS SHOWN 16. Align the bull bar to vehicle so that the

guard clearance is 20 to 25 mm, and wing is aligned with wheel arch, then tighten all bolts.

17. Once bull bar is aligned with vehicle and bolts tightened, drill Ø8.5 mm through pin-ing hole between bar mount and clamping angle as indicator, and then secure with using :

• M8 x 1.25 x 30mm hex bolt (1) • M8 x Ø19mm Flat Washers (2) • M8 x 1.25 Nyloc Nut (1)

Repeat step 15 for the opposite side of the vehicle.

Repeat step 17 for the opposite side of the vehicle.

RHS SHOWN

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18. Install lamps to bullbar. Indicator from front and fog from rear using supplied fasten-ers. Patch Indicator/park wiring into vehi-cle lamp wiring loom. Plug in foglamps. Check all light operate correctly.

Fit plastic lamp housing to bull bar as shown, and secure it using :

• M5 x 20mm Socket Head Bolts (10) • M5 Flange Nuts (10) • M5 Spring Washer (10) • Bocar Indicator

RHS SHOWN

Repeat steps 18 to 19 for the opposite side of the vehicle.

19. Fit wing guard to bull bar, and secure it with supplied fasteners, then neatly trim plastic guard liners to suit. Use zip ties to secure guard liner if required.

• M6 x 1.0 x 20mm Head Bolts (4) • M6 Cage Nuts (4) • M6 Ø12.5 mm Flat Washers (4) • M6 Spring Washer (4)

RHS SHOWN

20. Fit center guard to bull bar and re-fit the OE underbody guard in under position of the center guard, then secure it with using supplied fasteners.

• M6 x 1.0 x 20mm Head Bolts (4) • M6 Cage Nuts (4) • M6 x Ø12.5 mm Flat Washers (4) • M6 Spring Washer (4) • M10 x 1.25 x 35mm Head Bolts(2) • M10 x 1.25 Nyloc Nuts (2) • M10 x Ø30mm Flat Washer (4)

OE underbody guard

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21. Fit the number plate to bull bar.

• In upper or lower mounting position (Do not cover Radar with number plate)

• If winch and central radar is fitted it is rec-ommended to attach number plate to the optional hinged mount. See below.

Upper position

Lower position

Note : For Ford Ranger PXIII installation, the number plate mount hinged is referred to fit as shown.

22. Ensure that all of fasteners are fully tight-ened to bull bar with vehicle.

23. Provide ‘product care and information’ sheet on next page to customer.

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Corrosion Protection Tips –

• Going on an adventure! Be sure to rinse all areas and remove any sand, mud or de-

bris in and around any areas that can catch this type of matter.

• Going to the beach! Make sure to rinse all salt water and sand off. To improve the

longevity and life of this product, be very thorough with fresh water and a sponge.

Nuts and Bolts –

• At Bocar we do not get to experience your adventures or service your vehicle, so be

sure to regularly check all nuts and bolts, especially after a large Off Road trip or

regular use on Civil, Mining and construction sites.

Love Care and Attention –

• Planning to drive in a salty environment! If so, spray all fasteners with a Lanolin or

WD40 protectant for longevity.

• If you spot a deep scratch touch up with paint to help prevent rust and inhibit corro-

sion.

• Regularly Wash & Dry the product the same as your vehicle using normal car wash

to maintain appearance.

Modifying Your Vehicle –

• Modifications to your vehicle involves some risk, all care has been taken to test driv-

er aids so they work as the vehicle manufacturer intended. There may be the need to

re-calibrate after fitment by the vehicle manufacturer. As the owner of your vehicle

the driver remains, responsible for the vehicle at all times when driving.

• Check and re-tighten any components after your first adventure. Regular up keep will

help you get the most out of your Genuine Bocar Product and your pride and joy.

Warranty –

• 2yr/40,000km. Warranty conditions apply. Our goods come with consumer guaran-

tees that cannot be excluded under the Australian Consumer Law. Our warranty does

not limit and may not exceed your rights under those guarantees. For full details on

our warranty please refer to www.bocar.com.au/warranty

PRODUCT CARE & INFORMATION

Customer copy