BULL BAR
1
Bull Bar
4
12-1.75mm x 35mm Hex Bolts
1
Driver/Left Frame Mounting Bracket
8
12mm Lock Washers
1
Passenger/Right Frame Mounting Bracket
12
12mm x 32mm OD x 3mm Flat Washers
2
50mm x 90mm x 9mm Spacer Plates
6
12mm Hex Nuts
2
12-1.75 x 35mm Bolt Plates
1
5mm x 25mm Screw
2
12-1.75mm Nut Plate
2
5mm x 10mm OD x 1mm Flat Washers
2
12-1.75mm x 50mm Hex Bolts
1
5mm Nylon Lock Nut
Driver/Left Side Frame
Mounting Bracket
Passenger/Right Side
Frame Mounting Bracket
(2) 12mm Bolt Plates
(2) 12mm Nut Plates
50mm x 90mm Spacer Plates
2011 FORD EXPLORER
PARTS LIST:
PROCEDURE:
1. REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT. READ INSTRUCTIONS
CAREFULLY BEFORE STARTING INSTALLATION. ASSISTANCE IS RECOMMENDED. CUTTING
IS REQUIRED. DRILLING IS OPTIONAL.
2. Start installation under the driver side front of the vehicle, (Figure 1). Insert (1) 12mm Nut Plate into the
large oval opening in the bottom of the frame channel and slide it forward in the frame with the flat side
down against the frame channel and welded nut up, (Figure 2B). Line up the threaded hole in the Nut
Plate with the factory hole at the front of the frame, (Figure 2A). Next, insert (1) 12mm Bolt Plate into
the large oval opening and center the threaded bolt in the oval hole, (Figure 2C).
3. Select the driver side Frame Mounting Bracket. Hold the Mounting Bracket up in position against the
bottom of the frame and over the threaded bolt on the Bolt Plate, (Figure 3A). Secure the Bracket to
the Bolt Plate with (1) 12mm Flat Washer, (1) 12mm Lock Washer and (1) 12mm Hex Nut. Leave
hardware loose at this time. Slide (1) Spacer Plate between the frame channel and the Bracket, (Figure
3A & 3B). Insert (1) 12-1.75mm x 35mm Hex Bolt with (1) 12mm Lock Washer and (1) 12mm Flat
Washer through the hole in the Bracket, Spacer Plate and into the Nut Plate, (Figure 4). Snug but do
not tighten hardware at this time.
4. Move to the passenger side of the vehicle. Determine if the vehicle is equipped with the factory installed
fresh air inlet in the plastic bumper cover.
a. Vehicles without air inlet: Repeat Steps 2 & 3 for passenger side Frame Mounting Bracket
installation, (Figures 5A, 5B & 5C).
b. Vehicles equipped with air inlet, (Figure 6): Repeat Step 2 to install the 12mm Bolt Plate and
12mm Nut Plate. Hold the Frame Bracket in the approximate position over the Bolt and Nut
Plates. Mark the outline of the Bracket onto the mounting tab on the plastic air inlet, (scoop),
(Figure 7). Remove the inlet and place it on a clean, stable work surface. Use a hacksaw to cut
the required material from the mounting area on the inlet. Check the fit often and trim material
away as necessary. Do not cut off the mounting tab. Carefully pry off the metal clip and move it
as indicated in Figure 7 or drill a 1/4" hole through the top and bottom of the scoop and replace
the clip with the included (1) 5mm x 25mm Screw, (2) 5mm Flat Washers and (1) 5mm Nylon
Lock Nuts. Do not over-tighten 5mm hardware. IMPORTANT! Any cutting tool may break or
shatter. Government regulations require safety glasses & equipment at all times when cutting.
Install the Frame Bracket as described in Step 3. NOTE: Complete the Bull Bar installation
before reinstalling the plastic air inlet scoop.
Page 1 of 5 6/17/11 (DP)
2011 FORD EXPLORER
NOTE: Before proceeding, it may be considerably easier to remove the plastic bumper cover to
cut the slots for the Bull Bar. However, on some models, the bumper cover may be held in place
on the ends with factory rivets making removal and reinstallation extremely difficult and best done
by a professional, (Figure 6). Determine if the bumper is held in place with rivets, (visible from the
outside-below the fog lights), before attempting to remove the bumper cover.
Insert Nut Plate into
opening and line up with
forward hole in frame
(Fig 1) Driver side pictured from below
Fig 2A
Fig 2B
Fig 2C
Front
Front
Up
Front
5. Measure the width across the Bull Bar, (mounting tab to mounting tab appx. 36-1/4" to 36-1/2"). Use a
tape measure to locate the middle of the plastic bumper cover, (Figure 8). Mark the mid point on the
back of the bumper. NOTE: You can also locate the mold mark on the back of the bumper to determine
the mid point. Place a layer of masking tape on the back of the bumper cover in front of the Frame
Mounting Brackets. On the driver side, draw a vertical line on the tape 18" out from the middle of the
bumper. Draw a second vertical line 19" out from the middle, (Figure 8). Repeat this Step on the
passenger side of the bumper cover.
6. Use the location of the previously installed Frame Mounting Bracket to determine where to draw the top
and bottom horizontal lines, (Figure 9). Carefully cut this area out of the bumper cover with a sharp
knife or hacksaw, (Figure 10). IMPORTANT: Do not cut through the top or bottom edge of the bumper
cover. Only remove enough material to clear the mounting tabs on the Bull Bar.
7. Reinstall the bumper cover if removed as described in Step 4.
8. With assistance, position the Bull Bar onto the inside of the Mounting Brackets. Attach the Bull Bar to
the Mounting Brackets with (4) 12mm x 35mm Hex Bolts, (8) 12mm Flat Washers, (4) 12mm Lock
Washers and (4) 12mm Hex Nuts, (Figure 11). Do not tighten at this time.
9. Level and adjust the Bull Bar and tighten all of the hardware.
10. Reinstall the air inlet, (scoop), removed in Step 4b. Trim scoop to clear Brackets as necessary.
11. Do periodic inspections to the installation to make sure that all hardware is secure and tight.
To protect your investment, wax this product after installing. Regular waxing is recommended to add a protective layer
over the finish. Do not use any type of polish or wax that may contain abrasives that could damage the finish.
For stainless steel: Aluminum polish may be used to polish small scratches and scuffs on the finish. Mild soap may be
used also to clean the Bull Bar.
For gloss black finishes: Mild soap may be used to clean the Bull Bar.
Driver Side installation Pictured
Page 2 of 5 6/17/11 (DP)
BULL BAR
12mm x 50mm Hex Bolt
12mm Lock Washer
12mm Flat Washer
Spacer Plate
Fig 3A
(Fig 5A) Passenger side installation pictured
Fig 4
Fig 3B
12mm Lock Washer
12mm Flat Washer
12mm Hex Nut
Front
Front
Front
Forward
Fig 5B
Fig 5C
BULL BAR
2011 FORD EXPLORER
Driver Side Installation Pictured
Page 3 of 5 6/17/11 (DP)
Passenger Side Installation Pictured
18"
19"
Passenger side
Middle of bumper/spoiler insert location
pictured from back of bumper
Driver side
Fig 8
Fig 7
Front
Do not cut on this side
(Fig 6) Passenger side pictured with air intake
Factory rivets
Air inlet for scoop
(behind bumper cover)
Move metal clip to here (See Dot)
after cutting OR drill a 1/4" hole and
replace the clip with the included:
(1) 5mm x 25mm Screw
(2) 5mm Flat Washers
(1) 5mm Nylon Lock Nut
Illustrations, diagrams and
measurements provided for
example only. It is the installer's
responsibility to determine exact
cuts/modifications to the vehicle
required for proper installation.
BULL BAR
2011 FORD EXPLORER
Page 4 of 5 6/17/11 (DP)
Fig 9
Fig 10
(Fig 11) Driver side installation
pictured with lower bumper removed
Front
Front
Cut as little as possible to clear
mounting tabs on Bull Bar
Trace the location of the top and
bottom of the Frame Bracket onto
back of spoiler and cut out to clear
mounting tabs on Bull Bar
(2) 12mm x 35mm Hex Bolts
(4) 12mm Flat Washers
(2) 12mm Lock Washers
(2) 12mm Hex Nuts
Complete
Installation
Illustrations, diagrams and
measurements provided for
example only. It is the installer's
responsibility to determine exact
cuts/modifications to the vehicle
required for proper installation.
BULL BAR
2011 FORD EXPLORER
Passenger Side Installation Pictured
Page 5 of 5 6/17/11 (DP)
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