Dobinsons BU59-5558 Toyota Tundra 2014-2021 Deluxe Bull Bar Installation Guide

BullBar Installation Guide
Part Number: BU59-5558
Fits: Toyota Tundra 2014-2021

BU59-5558 Toyota Tundra 2014-2021 Deluxe Bull Bar

This BullBar will take aproximately 6-8 hours to install
Dobinsons products should be installed by a qualified installer and it is the installers responsibility to ensure correct fitment.
Dobinsons is not responsible for any damage incurred to the vehicle during installation.

Tools Required

• Spanners and Socket Set
• Allen / Torx Key Set
• Screw Drivers
• Drill with Assorted Drill Bits
• Clip Removal Tool
• Torque Wrench
• Rubber Mallet / Deadblow Mallet
• JigSaw or other plastic cutting tool
• Masking Tape
• Black Paint

Remove OEM Bumper

1. Remove tow hooks and bolts.

2. Remove lower bumper bolts.

3. Remove all lower fender liner bolts. P1.1

4. Remove upper fender liner bolts. P1.1

5. Remove the lower fender liner clips. 6.

6. Remove the front grill by removing the bolts and clips on the upper part of the grill, then gently pulling the lower edge. P1.2

7. Temporarily remove the grill support bracket, unbolt two nuts on each side from studs. P1.3

8. Remove all fasteners from the top of the bumper.

9. Remove the side trim pieces (remove both pop clips under each head light), then gently pull away from the vehicle.

10. Remove all remaining bolts from lower bumper sec on.

11. Unplug Fog lights and parking sensors if installed.

12. Remove the lower bumper.

13. Remove the crash bar. (Do not discard frame nuts as these will be re used later.) P1.4

14. Remove (4) frame plas c covers above ssway bar.

15. Remove plas c bumper retainer, located on each fender. P1.5

16. Reinstall the grill support bracket, previously removed in step 7.

17. Using a cu ng tool, cut the lower sec on of the plas c bumper retainers off. Reinstall. P2.1

18. Using the provided template, cut the bumper trim pieces, deburr and apply bumper trim pieces, deburr and apply edge trim. we recommend the ini al cut to be done with a 10mm buffer to prevent excessive cu ng of the OEM bumper. P2.2

19. Refit the bumper trim pieces to the vehicle.

20. Mask the lower sec on of the grill, mark using the p mark using the provided measurements. (TIP: Use center line measurement). May require further trimming depending on chosen winch. P2.3

21. Do not re install the grill yet. Winch Cradle Installation

22. Insert the clevis nut through the rectangular hole on the frame.
    NOTE: the threaded hole is offset on the clevis, insert with the threaded por on toward the outside of the frame. P2.4

23. Insert and fasten the stud un l it is flush with the frame studs.

24. Mount the winch cradle and loosely fasten using the 4 OEM studs on each side and the central stud previously installed. P2.5

25. Center the winch cradle to the vehicle, Torque all bolts. M12 – 77Nm / 56.8ft/lb M10 – 62Nm / 49.5ft/lb

26. If in26. If installing a winch, do so now.

27. With the help of a mate, carefully li the Bull Bar Shell and mount to the winch cradle. Loosely fasten the Bull Bar Using 6 x M12 Bolts, oversized flat washers, spring washers and flange nuts.

28. Level the Bull Bar Shell to the vehicle bodbody, ensure to leave an 8-10mm gap between the Bull Bar and the body. Tighten ll snug.P3.1

29. Ensure the Bull Bar is centered to the vehicle, if not, remove the bull bar and center the winch cradle.

30. Once happy with Bull Bar placement, torque all M12 bolts. M12 – 77Nm / 56.8ft/lb

31. Install fog light surround and op tonal fog lights (wiring guidelines on the following page).

32. Test to make sure all lights are funconing correctly before moving on to the the next step. Bash Guard Installation

Bash Guard Installation

28. Insert 4 cage nuts to the lower-middle part of the Bull Bar.
29. Fasten the front of the central bash guard to the Bull Bar. P3.2 30. Fasten the rear part of the central bash plate tto the sides of the winch cradle with a bolt, nut and washers. (This is height adjustable to suit your specific skid plate).
31. Insert 5 cage nuts to the lower part on each side of the bumper. P3.3 32. Fasten the side bash plates to the bull bar.

33. Fasten the rear part of the side bash plates tto the sides of the winch cradle with a bolt, nut and washers.
34. Torque all bash plate bolts. Torque bash plate bolts to 22Nm / 16.25ft/lb

Wiring Guidelines – Zenith Bullbars
Dobinsons Zenith Bullbars are supplied with LED indicator/Parker lights. Available extra are DRL’s and Fog Lights.
Indicator/Parker Lights
Use a multimeter to locate the existing positive and negative lights for the existing vehicle headlights park light circuit and indicator circuit and using the scotch-locks or soldering, connecting directly to the existing vehicle wiring circuit using the diagram on the following page.
NOTE: For some later model Toyota 150 prado vehicles the Parker lights must be wired using a relayed wiring loom (a modified spotlight/foglight loom or similar) as the vehicle headlight wiring will not work — see the specific instructions with the bulbar for more information on these.

Fog lights (optional extra)

Install the fog lights into the bulbar before installing the bulbar. Use a sharp knife and from the back side of the bar carefully cut the retaining tabs on the plastic cover insert and remove. Install the fog light with the breather at the top. Use the 6mm bolt and washer, then place the tooth washer between the light insert mount and light, then the flat washer and nyloc nut as seen on the diagram below.

Wire the fog lights as per the diagram on the following page. There are 2 switches provided —a prewired universal single large din switch and a small universal switch. Dobinsons have some other plug and play switches available that are vehicle specific. Ashdown Ingram and similar electric wholesalers also have these switches —Check the wiring diagrams on the packet of the switch first to ensure they will plug in and work correctly or need wiring altered. A round universal switch is also supplied — install the switch by drilling a xxmm hole and altering the wiring as shown.
DRL Lights (optional extra)
Install the DRL lights into the bulbar before installing the bulbar. Use a sharp knife and from the back side of the bar carefully cut the retaining tabs on the plastic cover insert and remove. Attach with 2 x screws supplied (there are left and right sides). Wire the lights as per the diagram on the following Page — the switching wires can be wired to ignition for lights to operate when vehicle is running, or to parker / low beam for operation when the lights are turned on only. Use screws or good quality double sided tape (such as 3m brand) to fix the control box to the vehicle body.

FOG LIGHT WIRING DIAGRAM SERIES 2

Toyota Tundra Template
If prinng from PDF, Be sure to turn off scaling. Confirm scale is correct before proceeding.

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