ROUGH COUNTRY 921510400 Bronco Sport Bull Bar Installation Guide
- June 13, 2024
- Rough Country
Table of Contents
921510400
Bronco Sport Bull Bar
Thank you for choosing Rough Country for all of your suspension needs.
Rough Country recommends that a certified technician install this system. In
addition to these instructions, professional knowledge of
disassemble/reassembly procedures as well as post installation checks must be
known. Attempts to install this system without this knowledge and expertise
may jeopardize the integrity and/or operating safety of the vehicle. Please
read all the instructions before beginning the installation. Check the kit
hardware against the ‘’Kit Contents’’ list below. If question exist, please
call us @1-800-222-7023. We will be
happy to answer any questions concerning this product. Check all fasteners for
proper torque. Check to ensure for adequate clearance between all components.
Check and retighten wheels at 50 miles and again at 500 miles. Periodically
check all hardware for tightness. Be sure you have all the needed parts and
understand where they go. Also, please review the “Tools Needed” list to be
certain you have the necessary tools to complete the installation.
PRODUCT USE INFORMATION
WARNING
As a general rule, the taller a vehicle is the easier it will roll. We
strongly recommend that seat belts and shoulder harnesses be worn at all
times. Braking performance and capabilities are decreased when significantly
larger/ heavier tires and wheels are used. Do not add, alter, or fabricate any
factory or after-market parts which increase vehicle height over the intended
height of the Rough Country product purchased. Rough Country makes no claims
regarding lifting devices and excludes any and all implied claims. We will not
be responsible for any product that is altered.
NOTICE TO DEALER AND VEHICLE OWNER
NOTICE
Any vehicle equipped with any Rough country product must have the “Warning to
Driver” decal installed on the sun visor or dash. The decal is to act as a
constant reminder for whoever is operating the vehicle of its unique han-
dling characteristics. INSTALLING DEALER—It is your responsibility to install
the warning decal and to forward these installation instructions on too the
vehicle owner for review and to be kept in the vehicle for its service life.
TOOLS NEEDED:
Jack Wheel Chocks
Pry Tool
Needle Nose Pliers
Cutting Tool
T-25 Torx Driver
Metric Wrench/Socket
7mm 10mm
14mm
17mm
18mm| KIT CONTENTS:
Driver Bracket
Passenger Bracket
Bull Bar
20” Light Bar Bracket
Spacer (2)| HARDWARE INCLUDED:
10mm x 25mm Black Bolt (4)
10mm x 35mm Silver Bolt (4)
10mm Washer (12)
10mm Black Flange Nut (4)
10mm Silver Lock Nut (4)
8mm Bolt (4)
8mm Washer (4)
8mm Flange Nut (4)
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Bull Bar Installation
- This installation requires the removal of the front plastic bumper / facia. You do not need to remove the front tires or jack the vehicle up, but it can make things easier. If you decide to do this, refer to the owners manual for jacking in- structions. Always use jack stands under the vehicle. Park your vehicle on a clean flat surface, engage the parking brake and block the rear tires. Save all hardware removed from the vehicle unless otherwise noted.
- Open the hood and disconnect the negative terminal on the battery.
- Under the vehicle you will need to remove the bumper to skid plate hardware (x8) using a T-25 Torx driver. Photo 1
- In each of the wheel wells you will need to remove the wheel liner to bumper hardware (x3) using a 7mm socket. Photo 2
- Use a pry tool to pop out the head of the plastic rivets, and then remove the base of the rivet (x3). Photo 3
- Pull the liner back and look into the opening. Remove the two bumper mount bolts using a 10mm socket. Photo 4
- Remove the headlight hardware using a 10mm socket. Photo 5
- In the passenger side wheel well, disconnect the bumper harness. Photo 6
- Under the hood, disconnect the headlight electrical connector by pressing the release clip and pulling away. Photo 7
- Remove the headlight harness from its retaining clip on the back of the headlight. Photo 8
- Remove the upper headlight hardware using a 10mm socket. Photo 9 / 10
- Under the fender edge there is a clip the will need to be released by using a pair of needle nose pliers. As you pinch the clip, pull the headlight away from the fender enough to release the clip. Photo 11
- Remove the bumper to core support hardware (x6) using a 5mm socket. Photo 12
- Use a pry tool to pop the fender flare off the bumper cover. Photo 13
- Gently pull down on the bumper to release it from the fender. Make sure your headlight clip is still undone. Photo 14
- Once both sides are released, lift the headlights and bumper cover off the vehicle. Shows the vehicle without bumper cover. Photo 15 .
- Lay the bumper cover down and prepare for marking and cutting. Photo 16
- At the corner of the trim ring and block off panel, mark as shown. You will be cutting into the trim ring as well as the block off panel to insure fitment of the brackets. Photo 17
- Drill a 3/8” hole at the top and bottom of the mark. Photo 18
- Use a suitable cutting tool (air body saw was used) to cut out the mark 3/8” wide to each drilled hole. Sand any burrs smooth for a clean look. Photo 19
- On the vehicle, remove the outermost nuts on the lower frame rail using a 10mm socket. You will reuse these. Pho- to 20
- Loosely install the Rough country bull bar bracket to the lower frame mount using the factory hardware. Photo 21
- Install the upper bracket and spacer to the frame using the provided 10mm x 35mm silver bolts, 10mm black washers, and silver lock nuts to the two lower holes in the bumper edge. Torque the upper hardware to 45 ft-lbs and the lower hardware to 5 ft-lbs. Photo 22
- If you opted for the light option bull bar, route your wiring harness along the plastic center rib of the radiator and up to the driver side of the vehicle. Doing this now allows you access before the bumper is installed. Photo 23
- Round light bar optioned kits: Install the light bar brackets to the lights using the hardware provided in the light bar kit. Make sure you install the short bolt going through the bracket bottom hole before installing the bracket to the light using the long bolts. Only snug these so that you can adjust the light later. Photo 24
- Install the assembled light and bracket to the bull bar using the hardware from the light kit. Photo 25
- 20” Light bar optioned kits: Locate the 20” light bar bracket and 8mm bolts, washers and flange nuts. Photo 26
- Install the light bar bracket to the mounting tabs using the 8mm bolts, washers, and flange nuts. Make sure the bracket looks as shown for the light bar to fit properly. Photo 26
- Install the 20” light bar to the bracket using the hardware provided in the light bar kit. Non-DRL light bars may require the use of spacers and longer hardware included in their kits. Photo 27
- Reinstall the front fascia in the reverse order of disassembly making sure the bull bar brackets come through the bumper. Install the bull bar using the 10mm x 25mm black bolts, black washers and black flange nuts. Level the bull bar side to side. Photo 29
- Make sure the bull bar is vertical from the side and has clearance between the bumper cover and the light bar brackets. Torque the bull bar mounting bolts to 35 ft-lbs once you are satisfied with the fitment. Route the electrical to suit. Reconnect the battery negative terminal. Photo 30
By purchasing any item sold by Rough Country, LLC, the buyer expressly warrants that he/she is in compliance with all applicable , State, and Local laws and regulations regarding the purchase, ownership, and use of the item. It shall be the buyers responsibility to comply with all Federal, State and Local laws governing the sales of any items listed, illustrated or sold. The buyer expressly agrees to indemnify and hold harmless Rough Country, LLC for all claims resulting directly or indirectly from the purchase, ownership, or use of the items.
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