XROX Steel Tube Bar
More of a detail list of the install combinned with some of the instruction so kindly given to me.
1. Remove the nudge bar
• Important retain the OEM bolts that are at the rear of the mounting bracket
• I placed them back in with a couple of turns so I new were they were.
2. Remove the grill – This will allow more access and visial to align the bar.
• Remove the two screws on the left and right of the grill
• I placed a screw driver beween the bumper and the bottom of grill to release the tabs.
• Use a blade screw driver to pop the insert plugs be carefull you will need them to go back in
• Remove the grill.
3. Remove the bumper from vehicle.
4. Remove the plastic clip that retains the OE plastic bumper between the light and wheel arch on both sides.
• These are tricky I removed most of the screws from the plastic inner guards to get to them
5. Remove both head lights then remove the black plastic brackets from the bottom of the light housing and discard the bracket.
• I didn’t disconnect the light, once I removered the screws there was enough room to get a stuby Phillips head in there and undo them.
6. Sit the Hilux mounts to the chassis. 2) M12x40x1.25 bolts, thick flat washers, s/washers, 2) M10x100 bolt, Camp Plate, Tube Spacer, flat washer, s/washer, Nuts. 2) M10x1.25 Nuts, flat washer, s/washer per side.
• I used the OEM bolt from the nudge bar to hold it in place while I worked on all the other bolts
• Insert the crush tubes in the chassis, I had to grind them a little to make them fit and the only way I could get them in was to insert them from the front hole of the chassis and twist them in to align them with the hole, a screw driver and rubber mallet helped, then insert the 100mm bolts
• Don’t tighten any thing up as it all has to be loose to be able to align the bar
7. Fit the assembled bar to the mounts and align the bar to the vehicle. 4) M12 bolts, flat washers, s/washers and nuts per side. Tighten all bolts.
• Insert the rest of the bolts these linned up realy well as there is a heap of play for aligning the bar
• I used a trolly jack and a stand to support the bar as close to the position as possible
• Nip up the bolts holding the bracket
• Then nip up the bolts holding the bar, keep an eye on the alignment.
8. Fit the rubber pinch weld to the front edge of the bash plate and fit the bash plate to the two inner studs on the front of the chassis, then fit the bottom of the plate two M8 bolts that secures the lower plate on the front end. (Note: The front edge of the bash plate fits on the inside edge of the xrox bar).
• This is still on my list of things to do when I get the bash plates I may have to get some any sugestion as to what works best with this bar would be good
9. Refit the grill
• I refitted an aftermarket TRD grill so the top lined up to all the OEM points though I had to drill out the lugs that would normaly click into the OEM bumber and just cable tied them to the OEM points on the lights and the centre bracket that holds the horn relay.
• I had to get some compression rubber from Clark Rubber to infill the gap between the bonnet and the new TRD grill, used double sided tape, not the white stuff but the industrial red stuf its actualy clear and is designed for exsternal use.
10. The plastic Inner gaurds need trimming.
• Not difficult I used a straight edge and followed the line of the Xrox and marked it with a crayon then nipped it of with a dremell type tool mines a cheap ozito but dose the job.
11. Spot Lights
• For know I have wired them to the fog lights that were removed including the led ones you can see down lower, but I change this so the led will work on the fog light switch and the spotties will have a dedicated rocker in the cab, I think I will pull the feed from the high beams so they will only work if the high beams are on and at least when oncoming traffic is coming I can drop the high beams of and the spotties will go off, that’s for another week end
12. I hit the under neath with a can of matt black just to tidy everthing up, even the wiper bottle cant believe how low that thing hangs down, I should have hit the underside of the driving lights aswell, as you can see the white plastic from the sides of the bar, Imposible now that the bar is on, I may try some black garden edging as an infill, will let you know how I go.
13. Fit the number plate with the existing screws.
so playing beer wench at the moment will start on it again in the morning,
