R O A D M A S T E R, I N C.



Similar documents
R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C.

R O A D M A S T E R, I N C.

FRONT BUMPER INSTALLATION INSTRUCTIONS DODGE / MERCEDES SPRINTER

Installation instruction do88 Intercooler for Volvo S40 / V50 / C30

INSTALLATION INSTRUCTIONS Air Spring Kit Ford F250/F-350 Single Wheel 2WD Ford F350 Dually 2WD IMPORTANT NOTES

INSTALLATION INSTRUCTIONS Air Spring Kit Ford F250 Single Wheel 4WD Ford F350 Dually 4WD (2011 F350 Single Wheel 4WD use p/n 6113)

LG G5 Chassis Brace Gen 5 Camaro THE MOST POWERFUL HEADERS ON THE PLANET Brought to you by LG Motorsports

MGB Chrome Bumper Conversion

WARNING TO END USER, INSTALLER AND SELLER OF THIS PART!

LIFT-505. BMF Lift Kit. Yamaha Drive Gas or Electric. Installation Instructions

BUGGY SETUP GUIDE. Volume GOKARTSUSA GY6 150, CN250. Buggy Setup Guide

Solstice/Sky Water Pump Replacement

VW GOLF Mk4 TDI FRONT MOUNTING INTERCOOLER INSTALLATION INSTRUCTIONS

F250 6 RADIUS ARM KIT

Figure 2 The fan and shroud also needs to be removed for access to the four a/c compressor bolts and removal of the compressor from the top.

Installation Instructions GOOSENECK MOUNTING KIT Chevrolet/GMC 1500/2500/3500 All except 4-door Crew-Cab

Installation Instructions: (Part # SB76880) XRC Armor Front Fender Kit

Equipped with AEM Dryflow Filter No Oil Required! INSTALLATION INSTRUCTIONS PART NUMBER DS BMW 335i 3.0L

»Product» Safety Warning

TJ Quick Disconnect Instructions

Installation Instructions

AWE Tuning Air/Air Intercooler Kit for Audi 2.7T

POWER LOCK KIT GENERAL INSTALLATION -J04427 REV Kit Number. Models. Additional Parts Required. Kit Contents

M-2004-MBA Brake Duct Kit 2013 BOSS 302, Mustang GT and California Special INSTALLATION INSTRUCTIONS

TOYOTA Tundra BACK-UP CAMERA SYSTEM Preparation

KEYLESS ENTRY UPGRADE SECURITY SYSTEM for 2004 TOYOTA HIGHLANDER

Ford F-250 / /2 Coil Kit. Ford F-250, F Part#:

TOYOTA TUNDRA 2015 Billet Grille w/led DRL

4.5 LIFT BOX KIT DODGE RAM 2500 & WD DIESEL ENGINE ONLY FTS23031

ReadyLift (Part# ) Strut Extension, Installation Instructions Toyota Tundra New Body Style 2WD & 4WD

16 April F Dodge Adjustable Track bar with Relocation Bracket 1

Gripper Kit for the Boe-Bot Robot (#28202)

2003 Audi A4. AUDI' '3.0L V6 - AVK Engine - A4 & A6

Owner s Manual Read and keep this manual. Patents World Wide

Front brakes (FN- 3), servicing

WARNING! REQUIRED TOOLS & SUPPLIES: HIGH VOLTAGE

Installation Guide 2010 BMW S1000RR Full Exhaust System

Installation Guide for the TJ LCG PRO Suspension System (Low Center of Gravity) Available 4 or 5

TOOL SVC NUMBERS: , SVC CONTENTS ITEM QTY DESCRIPTION PART NUMBER 1 1 CUTTING TOOL EXTRACTION TOOL/PART#

Instrument panel. Volkswagen Touareg - Instrument panel. Special tools, testers and auxiliary items required. Release lever T10039

2003 ACCORD - Automatic Transmission Removal

Table of Contents WARNING SYMBOLS AND DEFINITIONS

JK 2.5 Spring Lift Part # # #

9,000lb capacity 4 Post Lift Installation Manual

GENERAL MOTORS 3/4 &1 TON RT3 UNDERCARRIAGE MOUNTING INSTRUCTIONS (PART NO. LTA04767B)

Volkswagen Jetta, Golf, GTI 1999, 2000 Brake System 46 Brakes - Mechanical Components (Page GR-46)

BULB REPLACEMENT BROCHURE

INSTALLATION INSTRUCTIONS FOR VW MK5

Service Manual Supplement

INSIDE ENGINE COMPARTMENT TOYOTA AIR CONDITIONING ENGLISH EUROPE,GENERAL,AUSTRALIA

Rating when used as a weight carrying hitch without spring bars:

Range Road RR Series Semi-Automatic Firewood Processor. Crated Unit Assembly Manual

READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS PRIOR TO INSTALLATION OF SYSTEM AND OPERATION OF VEHICLE.

Thank You For Choosing. INSTALLATION INSTRUCTIONS Portal Gear Hubs Polaris RZR 800. (installation performed on 60 Model) (Right) (Left)

SELF-STEERING AXLE TABLE OF CONTENTS

MKV Golf GTI Rear Brake Service - Replace Pads and Rotors

INSTALLATION INSTRUCTIONS MULTI-MOUNT KIT Part Number: Application: Warn HP PowerPlant P/N 71800

2003/2004/2005 TOYOTA COROLLA

PRODUCT: WASHER / WASHER-DRYER COMBO MODEL: AW 120 / AW 122 / AW 125 AWD 120 / AWD 121 / AWD 129

INSTALLATION GUIDE. APPLICATION LENGTH MODEL YR PART # Bestop PART #

COOPER S PULLEY UPGRADE KIT INSTALLATION INSTRUCTIONS PART NUMBER NME5011

READ CAREFULLY - FAILURE TO FOLLOW INSTRUCTIONS AND SAFETY RULES MAY RESULT IN SERIOUS INJURY

SECURITY SYSTEM SMART SIREN KIT

XL PREMIUM OIL COOLER KIT

REMOTE AUXILIARY AIR CONDITIONING SYSTEM AND AIR DISTRIBUTION

Tooling List 17mm Socket 17mm Wrench 24mm Wrench 26mm Wrench 3/8 Drive Ratchet Torque Wrench

- power windows - alarm system - electric door mirror control - door warning light - central locking - seat memory

Rack Installation Instructions

Check for deteriorated, shifting or missing tie-down pads. Replace if needed.

Installation Instructions

MEASURING WHEEL ALIGNMENT

PERFECT FIT SERIES IN-DASH HEAT/ COOL/ DEFROST 1967 CHEVROLET IMPALA

Casio 9860 Self-Guided Instructions TABLE-GRAPH Mode

SCION FR-S PERFORMANCE AIR INTAKE Preparation 2.0L F-4

INSTALLATION MANUAL INSIDE PASSENGER COMPARTMENT. HFC 134a FOR EUROPEAN SPEC. / GENERAL SPEC. AIR CONDITIONING ENGLISH

P150SC15. Designed for 2015 Ford F150 Super-Cab and Super-Crew vehicles without Sony System Stillwater Designs P150SC15-A

Rear wheel brakes, servicing. Стр. 1 из 45. Note:

HP Laser Jet 4200/4240/4250/4300/4350 Swing Plate

EZ-Steer Assisted Steering System

Installation Instructions

HOME GYM. Model. Retain This Manual for Reference OWNER'S MANUAL.

INSTALL/REMOVAL INSTRUCTIONS: WINDOW REGULATOR

Installation Guide for the TJ LCG ENDURO Suspension System (Low Center of Gravity)

FOR ANY QUESTIONS, PLEASE CALL M-F 8:00a.m.-8:00p.m. EST. REAR BRAKES 1 AEROSPACE COMPONENTS

Volkswagen Jetta, Golf, GTI 1999, 2000 Brake System 47 Brakes - Hydraulic Components (Page GR-47)

CONTENTS TOOLS REQUIRED: Ratchet 13mm Socket 10mm Socket Phillips Screwdriver Pliers Panel Removal Tool. Amp Installation

88-98 Chevy / GMC Fullsize 4WD 6-Lug 2"- 2 1/2" Suspension Lift Installation Instructions

MUSTANG II IFS COMPLETE PARTS PACKAGE

Transcription:

R O A D M A S T E R, I N C. 11 7 6 1 2 10 13 8 ITEM QTY NAME PART # 1...2...1/2 x 5 1/2 BOLT...350108-00 2...4...1/2 x 1 3/4 BOLT...350096-00 3...6...1/2 LOCK WASHER...350309-00 4...6...1/2 HEX NUT...350258-00 5...2...1/2 PLATE WASHER...A-003086 6...2...QUICK LINK...200008-00 7...2...8 SAFETY CABLES...650646-08 8...2...3/16 x 1 1/2 x 3 BACKING PLATE...A-004472 9...2...3/16 x 2 x 3 BACKING PLATE...A-004473 10...1...DRIVER SIDE ARM...C-002223 11...1...PASSENGER SIDE ARM...C-002224 12...1...DRIVER SIDE RECEIVER...C-002225 13...1...PASSENGER SIDE RECEIVER...C-002226 12 9 Special tools needed: ½" x 12" drill bit 3 5 4

This is one of our EZ2 series brackets, which allows the visible front portion of the bracket to be easily removed from the front of the vehicle (Fig.A and Fig.B). The bracket consists of a main receiver brace, two removable front braces and a hardware pack. The main receiver brace mounts to the frame rails and the bumper core. The removable front braces install in the main receiver brace. Before starting the installation, lay out the kit components in order, as they will be used. This will give you a visual idea of how the components work, and will also confirm that everything is present and accounted for. Fig.A Fig.B IMPORTANT: All brackets must be assembled with all the bolts left loose for final adjustment and positioning (before tightening) unless otherwise instructed. All bolts must be torqued for proper strength. If more than one bolt is used per fastening point, the diagram may only show one. Use flat washers over all slotted holes Use lock washers on all fasteners ROADMASTER Limited Warranty, including One-Year Conditional Warranty Text and Product Registration Card, in Carton. Failure to follow these instructions can result in property damage, WARNING personal injury or even death. Installation of most mounting brackets requires moderate mechanical aptitude and skills. We strongly recommend professional installation by an experienced installer. The installer must read the instructions and use all bolts and parts supplied. Failure to do so could result in loss of the towed vehicle. Use Loctite Red on all bolts used for mounting this bracket. Every 3,000 miles, the owner must inspect the fasteners for proper torque, according to the bolt torque requirements chart on the last page of these instructions. The owner must also inspect all mounts and brackets for cracks or other signs of fatigue every 3,000 miles. Failure to do so could result in loss of the towed vehicle. The owner must check the vehicle manufacturer's instructions for the proper procedure(s) to prepare the vehicle for towing. Some vehicles must be equipped with a transmission lube pump, an axle disconnect, driveline disconnect or free-wheeling hubs before they can be towed. Failure to properly equip the vehicle will cause severe damage to the transmission. If running changes were made by the vehicle manufacturer after this bracket was designed, some bolts or other fasteners in the hardware pack may no longer be the correct size. It is the installer s responsibility to verify that the bracket is securely fastened to the vehicle and fitted with the correct hardware to account for these changes. Failure to securely fasten the bracket could result in loss of the towed vehicle. If the towed vehicle has been in an accident, it must be properly repaired before attaching the bracket. Do not install the bracket if any structural frame damage is found. Failure to repair the damage could result in the loss of the towed vehicle. Roadmaster manufactures many styles of brackets. If your bracket has removable arms, they must be removed before driving the vehicle, unless the arms can be pinned or padlocked in place. If not secured, the arms could vibrate out, resulting in non-warranty damage or personal injury. Some motorhome chassis have such a tight turning radius that you can damage your motorhome, towed vehicle, tow bar or bracket while turning sharply. Before getting on the road, test your turning radius in an empty parking lot. Turning too sharply could result in non-warranty damage to towing system, motorhome and/or towed vehicle. Do not back up with the towed vehicle attached or non-warranty damage will occur to your towing system, motorhome and/or towed vehicle. The safety cables must connect the towing vehicle to the towed vehicle frame to frame, with the cables crossed, with enough slack for sharp turns. Refer to the cable instructions for proper routing. Failure to leave enough slack in the safety cables, or failure to connect the safety cables frame to frame, will result in the loss of the towed vehicle. This bracket is designed for use with ROADMASTER tow bars and ROADMASTER adaptors only. Using this bracket with other brands, without an approved ROADMASTER adaptor, may result in nonwarranty damage or injury. Do not use this document for custom fabrication, as it may not show all parts or structural components. Custom fabrication or an attempt to copy this bracket design could result in loss of the towed vehicle. Upon final installation, the installer must inspect the bracket to ensure adequate clearance, particularly around hoses, air conditioner lines, radiators, etc., or non-warranty damage to the towed vehicle will result. This bracket is only warranteed for the original installation. Installing a used bracket on another vehicle is not recommended and will void the warranty.

Fig.C Fig.D 1. Important: please use all supplied bolts and parts and read all instructions carefully before beginning this installation. The majority of questions you may have can be answered within the text, and proper installation will ensure safe and secure travel. Now, begin the installation. Remove four plastic fasteners and two T30 Torx bolts attaching the top of the fascia to the core support (Fig.C). 2. On the passenger side, disconnect the hood latch cable by releasing it from two clips and then pull the cable end out from the latch handle (Fig.D). Fig.E 3. On the driver's side, remove three T30 Torx attaching the fender liner to the fascia and one plastic fastener attaching the fender to the corner of the fascia (Fig.E). 4. On the passenger side, remove one plastic fastener attaching the fascia to the corner of the fender and five T30 Torx bolts attaching the fender liner to the fascia and frame rail (Fig.F and Fig.G). Fig.F Fig.G

Fig.H Fig.I 5. Remove six plastic fasteners and seven T30 Torx bolts attaching the forward splash shield to the fascia and bottom of the radiator support (Fig.H). Now, pull down to remove the forward splash shield. 6. On the driver's side, disconnect the fascia wiring harness plug (Fig.I). Fig.J 7. On each side, remove two T30 bolts attaching the headlight to the core support (Fig.J). Remove the headlights and set on top of the engine compartment. 8. Using the yellow arrow as a reference, lift up on the gray plastic locking tab to release the fascia (Fig.K driver's side) and then pull forward to remove the fascia (Fig.L). Fig.K Fig.L

Fig.M Fig.N 9. Remove two T30 Torx bolts attaching the air ducting to the bumper core (Fig.M). 10. Squeeze together four sets of plastic tabs located in the middle of the shock absorption pad (Fig.N) and pull out to remove it. Fig.O Fig.P 11. Working on the passenger side only, pull up on the washer bottle filler neck to remove it (Fig.O). 12. Remove one T30 Torx bolt attaching the lower engine splash shield to the fender liner to gain access to the washer bottle mount (Fig.P). 13. Remove two 10mm (head) bolts attaching the washer bottle mount to the bottom of the frame rail (Fig.Q). 14. Slide the washer bottle reservoir back and down so it rests on the lower engine splash shield (Fig.R). Fig.Q Fig.R

Fig.S Fig.T line indicates drill path through frame 15. On each side, locate the pre-existing hole on the outside of the frame rail, as well as the corresponding hole on the inside of the frame rail. Using a ½" x 12" drill bit, enlarge the two holes in the frame rail (Fig.S and Fig.T). Make certain you use a sharp drill bit. Note: use a piece of metal as a buffer between the drill bit and the engine components. Fig.U Fig.V 16. On each side, push the main receiver brace up Fig.W against the bottom of the bumper core, placing the rear mount along the inside of the frame rail. Now, on each side, ensure that the hole in the rear of the main receiver brace is aligned with the two holes enlarged in the previous step. Place a ½" plate washer over a ½" x 5½" bolt, and then bolt through the frame and the main receiver brace. Finish with a ½" lock washer and nut (Fig.U). 17. Aligning the hole in the main receiver brace with the existing hole on the face of the bumper core, bolt through the main receiver brace and bumper core using a ½" x 1¾" bolt, and finish with a 3/16" x 2" x 3" backing plate, ½" lock washer and nut (Fig.V). 18. On each side, ensure that the mount is clamped to the bottom of the bumper core. Using the hole in the main receiver brace as a template, drill up through the bumper core (Fig.W). Bolt up through the main receiver brace and bumper core using a ½" x 1¾" bolt and finish with a 3/16" x 1½" x 3" backing plate, ½" lock washer and nut.

Fig.X Fig.Y 19. Use the drawing on page 1 as a guide to ensure the bracket is centered on the car and that the attachment points for the quick-disconnects are 28½" from center to center. Torque the bolts to the bolt torque requirements found at the end of these instructions. 20. Hold the shock absorption pad in place and mark it for trimming to allow clearance for the main receiver brace upper mounting points. Replace the shock absorption pad by reversing step 10. Figure X shows the trimmed and reinstalled pad. Now, replace the air ducting by reversing step 9. 21. On the back of the fascia, squeeze together four plastic clips on each side to remove the grille backing (Fig.Y). Note: due to manufacturing variances, a removable backing may not be present. Fig.Z Fig.AA 22. Using the yellow lines in Figure Z as a guide for trimming, trim and reinstall each grille backing. 23. Insert the removable front bracket arms into the front receiver braces, and twist each one 90 degrees to lock. 24. Install the tow bar to the mounting bracket according to the manufacturer's instructions. IMPORTANT! Safety cables are required by law. When towing, connect safety cables to the safety cable tabs illustrated on page 1 and in Figure AA. Make certain there is adequate slack in the cables to allow a full turning radius; otherwise, damage will result. If necessary, longer cables or cable extensions are available.

BOLT TORQUE REQUIREMENTS Note: The torque values represented below are intended as general guidelines. Torque requirements for specific applications may vary. Roadmaster does not warrant this information to be accurate for all applications and disclaims all liability for any claims or damages which may result from its use. STANDARD BOLTS Thread Size Grade Torque 5/16... 5... 13 ft./lb. 3/8... 5... 23 ft./lb. 7/16... 5... 37 ft./lb. 1/2... 5... 56 ft./lb. 5/8... 5... 150 ft./lb. METRIC BOLTS Thread Size Grade Plated / Unplated 8mm-1.0...8.8...20 ft./lb. 18 ft./lb. 8mm-1.25...8.8...19 ft./lb. 18 ft./lb. 10mm-1.25...8.8...38 ft./lb. 36 ft./lb. 10mm-1.5...8.8...37 ft./lb. 35 ft./lb. METRIC BOLTS Thread Size Grade Plated / Unplated 12mm-1.25...8.8...70 ft./lb. 65 ft./lb. 12mm-1.5...8.8...66 ft./lb. 61 ft./lb. 12mm-1.75...8.8...65 ft./lb. 60 ft./lb. 14mm-2.0...8.8...104 ft./lb. 97 ft./lb.