XHD Bull Bar w/ Dual Row LED Light Bar (10-17

J116521
XHD Bull Bar w/ Dual Row
LED Light Bar (10-17 Jeep JK)
PARTS LIST:
1
1
1
1
1
1
1
1
2
4
4
4
4
12
12
16
12
Driver/Left Side Bull Bar Upright
Passenger/Right Side Bull Bar Upright
Top Cross Bar
Center Cross Bar
Driver/Left Side Frame Bracket
Passenger/Right Side Frame Bracket
Driver/Left Side Bull Bar Bracket
Passenger/Right Side Bull Bar Bracket
12-1.75mm Double Nut Plate
12-1.75mm x 30mm Hex Bolts
12mm x 24mm x 2.5mm Flat Washers
12mm Lock Washers
10-1.5mm x 35mm Hex Bolts
10-1.5mm x 25mm Hex Bolts
10mm x 30mm x 2.5mm Flat Washers
10mm x 20mm x 2mm Flat Washers
10mm Lock Washers
8
4
2
2
2
6
4
2
1
4
6
4
2
1
2
2
10-1.5mm Hex Nuts
10-1.5mm Nylon Lock Nuts
Light Bar Brackets
8-1.25mm x 16mm Hex Bolts
8-1.25mm x 25mm Hex Bolts
8mm x 24mm x 2mm Flat Washers
8mm Lock Washers
8-1.25mm Hex Nuts
License Plate Bracket
6-1.0mm x 20mm Button Head Bolts
6mm x 18mm x 1.6mm Flat Washers
6mm Lock Washers
6-1.0mm Hex Nuts
4mm Allen Wrench
Black Rubber Self-Adhesive Top Seal
Black Rubber Self-Adhesive Center Seal
(2) 12mm Double
Nut Plates
Passenger/Right
Bull Bar Upright
Top Cross Bar
Center
Cross Bar
Passenger/Right
Bull Bar Bracket
(2) Rubber
Adhesive
Top Seal
Driver/Left Bull
Bar Upright
(2) Light Bar
Brackets
License Plate
Bracket
Passenger/Right
Frame Bracket
Driver/Left Frame
Bracket
(2) Rubber
Adhesive
Center Seal
Driver/Left Bull
Bar Bracket
PROCEDURE:
1. REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT. READ INSTRUCTIONS
CAREFULLY. CUTTING IS REQUIRED. ASSISTANCE IS RECOMMENDED.
2. Remove the plastic splash guard from under the front bumper and place it on a clean, stable work
surface, (Figure 1).
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J116521
3. Starting on the driver side, insert (1) 12mm Double Nut Plate, (Figure 2), into the opening in the end of
the frame cross-member. Line up the (2) holes in the Nut Plate with the (2) holes in the frame.
4. Select the driver side Frame Bracket, (Figure 3). Insert (2) 12mm x 30mm Hex Bolts, (2) 12mm Lock
Washers and (2) 12mm Flat Washers through the (2) rear slots in the Bracket, cross-member and into
the Double Nut Plate, (Figure 4). Leave hardware loose at this time.
5. Select driver side Bull Bar Bracket, (Figure 5). Position the Bull Bar Bracket on the outside of the
Frame Bracket. Use (2) 10mm x 35mm Hex Bolts, (4) 10mm x 30mm Flat Washers, (2) 10mm Lock
Washers and (2) 10mm Hex Nuts to attach the Bull Bar Bracket to the Frame Bracket, (Figure 6).
6. Repeat Steps 3—5 for passenger side Frame and Bull Bar Bracket installation.
7. Select the driver side Bull Bar Upright and the Top Cross Bar. Attach the Black Rubber Self-Adhesive
Top Seal between the Upright and Top Cross Bar. Bolt through the Top Cross Bar, Self-Adhesive Top
Seal and Upright using (2) 10mm x 25mm Hex Bolts, (4) 10mm x 20mm Flat Washers, (2) 10mm Lock
Washers and (2) 10mm Hex Nuts, (Figure 7). Do not fully tighten hardware.
8. Select the Center Cross Bar. Attach the Black Rubber Self-Adhesive Center Seal between the Upright
and the Center Cross bar. Bolt through the Center Cross Bar, Self-Adhesive Center Seal, and Upright
with (2) 10mm x 25mm Hex Bolts, (4) 10mm x 20mm Flat Washers, (2) 10mm Lock Washers and (2)
10mm Hex Nuts, (Figure 7). Do not fully tighten hardware.
9. Repeat Steps 7 & 8 to attach the passenger side Bull Bar Upright to the Top Cross Bar and Center
Cross Bar. Place assembled Bull Bar face down on a clean flat surface and fully tighten top and center
cross bar to upright hardware only at this time.
10. Relocation of front license plate is not required, but strongly recommended.
a. Attach the License Plate Bracket to the Center Cross Bar with (2) 6mm Button Head Bolts, (4)
6mm Flat Washers, (2) 6mm Lock Washers and (2) 6mm Hex Nuts, (Figure 8). Use the (2)
6mm Button Head Bolts, (2) 6mm Lock Washers and (2) 6mm Flat Washers to attach the front
license plate to the Bracket, (Figure 8).
11. LED light installation available on Center Cross Bar as supplied with Bull Bar or sold separately.
a. Start at the driver/left side of the vehicle. Select (1) LED Bracket. Attach the slot on the short
side of the Bracket to the slot on the center cross bar with (1) 8mm x 25mm Hex Bolt, (2) 8mm
Flat Washers, (1) 8mm Lock Washer and (1) 8mm Hex Nut, (Figure 9). NOTE: The short side
on the LED Bracket must be facing the center of the vehicle.
b. Repeat Step 11a to install LED bracket on passenger/right side.
c. Use (1) 8mm x 16mm Hex Bolt, (1) 8mm Lock Washer and (1) 8mm Flat Washer to attach the
slot on the long side of the LED Bracket to the LED light bar, (Figure 9). Repeat this step to
attach the LED Bracket to the LED light bar on the passenger/right side of the vehicle.
d. Follow the light manufacturer’s instructions to attach the LED light bar and properly wire.
12. With assistance, position the assembled Bull Bar up to the Bull Bar Brackets. Use the included (4)
10mm x 25mm Hex Bolts, (4) 10mm Lock Washers and (4) 10mm x 30mm Flat Washers to attach the
Bull Bar to the Bull Bar Brackets, (Figure 10 & 11). Do not tighten hardware at this time.
13. Align the Bull Bar properly and fully tighten the Frame Bracket hardware only. Temporarily remove the
assembled Bull Bar with the Bull Bar Brackets attached.
14. Position the splash guard back up to the vehicle and attach with the factory hardware. Trace the
location of the Brackets onto the splash guard, (Figure 12). NOTE: To maintain the integrity of the
plastic Splash Guard, remove only material necessary to clear the Bull Bar and Brackets. Make small
cuts and check the fit often before final installation, (Figure 13). After the appropriate cuts are made to
the splash guard, reinstall the splash guard with factory hardware.
15. Reinstall the assembled Bull Bar with the Bull Bar Brackets and tighten all hardware.
16. Do periodic inspections to the installation to make sure 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. Mild soap
may be used to clean the Bull Bar.
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J116521
Driver Side Installation Pictured
Front
Fig 1
(Fig 2) Insert the 12mm Double Nut Plate into the
opening in the bottom of the end of the cross-member
(2) 12mm Hex Bolts
(2) 12mm Lock Washers
(2) 12mm Flat Washers
Front
(Fig 3) Driver/left side Frame Bracket
Front
(Fig 4) Driver /left side Frame Bracket Installed
Front
(Fig 5) Driver/left side Frame and
Bull Bar Bracket assembly
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J116521
Driver Side Installation Pictured
(2) 10mm x 35mm Hex Bolts
(4) 10mm x 30mm Flat Washer
(2) 10mm Nylon Lock Nuts
(4) 10mm x 25mm Hex Bolts
(8) 10mm x 20mm Flat Washers
(4) 10mm Lock Washers
(4) 10mm Hex Nuts
Front
Front
(Fig 6) Driver/left side Bull Bar Bracket
attached to Frame Bracket pictured
(2) 6mm Button Head Bolts
(4) 6mm Flat Washers
(2) 6mm Lock Washers
(2) 6mm Hex Nuts
(Fig 7) Driver/Left Side Bull Bar Upright
attached to Top and Center Cross Bars
(1) 8mm x 25mm Hex Bolt
(2) 8mm Flat Washers
(1) 8mm Lock Washer
(1) 8mm Hex Nut
Front
Front
Fig 8
(2) 6mm Button Head Bolts
(2) 6mm Lock Washers
(2) 6mm Flat Washers
8mm x 16mm Hex Bolt
8mm Lock Washer
8mm Flat Washer
Fig 9
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J116521
Driver Side Installation Pictured
(2) 10mm x 25mm Hex Bolts
(2) 10mm Lock Washers
(2) 10mm x 30mm Flat Washers
Front
Front
(Fig 10) Driver/left side Bull Bar bracket
and assembled Bull Bar illustrated
(Fig 11) Driver/left Bull Bar Bracket
attached to assembled Bull Bar pictured
Cut two openings to clear Brackets
(Fig 12) Approximate cut out
area on splash guard
Fig 13
NOTE: Cut only what is needed to
insert brackets through splash guard.
Complete
Installation
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