BOlT TORQuE sPECiFiCATiONs

sTANDARD BOlTs: size grade Torque

5/16”

3/8”

7/16”

1/2”

5

5

5

5

20 ft/lbs.

35 ft/lbs.

56 ft/lbs.

85 ft/lbs.

mETRiC BOlTs: size

8mm

10mm

12mm

14mm

Torque

22 ft/lbs.

42 ft/lbs.

70 ft/lbs.

95 ft/lbs.

7

9

14

Ford Explorer

With Adaptive Cruise

Control

7-12

TP20299,Rev.0

Centers - 23-5/8 ” Pin height - 17”

12

16

15

2

1

6

3

10

17.

4010 320TH ST. PO BOX 189

BOYDEN, IOWA 51234

DRAWN BY

ENG APPOV.

DKY

JK

ITEM

1

2

3

4

DATE

DATE

PART #

04055

00057

13612

00062

09/24/09

08/25/10

SPECIFIEDALL DIMENSIONS

PROJECTION

TOLERANCES

.X = .060 MIN. MACHINE SURFACE 250

13

5

4

8

11

.25-20NC X 1 GD5 HEX

WASHER, .25 SPRING LOCK

Plug Mount

DESCRIPTION

NUT .25NC HEX

DRAWING. NO.

5937

SCALE: 1:2

REV

A

SHEET 2 OF 2

REF. PART

QTY

2

2

1

2

NO.

1.

2.

3.

4.

00060

00061

00083

THIRD ANGLE

00084

00085

ARE IN INCHES

8

2

3

APPOV. BY

1/2” Lock Washer

3

3

DRAWN BY

SAVED BY

ITEM

1

2

3

4

5

6

7

8

9

10

11

13

14

PART #

00060

00061

00083

00084

00085

00253

00254

00482

00492

00523

01235

12979

12980

8 3/8” NC Hex Nut

1/2” NC Hex Nut

1/2” Flat Washer

.375 HEX NUT

SIDE BRACE

DESCRIPTION

.375 LOCKWASHER

NUT, HEX, .50NC

.50 LOCKWASHER

.50 FLAT WASHER

.75 NC HEX NUT

.75"-LOCKWASHER

BOLT .50NC X 1.75 GR5 HEX

WASHER, FLAT, .75

BOLT, .375NC X 1.25 HEX HEAD GR. 5

BOLT .75NC X 2.00 GR5 HEX

BASEPLATE PULL EAR COVER, "A"

BASEPLATE PULL EAR COVER, "B"

BENT NUT STRIP

CROSSMEMBER F/ 9518299

DESCRIPTION

BASEPLATE F/ FORD EXPLORER

DRAWING. NO.

9518299

1/2”-NC x 1-3/4” Hex Bolt Gr.5

_

2

1

1

1

1

8

2

3

2

2

2

3

3

QTY

8

8

2

REV

7.

8.

9.

10.

11.

12.

13.

14.

14073-35

15.

14483-35

16.

14484-35

17.

18.

VOLUME

00254

00482

00492

00523

01235

12979

12980

5937

12329

2

2

2

8

2

1

1

2

1

1

1

2

3/4” NC Hex Nut

.XX = ±.030 BREAK ALL SHARP EDGES

.XXX = ±.010 BEND AND DRAFT ±1°

3/4” Flat Washer

SCALE: 1:7

3/8”-NC x 1-1/4” Hex Bolt Gr.5

3/4”-NC x 2” Hex Bolt Gr.5

Pull Ear Cover “A“

Pull Ear Cover “B”

Side Brace

Bent Nutstrip

Baseplate Crossmember

Plug Mount Kit

Loctite (not shown)

Please order replacement parts by PART NO. and DEsCRiPTiON.

SHEET 1 OF 1

Doing Our Best to Provide You the Best

WARNiNg:

FAiluRE TO FOllOW ThEsE iNsTRuCTiONs CAN REsulT iN lOss OF TOWiNg vEhiClE CONTROl, sEPARATiON

OF ThE TOW BAR FROm ThE TOWiNg vEhiClE, sEPARATiON OF ThE TOWED vEhiClE FROm ThE TOW BAR, CAusiNg sEvERE PERsONAl iNjuRy, DEATh, OR PROPERTy DAmAgE.

CAuTiON

Safety is of utmost importance at all times. There are several items that must be checked each time before using and while using a tow bar.

Before allowing anyone to hook up or operate a tow bar, be sure they have read and understand the proper operating procedure.

DO NOT use worn or damaged cables and/or pins.

Be sure the

sAFETy CABlEs are hooked, chassis to chassis, to both the towing and towed vehicles using the crisscross method.

Check clearance between vehicles in a turning situation.

Check base plate mounting bolts for tightness and frame for metal fatigue.

Do not load the towed vehicle with anything as you may exceed the towing capacity of the tow bar.

Keep fingers away from pivot points to prevent personal injury.

Be sure the steering components of the towed vehicle are properly aligned.

NOTE: This unit can be backed up in moderate increments. Any severe backwards cornering could result in damage to the Tow Bar and/ or towed vehicle chassis.

For automatic transmissions: Consult your vehicle owners manual for towing suitability with the drive shaft connected. Otherwise, the towed vehicle will have to be equipped with a transmission pump or drive shaft disconnect.

Check to make sure that all lights are in proper working order.

The information on towability of vehicles is reprinted with permission of motorhome

©

magazine, and is believed to be reliable. However,

Demco does not warrant the information to be correct. Always consult your towed vehicle owner’s manual and follow towing instructions. Each year,

motorhome

©

magazine, compiles a list of vehicles that can be towed four-down behind a motorhome with no modifications required.

This guide contains only those vehicles that have been approved by their manufacturers for towing.

This list is enclosed with this manual.

Caution: motorhome

©

magazine left out any vehicles that have towing speed limits slower than 55 m.p.h., or distance limits of less than

200 miles. At a minimum, these vehicles require significant modification, such as the use of an aftermarket product, to make them towable.

The availability of a

Demco Tow Bar Base Plate does not imply that these vehicles can be modified or that there is an aftermarket product available. Refer to your vehicle owner’s manual or consult your dealer to determine whether your vehicle can be modified to make it towable.

Failure to observe this precaution could result in property damage or personal injury.

imPORTANT iNsTAllATiON iTEms

DEMCO products and accessories are intended to be installed by professional installers with experience, proper equipment and the ability to do modification work. Installers with these qualifications can be found in RV and Automotive Service

Centers.

If the car to be towed has been in an accident, the chassis may be damaged in an area where the Base

Plate attaches. It may no longer be suitable for towing. Extreme caution and careful examination are required in such a situation. It is also likely, even from a minor accident, that the hole alignment will be more difficult due to hole alignment problems.

Many DEMCO Base Plates are designed to use existing holes and hardware to mount the Base

Plate to the towed vehicle. Even though the bolt is there, however, do not assume it is adequate for mounting the Base Plate. Manufacturers make many changes in hardware both within and between model years. Be sure the bolt is long enough to protrude past the nut a distance no less than 1/2 the diameter of the bolt, after the Base Plate is mounted. The threads should be in good condition.

We require that “

Grade 5 or Metric 8.8.

R

Blue” be used on all

bolts. If a new bolt is required, be sure it is SAE

NOTE: The dimensional variations between otherwise identical vehicles can be considerable. some minor modifications may have to be made to ensure a proper fit.

iNsTAllATiON iNsTRuCTiONs

1. Open hood and remove seven screws and two plastic push fasteners from top cover. Remove plastic cover.

2. Remove four screws front the front of each wheel well.

3. Pull fender flare out and remove two screws on each side from behind fender flare.

7. Remove three bolts from adaptive cruise control box bracket, unplug box, and remove.

4. Remove three screws from underside of wheel well liner on each side.

8. Cut bracket on red line as shown so bracket is straight.

5. Remove three screws from underside of facia. With an assistant pull out and ahead on facia by fender.

NOTE: Be careful not to drop facia when facia releases.

Unplug fog lights and side sensors if equipped.

9. Drill three spot welds on passenger side of bumper and two spot welds on drivers side of bumper. Remove four bolts from each side of bumper and remove bumper.

6. Cut air deflectors flush with bottom of bumper and remove bottom section by removing plastic push fastener.

10. Grind bottom of bumper to remove lip and welds flush on the outer six inches on each end.

11. Remove slug from inside of frame on both sides.

14. Drill back holes using the baseplate as a jig using a 1/2” drill bit. Fasten back of baseplate using 1/2” x 1-3/4” bolts,

1/2” flat washers, 1/2” lock washers and 1/2 nuts.

NOTE:

Use Blue on all bolts and tighten all bolts according to chart on front page.

12. With two hands push cooler tube down for clearance of baseplate.

15. Remove two nuts and one screw from washer tank and wires from frame in needed so tank can be moved for clearance.

13. With an assistant slide baseplate under frame and bolt with one 3/4” x 2” bolt, 3/4” flat washer, 3/4” lock washer and 3/4” hex nut thru hole in bottom of frame on each side and tighten.

NOTE: Use

R

Blue on bolts and tighten all bolts according to chart on front page.

16. Grind notch as shown for clearance when drilling hole for side bracket.

17. Fasten side brace using 3/8” x 1-1/4” bolts, 3/8 lock washer, and 3/8” nuts. Repeat on the passenger side.

NOTE: Use Blue on all bolts and tighten all bolts according to chart on front page.

20. Reinstall bumper using factory bolts. Fasten baseplate to bumper using 1/2” x 1-4/4” bolt, 1/2 lock washer, 1/2” flat washer, and bent nutstrip.

NOTE: Use

Blue on all bolts and tighten all bolts according to chart on front page.

18. Use the brace as a jig and drill with a 3/8” bit. Place

3/8” x 1-1/4” bolts with 3/8” lock washers, and 3/8” nuts.

NOTE: Use Blue on all bolts and tighten all bolts according to chart on front page.

21. Reinstall adaptive cruise control bracket with factory screws and plug in wires

19. Reinstall washer tank and wires.

22. Cut lower grill insert on passenger side as shown above.

NOTE: Picture is looking at back of grill insert. Some trimming may be needed.

23. Cut lower grill insert on drivers side as shown above.

Sand or cut away material from back side of grill insert as shown in red box.

NOTE: Picture is looking at back of grill insert. Some trimming may be needed.

24. Reinstall facia and cover in reverse order. Plug mount

(item #17) may be installed if desired in convenience holes on either chain anchor or as desired. NOTE: Excess material may be trimmed from bracket and pullear covers to miss fog lights.

NOTEs

NOTEs

Warranty Registration

4010 320th Street • Box 189 • Boyden, Iowa 51234

Toll Free 800-54DEMCO (800-543-3626) • FAX 800-845-6420 www.demco-products.com

How satisfied are you with our product?

Very

Satisfied m

Satisfied m

Ag

RV m m

Rental m

Brakes m

Marine m

Dissatisfied

Very

Dissatisfied m m

How satisfied are you with the dealership/distributor sales staff?

m m m m

Dealer/Distributor Name City State

How satisfied are you with the company sales staff?

m m m m

How satisfied are you with the delivery?

Did you have any contact with a Demco Representative?

If

YES, how satisfied were you?

I would recommend this product to my family and friends.

Would you purchase again from DEMCO?

Since taking delivery, have you been contacted by the dealer?

Did you have any problems with this DEMCO product?

If

YES, are you satisfied with the company’s resolution of your problem?

m

YES m

YES

YES

YES

YES m m

NO m

NO

NO

NO

NO m m m m m m m

Please list the specific source of information prompting this purchase.

After purchasing this product, do you see any needed product improvement? If yes, what improvement?

What other products would you like to see DEMCO offer?

Comments

Owner’s Name: Mailing Address:

City: State: Zip Code:

Model#:

Serial #:

Purchase Date:

Owner’s Signature:

Please return to DEMCO By FAX or tri-folding this form to the backside, it is pre-addressed.

Demco

4010 320th Street, Box 189

Boyden, Iowa 51234

Postage

DEmCO PRODuCTs ORigiNAl

PuRChAsERs limiTED WARRANTy

1. Extent and Duration of this Warranty:

Your Demco product has a Lifetime Limited

Warranty to be free from defects in materials and

workmanship under normal use and service from date of purchase by the original (first) retail owner, or until it is resold or transferred by the original owner. Any part of the Demco product found in the judgement of the

manufacturer to be defective in materials or workmanship will be repaired or replaced at the manufacturer’s option without charge for parts or labor to the original owner.

In addition, the warranty does not extend to repairs made necessary by normal use of parts, accessories or other equipment which in the judgment of Warrantor, are either incompatible with the Demco product, or affect its operation, performance or durability.

This warranty does not cover:

1) normal wear and tear

2) road film or gravel damage to paint

3) paint

4) rust damage

2. manufacturer and Warrantor:

Demco

4010 320th Street

P.O. Box 189

Boyden, IA 51234

(712) 725-2311

Warrantor has a policy of continuous product improvement.

We reserve the right to change or improve the design of any Demco product, including but not limited to state of the art changes, without assuming any obligation to modify any product previously manufactured.

3. Repair or Replacement Procedure:

If your Demco product develops a defect during the warranty period, promptly notify Demco customer service department. Until such notice is received, Warrantor will not be responsible for any repair or replacement.

Upon receipt of notice from you, Warrantor will have a choice of options in replacing any part it determines to be defective:

Warrantor assumes no responsibility to the owner for loss of use of the product, loss of time, inconvenience or other damage consequential or otherwise, including, but not limited to expense for gasoline, expense of transporting the product to the dealer and expense of returning the product, mechanic’s travel time, telephone or telegram charges, road service/towing charges, rental of another product during the time warranty repairs are being performed, travel, lodging, loss or damage to personal property or loss of revenue or earnings.

a) Warrantor may require you at your own expense to deliver or ship the part to its factory or authorized dealer. Any defective part will be repaired or replaced and returned to you free of charge. Any part returned to Warrantor and found not to be defective will be returned to you freight collect with an explanation.

5. limitations of implied Warranties:

All implied warranties, if any, expire and terminate upon expiration of this warranty. Some states do not allow limitation on how long an implied warranty lasts, so this limitation may not apply to you.

b) Warrantor may elect to ship a new part to its dealer to be exchanged free of charge for the defective part returned by you to the dealer.

c) Warrantor may elect to ship or deliver a replacement part to your address.

4. limitations on Warranty Coverage:

Coverage under this warranty will be valid only if the customer warranty card is returned by the original purchaser within 30 days of purchase.

6. limitation of Consequential Damages:

Warrantor’s responsibility under this warranty extends solely to repair or replacement of your Demco product and its component parts.

Warrantor does not assume responsibility for, nor shall it be liable for, any special, incidental or consequential damages. Some states do not allow the exclusion or limitation on incidental or consequential damages, so the above exclusion or limitation may not apply to you.

7. Purchaser’s Rights:

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

Coverage under this warranty will be effective only when a copy of the original invoice, showing the date and location of purchase, accompanies any claim for warranty.

This warranty is limited to the original owner and is NON

TRANSFERABLE to a second party.

Warrantor has no liability whatsoever and this warranty is null and void if any Demco product has been misassembled or subjected to neglect, negligence, misuse, accident or operated in any way contrary to the operating and maintenance instructions as specified in the Demco Owner’s

Manual for that model.

8. Exclusive Warranty:

This is the only express warranty made by Demco on your Demco product and no agent, employee, or other person is allowed to change or add to this warranty.

This warranty does not cover any product that has been altered or modified so as to affect it’s operation, performance or durability, or that has been modified to change the intended use of the product.

4010 320th st., P.O. BOX 189, BOyDEN, iA. 51234

Ph: (712) 725-2311

FAX: (712) 725-2380 or 1-800-845-6420

TOll FREE: 1-800-54DEmCO (1-800-543-3626) www.demco-products.com