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Place these instructions in vehicle’s glove box after installation is complete

Ford Falcon Ute 2008

Part Number: SBAR0015

SPORTS BARINSTALLATION INSTRUCTIONS

Clean Sports Bar with a milddetergent and water solution.

Do not use abrasivecleaners or solvents.Care Instructions:

Item

1

2

3

4

5

6

7

8

9

10

11

12

13

1

1

1

6

2

2

1

1

1

1

1

1

2

2

2

4

4

2

6

8

2

8

2

Front Sports Bar Tube

Rear Sports Bar Leg LHS

Rear Sports Bar Leg RHS

Cam Nuts

Front Clamp Plates

Rear Clamp Plates

Foot Gasket LHS Front

Foot Gasket LHS Rear

Foot Gasket RHS Front

Foot Gasket RHS Rear

Leg Joiner LHS

Leg Joiner RHS

Nylon Spacers

Component Name Qty Item

14

15

16

17

18

19

20

21

22

23

Grommets

M12x80mm Screws

M8x25mm Screws

M8x20mm Screws

M6x50mm Screws

M4x12mm Countersunk Screws

M8 Spring Washers

M6 Spring Washers

M8 Flat Washers

M6 Flat Washers

Component Name Qty

LIST OF PARTS

Socket Drive Handle and Extension Bar (½” Drive)

Socket Drive Allen Key Long Series M12 (Kincrome)

Socket Drive Allen Key to Suit M6

Socket Drive Allen Key to Suit M8

Torque Wrench Rated to at Least 30Nm

Phillips Head Screwdriver to Suit M4

Tape Measure

RECOMMENDED TOOL LIST

20/01/10

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FORD FALCON UTE 2008 SPORTS BAR

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1 2 3 4 5

6 7 8 9 10

11 12 13 14 15

16 17 18 19 20

21 22 23

IMPORTANT: To obtain correct installation, we recommend that you follow these step by step instructions carefully.

Please take care when assembling and installing this product to protect the finish and your investment. Regular polishing and waxing is required to protect the finish.

Finish Protection: Our products have a high finish that must be maintained such as any other high finish product on the vehicle.Protect the finish with a non-abrasive automotive wax after polishing.Regular polishing of the sportsbar is required to prevent staining or corrosion of the finish.Use products formulated for stainless steel. Failure to maintain the finish may cause unrepairable damage to the sportsbar.

Disclaimer: The buyer assumes all risk and liability whatsoever from the installation and use of our products.Our products are sold as decorative accessories and should not be relied upon as protection for the vehicle or occupants in theevent of a collision or rollover.The manufacturer assumes no liability for injury, loss, incidental or consequential damages in the event of a collision or rollover.

EGR Customer service hotline, phone; +61 7 3337 0155 (Business hours, Australia)

REAR LEGLEFT HAND SIDE

(LHS)REAR LEG

RIGHT HAND SIDE(RHS)

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2. Insert the leg joiner with “LHS” marked on the front face, into the top end of the rear Sports Bar leg LHS as shown, ensuring the spigot inserts correctly into its hole as shown. Repeat process for the other side of the Sports Bar. See Dia #2.

Diagram #2

1. NOTE: Two people are required to complete installation. Thoroughly clean and dry the installations areas. See Dia #1.

Diagram #1

REAR LEGLEFT HAND SIDE

(LHS)

LEG JOINERLEFT HAND SIDE

(LHS)

SPIGOT

3. Insert the M12x80mm screws into the nylon spacers as shown. See Dia #3.

Diagram #3

NYLONSPACER

x2

FRONT VIEW

“LHS”AT TOP

M12x80SCREW

4. Lay the Sports Bar front tube and rear legs out on a non-abrasive surface. Using two people, attach the front Sports Bar tube to the rear Sports Bar leg LHS using the M12x80mm screws as shown. Tighten to torque 20Nm. Repeat process for the other side of the Sports Bar. Insert the grommets into the holes on the front Sports Bar tube as shown. See Dia #4.

Diagram #4

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6. Attach the foot gaskets to their correct Sports Bar foot as shown, ensuring the holes in the Sports Bar feet remain accessible. Repeat process for the other side of the vehicle. See Dia #6.

Diagram #6

5. Remove the protective lining from all of the foot gaskets. See Dia #5.

Diagram #5

LHS SHOWN LHS SHOWN1 2

FRONTTUBE

REAR LEGLHS

LEG JOINERLHS

FRONT TUBE

GROMMETM12x80 SCREW &NYLON SPACER

NON-ABRASIVESURFACE

TORQUE 20Nm

FOOT GASKETREAR RHS

REAR LEGRHS

FRONT TUBE

FOOT GASKETFRONT RHS

RHS SHOWN

FOOT GASKETFRONT RHS

FOOT GASKETREAR RHS

FOOT GASKETFRONT LHS

FOOT GASKETREAR LHS

7. Loosely attach the cam nuts (4 turns only) to the front clamp plates, ensuring they are attached to opposite ends of the plates as shown. Remove the screw from the end opposite the attached cam nut as shown. Note which side of the vehicle the front clamp plates will be attached to later, as indicated in the diagram. See Dia #7.

Diagram #7

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9. Fit the front clamp plate to the side rail as shown. Ensure bottom screws lip onto bottom edge of side rail opening. Rotate the cam nut so that it sits behind the bottom lip of the side rail as shown. Slide the front cam plate into place at the front of the side rail as shown and loosely insert the M6x50mm screw through the hole in the front clamp plate and into the existing threaded hole in the side rail. Finally, tighten the M4x12mm screw to torque 10Nm. Repeat process for the other side of the vehicle. See Dia #9.

Diagram #9

8. Loosely attach the cam nuts (4 turns only) to the rear clamp plates as shown. Rotate the cam nuts on both the front and rear clamp plates so that they sit above the screws protruding from the back of the clamp plates as shown. See Dia #8.

Diagram #8

M4x12mmSCREWS

(4 TURNS ONLY)

M4x12mmSCREWS

(4 TURNS ONLY)

CAM NUTS

FRONT CLAMP PLATE (FOR LHS OF VEHICLE)

FRONT CLAMP PLATE (FOR RHS OF VEHICLE)1 2

1 2

REAR CLAMP PLATE x2

FRONT CLAMP PLATE (FOR LHS OF VEHICLE)

ROTATECAM NUTS

REAR CLAMP PLATES

FRONT CLAMP PLATES

(RHS)(LHS)

FRONT CLAMP PLATE (FOR RHS OF VEHICLE)

REMOVE SCREWIMPORTANT:

ENSURE “F” ISALWAYS FACING

TOWARD YOU

IMPORTANT: ENSURE “R” & “F”

ARE ALWAYSFACING

TOWARD YOU

CAMNUTS

RHS SHOWN

SIDE RAILBOTTOMSCREW

M6x50mmSCREW

RHS SHOWN

SIDE RAIL

SLIDE

ROTATECAM NUT

TIGHTEN TOTORQUE 10Nm

3

SIDE VIEW

SIDERAIL

FIT1

FRONTCLAMPPLATE

(FOR RHS)2 4 5

10. Fit the rear clamp plate to the vehicle’s side rail and position it 321mm from the front clamp plate as shown. Rotate the cam nuts so that they sit behind the bottom lip of the side rail as shown. Tighten the M4x12mm screws to torque 10Nm. Repeat process for the other side of the vehicle. See Dia #10.

Diagram #10

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12. Attach the Sports Bar foot to the vehicle’s side rail using the M6x50mm screw, M6 spring washer and M6 flat washer into existing front hole in vehicle as shown. Push down on the Sports Bar foot towards tub contact with gasket. Tighten to torque 10Nm. Attach the Sports Bar to the front clamp plate using the M8x20mm screw, M8 spring washer and M8 flat washer as shown. Also attach M8x20mm screw, M8 spring washer and M8 flat washer through the front clamp plate rearward position and into cam nut. Tighten both M8 screws to torque 20Nm. Repeat process for the other side of the vehicle. See Dia #12.

Diagram #12

11. Remove the M6x50mm screws from both of the front clamp plates as shown. Position Sports Bar on vehicle using two people either side of the vehicle and lower the Sports Bar down so the feet tags are aligned inside the tub over the clamp plate positions.See Dia #11. NOTE: If fitting with EGR 3pc Tonneau Cover, refer to Tonneau Cover Fitting Instructions to complete fitment.

Diagram #11

ROTATECAM NUTS

321mm2

TIGHTEN TOTORQUE 10NmFIT

3

RHS SHOWN

SIDE RAIL

FRONT CLAMP PLATE(FOR RHS) REAR CLAMP

PLATE1

21 RHS SHOWN

REMOVE M6x50mmSCREW

FRONT CLAMP PLATE

M6x50SCREW

M6 FLATWASHERTORQUE 10Nm

FRONT CLAMPPLATE

RHS SHOWNSPORTS

BAR

M8x20SCREWS

M8 FLATWASHERSTORQUE 20Nm

FRONT CLAMPPLATE

RHS SHOWNSPORTS

BAR

M6SPRINGWASHER

GASKET GASKET

M8SPRING

WASHERS

13. Attach the Sports Bar to the rear clamp plate in two places using the M8x25mm screws, M8 spring washers and M8 flat washers as shown. Push down on the Sports Bar foot towards tub contact with the gasket. Tighten to torque 20Nm. Repeat process for the other side of the vehicle. See Dia #13.

Diagram #13

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FORD FALCON UTE 2008 SPORTS BAR

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RHS SHOWNSPORTS

BAR

REAR CLAMPPLATE

GASKET

M8 FLAT WASHERS

M8 SPRINGWASHERS

M8x25SCREWS

TORQUE 20Nm