Ford - Explorer Sport Trac - Parts Catalogue - 2004 - 2005

BX2166 Serial Number 2002-03 Ford Explorer Sport (w/o Tow Hooks) 2004-05 Ford Explorer Sport 2001-03 Ford Explorer Sport Trac (w/o Tow Hooks) 2004-05 Ford Explorer Sport Trac Installation Instructions Attachment Tab Height: 19-1/2” Attachment Tab Width: 18” Please read BOTH these Installation Instructions and the General Instructions prior to installing or operating this equipment. 1. Blue Ox® towing products and accessories are intended to be installed by Blue Ox® Dealers who are familiar with our products and have the equipment and knowledge necessary to do “fit work”. If needed, Blue Ox® Dealers can be found at www.blueox.com or by contacting our Customer Care Department at (402) 385-3051. 2. Many Blue Ox® baseplates are designed to use existing holes and hardware to mount the baseplate to the towed vehicle. Even though bolts are there, do not assume they are adequate for baseplate mounting. Always use the hardware supplied in the hardware kit and existing hardware as specified in the installation instructions. Reference your vehicle owner’s manual for manufacturer’s towing specifications. ! Bolt Torque Specifications Torque in Foot-Pounds for Metric Bolts Bolt Size Grade 8.8 Grade 10.9 6MM 6 8 8MM 16 22 10MM 31 40 12MM 54 70 14MM 89 117 Bolt Torque Specifications Torque in Foot-Pounds for Inch Bolts Bolt Size Grade 5 Grade 8 1/4” 10 14 5/16” 19 29 3/8” 33 47 7/16” 54 78 1/2” 78 119 5/8” 154 230 WARNING Failure to read and follow these instructions could result in separation of the towed vehicle from the tow bar, causing property damage, loss of towed vehicle, personal injury or death. 292-6187 Rev C Page 1 of 4 2/19/13 BX2166 2002-03 Ford Explorer Sport (w/o Tow Hooks) 2004-05 Ford Explorer Sport 2001-03 Ford Explorer Sport Trac (w/o Tow Hooks) 2004-05 Ford Explorer Sport Trac Instruction Notes: The towhokks are removed for the baseplate installation. Some drilling and trimming is required. Place all components that are removed on a flat, sturdy surface. All items will be reinstalled unless otherwise noted after the baseplate is installed. The dimensional variations between otherwise identical vehicles can be considerable. While the baseplate was designed for easy installation, it may be necessary to tailor the baseplate slightly to compensate for vehicle manufacturer’s tolerances. The BX8869 Tail Light Wiring Kit is recommended for this vehicle. NOTICE • Handling of some cosmetic parts when installing this product may require the use of protective covers, rags, specialty tools, etc. to prevent damage. • When using power drills be aware of the dangers of torque and drill bit length. • When using a reciprocating saw be aware of objects behind the cutting surface. • Use a good quality paint to spray cut edges of frame to prevent rusting. • Be sure that ALL electrical connections are plugged in and accessories are functioning properly before reinstalling the fascia. • Do not use the towed vehicle for storing luggage, equipment, etc. This may cause you to exceed the towing capacity of the tow bar, baseplate and its accessories. • Be sure to use Loctite® Red on all bolts before tightening. Tighten all bolts according to the torque chart provided. • Dealer or installer be certain the user receives these instruction sheet. • If the baseplate is in an accident, it must be replaced. DO NOT use it again! An accident can cause unseen damage and using it again could result in more damage or serious injury. DO NOT use the baseplate if it is damaged or missing parts. 292-6187 Rev C Page 2 of 4 2/19/13 BX2166 2002-03 Ford Explorer Sport (w/o Tow Hooks) 2004-05 Ford Explorer Sport 2001-03 Ford Explorer Sport Trac (w/o Tow Hooks) 2004-05 Ford Explorer Sport Trac Tools Required Torque Wrench Drill Loctite® RED 17/32” Drill Bit 8MM Socket 10MM Socket 15MM Socket 3/4” Socket Item No. Part No. Description Qty. 1.................................61-5888..............................BX2166 Baseplate............................................................1 2.................................61-4029..............................1/2” Nut Wire....................................................................2 3.................................201-0051............................1/2”-13 x 1-1/2” Hex Head Bolt, Grade 5, ZP...................6 4.................................202-0005............................1/2”-13 Hex Nut, ZP..........................................................4 5.................................203-0012............................1/2” Lock Washer, ZP.......................................................6 6.................................201-0979............................#12-14 x 1” Self Drilling Screw, ZP...................................2 7.................................101-5822............................4 Way Connector Adapter................................................2 8.................................202-0047............................#10-32 Hex Nut................................................................2 9.................................201-0192............................#10-32 1/2” Round Slotted Head Screw...........................2 10...............................203-0054............................#10 Lock Washer, ZP.......................................................2 11................................226-0049(not shown).........Class IV Safety Cables.....................................................2 12...............................229-0512(not shown).........1/2” Quicklink, ZP.............................................................4 E.................................Existing.....................When tow hooks are on vehicle, use existing bolts & nut plates Important: Use only genuine factory replacement parts on your baseplate. Do NOT substitute homemade or non-typical parts. If a bolt is lost or in need of replacement, for your safety and the preservation of your baseplate, be sure to use a replacement bolt of the same grade (In most cases it will be Grade 5, please reference the parts list above). Replacement parts may be ordered through your nearest Blue Ox® Dealer or Distributor. Failing to follow and/ or altering these installation instructions in either installation or required equipment will void the manufacturer’s warranty. Towing behind a non-motorized vehicle will void the warranty. 292-6187 Rev C Page 3 of 4 2/19/13 BX2166 2002-03 Ford Explorer Sport (w/o Tow Hooks) 2004-05 Ford Explorer Sport 2001-03 Ford Explorer Sport Trac (w/o Tow Hooks) 2004-05 Ford Explorer Sport Trac 1. Remove the metric bolts from the belly pan with 8MM & 10MM sockets (5 total). If the vehicle has tow hooks, take both off, slide the baseplate up in position and bolt it to the frame with the existing four (4) 15MM bolts and two (2) nutplates. If the vehicle does not have tow hooks, use the four 1/2”-13 x 1-1/2” hex bolts, nuts, and lock washers(items 3, 4 and 5). 3. With all nuts and bolts tightened with loctite and torqued correctly, replace the belly pan and tighten all metric bolts. 2. Using the baseplate as a template, drill the two (2) holes on the outside of the baseplate into the bottom of the frame with the 17/32” drill bit, one on each side. Using the remaining 1/2”-13 x 1-1/2” hex bolts, 1/2” lock washer and 1/2” wire nuts(items 2, 3 and 5), finish bolting the baseplate to the frame. Note: There are slots on the outside of the tube to feed the wire nuts into. 4. Attach the permanent baseplate safety cables to the provided convenience link on the baseplate. Additional options may interfere with suggested mounting; in this case, secure the cables to a solid piece of the frame as described in the instructions included with the permanent baseplate safety cables. Be sure the safety cables do not rub against any hoses or moving parts. Do this on BOTH sides of the vehicle. CUSTOMER SERVICE COMMITMENT Blue Ox® is committed to providing you with exceptional customer care throughout your lifetime with our products. Our team is here to assist you with any questions you may have regarding the performance of your product. Simply call (402) 385-3051 and you can speak with our customer care team. Additionally, please visit our website to see which rallies our Destination America team will be attending. For a nominal fee, our service technician will service your towing system to ensure it’s in proper working condition. Also, as a commitment to our customers, should you visit our factory, you can stay at our full service Blue Ox® campground at no charge along with enjoying a factory tour. Again, thank you for being our customer and for the confidence you have shown in the performance of our products. It is because of customers like you we enjoy the success we have today. 292-6187 Rev C Page 4 of 4 © 2012 Blue Ox One Mill Road, Industrial Park Pender, Nebraska 68047 Phone: (402) 385-3051 Fax: (402) 385-3360 www.blueox.com 2/19/13 General Information 1. Ensure that your product(s) are registered online at www.blueox.com. It is crucial to register your product(s) so that you may be alerted of product offerings, updates, upgrades, maintenance and safety bulletins, and/ or recalls. 2. It is the owner’s responsibility to inspect all towing equipment for cracked welds, missing or worn parts and loose bolts before each towing trip. Be sure to use Loctite® Red on all bolts and tighten to the recommended specifications. 3. It is the owner’s responsibility to hook up all towing equipment per manufacturer’s instructions/ recommendations. 4. Remove the attachment tabs when not in use (if applicable). Notice To Baseplate Installer 1. It is YOUR responsibility to watch for: • Oil cooler and air conditioner lines • Electrical wires and hoses • Missing parts or attaching points on the frame ** If the baseplate is improperly installed and is against a wire or hose, it could cause fluid leaks or electrical shorts some time after the actual baseplate installation. Permanent Baseplate Safety Cable Installation Permanent baseplate safety cables are strongly recommended when towing a vehicle with a tow bar. The principle function of the permanent baseplate safety cables is to prevent the towed vehicle from breaking loose in the event the connection between the frame of the towed vehicle and the baseplate fails or becomes disconnected. The cables must be connected from the baseplate to the frame rail or cross member of the vehicle’s frame. The illustrations below show the possible arrangements recommended by Blue Ox®. Each permanent baseplate safety cable must have an adequate weight rating for the towing system. The weight rating of the two (2) cables together will not qualify. Do not mount the permanent baseplate safety cables against wires, hoses or brake lines. These permanent baseplate safety cables should remain installed as long as the baseplate is installed on the vehicle. Permanent baseplate safety cables are to be used in conjunction with, and NOT a replacement for legally required safety cables attaching the towed vehicle to the towing vehicle. 5/11/15