Place these instructions in the vehicle’s glovebox after installation is complete

Tools Required:

Page 1 of 7

Installation Time: 60minApprox Nudge Bar Weight: 5KG

ISSUE: 10th November 2010

Important: Please read each step of these instructions carefully prior to commencing installation! !

Accessory Part No. NBAR0010

FORD FALCON FG

(2008 model onwards)NUDGE BAR

INSTALLATION INSTRUCTIONS

- 7mm Socket / Spanner- 10mm Socket / Spanner- 16mm Socket / Spanner- 17mm Socket / Spanner

- 18mm Socket / Spanner- 19mm Socket / Spanner- Sharp Knife- File

- Philips Head Screwdriver - Flat Head Screwdriver- Tinsnips

SK568

Important:Do not use this product in any other motor vehicle for which it is not designed.Do not use any other mounting location / method other than described in this instruction.It is advisable to seek assistance of another person when installing this product.

Do not remove the label from the Nudge Bar.

!

Do not repair or modify the Nudge Bar and / or its Mounting Brackets in any way - repairor modification may effect proper operation of the airbag resulting in serious injury.

Layout:

1

2

117

3

7

94

56 8

86

6

10

10 6

NON-TURBO SEDANS AND UTES

SK568 Page 2 of 7

FORD FALCON FG - NUDGE BARAccessory Part No. NBAR0010

Parts List

• To maintain your Nudge Bar properly, wash regularly with car wash detergent,hose off & chamois dry. Stubborn grime can be removed with kerosene.

• Polished surfaces can be maintained with Autosol® metal polish orsimilar products. Use as recommended.

Care Instructions:

IconQty.Component Name1NUDGE BAR

1RHS BRACKET - FRONT

1RHS BRACKET - REAR

LHS BRACKET - FRONT

LHS BRACKET - REAR

1

1

16

4

8

M10 FLAT WASHER

2

M12 FLAT WASHER

8

M10 NYLOCK NUT

2

M12 NYLOCK NUT

1

M10x30mm HEX HEAD BOLT

Item1

2

3

4

5

67

8

9

10

11

12

M12x110mm HEX HEAD BOLT

FITTING INSTRUCTIONS AUTOMOTIVEINSTRUCTION BOOKLET

RHS

SK568 Page 3 of 7

1.

Diagram 1: Remove the plastic splash guard

2.

Diagram 2: Detach the lower horizontal edge of the fender liner

FORD FALCON FG - NUDGE BARAccessory Part No. NBAR0010

3.

Diagram 3: Remove bumper retaining screws

Remove the 3 scrivets that hold the fender liner in place. Then peel back the lower vertical seam of the fender liner towards the tyre, in order to gain access to the bumper retaining screws. Undo and remove the 2 retaining screws.

Repeat procedure for the LHS.

Remove the plastic splash guard from underneath the front bumper, by undoing the 12 hex head screws, and sliding the guard out from under the vehicle.

NOTE: There are 2 screws partially hidden at the back of the splash guard.

Detach the lower horizontal edge of the fender liner from the bumper, by pulling down on the 3 clips, and simultaniously pulling the fender liner rearwards.

Repeat procedure for the LHS.

RHS

7mm

RETAINING SCREWS

SCRIVETS

CLIPS

PULL DOWN & BACK

TWO 2 x HIDDEN SCREWS

PLASTIC SPLASH GUARD

FENDERLINER

FENDERLINER

INTERNALVIEW

10mm

FORD FALCON FG - NUDGE BARAccessory Part No. NBAR0010

RHS

SK568 Page 4 of 7

4.

Diagram 4: Remove the plastic cover and intake snorkel

Diagram 5: Disconnect foglights

6.

Diagram 6: Remove hex head screws on top of the grille

Undo the 2 hex head screws on top of the grille.

Open the bonnet, and use a phillips head screwdriver to remove the 4 scrivets which hold the plastic radiator cover in place. Then release the 5 hidden clips along the front edge of the cover, by inserting a flat bladed screwdriver, and pushing rearwards. Remove the plastic cover and snorkel.

10mm

10mm

5 x HIDDEN CLIPS

4 x SCRIVETS

PLASTIC COVER

FOGLIGHT

2 X HEX HEAD SCREWS

2

1

5. FORD XR MODELS ONLY:

From inside the fender arches, locate the foglights. Then unclip the wiring from the back of the foglights (LHS and RHS), as follows:

1) Use a flat bladed screwdriver to carefully push the tabs outwards.

2) Simultaneously pulling down on the wiring harness plug.

FORD FALCON FG - NUDGE BARAccessory Part No. NBAR0010

RHS

RHS

10mm

SK568 Page 5 of 7

7.

Diagram 7: Remove the bumper

8.

Diagram 8: Remove the crash attenuators

9.

Diagram 9: Modify the crash attenuators

Using a sharp knife, completely remove the locating lugs from both of the crash attenuators.

Carefully separate the corners of the bumper from the vehicle, by pulling outwards, as shown, and remove the bumper.

Undo the 4 hex head screws, as shown, and remove the crash attenuators.

4 X HEX HEAD SCREWS

LHS CRASH ATTENUATOR

RHS CRASH ATTENUATOR

COMPLETELY REMOVE LOCATING LUG

CRASH ATTENUATOR

RHS

C

ROSS MEMBERM12x110mm HEX HEAD BOLT

M12 FLAT WASHERSM12 NYLOCK NUT

FORD FALCON FG - NUDGE BARAccessory Part No. NBAR0010

RHS

XR MODELS ONLY:

Remove the 4 horizontal elements from each side of the lower grille, as shown. File any sharp edges.

SK568 Page 6 of 7

10.

Diagram 10: Install the Mounting Brackets

11.

XT, R6 & UTE MODELS ONLY:

Removing the 2 horizontal elements on the far left & right hand sides of the lower grille. File any sharp edges.

12.Diagram 11: Modify the intake grille (XR models)

Diagram 12: Modify the intake grille (XT, R6, and UTE models)

Mount the RHS Brackets (Front and Rear), to the front crossmember, using an M12x110mm Hex Head Bolt, M12 Flat Washers, and M12 Nylock Nuts. Do not fully tighten.

Fasten the Front and Rear Brackets together using M10x30mm Hex Head Bolts, M10 Flat Washers, and M10 Nylock Nuts. Fully tighten.

Align the Bracket assembly so the slotted mounting tab is vertical, then fully tighten the M12x110mm Hex Head Bolt.

Repeat procedure for the LHS.

Note: Over-tightening may distort the vehicle cross-member.

BEFORE

BEFORE

4 HORIZONTAL ELEMENTS EACH SIDE

AFTER

2 HORIZONTAL ELEMENTS EACH SIDE

AFTER

RHS BRACKET - REAR

RHS BRACKET - FRONT

M10 NYLOCK NUTS

M10 FLATWASHERS

M10x30mm HEX HEAD BOLTS

FORD FALCON FG - NUDGE BARAccessory Part No. NBAR0010

RHS

RHS

SK568 Page 7 of 7

1.13.

Diagram 13: Refit the factory parts

Refit removed vehicle components in the following order:Crash attenuators, bumper, fender liners, plastic radiator cover, intake snorkel, plastic splash guard. FORD XR MODELS ONLY: Ensure the wiring harness is reconnected to each foglight.

14.

Diagram 14: Attach the Nudge Bar to Mounting Brackets

Carefully break the Nudge Bar protective packaging to expose the mounting tabs. Align the Nudge Bar mounting tabs to the outside surfaces of the Mounting Brackets, and attach using M10x30mm Hex Head Bolts, M10 Flat Washers, and M10 Nylock Nuts. Do not tighten fully.

15.

Diagram 15: Align Nudge Bar and tighten mounting bolts

Align Nudge Bar to desired position, and fully tighten the mounting bolts. Carefully remove the remaining protective packaging.

NOTE: Fitting the vehicle towing eye whilst the Nudge Bar is installed may be difficult, or cause damage. It is highly recommended that the Nudge Bar be removed to allow access to the front towing point.

UNDER NO CIRCUMSTANCES SHOULD THE VEHICLE BE TOWED BY THE NUDGE BAR !

FOGLIGHTS

BUMPER

FENDER LINERS

M10x30mm HEX HEAD BOLT

M10 FLAT WASHER

M10 NYLOCK NUT

INTAKE SNORKEL

PLASTIC COVER

GRILLE HAS BEEN REMOVED FROM ILLUSTRATION FOR CLARITY

MOUNTING TAB

16mm 17mm

16mm 17mm

CRASH ATTENUATORSPLASTIC SPLASHGUARD