Dee Zee DZ502684 - Manual (Page 3)

GRILLE GUARD
2011-12 FORD EXPLORER
Page 2 of 7 6/17/11 (DP)
b. Vehicles equipped with air inlet, (Figure 6): Repeat Step 2 to install the 12mm Bolt Plate and
12mm Nut Plate. Hold the Frame Bracket in the approximate position over the Bolt and Nut
Plates. Mark the outline of the Bracket onto the mounting tab on the plastic air inlet, (scoop),
(Figure 7). Remove the inlet and place it on a clean, stable work surface. Use a hacksaw to cut
the required material from the mounting area on the inlet. Check the fit often and trim material
away as necessary. Do not cut off the mounting tab. Carefully pry off the metal clip and move it
as indicated in Figure 7 or drill a 1/4" hole through the top and bottom of the scoop and replace
the clip with the included (1) 5mm x 25mm Screw, (2) 5mm Flat Washers and (1) 5mm Nylon
Lock Nut. Do not over-tighten 5mm hardware. IMPORTANT! Any cutting tool may break or
shatter. Government regulations require safety glasses & equipment at all times when cutting.
Install the Frame Bracket as described in Step 3. NOTE: Complete the Grille Guard installation
before reinstalling the plastic air inlet scoop, (Step 15).
5. Measure the width across the Grille Guard, (mounting tab to mounting tab-appx. 37" to 37-1/2"). Use a
tape measure to locate the middle of the plastic bumper cover, (Figure 8). Mark the mid point on the
back of the bumper. NOTE: You can also locate the mold mark on the back of the bumper to determine
the mid point. Place a layer of masking tape on the back of the bumper cover in front of the Frame
Mounting Brackets. On the driver side, draw a vertical line on the tape 18-1/2" out from the middle of
the bumper cover to the driver side. Draw a second vertical line 19-1/2" out from the middle, (Figure 8).
6. Use the locations of the previously installed Frame Mounting Brackets to determine where to draw the
top and bottom horizontal lines, (Figure 9). Carefully cut this area out of the bumper cover with a sharp
knife or hacksaw, (Figure 10). IMPORTANT: Do not cut through the top or bottom edge of the bumper
cover. Only remove enough material to clear the mounting tabs on the Grille Guard.
7. Repeat Steps 5 & 6 to cut out the passenger side of the bumper cover.
8. Reinstall the bumper cover if previously removed.
9. With assistance, position the Grille Guard onto the outside of the Mounting Brackets. Attach the Grille
Guard to the Mounting Brackets with (6) 12mm x 35mm Hex Bolts, (12) 12mm Flat Washers and (6)
12mm Nylon Lock Nuts, (Figure 11). Align, level and adjust the Grille Guard but do not completely
tighten the hardware at this time.
10. Open the front hood. Cover the top of the grille and plastic cover, (driver and passenger sides), with
removable tape, (masking tape preferred-tape not included), to avoid damage to finish during Top
Bracket installation, (Figure 12). Select the driver side Top Bracket. Hold the Top Bracket in
approximate position between the Grille Guard and the hex bolt on the top cover. Mark the location
onto the tape on the plastic cover, (Figure 13). Repeat this Step for passenger side Top Bracket.
11. Remove the cover. Note the type and location of all factory hardware for reinstallation.
12. Next, place a 2" x 2" piece of the Thin Adhesive Backed Foam Tape on the underside of the Top
Brackets anywhere it can come in contact with the top of the plastic grille, (Figure 14). Trim the Foam
Tape as necessary.
13. Cut out the front edge of the cover and the front side of the indented pocket for the hex bolt, (Figures
15 & 16), to clear the Top Brackets. Once properly trimmed, place the cover in the original position.
14. Insert the driver side Top Bracket through the opening cut into the top cover and line up the mounting
slot. Bolt the Top Bracket to the cover with the included (1) 6mm x 35mm Hex Bolt, (1) 6mm Flat
Washer and (1) 6mm Lock Washer, (Figure 17). Line up the remaining, (forward), end of the Top
Bracket with the hole in the upright on the Grille Guard. Bolt the Bracket to the inside of the upright with
(1) 10mm x 25mm Button Head Bolt, (2) 10mm x 20mm Flat Washers and (1) 10mm Nylon Lock Nut,
(Figure 18). Repeat this Step for passenger side Top Bracket installation.
15. Align and adjust the Grille Guard properly and tighten all hardware. Remove protective masking tape
from the top of the plastic grille, (Step 9).
16. Reinstall the air inlet, (scoop), removed in Step 4b. Trim scoop to clear Brackets as necessary.
17. Do periodic inspections to the installation to make sure that all hardware is secure and tight.
NOTE: Before proceeding, it may be considerably easier to remove the plastic bumper cover to cut
the slots for the Grille Guard. However, the bumper cover may be held in place with rivets making
removal and reinstallation very difficult, (Figure 6). Determine if the bumper is held in place with
rivets, (visible from the outside-below the fog lights), before attempting to remove the bumper cover.