INSTALLATION GUIDE BBCD071 - TO SUIT SSANGYONG MUSSO Q200 / Q201 AND REXTON 10/2018+ - Ironman 4x4
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INSTALLATION
GUIDE
BBCD071
TO SUIT SSANGYONG MUSSO Q200 / Q201
AND REXTON 10/2018+
• Ironman 4x4 BBCD071 Bull Bar to suit SsangYong Musso Q200 / Q201, Rexton
• It will take about 4 hours to install
• All bolts, washers, spring washers and nuts are supplied unless otherwise indicated
• All drilled holes must have anti-corrosion treatment applied
BB071/240920
NOTE: This product has been tested for air bag compatibility and
therefore the mounting system MUST NOT BE modified
IMPORTANT: Bull Bar installations should only be done by a qualified person and it’s the
responsibility of this person to ensure correct fitment.
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Installation Guide BBCD071
1. Before installation check bull bar application is compatible with your vehicle.
Before making any cuts, please refer to bumper cutting instructions applicable to your
vehicle model (SsangYong Musso and Rexton).
2. Unwrap bull bar. Check over riders and light assemblies are tight in bull bar before
installation.
3. Remove grill, front bumper,
bumper bar reinforcement,
bumper bar support brackets and
front protection plate from under
chassis.
Undo the power steering
cooler and leave hanging for
reattachment later in the process.
4. Apply masking tape to bumper bar,
use provided template to mark the
bumper cut lines on each side.
Note:
If fitted with park sensors and
camera - remove sensors, camera
and loom.
Image is for illustrative purposes
only and cutting should be
performed with bumper removed
from vehicle.
Page 2 of 16
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Installation Guide BBCD071
5. At the centre point, measure down
25mm from the grill as shown.
Join to left and righthand side
template cut line.
With the bumper removed from the
vehicle, mark cut line across the
bumper and cut as shown.
Image is for illustrative purposes
only and cutting should be
performed with bumper removed
from vehicle.
6. Slide the chassis strengthening
brackets in position on the chassis,
(ensure the bracket that has the
undertray bolt hole to the outside)
using 2 x 100mm M12 bolts,
spring and flat washers as shown.
7. Insert the crush tube into the
radiator support bracket as shown
using 1 x 120mm M12 bolt,
washer and nut.
Tighten all bolts
Page 3 of 16
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Installation Guide BBCD071
8. Using holes in the inner and outer
of chassis strengthening brackets
as a guide, drill a 12.5mm
hole and install a 100mm M12
mounting bolt, washer, spring
washer and nut.
Repeat Steps 3, 4 and 5 for the
opposite side of the vehicle.
9. Lift winch cradle into position and
attach using 8 x M12 bolts. Centre
the bracket to vehicle body and
tighten all bolts.
10. Install the power steering mounting
plate and attach the power
steering lines using 4 x M8 bolts,
washers and nuts.
Page 4 of 16
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Installation Guide BBCD071
11. Mount camera to bull bar using
2 x M6 bolts, spacers and Nyloc
nuts.
Run wire behind camera mounts
as shown.
Re-fit the grill and bumper to the
vehicle. Attach crimp weld.
12. If winch is being installed, refer to winch
installation instructions on page 11.
13. Fit bezels and parking sensors to bull
bar as per instructions on page 7.
14. Fit bull bar to chassis brackets using
6 x M12 bolts, flat washers, spring
washers and nuts.
15. Align bull bar with vehicle.
15 - 20mm gap required between
bull bar and body is required.
A larger gap may be required
under certain driving conditions,
as per customer requirements.
Drill and pin bar with 4 x M10
bolts, washers and nuts.
Page 5 of 16
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Installation Guide BBCD071
16. Connect park lights, indicators, DRL
(if fitted) and fog lights as per wiring
diagram from page 13.
Note:
Supplied fog light loom must be used.
17. Attach protection plates to bull bar
as shown.
18. Trim guard liners to suit.
Page 6 of 16
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Plastic Parking Sensor Installation Guide BBCD071
Plastic Parking Sensor Installation
IMPORTANT: Parking sensors should be installed as close to the same direction
as when they sit in the factory bumper.
1. For new vehicles with parking
sensors, the new bars will now
come with a plastic parking sensor
holder kit. The sensor mounting
kit will be inside the bar mounting
hardware box.
2. The bars come with a rubber plug
in the sensors hole. This plug
needs to be pushed out if you need
to install the sensors into the bar.
Page 7 of 16
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Plastic Parking Sensor Installation Guide BBCD071
3. Using supplied wipes, clean
around the sensor hole on the
INSIDE of the bar.
4. The kit comes with double sided
stickers to enable you to stick the
sensor holder in place.
5. Remove the middle of the sensor
holder to allow the vehicle sensor
to go through.
Page 8 of 16
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Plastic Parking Sensor Installation Guide BBCD071
6. Before applying double sided
sticker, wipe down sensor holder
and surrounding area of bull bar
with adhesion promotor supplied.
Apply double sided sticker (also
supplied) to rear of sensor.
7. Remove the double sided stickers
protective layer and install the
sensor holder into the bar.
IMPORTANT: Parking sensors
should be installed as close to the same
direction as when they sit in the factory
bumper.
Page 9 of 16
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty Ltd
Plastic Parking Sensor Installation Guide BBCD071
10. Install the backing plate to suit the
sensor.
11. Ensure that the sensor is installed
correctly and centred.
Page 10 of 16
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty LtdInstallation Guide BBCD071
Winch Installation
1. Bolt fairlead to recess in front of
bull bar using bolts, washers and
nuts provided.
2. Fit bull bar to vehicle referring to
steps of bull bar fitting instructions.
3. Mount control box in desired
location.
4. Connect three colour coded cables
to the corresponding poles on
winch motor.
Page 11 of 16
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty LtdInstallation Guide BBCD071
5. Connect the thin black earth wire
and negative battery cable to the
earth connection on the opposite
side of winch motor.
6. Run the positive and negative
battery cables into the engine bay
taking care to secure cables away
from any sharp or moving objects.
7. Connect positive and negative
battery cables main battery of
vehicle (Not Auxilliary Battery).
8. Attach breather hose to barb fitting
on winch motor. Run hose to the
highest available point in engine
bay and cable tie in position. Cable
tie hose away from any sharp, hot
or moving objects.
Refer back to step 18 of the Bull
Bar fitting instructions on page 7
Page 12 of 16
©Copyright 2020 Ironman 4x4 Pty Ltd. No part of this publication may be reproduced or replicated without the prior written consent of Ironman 4x4 Pty LtdInstallation Guide BBCD071
Wiring Diagrams
PARK LIGHT, INDICATOR LIGHT AND DAYTIME RUNNING LIGHT
Red R/H Headlight wiring
Daytime Running Light
Brown Red (DRL) to Yellow/Green
Park Light Brown (Park) to White/Green
Yellow
Indicator Light White (Ground) to Black
Yellow (Indicator) to Brown/Yellow
White L/H Headlight wiring
Red (DRL) to Blue/Green
Brown (Park) to Yellow/Black
Ground
White (Ground) to Black
If vehicle is not fitted with DRL, leave red wire disconnected Yellow (Indicator) to Blue/Yellow
FOG LIGHTS
Ground Red
Red Lamp
Fuse
85 30
Connector
87
86 87a Relay
Black
Blue
Battery Lamp
Positive power supply
at connector to factory fog light
Page 13 of 16
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