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Kit No. 1401-1 12-12-97

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R 1-800-669-9690 O A D M A S T E R MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 PARTS LIST: 1- FACE PLATE (A) 1- FRONT BRACE (B) - Passenger side 1- FRONT BRACE (C) - Driver's side 1-800-669-9690 fax 360-735-9300 www.roadmasterinc.com KIT NO. 1401-1 12-12-97 IMPORTANT: IMPORTANT: All All brackets brackets must must be be assembled assembled with with all all the the bolts bolts left left loose loose for for final final adjustment adjustment and and positioning positioning (before (before tightening) tightening) unless otherwise instructed. All bolts must be torqued for proper strength. If more than one bolt is used per unless otherwise instructed. All bolts must be torqued for proper strength. If more than one bolt is used per fastening fastening point, point, the the diagram diagram may may only only show show one. one. •• Use Use flat flat washers washers over over all all slotted slotted holes holes •• Use Use lock lock washers washers on on all all fasteners fasteners ROADMASTER ROADMASTER Limited Limited Warranty, Warranty, including including One-Year One-Year Conditional Conditional Warranty Warranty Text Text and and Product Product Registration Registration Card, Card, in in Carton. Carton. WARNING Failure Failure to to follow follow these these instructions instructions can can result result in in property property damage, damage, perpersonal sonal injury injury or or even even death. death. Installation of of most most mounting mounting brackets brackets requires requires moderate moderate mechanical mechanical •• Installation • aptitude Installation ofskills. most mounting brackets requires moderate mechanical aptitude and and skills. We strongly strongly recommend professional installation by We recommend professional installation by aptitude and skills. We strongly recommend professional installation by an experienced installer. an experienced installer. an installer. Theexperienced installer must must read the the instructions instructions and and use use all all bolts bolts and and parts parts •• The installer read • supplied. The installer must read thefasten instructions use all bolts andthread parts supplied. When instructions require the and reuse of factory Failurethe to securely the bracket could result inbolts, loss of the supplied. Failure to securely fasten could result in loss fasten of the lock and/or lock washers must also the be bracket used. Failure to securely towed vehicle. towed vehicle. the bracket could result in loss of the towed vehicle. • Do not use this document for custom fabrication, as it may not show all • parts Do not this document for custom asan it may not show all oruse structural components. Custom fabrication, fabrication or attempt to copy partsbracket or structural Custom an attempt to copy this designcomponents. could result in loss offabrication the towedor vehicle. this bracket design could result in loss of the towed vehicle. • The owner must inspect all mounts and brackets before each use • for Every 3,000 miles,signs the of owner must inspect for proper proper cracks or other fatigue. Also, inspectthe thefasteners fasteners for torque, according according to of torque, to the the bolt bolt torque torque requirements requirementschart charton onthe thelast lastpage page. these instructions. The result ownerinmust inspect mounts and brackets Failure to do so could lossalso of the towedall vehicle. for cracks or other signs of fatigue every 3,000 miles. Failure to do so • The check the vehicle manufacturer's instructions for the couldowner resultmust in loss of the towed vehicle. proper procedure(s) to prepare the vehicle for towing. Some vehicles • must The owner must check the vehicle manufacturer's instructions fordrivthe be equipped with a transmission lube pump, an axle disconnect, proper procedure(s) to prepare hubs the vehicle for towing. eline disconnect or free-wheeling before they can be Some towed.vehicles Failure must be equipped withvehicle a transmission lube pump,damage an axle to disconnect, drivto properly equip the will cause severe the transmiseline disconnect or free-wheeling hubs before they can be towed. Failure sion. to properly equip the vehicle will cause severe damage to the transmis• Ifsion. running changes were made by the vehicle manufacturer after this bracket was designed, some bolts or other fasteners in the included hard• ware If running changes were by the vehicle manufacturer this pack may no longer bemade the correct size. It is the installer’s after responbracket to was designed, some boltsisorsecurely other fasteners sibility verify that the bracket fastenedintothe theincluded vehicle,hardand ware with packthe maycorrect no longer be the to correct size.forIt these is the changes. installer’sFailure responfitted hardware, account to sibility to verify that the bracket is securely fastened to the vehicle, and fitted withfasten the correct hardware, account for of these Failure to securely the bracket couldtoresult in loss the changes. towed vehicle. securely fasten the bracket could result in loss of the towed vehicle. • If the towed vehicle has been in an accident, it must be properly repaired • before If the towed vehicle has beenDo in not an accident, it must be if properly repaired attaching the bracket. install the bracket any structural before damage attachingisthe bracket. Do not installthe thedamage bracketcould if any structural frame found. Failure to repair result in the frame found. Failure to repair the damage could result in the loss of damage the towedisvehicle. loss of the towed vehicle. • Some motorhome chassis have such a tight turning radius that you can • damage Some motorhome chassistowed have vehicle, such a tight turning radius while that you can your motorhome, tow bar or bracket turning damageBefore your motorhome, towed vehicle, tow turning bar or bracket sharply. getting on the road, test your radius while in an turning empty sharply. Before getting the road, testresult your in turning radius indamage an empty parking lot. Turning tooonsharply could non-warranty to parkingsystem, lot. Turning too sharply in non-warranty damage to towing motorhome and/orcould towedresult vehicle. towing system, motorhome and/or towed vehicle. • Do not back up with the towed vehicle attached or non-warranty dam• age Do not with towing the towed vehicle attached or non-warranty damwill back occur up to your system, motorhome and/or towed vehicle. age will occur to your towing system, motorhome and/or towed vehicle. • The safety cables must connect the towing vehicle to the towed ve• hicle The safety must connect the towing vehicle to the towed veframe cables to frame, with the cables crossed, with enough slack for hicle frame frame, with the cables crossed, with enough slack for sharp turns.to Refer to the cable instructions for proper routing. Failure to sharpenough turns. Refer for proper routing.the Failure to leave slack to in the the cable safetyinstructions cables, or failure to connect safety leave enough in the safety incables, or of failure to connect the safety cables frame toslack frame, will result the loss the towed vehicle. cables frame to frame, will result in the loss of the towed vehicle. • This bracket is designed for use with ROADMASTER tow bars and ROAD• MASTER This bracket is designed for use with ROADMASTER bars and ROADadaptors only. Using this bracket with othertow brands, without an MASTER adaptors only. Using this bracket with in other brands, without an approved ROADMASTER adaptor, may result non-warranty damage approved or injury. ROADMASTER adaptor, may result in non-warranty damage or injury. • Upon final installation, the installer must inspect the bracket to ensure • adequate Upon final clearance, installation,particularly the installeraround must inspect bracket to ensure hoses, the air conditioner lines, adequate clearance, particularly around air vehicle conditioner lines, radiators, etc., or non-warranty damage to hoses, the towed will result. radiators, etc., or non-warranty damage to the towed vehicle will result. • This bracket is only warranteed for the original installation. Installing • aThis bracket only warranteed therecommended original installation. used bracketison another vehicle for is not and will Installing void the a used bracket on another vehicle is not recommended and will void the warranty. warranty. R 1-800-669-9690 O A D M A S T E R MOUNTING BRACKET KIT INSTALLATION INSTRUCTIONS ROADMASTER, Inc. 6110 NE 127th Ave. Vancouver, WA 98682 1-800-669-9690 fax 360-735-9300 www.roadmasterinc.com KIT NO. 1401-1 Note: the front bumper and brackets must be removed. This is simple with the removal of 4 bolts from the bumper and 6 bolts from the brackets. Note: if there is a center metal splash guard, remove it to gain access to the ½” x 3½” bolt and spacer for main brace just in front of the steering gear housing. The clearance is close but reachable. 1. Important: please use all supplied bolts and parts and read all instructions carefully before beginning this installation. The majority of questions you may have can be answered within the text, and proper installation will ensure safe and secure travel. Now, begin the installation. There is a rubber splash guard in the fender well, ahead of the front tires. This splash guard drops down and forward. Work it back, out of the position it is in. This will expose all of the bolts necessary to mount the brackets. Don't forget, when re-assembling, to put this splash guard back in place. 2. Remove the two bolts on the outside of the bumper and remove the two top bolts from the inside of the bumper. Now, set the bumper aside. 3. Remove the bracket that secures the bumper to the frame. 4. Place the main brace against the outside of the passenger side of the frame, and then position the bumper bracket back in place with main brace sandwiched in between. Now, bolt it to the frame with ¼” x 1” x 4½” backing plate with bolts in the front two holes. Note: the two front bolts must go from the inside out. Use the existing 10mm bolts originally removed from the bumper bracket for the rear hole only. 5. Locate the existing hole directly behind the face of the main brace. Using the 1¼” spacer and ½” x 3½” bolt, fasten this last hole of the brace to the car. There is a large access hole in the driver side of the cross member to reach the hole. 6. Repeat this step on the driver's side. 7. Bolt the face plate to the braces using ½” x 1½” carriage bolts provided. Now, starting with the face plate, tighten all bolts according to the torque chart shown below. 8. Remove the face plate to gain access for re-installing the bumper. Replace the bumper. Bumper may have to be notched to fit around the main braces. 9. Reinstall the face plate and torque. 10. Bolt the tow bar to the face plate according to the instructions provided with the tow bar. HARDWARE LIST: 4-1/2” X 1 ½” CARRIAGE BOLTS 10-1/2” LOCK WASHERS 2-1/2” FLAT WASHERS 2-1/2” X 3” BOLTS 10-1/2” NUTS 2-7/16” FLAT WASHERS 2-1/2” X 1 ¼” PIPE SPACERS 2-1/4” X 1” X 4 ½” BACKING PLATES W/HOLES 12-12-97 BOLT TORQUE REQUIREMENTS Note: The torque values represented below are intended as general guidelines. Torque requirements for specific applications may vary. Roadmaster does not warrant this information to be accurate for all applications and disclaims all liability for any claims or damages which may result from its use. STANDARD BOLTS Thread Size Grade METRIC BOLTS Torque 5/16 ................... 5 ......................... 13 3/8 ...................... 5 ......................... 23 7/16 ................... 5 ........................ 37 1/2 ...................... 5 ........................ 56 5/8 ...................... 5 ...................... 150 ft./lb. ft./lb. ft./lb. ft./lb. ft./lb. Thread Size Grade 8mm-1.0 ......... 8mm-1.25 ....... 10mm-1.25 ..... 10mm-1.5 ....... 8.8 8.8 8.8 8.8 METRIC BOLTS Plated / Unplated ...... 20 ft./lb. ...... 19 ft./lb. ..... 38 ft./lb. ..... 37 ft./lb. 18 18 36 35 ft./lb. ft./lb. ft./lb. ft./lb. Thread Size Grade 12mm-1.25 ..... 12mm-1.5 ....... 12mm-1.75 ..... 14mm-2.0 ....... 8.8 8.8 8.8 8.8 Plated / Unplated ...... 70 ft./lb. ...... 66 ft./lb. ..... 65 ft./lb. ... 104 ft./lb. 65 61 60 97 ft./lb. ft./lb. ft./lb. ft./lb. All illustrations and specifications contained herein are based on the latest information available at the time of publication approval. ROADMASTER, INC. reserves the right to make changes at any time without notice in material, specification and models or to discontinue models.