This is the installation guide for the STEDI Rally Bar.
You will require the following tools:
• Flat blade screwdriver
• Socket Ratchet (with Extension)
• T25 Allan Key
• 10mm spanner
• 2 x 13mm spanner
• Hacksaw blade
Note: Do not use any power tools, as this will damage the stainless hardware.
Step 1: Remove Support Cover
Lift Bonnet in order to remove the Black radiator support cover.
To do this, loosen the 4 clips, along with the 2 Torx screws located on the left-hand side (as seen in the image below). A flat blade screwdriver will suffice for removing these clips/screws
(Note: There are clips located on the left and right ends of the cover. You will need to place one hand underneath the cover in order to remove it from the vehicle).
Step 2: Remove Grill
(Note: the grill for the Wildtrak is lower, but follows a similar process)
Locate the 2 bolts at the top of the grill (10mm head). Remove bolts.
There are 2 additional bolts that are located pretty far down behind the grill, so you will need to use an extension in order to loosen these bolts.
The Everest also has two horns (one per side), that can be removed in order to get the bolts out.
As seen in the image below, the back of the Grill has male tabs that fit into the female slots of the bumper. So in order to remove the grill completely, you will need to reach in behind and use a screwdriver to pop the tabs out of their respective sockets.
Step 3: Remove Splash Cover
There are 4x Torx head bolts that need to be unscrewed in order to remove the splash cover (use a T25 Allan Key).
Once screws have been removed, simply slide the Splash Cover out.
Now it's time to install the Rally Bar!
Step 4: Fitting the Structural Plates
There are 2x Structural Plates. One has the STEDI branding. This will be fitted to the Right-Hand side of the Vehicle (or on the Australian Driver’s side). Ensure that the SEDI Branding faces inwards when fitting. The second structural plate will be fitted to the Left-Hand side of the vehicle (or on the Australian Passenger’s side).
To get the Structural Plates into place, you will need to avoid any contact with the plastic intercooler in order to prevent any potential damage (however contact can be made with the top of the intercooler).
Trying to insert the Structural Plate (as seen below) will be problematic.
Instead, we suggest weaving each structural plate into place as seen below:
To fit the Structural Plates, you will need to ensure that the Plates are resting on top of the Lower Radiator Support Bracket, along with ensuring the holes on the top of the Structural Plates line up with the holes at the top of the intercooler. Ensure that a washer is placed on both sides of the bolt when securing.
We recommend using a 10mm spanner for holding the top bolts when tightening (as seen below).
(Note: we recommend lubricating the bolts and nuts before fitment).
For the bottom - you will need 2 x 13mm Spanners, which will be used to tighten the Hex Head Bolt and Nylock Nut.
(Note: Ensure that the bracket remains parallel to the intercooler).
The Boomerang piece will rest on the two secured structural plates. Ensure that the STEDI Owl is on the left-hand side (as seen below):
Use 4 x M8 Cap Screw Bolts to fit the Boomerang Piece to the structural plates. Tighten with socket ratchet.
Step 5: Ford Everest Grill
Now you will need to cut into your Front Grill so as to allow the Extension Brackets to fit through.
Using the Ford Emblem as the center line, use masking tape to outline two even areas (on either side of the emblem) for the Extension Brackets to fit through. We suggest a 290mm gap between the minimum cuts on either side and a 250mm gap between the maximum cuts on either side. Make sure you allow 30mm of height for the extension bracket to fit through.
Remove the vertical sections. You can remove these sections of the grill with any tool you think is suitable. We’re using a thin hacksaw blade, along with a set of pliers to assist in removing the marked-out sections of the grill.
Step 6: Securing the Extension Plates
• Set the grill back into position, but make sure that you don’t clip the bottom of the grill in.
• You should have around 10mm of clearance between the grill and the bonnet latch cover
• Insert the Extension Plates behind the grill (you can move the grill if you need to). Again, make sure you don’t touch the intercooler!
Take one bolt and screw it through the Extension Plate to the vertical Structural Plates. Make sure you don’t tighten your screws just yet, as you may need to make adjustments. Just tighten them with your hands. Once the bolt has been fitted, make sure the Extension Plate fits suitably through the front grill like so:
You can then fit the other bolt to the Extension Plate. Slide the bolt along the slot of the bracket until it fits into the appropriate hole.
The 3rd bolt can also be fitted through the front of the Extension Plate, into the vertical Structural Plate.
Now use your Allan key (for the screw head) and Socket Ratchet (with an extension bar) to tighten up the bolts. Make sure your ratchet does not touch the intercooler. You can use the lower opening of the bumper in order to reach the bolts on the side of the Extension Bracket (as seen below).
Now that the Extension Brackets are set in their height, you can unclip the front Grill and slide it out so that it's resting on the brackets. This will allow easy access to the front bolts. You will need to use a spanner for the nuts facing the intercooler as shown below:
You can now clip the grill back to its original position, but don't fit bolts just yet.
Step 7: Rally Bar
Now it's time to fit the Rally Bar to the Extension Brackets. If you wish to attach your Hex brackets before the install, then go right ahead. Just make sure the brackets are fitted to be on the inside of the Extension Plates.
Fit the Rally Bar to the Extension Brackets, so that the bolt holes are matching up. Fit the bolts and then tighten with the Allan key and Socket Ratchet. Make sure the angle of the Rally Bar is as straight as possible and parallel with the ground.
Step 8: Final Steps
You can now fit the Grill back into your vehicle, along with any other original parts that you removed throughout the process.