UNDERCARRIAGE INSTALLATION INSTRUCTIONS
UNDERCARRIAGE HARDWARE KIT FOR MODELS:

31085 61270

FORD EXPEDITION 1999-2003 FORD F-150 FX4 PICKUP 2002-2003

64107 3/1/06

INSTALLATION INSTRUCTIONS
1. Remove the front bumper. 2. Remove the plastic bumper fascia from the bottom of the bumper. NOTE: The bumper fascia will need to be permanently removed or notched to accommodate the undercarriage. If your truck has frame rail mounted tow hooks these will have to be permanently removed as well. 3. Align the front mount holes on the pushbeam (Ref 1) with the tow hook mount holes on the truck frame rail. NOTE: Use a hydraulic floor jack to hold the pushbeam in place. Secure the pushbeam to the truck with bolts (Ref 9), washers (Ref 10) and nuts (Ref 11). Finger tighten the hardware until all undercarriage parts are in place. 4. Position the rear pushbeam support arm mount holes with the holes located in the truck frame crossmember. NOTE: The crossmember contains two rubber access caps that need to be removed to gain access to the inside of the crossmember. Using grease or other adhesive, attach washers (Ref 10) to bolts (Ref 12). Then attach a thin gauge wire to each bolt and position the wire through each crossmember access hole to the middle mount holes. Pull the bolt through the holes into the crossmember and pushbeam support arms. Fasten each bolt with nut (Ref 11) and additional washer. Replace the rubber access caps. 5. Finish securing the pushbeam to the truck frame with the bolts (Ref 6), washers (Ref 7) and nuts (Ref 8) through the bottom of the pushbeam at the tow hook mount holes located under the truck frame rail 6. Level the pushbeam with the floor and tighten the hardware to torque specifications 7. Replace the bumper and notched fascia using existing hardware. 8. Position the Light Tower into the mount pockets on the push beam. Each pocket has a lock pin that secures both light tower arms. Pull out and twist each ring handle to temporarily unlock the pins. Place the light tower into the pockets and relock the pins. Mount each Plow Headlight to the light tower with the hardware kit provided. 9. Plug the connectors from the snowplow headlights into the connectors on the vehicle wire harness. Adjust both lights with the plow in the raised position.
A label identifying the undercarriage assembly part number and push beam part number is applied to the rear of the push beam.
16 P/N 30042 PUSH BEAM P/N 30037
The recommended push beam height for this undercarriage assembly is 12-1/2" from the center of the push beam to level ground. DO NOT exceed 14-1/2" in height for this undercarriage.
WARNING: Always perform vehicle undercarriage installations with the keys removed from the vehicles ignition. Properly tag the ignition switch to alert others work is being performed on the vehicle. Most newer trucks are equipped with driver and passengers side air bags. DO NOT remove, disable, or reposition any sensory equipment related to the safe operation of the air bags. ALWAYS follow the vehicle manufacturers recommendations for installing snowplowing equipment. FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH.

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64107-B (31085) 3/1/06

UNDERCARRIAGE PARTS

REF 11 12

PN 61020 61276

QTY 4 2
DESCRIPTION Asm, Undercarriage Kit, Hardware UC Weldment, Push Beam 2 X 4 X 36-3/4 Decal, Push Beam 1-1/2" x 6-1/2" Spring, Draw Latch Lock Pin Ring, Standard Split, 1.48" O.D Pin, 3/8" DIA. x 1-3/4" SS Screw, 9/16-12 x 1-1/2 HHCS GR8 YZ Washer, 9/16 USS Hardened Nut, 9/16-12 Top Lock Z Screw, 1/2-13 x 1-1/2 HHCS GR8 YZ Washer, 1/2 SAE Hardened Nut, 1/2-13 Top Lock Z Screw, 1/2-13 x 2-3/4 HHCS GR8 YZ
NOTES INCLUDES 1-12 INCLUDES 6-12
Note: The reference numbers listed identify parts shown in the illustration above. These numbers are specific to this illustration only. Always review the part number given for proper component identification. Blizzard reserves the right, under its Continuous Improvement Policy, to change construction or design details and furnish equipment when so altered without reference to illustrations or specifications.

64107-A (31085) 3/1/06

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HEADLIGHT CONVERSION HARNESS GUIDE

VEHICLE APPLICATION

1998-2003 FORD EXPEDITION 2002-2003 FORD F-150 FX4 PICKUP

HEADLIGHT CONNECTOR

HEADLIGHT DESCRIPTION

HEADLIGHT NUMBERS

CONVERSION HARNESS
DUAL RECTANGULAR HB5 9007, HCOMPOSITE HALOGEN Note: Headlight conversion harness kits are not included with undercarriages. All headlight conversion harness kits sold separately.
TORQUE SPECIFICATIONS (For reference only)
Grade Identification Marking for J429-Grade 5 Bolt SAE J429 Grade 5 Nominal Clamp Loads Tightening Torque Thread Size (lbs) Lubricated Dry 1/4-20 2,ft-lbs 8 ft-lbs 5/16-18 3,ft-lbs 18 ft-lbs 3/8-16 4,ft-lbs 31 ft-lbs 7/16-14 6,ft-lbs 50 ft-lbs 1/2-13 9,ft-lbs 75 ft-lbs 9/16-12 11,ft-lbs 109 ft-lbs 5/8-11 14,ft-lbs 151 ft-lbs 3/4-10 21,ft-lbs 266 ft-lbs 7/8-9 29,ft-lbs 430 ft-lbs 1-8 38,ft-lbs 640 ft-lbs Grade Identification Marking for J429-Grade 8 Bolt SAE J429 Grade 8 Nominal Clamp Loads Tightening Torque Thread Size (lbs) Lubricated Dry 1/4-20 2,ft-lbs 12 ft-lbs 5/16-18 4,ft-lbs 25 ft-lbs 3/8-16 6,ft-lbs 44 ft-lbs 7/16-14 9,ft-lbs 70 ft-lbs 1/2-13 12,ft-lbs 107 ft-lbs 9/16-12 16,ft-lbs 154 ft-lbs 5/8-11 20,ft-lbs 211 ft-lbs 3/4-10 30,ft-lbs 376 ft-lbs 7/8-9 41,ft-lbs 606 ft-lbs 1-8 54,ft-lbs 900 ft-lbs
Grade Identification Marking for Metric-Grade 8.8 Bolt Metric Class 8.8 Diameter Clamp Loads Tightening Torque (mm) (Pounds) Lubricated Dry 5 1,ft-lbs 5 ft-lbs 6 1,ft-lbs 8 ft-lbs 7 2,ft-lbs 13 ft-lbs 8 3,ft-lbs 19 ft-lbs 10 5,ft-lbs 37 ft-lbs 12 8,ft-lbs 65 ft-lbs 14 11,ft-lbs 103 ft-lbs 16 15,ft-lbs 167 ft-lbs 18 19,ft-lbs 229 ft-lbs 20 24,ft-lbs 325 ft-lbs
Grade Identification Marking for Metric-Grade 10.9 Bolt Metric Class 10.9 Diameter Tightening Torque Clamp Loads (mm) (Pounds) Lubricated Dry 5 1,ft-lbs 7 ft-lbs 6 2,ft-lbs 11 ft-lbs 7 4,ft-lbs 19 ft-lbs 8 5,ft-lbs 27 ft-lbs 10 8,ft-lbs 53 ft-lbs 12 11,ft-lbs 92 ft-lbs 14 16,ft-lbs 148 ft-lbs 16 21,ft-lbs 231 ft-lbs 18 26,ft-lbs 317 ft-lbs 20 34,ft-lbs 450 ft-lbs

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64107-A(31085) 3/1/06

January 15, 2008 Lit. No. B64107, Rev. 03

B31085

UNDERCARRIAGE KIT
Ford F-150 FX4 Ford Expedition 2002 - - 02
Parts List and Installation Instructions

CAUTION

Read this document before installing the snowplow.
See your BLIZZARD outlet/Web site for specific vehicle application recommendations before installation. The Undercarriage Selection Guide has specific vehicle and snowplow requirements.
A DIVISION OF DOUGLAS DYNAMICS, L.L.C.

SAFETY

SAFETY DEFINITIONS WARNING
Indicates a potentially hazardous situation that, if not avoided, could result in death or serious personal injury.

SAFETY PRECAUTIONS

Improper installation and operation could cause personal injury, and/or equipment and property damage. Read and understand labels and the Owner's Manual before installing, operating or making adjustments.
Indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. NOTE: Indicates a situation or action that can lead to damage to your snowplow and vehicle or other property. Other useful information can also be described.

WARNING

Lower blade when vehicle is parked. Temperature changes could change hydraulic pressure, causing the blade to drop unexpectedly or damaging hydraulic components. Failure to do this could result in serious personal injury.
The driver shall keep bystanders clear of the blade when it is being raised, lowered or angled. Do not stand between the vehicle and the blade or within 8 feet of a moving blade. A moving or falling blade could cause personal injury.
Keep hands and feet clear of the blade and A-frame when mounting or dismounting the snowplow. Moving or falling assemblies could cause personal injury.
Do not exceed GVWR or GAWR including the blade and ballast. The rating label is found on the driver-side vehicle door cornerpost.
To prevent accidental movement of the blade, always turn the ON/OFF switch to OFF whenever the snowplow is not is use. The control indicator light will turn off.
Remove blade assembly before placing vehicle on hoist.

Lit. No. B64107, Rev. 03

January 15, 2008
Refer to the Undercarriage Selection Guide for minimum vehicle recommendations and ballast requirements.
FIRE AND EXPLOSION WARNING
Gasoline is highly flammable and gasoline vapor is explosive. Never smoke while working on vehicle. Keep all open flames away from gasoline tank and lines. Wipe up any spilled gasoline immediately. Be careful when using gasoline. Do not use gasoline to clean parts. Store only in approved containers away from sources of heat or flame.

PERSONAL SAFETY

Remove ignition key and put the vehicle in park or in gear to prevent others from starting the vehicle during installation or service. Wear only snug-fitting clothing while working on your vehicle or snowplow. Do not wear jewelry or a necktie, and secure long hair. Wear safety goggles to protect your eyes from battery acid, gasoline, dirt and dust. Avoid touching hot surfaces such as the engine, radiator, hoses and exhaust pipes. Always have a fire extinguisher rated BC handy, for flammable liquids and electrical fires.

VENTILATION WARNING

Vehicle exhaust contains lethal fumes. Breathing these fumes, even in low concentrations, can cause death. Never operate a vehicle in an enclosed area without venting exhaust to the outside.

TORQUE SPECIFICATIONS

TORQUE CHART CAUTION
Read instructions before assembling. Fasteners should be finger tight until instructed to tighten according to the torque chart. Use standard methods and practices when attaching snowplow including proper personal protective safety equipment.
Grade Identification for J429Grade 5 Bolt SAE J429 Grade 5 Torque Values Nominal Thread Size 1/4-20 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 3/4-10 7/8-9 1-8 Clamp Loads (lb) 2,000 3,350 4,950 6,800 9,050 11,600 14,500 21,300 29,435 38,600 Tightening Torque "Lubricated" 6 ft-lb 13 ft-lb 23 ft-lb 37 ft-lb 57 ft-lb 82 ft-lb 113 ft-lb 200 ft-lb 321 ft-lb 482 ft-lb "Dry" 8 ft-lb 18 ft-lb 31 ft-lb 50 ft-lb 75 ft-lb 109 ft-lb 151 ft-lb 266 ft-lb 430 ft-lb 640 ft-lb
Grade Identification for J429Grade 8 Bolt SAE J429 Grade 8 Torque Values Nominal Thread Size 1/4-20 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 3/4-10 7/8-9 1-8 Clamp Loads (lb) 2,850 4,700 6,950 9,600 12,800 16,400 20,300 30,100 41,550 54,540 Tightening Torque "Lubricated" 9 ft-lb 18 ft-lb 32 ft-lb 53 ft-lb 80 ft-lb 115 ft-lb 159 ft-lb 282 ft-lb 454 ft-lb 680 ft-lb "Dry" 12 ft-lb 25 ft-lb 44 ft-lb 70 ft-lb 107 ft-lb 154 ft-lb 211 ft-lb 376 ft-lb 606 ft-lb 900 ft-lb
Grade Identification for MetricGrade 8.8 Bolt Metric Class 8.8 Torque Values Diameter (mm) Clamp Loads (lb) 1,389 1,965 2,826 3,579 5,672 8,243 11,246 15,882 19,423 24,784 Tightening Torque "Lubricated" 3 ft-lb 6 ft-lb 10 ft-lb 14 ft-lb 28 ft-lb 49 ft-lb 77 ft-lb 125 ft-lb 172 ft-lb 244 ft-lb "Dry" 5 ft-lb 8 ft-lb 13 ft-lb 19 ft-lb 37 ft-lb 65 ft-lb 103 ft-lb 167 ft-lb 229 ft-lb 325 ft-lb
Grade Identification for MetricGrade 10.9 Bolt Metric Class 10.9 Torque Values Diameter (mm) Clamp Loads (lb) 1,987 2,812 4,044 5,121 8,116 11,796 16,092 21,970 26,868 34,284 Tightening Torque "Lubricated" 5 ft-lb 8 ft-lb 14 ft-lb 20 ft-lb 40 ft-lb 70 ft-lb 111 ft-lb 173 ft-lb 238 ft-lb 338 ft-lb "Dry" 7 ft-lb 11 ft-lb 19 ft-lb 27 ft-lb 53 ft-lb 92 ft-lb 148 ft-lb 231 ft-lb 317 ft-lb 450 ft-lb

PUSHBEAM

PUSHBEAM HEIGHT
The recommended pushbeam height for this undercarriage assembly is 12-1/2" from the center of the pushbeam to level ground. DO NOT exceed 14-1/2" in height for this undercarriage.

12-1/2"

UNDERCARRIAGE INSTALLATION
NOTE: For easier assembly and installation, vehicle and all snowplow components should be on a smooth, level, hard surface, such as concrete. 1. Remove the front bumper. 2. Remove the plastic bumper fascia from the bottom of the bumper. NOTE: The bumper fascia will need to be permanently removed or notched to accommodate the undercarriage. If your truck has frame rail mounted tow hooks these will have to be permanently removed as well. 3. Align the front mount holes on the pushbeam (Item 1) with the tow hook mount holes on the truck frame rail. NOTE: Use a floor jack to help facilitate the installation procedure. Secure the pushbeam to the truck with cap screws (Item 9), washers (Item 10) and locknuts (Item 11). Add 9/16" washers (Item 7) as spacers to keep the pushbeam centered. Finger tighten the hardware until all undercarriage parts are in place.
4. Position the rear pushbeam support arm mount holes with the holes located in the truck frame cross member. NOTE: The cross member contains two rubber access caps that need to be removed to gain access to the inside of the cross member. Using grease or other adhesive, attach washers (Item 10) to cap screws (Item 12). Then, attach a thin gauge wire to each cap screw and position the wire through each cross member access hole to the middle mount holes. Pull the cap screw through the holes into the cross member and pushbeam support arms. Fasten each cap screw with a locknut (Item 11) and an additional washer. Replace the rubber access caps. 5. Finish securing the pushbeam to the truck frame with the cap screws (Item 6), washers (Item 7) and locknuts (Item 8) through the bottom of the pushbeam at the tow hook mount holes located under the truck frame rail. 6. Level the pushbeam with the floor and tighten the hardware according to the torque chart. 7. Replace the bumper and fascia using existing hardware. Notch fascia to fit. NOTE: After five to ten hours of snowplow usage, retorque all undercarriage assembly fasteners.

UNDERCARRIAGE PARTS LIST

B31085 Undercarriage Kit
Item 9 Part B63162 B90201 Qty Description 2 Pushbeam Decal, Pushbeam Compression Spring SS 9/16-12 x 1-1/2 Hex Cap Screw G8 9/16 Hardened Flat Washer 9/16-12 Hex Locknut 1/2-13 x 1-1/2 Hex Cap Screw G5 Item ns 12 Part B61309 B40079 B90593 B61276 Qty Description Split Ring, 1.25 OD A-Frame Latch Pin Hardware Kit 1/2 Hardened Flat Washer 1/2-13 Hex Locknut GC 1/2-13 x 2-3/4 Hex Cap Screw G8 ns = not shown

B61270 Hardware Kit

G = Grade

SS = Stainless Steel

Blizzard P.O. Box 245038 Milwaukee, WI 53224-9538 www.blizzardplows.com
Copyright 2008 Douglas Dynamics, L.L.C. All rights reserved. This material may not be reproduced or copied, in whole or in part, in any printed, mechanical, electronic, film or other distribution and storage media, without the written consent of Blizzard. Authorization to photocopy items for internal or personal use by Blizzard outlets or snowplow owner is granted. Blizzard reserves the right under its product improvement policy to change construction or design details and furnish equipment when so altered without reference to illustrations or specifications used. Blizzard or the vehicle manufacturer may require or recommend optional equipment for snow removal. Do not exceed vehicle ratings with a snowplow. Blizzard offers a limited warranty for all snowplows and accessories. See separately printed page for this important information. The following is a registered () trademark of Douglas Dynamics, L.L.C.: BLIZZARD.
Printed in U.S.A. Lit. No. B64107, Rev. January 15, 2008