BX3225 Installation Instructions 2003-04 Pontiac Sunre Coupe

Serial No.

The headlight assembly, blinker assembly, front fascia, horn bracket, windshield washer reservoir and lower grill inserts are removed for baseplate installation. Lower grill inserts will not be reinstalled. Drilling is required. The BX8869 is available for the vehicle. Attachment Tabs are 24 inches center to center and a height of 14 inches.
1. Remove the seven push pins from the top side of fascia's black plastic cover.
2. Using the 10MM socket, remove the metric bolt on blinker assembly brace, remove one phillips screw, unplug electrical and set aside, both sides.
3. Remove two metric bolts from headlight assembly with the 10MM socket, pull forward, unplug electrical and set aside, both sides.
4. On the back side of fog lights remove one push pin, both sides.
5. Just forward of front tire, on wheel well plastic, remove one push pin and two metric bolts with the 7MM socket, both sides.
6. Using the 7MM socket, remove three metric bolts from passenger's side and two bolts on the driver's side.
2003 Blue Ox Division, Automatic Equipment Mfg. Co. One Mill Road, Industrial Park Pender, Nebraska 68047 Phone 402-385-3051 Fax 402-385-3360 www.blueox.us Page 1 of 4 292-6126 7/28/08
7. Remove the three metric bolts just forward of the front tire, on the bottom side of fascia, both sides.
8. Just forward of front tire, on lower black plastic remove two metric bolts on the passenger's side and one on the driver's side, using the 7MM socket.
9. Remove metric bolt from fascia corner, on inside of fender well using the 10MM socket, both sides.
10. Just behind headlight assembly, are two metric bolts to be removed using the 10 MM socket, both sides.
11. Remove two christmas tree clips on lower grill just under metal bumper, set lower grill insert aside. Lower grill insert will NOT be reinstalled.
12. Using the 13MM socket, remove metric bolt from horn bracket and set aside.
2003 Blue Ox Division, Automatic Equipment Mfg. Co. One Mill Road, Industrial Park Pender, Nebraska 68047 Phone 402-385-3051 Fax 402-385-3360 www.blueox.us Page 2 of 4 292-6126 7/28/08
13. Remove three metric bolts from windshield washer reservoir on driver's side. Using the phillips screw driver, remove screw from tubing on reservoir and set aside.
14. On bottom center of metal bumper, align baseplate's (item 1) upper hole, clamp in place with vise grip. Using item 1 as a template, drill upper hole with the 13/32" drill bit, both sides. Insert items 2 into opening on the end of metal bumper to align with drilled hole and tighten items 3 and 4 according to drawing on last page, both sides. Be sure and use loctite on all bolts before tightening. Torque all bolts according to torque chart in General Instructions.
15. Using item 1 as a template, drill all remaining holes on end plates with the 13/32" drill bit, both sides. Insert item 2 into opening on the bottom frame to align with drilled hole. Tighten items 3 and 4 according to drawing on last page, both sides. Be sure and use loctite on all bolts before tightening. Torque all bolts according to torque chart in General Instructions. 16. Reinstall horn bracket, windshield washer reservoir, fascia and headlight assemblies. Be sure all electrical components and hoses are plugged in properly. 17. The dimensional variations between otherwise identical cars can be considerable. While the location and size of the holes in the baseplate were designed to allow for easy installation, it may be necessary to le a hole slightly to allow a bolt to clear. 18. Install the tow bar and safety cables according to the instructions included in their packages. 19. Do not substitute other devices if the tow bar pin and clip are lost. 20. DEALER OR INSTALLER: BE CERTAIN THE USER RECEIVES THE INSTRUCTION SHEET.
2003 Blue Ox Division, Automatic Equipment Mfg. Co. One Mill Road, Industrial Park Pender, Nebraska 68047 Phone 402-385-3051 Fax 402-385-3360 www.blueox.us Page 3 of 4 292-6126 7/28/08

Tools Required

7MM Socket 13MM Socket Phillips Screw Driver 10MM Socket Loctite Vise Grips 9/16" Socket 13/32" Drill Bit

Parts List Ref. No. Qty.

Part No.

Description

61-5865... Weldment, Base Plate, BX3225 61-5208... 3/8" Nut Plate, with Wire 201-0440...3/8-16 x 1 1/2 Bolt, Grd. 5, ZP 203-0010... 3/8 Lock Washer, ZP 201-0553...1/4-20 x 1/2 Hx. Wshd, Type F Screw 202-0047.... #10-32 Hex Nut 203-0054.... #10 Lock Washer 201-0192...#10-32 x 1/2 Slot, Rd. Hd. Screw 101-5822... Adapter, 4 Way Connector 62-3469... Attachment, Assembly, SF/ LB (R) 226-0046.. Baseplate Safety Cable, 36" CL III (Not Shown) 229-0359... Quicklink, 3/8, ZP (Not Shown) 290-0437.. Receiver, Cap Plug (BLK) (Not Shown) Location for the Bx8869 on driver's side tail light assembly.
IMPORTANT: Use only genuine factory replacement parts on your Base Plate. Do not substitute
homemade or nontypical parts. If a bolt is lost or in need of replacement, for your safety and the preservation of your Base Plate, be sure to use a replacement bolt of the same grade (Usually Grade 5, refer to parts list). Repair parts may be ordered through your nearest Blue Ox dealer or distributor.
2003 Blue Ox Division, Automatic Equipment Mfg. Co. One Mill Road, Industrial Park Pender, Nebraska 68047 Phone 402-385-3051 Fax 402-385-3360 www.blueox.us Page 4 of 4 292-6126 7/28/08