Installing used Nerf Bars

[gmanpaint]

I just bought a used pair of '00 4 dr Explorer Nerf Bars for my '95 4 dr X. I am going to paint them with epoxy to match my rig, (gray to black). My Question is, do I need to remove the existing piece of rocker trim that is on the bottom? Will it bolt over the trim pc? The bars were held on with 12 bolts each, they have slots for 16 bolts, does it matter? 3 out of 4 slots on each hanger were used. Do they need torqued? My understanding is all the holes are already on my rig for the install, even though it did not have them stock, true?
Any help is appreciated. Thanks.

 

[bad*dawg]

Replace rusted nerf bars with later model

1998 sport. Bars were replaced twice under warranty but alas the rusted again and while I would poop can them daughter who now owns it likes "them" so purchased a pair from a 2002. As usual with Ford engineering brackets, trim, and the bars had all changed. Was able to use One of Two existing holes on each of the Three attach brackets and had to drill Three NEW holes in the new bars for the other Three bolts then used threaded plugs in those holes. I first removed the old bars, laid the new bars on the brackets and did the best I could to salvage as many OEM holes. Thought about moving the brackets but too much rust on the fastener clips plus too hard to access if a clip twisted off! (one did so I gave up).

 

[gmanpaint]

Whoa! I almost forgot about this thread! I was able to do the install with out to many problems. I figured it out as I went. The trim pc stayed, and the bolt number was 12 each. I did have to go to the dealer to get the mounting hardware, bolts and clips. I used lacquer paint with multiple coats of clear instead of epoxy. There was no need for torquing the bolts. The holes for the install were there for a direct mount. I did have to move the hangers on the '00 bars over one notch, and they lined right up. I like the way they look. Eventually I would like to get a pair of rock sliders for some real protection, but for now these will have to do. Click on my albums if you want to see pics of the install, paint, finished work.

It really helps to stay in your own gen for an install,

 

[bad*dawg]

Going from a 98 sport to the 2002 there was no need to remove or rework the plastic sleeves over the brackets as there is no material in the pockets the bars lay in. Yes there are 16 attach points on both but I doubt the factory used more than Two per bracket. As I indicated earlier I was only able to use a few of the OEM holes in the 2002 bars (#10 metric) so in order to get Two bolts per bracket I used 1/4 x 20 expansion fasteners with brass threaded inserts in order to do that.

 

[gmanpaint]

I Dont know how the 3rd gens are, but the 2nd gen has the holes for the rocker trim, step sides, and nerf bars, They all share the same mount points.
4 holes per hanger on the bolt, 4 holes for the nerf bars. The nerf bar holes are off set so you can move them forward and back. I opted to keep my rocker trim, and share the holes. I used 3 oem bolts with oem clips per hanger. That is exactly how many were on the stock donor rig I got the nerf bars from.

You can see the hanger bolt holes. The mounting holes on the nerfs are offset, for adjusting. No matter how you hang them, you can use 3 bolts.

 

[corkey]

yeah changing the parts from 1st to 2nd, to 3rd can be a bit tougher , as they are almost always bolted on certain ways,, and the next gen might not have the same mounting points as things change year to year,
body styles, interior , and suspensions change,,

 

[bad*dawg]

Attempted to remove / move one of my brackets to get a shot at using more of the OEM holes in the new bars but the first bolt I tried to removes was rusted so bad it caused the clip nut to fail so gave up on that idea.

 

[vegasjoe1969]

I just bought a used pair of '00 4 dr Explorer Nerf Bars for my '95 4 dr X. I am going to paint them with epoxy to match my rig, (gray to black). My Question is, do I need to remove the existing piece of rocker trim that is on the bottom? Will it bolt over the trim pc? The bars were held on with 12 bolts each, they have slots for 16 bolts, does it matter? 3 out of 4 slots on each hanger were used. Do they need torqued? My understanding is all the holes are already on my rig for the install, even though it did not have them stock, true?
Any help is appreciated. Thanks.

I also bought the same as you did but from an 01, also for a 95 black XLT. Did you install it with the brackets connected to the bar? coz, I was installing mine brackets off the bar then when I try to place the bar in place, the plastic ends are hitting the rocker trims.

If you have any tricks you can share, please.

Btw, mine is stock height for now but I have rims and tires from an 02 16"

Thanks

 

[bad*dawg]

updated nerf bars

The replacement bars had (as I'm sure yours do) unused screw holes. I first attempted to move the brackets on the underbody but gave up due to rusted bolts and pockets in the rocker trim (wouldn't match) so I positioned the new bars on the old brackets in such a way I was able to pick up (as I recall) 0NE
hole on the back, TWO in the middle and NONE on the front. Through the slots in the brackets I marked and drilled holes for the missing bolts, bought some 1/4" x 20 rubber expansion fasteners and as a result have TWO fasteners on each bracket. Painted the new bars bumper gray and they made it through the winters salt and slop looking great. I have lots of fasteners left over and will send you a half dozen if interested email me at mwalters1@comcast.net