ICON High Clearance Crash Bar Kit

[Dusty at ICON]

The factory crash bars are standard equipment on non-Sasquatch equipped Broncos. To take full advantage of 35" or larger tires these crash bars must either be removed (not recommended by ICON) or replaced with the ICON High Clearance Crash Bar Kit. For those who would like to retain the functionality of the crash bars but still clear 35" tires, or for those who would like to add that functionality to Sasquatch-equipped Broncos, ICON offers our new High Clearance Crash Bar Kit.

42000 21-UP BRONCO HIGH CLEARANCE CRASH BAR KIT​

These crash bars are made with three layers of beefy 3/16" thick plate steel, CNC laser cut, brake-formed and professionally fixture-welded for a easy, secure fit into the factory crash bar mounts. Note that hardware is not included as the factory crash bar bolts are re-used. Those wishing to add these High Clearance Crash Bars to Broncos that did not come with factory crash bars will need to source the needed hardware.

The ICON High Clearance Crash Bar Kit for 21-Up Bronco will be available soon. Contact your favorite Authorized ICON Dealer or watch this thread to be the first to know when ordering opens on the ICON website!

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[Pony Collector]

Anyone have part #'s for the factory crash bar nuts/bolts ? Second company to make replacement crash bars without any mounting hardware.

 

[yeet]

Deleting crash bars were holding me back from going to 35's. Thanks for the opportunity to spend more money!

 

[drew707]

Anyone have part #'s for the factory crash bar nuts/bolts ? Second company to make replacement crash bars without any mounting hardware.

W500748S450B

It’s just bolts, the nuts are built into the frame portion. FYI my Sasquatch came with the bolts in the holes. Not sure if every Bronco with Sasquatch does though.

 

[FlyingScot]

W500748S450B

It’s just bolts, the nuts are built into the frame portion. FYI my Sasquatch came with the bolts in the holes. Not sure if every Bronco with Sasquatch does though.

For the sake of others looking into this, my 4/4/22 blend WT came with some variety of bolts, but they're far too short to engage both the top and bottom surfaces of the crash bar "socket," and only one bolt present in each position:

 

[mikelicalsi]

W500748S450B

It’s just bolts, the nuts are built into the frame portion. FYI my Sasquatch came with the bolts in the holes. Not sure if every Bronco with Sasquatch does though.

Thank you - is it the same for front and rear crash bars? I found this, but it’s a pack of four (not eight) https://www.onlinefordpartscatalog.com/oem-parts/ford-bracket-screw-w500748s450b

 

[Bellime]

The factory crash bars are standard equipment on non-Sasquatch equipped Broncos. To take full advantage of 35" or larger tires these crash bars must either be removed (not recommended by ICON) or replaced with the ICON High Clearance Crash Bar Kit. For those who would like to retain the functionality of the crash bars but still clear 35" tires, or for those who would like to add that functionality to Sasquatch-equipped Broncos, ICON offers our new High Clearance Crash Bar Kit.

42000 21-UP BRONCO HIGH CLEARANCE CRASH BAR KIT​

These crash bars are made with three layers of beefy 3/16" thick plate steel, CNC laser cut, brake-formed and professionally fixture-welded for a easy, secure fit into the factory crash bar mounts. Note that hardware is not included as the factory crash bar bolts are re-used. Those wishing to add these High Clearance Crash Bars to Broncos that did not come with factory crash bars will need to source the needed hardware.

The ICON High Clearance Crash Bar Kit for 21-Up Bronco will be available soon. Contact your favorite Authorized ICON Dealer or watch this thread to be the first to know when ordering opens on the ICON website!

Any installed photo’s ?

 

[PizzaBronco]

Anyone install these? I bought them, fronts went in great, rears did NOT fit. I pounded on them with a rubber mallet and got nowhere. At first I thought maybe the paint was just too thick but it actually looks like there’s a little lip on the ends where the metal is bent into shape, so it isn’t rounded off and throws the already tight tolerance completely out of whack.

 

[Coffeegrinds]

Anyone install these? I bought them, fronts went in great, rears did NOT fit. I pounded on them with a rubber mallet and got nowhere. At first I thought maybe the paint was just too thick but it actually looks like there’s a little lip on the ends where the metal is bent into shape, so it isn’t rounded off and throws the already tight tolerance completely out of whack.

Were you able to fix this? I was going to order them, but if it doesn't work, then I'll definitely not order them.

 

[35tires]

How many cars have you crashed to check the safety of these things?

 

[PizzaBronco]

Were you able to fix this? I was going to order them, but if it doesn't work, then I'll definitely not order them.

I was not. I talked with a guy at Icon about it, he seemed to forget about me for a couple weeks, and then got back to me with “hit it harder with a dead blow hammer instead of a rubber mallet” which doesn’t seem like the best answer... In the meantime I’d already returned them.

I also ordered a new set from Ready Lift, they cost less, seem very burly, and the rear bars actually fit nicely - did take a few whacks with a mallet to get in, though. The front bars hide better than the Icons but are pretty loose in the sleeves. Ready Lift claimed that their engineers have seen a difference over model years but said that if it was loose, to use some foam tape to prevent rattling. I haven’t noticed any rattling yet.

 

[jensht]

It's 2024 now and it seems that the fitment issue with the rear crash bars still hasn't been resolved. I recently ordered a set and went to install them today. Fronts fit just fine. Rears don't. I tried a rubber mallet, then a normal hammer, then a sledge (carefully to not hit the fender). The rear crash bars are too thick. I'll see if I have time this weekend to take a grinder to them and make them fit.

A shame, since the quality of the metal work seems stout, and the powder coating held up reasonably well to the pounding I gave it.

 

[Area51BS]

Why on earth did Ford not design the Bronco with crash bars and a 35 inch tire they supply is mind boggling.

 

[H0pelessOpus]

@Dusty at ICON Have the fitment issues on the rear crash bars been addressed?

 

[Dusty at ICON]

@Dusty at ICON Have the fitment issues on the rear crash bars been addressed?

I'm not aware that there has been a revision to those. I've made an inquiry to our engineering department for clarification, I'll let you know what I find out.

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