JEep JK-JKU Rear Bumper

JEep JK-JKU
Rear Bumper
i n sta l l a ti o n
i n str u cti o n s
Fig 1
• Removal of the stock bumper and spare tire carrier
Remove spare tire.
Remove the 4 t-20 torx screws from the
backside of the 3rd brake light assembly.
(Fig 1) Disconnect brake light harness and
set brake light aside. Pull harness through
spare tire mount and lay it over top of
tailgate. Shut the tailgate, taking care not to
pinch or damage the harness or connector
for 3rd brake light.
Remove the 8 bolts that hold the spare tire
mount using a 13mm socket. Set these bolts Fig 2
aside, you will use them to mount the door
plate later.
On both sides of the bumper there are two
bolts that need to be removed using a 16mm
socket. (Fig 2) Set two of the four bolts aside
for later use. There are also 4 bolts behind
the bumper that will need to be removed.
Don’t confuse them with the 4 bolts for the
receiver. Remove the brackets that were
bolted on with the bolts you just removed..
Now you should be able to remove the rear
bumper.
Next you can remove the 4 bolts that secure
Fig 3
the factory receiver (if equipped) using an
18mm socket. If you have a tow hook on
the drivers side this will also need to be
removed using the 18mm socket. Once the
bolts are removed from tow hook remove
captured nut tab from inside the frame.
Hardware:
Bumper Hardware
• (4) – 1/2” x 11/2” GRD 8 bolts
• (4) – 1/2” SAE washers
• (2) – 1/2” nut tabs
• (2) – 8mm x 1.25 x 30mm bolts
• (2) – 5/16” SAE washers
• (4) – 7/16” x 4” GRD 8 bolts
• (4) – 7/16” SAE washers
• (4) – 7/16” serrated flange nuts
• (4) – Zinc coated strut washers
• (8) – 13/4” button head bolts
• (2) – 5/16” x 1” bolts
• (2) – 5/16”SAE washers
• (2) – 5/16” serrated flange nuts
• (2) – 1/4” x 1/2” button head bolts
• (2) – 1/4” serrated flange nuts
Swing Arm Hardware
• (4) – 1/2” x 11/2” GRD 8 bolts
• (4) – 1/2” SAE washers
• (2) – 1/2” nut tabs
• Install
3rd Break Light Assembly
• (1) – Break light mount
• (1) – LED break light
• (2) – Wire crimps with heat shrink
• (3) – 6” Zip ties
For questions or
further help:
Call: 866-522-0697
Email: [email protected]
page 1–4
J K- J KU
R EAR
Install the frame plate mounts. There is a
passenger and drivers side frame plate. Install each plate using the captured nut tabs,
along with the four ½” x 1 ½” grade 8 bolts
and 4 washers. (Fig 3)
** NOTE: Run your ½” bolts through the
captured nut tabs to ensure there is no
obstruction preventing you from easily hand
threading the bolt in during the install.
Fig 4
For this next step I recommend getting
someone that has small hands. Grab the
DRIVERS side frame mount in your right
hand and with your left reach through
the small hole on the mount and then
grab one of the captured nut tabs. (Fig 4)
Now thread the two 1/2’ bolts through the
aligning holes on the frame mount and
BU M PER
IN S TA LLAT ION
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JEep JK-JKU
Rear Bumper
i n sta l l a ti o n
i n str u cti o n s
Fig 5
frame. For reference, the back 2 slotted holes
on the frame mount should line up with the
threaded bolt holes that previously held the
factory bumper.
Take the two factory bolts and loosely install
them back in their original hole.
Before you move on to the passenger side,
grab the spindle support bracket and the 2
10mmx1.80x45mm bolts and the ⅜” washers.
(Fig 5)
Looking at the picture grab the PASSENGER
side frame mount and spindle support bracket and one of the supplied 10 mm bolts. Get
the top left hole of both brackets lined up and
start one of the 10mm bolts in top factory
threaded hole.. Let it hang down like in the
picture. I have found the following method
to be the easiest. With your hand reaching
through the frame mount (Like you did on
the Drivers side) hold the captured nut tab.
With the two ½” bolts in your hand Slide
the spindle support bracket up and align the
holes and start the other two ½” bolts. Put
the remaining 10 mm bolt in the remaining
factory threaded hole. Do not tighten any of
the hardware at this time. (Fig 6)
Hardware:
Bumper Hardware
• (4) – 1/2” x 11/2” GRD 8 bolts
• (4) – 1/2” SAE washers
• (2) – 1/2” nut tabs
• (2) – 8mm x 1.25 x 30mm bolts
• (2) – 5/16” SAE washers
• (4) – 7/16” x 4” GRD 8 bolts
• (4) – 7/16” SAE washers
• (4) – 7/16” serrated flange nuts
• (4) – Zinc coated strut washers
• (8) – 13/4” button head bolts
• (2) – 5/16” x 1” bolts
• (2) – 5/16”SAE washers
• (2) – 5/16” serrated flange nuts
• (2) – 1/4” x 1/2” button head bolts
• (2) – 1/4” serrated flange nuts
3rd Break Light Assembly
• (1) – Break light mount
• (1) – LED break light
• (2) – Wire crimps with heat shrink
• (3) – 6” Zip ties
For questions or
further help:
Fig 7
Now take the main body of the bumper
and set on top of the frame mounts you just
installed. Take the supplied 7/16”x4” grade
8 bolts, washers, square strut washers and
flange nuts. (Fig 7)
Swing Arm Hardware
• (4) – 1/2” x 11/2” GRD 8 bolts
• (4) – 1/2” SAE washers
• (2) – 1/2” nut tabs
Fig 6
With the bolt and the small washers run the
bolts through the 4 holes in the face of the
bumper and through the holes in the frame.
Put the square strut washer on and then the
flange nut. Do not tighten.
With the eight ½”x1-¾” button head bolts
and the two d-ring mounts and line up the
holes on the bumper with the ones with the
d- ring mounts and start the button head
bolts You may need to loosen the frame
mounts to make it easier to line up the holes.
Once you have all eight bolts started you will
need to install the two 5/16”x1” grade 8 bolts
that attach the spindle support bracket to the
bumper. Do not tighten. (Fig 8) (Fig 9)
Fig 8
Call: 866-522-0697
Email: [email protected]
page 2–5
J K- J KU
R EAR
BU M PER
IN S TA LLAT ION
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Fig 9
JEep JK-JKU
Rear Bumper
i n sta l l a ti o n
i n str u cti o n s
Fig 10-10.5
• Tire Carrier
Identify the door plate. (Fig 10-10.5) also,
take the black UHMW pillow block and the
3/8x1 1/4 bolts, washers, and flange nuts.
You will place the door plate on the back of
the tail gate and with the factory bolts that
you set aside from removing the factory tire
carrier and bolt the door plate to the back
of the tail gate tighten the bolts in a star
sequence to ensure even pressure. Take the
pillow block and the 3/8” bolts and loosely
bolt the pillow block to the doorplate.
Hardware:
Bumper Hardware
• (4) – 1/2” x 11/2” GRD 8 bolts
• (4) – 1/2” SAE washers
• (2) – 1/2” nut tabs
• (2) – 8mm x 1.25 x 30mm bolts
• (2) – 5/16” SAE washers
• (4) – 7/16” x 4” GRD 8 bolts
• (4) – 7/16” SAE washers
• (4) – 7/16” serrated flange nuts
• (4) – Zinc coated strut washers
• (8) – 13/4” button head bolts
• (2) – 5/16” x 1” bolts
• (2) – 5/16”SAE washers
• (2) – 5/16” serrated flange nuts
• (2) – 1/4” x 1/2” button head bolts
• (2) – 1/4” serrated flange nuts
The bushings will not seat flush with the spindle hub. About a 1/6” will stay showing. (Fig
12) Before you install the swing arm on the
spindle. Make sure that the spindle is clean
and free of debris also. Place swing arm on
the spindle and swing the arm back and forth
while pushing down on the swing arm. This
will help in sliding the arm on. Its normal for
the bushings to be tight going on. (Fig 13)
Swing Arm Hardware
• (4) – 1/2” x 11/2” GRD 8 bolts
• (4) – 1/2” SAE washers
• (2) – 1/2” nut tabs
Fig 11
There are 2 brass bushings in the hardware
bag. (Fig 11) These are the spindle bushings
that need to be installed in the swing away
hub. Take a paper towel with some WD- 40
on it and wipe out the hub bore on the swing
arm to get rid of any debris. Take some 3in1
oil lightly coat the inside of the bore where
the bushings will sit. Take a rubber mallet
and line up the bushings with the hole and
evenly tap the bushings until they seat.
3rd Break Light Assembly
• (1) – Break light mount
• (1) – LED break light
• (2) – Wire crimps with heat shrink
• (3) – 6” Zip ties
Fig 12
Once you have the swing arm on the spindle,
slowly swing the arm till it fully seats in the
pillow block on the door plate. At this time
tighten the bolts on the pillow block this is
setting the position of the pillow block before
the swing arm is loaded with the spare tire
and jack. (Fig 14)
• Assembly of turnbuckle
For questions or
further help:
Call: 866-522-0697
Email: [email protected]
page 3–5
J K- J KU
R EAR
Installing it on the swing arm and door plate
(Fig 15)
Parts for the turnbuckle assembly-Turn buckle body
(1) -LH 1/2” nut
(1) -RH ½” nut
(1) -LH ROD END
(1) -RH ROD END
(1) -2-¾” ½” bolt
(2) 1/2 flange nuts
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Fig 13
Fig 14
JEep JK-JKU
Rear Bumper
i n sta l l a ti o n
(1) 1 3/4 1/2 bolt
(1) 1/2 washer
Thread the rod ends and matching jam nuts
into the turnbuckle body all the way. Take
the 2-3/4”bolt without a washer and bolt on
the turnBuckle to the bottom of the extended
attachment on the swing arm. (Fig 16) Tighten the bolt. Open the tailgate about halfway
and hold the other side of the turnbuckle and
twist the turnbuckle out until you can slide
the remaining bolt in to the two tabs on the
tailgate. Tighten the bolt. Close the door until you can see about 2”-1/2” of a gap before
you shut the tailgate. Twist the turn buckle
until you see the swing arm fully seat in the
pillow block. (this is setting up the right
amount tension when the tailgate is in the
closed position) Shut tailgate and the swing
arm should be tight. Grab the swing arm and
check for movement. Open the tailgate again
and see that the arm is still seating in the pillow block before your original adjustment. If
it has adjust the turnbuckle and then Tighten
the jam nuts on the turnbuckle. (Fig 17)
Hardware:
Bumper Hardware
• (4) – 1/2” x 11/2” GRD 8 bolts
• (4) – 1/2” SAE washers
• (2) – 1/2” nut tabs
• (2) – 8mm x 1.25 x 30mm bolts
• (2) – 5/16” SAE washers
• (4) – 7/16” x 4” GRD 8 bolts
• (4) – 7/16” SAE washers
• (4) – 7/16” serrated flange nuts
• (4) – Zinc coated strut washers
• (8) – 13/4” button head bolts
• (2) – 5/16” x 1” bolts
• (2) – 5/16”SAE washers
• (2) – 5/16” serrated flange nuts
• (2) – 1/4” x 1/2” button head bolts
• (2) – 1/4” serrated flange nuts
Swing Arm Hardware
• (4) – 1/2” x 11/2” GRD 8 bolts
• (4) – 1/2” SAE washers
• (2) – 1/2” nut tabs
3rd Break Light Assembly
• (1) – Break light mount
• (1) – LED break light
• (2) – Wire crimps with heat shrink
• (3) – 6” Zip ties
For questions or
further help:
Call: 866-522-0697
Email: [email protected]
page 4–5
J K- J KU
R EAR
i n str u cti o n s
Install the tire mount plate. The tire plate
has two parts plus the 5/8 fine thread grade
8 bolt and washer. IT is recommended that
you identify the mating surface of the tire
mount. Is the surface that will need to be
cleaned off the sandpaper. (Fig 18)
File or any other method of removing the
powder coat. (Fig 19) It is recommended
to lightly coat with antiseize on the surface
to make movement easier. Start the 5/8 bolt
just before the two wedges start to widen.
Slide the mount into the receiver tube with
the longer part of the plate upward. (Fig 20)
Leave 2-3” of the 2” square tubing exposed.
You were provided with six ½” washers slide
2 on each wheel stud. These are for setting
the tension on the final installation of the
spare tire. Once you have the spacers/washers on, bolt up your spare tire (this swing
away is designed to only fit the stock wheel
or bigger) Tighten the lug nuts. Open the
tailgate and loosen the 5/8 bolt enough to
pull the spare tire mount and tire towards
you until it contacts the tubing of the swing
away. Once the tire is touching in at least 2 or
more points on the frame of the swing away.
TIghten the 5/8”bolt and torque to 200 ft lbs.
Remove the spare tire and pull off the spac-
BU M PER
IN S TA LLAT ION
Fig 15
Fig 16
Fig 17
Fig 18
Fig 20
INS T RUCT IONS
Fig 19
JEep JK-JKU
Rear Bumper
i n sta l l a ti o n
i n str u cti o n s
ers/washers and reinstall the tire torque the
wheels to manufacturer’s torque specs. Shut
the swing away and grab the tire try to move
it in and out. It should feel tight against the
swing arm.
To assemble the lock pin, unscrew the knob
off the pin and apply red loctite to the threads
of the knob. Screw it back on and twist it
tight with some plyers. You then can apply
red loctite on the threads of the spindle cap.
Put a small amount of clear grease on the
spring of the pin for keeping the pin moving
freely. Screw the pin into the spindle cap.
(Fig 21) (Fig 22) (Fig 23) (Fig 24)
Hardware:
Bumper Hardware
• (4) – 1/2” x 11/2” GRD 8 bolts
• (4) – 1/2” SAE washers
• (2) – 1/2” nut tabs
• (2) – 8mm x 1.25 x 30mm bolts
• (2) – 5/16” SAE washers
• (4) – 7/16” x 4” GRD 8 bolts
• (4) – 7/16” SAE washers
• (4) – 7/16” serrated flange nuts
• (4) – Zinc coated strut washers
• (8) – 13/4” button head bolts
• (2) – 5/16” x 1” bolts
• (2) – 5/16”SAE washers
• (2) – 5/16” serrated flange nuts
• (2) – 1/4” x 1/2” button head bolts
• (2) – 1/4” serrated flange nuts
Fig 22
Fig 23
Fig 24
Fig 25
Fig 26
Fig 27
Fig 28
Now you will need to set your spindle top cap
and lock pin. The idea is to have the lock pin
engage before the factory stop in the tailgate
does. The factory stop mechanism will not
hold up to the added stress of the swing away
tire. So to set up the stop/lock pin open the
door slowly till you feel the tailgate reach
its maximum stop point From there close
the tailgate so that it is about 2-3” before the
factory stop would engage. Slide your spindle
cap on with the assembled lock pin and tighten the set screw with a 3/16” allen key.
(Fig 25) (Fig 26)
Swing Arm Hardware
• (4) – 1/2” x 11/2” GRD 8 bolts
• (4) – 1/2” SAE washers
• (2) – 1/2” nut tabs
Fig 21
3rd Break Light Assembly
• (1) – Break light mount
• (1) – LED break light
• (2) – Wire crimps with heat shrink
• (3) – 6” Zip ties
3rd brake light- Position the light tab on the
back side of the tire mount plate so that it will
be seen through your wheel spokes. Refer
to the picture for splicing in the new brake
light to the existing harness. Always check
for light operation before crimping. (Fig 27)
(Fig 28)
Check and ensure all hardware is tight before
use. After the first 500 miles check tire mount
for looseness, it will loosen as the wedge lock
mechanism seats in the powder coating. You
will need to periodically check your hardware
for tightness.
For questions or
further help:
Call: 866-522-0697
Email: [email protected]
page 5–5
J K- J KU
R EAR
BU M PER
IN S TA LLAT ION
INS T RUCT IONS