G-2 SERIES BUMPER SYSTEM PART # 66701
Transcription
G-2 SERIES BUMPER SYSTEM PART # 66701
G-2 SERIES BUMPER SYSTEM PART # 66701 PARTS LIST STOP LIGHT BRACKET KIT ( PAGE 7 ) 2 - TOP SUPPORT BRACKETS 2 - 1/4 X 3/4 BOLTS 2 - 1/4 THIN NYLON LOCK NUTS 4 - 1/4 SAE FLATWASHERS ( 5/8 “ DIA. ) 2 - 5/16 X 1 CARRIAGE BOLTS 2 - 5/16 NYLON LOCK NUTS 2 - 5/16 FLATWASHERS ( 11/16 DIA. ) ALUMINUM TOP COVER KIT ( PAGE 6 ) 1 - ALUMINUM TOP COVER ( 1/4 X 4 X 56 1/2 ) 4 - 5/16 X 1 BUTTON HEAD ALLEN BOLTS 4 - 5/16 USS FLATWASHERS ( 7/8” DIA. ) 2 - 5/16 LOCKWASHERS 2 - 5/16 NUTS 1 - 3/16 ALLEN WRENCH TIRE MOUNT BRACKET KIT ( PAGE 10 ) 1 - JK TIRE MOUNT 5 ON 5 PAGE 1 OF 10 HI-LIFT BRACKET KIT ( PAGE 9 ) 1 - DRIVERS SIDE MOUNT ( 4 3/4” ) 1 - PASSENGERS SIDE MOUNT ( 5 1/2” ) 2 - HI- LIFT SUPPORT BRACKETS 2 - 1/2 WING NUTS 2 - 1/2 SAE FLATWASHERS 2 - 1/2 LOCKWASHERS 4 - 3/8 X 1 1/4 CARRIAGE BOLTS 4 - 3/8 USS FLATWASHERS 4 - 3/8 NYLON LOCK NUTS ALUMINUM END CAP KIT ( PAGE 6 ) 2 - ALUMINUM REAR BUMPER END CAPS 16 - 7/16 SAE FLATWASHERS 4 - 7/16 LOCKWASHERS 4 - 7/16 NUTS FACTORY INSTALLED PARTS 1 - 1/2 X 3 BOLT 1 - 1/2 NYLON LOCKNUT 2 - 1/2 SAE FLATWASHERS LATCH ASSEMBLY ( PAGE 8 ) 1 - LATCH ASSEMBLY FACTORY INSTALLED PARTS 4 - 1/4 X 3/4 BOLTS 4 - 1/4 FLATWASHERS 4 1/4 LOCKWASHERS REAR BUMPER KIT ( PAGE 4 ) SPRING LOADED PULL PIN KIT ( PAGE 8 ) 1 - SPRING LOADED PULL PIN FACTORY INSTALLED PARTS ( PAGE 8 ) TAILGATE BRACKET KIT ( PAGE 5 ) 1 - TAILGATE MOUNTING BRACKET 1 - 2” DIA. RUBBER BUMPER 1 - 3/8 X 3 1/2 TAP BOLT ( ALL THREAD ) 1 - 3/8 FENDER WASHER ( 2” DIA. ) 3 - 3/8 USS FLATWASHERS ( 1” DIA. ) 3 - 3/8 NUTS 1 - 3/8 LOCKWASHER DRAWING# 66701-H 4 - 5/8 X 1 1/2 BOLTS 4 - 5/8 LOCKWASHERS 4 - 5/8 USS FLATWASHERS 1 3/4” DIA. 2 - 1/2 X 4 1/2 BOLTS 2 - 1/2 NUTS 2 - 1/2 LOCKWASHERS 4 - 1/2 USS FLATWASHERS 1 3/8” DIA. 2 - GREASE FITTINGS ( PLASTIC BAG ) 1 - SPRING LOADED PIN ( PLASTIC BAG ) 1 - 1/2 X 3 BOLT, FLATWASHERS & LOCK NUT 4 - 1/4 X 3/4 BOLTS, LOCKWASHERS AND FLATWASHERS ( LATCH ASSEMBLY ) ALL SWING ARM PIVOT HARDWARE 1 - 1 1/2 NYLON THIN LOCK NUT 1 - 1/4” STEEL SPACER ( SILVER IN COLOR ) 1 - 1 1/2 GRAY NYLON FLATWASHER 1 - THRUST WASHER ( GOLD IN COLOR ) GARVIN INDUSTRIES 316 MILLAR AVE EL CAJON CA 92020 (619)-440-7415 Part#66701 Installation Instructions 1. 2. 3. 4. 5. 6. For a more simple installation, leave all fasteners loose until directed to tighten. Remove factory rear bumper and all attaching brackets. Unplug stop light wiring behind panel inside tailgate. Remove factory tire mount and stop light assembly. Re-install tire mount bolts in tailgate, except for the top two. Modify stop light housing as shown on page 7. Install modified stop light and rubber bump stop to tailgate as shown on page 5 and 7. Re-connect wiring to inside tailgate. 7. Install rear bumper assembly as shown on page 4. 8. Install bumper ends and top cover as shown on page 6. Align and tighten mounting hardware. 9. Install swing arm to bumper as shown on page 8. Tighten top nut until there isn’t any up and down movement on swing arm. 10. Install latch assembly as shown on page 8. 11. Install grease fittings and swing-arm stop pin to swing arm as shown on page 8. Please note: Adjusting directions for swing pin lock on page 8. Tighten all fasteners. 12. Install Hi-Lift mounting brackets to swing arm, refer to page 9. 13. Install spare tire assembly as shown on page 10. 14. After installing spare tire and any accessories, adjust rubber bump stop to swing arm. Make sure there is tension on bump stop when swing arm is closed and latched. 15. When adjusting latch assembly, adjust the “u” bolt so that the handle snaps closed. 16. Grease pivot point on a regular basis. If swing arm becomes hard to pivot, remove and clean off pin, grease and re-install. 17. Note! Use caution when opening the swing arm and engaging the pin stop. Open the swing arm slowly until the pin engages. The pin system is not designed to push the swing arm open and let the pin stop it. The pin was designed to hold the swing arm open while accessing the back. Excessive force will cause the stop pin to bend or break. This is not covered under warranty. Page 2 of 10 WILDERNESS PRODUCTS G-2 SERIES REAR BUMPER PART # 66701 GENERAL ASSEMBLY DRAWING PAGE 3 OF 10 OPTIONAL TRAIL RACK ( MOUNTS TO JK TAILGATE ) PART # 66703 OPTIONAL POWER TANK HOLDER (DRIVERS SIDE ONLY) PART # 66707 OPTIONAL DRIVERS SIDE CAN MOUNT PART # 66705 OPTIONAL AX AND SHOVEL MOUNTING BRACKET PART # 66708 OPTIONAL PASSENGERS SIDE CAN MOUNT PART # 66706 AX & SHOVEL MOUNTING POINT LATCH ASSEMBLY HI-LIFT JACK & LOWER CAN MOUNTING BRACKET MOUNTING POINT 1 1/2 LOCKNUT STEEL SPACER ( SILVER ) GRAY NYLON FLATWASHER GREASE FITTINGS (2) THRUST WASHER ( GOLD COLOR ) LATCH ASSEMBLY ADJUSTING NUT ( NYLON LOCKING ) ADJUSTING NUT ( REG ) HANDLE LOCKING LEVER 4 - 1/4 X 3/4 BOLTS 4 - 1/4 LOCKWASHERS 4 - 1/4 FLATWASHERS U BOLT DRAWING# 66701-A GARVIN INDUSTRIES 316 MILLAR AVE EL CAJON CA 92020 (619)-440-7415 WILDERNESS PRODUCTS JK REAR BUMPER/TIRE CARRIER G-2 SERIES PART # 66701 REAR BUMPER INSTALLATION PAGE 4 OF 10 5/8 X 1 1/2 BOLTS 5/8 LOCKWASHERS 5/8 USS FLATWASHERS REAR CROSSMEMBER REFER TO FIGURE A TOP ALUMINUM COVER THREADED PLATE SUPPORTS PARTS LIST 4 - 5/8 X 1 1/2 BOLTS 4 - 5/8 LOCKWASHERS 4 - 5/8 USS FLATWASHERS 1 3/4” DIA. 2 - 1/2 X 4 1/2 BOLTS 2 - 1/2 NUTS 4 - 1/2 USS FLATWASHERS 1 3/8” DIA. INSTALLATION INSTRUCTIONS 1 - REMOVE REAR BUMPER AND ALL BUMPER RELATED MOUNTING BRACKETS 2 - SLIDE REAR BUMPER INTO FRAME AS SHOWN 3 - INSTALL CROSSMEMBER BOLTS AS SHOWN IN FIGURE A 4 - INSTALL 5/8 X 1 1/2 BOLTS INTO FRAME BRACKETS 5 - ALIGN REAR BUMPER AND TIGHTEN CROSSMEMBER BOLTS FIRST AND THEN TIGHTEN FRAME BOLTS DRAWING# 66701 FIGURE A 1/2 USS FLATWASHER 1/2 LOCKWASHER 1/2 NUT REAR CROSSMEMBER 1/2 X 4 1/2 BOLT 1/2 USS FLATWASHER GARVIN INDUSTRIES 316 MILLAR AVE EL CAJON CA 92020 (619)-440-7415 G - 2 SERIES BUMPER SYSTEM PAGE 5 OF 10 PART # 66701 TAILGATE BRACKET ASSEMBLY INSTALLATION INSTRUCTIONS FIGURE A FACTORY TAILGATE TAILGATE MOUNTING BRACKET TAILGATE MOUNTING BRACKET THREADED NUTS INSIDE TAILGATE 3/8 NUT 3/8 LOCKWASHER 3/8 NUTS 5/16 USS FLATWASHERS RE-USE FACTORY TIRE CARRIER BOLTS 3/8 X 3 1/2 TAP BOLT (ALL THREAD ) TAILGATE BRACKET KIT 1 - TAILGATE MOUNTING BRACKET 1 - 2” DIA. RUBBER BUMPER 1 - 3/8 X 3 1/2 TAP BOLT ( ALL THREAD ) 1 - 3/8 FENDER WASHER ( 2” DIA. ) 3 - 3/8 USS FLATWASHERS ( 1” DIA. ) 3 - 3/8 NUTS 1 - 3/8 LOCKWASHER INSTALLATION INSTRUCTIONS 1 - INSTALL TAILGATE MOUNTING BRACKET TO THE TOP TWO HOLES IN THE TAILGATE, CENTER AND TIGHTEN FASTENERS. 2- INSTALL THIRD BRAKE LIGHT AND BRACKETS ( REFER TO PAGE 7 ) TO TAILGATE BRACKET, ADJUST AND TIGHTEN FASTENERS. 3 - RECONNECT STOP LIGHT WIRING. 4 - INSTALL RUBBER BUMPER AND HARDWARE TO BRACKET AS SHOWN IN FIGURE A 5 - ADJUST RUBBER BUMPER TO TOUCH SWING ARM AFTER ALL ACCESSORIES AND TIRE HAVE BEEN INSTALLED, TIGHTEN ALL BUMPER FASTENERS 6 - IF TRAIL RACK IS INSTALLED, REMOVE TAILGATE MOUNTING BRACKET, INSTALL TRAIL RACK AND THEN RE-INSTALL MOUNTING BRACKET AS SHOWN IN FIGURE B DRAWING # 66701-G 5/16 USS FLATWASHERS FACTORY TIRE CARRIER MOUNTING BOLTS 3/8 USS FLATWASHERS ( 1' DIA. ) 3/8 FENDER WASHER ( 2" DIA. ) RUBBER BUMPER ( 2" DIA. ) 3/8 USS FLATWASHER ( 1' DIA. ) FIGURE B FACTORY HARDWARE AND (8) 5/16 USS FLATWASHERS RE-USE FACTORY TIRE CARRIER MOUNTING HARDWARE ( 8 BOLTS ) G-2 SERIES TIRE CARRIER BUMP STOP BRACKET MOUNTS OUTSIDE THE TRAIL RACK MOUNTING BRACKETS RE-USE FACTORY BOLTS MFG. BY GARVIN INDUSTRIES 316 MILLAR AVE EL CAJON CA. 92020 (619) 440 7415 REAR BUMPER / TIRE CARRIER G-2 SERIES PART # 66701 ALUMINUM END CAPS AND TOP COVER PAGE 6 OF 10 INSTALLATION INSTRUCTIONS FIGURE A ALUMINUM END CAP INSTALLATION ALUMINUM END CAP 7/16 SAE FLATWASHERS USED AS SPACERS 7/16 SAE FLATWASHER 7/16 LOCKWASHER 7/16 NUT (4 EACH REQUIRED PER BUMPER ) FIGURE B BUMPER 7/16 SAE FLATWASHERS USED AS SPACERS 3 PER BOLT 12 REQUIRED PER BUMPER TOP COVER INSTALLATION 5/16 X 1 BUTTON HEAD ALLEN BOLTS ----- 5/16 USS FLATWASHERS NOTCH 5/16 LOCKWASHER 5/16 NUT 5/16 LOCKWASHER 5/16 NUT TOP ALUMINUM COVER THREADED PLATE SUPPORTS FIGURE A 2 - ALUMINUM REAR BUMPER END CAPS 16 - 7/16 SAE FLATWASHERS 4 - 7/16 LOCKWASHERS 4 - 7/16 NUTS DRAWING# 66701-D PARTS LIST FIGURE B 1 - ALUMINUM TOP COVER ( 1/4 X 4 X 56 1/2 ) 4 - 5/16 X 1 BUTTON HEAD ALLEN BOLTS 4 - 5/16 USS FLATWASHERS ( 7/8” DIA. ) 2 - 5/16 LOCKWASHERS 2 - 5/16 NUTS 1 - 3/16 ALLEN WRENCH GARVIN INDUSTRIES 316 MILLAR AVE EL CAJON CA 92020 (619)-440-7415 G-2 SERIES BUMPER SYSTEM PAGE 7 OF 10 PART # 66701 INSTALLATION INSTRUCTIONS BRAKE LIGHT ASSEMBLY 1- REMOVE 4 SCREWS ( TORQ T-20 ) FROM REAR OF BRAKE LIGHT ASSEMBLY AND REMOVE BACK COVER. 2- UNPLUG WIRING FROM LIGHT ASSEMBLY AND REMOVE WIRING FROM SPARE TIRE MOUNTING BRACKET. 3- REMOVE SPARE TIRE BRACKET FROM TAILGATE. ( 13 MM SOCKET ) 4- MEASURE UP 2 5/8" FROM CENTER OF LOWER T-20 SCREW HOLE ( FIGURE A ), MARK AND CUT TOP SECTION OFF. FIGURE A 5- AFTER CUTTING OFF, SAND EDGES AND PAINT WITH A SATIN BLACK. 6- RE-INSTALL METAL COVER BACK ON LIGHT, MARK PLASTIC AND CUT PLASTIC AT SAME LENGTH AS METAL BACK COVER, REMOVE METAL COVER. 7- MARK, DRILL, AND INSTALL LIGHT ASSEMBLY AS SHOWN IN FIGURE B 8- INSTALL LIGHT ASSEMBLY TO TAILGATE MOUNTING BRACKET AS SHOWN IN FIGURE C. LIGHT ASSEMBLY IS ADJUSTABLE TO FIT LARGER DIAMETER TIRES. 9- RE-INSTALL LIGHT WIRING AND METAL BACK COVER. REMOVE REAR METAL COVER ON 3RD. BRAKE LIGHT ( TORQ T-20 ) FIGURE C 2 5/8" 1/4 THIN NYLON LOCKNUT 1/4 FLATWASHER FIGURE B REAR VIEW OF LIGHT ASSEMBLY , COVER OFF 5/16 FLATWASHER 5/16 NYLON LOCKNUT MARK AND DRILL 9/32" DIA. HOLE THROUGH PLASTIC DRAWING # 66701-E BRAKE LIGHT TOP SUPPORT BRACKET S (2) 5/16 X 1 CARRIAGE BOLT RUBBER BUMPER 2" DIAMETER 3/4" BRAKE LIGHT TOP SUPPORT BRACKET 1/4 X 3/4 BOLT 1/4 FLATWASHER TAILGATE MOUNTING BRACKET TAIL GATE SPARE TIRE MOUNTING AREA RE-USE FACTORY BOLTS RE-INSTALL FACTORY BOLTS INTO THREADED HOLES IN TAIL GATE MFG. BY GARVIN INDUSTRIES 316 MILLAR AVE EL CAJON CA. 92020 (619) 440 7415 WILDERNESS PRODUCTS G-2 SERIES REAR BUMPER PART # 66701 SWING-ARM INSTALLATION PAGE 8 OF 10 SPRING LOADED PULL PIN KIT 1 - PULL HANDLE AND LOCK INTO THE RETRACT POSITION 2 - SCREW THE PULL PIN INTO THE PIVOT ADAPTOR AND TIGHTEN 3- THE SPRING LOADED PULL PIN CAN BE MANUALLY HELD OPEN OR MANUALLY CLOSED BY TURNING THE HANDLE. CAUTION !!! REFER TO INSTRUCTION SHEET LINE 17 PAGE 2 LATCH ASSEMBLY 1 1/2 LOCKNUT STEEL SPACER ( SILVER ) GRAY NYLON FLATWASHER ITTINGS GREASE F (2) THRUST WASHER ( GOLD COLOR ) SPRING LOADED PULL PIN 1 - INSTALL THRUST WASHER ON PIVOT PIN IN BUMPER. 2 - SLIGHTLY GREASE PIVOT PIN AND SLIDE SWING ARM ON BUMPER. 3 - INSTALL NYLON FLATWASHER, STEEL SPACER AND LOCK NUT. TIGHTEN LOCK NUT UNTILL THERE IS NO UP OR DOWN MOVEMENT ON SWING ARM. 4 - INSTALL LATCH ASSEMBLY ON SWING ARM AS SHOWN IN FIGURE A. ADJUST LATCH U BOLT UNTILL YOU GET A SNAPING WHEN YOU CLOSE THE LATCH. 5 - INSTALL BOTH GREASE FITTINGS AND GREASE WITH POWER GREASE GUN. FIGURE A FACTORY INSTALLED PARTS LATCH ASSEMBLY ADJUSTING NUT ( NYLON LOCKING ) ADJUSTING NUT ( REG ) U BOLT DRAWING# 66701-F HANDLE LOCKING LEVER 4 - 1/4 X 3/4 BOLTS 4 - 1/4 LOCKWASHERS 4 - 1/4 FLATWASHERS 2 - GREASE FITTINGS ( PLASTIC BAG ) 1 - SPRING LOADED PIN ( PLASTIC BAG ) 1 - 1/2 X 3 BOLT, FLATWASHERS & LOCK NUT 4 - 1/4 X 3/4 BOLTS, LOCKWASHERS AND FLATWASHERS ( LATCH ASSEMBLY ) ALL SWING ARM PIVOT HARDWARE 1 - 1 1/2 NYLON THIN LOCK NUT 1 - 1/4” STEEL SPACER ( SILVER IN COLOR ) 1 - 1 1/2 GRAY NYLON FLATWASHER 1 - THRUST WASHER ( GOLD IN COLOR ) GARVIN INDUSTRIES 316 MILLAR AVE EL CAJON CA 92020 (619)-440-7415 WILDERNESS PRODUCTS JK REAR BUMPER/TIRE CARRIER G-2 SERIES PART # 66701 HI-LIFT JACK MOUNTINGS BRACKETS INSTALLATION INSTRUCTIONS PAGE 9 OF 10 PARTS LIST 1 - DRIVERS SIDE MOUNT ( 4 3/4” ) 1 - PASSENGERS SIDE MOUNT ( 5 1/2” ) 2 - OUTBOARD SUPPORT BRACKETS 2 - 1/2 WING NUTS 2 - 1/2 SAE FLATWASHERS 2 - 1/2 LOCKWASHERS 4 - 3/8 X 1 1/4 CARRIAGE BOLTS 4 - 3/8 USS FLATWASHERS 4 - 3/8 NYLON LOCK NUTS INSTALLATION INSTRUCTIONS 1 - INSTALL HI-LIFT BRACKETS TO SWING A WAY AS SHOWN ( 1-LONG & 1- SHORT ) 2 - SLIGHTLEY TIGHTEN TO HOLD IN PLACE. 3 - FIT HI-LIFT TO BRACKETS AS SHOWN, ADJUST MOUNTING BRACKETS SO HI-LIFT JACK WILL REMOVE EASILY AND TIGHTEN MOUNTING BRACKET HARDWARE 4 - SECURE HI-LIFT TO BRACKETS AS SHOWN AND TIGHTEN 3/8 USS FLATWASHERS 3/8 NYLON LOCK NUTS DRIVERS SIDE 4 3/4” PASSENGERS SIDE 5 1/2” HI-LIFT JACK & LOWER CAN MOUNTING BRACKET MOUNTING POINT THESE 1 1/4 CARRIAGE BOLTS CHANGE TO 1 1/2 CARRIAGE BOLTS WHEN CAN HOLDER IS USED. THE 1 1/2 BOLTS ARE PROVIDED IN THE CAN HOLDER KIT. 3/8 x 1 1/4 CARRIAGE BOLTS HI - LIFT OUTBOARD SUPPORT BRACKET HI-LIFT JACK 1/2 WING NUT 1/2 LOCKWASHER 1/2 SAE FLATWASHER USE A AFTERMARKET HANDLE HOLDER TO SECURE HANDLE DRAWING# 66701-B GARVIN INDUSTRIES 316 MILLAR AVE EL CAJON CA 92020 (619)-440-7415 G-2 SERIES BUMPER SYSTEM PAGE 10 OF 10 PART # 66701 INSTALLATION INSTRUCTIONS TIRE MOUNTING BRACKET PARTS LIST 1 - TIRE MOUNT ( 5 ON 5 ) 1 - 1/2 X 3 BOLT 1 - 1/2 NYLON LOCK NUT 2 - SAE FLATWASHERS ( 1” DIA. ) CUT OFF END IF NEEDED WITH HACKSAW PARTS FACTORY INSTALLED ON SWING ARM TIRE MOUNTING BRACKET DRILLED 1/2" HOLE IS 1/4" FORWARD FROM MARKED HOLE TWO BOLTS GO TO THE TOP TWO BOLTS GO TO THE TOP MARKED HOLE ACTUAL DRILLED 1/2" HOLE USE 1/2" HOLE AS A GUIDE AND MARK THE TIRE MOUNT FOR DRILLING 1/2 NYLON LOCKNUT 1/2 SAE FLATWASHER 1/2 X 3 BOLT 1/2 SAE FLATWASHER INSTALLATION INSTRUCTIONS 1 - INSTALL THE TIRE MOUNTING BRACKET TO THE WHEEL, SLIGHTLEY TIGHTEN TO HOLD IN PLACE. 2 - WITH THE TWO WHEEL STUDS ON THE TOP, AS SHOWN, PICK UP THE TIRE AND WHEEL ASSEMBLY AND SLIDE THE SQUARE TIRE MOUNT INTO THE TIRE CARRIER. 3 - TIRE WIDTHS AND WHEEL OFF SETS VARY GREATLY. IF THE TIRE MOUNTING BRACKET BOTTOMS OUT IN THE RECEIVER BEFORE THE TIRE TOUCHES THE THREE UPRIGHTS, THEN THE TIRE BRACKET MUST BE TRIMMED SHORTER. (REFER TO DRAWING). THE END CAN BE CUT OFF WITH A BASIC HACKSAW WITH A GOOD BLADE. 4 - OPEN THE TIRE CARRIER TO GAIN ACCESS BEHIND THE TIRE, WITH THE TIRE TOUCHING THE THREE VERTICAL SUPPORT ARMS. USE THE HOLE IN THE TIRE MOUNT AS A GUIDE, MARK THE TIRE BRACKET FOR THE 1/2" HOLE. THE ACTUAL 1/2" HOLE IS DRILLED 1/4" FORWARD OF THE MARKED HOLE, REFER TO THE ABOVE DRAWING. 5 - REMOVE TIRE ASSEMBLY, REMOVE THE TIRE MOUNT BRACKET. MOVE MARKED HOLE ON THE MOUNT BRACKET 1/4" FORWARD, RE-MARK AND DRILL 1/2" DIA. HOLE IN TIRE MOUNT 6 - RE-INSTALL MOUNT BRACKET INTO TIRE CARRIER AND SECURE 1/2 X 3 BOLT, FLATWASHERS AND NYLON LOCKNUT 7 - INSTALL TIRE TO TIRE CARRIER DRAWING # 66701-C MFG. BY GARVIN INDUSTRIES 316 MILLAR AVE EL CAJON CA. 92020 (619) 440 7415