INSTALLATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS
Tools: 1. 2. 3. 4. 5. 6. 12mm & 13mm Socket T40 Torx Bit (Rock Block installation) 6mm Allen Bit (Crossmember installation) 13mm Wrench 8mm ´ 1.25 Tap Beer. Lots of it. For all parts: 1. Chasing all Frame Threads with an 8mm ´ 1.25 Tap is highly recommended where appropriate. 2. Applying Permatex 80078 Anti – Seize Lubricant 133K to the threads is recommended. 3. A torque setting of 30 – 40 ft. lbs is suggested (or 1/8 th turn more when the washers are flush) 4. Doing “a corner at a time” prevents the components from landing on one’s noggin. 5. Beers are mandatory upon the installation of each component. Orientation: Anterior = Front; Posterior = Behind Superior = Above; Inferior = Under Front Bash Plate for FJ Cruiser (P/N 999­1C) Removal of this plate is required for Oil Changes. Locking Washers are thus not provided with this component. Components are installed in the following order, and tightened upon completion: Hex Bolt > Cup Washer > Spacer > Front Bash Plate
Engine Skid Plate for FJ Cruiser (P/N 999­2) 1. Remove the plastic filler in the factory Skid Plate. 2. Remove a pair of diagonally opposed bolts, one in the front and another in the rear. 3. Place the skid in position. 4. Install components in the following order: Hex Bolt (90mm front, 45mm rear) > Lock Washer > Cup Washer > Spacer (long for front, short for rear) > Engine Skid 5. Repeat for the remaining bolts. Note: The Transmission Skid Plate goes towards the POSTERIOR and is SUPERIOR to the Engine Skid plate; when installing this component, remove the rear bolts and slide in + affix one corner at a time. 6. Square up plate, and tighten bolts if with no subsequent components pending.
Transmission Skid Plate for FJ Cruiser (P/N 999­3) 1. Remove the Catalytic Converter Guards (4 bolts each). 2. Remove the Engine Skid’s rear bolts and slide the ANTERIOR corner of Transmission Skid SUPERIOR to the POSTERIOR corner of the Engine Skid and re – affix the Engine Skid’s rear bolts, one corner at a time. 3. Reinstall the Catalytic Converter Guards. Note: The Rock Blocks and Transfer Case Skid are installed at this point; the ANTERIOR of the Transfer Case Skid is SUPERIOR to the POSTERIOR of the Transmission Skid. 4. Square up plate, and tighten bolts if with no subsequent components pending.
Rock Blocks for FJ CRUISER (P/N 999­6) 1. Remove the Catalytic Converter Guards (4 bolts each). 2. Place the Rock Blocks in the recesses where the factory bolts were. 3. If the flanges have already been deformed by impact, some straightening may be necessary. 4. Install using the supplied Torx bolts. 5. Tighten bolts if with no subsequent components pending.
Supporting Crossmember for FJ Cruiser (P/N 999­C) 1. Chasing all Frame Threads with a 8mm ´ 1.25 Tap is highly recommended. 2. Unbolt the Exhaust Hanger from the Frame Rail (passenger’s side). 3. Unbolt the Brake Line Bracket from the Frame Rail (driver’s side). 4. Wedge (note taper) Crossmember in; flanges should be positioned inferiorly. 5. Secure the Crossmember with the supplied bolts and washers. Note: There are 4 bolts for the Crossmember, 2 per side. On the passenger's side you will use a hole that the Exhuast Hanger bolts to. There is also an unused frame mount hole which matches with the top left hole of this bracket. On the driver's side, a hole is shared with the Brake Line bracket. The hole on the bottom left of this bracket will coincide with an unused frame mount hole. 6. Reattach the Exhaust Hanger and Brake Line Bracket through the Crossmember in their corresponding threads. 7. Tighten all bolts, unless the Transfer Case Skid is also being installed (wherein the bolts are tightened when the Transfer Case Skid is in position).
Transfer Case Skid Plate for FJ Cruiser (P/N 999­4) 1. Remove the Catalytic Converter Guards (4 bolts each). 2. Remove the Transmission Skid’s rear bolts (which also secure the Rock Blocks and Catalytic Converter Guards) and slide the ANTERIOR corner of Transfer Case Skid SUPERIOR to the POSTERIOR corner of the Transmission Skid and reaffix the Catalytic Converter Guards + Rock Blocks + Transmission Skid’s rear bolts, one corner at a time. 3. Affix the POSTERIOR end of the Transfer Case Skid to the Crossmember, in the following order (note: The Fuel Tank Skid gets installed at this point, before the bolts are inserted): Long (8 ´ 60) Hex Bolt > Large Washer > Transfer Case Skid > Crossmember > Small Washer > Nylock Nut 4. Loosely insert the Short Hex Bolt (no Small Washer and Nylock Nut) into the 5 th hole (threaded and cannot accommodate the longer bolts) on the Crossmember in preparation for Fuel Tank Skid installation, keeping the Transfer Case Skid in place. 5. Square up plate, and tighten bolts if with no subsequent components pending.
Fuel Tank Skid Plate for FJ Cruiser (P/N 999­5) 1. If installing the Transfer Case Skid, this part and the Crossmember must be installed first. 2. Position the Fuel Tank Skid, slide a Large Washer over the 4 Fuel Tank Studs, and loosely affix Nylock Nuts over each. 3. Affix the ANTERIOR end of the Fuel Tank Skid to the Crossmember, in the following order: Long Hex Bolt > Large Washer > Fuel Tank Skid > Crossmember > Small Washer > Nylock Nut 4. If the Transfer Case is installed, the last Long Hex Bolt is installed in the following order (the 2 Large Washers take up the space introduced by the Transfer Case Skid between the Fuel Tank Skid and the Crossmember): Long Hex Bolt > Large Washer > Fuel Tank Skid > 2 Large Washers > Crossmember > Nylock Nut 5. Square up plate, and tighten bolts if with no subsequent components pending.
Bumper Skid for FJ Cruiser (P/N 999­7) 1. Relace the 4 Hex Bolts that secure the bumper’s plastic trim piece (silver – colored on non – TTSE models) with low – profile, wide – thread screws; this allows the Bumper Skid to be positioned flush to the inferior aspect of the bumper. 2. If you have a factory hitch, remove the one bolt that secures the Wiring Harness to the frame; let it dangle free in the meantime. 3. Affix the 4 “L” Brackets to the Frame (2 are inboard, close to the centerline of the bumper, while the remaining 2 are at the ends): Short (8 ´ 30) Hex Bolt > Lock Washer > Small Washer > “L” Bracket > Frame 4. Set the Bumper Skid into position, and affix to the “L” Brackets in the following order: Long (8 ´ 45) Hex Bolt > Lock Washer > Small Washer > Bumper Skid > “L” Bracket 5. Reattach the Wiring Harness to the hole on the Bumper Skid. 6. Square up plate, and tighten bolts.
Control Arm Guards for an FJ Cruiser (P/N 999­A1) 1. Position Control Arm Guards. 2. Install at the rear corner (with the weld – on spacer) in the following order: Longest Hex Bolt (8 ´ 100) > Lock Washer > Cup Washer > Control Arm Guard > Control Arm > Really Large Washer > Nylock Nut 3. Install at the front corner (directly in front of the corner with the weld – on spacer) in the following order: Long Hex Bolt (8 ´ 90) > Lock Washer > Cup Washer > Control Arm Guard > Control Arm > Really Large Washer > Nylock Nut 4. Install at the last corner (closest to the ball joint) in the following order: Short Hex Bolt > Lock Washer > Cup Washer > Control Arm Guard > Control Arm > Really Large Washer > Nylock Nut 5. Repeat for other Control Arm Guard, square up plate, and tighten bolts.