ABERLE OFFROAD ALUMINUM JK REAR BUMPER INSTALLATION FOR ALL MODELS 2007 - 2011!
:BEFORE PERFORMING ANY WORK ON YOUR VEHICLE, CHECK TO MAKE SURE VEHICLE IS ON STABLE, LEVEL GROUND. VEHICLE MUST BE SECURED:
:BEFORE PERFORMING ANY WORK ON YOUR VEHICLE, CHECK TO MAKE SURE VEHICLE IS ON STABLE, LEVEL GROUND. VEHICLE MUST BE SECURED:
** Remove factory bumper and all hardware!
** Using a fine tooth sawzall blade, or dremel tool, remove enough material in the rear cross member so that the welded nut plate will fit through the cross member as shown! (Pic. 1A & 1B)
** Using a fine tooth sawzall blade, or dremel tool, remove enough material in the rear cross member so that the welded nut plate will fit through the cross member as shown! (Pic. 1A & 1B)
** Drill two 9/16" holes on the under side of frame rails. Measuring from the end of the frame rail, mark lines at 1-1/2" and 5-1/2" towards the front of the vehicle. From the outside of the frame rail mark center lines at 1-1/4" towards the center of the vehicle. (Pic. 2A)
:NOTE:
Holes should be slightly offset to the outside of the frame rail on each side, when drilled properly. The picture below is of the passenger side view. On some models, drivers side frame rail may only require one hole to be drilled because one hole may already exist.
:NOTE:
Holes should be slightly offset to the outside of the frame rail on each side, when drilled properly. The picture below is of the passenger side view. On some models, drivers side frame rail may only require one hole to be drilled because one hole may already exist.
** Insert the mounting brackets into the frame rails with the holes in the main body of the bracket down (Pic. 3A). It has been from our experience that on some vehicles, the end of the frame rails are somewhat bent in. If the bracket does not slide in freely, you may need to use a pry bar, or something similar, to make the opening in the frame rail big enough for the mounting bracket (Pic 3B).
** When properly placed the bracket will measure 1-3/16" to 1-1/4" from the end of the frame rail to the back side of the mounting plate of bracket. (Pic. 3C)
** The holes in the bottom of the bracket should be offset matching the holes previously drilled in the frame rail.
** Install 7/16 x 1-1/2" bolts and washers into the bottom holes and snug (Pic. 4A).
** Install 7/16 x 4-1/2" bolts and washers from the outside of the frame rail towards the center. The washer plate must rest against the frame as shown with washers on the outside (Pic. 4B). And fasten to nut plate on opposite side of frame.
NOTE: Do not tighten bolts at this time.
** Slide bumper over the mounting brackets.
** Use 7/16 x 2-1/2" bolts and washers to go through tow hooks and bumper, and start them into the brackets. ( Tow hooks are indicate with a "T" on the outer most flange of the hook. the "T" must be installed so that they face each other. ie.., towards the center of vehicle )
** Tighten, but do not torque the eight tow hook bolts.
** Check the clearance and alignment of bumper. If satisfactory torque bolts in this order.
1). All eight tow hook bolts
2). Bottom two frame rail bolts
3). Remaining frame rail side bolts.
NOTE: If installing a rear tire carrier, do not torque bolts untill carrier arm has been checked for alignment!!
** Use 7/16 x 2-1/2" bolts and washers to go through tow hooks and bumper, and start them into the brackets. ( Tow hooks are indicate with a "T" on the outer most flange of the hook. the "T" must be installed so that they face each other. ie.., towards the center of vehicle )
** Tighten, but do not torque the eight tow hook bolts.
** Check the clearance and alignment of bumper. If satisfactory torque bolts in this order.
1). All eight tow hook bolts
2). Bottom two frame rail bolts
3). Remaining frame rail side bolts.
NOTE: If installing a rear tire carrier, do not torque bolts untill carrier arm has been checked for alignment!!
ABERLE OFFROAD ALUMINUM TIRE CARRIER INSTALLATION FOR ALL MODELS 2007 - 2010!
** Remove spare tire and factory tire carrier and save factory mounting hardware.
** Take off passenger side tail light by removing the two screws on the left side of the assembly (Pic. 5A).Pop out light assembly and disconnect wiring harness from back of light (Pic. 5B).
** Take off passenger side tail light by removing the two screws on the left side of the assembly (Pic. 5A).Pop out light assembly and disconnect wiring harness from back of light (Pic. 5B).
** Make sure spindle is clean. Slide carrier arm into the rear bumper spindle (Pic. 6A). DO NOT INSTALL SEAL YET!!! Check to make sure that the arm will move freely in the needed range of motion with no interference with the vehicle.
NOTE: The carrier arm should sit parrallel to the body throughout its range of motion (Pic. 6B). If it does not sit parrallel or is hitting the vehicle, some adjustment will need to be made. Depending on which way the bumper needs to tip, use the extra washers supplied to shim bumper. Shimming can be done by placing washers between the bumper and mounting bracket either on the bottom or top bolts for adjustment.
** If everything lines up with no interference, torque bolts as described in the last steps of the " Rear bumper installation." ( Torque all bolts to 70 lbs./ft. )
NOTE: The carrier arm should sit parrallel to the body throughout its range of motion (Pic. 6B). If it does not sit parrallel or is hitting the vehicle, some adjustment will need to be made. Depending on which way the bumper needs to tip, use the extra washers supplied to shim bumper. Shimming can be done by placing washers between the bumper and mounting bracket either on the bottom or top bolts for adjustment.
** If everything lines up with no interference, torque bolts as described in the last steps of the " Rear bumper installation." ( Torque all bolts to 70 lbs./ft. )
** Remove carrier arm from spindle and make sure that spindle is free of all dirt and debris. Also make sure carrier arm pin is clean as well. Install supplied seal with flat side up, using a wide dead blow hammer and a flat block of wood to seat the seal. ( Take time to make sure that there is no damage done to the seal.)
** Re-install carrier arm into spindle after applying a small amount of bearing grease to the rifling inside the spindle (Pic. 7A).
** Grease spindle through zerk periodically for first couple weeks to ensure that the bearing is packed sufficiently (Pic. 7B)!
NOTE: These are close tolerance parts and will fit properly without being forced. Forcing these parts to fit or beating with a hammer will result in damage to both parts and will no longer be useable!!!
** Re-install carrier arm into spindle after applying a small amount of bearing grease to the rifling inside the spindle (Pic. 7A).
** Grease spindle through zerk periodically for first couple weeks to ensure that the bearing is packed sufficiently (Pic. 7B)!
NOTE: These are close tolerance parts and will fit properly without being forced. Forcing these parts to fit or beating with a hammer will result in damage to both parts and will no longer be useable!!!
** Remove factory tailgate vent, and discard.
** Install new rear tailgate bracket using factory bolts and supplied rubber washers (Pic. 8A). Washers will go between the bracket and the tailgate (Pic. 8B), then tighten.
** Install supplied heim joint links as shown with tailgate in the opened position. Using a washer on each side of the casting surfaces along with a 1/2-20 nut on the bottom. Do not install with door closed as can result in improper tensioning (Pic. 8C).
** To set tension of tire carrier against bump stop, move the door so that it is approximately 1-1/2" from the closed position. At this point adjust the heim joint links so that the carrier arm just touches the bumpstop.The arm should swing freely with ease up to this point. Adjust top linkage first then bottom.
** Close tailgate firmly and swiftly, then determine if the arm is securely held against the tailgate. Additional adjustments may be made to reach desired performance and feel.
NOTE: This adjustment is done at owners discretion, as it is different for every vehicle. Be careful not to overtighten linkages as door damage may result during extreme off roading!!!
** Install new rear tailgate bracket using factory bolts and supplied rubber washers (Pic. 8A). Washers will go between the bracket and the tailgate (Pic. 8B), then tighten.
** Install supplied heim joint links as shown with tailgate in the opened position. Using a washer on each side of the casting surfaces along with a 1/2-20 nut on the bottom. Do not install with door closed as can result in improper tensioning (Pic. 8C).
** To set tension of tire carrier against bump stop, move the door so that it is approximately 1-1/2" from the closed position. At this point adjust the heim joint links so that the carrier arm just touches the bumpstop.The arm should swing freely with ease up to this point. Adjust top linkage first then bottom.
** Close tailgate firmly and swiftly, then determine if the arm is securely held against the tailgate. Additional adjustments may be made to reach desired performance and feel.
NOTE: This adjustment is done at owners discretion, as it is different for every vehicle. Be careful not to overtighten linkages as door damage may result during extreme off roading!!!
1A
1B
2A
3A
3B
3C
4A
4B
5A
5B
6A
6B
7A
7B
8A
8B
8C
!!Please read all instructions before getting started!!
!!Please read all instructions before getting started!!