Bushwacker Body Gear 10911-07 Fender Flare Installation

Bushwacker Body Gear 10911-07 Fender Flare Installation
Jeep Cherokee
84-96 4 Door XJ
Set Part # 10911
Revision J 6-5-06
Step 1:
Prior to Installation:
A) Fit: Verify the fit of the flares to vehicle. (Some filing, sanding, or
cutting may be necessary to ensure proper fit).
B) Painting: (Optional) if paint is desired it must be done prior to
installing flares on the vehicle clean outer surface with a good
grade degreaser. DO NOT USE LACQUER THINNER OR ENAMEL
REDUCER AS A DEGREASER. Wipe outer surface thoroughly with a
tack rag prior to paint.
Paint flares using a high quality enamel, or polyurethane automotive
paint. (Application of a primer coat is optional)
If painting edge trim (not recommended), use a flex additive.
C) Performance: Using larger Tires may increase the area required to
turn the vehicle. Some Tire/Rim combinations may require lowering
bump stops and or installing steering stops to prevent tire from
contacting flare.
D) Exhaust System: Modifications may be necessary to maintain a
minimum 4” clearance between flares and exhaust pipes.
(Exhaust gases should not vent directly onto flares)
E) Metal Protection: All exposed fasteners and bare metal should be
treated with red oxide primer BEFORE installing flares. Spray inner
fender wells with undercoating AFTER flare attachments have been
completed.
TOOLS FOR EASY
INSTALLATION
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Adhesive Remover (optional)
Electric Drill
5/32” Drill Bit
Grease Pencil
Angle Grinder
Reciprocating Saw
Cut Off Wheel
#2 Phillips Bit
Hammer
10 mm Socket
7 mm Socket
Awl
NOTE: THESE INSTRUCTIONS INVOLVE CUTTING THE FENDERS OF THE VEHICLE. IT IS
IMPORTANT TO READ ALL INSTRUCTIONS PRIOR TO CUTTING AND INSTALLATION OF
FLARES.
FLARE INSTALLATION PROCEDURES
Step 2: Preparing the Work Area
A) Remove factory flares, fender trim, mud flaps and mud
flap brackets (when installed).
Step 3: Edge Trim Installation
(See Illustration #1)
A) Peel two to three inches of red vinyl backing away
from edge trim tape. Applying the adhesive side of the
edge trim to the inner side of the flare, affix the edge
trim to the top edge of the flare (the portion that comes
in contact with the vehicle). See Illustration #1.
B) Press edge trim into place along the top edge of the
flare in one-foot increments, pulling red vinyl backing
free as you continue to work your way around the top
edge of the flare.
Illustration #1
6710 N. CATLIN AVE. • PORTLAND, OR 97203 • 503-283-4335 • 1-800-234-8920 (USA AND CANADA) • FAX 503-283-3007
Step 4: Front Fender Cutting and Installation (See Photos #1 through #29)
1
2
Remove the front factory flare starting with the
lower rear factory fastener, using a 7mm socket.
Using a 10mm socket, remove the factory
fastener located inside the top front of the fender
well.
3
4
Using a 10mm socket, remove two factory
fasteners underneath bumper on either side.
Remove fascia piece.
Apply adhesive remover to the Cherokee emblem
for ease of removal. Using a putty knife, carefully
remove the Cherokee emblem, taking caution not to
scratch the paint.
6
5
Using a grease pencil, make a horizontal line
horizontally from the bottom of the headlight
bezel to the inside of the fender well opening.
Starting at the bottom of the headlight bezel,
measure in 5” and mark a line on the fender.
8
7
Trace a line from the mark made in Step 6 up
along the contour to the third factory hole
(counting from bottom front). From there, angle
the line toward the edge of the fender.
Starting at the edge of the door seam, measure
in (towards fender well opening) 5-1/4” and
make a mark.
10
9
Trace a line from the mark made in Step 8 up
along the contour to the third factory hole
(counting from bottom rear). From there, angle
the line toward the edge of the fender.
11
Cut along the horizontal line made in Step 9.
Starting at bottom rear of fender, cut along lines
using a reciprocating saw or grinder. Note: it is
helpful to use a block of wood to separate the
fender from the splash guard, which will be
trimmed later.
12
Cut along the line made at the front of the fender,
starting at the top. Note: Use a block of wood to
separate the fender from the splash shield and to
protect the bumper.
13
Cut along the horizontal line made in Step 7.
CUT
14
Carefully cut along the line parallel to the bottom
of the headlight bezel, taking care not to cut the
bezel or the bumper.
16
15
Carefully cut lower sheet metal strut attached to
fender.
At the rear of the front fender, using the cut sheet
metal edge as a guide, mark the inner sheet
metal structure to match.
17
Using a reciprocating saw, cut away the inner
sheet metal as marked in Step 16.
18
Grind the sheet metal back so that it is in line
with the cut fender.
19
20
Grommet
Trim the plastic splash guard to match the
contours of the sheet metal.
At the front of the splash shield, draw a line from
the area cut in Step 19 down to the plastic
grommet, taking care not to cut through the
grommet. Trim on this line.
21
Fold the remaining flap under the bumper.
22
The fender should look like this. Some additional
grinding may be needed. Optional: use caulking
to seal all cut edges and seams.
24
23
Hold the Front Flare in place on the fender,
pressing firmly. Using the holes in the part as a
guide, mark hole locations on fender (9 places).
Drill marks with a 5/32” bit.
25
Insert screw and washer through each pocket in
flare.
Place a supplied washer onto a supplied Torx
head screw.
27
Place a 3/8” thick rubber spacer on each screw from
the backside of the pocket. Threads must protrude
through spacer for proper attachment of flare. All
spacers must be installed prior to installation on
fender.
29
Optional: To secure splash shield, drill a hole
and use a zip tie to attach it to the bumper.
26
28
Start each screw with supplied Torx bit in each
pocket but do not tighten until all screws have been
started. Over-tightening screws may cause them
to strip! Use a Torque setting of 90 inch/ounces.
Step 5: Rear Fender Cutting and Installation (See Photos #30 through #63)
31
30
Remove the factory flare starting with removal of
the lower rear factory fastener, using a 7mm
socket.
Using a 10mm socket, remove the factory
fastener located inside the front of the wheel
well.
32
33
At bottom front of wheel well opening, measure
in 2” and make a mark using a grease pencil.
Using a 7mm socket, remove the lower front
factory fastener.
35
34
Follow contour up to 1” past the door edge,
maintaining a distance of 2” from edge of wheel
well.
Make a vertical line 1” back from door edge,
intersecting with line made in Step 34.
36
37
At bottom rear of wheel well opening, measure in
1-5/8” and make a mark.
Trace a line from the mark made in Step 36 up
along the contour to the third factory hole (counting
from bottom rear). Drop line down to intersect hole.
39
38
Measure up 3/8” from edge of fender well,
intersecting with line made in Step 35 and mark a
line continuing along edge of fender until
intersecting with line made in Step 37.
Starting at top of fender, cut along lines using a
reciprocating saw or cut-off wheel.
41
40
Along rear fender well edge, take care not to cut
through weld seam. Cut close to seam, then
grind back.
The weld seam should look like this.
42
43
Along front fender well edge, cut through sheet
metal down to the flare-out feature at the bottom.
Carefully cut only the outer sheet metal layer
from the flare-out feature down, leaving the inner
sheet metal layer intact.
44
45
Using a hammer or mallet, pound the inner sheet
metal layer over the seam.
Grind back excess metal as needed. Trim the
inner wheel well to match the contours of the
sheet metal.
46
47
The fender should look like this. Some additional
grinding may be needed. Optional: use caulking
to seal all cut edges and seams.
Open door. Install cover piece over “dog leg”
using five supplied drill screws. Place drill screw
in indent in part and drill into sheet metal. NOTE:
Some trimming may be required.
48
Hold the Rear Main Flare on the fender, aligning with
door seam and fender contours. Press firmly. Using
the holes in the part as a guide, mark hole locations
on fender (5 places).
49
Drill marks with a 5/32” bit.
51
50
Place a supplied washer onto a supplied Torx
head screw.
Insert screw and washer through each pocket in
flare.
52
Place a 3/8” thick rubber spacer on each screw
from the backside of the pocket. Threads must
protrude through spacer for proper attachment of
flare. All spacers must be installed prior to
installation on fender.
53
Start each screw with supplied Torx bit in each
pocket but do not tighten until all screws have
been started. Over-tightening screws may
cause them to strip! Use a Torque setting of 90
inch/ounces.
54
55
Hold the Rear Door Piece on the door, aligning
with the Rear Main Flare. Press firmly to ensure
proper hole location alignment.
Using the holes in the part as a guide, mark hole
locations on fender (4 places).
57
56
Place a supplied washer onto a supplied Torx
head screw.
Open Door. Drill marks with a 5/32” bit.
58
59
Insert screw and washer through each pocket in
flare.
Place a 3/8” thick rubber spacer on each screw
from the backside of the pocket. Threads must
protrude through spacer for proper attachment of
flare. All spacers must be installed prior to
installation on fender.
61
60
Drill Screws
Start each screw with supplied Torx bit in each
pocket but do not tighten until all screws have
been started. Over-tightening screws may
cause them to strip! Use a Torque setting of 90
Optional: There are extra drill screws supplied in
the kit. If desired, further secure the rear of the
rear flare using drill screws. Place drill screw on
part and drill into sheet metal.
inch/ounces.
62
Using flat end of supplied Edge Trim Tool, seat
bottom edge of edge trim first by inserting
straight flat end between bottom edge of edge
trim and part at one open end and slide over
entire top edge to the other end.
63
Using curved end of supplied Edge Trim Tool,
seat top edge of edge trim first by hooking
curved end under top edge at one open end and
slide over entire top edge to the other end.
IF YOUR VEHICLE HAS FACTORY TRIM:
1
Prior to marking hole locations, hold the Flare on
the fender, pressing firmly. Making sure the flare
is properly positioned, trace the outline of the
flare on the factory trim.
3
Use a utility knife to cut factory trim and discard.
2
Use a putty knife to separate the factory trim
from the fender, stopping at line made in Step 2.
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