Jeep® Flat Style Included in Hardware Kit: Set of 4 Fender Flares

Jeep® Flat Style Included in Hardware Kit: Set of 4 Fender Flares
Jeep® Flat Style
Fender Flares
Set of 4
STEP 1 – PRIOR TO INSTALLATION
A) Bushwacker only approves installing the flares according to these
written instructions with the hardware provided. WARNING: Failure to
install according to these instructions will invalidate the warranty. This
includes, but is not limited to using alternative installation methods,
hardware, or materials. DO NOT USE: Loctite, SuperGlue, or similar
products on the hardware or the flares.
B) Fit: Verify the fit of the flares to vehicle. (Some filing, sanding, or
cutting may be necessary to ensure proper fit).
C) Painting: (Optional) if paint is desired it must be done prior to installing
flares on 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. Application of plastic adhesion promoter for ABS plastic as per
your paint system manufacturer’s recommendations is required. Paint
flares using a high quality enamel, or polyurethane automotive paint. If
painting edge trim (not recommended), use a flex additive.
D) 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.
E) 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)
F) Metal Protection: All exposed fasteners and bare metal should be
treated with rust resistant paint BEFORE installing flares. Spray inner
fender wells with undercoating AFTER flare attachments have been
completed.
G) Decals: Flares may interfere with existing decals on vehicle. If you
wish, remove decals prior to installation of flares.
H) Care & Cleaning: Bushwacker fender flares are built to last; any
detergent you use to wash your vehicle is sufficient to clean the flare.
Do not use any harsh abrasive detergents.
Set Part #10918-07
Rev-9 1/6/2016
For complete fitment info visit : www.bushwacker.com
TOOLS FOR EASY INSTALLATION:
• Utility Knife
• Pneumatic Hand Saw or Metal Hacksaw
(optional, Step 12, 61)
• #2 Phillips Drive Bit
• Electric Drill
• 5/16” Drill Bit
• #2 Phillips Screwdriver
• Socket Wrench
• 1/2”, 11/32”, & 10mm Sockets
• 1/2” Wrench
• 8” Socket Extension
• Needle Nose Pliers or Vise Grips
• Scratch Awl (optional Step 44, 81)
• Wire Cutter & Stripper
• 22-18 Gauge Wire Crimp
• Soft Wiping Cloth/Shop Towels
• Heat Gun
• Pry bar/Claw Hammer
• Safety Glasses
• Grease Pencil
PLEASE READ: Dirt and debris can become lodged
between the fender flares and the vehicle’s fenders,
causing scratching and paint wear from vibration. Lund
International is not responsible for any damage, and the
installation of our fender flares is done with the buyer’s
understanding that this scratching and paint wear may
occur.
LIMITED LIFETIME WARRANTY AGAINST
ANY MANUFACTURING DEFECTS
• To claim a warranty, you must provide
Proof of Purchase.
Included in Hardware Kit:
1.
3.
2.
26 pcs
9.
26 pcs
10.
4 pcs
4.
20 pcs
11.
10 pcs
5.
20 pcs
12.
2 pcs
6.
20 pcs
13.
2 pcs
20 pcs
4 pcs
4 pcs
4 pcs
15.
14.
4 pcs
8.
7.
16.
1 pc
4325 HAMILTON MILL RD • BUFORD, GA 30518 • 800-241-7219 (USA AND CANADA) • FAX 800-438-37881
249 inches
1
STEP 2 - EDGE TRIM INSTALLATION (DO NOT
INSTALL EDGE TRIM ON THE SMALLER INNER
PIECES! ONLY THE FLARE PIECES NEED IT!)
The edge trim for this application is double-tape edge trim
so special care needs to be taken while installing. There is
red vinyl backing on the inside of the edge trim where it will
adhere to the flare and red vinyl backing on the outside where
it will adhere to the vehicle. The following steps only concern
where the edge trim will adhere to the flare. Additional edge
trim installation instructions are included during the rest of the
installation process.
Tube
feature
Inner
Underside
of Flare
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). Stop
at tube feature of flare. Picture 1 for tube feature reference
Picture 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.
Picture 2 for additional edge trim orientation
Inner
Underside
of Flare
Picture 2
Front Flare Installation Procedures (Driver’s Side):
1
2
1
2
Using a socket wrench with a 10mm socket, remove
four factory bolts from inside of splash shield. Save
bolts for reinstallation.
Using a socket wrench with a 10mm socket,
remove bolt located in hole inside of splash shield
(location 1) and bolt in location 2. Save fasteners for
reinstallation. Note: 2007-2010 model years have a
plastic thread engager in location 2. Remove and
save for reinstallation.
4325 HAMILTON MILL RD • BUFORD, GA 30518 • 800-241-7219 (USA AND CANADA) • FAX 800-438-37882
2
3
Remove light receptacle from light lens housing,
letting it hang free of the housing.
4
Starting at front of flare, pull firmly to release flare and
splash shield from fender, working your way to the
back. You will hear popping noises as clips release.
It is okay. If clips break, they will be discarded.
5
Once flare is free of fender, disconnect light
connector. This will allow the flare to come away from
fender completely. Save connector for reinstallation.
6
Using a pry tool or flat head screwdriver, remove
any plastic clips still in fender.
8
7
Use a pry tool or flat head screwdriver to remove
four plastic fasteners.
Use a drill with 5/16” bit to drill through six plastic
rivets along edge of flare/splash shield. Discard
flare. Save splash shield for reinstallation.
4325 HAMILTON MILL RD • BUFORD, GA 30518 • 800-241-7219 (USA AND CANADA) • FAX 800-438-37883
3
9
10
Inside of
Wheel Well
Reinstall the splash shield, in preparation for marking
before cutting, using supplied 1.25” Washer on
factory bolt/washer assembly and reinstall through
factory threads in sheet metal (2 locations).
Mark the front portion of the splash shield with a
grease pencil in location shown in preparation for
trimming. The splash shield should be flush with the
sheet metal after being trimmed. NOTE: If trimmed
too little, flare won’t fit; if trimmed to much, shield
won’t stay behind flare.
12
11
Using sheet metal as a guide, mark the rear
portion of the splash shield with a grease pencil in
preparation for trimming. The splash shield should
be flush with the sheet metal after being trimmed.
NOTE: If trimmed too little, flare won’t fit; if trimmed
to much, shield won’t stay behind flare.
Remove splash shield. Save factory hardware for
reinstallation. Using a metal hacksaw, pneumatic
hand saw, or other suitable cutting device, trim the
splash shield along the marked lines.
13
Hold splash shield up to inner wheel well to ensure
that the edge is flush with the sheet metal. Remove
from wheel well and trim or sand if splash shield
extends beyond the sheet metal.
14
Thoroughly clean the exposed metal fender with a
damp cloth and dry.
4325 HAMILTON MILL RD • BUFORD, GA 30518 • 800-241-7219 (USA AND CANADA) • FAX 800-438-37884
4
15
Locate the flat flare front inner pieces. The driver
side front inner pieces are marked D1, D2, & D7.
The passenger side front inner pieces are marked
P1, P2, & P7.
16
Install a speed clip at each clip location on the inner
pieces, centering them on the predrilled holes with
threaded portion on inside (6 locations). NOTE:
Clips may slide out of place. Try pinching the metal
tightly onto the inner piece with pliers.
17
Secure inner piece D1 (and P1 for passenger side
installation) to the sheet metal using the following
4 Steps: Step 1 Position inner piece on fender,
aligning with existing factory holes in sheet metal.
19
Step 3 For the rearward two mounting locations,
use a vice grip to place the Nylok Nut on the back
side of the bolt. Start the bolts but do not tighten.
18
Step 2 Slide a .700” Washer onto 5/16” Hex Head
Bolt. Insert a bolt/washer assembly through inner
flare piece and fender and secure with 5/16” Nylok
Nut. Start the bolts but do not tighten.
Upper Style Line
20
Step 4 Using a 1/2” socket wrench and a 1/2”
wrench, tighten all bolts until inner piece is snug
against fender and washers do not spin. Do not
overtighten: see step 21. Inner piece should rest
along upper style line of sheet metal radius and
not below it: see step 22.
4325 HAMILTON MILL RD • BUFORD, GA 30518 • 800-241-7219 (USA AND CANADA) • FAX 800-438-37885
5
21
22
Upper Style Line
Bolt on left: Properly tightened; lower edge of inner
piece runs straight
Bolt on right: Overtightened; lower edge of inner
piece bows down; if accidentally overtightened,
remove inner piece completely before reinstalling
Picture on left: Top edge of inner piece along upper
style line
Picture on right: Top edge of inner piece tucked
below upper style line; this forcibly angles and
deforms inner pieces and flare is difficult or
impossible to install
23
24
Hole
Locations
Secure inner pieces D2 (and P2 for passenger side
installation) to the sheet metal using the following
3 Steps: Step 1 Position inner piece on fender,
aligning with existing factory holes in sheet metal.
Upper Style Line
Step 2 Slide a .700” Washer onto 5/16” Hex Head
Bolt. Insert a bolt/washer assembly through inner
flare piece and fender and secure with 5/16” Nylok
Nut. Start the bolts but do not tighten.
25
26
Hole
Locations
Step 3 Using a 1/2” socket wrench and a 1/2”
wrench, tighten all bolts until inner piece is snug
against fender. Do not overtighten: see step 21.
Inner piece should rest along upper style line of
sheet metal radius and not below it: see step 22.
Secure inner pieces D7 (and P7 for passenger side
installation) to the sheet metal using the following
2 Steps: Step 1 Position inner piece on fender,
aligning with existing holes in first two inner pieces.
4325 HAMILTON MILL RD • BUFORD, GA 30518 • 800-241-7219 (USA AND CANADA) • FAX 800-438-37886
6
Upper Style Line
27
Step 2 While holding the inner piece in place, install
a plastic push retainer through holes in both inner
pieces. Inner piece should rest along upper style
line of sheet metal radius and not below it: see
step 22.
28
Reinstall light connector removed in step 5. Position
inner splash shield for reinstallation, making sure
that side marker light wires are outside of splash
shield.
29
Reinstall inner splash shield by first placing a
supplied plastic push retainer through the mounting
hole in the sheet metal and splash shield as shown
in picture. Note: Splash shield should be behind
sheet metal.
30
Install a supplied 1.25” Washer on factory bolt/
washer assembly and reinstall through factory
threads in sheet metal (2 locations).
31
Reinstall factory fastener removed in Step 2 in
location shown. 2007-2010 model years, fastener is
a plastic thread engager. 2011-newer model years,
fastener is a 10mm bolt.
32
Use wire cutters to cut the two wires at the base of
the factory side marker lamp.
4325 HAMILTON MILL RD • BUFORD, GA 30518 • 800-241-7219 (USA AND CANADA) • FAX 800-438-37887
7
33
Use wire strippers to strip away approximately
3/8” of wire covering from the factory installed side
marker lamp wires.
34
Install a Female Bullet Connector to the end of each
factory side marker light wire and secure by pressing
firmly with a wire crimp.
35
Seal heat shrink tubing on wire using a heat gun.
36
Position the supplied side marker light onto the outer
flare piece, threading the wires through the center
predrilled hole.
37
Secure the side marker light to the outer flare with
8-32 screw, 8-32 nut, and washer using a #2 Phillips
bit and a 11/32” socket with 8” extension (2 places).
NOTE: If you are having trouble putting the washer
and nut on the screw, use needle nose pliers.
38
Before installing the outer flare, make sure that the
speed clips on the inner pieces are centered over
the predrilled holes.
4325 HAMILTON MILL RD • BUFORD, GA 30518 • 800-241-7219 (USA AND CANADA) • FAX 800-438-37888
8
39
Before installing the outer flare, install speed clip on
metal frame angle support bracket at top center of
wheel well. Make sure that it is centered over the
factory slot with threaded portion facing up.
40
Use one supplied alcohol prep pad to clean the
sheet metal above each inner piece in preparation
to tape the edge trim to the sheet metal. This must
be done for proper flare installation.
41
Peel back 1-2” of red liner on each end of the edge
trim and bend toward the outside of the flare.
42
Connect the side marker light wires with the vehicle
wires by attaching the male connectors to the female
connectors. Test the connection by turning on the
front marker/parking lights. Switch connectors if
necessary.
43
Place the outer flare over the inner pieces and push
until snug against the sheet metal. Make sure that
the side marker light wires are inside the flare. Make
sure splash shield is tucked behind flare.
44
Use a scratch awl (or another pointed tool) to line
up the speed clips with the outer flare holes (7
locations). If needed, use a flashlight to better locate
the speed clips.
4325 HAMILTON MILL RD • BUFORD, GA 30518 • 800-241-7219 (USA AND CANADA) • FAX 800-438-37889
9
45
46
Press
Firmly
Hold flare in place on fender and start a pan head
screw into each hole location and through speed clip
on inner structure and metal frame angle support
bracket (7 locations). Do not tighten.
After all screws have been started, tighten the pan
head screws by firmly pressing the flare toward the
vehicle while tightening.
47
Peel outer tape liner from the double-tape edge
trim. Push down lightly on the fender flare to create
a small gap between the sheet metal and the edge
trim. This makes it easier to pull the red liner.
48
After the red liner is removed, firmly press the flare
toward the vehicle for 10 seconds to adhere the
tape to the vehicle surface. Repeat this process for
the entire length of the flare. The vehicle surface
temperature must be between 65-110° F for proper
adhesion. Allow 24 hours for full adhesion.
50
49
Starting at one end, use the flat edge of the supplied
edge trim tool to further adhere the edge trim to the
vehicle surface. Slide the tool along the edge trim
while pressing it in toward the vehicle surface.
Use the hooked end of the edge trim tool to check for
full adhesion. Do this by sliding it along the top of the
edge trim to visually verify that the tape is adhered
to the vehicle surface. Repeat step 49 if tape is not
fully adhered to the vehicle surface.
4325 HAMILTON MILL RD • BUFORD, GA 30518 • 800-241-7219 (USA AND CANADA) • FAX 800-438-378810
10
51
Attach one side reflex reflector to the side of the
vehicle by peeling off the adhesive backing and
pressing it firmly onto the cleaned vehicle surface.
NOTE: Once reflector has adhered it cannot be
repositioned.
52
Completed front driver’s side flare installation.
Rear Flare Installation Procedures (Driver’s Side):
53
Using a pry tool, pliers, or flat head screwdriver,
remove four plastic fasteners from inside of splash
shield.
54
Starting at front of flare, pull firmly to release flare and
splash shield from fender, working your way to the
back. You will hear popping noises as clips release.
It is okay if clips break, they will be discarded.
55
Using a pry tool or flat head screwdriver, remove
any plastic clips still in fender.
56
Use a drill with a 5/16” bit to drill through six plastic
rivets along edge of flare/splash shield. Discard the
flare. Save splash shield for reinstallation.
4325 HAMILTON MILL RD • BUFORD, GA 30518 • 800-241-7219 (USA AND CANADA) • FAX 800-438-378811
11
57
Thoroughly clean the exposed metal fender with a
damp cloth then dry.
58
Hold the splash shield in place using supplied 1/4”
Panel Retainers through factory holes halfway.
Do not fully install Retainers, leave them half out.
They are only used to hold splash shield in place for
marking. See step 76 for locations.
60
59
Using sheet metal as a guide, mark the splash shield
with a grease pencil in preparation for trimming. The
splash shield should be flush with the sheet metal
after being trimmed. NOTE: If trimmed too little,
flare won’t fit; if trimmed to much, shield won’t stay
behind flare.
Remove splash shield. Trace around upper mounting
tabs with grease pencil as shown. Mounting tabs are
necessary for reinstallation.
62
61
Using a metal hacksaw, pneumatic hand saw, or
other suitable cutting device, trim the splash shield
along the marked lines.
After trimming, mark the rear portion of the splash
shield as shown and trim. NOTE: If trimmed too
little, flare won’t fit; if trimmed to much, shield won’t
stay behind flare.
4325 HAMILTON MILL RD • BUFORD, GA 30518 • 800-241-7219 (USA AND CANADA) • FAX 800-438-378812
12
63
Sand mounting tabs flat using an angle grinder or
sand paper.
64
Place a grease pencil mark 1/8” below the hole on
the rear mounting tab.
66
65
Use a drill and 5/16” drill bit to drill through mark
made on rear mounting tab.
Locate the flat flare rear inner pieces. The driver
side rear inner pieces are marked D5, D6 & D9. The
passenger side rear inner pieces are marked P5, P6
& P9.
67
Install a speed clip at each clip location on the inner
pieces, centering them on the predrilled holes with
threaded portion on inside. (6 locations) NOTE:
Clips may slide out of place. Try pinching the metal
tightly onto the inner piece with pliers.
68
Secure inner piece D5 (and P5 for passenger side
installation) to the sheet metal using the following
2 STEPS: Step 1 Position inner piece on fender,
aligning with existing factory holes in sheet metal.
4325 HAMILTON MILL RD • BUFORD, GA 30518 • 800-241-7219 (USA AND CANADA) • FAX 800-438-378813
13
Upper Style
Line
69
70
Hole
Locations
Step 2 While holding the inner piece in place, install
a plastic push retainer in each hole location. Inner
piece should rest along upper style line of sheet
metal radius and not below it: see step 22. NOTE:
Foam insulation may need to be trimmed out of the
holes.
Secure inner piece D6 (and P6 for passenger side
installation) to the sheet metal using the following
4 STEPS: Step 1 Position inner piece on fender,
aligning with existing factory holes in sheet metal.
71
Step 2 While holding the inner piece in place, install
a plastic push retainer in the rearward three hole
locations.
Upper Style Line
72
Step 3 Slide a .700” Washer onto 5/16” Hex Head
Bolt. Insert a bolt/washer assembly through inner
flare piece and fender in frontward two locations and
secure with 5/16” Nylok Nut. Start the bolts but do
not tighten.
73
74
Hole
Location
Step 4 Using a 1/2” socket wrench and a 1/2”
wrench, tighten all bolts until inner piece is snug
against fender. Do not overtighten: see step 21.
Inner piece should rest along upper style line of
sheet metal radius and not below it: see step 22.
Secure inner piece D9 (and P9 for passenger side
installation) to the sheet metal using the following
2 STEPS: Step 1 Position inner piece on fender,
aligning with existing factory hole in sheet metal.
4325 HAMILTON MILL RD • BUFORD, GA 30518 • 800-241-7219 (USA AND CANADA) • FAX 800-438-378814
14
Upper Style Line
75
Step 2 While holding the inner piece in place, install
a plastic push retainer. Inner piece should rest
along upper style line of sheet metal radius and
not below it: see step 22.
76
Reinstall modified splash shield using supplied 1/4”
Plastic Retainers (5 locations).
77
Before installing the outer flare, make sure that the
speed clips on the inner pieces are centered over
the predrilled holes.
78
Use one supplied alcohol prep pad to clean the
sheet metal above each inner piece in preparation
to tape the edge trim to the sheet metal. This must
be done for proper flare installation.
79
Peel back 1-2” of red liner on each end of the edge
trim and bend toward the outside of the flare.
80
Place the outer flare over the inner pieces and push
until snug against the vehicle surface. Make sure
splash shield is tucked behind flare.
4325 HAMILTON MILL RD • BUFORD, GA 30518 • 800-241-7219 (USA AND CANADA) • FAX 800-438-378815
15
81
Use a scratch awl (or another pointed tool) to line
up the speed clips with the outer flare holes (6
locations). If needed, use a flashlight to better locate
the speed clips.
82
Hold flare in place on fender and start a pan head
screw into each hole location and through the speed
clip on inner structure (6 locations). Do not tighten.
83
After all screws have been started, tighten the pan
head screws by firmly pressing the flare toward the
vehicle while tightening.
84
Peel outer tape liner from the double-taped edge
trim. Push down lightly on the fender flare to create
a small gap between the sheet metal and the edge
trim. This makes it easier to pull the red liner.
85
Firmly press the flare toward the vehicle for 10
seconds to adhere the tape to the vehicle surface.
Repeat this process moving along the entire length
of the flare. The vehicle surface temperature must
be between 65-110° F for proper adhesion. Allow 24
hours for full adhesion.
86
Starting at one end, use the flat edge of the supplied
edge trim tool to further adhere the edge trim to the
vehicle surface. Slide the tool along the edge trim
while pressing it in toward the vehicle surface.
4325 HAMILTON MILL RD • BUFORD, GA 30518 • 800-241-7219 (USA AND CANADA) • FAX 800-438-378816
16
87
Use the hooked end of the edge trim tool to check
for full adhesion. Do this by sliding it along the top
of the edge trim to visually verify that the tape is
adhered to the vehicle surface. Repeat step 86 if the
tape is not fully adhered to the vehicle surface.
88
Completed rear driver’s side flare installation.
4325 HAMILTON MILL RD • BUFORD, GA 30518 • 800-241-7219 (USA AND CANADA) • FAX 800-438-378817
17
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