JK Titan Tub Armor 2 and 4 Door

Transcription

1 JK Titan Tub Armor 2 and 4 Door Thank you for purchasing one of our quality products. From product conception to the moment we packaged this product our focus has been on providing you with the very best. A great deal of effort is spent making sure you receive a quality part that will hold up to years of abuse. If for any reason you are unsatisfied with the purchase of any of our products they may be returned within 10 days in unused condition for your choice of an exchange or a full refund, less shipping charges. Thank you for your purchase and we hope to see you on the trail soon. Pre-Install Notes: Before you start it is imperative that you read these instructions carefully. Failure to do so may result in damage to your vehicle, unsatisfactory installation, or personal injury. 1) Your personal safety is of the utmost importance. Please, exercise extreme caution when working around and under your vehicle. 2) Wear personal protective equipment such as safety glasses, hearing protection and gloves when working on your vehicle. 3) Carefully read the Product Warranty and Assumption of Risk Agreement at the end of this document. 4) It is the purchasers/installers responsibility to inspect the package for any missing or damaged pieces prior to beginning installation. If any discrepancies are discovered please contact us immediately so we may rectify the situation. Installation Instructions

2 Box Contents: 4 Door Right Side Tub Armor 4 Door Left Side Tub Armor 2 Door Right Side Tub Armor 2 Door Left Side Tub Armor Hardware Pack Contents: Part Size Length Quantity 2/4 Door Flat Head (SS) 1/4 3/4 20/26 Nut Insert 1/4 N/A 20/26 Page 1

3 Tools Required: 3/8 Drive Ratchet Center Punch 3/8 Drive 7/16 Socket Quick Grip Clamps (6) 3/16 Hex Key Nut Insert Tool (Recommended) Drill 1/4 20 Tap (Recommended) W Size Drill Bit.386 or mm Red Loctite Counter Sink or 1/2 Drill Bit Anti-Seize or Brake Caliper Grease Hammer Precautions: 1. Make sure the vehicle is in park or first gear with the parking brake set. Vehicle should be on a level, sturdy surface and properly secured to prevent movement while working on it. We recommend using wheel chocks or blocks to ensure the vehicle does not move during the installation process. 2. If lifting of the vehicle is required please consult the vehicle owner s manual for proper lifting techniques and jack placement. Use jack stands to support the vehicle when working under it. 3. Always wear appropriate personal protective equipment: gloves, hearing, and eye protection at a minimum. 4. Use caution when lifting components into place, make sure components are secured during installation. 5. If drilling is required eye protection is especially important to avoid injury. Also be sure to thoroughly inspect the area around where you are drilling to avoid damaging wiring or other components. 6. Use extreme caution when cutting or trimming is required. 7. Please follow the recommended specifications for torque on all hardware. We recommend checking the torque during regular routine maintenance on all aftermarket accessories. Page 2

4 8. Use caution when routing electrical cables and lines. Avoid moving parts, components that become hot and rough or sharp edges. 9. Always insulate and protect all exposed wiring and electrical terminals. 10. Disconnect the battery cables from both terminals with caution, and ensure that they do not touch. 11. Follow the instructions included with the nut insert tool for proper installation. We recommend applying red Loctite to the exterior ribs of the nut insert to ensure a long lasting and hassle free install. Page 3

5 Install Procedure: Please follow these instructions only, if you are having difficulty with a particular step or a part is not fitting as described STOP and contact us before proceeding. Taking actions outside of these instructions can result in damage to your vehicle. Remove factory side steps or rock rails. 1. Remove the nuts that hold the step/rail to the pinch seam on the body of the Jeep. Tools: 10mm open end wrench Page 4

6 2. Remove the bolts holding the step/rail to the underside of the tub. Tools: 3/8 ratchet, 3/8 drive 13mm socket Tip: Have someone hold the step/rail as you remove the bolts to keep it from falling on you. If an extra person is not available, keep 2 of the small nuts loose on the bolts that go through the pinch seam while removing the remaining bolts. 3. Remove step and set aside. Tip: Save the three (3) 8mm x 1.25 bolts that came out of the bottom holes, they can be reused to help with alignment later. Page 5

7 Install Titan Tub Armor 1. If your Jeep has factory rock rails or side steps remove them from the vehicle before beginning the install procedure. Tools: 3/8 ratchet, 3/8 drive 13mm socket, 10mm open end wrench 2. Thoroughly clean the area where the Tub Armor is to be installed. Tip: If your tub armor has a custom cut out you can install reflective material or a colored vinyl behind the cutout to make it stand out. We recommend installing this prior to the final install of the tub armor to keep from scuffing it during mock up. 3. Locate the Titan Tub Armor on the tub by using the bend in the armor to position the armor vertically. There should be close to a 1/4 gap from the bottom of the door sill to the top of the Titan Tub Armor. Tip: We typically start with the right side of the Jeep first. Page 6

8 4. Locate the armor front to rear by centering it on the B-pillar. There should be approximately a 1/8 gap from the door openings to the Titan Tub Armor. 5. Use clamps to securely hold the armor once you have it centered properly. This is the most important step, before you drill any holes make sure the Titan Tub Armor is located correctly. TAKE YOUR TIME. Tools: Quick grip clamps Tip: Use as many clamps as you can. The picture below is the absolute minimum required to perform the install. If your clamps do not have a non-marking pad on them be sure to wrap the ends in a soft towel to avoid scratching the vehicle or tub armor. Page 7

9 6. With the Titan Tub Armor in place, drill a pilot hole using a 1/4 drill bit. The Titan Tub Armor will act as a guide ensuring the drill bit does not walk. Tools: Hammer, center punch, drill, 1/4 drill bit Note: Accurate hole placement is the essential element of a successful install. 7. Remove the Titan Tub Armor and enlarge the pilot hole you drilled in step 6 using the W size drill bit. Tools: Drill, W size drill bit 8. De-burr the hole to ensure the nut insert is installed flat against the body. Tools: Drill, countersink drill bit Tip: If you do not have a countersink bit use a 1/2 drill bit and by hand spin it on the hole to clean out the debris. This This or Page 8

10 9. Apply red Loctite to the outside of the nut insert before inserting it into the enlarged hole. Tools: Red Loctite HDW: (1) 1/4 nut insert 10. Install the nut insert into the drilled and de-burred hole. Tools: Nut insert tool Tip: For proper use of the nut insert tool, please refer to the instructions included with the tool itself. Page 9

11 11. Using the 3/16 hex key and a single flat head bolt coated in anti-seize, install the tub armor. Tools: 3/16 hex key HDW: (1) - 1/4 x 3/4 flat head bolt Tip: DO NOT over tighten the bolt as it will need to be removed shortly. Double check the positioning once installed. 12. Position the clamps as described in step 4. Tools: Quick grip clamps Page 10

12 13. With the Titan Tub Armor securely held in place, drill the remaining top holes on the tub armor (four (4) for a 4 door and three (3) for a 2 door). Again, the tub armor will act as a drill guide ensuring proper placement of the nut inserts. Tools: Drill, 1/4 drill bit Tip: Drill holes working from the center (B-pillar) out. To minimize movement of the tub armor further place a flat head bolt into each hole that you drill before, moving on to the next. Note: DO NOT MARK THE HOLES BELOW THE BEND AT THIS POINT. 14. Remove the tub armor and enlarge the piloted holes. Tools: Drill, W size drill bit 15. De-burr the holes to ensure the nut inserts are installed flat against the body. Tools: Drill, countersink drill bit Tip: If you do not have a countersink bit use a 1/2 drill bit and by hand spin it on the hole to clean out the debris. This This or Page 11

13 16. Apply red Loctite to the outside of the nut inserts before pushing them into the drilled hole. Tools: Red Loctite HDW: (4) 1/4 nut insert 17. Install the nut inserts into the drilled and de-burred holes. Tools: Nut insert tool 18. Clean debris left over from drilling, off of the back side of tub armor and the body of the Jeep. 19. Re-mount the tub armor using the 3/16 hex key and four (4) or five (5) flat head bolts coated in anti-seize. Tools: 3/16 hex key HDW: (4) or (5) - 1/4 x 3/4 flat head bolt Tip: Install the flat heads loosely until all are in place. Note: If bolts are not lining up correctly DO NOT FORCE THEM. It does not take much force to spin a nut insert. See trouble shooting section for tips on working with nut inserts. 20. Tighten the (4) or (5) flat head bolts to secure the tub armor to the Jeep. Tools: 3/16 hex key Note: Tighten the flat heads to no more than 35 in./lbs. or 3 ft./lbs. of torque. Page 12

14 21. Clamp the lower portion of the tub armor against body of the Jeep as pictured. Tools: Quick grips Page 13

15 22. With the Titan Tub Armor securely held in place, drill the bottom holes on the tub armor (eight (8) for a 4 door and six (6) for a 2 door). The tub armor will again act as a drill guide ensuring proper placement of the nut inserts. Tools: Drill, 1/4 drill bit Tip: Drill holes working from the center out. Drill through both layers of body to ensure there is plenty of room for the nut insert. 23. Remove the tub armor and enlarge the remaining holes. Tools: Drill, W size drill bit 24. De-burr the holes to ensure the nut inserts are installed flat against the body. Tools: Drill, countersink drill bit 25. Apply red Loctite to the outside of the nut inserts before pushing them into the drilled hole. Tools: Red Loctite HDW: 6 or 8 1/4 nut inserts 26. Install the nut inserts into the drilled and de-burred holes. Tools: Nut insert tool Page 14

16 27. If you are installing the Billy Rockers along with the Titan Tub Armor, re- mount the tub armor using the top four (4) or five (5) flat head bolts coated in anti-seize and then proceed to the Billy Rocker install instructions. Tools: 3/16 hex key HDW: 4 or 5-1/4 x 3/4 flat head bolts Tip: Install the flat heads loosely until all are in place. Note: If bolts are not lining up correctly DO NOT FORCE THEM. It does not take much force to spin a nut insert. See trouble shooting section for tips on working with damaged nut inserts. 28. If you are installing the Titan Tub Armor by itself, re-mount the tub armor using the ten (10) or thirteen (13) flat head bolts coated in anti-seize. Tools: 3/16 hex key HDW: (10) or (13) - 1/4 x 3/4 flat head bolt Tip: Install the flat heads loosely until all are in place. Note: If bolts are not lining up correctly DO NOT FORCE THEM. It does not take much force to spin a nut insert. See trouble shooting section for tips on working with nut inserts. 29. Tighten the 10 or 13 flat head bolts to secure the tub armor to the Jeep. Tools: 3/16 hex key Note: Tighten the flat heads to no more than 35 in./lbs. or 3 ft./lbs. of torque. 30. Repeat on opposite side. 31. Reconnect battery cables. ATTENTION: IF YOU ARE INSTALLING THE TITAN TUB ARMOR TO BE USED WITH THE BILLY ROCKERS DO NOT INSTALL THE BOLTS INTO THE LOWER HOLES ON THE TUB ARMOR. NEW HARDWARE FOR THESE HOLES IS SUPPLIED WITH THE BILLY ROCKERS. Page 15

17 Troubleshooting: 1. Nut insert alignment: If a nut insert is installed slightly out of alignment with the flare you can follow the below steps to avoid ruining the nut insert. a. Bolt the flare to the Jeep using all of the holes that are properly aligned. b. Use a 1/4-20 tap and gently thread it into the nut insert, be sure to use drill/tap fluid to keep from damaging the tap or the nut insert. The tapered end of the tap has to be able to align to the nut insert for this to work. c. Gently run the tap through the nut insert and allow it to cut away some of the aluminum from the flare. d. Remove the tap and clean out any debris left over from the inside of the nut insert. e. Reinstall the flat head into the nut insert. 2. Removing a damaged nut insert: Nut inserts can be drilled out if they are damaged during the install process, you can follow the below steps to remove a damaged nut insert. a. Remove the flare from the vehicle. b. Using the W size drill bit carefully drill into the nut insert. This will cut away the front lip that holds the nut insert to the body. Be careful not to enlarge the hole since you will need to install a new nut insert into the existing location. Tip: Avoid putting too much pressure on the drill bit. Using excessive force can cause the bit to catch and in turn spin the nut insert making removal even more difficult. c. The nut insert will drop into the body cavity of the Jeep and most likely be unable to be removed. Page 16