Installation for Full Size Polaris Ranger Crew Doors

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1 Installation for Full Size Polaris Ranger Crew Doors

2 Order of Installation: Heater Doors Wiper on to Windshield Windshield Top & Back Panel Note: Most of the steps in these instructions need to be repeated for the other side of the vehicle. Note: Retain OEM fasteners, some are used in the enclosure installation. Retain D-loops, side nets and remaining fasteners in case cab system is removed. The restraint protection can be reinstalled on the vehicle. Note: Never operate vehicles with doors removed and without reinstalling D-loops and side safety nets. Note: If you have previously installed the Wide Open Company windshield, the windshield will have to be removed before installing the door system.

3 Step 1: Remover side net latches, dash pad and front roll cage bolts Photo 1A Remove (4) push in rivets slide dash panel back and remove Step 1B: Tip Out: Install lower windshield brackets, there is a notch at the lower edge of brackets that determine passenger or driver. Using (2) 10 x 55mm button head bolts and flat black washers per side, reverse the direction of the roll cage bolts from the originals. Run the bolts through the lower tip out brackets, then thread the bolts through the inner half of the roll cage, then through the outer half of roll cage. Secure with 10 x 25mm nut couplers. (Refer to Photo 1B) The lower windshield brackets, bolts and nut couplers are provided in the windshield kit bag.. Remove side net latches Front Roll Cage Bolts Photo 1C Step 1A: Remove the (4) push in rivets along the front edge of the dash pad. Slide dash towards the rear of the Ranger and lift off. Remove all (4) side net latches and bolts. Remove front roll cage bolts. The roll cage has tension so remove one bolt at a time and replace it with the proper brackets and fasteners according to the windshield you are installing in steps 1B or 1C. (Photo 1A) 10mm x 55mm black bolt & 10mm washer 10mm coupler nuts Note: Step 1B refers to installing a WOC Tip Out windshield and Step 1C refers to the WOC Fixed Glass windshield. Refer to the proper step for your windshield 10 x 55 mm button head bolts Photo 1B 10mm nut couplers Step 1C: Fixed Glass windshield, using (2) 10 x 55mm button head bolts and 10mm flat washer reverse direction of the roll cage bolts from the originals. Thread the bolt through the inner half of roll cage then through the outer half. Secure with 10 x 25 nut couplers on the outside of roll cage. (Refer to Photo 1C) The bolts, washers and nut couplers are provided in your WOC windshield kit bag. Install windshield brackets with notch on the bottom edge

4 Step 2: Loosen rear plastic panel and remove rear passenger and driver seat backs. Photo 2A Remove side safety nets Photo 3 Remove (9) push in rivets Remove D-loops Step 2A: Remove the (9) plastic push in rivets that are along the top edge of the lower back plastic panel. (Photo 2A) Photo 2B Step 3: Remove D loops and side safety nets. Retain all fasteners, some are used in the enclosure system installation, the other need to be retained with the D Loop bars and side safety nets in the case of door removal. (Refer to Photo 3) DO NOT DRIVE RANGER WITHOUT THE DOORS OR D LOOP AND SIDE SAFETY NETS!!! Photo 4 Step 2B: Bow the back panel out to access the seat back bolts. Using a Torx head screw driver, push the screw driver through the access holes in the back panel. Remove the (4) screws that attach the passenger side rear seat back, lift up and remove. Remove the (2) screws that attach the driver side rear seat back. Lift up and remove. Also remove the (2) screw that attach the front passenger side seat back, lift up and remove. Step 4: Remove hood Panel ( Photo 4)

5 1 bolt Photo 5 Photo 6B Remove push in rivets Remove bolts Step 5: Remove front fenders. Using a T-40 Torx driver or socket, remove (6) bolts per fender. Then remove (6) push in plastic rivets and remove the fender. (Photo 5) Step 6B: First remove center panel, next front lower side and then the rear lower panel. Photo 6A Center Side Plastic Panel Photo 6C Rear Lower Side Panel Front Lower Side Panel Loosen hose clamp and remove driver rear side panel. Step 6: Remove center and lower side plastic panels. Step 6A: Remove all bolts and plastic rivets that secure the three plastic side panels. Step 6C: On the driver side it is necessary to remove gas tank hose from filler neck. Tilt the box to dump position, loosen hose clamp and remove the lower panel with gas and fill tube still attached to the panel and unhook the filler neck as shown in Photo 6C.

6 Photo 7A Cut out this notch Step 8: Drilling holes in lower kick panels for lower door hinges. Photo 8A Remove (2) Push in Rivets Step 7: Trimming of Lower side plastic panels. Step 7A: It is necessary to trim the bottom edge of the lower plastic side panels to accommodate the lower rear door hinge support brackets. There are templates supplied with the instructions which will help you achieve the line you need. Starting with the passenger front lower panel using the template for that panel cut out along line of template. Using tape to secure the template to the lower rear edge of panel mark the line that needs to be cut. Using a Jig Saw or a Razor Knife remove this portion of the panel. Repeat this procedure for the driver side lower front panel. Photo 7B Slide drink holder upwards and remove Step 8A: It is necessary to remove the rear drink holders to install lower rear hinges. Remove (2) push in rivets and slide the drink holder upward and remove. (Photo 8A) Photo 8B Transfer center marks of hinge holes to plastic Cut Out Corner Step 7B: There is a small portion of the rear lower panels that also need to be trimmed. Using the same procedure as in step 7A cut out the templates and tape them to the lower front edge of rear panels, mark the line on the panels and trim them. (Photo 7B) Step 8B: There are (4) templates provided for lower hinge holes. Using scissors cut along template lines. Tape templates into place according to each kick panel. Using a scribe or ice pick transfer the center mar of each hole through the template onto the plastic.

7 Photo 8C Drill 1/8 pilot holes Step 9A: Place a piece of 2 tape on the outside edge of front vertical frame rail as shown in Photo 9A. Using a small square, mark through the center of the middle front fender bolt hole out to the tape. (Photo 9A) Photo 9B 3/4 3/16 Step 8C: Using a 1/8 drill bit, drill pilot holes at the scribed marks. (Photo 8B) Photo 8D Step 9B: Using the square follow the same line around to the outside of the square tube. Measure up from the line 3/16 and make a mark. Then measure in 3/4 from the outside edge of the tube to get to the center mark. (Photo 9B) Photo 9C Step 8D: Using a 3/4 hole saw, drill out the pilot holes to 3/4. (Photo 8C) Using sandpaper clean up edges of holes. Photo 9A 3 lower fender bolt holes Drill 1/8 pilot hole Step 9C: Using a 1/8 drill bit, drill a pilot hole through the first layer of tubing. (Photo 9C) Step 9: Drilling mounting holes through front frame rail for front door lower hinge mounting brackets.

8 Photo 9D 9F: Using a paint marker or brush, dab in hole to protect from rust. (Photo 9F) Photo 10 Lower hinge mounting bracket 3/8 x 3 button head bolt 1/4 pilot hole through tube and plastic panel Step 9D: Using a 1/4 drill bit, drill through 1/8 pilot hole. (Make sure you drill perpendicular to the surface of the tubing.) Drill through both side of the tubing and through the interior plastic kick panel. (Photo 9D) Photo 9E 3/8 x 1 spacer Step 10: Install lower door hinge bracket. Using a 3/8 x 3 black button head bolt and a 3/8 black flat washer, run bolt from inside through the hole in the kick panel, through upper slot in hinge bracket, through a 3/8 x 1 nylon spacer, then through hole in square tube. Secure with a 3/8 flat washer and 3/8 nylock nut. (Do not tighter after hinge brackets are all loosely bolted together, there will be a tightening sequence.) (Photo 10) 3/8 drill bit Photo 11 Bolt the (2) lower hinge brackets together Step 9E: Remove tape from tubing and finish hole with 3/8 drill bit through all surfaces. (Photo 9E) Photo 9F Self threading bolts Step 11: Install bottom door hinge lower bracket into position. Using (2) 1/4 x 1 Hex head self threading bolts and flat washers, run bolts through slotted holes in bracket then through existing pierced holes in lower frame rails. (DO NOT TIGHTEN!) Using (2) 5/16 x 3/4 hex head bolts, run bolts through outer slotted holes in bracket then into weld nuts in the lower hinge bracket. ( DO NOT TIGHTEN!) (Photo 11)

9 Photo 12A On the inside of kick panel, line up the 3/4 holes with the 3/4 holes in cage nut then tighten bolt. Step 13: Install rear door lower hinge mounting brackets. Photo 13A Bolt Kick panel Inner mounting bolts Step 12: Tightening sequence for lower door hinge brackets. Step 12A: First line up the large cage nut holes (3/4 ) with the 3/4 holes in the kick panel and then tighten the 3/8 x 3 bolt. (Photo 11A) Photo 12B Tighten these (2) bolts second. Tighten these last Rear mounting bolts Outer mounting bolt Lower rear hinge bottom bracket Step 13A: First install the lower hinge bottom bracket. Remove the (2) frame bolts located below the center door post area. Position bottom bracket and replace center frame bolts, bolting through bracket then through frame rails. Using (2) 5/16 x 1 hex head bolts and flat washers, bolt through frame support bracket then through rear mounting holes of bottom bracket. Secure with flat washers and 5/16 nylock nuts. Using a 1/4 x 3/4 head bolt and flat washer bolt through outer mounting hole of bracket then through outer angle support of Ranger. Secure with flat washer and 1/4 nylock nut. Do not tighten any fasteners until lower hinge upper mounting bracket is installed, after that point there will be a tightening sequence. (Photo 13A) Step 12B: Next tighten the (2) self taping 1/4 bolts in the lower bracket. Then tighten the (2) 5/16 bolts that bolt the 2 brackets together. (Photo 12B) Photo 13B Cut flush along back edge 3/8 Cut along this line to make room for upper mounting bracket for lower rear door hinge. Step 13B: It is necessary to remove a piece of plastic from the rear kick panel so the upper bracket can be installed. Using a utility knife, cut and remove plastic tab. (Photo 13B)

10 Photo 13C Step 14: Install front door striker brackets. Photo 14A Upper mounting holes Lower mounting bolts Step 13C: Install rear lower door hinge upper mounting bracket. Be sure the cage nut is inserted into the cage properly so the three hole pattern line up. Position bracket, using (2) 5/16 x 1 hex head bolts and flat washers bolt down through Ranger weldment at the lower end of middle roll bar, then through upper flange of lower hinge upper mounting bracket. Secure with flat washers and 5/16 nylock nuts. Using (2) 5/16 x 1 hex head bolts and flat washers bolt up through slotted holes in bottom bracket, through lower holes in upper bracket. Secure with flat washers and 5/16 nylock nuts. (Photo 13C) Photo 13D Step 14A: First assemble striker pin bracket to striker bracket using (3) 1/4 X 3/4 hex head bolts and flat washers. Bolt through slots in pin brackets into weld nuts in striker bracket. Leave bolts a little loose to enable adjustment of striker pin later in assembly of doors. ( Photo 14A) Photo 14B Upper mounting bolt Align holes in kick panel with cage nut holes. Then start tightening sequence. 1 2 Lower mounting bolt Step 13D: Tightening sequence for lower hinge mounting brackets. First line up hinge holes that were drilled into the inner kick panel with the cage nut holes in upper mounting bracket then refer to tightening sequence in Photo 13D Step 14B: Position striker bracket into place. Using original 6mm hex head bolt, bolt through inner top hole of bracket into weldment on Ranger. (Previously a side net bolt.) Using original 8mm bolt, bolt through lower slotted hole in bracket into previous lower D loop mount. (Photo 14B)

11 Step 15: Install preassembled door filler panel, rear upper door hinge and hinge support bracket. Photo 15C Photo 15A Upper mounting hole of door filler panel. Step 15A: Position the (3) parts according to Photo 15A. Using the original 6mm bolt, bolt through the upper mounting hole of filler panel and into Ranger bracket on roll cage. Using (2) 1/4 x 1 bolts and flat washers, bolt through slotted holes in front door striker bracket into weld nuts in hinge support bracket. Leave all fasteners loose for a tightening sequence to follow. (Photo 15B) Upper hinge mounting bolts Step 15C: Using (2) 5/16 x 1 hex head bolts and flat washers, bolt through the bracket located behind the front seat backs, through the hinges and then into the weld nuts in the door filler panel. (Photo 15C) Step 16: Install rear door striker bracket and striker pin bracket. Photo 16A Photo 15B Hinge support bracket Lower mounting holes Step 16A: Using (3) 1/4 x 3/4 hex head bolts and flat washers bolt through striker pint and into weld nuts in striker bracket. (Photo 16A)

12 Photo 16B Photo 17B Inner mounting bolt Original 6mm Torx head bolts Striker Pin Bracket Striker Pin Center rear mounting hole Step 16B: Remove (2) torx head bolts that are the upper fasteners for the rear plastic panels. Using original 6mm hex head bolt, bolt through inner mounting hole of striker bracket and into weldment of Ranger. Then replace (2) 6mm torx head bolts, bolting through striker bracket, through upper rear plastic panel and into weldment of Ranger. (Photo 16B) Step 17: Reinstall side plastic panels Photo 17A Step 17B: Slide center plastic panel into position. Using original torx head bolts bolt through the striker bracket, through plastic panel and into weldment of Ranger. Using original 6mm bolt, bolt through plastic center rear mounting hole. ( Photo 17A) Photo 17C 1/2 Step 17A: It is necessary to trim the upper portion of the center plastic panel in (2) areas. Refer to Photo 17A. Mark your center panels. Using a utility knife or jigsaw trim off plastic. Fit the panel into place and make sure enough has been cut off. Step 17C: Reinstall front lower plastic panel using the original bolts and plastic push rivets.

13 Photo 17D Step 19: Installing upper and lower cab side hinges. Photo 19A Step 17D: Reinstall the rear lower plastic panel using the original bolts and plastic push rivets. Step 18: Tightening sequence for center door post fasteners. Refer to Photos 18A & 18B. Photo 18A 1 Keep limiter strap vertical when tightening bolt Step 19A: First install front lower hinge. Position lower hinge, using (3) 5/16 x 1 button head bolts, (2) flat washers and (1) limiter strap bracket. Run the bolts through the hinge and then through the 3/4 holes in kick panel and into cage nut. On the lower bolt for the hinge run the bolt through the limiter strap bracket first instead of using a flat washer. (Photo 19A) 2 Make sure when tightening this bolt that the holes in the limiter bracket are veritical Photo 19B Photo 18B Step 19B: Install the rear cab side door hinge using (3) 5/16 x 1 button head bolts and (3) flat washers, bolts go through hinges, then 3/4 holes in rear kick panel and into cage nut. (Photo 19B) 7

14 Photo 19C Photo 21 Step 19C: Install front upper cab-side hinge using (2) 8mm x 15mm black button head bolts. Bolt through hinge into threaded holes in roll bar. Using (1) 10mm x 12mm black button head bolt and 10mm black flat washer bolt through front mounting hole of hinge and into 10mm nut coupler. (Photo 19C) Step 21: Reinstall the dash panel using the (4) original push in rivets. Photo 22A Photo 20 Place ruler against hinge pins and adjust hinges so they are in line and 28 1/2 apart. 28 1/2 Step 20: Reinstall the front fenders and hood panel using the original bolts and plastic push rivets. Step 22: Adjusting body side hinges. Step 22A: The front door upper hinge has a small amount of adjustability mainly for upper and lower hinge pins. First get over the top of the upper hinge pin and line it up by eye with the lower pin and tighten one bolt. The lower front door hinge has a lot of adjustability because of the cage nut forward/ backward, up/down and also be able to tilt the pin for lining up with the upper hinge pin. Using a long straight edge measure between the top of the brass washer on the lower hinge to the top of the brass washer on the upper hinge, it should measure 28 1/2. When setting the lower hinge, push hinge forward as far as possible. Make sure you keep that 28 1/2 measurement and tighten one of the lower hinge bolts. Now place the straight edge against the hinge pins and make sure they are in line with each other. If not loosen hinges and adjust accordingly until you have them lined up and 28 1/2 apart. Tighten body side front hinge bolts. Photo 22A

15 Photo 22B Place ruler against hinge pins and adjust lower hinge so it is line with upper hinge and 30 7/8 apart. 30 7/8 Step 22B: The rear door upper body side hinge is virtually non adjustable. The lower rear hinge has a lot of adjustability forward/backward, up/down and also tilting the pin for lining up with the upper hinge pin. Using a long straight edge ruler measure between the top of the brass pin washer on the lower hinge to the top of brass washer on the upper hinge, it should measure 30 7/8. When setting the lower hinge push hinge forward as far as possible making sure you maintain that 30 7/8 measurement between the hinge pin washers, tighten one of the lower hinge bolts. Now place the straight edge against the two hinge pins and make sure they are in line with each other. If not loosen the lower hinge and adjust accordingly until you have them lined up and 30 7/8 apart. Tighten all body side rear hinge bolts. Photo 22B Step 23: Assembling the doors onto the Ranger and adjusting the door side hinges and striker pins. Photo 23A-1 Position hinge caps over hinge pins and slide door down until hinges bottom out. Do Not close door until hinges are tight together! Step 23A: Mounting the front doors. (A little grease on the hinge pin doesn t hurt but just a little.) With the doors in the open position align hinge caps of the door with the hinge pins of the cab side hinges, slide the hinges downward moving the rear edge of the door back and forth until the hinge caps bottom out on the brass washers on the cab side hinges. Slowly close the door, the striker pin bracket will need to be adjusted before you can close the door completely. Line up the height of the striker pin bracket with the door latch and tighten one of the bolts on the pin bracket. Latch the door, then standing by the rear wheel of the Ranger eye down the center body line of the door to the body line of the fender. The door may need to be adjusted up or down until the body line matches from fender to door. Check the gaps around the outer surface of the door and determine if the door needs any adjustment. When adjusting door side hinges it is much easier to remove the door by simply lifting the door up and off the Ranger. Use a padded surface to protect the outer surface of the door. Loosen the hinges and adjust according to the direction that was determined. Keep in mind that the door side hinges need to stay in line with each other and also 28 1/2 apart. Use a long straight edge ruler to obtain hinge alignment and distance between hinges. When door is adjusted properly tighten all hinge bolts, recheck striker pin and tighten all pin bracket bolts. The striker pin can be adjusted in/out by loosening pin, slide and retighten. The door latch is similar to automotive style as it has a second latch. Adjust striker pin until you achieve a good seal on the second click. Using the push pins attach the limiter strap to the limiter strap bracket on the lower bolt of the cab side hinge. (Refer to Photos 23A-1 to 23A-4) Photo 23A-2 Slightly move door back and forth until hinges are seated.

16 Photo 23A-3 Make sure the door body line is at the same height as the fender body line! Photo 23A-4 Limiter strap Adjust door so there are even gaps Limiter strap pin Step 23B: Mounting the rear doors. With the door in the open position align the hinge caps on door side hinges with hinge pins of cab side hinges. (A little grease on the brass pin would be good.) Slide hinges downward moving the rear edge of the door back and forth until the hinges bottom out. Slowly close the door, adjust the striker pin bracket to the height of the door latch. Latch the door, stand back by the rear of the Ranger and eye down the center body line of the rear door and down the body line of the front door to the front fender. Determine whether the rear door needs to be adjusted up or down. Check the gaps around the edge of the door and determine whether the door side hinges need to be adjusted according to the gaps. Just like the front door it is easier to adjust the door side hinges with the door lifted off the Ranger. Remove door, loosen hinges and adjust hinges according to the direction that was determined. Keep in mind the hinge caps on the door side of the hinges need to stay in line with each other and remain 30 7/8 apart. Use a long straight edge ruler to obtain hinge alignment and distance between hinges. When door is adjusted properly tighten all hinge bolts then recheck the striker pin height and tighten all pin bracket bolts. Adjust striker pin in or out to achieve a good seal on the second click. Using a push pin attach the door limiter strap to the strap bracket mounted to the upper cab side hinge. (Refer to Photos 23B-03 to 23B-3) Photo 23B-1 NOTE: Always adjust front door to fender first and then adjust the rear door to the front door body lines. Grease hinges and door latches every 6 months to keep doors working smoothly. Line up hinge caps with pins and work door back and forth until hinges bottom out

17 Photo 24B-2 Photo 24B-3 Sight down body lines and adjust rear doors so the body lines are in line. Limiter strap push pin Step 24: Install Sticker Tight (Adhesive backed High Density Foam.) around hinge pockets to achieve a good seal around the hinges after the doors have been installed. Provided in the door kit are (3) different sizes of sticker tight. Using scissors cut foam to length to fill in around the hinges. Clean the area with wax and grease remover or alcohol. Remove the adhesive cover on the sticker tight and adhere. Rear limiter strap

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