Part# 85200, 86200, 85095, 86095, TC200,TT200,TC095,TT095 Bag Hardware: (8) 5/16 x 1 ½ Allen flat head (14) 3/8 x 1 Hex bolt G5 (2) ½ x 2 ½ Hex Bolt G5 (6) 5/16 flange nuts (14) 3/8 flange nuts (2) ½ stove lock nuts (6) ½ steel washers (6) ½ brass washers (14) 3/8 steel washers (1) Bump stop w/ 3/8 thread (2) 3/8 wing nuts (can carrier only) (3) #12 x 3/4 (for tail light) (2) 5/16 x 1 Hex bolt (1) 2 x 2 Self adhesive pad TC095 & TT095 additional following items (1) 1/4 x 1 Allen button head (1) 1/4 square nut Box hardware: (1) Carrier rack (1) Left body reinforcement bracket (1) Right body reinforcement bracket (1) Hinge plate 16 x8 (1) Lower Support Brace (2) tail gate spacer plates (1) Striker landing mount (1) Tire hub plate (1) T-handle *Bracket box contents for Tire/Can carrier (2) Gas can L- brackets (can carrier only) (2) Threaded rod (can carrier only) (1) Lock bar Tools needed: *Set of hand box wrenches standard * T40,T45,T50 torx bits *3/8 rachet and extensions *Standard set of 3/8 sockets * 3/16 & 7/32 allen wrench or sockets * 7/16 center punch * Ball pin hammer *1/8 drill bit, 7/16 drill bit or Uni-Bit. *Angle drill air or electric. *Hacksaw *Bench vise Option tools: * Hobby knife * 1/8 to ½ Uni-bit * Die grinder Install time is about 120 minutes to?, depending on your skills. Check to make sure all hardware is present before you start. We recommend a extra helper to help speed up the install. Copy of these instructions are also on our web site @ www.orfab.com * Please note these instructions cover TJ & YJ models and some images may very from your year and model. Tire/Can carrier is design to use Lip style Gerry cans. Optional non-lip can adapter available. page 1 of 5 Revision 0203 O-R FAB,Inc. 2003
(1) Remove stock tire carrier and third third brake light. * Hint if you have Dual Top option you ll need to remove the hard top to remove the soft top bow assembly to access area at roll bar foot. (2) Remove seat belt retractor from roll bar. Use T50 torx. (3) Remove Tail gate with hinges attached. Using T40 torx. Lay flat and remove hinges from tail gate.*hint use a hobby knife to cut the factory paint around the bolts. (4) Pull under fender liner back under rear quarter panel. Pull out one plastic rivet. (5) Remove tail light assembly and reach under body to disconnect light wiring plug. (6)Remove and save the roll bar mount bolts with T45 torx. *Hint use a hobby knife to cut the factory paint around the bolts. (7) Remove the factory tail gate striker mount with T40 torx. Save bolts for installation. (7A) Now anchor the bracket in a vise and with a small drill bit drill out the rivet and remove the striker post and the flat nut. Save for installation. (7B) Now anchor the striker post in a vise and cut 1/4 from the thread for install. (8) Install both left and right body reinforcement brackets to the base of the roll bar and snug against back wall of body. (9) Install the stock bolts removed in step 6,but don t tighten at this time page 2 of 5
(10) Now center punch holes starting with left rear body bracket make sure the bracket is snug flush to back of the body. Repeat center punches for right bracket. (11) With a 1/8 drill bit and a Angle drill begin pilot drilling holes. Then change drill bit to 7/16 and enlarge holes. *Hint a good UNI-BIT from your local hardware store works best. (12) Install striker plate using 3/8 x1 hex head bolt and 2 x 3/8 flange nuts. Snug but don t tighten yet. (12A)YJ only Install (1x) 1/4 x 1.0 Allen button head bolt and 1/4 square nut to factory mount hole. Snug but don t tighten yet. (13) Slide the flat nut and install striker post from step 7A/B. Use 2x ½ flat washers under post.. (14) Now install the Carrier hinge plate and tail gate hinges using (4x) 5/16 x1.5 Flat head allen bolts and 5/16 flange nuts. Align with tail light cut out and snug bolts don t tighten at this time. Adjustments may be needed later. *Hint you can attach hinges to tail gate first by placing spacer plates between hinge and tail gate (15) Now place (2x) 5.75 spacer plates between tail gate and hinge and use (4) 5/16 x1.5 flat head allen bolts. (16) Now install tail gate back up to body and have extra help hold in place. *Note you will need to align and adjust tail gate with body. Make sure to center tail gate so striker post matches.once aligned snug down bolts enough to hold in place. page 3 of 5
(17) Now begin installing body reinforcement bracket bolts starting with factory bolts on left side bracket and (12x) 3/8 x 1.0 bolts and 3/8 flange nuts supplied. Repeat for right side. (18) Center punch and drill out the 3 holes on the hinge plate and install (3x) 3/8 x1 Hex bolts with 3/8 flange nuts. Snug but don t tighten. (19)Install the lower hinge plate support bar under the right rear body as shown here (1x)3/8 x1 bolt and flange nut through factory bracing. (20) Now with extra help install the Carrier to the hinge plate using (2x) ½ x 2.5 bolts,(2x) ½ washers & (6x) ½ brass washers. Place 1 brass washer above carrier leg and 2 below leg. Install bolts. but don t tighten. *Hint sharpen the ½ bolts with a grinder to ease installation through powder coat. (21) Align the Carrier with the striker plate on the left side. Check to see if it closes and alignment is correct if not loosen and adjust the hinge plate. Once alignment is achieved Begin tightening Hinge bolts and tail gate bolts. *Note on some vehicles striker plate maybe to close. This is due to factory holes out of tolerance. You ll need to remove the striker landing plate and enlarge holes with a die grinder. page 4 of 5
(22) Tighten all bolts and adjust tail gate striker post to correct depth. Install the lower bump stop. Peel and stick 2 x 2 stainless pad to tail gate just where bump stop will make contact with tail gate Adjust bump stop to just touch pad on tail gate. (23) Fold back carpet and reinstall rear seat belt retractor Reinstall and plug in rear tail light using #12x3/4 bolts. Install Lock bar to the top of the spin mount on the rack using (2)5/16 x1 hex bolts and 5/16 Flange nuts. (24) )Tire/Can carrier only install your gas cans by inserting the lip of the bottom of the Gerry can into the clip of the lower frame of the rack and anchor using 3/8 x 8 threaded rod,l-bracket and wing nut. *Note you can install a Hi-Lift jack to the upper or lower holes inside the tire carrier with 3/8 x 1.5 bolts you can get from your local hardware store. Now you ready for the trails! Lubricate once per month pivots and threaded bolt holes with Silicone Spay you can purchase from your local Auto parts store. *Note max. Load rating closed is 200lbs. if total weight of your Tire,wheel and cans exceed we recommend not mounting Jack to carrier. WARRANTY STATEMENT O-R FAB, INC. Warrants all products against defects in material and workmanship for a period of 180 days from the date of proof of purchase receipt. Warranty shall not extend to any piece of merchandise or part thereof which has been subjected to improper installation, misuse or neglect. Warranty is limited to replacing or repairing part or parts which are defective and are returned to O-R FAB, Inc. Freight prepaid. No returns will be accepted without RMA #. Finishes (powder coating) has a 3 month warrantee. Warranty DOES NOT COVER RUST. page 5 of 5