INSTALLATION INSTRUCTIONS: ULTRA FRONT FENDER FLARES Thank you for your purchase of Crawler Conceptz Ultra Series Front Fender Flares. While these flares are easily installed with basic hand tools and general mechanical knowledge, it is advised to seek help from a professional. These instructions are a step by step tutorial on how to remove the factory flares and install the Ultra Series Front Fender Flares. However, if you need further direction please contact us at (951) 654-0136 or Support@crawlerconceptz.com. REQUIRED TOOLS 10MM wrench (2) 1/2 combo wrenches (2) 7/16 combo wrenches Door panel removal tool Drill gun Drill bits stepping up to 3/8 1/4 drill bit Paint Felt pen Cutoff wheel or shears (if reusing factory liner) PART LIST (2) ULTRA SERIES FRONT FENDER FLARES (2) SMALL REINFORCEMENT BRACKETS (2) LARGE REINFORCEMENT BRACKETS (2) L-SHAPED BRACKETS (6) 10MM bolt reused from factory flare (2) 10 MM long nut (2) 1/4 Gr. 8 Flat Washer (2) 1/4-20x1 1/4 Gr. 8 Bolt (2) 1/4-20 Gr. 8 Nut (46) 5/16 Gr. 8 FLAT WASHER (28) 5/16-18x1 1/4 Gr. 8 BOLT (8) 5/16-18 CLIP NUT NOTE: INSTRUCTIONS WERE DONE USING A 2014 WRANGLER UNLIMITED AND AN ULTRA FRONT FENDER FLARES. WHILE THIS BUMPER FITS 2007 PRESENT JEEP WRANGLERS, THERE MAY BE SOME DIFFERENCES BETWEEN MODEL YEARS. 1
STEP 1: REMOVE FACTORY FLARE Step 1a Lift the vehicle and remove the tire on the side you are working on. Step 1b Using a 10mm wrench and Door Panel Removal tool, remove the long nut (blue circle) and 6 push in retainers (green circles) while holding the factory inner fender liner on. Save all parts for later if reusing the factory inner fender liner. (pic 1) PIC 1 Step 1c Disconnect the marker light harness (pic 2) and the marker light wire retainer (pic 3). Once done, remove the inner fender liner by prying and twisting until free. PIC 2 PIC 3 2
STEP 1: REMOVE FACTORY FLARE Step 1d Remove the (5) 10mm bolts (green circles) and save for later use. (pic 4) PIC 4 Step 1e Remove the factor flare by pulling. Be extremely careful as the sheet metal is thin and can easily be bent. (pic 5) PIC 5 Step 1f Remove any retaining clips that did not come free with the bumper by reaching behind the clip and pinching it from the backside. (pic 5) Clean any debris or dirt under the factory flare. PIC 6 3
STEP 2: DRILLING NOTE: Picture shows Driver Side bracket. Step 2a Install 4 nut clips (green circles) onto the Large Reinforcement Bracket. (pic 7) PIC 7 Step 2b Loosely install the Large Reinforcement bracket (green circles). Align the nut clips (blue circles) so that bolts ban be threaded when test fitting the flare. (pic 8) PIC 8 Step 2c Install the flare with as many 5/16 nuts and bolts as possible. This will help when marking the holes for drilling. Once all are loosely threaded, tighten several. (pic 9) PIC 9 Step 2d With a felt pen mark the three holes (green arrows). Remove the fender and Large Reinforcement Bracket. Drill all three marked holes to 3/8. Drill slowly and gradually step up in size to 3/8, as the sheet metal can easily be twisted. (pic 10) PIC 10 4
STEP 2: DRILLING Step 2e Install the Small Bracket, but only use the two outermost bolts (green arrows). Mark the two inner holes for drilling (blue arrows). Remove the bracket and drill the marked holes to 3/8. Drilling through two of the holes in Step 2d can make this easier. (pic 10) PIC 11 NOTE: There is a left and right side as well as a top and bottom. Make sure to orient correctly. STEP 3: INSTALL ULTRA FRONT FLARE DO NOT TIGHTEN ANY BOLT UNTIL ALL BOLTS ARE STARTED. Step 3a In order, install the Large Bracket (green arrow) using the (3) 10mm bolts retained from Step 1d, Ultra Front Fender Flare (white arrow), and then the Small Bracket (blue arrow). Start all (14) 5/16 bolts before tightening. (pic 12) PIC 12 NOTE: If reusing the factory inner fender liner continue to Step 4. If using an after market inner fender liner, finish with those instructions. If using Crawler Conceptz Aluminum Front Inner Panels, continue with STEP 2 in those instructions 5
STEP 4: TRIM INNER FENDER LINER Step 4a Put the factory liner in place and using a felt tip pen mark along the edge for trimming. (pic 13) PIC 13 Step 4b Using a quality shear, cut the fender liner along the line made in Step 4a. Repeat these two steps until you have perfect fit. (pic 14) PIC 14 Step 4c Install the fender liner using the 10mm long nut from Step 1b (blue circle). (pic 15) PIC 15 6
STEP 4: TRIM INNER FENDER LINER Step 4d Use the factory 10mm bolt saved from Step 1b to install the L bracket. Make a mark on the bottom side of the L bracket. Remove the liner and drill a 1/4 on the marked spot. (pic 16) PIC 16 Step 4e Install the L bracket to the liner using (2) 7/16 combo wrenches. (pic 17) PIC 17 Step 4e Reinstall the liner using the 10mm long nut (blue circle) and 10 mm bolt (green circle). (pic 18) PIC 18 7
Thanks again for your purchase from Crawler Conceptz. We hope you enjoy your new Ultra Series Fender Flares and if you have any other needs please contact us at (951) 654-0136 or Support@crawlerconceptz.com. 8