or TECICAL SUPPOT Call: onday- riday 8:00 A.. to 4:30 P.. ( PACIIC ) ASSEBLY & OUTI for COO CAE AWAE IT # I 05 03 06 04 E LOCTITE 01 front mount plates E LOCTITE L E J 02 01b C etail for COO CAE ear Leg inge Joint P E LOCTITE B A IPOTAT: When installing rear leg into rear U bar, ensure that hinge barrel is BEI the leg as shown. 06 inge Barrel BEI Leg. JEEP JEEP 02
or TECICAL SUPPOT Call: onday- riday 8:00 A.. to 4:30 P.. ( PACIIC ) AWAE IT O COO CAE ASSEBLY AWAE IT # A 1/2" x 1 3/4" Cap Screw B 1/2" C 1/2" SAE lat Washer 1/2" ubber Washer x 5" ex Bolt E x 1 1/4" ex Bolt (12 ea.) yloc ut (10 ea.) lat Washer x 2" Button ead Bolt I x 2 1/4" Button ead Bolt (6 ea.) 1/4" L (6 ea.) 1/4" SAE lat Washer J (6 ea.) 1/4" x 20 x 1" Thread Cutting Screw O ing Contoured lat Washer (10 ea.) -18 x 1" Button ead Bolt P Shown Actual Size
or TECICAL SUPPOT Call: onday- riday 8:00 A.. to 4:30 P.. ( PACIIC ) AWAE IT # SEE PAE 1 #1= emove existing bolts from the upper half of the windshield hinge plates. Put a small bead of silicone inside and around the countersunk bolt holes in the existing windshield hinge plates. Attach front LE OUT PLATES 01 with bolts, and with lock washers, as shown. Attach the rear LE OUT PLATES, by removing the tail lights and sliding the rear LE OUT PLATES 02 in behind tail lights and secure with thread cutting screws, lock washers and flat washers. ext, at the upper hole of the rear LE OUT PLATES 02, drill a hole through vehicle body. Secure with bolts, flat P washers, and nyloc nuts. J L E #2= Assemble the cage on the ground. Cover entire swaged joint surfaces with silicone sealant (see page 5). Assemble OT 'U' BA 03 ( it's the wider one) to OT LES 04 (they are the shorter ones) with button head bolts and nyloc nut. IPOTAT: Orient bolts so that nut is in front of leg (hood side) and bolt head is behind leg (cab side). #3= ow attach EA 'U' BA 05 to the EA LES 06, (see the detail drawing for the ear Leg inge Joint), with button head bolts and nyloc nuts. Cover entire swaged joint surfaces with silicone sealant (see page 5). #4= ind COSS TUBES. Cover entire swaged joint surfaces with silicone sealant (see page 5). Insert the COSS TUBES into the cups on the OT and EA U BAS. Secure with bolt I, then (on top side only) place O-rings and contoured washer, with lock nuts, (on the bottom side). TITE UP ALL BOLTS. TAT'S IT for the cage part. Lift the cage up onto the LE OUT PLATES and secure with hex bolts, rubber washers (see attached detail: ront Leg Shock Absorbers), lock washers, flat washers. for the front, and hinge bolts, flat washers, and nyloc nuts for the rear. B C A SEE PAE 4 TO ATTAC BASET AC. #5= Align bolt holes of OUT PLATES 10 with holes of CLAP PLATES 08 (inside rack cross beams 09 ), and loosely attach OUT PLATES 10 with button head bolts, lock washers, and flat washers see IAA#1a. Position rack to desired location front to back and confirm position of rack side to side with equal distance from all end caps to mounting plates. After rack is centered, tighten bolts. #6= With rack in it's final spot, attach OUT CLAP STAP 11, around COSS TUBES and secure into OUT PLATE 10, T U V with bolts, lock washers, and flat washers. Tighten all bolts. TAT'S IT! YOU ISTALLATIO IS COPLETE. OTE: Any time an overhead rack is mounted on a vehicle, there will be some incremental wind noise. In the vast majority of cases, the additional noise is subtle and not objectionable. Sometimes, for reasons we cannot explain, customers complain that the wind noise is intolerable. or these customers, we offer this Optional Wind eflector. Be sure to specify the Wind eflector part number that is appropriated for your Congo Cage. #60141 for CJ Congo Cage # and TJ Congo Cages # & #.
or TECICAL SUPPOT Call: onday- riday 8:00 A.. to 4:30 P.. ( PACIIC ) ASSEBLY & OUTI for SAAI AC on COO CAE AWAE IT # Page 4 50561 IAA #1a 08 same distance each bracket Clamp Plate (inside) 08 ack Cross Beam OO CAE ount Plate 10 C Cross Tub e 10 ount Clamp Strap 11 COO CAE 'U' Bars Cross Tube "Attach, Position and Sucure these bolts IST" 11 "inish with these bolts." O x 3/4" ex Bolt SAE lat Washer AWAE IT O COO CAE OUT O 3/8" x 1" Button ead 3/8" 3/8" SAE lat Washer Shown Actual Size
or TECICAL SUPPOT Call: onday- riday 8:00 A.. to 4:30 P.. ( PACIIC ) AWAE IT O COO CAE ASSEBLY AWAE IT # ETAIL: ront Leg Shock Absorbers OT LES UBBE WASES (IVES SIE) LAT WASE EXTEAL TOOT LOC WASE CAP SCEW ( TITE OW TO COPESS UBBE TO 1/8 ) ETAIL: Seal swage joints: (WITOUT SEALAT) SILICOE SEALAT usty Joint Apply a healthy air tight bead of silicone around every swaged joint to prevent moisture from leaking into and out of the joint. If this is not done properly, the inside surface of the tubes can rust and rusty water can leak out. aintain this joint seal throughout the life of your rack. Tighten down all nuts & bolts and TAT'S IT! You are now ready to use your rack.
Page 6 or TECICAL SUPPOT Call: onday- riday 8:00 A.. to 4:30 P.. ( PACIIC ) OTE: When raising Congo Cage to install or remove top, O OT rotate the Cage completely back as this will spring the rear hinge and/or damage the body of your jeep. otate only to the extent necessary. old the Congo Cage in the raised position by inserting the two support rods (provided) into the hole of the front bracket and the hole in the bottom of the front leg. SUPPOT OS POVIE YES O