Instructions Created by an: Sidekick/Tracker 4 Door & 2 Door Roof Racks for Solid Tops (SKU# KEB-RR-4D & KEB-RR-2D) Installation Instructions Revised 4-16-14 Notice: These instructions (Pictures and Text) were written to be used with the 4 Door Sidekick or Tracker. However, we have included notes and tech tips so these instructions can be used with the 2 door model as well. CAUTION: Safety glasses should be worn at all times when working with vehicles and related tools and equipment. For additional copies of these and other instructions go to: www.lowrangeoffroad and click on the Instructions tab. Suggested Tools: Metric Socket: 12mm Standard Sockets: 1/2,7/16 Ratchet Torque Wrench: Inch Pound 5/32 Allen Wrench (Supplied) Combination Wrenches: 12mm & 1/2 Electric Hand Drill Socket Driver (to fit the hand drill): 5/16 Drill Bits: 1/4 & 1/2 (Supplied) 2 - C-Clamps (4 to 6 ) Center Punch Hammer 4-2X4X12 Boards
Roof Rack Mounting Parts & Hardware Mounting Parts 2D = 2 Door Models 4D = 4 Door Models L-Bracket (6 ea. for 4D) (4 ea. for 2D) 1/4 Hinge Bolt (6 ea. for 4D) (4 ea. for 2D) Rack Clamp (6 ea. for 4D) (4 ea. for 2D) Rack Plate (6 ea. for 4D) (4 ea. for 2D) 5/16 Cap Bolts 5/16 Flat Washers 5/16 Flat Washers 5/16 Split Washers 5/16 Nuts 1/4 Cap Bolts 1/4 Self Locking Nut (6 ea. for 4D) (4 ea. for 2D) 1/4 Split Washer 1/4 Flat Washer Well Nut M8 Flange Bolts M8 Serrated Flange Nuts Hinge Mount (double loop) (6 ea. for 4D) (4 ea. for 2D) Hinge Mount (triple loop) (6 ea. for 4D) (4 ea. for 4D) Hardware 1/2 Drill 1/4 Drill Qty 2D Qty 4D Size Description 8 12 5/16X18X3/4 Cap Bolts 8 12 5/16X18X3/4 Nuts 16 24 5/16 Flat Washers Hardware Qty 2D Qty 4D Size Description 8 12 M8X1.25X25m Flange Bolts 8 12 M8X1.25 Serrated Flange Nuts 1 1 1/4 Drill Bit 8 12 5/16 Split Washers 8 12 Well Nuts 8 12 1/4X20X1 Cap Bolts 8 12 1/4 Split Washers 8 12 1/4 Flat Washers 4 6 1/4X20X51/2 Bolt 4 6 1/4 Self Locking Nut 1 1 1/2 Drill Bit
Roof Rack Parts & Hardware Roof Rack Parts Extension (2 Door Models will not have this extension) Rear Section 5/32 Allen Wrench Button Head Allen Screw Front Section Wind Fairing Self-drilling screws Rubber Washers Hardware Qty 2D Qty 4D Size Description 8 8 10X32 Self Drilling Screws 16 16 Rubber Washers 2 4 Button Head Screws 1 1 5/32 Allen Wrench
Assembling the Roof Rack Note: Roof rack assembly procedure is the same for the 2 door roof rack as for the 4 door, except there is no extension for the 2 door models. Rear Section Extension Front Section Step 1 Unbox the package contents and insure that all the necessary pieces and hardware are accounted for. (See page 2 & 3) If anything is missing please call 801-805-6644 or email: Sales@lowrangeoffroad.com Step 2 Place the rack extension between the front and rear sections of the rack. Note: There is no extension piece supplied for the 2 Door Models. Note: Keep the packaging boxes to be used as a protective work surface. Step 3 Remove all the protective end caps from the extension. Step 4 Connect the rack extension to the front section.
Step 5 Connect the rear section to the extension. Step 6 Turn the rack over. Screw Holes Step 7 Adjust the rack pieces so that the screw holes align. Step 8 Start the four (2 for 2 door models) button head allen screw. Note: Leave them loose for now.
Step 9 Once all the button head allen screws are started, tighten them with the supplied 5/32 supplied allen wrench. Tech Tip 9 The remainder of package contents will not be used with this installation. They are used to attach the roof rack to many OEM (Original Equipment Manufacturers) roof racks. Put these items in a safe place. You may need them in the future. Attaching the Wind Fairing Step 10 Turn the rack over again. Step 11 Remove the protective covering from the front of the rack. Note: The rack is the same on both ends. So which ever end you chose to install the wind fairing on, becomes the front of the roof rack.
Step 12 Position the fairing such that all 8 holes are centered on the tubing where the screws will be installed. Step 13 Once the fairing is properly positioned, clamp it into place using the 2 C- Clamps. Caution: It is very important that the holes be centered on the tubes. If they are not centered, the self drilling screws will be difficult to install. Step 14 Using a center punch and hammer, make a small dent in the tube, centered with the fairing hole. Note: It works best to begin at one end of the fairing and work toward the other. We chose to start on our right work toward the left. Step 15 Each self drilling screw has two rubber washers. One goes on the back side of the fairing and the other goes on the front side of the fairing.
Step 16 Install the first self drilling screw using a 5/6 socket and electric hand drill. Note: Leave it loose for now. Step 17 Repeat steps 14 through 16 on the other 7 attaching points working from right to left. Step 18 Now that all the screws are started, tighten all the screws working right to left.
Attaching the Mounting Brackets to the Rack Step 19 Turn the rack over again. Tech Tip 19A The placement of the six (four for the 2 door models) mounting brackets is somewhat optional. We recommend placing them on the 2nd and 3rd tubes from the front end and the 2nd and 3rd tubes from the rear. (See Tech Tip 19B). Then placing the middle mounting brackets evenly spaced between the front and rear locations. It really is your choice. Also keep in mind this is only a preliminary location at this point. The positioning of all the brackets can be changed when the rack is initially placed on top the vehicle.
Figure A
Tech Tip 19B Recommended mounting bracket locations. Tech Tip 19C This shows the recommended rack mount locations for the 2 Door Models. Step 20 Position one of the rack clamps as shown. Step 21 Position one of the rack plates and align the holes.
Outside Holes Inside Holes Step 22 Position (2) 8X1.25X25mm flange bolts through the holes as shown. Step 23 Position one of the L-Brackets on the bolts as shown. Note: We used the inside holes of the L-Bracket for our instructions. However, a f t e r c o m p l e t i n g o u r r o o f r a c k installation we decided that using the outside holes would have given the brackets greater strength. So we recommend using the outside holes. Step 24 Start two of the serrated flange nuts on the bolts. Leave the nuts loose for now. Step 25 Position the double loop half of the hinge bracket and install a 5/16X18X3/4 bolt and flat washer. See Figure A, Diagram 1. Note: See Figure A Diagram 3 for an alternate method of installing the hinge. We will show the method used in Diagram 2, but you could use the method shown in Diagram 3 if desired.
Step 26 Install a 5/16 flat washer, a 5/16 lock washer and a 5/16 nut. Leave the nut loose for now. Step 27 Repeat Steps 25 and 26 on the second bolt. Leave this loose as well. Step 28 Position the 3 loop part of the hinge bracket as shown and install the 1/4X20X51/2 bolt. Step 29 Install a 1/4 self locking nut. Leave the nut loose for now.
Step 30 Repeat Steps 20 through 29 on the other (5) bracket locations leaving all the nuts and bolts loose for now. Step 30 (For 2 Door Models) Repeat Steps 20 through 29 on the other (3) bracket locations leaving all Attaching the Rack to the Front Step 31 With help from and assistant, turn the rack over and carefully place the rack on top the vehicle. Note: Be sure the rack is oriented with the fairing toward the front of the vehicle. Step 32 Position each mounting bracket assembly according to your best judgement. You will want the well nuts (See Figure A) to be located in areas where water will NOT pool; such as on raised areas of the roof. Also, be sure there is plenty of room between the roof and the headliner for drilling and well nut placement.
Step 33 Further position the rack such that it is centered side-to-side and front-to-back. Also, double check that the brackets are positioned where you want them to be. Remember, we left all the nuts and bolts loose so these brackets could be adjusted. Step 34 Once you are sure the rack and the mounting brackets are positioned where you want them, beginning at the driver side from mount, mark the location of the (2) well nuts, using a center punch and hammer. Note: Be sure the center punch is centered on the hole of the hinge. Step 35 Drill (2) pilot holes precisely where the center punch marks were made using a supplied 1/4 drill bit. Caution: Do not drill down through the headliner. Step 36 Flip the hinge up out of the way and drill the well nut hole using the supplied 1/2 drill bit. Caution: Do not drill down through the headliner.
Well Nut Roof Step 37 Install the two well nuts. They must fit all the way down such that the flange contacts the roof. (See Tech Tip 37) Tech Tip 37 Well nut must sit down all the way as shown above. Note: In some cases you may find that the well nut does not go all the way down in the hole. If this happens, you will need to drill a little deeper into whatever is preventing the well nut from sitting properly. Do not drill too deep. Step 38 Reposition the hinge and install the 1/4X20X1 cap bolt, flat washer and lock washer as shown in Tech Tip 38. Note: Leave the bolts loose for now. Tech Tip 38 This shows proper hardware installation of the well nut bolt, flat washer and lock washer.
Step 39 Repeat Steps 34 through 38 at the other 5 (3 for the 2 Door Models) locations. Step 40 Beginning at any of the 6 (4 for the 2 door models) bracket locations, press down on the hinge (to hold the well nut secure and prevent it from turning) and tighten the (2) 1/4 bolts using a 7/16 socket to 10 Inch Pounds. Note: Do not over-tighten these bolts. Step 41 Repeat Step 40 at all 5 (3 for 2 Door Models) bracket locations. Step 42 Beginning at any of the 6 (4 for 2 Door Models) locations, tighten the hinge bolt and nut using (2) 7/16 end wrenches. Note: Be careful not to damage the paint on the roof.
Step 43 To accurately space the rack above the roof we used (4) 2X4X12 boards under the rack as shown. Rack to Roof spacing is optional, but we recommend you leave plenty of space so that when the rack is loaded with gear, it will not touch the roof. These 2X4 s seem to be just the right height. Step 44 Tighten the (2) hinge-to-l-bracket hardware using a 7/16 box end wrench and socket. Step 45 Tighten the rack-to-l-bracket clamps using a 12mm box end wrench and socket. Step 46 Repeat Steps 44 & 45 at the other 5 (3 for 2 Door) bracket locations.
Step 47 Remove the 2X4 s. Step 48 Remove the protective covering. Congratulations! You have successfully completed the installation of the a roof rack. We sincerely hope these instructions have been helpful. If you have suggestions about how we can improve our instructions (or products) please email us at: sales@lowrangeoffroad.com
As always, If you experience any difficulty during the installation of this product please contact Low Range Off-Road Technical Support at 801-805-6644 M-F 7:30am-5:30pm MST. Thank you for purchasing from Low Range Off-Road. These instructions are designed as a general installation guide. Installation of many Low Range Off-Road products require specialized skills such as metal fabrication, welding and mechanical trouble shooting. If you have any questions or are unsure about how to proceed, please contact our shop at 801-805-6644 or seek help from a competent fabricator. Using fabrication tools such as welders, torches and grinders can cause serious bodily harm and death. Please operate equipment carefully and observe proper safety procedures. Rock crawling and off-road driving are inherently dangerous activities. Some modifications will adversely affect the on-road handling characteristics of your vehicle. All products sold by Low Range Off-Road are sold for off road use only. Any other use or application is the responsibility of the purchaser and/or user. Some modifications and installation of certain aftermarket parts may under certain circumstances void your original dealer warranty. Modification of your vehicle may create dangerous conditions, which could cause roll-overs resulting in serious bodily injury or death. Buyers and users of these products hereby expressly assume all risks associated with any such modifications and use. Revised 4/14/14 Copyright 2014 Low Range Off-Road, LC All Rights Reserved