Rear Bumper & Tire Carrier Installation Instructions

DISCLAIMER:  These installation instructions are designed for current models of AtoZ Fabrication rear Jeep bumpers and tire carriers.  AtoZ Fabrication, employees and owners, are in no way liable for any injuries caused to vehicle passengers and others or damage to the vehicle due to the use of this product.  This product is required to be installed by a competent and certified installer and drilling is necessary.  AtoZ Fabrication assumes no liability to damage caused to the vehicle during installation.  There is no affiliation with Jeep or Chrysler LLC.

This kit may require additional fitting to fit your vehicle properly.

ITEMS INCLUDED:

(1)- REAR ROCK BUMPER

(8)-1/2” STUDS

(8)-GRADE 8 WASHERS

(8)-GRADE 8 NYLOCK NUTS

OPTIONAL ITEMS INCLUDED WITH TIRE CARRIER PURCHASE:

(1)-SWINGAWAY MAIN UNIT

(2)-BEARINGS

(1)-LOWER SEAL

(1)-NUT, WASHER, COTTER PIN KIT

(1)-UPPER DUST CAP

TOOLS REQUIRED FOR INSTALLATION:

-HAND TOOLS TO REMOVE EXISTING REAR BUMPER AND INSTALL NEW UNITS

-POWER DRILL WITH ¼” AND 9/16” DRILL BIT

-1.5” SOCKET OR LARGE ADJUSTABLE WRENCH

-WHEEL BEARING GREASE

• .REMOVE NECESSARY BOLTS TO REMOVE ORIGINAL OR AFTERMARKET BUMPER CURRENTLY ON VEHICLE. 

• .DRILL HOLES IN REAR CROSSMEMBER FOR NEW BUMPER PER INCLUDED DIAGRAM.  OPEN EXISTING HOLES TO 9/16” AND PRE-DRILL NEW HOLES TO ¼” AND THEN OPEN TO 9/16”.  MAKE SURE TO DRILL NEW HOLES BASED ON WHAT MODEL OF JEEP YOU ARE WORKING ON, PER DIAGRAM.         

• .INSTALL STUDS INTO REAR MOUNTS OF BUMPER, BASED ON WHAT HOLES ARE BEING USED.  YOU MAY NEED TO DOUBLE NUT THE STUDS TO GET THEM TIGHT.  WE ALSO RECOMMEND A THREAD LOCKING COMPOUND ON THE THREADS THAT GO INTO THE BUMPER MOUNTS. 

• .SLIDE BUMPER INTO PLACE WITH STUDS THROUGH REAR CROSSMEMBER AND LOOSELY INSTALL WASHERS AND NYLOCK NUTS TO STUDS FROM THE REAR OF THE CROSSMEMBER.  THE INNER STUDS ARE TOUGH TO REACH ON SOME MODELS, BUT A LONG EXTENSION FOR A 3/8” DRIVE RATCHET USUALLY HELPS.  DEEP SOCKETS WILL BE NEEDED FOR FINAL TIGHTENING AND THE REAR BODY MOUNTS MAY NEED TO HAVE THE BOLTS REMOVED FOR CLEARANCE TO TIGHTEN THE UPPER OUTSIDE NUTS, THEN REINSTALL BODY MOUNT BOLTS TO PROPER TORQUE.  BEFORE TIGHTENING THE NYLOCK NUTS, WE RECOMMEND INSTALLING YOUR STOCK LOWER FRAME TIE-IN BOLTS THROUGH THE TABS IN THE BUMPER AND TIGHTENING THEM TO POSITION THE BUMPER CORRECTLY.  GETTING ALL OF THE BOLTS IN CAN BE TOUGH AS JEEP HAS POOR TOLERANCES IN THEIR POSITIONING OF THE WELD-NUTS IN THE FRAME SO SOME SLIGHT GRINDING MAY BE NECESSARY.  TORQUE NYLOCK NUTS TO 95 LB. FT. 

ONCE ALL OF THE BOLTS ARE TIGHT YOUR REAR BUMPER IS FULLY INSTALLED.

THE FOLLOWING ARE ADDITIONAL STEPS FOR INSTALLING A TIRE CARRIER ONTO A BUMPER PRE-MADE FOR ONE.

• .REMOVE STOCK RUBBER SNUBBERS FROM TAILGATE. 

• .PREPARE HINGE ASSEMBLY FOR INSTALLATION BY FULLY GREASING THE BEARINGS WITH A HIGH QUALITY WHEEL BEARING GREASE.  MAKE SURE SPINDLE AND THREADS ARE CLEAN OF ANY DIRT OR DEBRIS.   

• .INSTALL GREASED LOWER BEARING INTO HINGE TUBE OF SWINGAWAY AND THEN INSTALL LIGHTLY GREASED LOWER GREASE SEAL.  TAP SEAL FULLY INTO PLACE. 

• . 

  

   

   

• .WITH THE GREASE SEAL INSTALLED SLIDE SWINGAWAY ASSEMBLY OVER SPINDLE AND INSTALL OTHER BEARING AND THEN THE WASHER AND NUT.  TIGHTEN NUT TO 100 LB. FT. AND THEN SPIN NUT ENOUGH TO PUT COTTER PIN THROUGH THE HOLE IN THE SPINDLE.  AFTER THE COTTER PIN HAS BEEN INSTALLED MAKE SURE ENDS ARE BENT ENOUGH TO LET DUST CAP TO BE INSTALLED AND GENTLY TAP THE DUST CAP IN PLACE.  IF IT IS TOO DIFFICULT TO GET THE DUST CAP STARTED YOU MAY WANT TO SLIGHTLY BEND THE LIP IN WITH NEEDLE NOSE PLIERS AND THEN INSTALL.  IF YOU RUIN THE DUST CAP SENT WITH THE SWINGAWAY, OR WHEN DOING MAINTENANCE TO THE BEARINGS, YOU CAN PURCHASE NEW DUST CAPS AT MOST AUTOMOTIVE OR TRAILER STORES AS THE ONES WE USE ARE STANDARD 2” DUST CAPS. 

• .INSTALL TIRE ONTO NEW CARRIER AND CLOSE TO CHECK CLEARANCE WITH T-HANDLE LATCH.  WE RECOMMEND USING SOME OIL OR ANTI-SIEZ LUBRICANT ON THE LUG STUDS AND T-HANDLE THREADS.   

• .AT THIS POINT YOU WILL NEED TO MODIFY YOUR STOCK RUBBER SNUBBERS TO APPLY LATERAL PRESSURE TO YOUR TIRE AS IT TIGHTENS AGAINST THE TAILGATE.  EACH VEHICLE MAY BE A LITTLE DIFFERENT SO YOU MUST MEASURE AND CUT TO SUIT YOUR PARTICULAR VEHICLE.  THIS STEP IS VERY IMPORTANT AS IT STOPS ANY WOBBLING AND SHAKING OF THE SWINGAWAY AS YOU DRIVE.  BASICALLY, YOU WANT THE SWINGAWAY TO TOUCH THE RUBBER PAD ABOUT 3/8” FROM FULLY CLOSED SO THAT WHEN YOU TIGHTEN THE T-HANDLE LATCH THE SWINGAWAY WILL COMPRESS THE RUBBER PAD SLIGHTLY.