2007-20XX JEEP WRANGLER

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Rev 03 8/24/15 Page 1 2007-20XX JEEP WRANGLER Spare tire carrier installation instructions Note: You must have Hammerhead rear bumper to use this product. SAFETY Know safety, no injury. Know injury, no safety. ~Author Unknown READ ALL SAFETY INSTRUCTIONS BEFORE INSTALLATION o FOLLOW ALL INSTRUCTIONS FOR PROPER ASSEMBLY o WEAR APPROPRIATE EYE PROTECTION o EXERCISE CARE WHEN LIFTING COMPONENTS o USE APPROPRIATE TORQUE FOR BOLTS o BLUE THREAD LOCKING COMPOUND IS RECOMMENDED ON ALL BOLTS WITHOUT LOCKNUTS. o SUGGESTED TORQUE VALUES FOR STEEL GRADE SAE 5 BOLTS BOLT DIAMETER (INCH) TREADS PER INCH TORQUE (POUND-FEET) 1/4 20 7 5/16 18 14 3/8 16 25 7/16 14 40 ½ 13 60 9/16 12 88 5/8 11 120 ¾ 10 200 7/8 9 302 1 8 466

Transcript of 2007-20XX JEEP WRANGLER

Page 1: 2007-20XX JEEP WRANGLER

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2007-20XX JEEP WRANGLER

Spare tire carrier installation instructions

Note: You must have Hammerhead rear bumper to use

this product.

SAFETY

Know safety, no injury. Know injury, no safety. ~Author Unknown

READ ALL SAFETY INSTRUCTIONS BEFORE INSTALLATION

o FOLLOW ALL INSTRUCTIONS FOR PROPER ASSEMBLY

o WEAR APPROPRIATE EYE PROTECTION

o EXERCISE CARE WHEN LIFTING COMPONENTS

o USE APPROPRIATE TORQUE FOR BOLTS

o BLUE THREAD LOCKING COMPOUND IS RECOMMENDED ON ALL BOLTS

WITHOUT LOCKNUTS.

o SUGGESTED TORQUE VALUES FOR STEEL GRADE SAE 5 BOLTS

BOLT DIAMETER (INCH)

TREADS PER INCH TORQUE (POUND-FEET)

1/4 20 7

5/16 18 14

3/8 16 25

7/16 14 40

½ 13 60

9/16 12 88

5/8 11 120

¾ 10 200

7/8 9 302

1 8 466

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I. PARTS LIST

QUANTITY PART NUMBER DESCRIPTION

1 600-56-0235 SPARE TIRE CARRIER

FRAME

1 60K-56-0019 HARDWARE KIT #19

1 601-56-0428 BOWTIE LINK

1 601-56-2080 TAILGATE MOUNT

WELDMENT

1 601-56-2235 THIRD BRAKE LIGHT

MOUNT

3 443-02-3468 CONE BUMP STOP (2 ARE

PRE INSTALLED ON

TAILGATE MOUNT

WELDMENT AND ONE IS PRE

INSTALLED ON THE SPARE

TIRE CARRIER)

1 60K-56-0061 HARDWARE KIT #61

SHIM KIT

2 601-56-2228 CUP BUMP STOPS

II. TOOL LIST

1. Standard tool kit

2. T20 Torx driver

3. OEM lug wrench

4. 13mm socket

5. 16mm socket

6. 9/16” wrench

7. 9/16” socket

8. ¾” wrench

9. ¾” socket

10. Torque wrench

11. 7/16” wrench

12. 7/16” socket

13. Red Loctite or equivalent

Note: If Hammerhead bumper has been previously installed, it will need to be loosened at

this time. Use a ¾” and 16mm socket to loosen all eight bolts one turn each.

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III. REMOVAL OF OEM SPARE TIRE CARRIER

1. Remove spare tire with OEM lug wrench.

2. Open tailgate to approximately 45° and remove four screws from

OEM third brake light with T20 Torx bit. Screws will be reused.

3. Unplug OEM third brake light and set aside. It will be reused. Close

tailgate.

4. Remove eight OEM spare tire carrier bolts with 13mm socket and set

aside. Bolts will be reused.

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IV. INSTALLATION OF HAMMERHEAD SPARE TIRE CARRIER

1. Install Hammerhead tailgate weldment using eight OEM bolts and

13mm socket. Center weldment in slots and tighten.

2. Remove OEM spare tire bumpers by twisting and pulling out.

Replace with ½” black plastic plugs from Hardware Kit#19.

3. Install Hammerhead third brake light mount on tailgate weldment

using three ¼”-20 x 0.750” bolts and three ¼”-20 nylock nuts from

hardware kit#19. Install bolts from tailgate side. Use 7/16” wrench

and socket. Do not fully tighten.

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4. Insert OEM Third brake light wire through back of light bracket and

plug in third brake light. Install OEM third brake light with OEM

hardware.

5. Install Spare tire carrier into Hammerhead bumper bushing.

2. Install ½”-20x1.5” bolt, ½” flat washer, and ½” lock washer from hardware

kit#19 in bottom of spare tire carrier shaft through bottom of Hammerhead

bumper bushing. Use ¾” socket and torque wrench, and tighten to 85 lb./ft.

NOTE: Use red Loctite on threads.

(View of bottom of Hammerhead bumper)

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3. Open spare tire carrier to 45°, and install cup bushings on spare tire carrier with

two 3/8”-16x1 1/4” bolts, four 3/8” flat washers, and two 3/8”-16 nylock nuts

from hardware kit#19. Use 9/16” wrench and socket. You need to tighten the

bolts so you can barley move the bushings by hand. This will allow them to self

center when you adjust the spare tire carrier.

4. Install link on spare tire carrier. It comes with all of the hardware you will need

installed.

Assembled link below

Steel washer (A), Nylon Washer (B), 3/8”-16x3” bolt GR5 (C), 3/8” Nylock nut (D)

A

B

B

A

A

A

B

B

D

C

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Use one 3/8”-16 x 3” bolt, two 3/8” flat washers, two 3/8”nylon flat washers and one

3/8”-16 nylock nut. Insert bolt with one flat washer in from the top. Use nylon washer on

the top and bottom of the link and then a 3/8” washer and nylock nut on bottom. Use a

9/16” socket and wrench to tighten. Link needs to swing easily by hand when tight.

5. Open tailgate to 45 degrees. Install link on tailgate weldment the same as you did

on the spare tire carrier. Use a 9/16” socket and wrench to tighten.

Slowly shut the tailgate/spare tire carrier. You will start to feel resistance when

the tailgate is almost closed.

6. Check preload on tailgate. When properly adjusted the tailgate will pop open 1.5”

to 2” when the latch button is pressed. Too much preload can damage tailgate. If

the tailgate has too much preload, loosen tailgate weldment and slide to the LEFT

of the vehicle and tighten. Check preload again.

7. If the spare tire carrier is does not have enough preload, open spare tire carrier and

unscrew both cone bump stops on tailgate weldment. Place one nylon shim

behind each bumper and screw them back in. Slowly shut the tailgate/spare tire

carrier and check preload. Preload will settle over time. Adjustments may need to

be made in the future. Place shim pack in glove box. NOTE: DO NOT SCREW

OUT CONE BUMP STOPS AND USE A NUT BEHIND THEM TO SET

PRELOAD. THIS WILL CAUSE DAMAGE TO YOUR BUMP STOPS AND

JEEP.

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8. Tighten rear bumper using ¾” wrench and 16mm socket. Using 9/16” wrench and

socket tighten cup bump stops installed in step 3 at this time.

9. Install spare tire with OEM lug wrench and tighten to OEM specs.

10. Ensure OEM third brake light can be seen over spare tire, and tighten the three

bolts on the bracket with 7/16” wrench and socket.

11. Check all hardware after first 100 miles and at every oil change. 12. The bumper may move slightly when the STC is properly adjusted. If the bumper

moves more than ¼ in, the STC may have too much preload and will need to be

readjusted.

NOTE: Check adjustment of Spare Tire Carrier periodically. Damage can occur to your

Jeep if it is not properly adjusted. The end user is responsible for maintaining this

product. Place these instructions in the glove box when installation is complete.

Congratulations! Your installation is now complete.

Thank you for your purchase.

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