Fab Fours fb1030 Ford Bronco Trail Doors Instruction Manual

Fab Fours fb1030 Ford Bronco Trail Doors

• Product number: fb1030
• Application: 2022+ ford bronco

IMPORTANT SAFETY GUIDE

Your safety and the safety of others is very important.

• In order to help you make informed decisions about safety, we have provided the following warnings, safety precautions, installation instructions, and other important information to alert you to potential hazards that could hurt you or others. Please do a job safety analysis before each task to identify potential hazards for your situation and remove/protect against them. Use own good judgment and take your time. Check packaged materials immediately upon arrival to ensure that all listed parts are included and undamaged. Read and understand all warnings, safety precautions, and instructions before installing this product. SENSORS FIELD OF VIEW MAY BE ALTERED WITH USE OF THE REPLACEMENT BUMPER.

WARNINGS

• Failure to observe the following warnings and instructions provided in this manual could lead to severe injury and/or death.
• For professional installation only. Careless installation and/or operation can result in serious injury, death, and/or equipment damage. All liability for installation and use rests with the user or consumer.
• Fab Fours, Inc. only approves installing this product according to these written instructions with the hardware provided. Failure to install according to these instructions will invalidate the warranty. This includes, but is not limited to, using alternative installation methods, hardware, or materials.
• This product is for off-road use only.

SAFETY PRECAUTIONS

• Always remove jewelry and wear eye protection.

• Always use extreme caution when jacking up a vehicle for work. Set the emergency brake and use tire blocks. Locate and use the vehicle manufacturer-designated lifting points. Use jack stands.

• Always use appropriate and adequate care in lifting components into place.

• Always ensure components will remain secure during installation and operation.

• Always wear safety glasses when installing this kit. A drilling operation will cause flying metal chips. Flying chips can cause serious eye injury.

• Always use extreme caution when drilling a vehicle. Always disconnect the power before welding. Thoroughly inspect the area to be drilled (on both sides of the material when possible) prior to drilling, and relocate any objects that may be damaged.

• Always use extreme caution when welding a vehicle. Thoroughly inspect the area to
  be welded (on both sides of the material when possible) prior to welding, and relocate any objects that may be a fire hazard. When welding in a cab, make sure the interior surfaces are covered (e.g., welding blanket) and a fire extinguisher is at hand.

• Always use extreme caution when cutting and trimming during fitting.

• Always tighten all nuts and bolts securely per installation instructions.

• Always route electrical cables carefully. Avoid moving parts, components that become hot, and rough or sharp edges.

• Always insulate and protect all exposed wiring and electrical terminals.

• Perform regular inspections and maintenance on mounts and hardware.

A message from the owner

Fab Fours’ was born out of a passion for customizing vehicles and a love of the outdoors. Our engineering team uses the latest 3D design software to turn new product ideas into reality. In our factory, designs come to life with the combination of cutting-edge technology for metal cutting and forming and an American workforce that puts its’ heart and pride into every product. From design and manufacturing to quality and delivery, Fab Fours’ mission is to be the market leader for steel truck and jeep accessories. We make sure a quality product is delivered on time, more than expected, and better than expected to our customers. Enjoy your new Fab Fours product. Welcome to the family! Greg Higgs Founder, Fab Fours

Getting started

Before you begin the installation process of your new Fab Fours product, we suggest laying out all materials and parts on a pad or protective surface. Failure to fully account for all components before beginning installation may leave the vehicle immobile until part is acquired. Refer to the next pages as an inventory check.

Provided materials

TOOLS REQUIRED

• 13mm Socket Wrench (Included in OE toolset)
• 7/16” Socket Wrench
• 1/8” Allen Wrench
• 7/16” Combination Wrench
• 1/2” Combination Wrench
• 3/8” Combination Wrench
• 5/16”-18 Tap (Optional)

assistance
 We recommend two people perform the installation as items are heavy and may need to be held in place while installing.

Organization
Disassemble the vehicle so that you can catalog and store everything. We suggest labeling and bagging all the OEM bolts when removing from the vehicle. Failure to keep track of parts could lead to an inability to properly reinstall components.

Hardware kit

Disassembly

1. Roll down all four windows. (Figure 1)
2. Push the side view mirrors forward. (Figure 2)
3. Place the fender and door protectors in the OE provided tool pouch; install one over the fender edge near the upper door hinge and the other on the door edge near the bottom door hinge; see your OE-provided Owner’s Manual for specific placement.
4. Pull on the electrical connector door to release the electrical connector. (Figure 3)
5. Install the door storage bag on the door being removed, if equipped. (Figure 4)
6. Using the OE provided 13mm socket and wrench, remove the lower hinge bolt. (Figure 5)
7. Using the OE provided 13mm socket and wrench, remove the upper hinge bolt. (Figure 6)
8. Lift the door, using the lift handle and exterior door handle to remove the door from the vehicle.(Figure 7)
9. Repeat these steps to remove the remaining doors.

preinstallation

  *  **Note:** The following preinstallation steps should be repeated on the remaining three doors **.**

10. Begin assembly with the driver side front door (Part#: 22730). Install the provided spacer (Part#: 22734) on the bottom of the upper mount flange using two (2) of the provided 1/4” hex head cap screws, flat washers, and lock nuts. (Figure 8-9)

11. Install one (1) of the provided bronze bushings into the open hole of the previously installed spacer and mount the flange from the bottom side. (Figure 9) Using a 7/16” combination wrench and socket wrench tighten the previously installed 1/4” hardware.

12. Install the provided spacer (Part#: 22735) on the top of the lower mount flange using one (1) of the provided 1/4” hex head cap screws, flat washers, and lock nuts. (Figure 10)

13. Assemble one (1) of the right-hand door latches with one of the provided driver-side door handles (Part#: 22759) using an 1/8” Allen wrench and 3/8” combination wrench with two (2) of the provided #10-32 screws and nylock nuts. The front doors will be assembled as shown in (Figure 11) and the rear doors will be assembled as shown in (Figure 12).

14. Install one (1) of the provided springs by looping one of the hooks through the upper most available hole in the door latch then looping the other hook through the designated cutout in the door. (Figure 13 & 14)

15. Using two (2) of the provided 1/4” hex head cap screws and flat washers, loosely install one (1) of the previously assembled right-hand door latches. (Figure 15)

16. Install one (1) of the provided studded bumpers into the welded-in nut near the door latch. Then, thread one (1) of the provided 5/16” nuts onto the stud of the bumper to be used as a jamb nut to set the depth of the bumper later.
    Note: A 5/16”-18 tap may be required to clean threads in welded in nut before assembly. (Figure 16)

17. Install on the driver’s side rear door (Part#: 22732), the provided logo backer plate (Part#: 22736) using a 7/16” combination wrench and socket wrench with two (2) of the provided 1/4” hex head cap screws, flat washers, and nylock nuts. (Figure 17)

18. Install on the passenger’s side rear door (Part#: 22733), the provided logo backer plate (Part#: 22737) using a 7/16” combination wrench and socket wrench with two (2) of the provided 1/4” hex head cap screws, flat washers, and nylock nuts.

19. Note: If the FB1031 sku is going to be installed in conjunction with these doors, skip this step. Install four (4) of the provided 3/8” black plastic plugs in the remaining four (4) open holes in the doors.
    (Figure 18 & 19)

installation

  *  **Note:** The following preinstallation steps should be repeated on the remaining three doors. **

20. Install the driver’s side front door (Part#: 22730) onto the vehicle in its corresponding location by seating the upper and lower mounting holes over the OEM mounting studs on the vehicle. (Figure 20)
21. Reinstall and lightly tighten the lower OEM mounting bolt removed previously. (Figure 21)
22. With all four (4) doors placed on the vehicle, the alignment can be adjusted using the lower mount bracket on all doors to set the gap around the doors and help align the latch. Once the desired position has been achieved, use a 13mm wrench to tighten the previously installed OEM lower hinge bolt. (Figure 22)
23. Using a 7/16” combination wrench and socket wrench tighten the previously installed 1/4” hardware in the lower mounting spacer. (Figure 23)
24. Close the doors and align the latch to the striker ensuring the latch is fully closed. Open the door careful to not move the position of the latch and use a 7/16” socket wrench to tighten the latch. (Figure 24)
25. Use the previously installed studded bumper to put slight tension on the door with it closed to prevent the latch from rattling. You want the bumper to be slightly compressed with the door latched and for the door to have no in and out movement. Once the bumper is set use a 1/2” combination wrench to tighten the jamb nut on the bumper stud to lock it in place. (Figure 25 & 26)
26. To remove or install the Fab Fours doors from this point forward, only the OEM bolt in the lower mounting flange needs to be removed or installed using the 13mm wrench provided in the tool kit that comes with the vehicle. No further alignment should be required. (Figure 27)

Contact information

Fab Fours Inc. 2213 Industrial Park Road Lancaster, SC 29720

• Phone: 866-385-1905
• Fax: 970-385-1914
• Email: [email protected]
• “If you’re looking for more of the same, Then you’ve come to the wrong place.

References

• Fab Fours

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