FRONT RUNNER FAJL002 Jeep Wrangler JL Instruction Manual

FRONT RUNNER FAJL002 Jeep Wrangler JL

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Don’t be a hero and muscle through this installation without reading these fitting instructions first! Improper installation of this gear may void certain aspects of your warranty.Before you begin, take a moment and open all your Front Runner rack kit boxes and gather the assembly instructions for the various components.
A complete kit will contain:

1.  Front Runner Mounting System specific to your vehicle
2.  Front Runner Rack Tray or Load Bar Slats This document will guide you through the assembly of the mounting system and assist you in fitting the roof rack tray or load bars to your specific vehicle. Please refer to the next page for a list of all the components, quantities and tools required.

IMPORTANT WARNING

IT IS CRITICAL THAT ALL FRONT RUNNER PRODUCTS BE PROPERLY AND SECURELY ASSEMBLED AND ATTACHED TO YOUR VEHICLE. IMPROPER ATTACHMENT COULD RESULT IN AN AUTOMOBILE ACCIDENT AND COULD CAUSE SERIOUS BODILY INJURY OR DEATH. YOU ARE RESPONSIBLE FOR ASSEMBLING AND SECURING ALL FRONT RUNNER PRODUCTS TO YOUR VEHICLE, CHECKING THE ATTACHMENTS PRIOR TO USE, AND PERIODICALLY INSPECTING THE PRODUCTS FOR ADJUSTMENT, WEAR AND DAMAGE. THEREFORE, YOU MUST READ AND UNDERSTAND ALL OF THE INSTRUCTIONS AND PRECAUTIONS SUPPLIED WITH YOUR FRONT RUNNER PRODUCT PRIOR TO INSTALLATION OR USE. IF YOU DO NOT UNDERSTAND ALL OF THE INSTRUCTIONS AND CAUTIONS, OR IF YOU HAVE NO MECHANICAL EXPERIENCE AND ARE NOT THOROUGHLY FAMILIAR WITH THE INSTALLATION PROCEDURES, YOU SHOULD HAVE THE PRODUCT INSTALLED BY A PROFESSIONAL INSTALLER OR OTHER QUALIFIED PERSONNEL.

NOTE:
Front Runner will not be responsible for any damage caused by the failure to install the product according to these instructions. Please call us if you have any questions about the installation of this product.

GET ORGANIZED
IN THE BOX IN THE BOX

1. 2 X :Foot Rail – 1LH + 1RH
2. 14 X: M8 X 20 Hex Bolt
3. 14 X:M8 x 16 x 1.6SS Flat Washer
4. 14 X:M8 Nyloc Nut
5. 14 X:M8 Nut Cap

TOOLS NEEDED

IN THE BOX IN THE BOX

1. 2 X: Rear Support Bracket – 1LH + 1RH :
2.  2 X :Middle Support Bracket – 1LH + 1RH:
3.  16 X: M6 Nut Cap:
4.  8 X: M6 x 40 Hex Bolt:
5.  8 X :M6 x 30 x 2 Laser Cut Washer:
6.  8 X :Foam Seal Washer:
7.  8 X :Aluminum Spacer:
8.  8 X :M6 x 12 x 1SS Flat Washer:
9.  8 X :M6 Nyloc Nut:
10.  6 X :M8 x 16 x 1.6SS Flat Washer:
11.  6 X :M8 SS Spring Washer:
12.  4 X :M8 x 25 Button Head Bolt:
13.  2 X :M8 Nut Cap:
14. 2 X :M8 x 100 Hex Bolt:
15.  2 X :M8 Cage Nut:
16.  1 X :Seal Plug Kit:

FIT AND SECURE INNER BRACKETS AND FOOT RAIL

For a Full Rack refer to FAJL004 Fitment Guide before starting.

Looking at the rear roll cage, remove the plastic trim covers located on the inside of the roll bar as shown. Do this on both the left and right side.

Fit the Inner Support Brackets (Items 6LH & 6RH) using the factory inserts in the roll bar, using M8 x 25 Button Head Bolts, M8 SS Spring Washer and M8 x 16 x 1.6SS Flat Washer (Items 15, 16 & 17). Refer to Figure 1.1 on page 3. Using the two top holes on the Inner Support Bracket as a guide, mark the hole positions on the roof. Do the same with the opposite side Support Bracket. You will drill these in Step 2.5Remove the Brackets.

Open the rear passenger doors and locate the hole shown. Before fitting the Middle Support Brackets (Item 7), assemble the Support Brackets and M8 Cage Nuts (Items 7 & 20). Refer to Figure 1.1 for positioning of the Cage Nuts. Fit the Middle Support Brackets (Items 7LH & 7RH) on top of the roll bar and secure them to the roll bar using M8 x 100 Hex Bolts, M8 SS Spring Washers and M8 x 16 x 1.6 SS Flat Washers (Items 15, 16 & 19). Refer to Figure 1.1 on page 3.Do this on both left and right side.

FIT AND SECURE INNER BRACKETS AND FOOT RAIL

Mark the two holes on both the brackets onto the roof. Remove the four brackets. Have a friend hold a vacuum cleaner with the nozzle attached, close the drill point. Drill pilot holes using a 4mm drill bit on the eight points marked on the roof.

Change the 4mm drill bit to a 22mm hole saw. From the outside of the vehicle, drill all the 4mm holes (8 in total) out to 22mm. Let the drill do the work. You do not want to scratch or damage your vehicle’s roof. Have your friend hold the vacuum cleaner underneath where you are drilling to catch all the dust and keep your vehicle clean.After drilling, clean the area around all the 22mm holes in the roof with a rag and methylated spirits/denatured alcohol.

Refit both LH and RH Inner Support Bracket. Refer to Step 2.2.

FIT AND SECURE INNER BRACKETS AND FOOT RAIL
Refit both the Middle Support Brackets. Refer to Step 2.3 and 2.4.

Insert the Aluminum Spacers (Item 12) into the Foam Washer (Item 11). Remove the paper backing from the Foam Washer to expose the adhesive. Insert the Washer/Spacer combination, adhesive side down, into the 22mm holes so that the Spacer comes to rest on the Inner and Middle Support Brackets. Firmly press the Foam Washer all the way around, securing it to the roof.

Place the Foot Rail (Item 1) onto the spacer and secure using M6 x 40 Hex Bolts, M6 x 30 x 2 Flat Washers, M6 x 12 x 1SS Flat Washer and M6 Nyloc Nuts (Items 9, 10, 13 & 14) as shown. Do this on both sides of the vehicle. Finish off by placing M6 Nut Caps (Item 8) on all the nylon nuts and bolt heads.

FIT AND SECURE ROOF RACK
Make sure that the wind deflector is installed before you proceed to the next step. Refer to Rack Fitment Guide (RRSTUNI).

Fit your Roof Rack to the Foot Rails using M8 x 20 Hex Bolts, M8 x 16 x 1.6SS Flat Washers and M8 Nyloc Nuts (Items 2, 3 & 4).

Center the rack and tighten fully. Use M8 Nut Caps (Item 5) to finish off the nuts.

REMOVING YOUR RACK

Should you wish to remove your rack, you will need to plug the holes you drilled in the roof (Step 2.5) using the supplied Seal Plug Kit. Remove the Tray and the Foot Rail by reversing the installation procedure. Leave the Foam Washer and the Aluminum Spacers in place. Screw in the Sealing Plugs, reusing the M6 Nyloc Nuts and Washers that held the Foot Rail in13mm position.

COMPLETION
Congratulations! You did it. Take a step back and admire your work!

INSTALL OTHER VEHICLE AND RACK ACCESSORIES
Now’s the time to visit your favorite Front Runner Dealer in person or online.

IMPORTANT

FRONT RUNNER RACK KITS OFTEN HAVE A HIGHER LOAD RATING THAN THE VEHICLES THEY ARE MOUNTED TO. PLEASE REFER TO YOUR SPECIFIC VEHICLE MANUFACTURER FOR A RECOMMENDED ROOF RATING. THE FRONT RUNNER CAN NOT BE RESPONSIBLE FOR IMPROPER LOADING BEYOND THE VEHICLE MANUFACTURER’S STATED LOAD CAPACITY.

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