BARNES 4WD B4WK12892 Gladiator Rear Tube Bumper Welders Kit Installation Guide

: September 24, 2024
: BARNES 4WD

Table of Contents

10-24 x 5/8” Button Socket Cap Screw 18-8 SS
10-3/4” Round Head Thread Forming Screw
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)

Jeep Gladiator Rear Tube Bumper Welding Instructions

Thank you for purchasing this product!

Installation Notes:

This kit requires welding, automotive mechanical knowledge, and general fabrication skills, it should only be done by qualified individuals.
The components of this kit will need to be painted or powder coated during installation.
We recommend tack welding the assembly and test fitting before fully welding the components.
Use the etch numbers on the parts to match them to the parts list and throughout the instructions.

Tools required:

Welding machine with the capability to weld at least 1/4″ thick steel.
Various hand tools
Grinder
Various C-Clamps

Contents of each box

Bill Of Materials For B4WK12892- JT Rear Tube Bumper DIY Prepack

QTY

| Part Number| Etch Number| Description
---|---|---|---
1| B4W188876| 876 B|

JT Rear Bumper End Cap L

1

| B4W188877| 877 B| JT Rear Bumper End Cap R
2| B4W188878| 878|

JT Rear Bumper Top Plate

1

| B4W188C42| C42 B| JT Rear Bumper Center Section
1| B4W250882| 882 B|

JT Rear Bumper Corner Mount L

1

| B4W250883| 883 B| JT Rear Bumper Corner Mount R
1| B4W250884| 884 B|

JT Rear Bumper Mounting Plate L

1

| B4W250885| 885 B| JT Rear Bumper Mounting Plate R
1| B4W125074| 074 D|

JT Rear Bumper Outer Dimple Plate L

1

| B4W125075| 075 D| JT Rear Bumper Outer Dimple Plate R
1| B4W125076| 076 D|

JT Rear Bumper Inner Dimple Plate L

1

| B4W125077| 077 D| JT Rear Bumper Inner Dimple Plate R
1| B4W075038| 038 B|

JT Rear Bumper Fog Light Tab L

1

| B4W075039| 039 B| JT Rear Bumper Fog Light Tab R
1| DOM0058| N/A|

JT Rear Bumper Top Tube L

1

| DOM0059| N/A| JT Rear Bumper Top Tube R
1| DOM0060| N/A|

JT Rear Bumper Lower Tube L

1

| DOM0061| N/A|

JT Rear Bumper Lower Tube R

Step 1:

Install one of the carriage head bolts into the lower slot in B4W250884 and B4W250885 as shown below.

Step 2:

Starting on the driver side, place DOM0058 and DOM0060 in their corresponding tabs on B4W250884. Tack the tubing to the bracket.

Step 3:

Place B4W188990 on the right side of the current assembly, it will tab into the corresponding tabs on the tubing. Tack the center section to the tubing. Place B4W188876 on the left side of the current assembly, it will tab into the corresponding tabs on the tubing. Tack the end cap to
the tubing.

Step 4:

Repeat steps 2 and 3 for the passenger side using B4W250885, DOM0059, DOM0061, and B4W188877.

Step 5:

Take both B4W188878 and place them on the top side of the assembly, tabbing into their corresponding slots on the center section. Ensure that the seams line up on B4W188876 and B4W188877. Tack the top plates in place, make sure to keep the top plates flat on the tubing when tacking it.

Step 6:

Fully weld up around each piece of tubing that is touching B4W188876 and B4W188877.

Step 7:

Place B4W250882 and B4W250883 in the respected locations on the back of B4W188876 and B4W188877. They should also tab into each piece of tubing. Tack these brackets in place.

Step 8:

Take each dimpled die plate and place them in their respected place on the bumper. From the dimpling process, the plates may be a little warped. We recommend tacking one side down on the tubing then clamping the other side down and tacking it in place.

Step 9:

Test fit the bumper on the vehicle. If applicable, we recommend test fitting the bumper with the bed guards and bed guard mounts before fully welding each component.

Step 10:

Once the fitment is verified, fully weld up all the seams. Fully weld up the bend reliefs on B4W250884 and B4W250885 as well. Be sure to leave room for the fog light mounts installed in Step 11.

Step 11:

Place B4W075038 and B4W075039 in their respected spots on the inside of the bumper, they will tab into B4W250884 or B4W250885. Make sure they are flat against the mounting plate and the tubing and tack them in place. Fully weld the fog light tabs in only in the designated spots as marked below.

Congratulations! You have completed the welding instructions of the Barnes 4WD Jeep Gladiator Rear Tube Bumper!

Professional Services Disclaimer:

The content of all pages of this website (collectively, the “Website”), such as text, graphics, images, information and other material (collectively, “Content”) is for informational purposes only. Any information furnished on this Website is not intended nor implied to be automotive advice and is not intended to replace personal consultation with a qualified automotive service technician, mechanic, or similar automotive professional.

Barnes 4WD has not examined the Content for accuracy, timeliness, completeness, appropriateness, or helpfulness. Barnes 4WD does not endorse any specific tests, products, procedures, opinions, or other information that may be mentioned on this Website. Your reliance upon information and Content obtained by you at or through this Website is solely at your own risk. IN NO EVENT SHALL BARNES 4WD BE LIABLE OR OTHERWISE RESPONSIBLE FOR ANY DAMAGE OR INJURY (INCLUDING DEATH) TO YOU, OTHER PERSONS, OR PROPERTY ARISING FROM ANY USE OF ANY PRODUCT, INFORMATION, IDEA, OR INSTRUCTION CONTAINED IN THE CONTENT.

BARNES 4WD DOES NOT MAKE ANY REPRESENTATION OR WARRANTY, EXPRESS OR IMPLIED, AT LAW OR IN EQUITY, WITH RESPECT TO ANY PRODUCT FEATURED ON THE WEBSITE, INCLUDING WITHOUT LIMITATION WITH RESPECT TO MERCHANTABILITY, FITNESS FOR ANY PARTICULAR PURPOSE, VALUE, VALIDITY, OR ENFORCEABILITY, AND ANY AND ALL SUCH OTHER REPRESENTATIONS OR WARRANTIES ARE HEREBY EXPRESSLY DISCLAIMED.

Jeep Gladiator Rear Bed Guard Welding Instructions

Thank you for purchasing this product!

Installation Notes:

This kit requires welding, automotive mechanical knowledge, and general fabrication skills, it should only be done by qualified individuals.
The components of this kit will need to be painted or powder coated during installation.
We recommend tack welding the assembly and test fitting before fully welding the components.

Tools required:

Welding machine with the capability to weld at least 1/4″ thick steel.
Various hand tools
Grinder

Contents of each box

Bill Of Materials For B4WK12893- JT Rear Bed Guards DIY Prepack

QTY

| Part Number| Etch Number| Description
---|---|---|---
1| B4W188872| 872 B|

JT Bed Guard Main Body L

1

| B4W188873| 873 B| JT Bed Guard Main Body R
2| B4W188874| 874|

JT Bed Guard Front Plate

2

| B4W188875| 875| JT Bed Guard Rear Plate
4| B4W125071| 071|

JT Bed Guard Step Cap

Step 1:

Align each part as shown below, each plate should align with tabs on the Main Bodies. Make sure the plates are orientated the correct way and each seam lines up. Tack weld all plates to the main body.

Step 2:

Once tacked together, test fit the bed guards to the bumper and the bed guard brackets on the Jeep. Once the fitment looks good, fully weld up every seam. May be necessary to grind some of the welds on the mounting plate to ensure the mounting surface is flat.

Professional Services Disclaimer:

The content of all pages of this website (collectively, the “Website”), such as text, graphics, images, information and other material (collectively, “Content”) is for informational purposes only. Any information furnished on this Website is not intended nor implied to be automotive advice and is not intended to replace personal consultation with a qualified automotive service technician, mechanic, or similar automotive professional.

Barnes 4WD has not examined the Content for accuracy, timeliness, completeness, appropriateness, or helpfulness. Barnes 4WD does not endorse any specific tests, products, procedures, opinions, or other information that may be mentioned on this Website. Your reliance upon information and Content obtained by you at or through this Website is solely at your own risk. IN NO EVENT SHALL BARNES 4WD BE LIABLE OR OTHERWISE RESPONSIBLE FOR ANY DAMAGE OR INJURY (INCLUDING DEATH) TO YOU, OTHER PERSONS, OR PROPERTY ARISING FROM ANY USE OF ANY PRODUCT, INFORMATION, IDEA, OR INSTRUCTION CONTAINED IN THE CONTENT.

BARNES 4WD DOES NOT MAKE ANY REPRESENTATION OR WARRANTY, EXPRESS OR IMPLIED, AT LAW OR IN EQUITY, WITH RESPECT TO ANY PRODUCT FEATURED ON THE WEBSITE, INCLUDING WITHOUT LIMITATION WITH RESPECT TO MERCHANTABILITY, FITNESS FOR ANY PARTICULAR PURPOSE, VALUE, VALIDITY, OR ENFORCEABILITY, AND ANY AND ALL SUCH OTHER REPRESENTATIONS OR WARRANTIES ARE HEREBY EXPRESSLY DISCLAIMED.

Jeep Gladiator Rear Bed Guard Brackets Welding and Installation Instructions

Thank you for purchasing this product!

Installation Notes:

This kit requires welding, automotive mechanical knowledge, and general fabrication skills, it should only be done by qualified individuals.
The components of this kit will need to be painted or powder coated during installation.
We recommend tack welding the assembly and test fitting before fully welding the components.
If you have the towing package, you will use the 1/2″ bolt that is 4″ long.
If you don’t have the towing package, you will use the 1/2″ bolt that is 1-1/4″ long.

Tools required:

Welding machine with the capability to weld at least 1/4″ thick steel.
Various hand tools
Grinder
15mm Socket
3/4″ Socket
3/4″ Wrench
Rachet

Contents of each box

Bill Of Materials For B4WK12894-JT Rear Bed Guard Brackets DIY Prepack

QTY

| Part Number| Etch Number| Description
---|---|---|---
2| B4W188868| 868|

JT Bed Guard Bracket Frame Plate

1

| B4W188869| 869 B| JT Bed Guard Bracket Frame Support L
1| B4W188870| 870 B|

JT Bed Guard Bracket Frame Support R

2

| B4W188871| 871| JT Bed Guard Bracket Bottom Plate
2| B4W188886| 886|

JT Bed Guard Bracket Cap

4

1/2” SAE Washer Yellow Zinc

2

1/2”-13 x 1-1/4” Hex Head Grade 8 Bolt

2

| 50C400HCS8Y| N/A|

1/2”-13 x 4” Hex Head Grade 8 Bolt

Welding Instructions

Step 1:

B4W188869 or B4W188870 will tab into each corresponding part as below. B4W188886 will fit in the opening on the side of the bracket. Make sure each plate is flat and orientated correctly.
Line up each seam and tack everything together.

Step 2:

Once tacked together, test fit the bracket onto the Jeep and bumper. Once test fitment looks good, fully weld up each seam.

Installation Instructions

Step 1:

Starting on the passenger side, place the drive side bed guard bracket on to the side of the frame where the top left and right holes line up with the holes in the frame that are tapped.
Using the provided M10 hex flanged bolts, loosely install the bracket.

Step 2:

If you have the towing package, you will use the 4″ bolt that will pass through a sleeve in the frame. If you do not have the towing package, you will use the 1-1/4″ bolt that will just go through the first part of the sheet metal. Take the 1/2″ bolt and place a washer on it and run it through the lower hole on the bracket. Take the other washer and nylock nut and loosely install them.

Step 3:

Repeat these steps for the driver side bracket.

Step 4:

After the bed guards are mounted to the bed guard brackets and the rear bumper, you can then fully tighten the brackets to the frame.

Congratulations! You have completed the installation of the Barnes 4WD Jeep Gladiator Rear Bed Guard Brackets!

Professional Services Disclaimer:

The content of all pages of this website (collectively, the “Website”), such as text, graphics, images, information and other material (collectively, “Content”) is for informational purposes only. Any information furnished on this Website is not intended nor implied to be automotive advice and is not intended to replace personal consultation with a qualified automotive service technician, mechanic, or similar automotive professional.

Barnes 4WD has not examined the Content for accuracy, timeliness, completeness, appropriateness, or helpfulness. Barnes 4WD does not endorse any specific tests, products, procedures, opinions, or other information that may be mentioned on this Website. Your reliance upon information and Content obtained by you at or through this Website is solely at your own risk. IN NO EVENT SHALL BARNES 4WD BE LIABLE OR OTHERWISE RESPONSIBLE FOR ANY DAMAGE OR INJURY (INCLUDING DEATH) TO YOU, OTHER PERSONS, OR PROPERTY ARISING FROM ANY USE OF ANY PRODUCT, INFORMATION, IDEA, OR INSTRUCTION CONTAINED IN THE CONTENT.

BARNES 4WD DOES NOT MAKE ANY REPRESENTATION OR WARRANTY, EXPRESS OR IMPLIED, AT LAW OR IN EQUITY, WITH RESPECT TO ANY PRODUCT FEATURED ON THE WEBSITE, INCLUDING WITHOUT LIMITATION WITH RESPECT TO MERCHANTABILITY, FITNESS FOR ANY PARTICULAR PURPOSE, VALUE, VALIDITY, OR ENFORCEABILITY, AND ANY AND ALL SUCH OTHER REPRESENTATIONS OR WARRANTIES ARE HEREBY EXPRESSLY DISCLAIMED.

Jeep Gladiator Rear Tube Bumper Installation Instructions

Thank you for purchasing this product!

Installation Notes:

This kit is designed to be compatible with 2020-Current Jeep Gladiator.
These instructions infer that you have the bed guard brackets already mounted on your Jeep, this bumper will work with the OEM Rubicon style bed guard mounts if already installed.
We suggest test fitting to verify fit and then painting or powder coating the parts.
This bumper does not accommodate back-up sensors.
We suggest using anti-seize on all stainless steel hardware.

Tools required:

16mm Deep-well Socket
5/8” Deep-Well Socket
9/16” Socket
9/16” Wrenches
5/16” Hex Driver
3/4” Wrench
3/8” Socket
1/8” Hex Drive
Phillips Screwdriver
Flat Head Screwdriver

These instructions infer that you have completed all the DIY Welding Kit instructions for the rear bumper, bed guards, and bed guard brackets (if applicable).

Possible Kits Included

B4WK12865- JT Rear Tube Bumper DIY Kit without Bed Guard Brackets

QTY

| Kit Part Number| Description
---|---|---
1| B4WK12863|

JT Rear Tube Bumper Hardware Kit

1

| B4WK12892| JT Rear Tube Bumper DIY Prepack
1| B4WK12893|

JT Rear Bed Guards DIY Prepack

B4WK12919- JT Rear Tube Bumper DIY Kit with Bed Guard Brackets

QTY

| Kit Part Number| Description
---|---|---
1| B4WK12863|

JT Rear Tube Bumper Hardware Kit

1

| B4WK12892| JT Rear Tube Bumper DIY Prepack
1| B4WK12893|

JT Rear Bed Guards DIY Prepack

1

| B4WK12894|

JT Rear Bed Guard Brackets DIY Prepack

Bill Of Materials For B4WK12863- JT Rear Tube Bumper Hardware Kit

QTY

| Part Number| Etch Number| Description
---|---|---|---
4| 43C100BCG5Z| N/A|

7/16”-14 x 1” Grade 5 Carriage Bolt

4

7/16”-14 Nylock Nut

8

3/8” SAE Washer

8

10-24 x 5/8” Button Socket Cap Screw 18-8 SS

12

| 10CNNES| N/A| #10-24 Nylock Nut 18-8 SS
4| 90380A248| N/A|

10-3/4” Round Head Thread Forming Screw

4

| 98550A108| N/A| Nylon Snap In #10 Nut
6| 50C100KBCS| N/A|

1/2”-13 x 1” Button Socket Cap Screw 18-8 SS

6

JT Rear Bumper Center Cap

2

| B4W075040| 040| JT Rear Bumper Tag Light Bracket
1| B4W075041| 041|

JT Rear Bumper Trailer Plug Bracket

Step 1:

Disconnect the trailer plug and the tag lights from the wiring harness from behind the bumper. The tag lights harness will need to be unpinned from the frame of the Jeep.

Step 2:

Remove the license plate. Use a 16mm socket to remove the two bolts behind the license plate. Remove the two nuts per side on the back side of the bumper. Remove the bumper and set it somewhere you can work on the back side of the bumper. If equipped, the Bed Side Rock Rails
will also have to be removed. The frame bracket can stay on the Jeep and the mounting hardware for the Rock Rails will be reused.

Step 3:

Unplug the tag light wiring harness from the tag lights and remove the harness from the bumper. Squeezing the two metal tabs, remove the trailer plug from the factory bumper.

Step 4:

Carefully pry the tabs on the tag light housings to remove them from the factory bumper. Remove the inner housing from the outer housing and remove the tag light from the inner housing.

Step 5:

Place the tag lights into the new brackets and install them into the bumper using the #10×5/8″ Button Head screws and nylock nuts. Plug the tag lights back into the wiring harness and secure the harness to the bumper.

Step 6:

Using a flat head screwdriver, remove the metal tabs on the trailer plug and place the trailer plug in the new trailer plug bracket. Place the metal tabs back on the trailer plug to lock it into the new bracket.

Step 7:

Place the plug and bracket into the bumper from the back side with the plug socket facing down. Use the provided #10×5/8″ Button Head screws and nylock nuts.

Step 8:

Install the bumper on to the end of the frame, using the provided 7/16″ USS washer and nylock nuts to secure the bumper onto the Jeep. Take the other two 7/16″ carriage head bolts and place them through the bumper into the frame of the Jeep. Use the remaining 7/16″ USS washers and nylock nuts to secure the bumper. Do not fully tighten the nuts. Center the bumper on the Jeep.

Step 9:

Install the bed side guards on both sides of the Jeep using the provided 3/8″ hardware to mount to the bumper, use a washer on both sides of the bolt. If you have installed our bed side guard brackets, you will use the provided 1/2″ stainless steel button socket cap screws and nylocks nuts. If you have the factory bed side guard brackets, you will reuse the factory hardware to mount the bed side guards to the bed side guard brackets.

Parts made transparent to show bolts.

Step 10:

With all the hardware loosely installed, make the bed side guards level with the rear bumper and fully tighten the 3/8″ hardware with the 9/16″ wrench and ratchet. Fully tighten the 1/2″ stainless steel hardware with the 5/16″ hex driver and 3/4″ wrench. Fully tighten the 7/16″ hardware with the 5/8″ deep- well socket.

Step 11:

Plug in the tag light wiring harness back in and plug the trailer plug back in. Snap in the plastic license plate nuts and using the provided #10 thread forming screws, install the license plate.

Congratulations! You have completed the installation of the Barnes 4WD Jeep Gladiator Rear Tube Bumper!

Professional Services Disclaimer:

The content of all pages of this website (collectively, the “Website”), such as text, graphics, images, information and other material (collectively, “Content”) is for informational purposes only. Any information furnished on this Website is not intended nor implied to be automotive advice and is not intended to replace personal consultation with a qualified automotive service technician, mechanic, or similar automotive professional.

Barnes 4WD has not examined the Content for accuracy, timeliness, completeness, appropriateness, or helpfulness. Barnes 4WD does not endorse any specific tests, products, procedures, opinions, or other information that may be mentioned on this Website. Your reliance upon information and Content obtained by you at or through this Website is solely at your own risk. IN NO EVENT SHALL BARNES 4WD BE LIABLE OR OTHERWISE RESPONSIBLE FOR ANY DAMAGE OR INJURY (INCLUDING DEATH) TO YOU, OTHER PERSONS, OR PROPERTY ARISING FROM ANY USE OF ANY PRODUCT, INFORMATION, IDEA, OR INSTRUCTION CONTAINED IN THE CONTENT.

BARNES 4WD DOES NOT MAKE ANY REPRESENTATION OR WARRANTY, EXPRESS OR IMPLIED, AT LAW OR IN EQUITY, WITH RESPECT TO ANY PRODUCT FEATURED ON THE WEBSITE, INCLUDING WITHOUT LIMITATION WITH RESPECT TO MERCHANTABILITY, FITNESS FOR ANY PARTICULAR PURPOSE, VALUE, VALIDITY, OR ENFORCEABILITY, AND ANY AND ALL SUCH OTHER REPRESENTATIONS OR WARRANTIES ARE HEREBY EXPRESSLY DISCLAIMED.