Front Runner FAJK010 Manuel

ENG

Jeep Wrangler JKU 2 Door (2007-2018)

inner brackets and Foot Rail

IMPORTANT WARNING!

Don’t be a hero and muscle through this without ﬁrst reading these ﬁtting instructions! 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. A Front Runner Mounting System speciﬁc to your vehicle

2. A 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.

FAJK010 / FAJK011

READ ME FIRST

START HERE!

FRONT RUNNER CAN NOT RECOMMEND A MAXIMUM LOAD CARRYING CAPACITY. PLEASE REFER TO YOUR VEHICLE MANUFACTURER'S RECOMMENDATIONS. 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.

IN THE BOX

FIGURE 1.1

IN THE BOX TOOLS NEEDED

T40

Torx Wrench

IN THE BOX

1GET ORGANIZED

FAJK011

13MM

10MM 10MM

13MM

4mm

22mm (7/8") Hole Saw

1RH

1LH

1 2 X Inner Bracket 1LH + 1RH

2 2 X Inner Bracket Clamp

3 16 X M6 Nut Cap

4 8 X M6 x 30 Hex Bolt

5 8 X Spacer 19 x 12.58 x 15

6 8 X M6 x 19 x 1SS Flat Washer

7 8 X Foam Washer

8 24 X M6 x 12 x 1SS Flat Washer

9 24 X M6 Nyloc Nuts

10 1 X Seal Kit

Rear Of Vehicle

FAJK010 / FAJK011_REV_A01

12R

1GET ORGANIZED

FIGURE 1.2

IN THE BOX

11 10 X M8 X 20 Hex Bolt

12 2 X Foot Rail - 1LH + 1RH

13 10 X M8 x 16 x 1.6SS Flat Washer

14 10 X M8 Nyloc Nut

15 10 X M8 Nut Cap

IN THE BOXIN THE BOX

FAJK010

Rear Of Vehicle

FAJK010 / FAJK011_REV_A01

FIT AND SECURE

13mm

2.1

2.2

2.3

Remove the two T-top roofs.

Disconnect the power socket and water

pipe in the back left corner of the vehicle.

Using a T40 Torx Wrench, remove the six

torx bolts holding the rear roof to the

vehicle's body.

Remove the two torx bolts either side of

the front headrests holding the rear roof

the vehicle's body.

With the help of a friend, lift the roof off

the vehicle.

Drill 4mm pilot holes on the marks you

have made.

Change the 4mm drill bit to a 22mm hole

saw. 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.

Place the left and right Foot Rails (Item

12LH & 12RH) in position as shown. Mark

the position of the four mounting feet.

Remove the Rails. Using masking tape,

tape the marked area on the roof where

the mounting feet sat. This is done to help

protect your vehicle's roof when drilling in

2.3.

Place the brackets back in position,

making sure to align the Foot Rail with the

ribs on the roof.

Using a measuring tape, adjust the Rails

so the centre of the rear hole is 130mm in

from the rear edge of the roof and 3mm

from the edge of the outer rib as shown.

Mark the position of all the holes onto the

roof.

10mm

6mm

130mm

FAJK010 / FAJK011_REV_A01

FIT AND SECURE

13mm

2.4

2.5

2.6

Remove the speaker box so that you have

access to the zips and padding that cover

the vehicles roll bars.

This is done by removing the six bolts that

hold it in place. Two bolts on the outside of

each speaker and one bolt either side of

the screw that hold the T-tops in place.

10mm

6mm

Loosen velcro, unzip and remove the

padding covering the roll bars. Remove the

foam shown.

Replace the roof, and fully tighten the

six torx bolts holding the rear roof to the

vehicle's body.

The two holes shown must be towards the

rear of the vehicle and the ribs of the

bracket must be on the inside of the roll

bar.

Align the holes in the Inner Brackets (Item

1LH & 1RH) with the holes drilled in 2.3.

Place the Inner Bracket Clamp (Item 2)

around the outside of the roll bar and

secure the Inner Bracket (Item 1) to the roll

bar using M6 Nyloc Nuts and M6 x 12 x 1

Flat Washers (Items 8 & 9) as shown.

Do this on both left and right side of the

vehicle.

Remove

Leave

Rear fo Vehicle

1RH

10mm

80mm

FAJK010 / FAJK011_REV_A01

FIT AND SECURE

13mm

2.7

2.8

2.9

If not already assembled, assemble your

Tray as per the Universal Tray Assembly

Instructions (Document RRSTUNI)

Clean the area around all the 22mm

holes drilled in the roof with a rag and

methylated spirits/denatured alcohol.

Insert the Aluminum Spacers (Item 5)

into the Foam Washer (Item 7). Remove

the paper backing from the Foam

washer to expose the adhesive.

Insert the washer/spacer assembly,

adhesive side down, into the 22mm

holes so that the spacer comes to rest

on the Rear Support Brackets

underneath.

Firmly press the foam washer all the

way around securing it to the roof.

After ﬁtting the wind deﬂectors, the tray

should still be upside down, loosely

mount the Foot Rails (Item 12L & 12R

from FAJK010 box) to the Tray using M8

x 20 Hex Bolts, M8 X 16 X 1.6SS Flat

Washers and M8 Nyloc Nuts (Items 11,

13 & 14). As before use the machined

slots to insert the hex bolts into the

Slats.

The Foot Rail should be mounted to the

tray with the product sticker at the

opposite end of the wind deﬂector.

The rear of the Foot Rail must mount

onto the very last Slat (Combined Slat)

and approximately 80mm in from the

outer edge of the side of the Tray. Do not

tighten the bolts yet.

13mm

NOTE: Before ﬁtting the Wind

Deﬂector, insert two M8 x 16 Hex

Bolts (Item 11 from FAJK010) or

if you are ﬁtting a full rack (Item 1

from FAJK009) into the ﬁrst slat

(Combined Slat), using the

Machined slots. Slide a bolt to each

of the outer corners.

For a Full Rack ﬁtment refer to FAJK009

Fitment Guide.

FAJK010 / FAJK011_REV_A01

2.10

FIT AND SECURE

With the help of a friend, ﬂip the Tray

end over end so that it is in the upright

position. (The Tray is ﬂipped end over

end so that bolts and brackets do not

slide left and right).

With one of you on either side of the

Tray, lift the Tray and walk it into

position above the vehicle, approaching

from either the front or the rear of the

vehicle.

The Foot Rail should still be loose

enough to move. Line the brackets up

with the holes on the roof and fasten

them into position using M6 x 19 x 1SS

Flat Washers, M6 x 30 (Items 4, 6, 8 & 9

from FAJK010 box). Centre the tray from

left to right. Use a tape measure to

double check. Once you are happy that

the Tray is in the correct position, fasten

all the nuts and bolts, both inside and

outside of the vehicle on all brackets

that were installed.

Fit the Plastic Nut Caps (Item 3 from

FAJK010 box) provided over all the

exposed bolts and close up all the roll

bar padding.

REMOVING YOUR RACK

13mm

3.1

Should you wish to remove your rack,

you will need to plug the holes you

drilled in the roof (Step 3.4), using the

supplied Sealing Plug Assemblies.

Remove the Tray, Front Uprights and the

Foot Rail, by reversing the instillation

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

in position.

10mm

13mm

FAJK010 / FAJK011_REV_A01

TAKE A TRIP

After your ﬁrst adventure, check that all nuts, bolts, screws and ﬁttings are tight. Re-tighten where needed. You'll ﬁnd a

small amount of settling has happened.

Go on many more adventures, periodically checking all nuts, bolts, screws and ﬁttings.

4.1

Front Runner can not recommend a maximum load carrying capacity. Please refer to your vehicle manufacturer's

recommendations

COMPLETION

5.1

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!

Be sure to tag us. We love to see our gear in action! #FrontRunnerOutfitters #BornToRoam

Share your adventures on:

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. FRONT RUNNER CANNOT BE RESPONSIBLE FOR IMPROPER LOADING BEYOND THE VEHICLE MANUFACTURER'S STATED LOAD CAPACITY.

Ce manuel convient aux modèles suivants

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