Installation Manual

ManualsBrandsBushwacker ManualsAutomotiveBushwacker 10919-07 Jeep Flat Style Fender Flare - Set of 4

6710 N CATLIN AVE. • PORTLAND, OR 97203 • 503-283-4335 • 1-800-234-8920 (USA AND CANADA) • FAX 503-283-3007

Bushwacker only approves installing the ﬂ ares according to these

written instructions with the hardware provided. WARNING: 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. DO NOT USE: Loctite, SuperGlue,

or similar products on the hardware or the ﬂ ares.

Fit: Verify the ﬁ t of the ﬂ ares to vehicle. (Some ﬁ ling, sanding, or

cutting may be necessary to ensure proper ﬁ t).

Painting: (Optional) if paint is desired it must be done prior to installing ﬂ ares

on vehicle. Clean outer surface with a good grade degreaser. DO NOT USE

LACQUER THINNER OR ENAMEL REDUCER AS A DEGREASER. Wipe

outer surface thoroughly with a tack rag prior to paint. Application of plastic

adhesion promoter for TPO plastic as per your paint system manufacturer’s

recommendations is required. Paint ﬂ ares using a high quality enamel, or

polyurethane automotive paint. If painting edge trim (not recommended),

use a ﬂ ex additive.

Performance: Using larger Tires may increase the area required to

turn the vehicle. Some Tire/Rim combinations may require lowering

bump stops and or installing steering stops to prevent tire from

contacting ﬂ are.

Exhaust System: Modiﬁ cations may be necessary to maintain a

minimum 4” clearance between ﬂ ares and exhaust pipes. (Exhaust

gases should not vent directly onto ﬂ ares)

Metal Protection: All exposed fasteners and bare metal should

be treated with rust resistant paint BEFORE installing ﬂ ares. Spray

inner fender wells with undercoating AFTER ﬂ are attachments have

been completed.

Decals: Flares may interfere with existing decals on vehicle. If you

wish, remove decals prior to installation of ﬂ ares.

STEP 1 – PRIOR TO INSTALLATION

Jeep Wrangler JK

2-Door

Utility Knife

Pneumatic Hand Saw or Metal Hacksaw

(optional, Step 12, 61)

#2 Phillips Drive Bit

Electric Drill

5/16” Drill Bit

#2 Phillips Screwdriver

Socket Wrench

1/2”, 11/32”, & 10mm Sockets

1/2” Wrench

8” Socket Extension

Needle Nose Pliers or Vise Grips

Scratch Awl (optional Step 44, 81)

Wire Cutter & Stripper

22-18 Gauge Wire Crimp

Soft Wiping Cloth/Shop Towels

Heat Gun

Pry bar/Claw Hammer

Safety Glasses

Grease Pencil

Pan Head

Screw, 26 pcs

8-32 Nylok

Nut, 4 pcs

1.25” Washer,

4 pcs

1/4” Panel

Retainer,

10 pcs

LED Side

Marker Light,

2 pcs

Speed Clip,

26 pcs

Alcohol Wipe,

4 pcs

Side Reﬂ ex

Reﬂ ector, 2 pcs

Edge Trim

Tool, 1 pc

8-32 Machine

Screw, 4 pcs

Female Bullet

Connector, 4 pcs

Plastic Push

Retainer,

20 pcs

5/16” Hex Head

Bolt, 20 pcs

Edge Trim,

243 in.

.700” Washer,

20 pcs

5/16” Nylok

Nut, 20 pcs

Set Part #10919-07 Patent No. D623,103

Rev-5 04-14-11

TOOLS FOR EASY INSTALLATION:

•

To claim a warranty, you must provide Proof

of Purchase.

LIMITED LIFETIME WARRANTY AGAINST

ANY MANUFACTURING DEFECTS

•

9. 11.

14.

12.

16.

6.3.

13. 15.

5. 7.

Included in Hardware Kit

FLAT STYLE FENDER FLARE

10.

Summary of content (17 pages)

PAGE 1
Jeep Wrangler JK 2-Door Set Part #10919-07 Rev-5 04-14-11 Patent No. D623,103 STEP 1 – PRIOR TO INSTALLATION A) Bushwacker only approves installing the flares according to these written instructions with the hardware provided. WARNING: 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. DO NOT USE: Loctite, SuperGlue, or similar products on the hardware or the flares.
PAGE 2
STEP 2 - EDGE TRIM INSTALLATION (DO NOT INSTALL EDGE TRIM ON THE SMALLER INNER PIECES! ONLY THE FLARE PIECES NEED IT!) The edge trim for this application is double-tape edge trim so special care needs to be taken while installing. There is red vinyl backing on the inside of the edge trim where it will adhere to the flare and red vinyl backing on the outside where it will adhere to the vehicle. The following steps only concern where the edge trim will adhere to the flare.
PAGE 3
Remove light receptacle from light lens housing, letting it hang free of the housing. 5 Once flare is free of fender, disconnect light connector. This will allow the flare to come away from fender completely. Save connector for reinstallation. 7 Use a pry tool or flat head screwdriver to remove four plastic fasteners. 4 Starting at front of flare, pull firmly to release flare and splash shield from fender, working your way to the back. You will hear popping noises as clips release. It is okay.
PAGE 4
9 10 Inside of Wheel Well Reinstall the splash shield, in preparation for marking before cutting, using supplied 1.25” Washer on factory bolt/washer assembly and reinstall through factory threads in sheet metal (2 locations). 11 Using sheet metal as a guide, mark the rear portion of the splash shield with a grease pencil in preparation for trimming. The splash shield should be flush with the sheet metal after being trimmed.
PAGE 5
15 Locate the flat flare front inner pieces. The driver side front inner pieces are marked D1, D2, & D7. The passenger side front inner pieces are marked P1, P2, & P7. 16 Install a speed clip at each clip location on the inner pieces, centering them on the predrilled holes with threaded portion on inside (6 locations). NOTE: Clips may slide out of place. Try pinching the metal tightly onto the inner piece with pliers.
PAGE 6
21 22 Upper Style Line Bolt on left: Properly tightened; lower edge of inner piece runs straight Bolt on right: Overtightened; lower edge of inner piece bows down; if accidentally overtightened, remove inner piece completely before reinstalling Picture on left: Top edge of inner piece along upper style line Picture on right: Top edge of inner piece tucked below upper style line; this forcibly angles and deforms inner pieces and flare is difficult or impossible to install 23 24 Hole Locations Secure i
PAGE 7
Upper Style Line 27 Step 2 While holding the inner piece in place, install a plastic push retainer through holes in both inner pieces. Inner piece should rest along upper style line of sheet metal radius and not below it: see step 22. 29 Reinstall inner splash shield by first placing a supplied plastic push retainer through the mounting hole in the sheet metal and splash shield as shown in picture. 31 Reinstall factory fastener removed in Step 2 in location shown.
PAGE 8
33 Use wire strippers to strip away approximately 3/8” of wire covering from the factory installed side marker lamp wires. 35 Seal heat shrink tubing on wire using a heat gun. 37 Secure the side marker light to the outer flare with 8-32 screw, 8-32 nut, and washer using a #2 Phillips bit and a 11/32” socket with 8” extension (2 places). NOTE: If you are having trouble putting the washer and nut on the screw, use needle nose pliers.
PAGE 9
39 Before installing the outer flare, install speed clip on metal frame angle support bracket at top center of wheel well. Make sure that it is centered over the factory slot with threaded portion facing up. 41 Peel back 1-2” of red liner on each end of the edge trim and bend toward the outside of the flare. 43 Place the outer flare over the inner pieces and push until snug against the sheet metal. Make sure that the side marker light wires are inside the flare.
PAGE 10
45 46 Press Firmly Hold flare in place on fender and start a pan head screw into each hole location and through speed clip on inner structure and metal frame angle support bracket (7 locations). Do not tighten. 47 Peel outer tape liner from the double-tape edge trim. Push down lightly on the fender flare to create a small gap between the sheet metal and the edge trim. This makes it easier to pull the red liner.
PAGE 11
51 Attach one side reflex reflector to the side of the vehicle by peeling off the adhesive backing and pressing it firmly onto the cleaned vehicle surface. NOTE: Once reflector has adhered it cannot be repositioned. 52 Completed front driver’s side flare installation. Rear Flare Installation Procedures (Driver’s Side) 53 Using a pry tool, pliers, or flat head screwdriver, remove four plastic fasteners from inside of splash shield.
PAGE 12
57 Thoroughly clean the exposed metal fender with a damp cloth then dry. 59 Using sheet metal as a guide, mark the splash shield with a grease pencil in preparation for trimming. The splash shield should be flush with the sheet metal after being trimmed. NOTE: If trimmed too little, flare won’t fit; if trimmed to much, shield won’t stay behind flare. 61 Using a metal hacksaw, pneumatic hand saw, or other suitable cutting device, trim the splash shield along the marked lines.
PAGE 13
63 Sand mounting tabs flat using an angle grinder or sand paper. 65 Use a drill and 5/16” drill bit to drill through mark made on rear mounting tab. 67 Install a speed clip at each clip location on the inner pieces, centering them on the predrilled holes with threaded portion on inside. (6 locations) NOTE: Clips may slide out of place. Try pinching the metal tightly onto the inner piece with pliers. 64 Place a grease pencil mark 1/8” below the hole on the rear mounting tab.
PAGE 14
Upper Style Line 69 70 Hole Locations Step 2 While holding the inner piece in place, install a plastic push retainer in each hole location. Inner piece should rest along upper style line of sheet metal radius and not below it: see step 22. NOTE: Foam insulation may need to be trimmed out of the holes. Secure inner piece D4 (and P4 for passenger side installation) to the sheet metal using the following 4 STEPS: Step 1 Position inner piece on fender, aligning with existing factory holes in sheet metal.
PAGE 15
Upper Style Line 75 Step 2 While holding the inner piece in place, install a plastic push retainer. Inner piece should rest along upper style line of sheet metal radius and not below it: see step 22. 77 Before installing the outer flare, make sure that the speed clips on the inner pieces are centered over the predrilled holes. 79 Peel back 1-2” of red liner on each end of the edge trim and bend toward the outside of the flare.
PAGE 16
81 Use a scratch awl (or another pointed tool) to line up the speed clips with the outer flare holes (6 locations). If needed, use a flashlight to better locate the speed clips. 83 After all screws have been started, tighten the pan head screws by firmly pressing the flare toward the vehicle while tightening. 85 Firmly press the flare toward the vehicle for 10 seconds to adhere the tape to the vehicle surface. Repeat this process moving along the entire length of the flare.
PAGE 17
87 Use the hooked end of the edge trim tool to check for full adhesion. Do this by sliding it along the top of the edge trim to visually verify that the tape is adhered to the vehicle surface. Repeat step 82 if the tape is not fully adhered to the vehicle surface. 88 Completed rear driver’s side flare installation. 6710 N CATLIN AVE.