yj metalcloak front fender installation instructions 1987-90

(c) Copyright 2009, Armored Works, LLC, All Rights Reserved Assembly Instruction Form

MetalCloak YJ Front Fender Installation Instructions 1987-90 Rev. C of 14

Assembly Step Detailed Instructions Picture/Illustration

READ INSTRUCTIONS IN FULL BEFORE INSTALLATION.

QUESTIONS? Call 916-631-8071

At MetalCloak we work hard to ensure every step of the MetalCloak experience is an incredible one. Part of that experience is the ease of installation of our products. While we design and plan for most contingencies, there are occasions the equipment under your hood may be different based on different configurations and years. In anticipation of such a contingency, our inner fender wells are made of alumi-num, so it will be easy for you to take a standard household drill and punch any necessary holes into the fender well. We ask that you provide feedback and send pictures if you find any part of our instructions that do not match your particu-lar Jeep. And if you have any difficulties at all, please feel free to give us a call. Our instructions can only be as good as the feedback we receive from our growing list of customers. Thank you and enjoy your MetalCloak Products! IMPORTANT NOTE: The tube of Silver Anti-seize provided should be used on all bolts—only a small amount is needed. This article is sold without warranty expressed or implied. No warranty or representation is made as to this products ability to protect the user from injury or death. The user assumes that risk. The effectiveness, warranty and longevity of this equipment are directly related to the manner in which it is INSTALLED, USED and/or MAINTAINED. THE USER ASSUMES ALL RISK.

1. Remove Battery

Tools/Parts • Wrench • Ratchet • Sockets

a. Loosen positive and negative battery cables. b. Remove positive cable then negative cable. c. Loosen and remove battery hold down. d. Remove battery.




2. Remove Inner Fender Well Components


a. Remove all components attached to inner fender well.

b. Hardware for most stock components will not be needed as new hardware is supplied.

c. Keep all bolts that hold both fenders and the battery total qty 18.

3. Remove Battery Fuse Box

Tools/Parts • Flat Head Screw

Driver • Ratchet • Sockets


b. Remove Battery and Fuse Box (Pic 3.1)

Battery

3.1

Fuse box

2.1




2. Remove Inner Fender Well Components

3. Battery Tray, Air Intake, Coolant, Washer



b. Hardware for most stock components will not be needed as new hardware is supplied.

c. Keep all 13mm bolts that hold both fenders and the battery and accessory trays on. Also keep hardware for Air Intake.

d. Air intake, Horn, Coolant, Washer (Pic 3.1)

4. Remove Fenders

Tools/Parts • Ratchet • Sockets

a. Un-bolt and remove lower fender tubes. (2 per side– will not be re-used.)

Air Intake

Horn Coolant Washer

3.1




4. Remove Fenders


a. Un-bolt and remove lower fender tubes. (2 per side– will not be re-used.)

5. Loosen Grill

Tools/Parts • Wrench (5/8)

a. Loosen 3 grill mount points. (See Pics 5.1 and 5.2)

5.1

5.2




6. Cut Battery Tray Bracket

Tools/Parts • Hack Saw • Vise

a. Measure 1/2” from top 1/4” hole and draw cut line. (See Pic 6.1)

b. With hack saw cut battery tray bracket to size.

7. Remove Air Filter Mount from Stock Fender

Tools/Parts • 3/16” Drill

a. Drill out 3 rivets from stock fender. (See Pic 7.1) b. Remove mounting bracket. c. Mounting bracket will be remounted on new in-

ner fender.

6.1

7.1




8. Install MetalCloak Inner Fenders


a. Install the inner fender by threading the 2 front bolts using the original hardware.-Grill side (See Pic 8.1) DO NOT tighten yet!

b. Repeat on other side.

9. Install MetalCloak Rear Support Bracket

Tools/Parts • Ratchet • Small Ratchet Exten-

sion • Sockets • 5/32 Allen Wrench • 1/4x20 Nut-1 • 1/4” Washer-1 • Button head screw

1/4x20x5/8”-1

a. Mount MetalCloak rear support bracket to Jeep on tub side using original hardware.

b. Attach rear support bracket to inner fender using supplied hardware. (See Pic 9.1)

8.1

9.1




10. Install MetalCloak Fender Frame

a. Fender frame mounts under inner fender. (See Pic 10.1)

b. Use one grill bolt and one tub bolt to hold in place and then install the remaining bolts.

11. Attach Fender Frame to Inner Fender

Tools/Parts • Ratchet • Small Ratchet Exten-

sion • 5/32 Allen Wrench • 1/4x20 Nut-9 • 1/4” Washer-9 • Button head screw

1/4x20/5/8”-9

a. Attach inner fender to fender frame using 1/4” hardware supplied, 9 sets per side. (See Pic 11.1)

b. Insert screws and washers on the underside of the fender frame to bolt the frame to the inner fender.

c. DO NOT tighten yet! d. Repeat steps on other side.

10.1

11.1




12. Finalize Fender Mount-ing

a. Set MetalCloak fender flush to the tub. b. Repeat on passenger side. c. Align MetalCloak fender to grill, working both

sides-checking hood alignment. d. Adjust upper hood brackets as needed. e. Tighten lower grill mount.

13. Re-Install Air Filter Bracket

Tools/Parts • 1/4x20 Nut-3 • 1/4” Washer-3 • Button head screw

1/4x20/5/8”-3

a. Angle of air filter bracket tabs will need to be adjusted for mounting.

b. Using supplied hardware, re-install air filter bracket onto inner fender. (See Pic 12.1)

14. Re-Mount Air Filter a. Mount air filter on air filter bracket using original hardware. (See Pic 13.1)

b. Reconnect hosing.

13.1

14.1




15. Re-Mount Horn


1/4x20x5/8”-1

a. Mount horn onto inner fender using supplied hardware. (See Pic 15.1)

16. Re-Mount Windshield Wiper Fluid Reservoir Bracket


1/4x20x5/8”-3

a. Angle of bracket tabs will need to be adjusted for mounting.

b. Mount windshield wiper fluid reservoir bracket onto inner fender using supplied hardware. (See Pic 16.1)

17.

15.1

16.1




17. Re-Mount Windshield Wiper Fluid Reservoir

a. Mount windshield wiper fluid reservoir to bracket using original hardware. (See Pic 17.1)

b. Re-connect all hosing.

18. Install Access Panel

Tools/Parts • Button head screw

3/8x16x1/2”-5

a. Install access panel onto fender frame using supplied hardware. (See Pic 18.1)

b. Repeat steps for other side.

17.1

18.1




19. Re-Mount Battery Bracket and Fuse Box

a. Mount battery bracket using original hardware. b. Mount fuse box using original hardware. (See

Pic 19.1)

19.1




20. Re-Install Engine cool-ant Reservoir


1/4x20x5/8”-2 • Button head screw

1/4x20x1”-1

a. Install engine coolant reservoir to inner fender using supplied hardware. (See Pic 20.1)

NOTE: Coolant Overflow Reservoir is relocated to passenger side of vehicle.

21. Re-Insert Hose to En-gine Coolant Reservoir

a. Insert hose to engine coolant reservoir. (See Pic 20.1 -21.1)

NOTE: May need to reposition hose direction.

20.1

21.1




23. Install Hood Latches

Tools/Parts • Stock Hood Latches-2 • Stock Rubber Sops-2

a. Insert rubber stops and pull snug with pliers. b. Mount and bolt down hood latches. Be sure to

adjust before tightening. (See Pic 23.1)

22. Install Battery a. Place battery on battery tray. (See Pic 22.1) b. Secure battery using factory bracket. c. Re-connect negative battery cable and then

positive.

23.1

22.1




24. Clean Up/ Complete Installation

a. Clean up and enjoy your new MetalCloak Body Armor!




Note: On some Wranglers the hood may rub against the fender. This is caused by the variability of the hood manufacture combined with our design to maximize tire clearance. The following an easy fix.

What to Do: Together with a friend, place your hands together and gently push at the exact point on the hood where the rubbing occurs as seen in Figure A & B. Push in about 1”. The hood will flex back out and provide the 1/4” of clearance needed as seen in Figure C. Pushing in the center of the hood may cause the rear of the hood to flare out. This is easily remedied by pressing firmly in at the point shown in Figure D.

C

B

A

D

yj metalcloak front fender installation instructions 1987-90

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