TJ/LJ Metal Cloak Front Fender Flare Install Rev. A Page 1 of 16 READ FITTING INSTRUCTIONS IN FULL BEFORE INSTALLATION 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 THE RISK. By purchasing this product and opening the packaging, purchasers expressly acknowledge, understand and agree that they take, select and purchase these Metal Cloak products from Armored Works, LLC., its affiliates, distributors, and agents (collectively, Armored Works, LLC) as is and with all faults. The entire risk as to the quality and performance of these Metal Cloak parts is with the purchasers. Working on your car can be a dangerous activity. If you are unsure of what you are doing, please leave mechanical or Safety critical work to a skilled mechanic. We take no responsibility for the incorrect use and/or installation of Metal Cloak products. Non powder coated products may contain oils and contaminants and should be cleaned and properly prepped before paint. It is recommended to paint prior to installation. 1. Remove Battery Wrench 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
Rev. A Page 2 of 16 2. Remove Inner Fender Well Components Wrench Sockets a. Remove all components attached to inner fender well. (Pass. Side 2.1, Driver Side 2.2) 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 Intake. 2.1 2.2
Rev. A Page 3 of 16 3. Remove Fenders 13mm Socket a. Un-bolt and remove fenders. There should be 14 bolts (RED dots in Pic 3.1) total for each fender. b. Save hardware for installation of the new fenders. 3.1 4. Remove Battery and Accessory Tray 13mm Deep Socket Flat Head Screw Driver a. Un-bolt battery tray top from the mounting bracket. There should be 4 bolts. (Pic 4.1) *Battery tray also has a sensor in it that needs to be disconnected before removal.* b. Un-bolt battery tray mounting bracket. There should be 2 bolts and 2 nuts. (Pic 4.2) c. Repeat steps a and b on driver side. d. Use a flat head screw driver to remove clips from the battery and accessory tray. (Pic 4.3) e. Save clips, bolts, and tops for installation of new fenders. 4.1
Rev. A Page 4 of 16 4.2 4.3
Rev. A Page 5 of 16 5. Loosen Grill Wrench (5/8 and 13mm) a. Loosen 3 grill mounting points. (Pic 5.1 and 5.2) 5.1 5.2
Rev. A Page 6 of 16 6. Re-Mount Black Box Black Vacuum Box Small Philips Screw (1) Small Nut (1) Small Washer (1) a. Locate screw, nut and washer. (Pic 6.1) b. Bolt black vacuum box to battery tray on passenger side using supplied hardware. (Pic 6.2) 6.1 6.2
Rev. A Page 7 of 16 7. Install REV 111 Battery Tray 13mm Deep Socket Factory Mounting Nuts and Bolts Factory Clips a. Install clips in positions shown for passenger bracket. (Pic 7.1 *Driver is mirror image of passenger.*) b. Install Metal Cloak battery tray and accessory tray using factory mounting hardware. c. DO NOT fully tighten bolts at this time. d. DO NOT install tray tops at this time. 7.1 8. Install REV 111 Inner Fenders 13mm Socket a. Install the inner fender by threading the front bolts first then the rear inside (Pic 8.1 and 8.2) DO NOT tighten yet! b. Repeat on other side. 8.1
Rev. A Page 8 of 16 8.2 9. Install REV 111 Fender Frames 13mm Socket Small Ratchet Extension 5/32 Allen Wrench a. Fender frame mounts under fender liner. b. Use one grill bolt and one tub bolt to hold in place and then install the remaining bolts. (Pic 9.1) c. Once all other frame bolts are in, bolt up the remaining 2 bolts that go thru the liner into the battery bracket. (The inner fender well needs to be lined up for this and may touch the hard brake lines on the driver side. This is ok as the lines are flexible and not much movement should be needed.) d. Open Hardware Pack 400 9.1
Rev. A Page 9 of 16 e. Remove 4 small button head cap screws and 4 washers. f. Insert screws and washers on the underside of the fender frame to bolt the frame to the liner. (Pic 9.2) g. DO NOT tighten yet! h. Repeat steps a-g on other side. 9.2 10. Align and Tighten Fenders 13mm Socket Small Ratchet Extension 5/32 Allen Wrench a. Tighten the tub bolts so that the fender frame can still move but is not loose. (Pic 10.1) b. Line up the height of the back of the fender by centering the range. You can do this by removing one of the bolts to see when the hole in the fender is centered with the hole in the tub. c. Tighten one of the center tub bolts. d. Line up the side of the fender with the side of the tub then tighten the other center bolt. 10.1
Rev. A Page 10 of 16 e. Once both center bolts are tight, tighten the top and bottom tub bolts. f. At this time tighten the small button head cap screws that hold the inner fender to the fender frame. g. Tighten battery / accessory tray top bolts then bottom bolts followed by the bolts that hold the inner fender and fender frame to the battery and accessory brackets. h. Push down on one side of the grill so that the grill mount on that side touches the frame then tighten the front fender frame bolts. (Pic 10.2) i. Push the front of the inner fender towards the engine to maximize room between it and the sway bar and then tighten the front inner fender bolts. (Pic 10.3) j. Repeat steps a-i on the other side. 10.2 10.3
Rev. A Page 11 of 16 11. Re-Mount Intake Intake Box Straight Bracket (1) Bent Bracket (1) 7/32 Allen Wrench 7/16 Wrench 10mm Wrench 8mm Nut Driver Hardware Pack 450 a. Remove the top of the intake box and the filter from the lower portion. b. Mount the Straight Bracket to the bottom of the intake box in location 1 (Pic 11.1) c. Remove the metal spacer from the bolt in location 3 (Pic 11.1) d. Open Hardware Pack 450. e. Bolt the intake box to the inner fender using holes 1,2, and 5 (Pic 11.2) f. Re-assemble air box. 11.1 11.2 12. Re-Mount Fuse Box 5/32 Allen Wrench 7/16 Wrench Flat Head Screw Driver a. Use flat head screw driver to remove fuse box from mounting bracket. b. Mount bracket, using hardware from pack 450, to inner fender using holes 3, 4,
Rev. A Page 12 of 16 and 6. (Pic 11.2) c. Once bracket is mounted remount fuse box to bracket. 13. Re-Mount Vacuum Center 5/32 Allen Wrench 7/16 Wrench Pliers or Vice Grips a. Route horn, light, and windshield washer wires under vacuum center. b. Bolt down bracket with to inner fender using holes 1, 3, and 4. (Pic 13.1) c. Use pliers to tweak the back piece of the bracket for a better fit (Pic 13.2 and 13.3) then bolt down to inner fender using hole 2. (Pic13.1) 13.1 13.2
Rev. A Page 13 of 16 13.3 14. Re-Mount Washer Fluid Tank Bent Bracket (1) 5/32 Allen Wrench 7/16 Wrench a. Mount bent bracket to inner fender using hole 7. (Pic 13.1) b. Route wires under bracket. c. Bolt washer fluid tank to holes 7, 6, and the remaining hole on the bent bracket. (Pic 13.1) 15. Re-Mount Horn 5/32 Allen Wrench 7/16 Wrench a. Bolt down horn using holes 8 and 9 on inner fender. (Pic 13.1)
Rev. A Page 14 of 16 16. Install Battery / Accessory Tray Top Stock Battery Tray Top Stock Accessory Tray Top Stock Mounting Bolts 13mm Socket a. Bolt battery tray to battery tray bracket on passenger side. b. Re-connect sensor on battery tray. (Pic 16.1) c. Bolt accessory tray to accessory tray bracket on driver side. 16.1 17. Install Battery Battery Battery Tie Down Wrench (Sizes May Vary a. Place battery on battery tray. b. Secure battery using factory bracket. c. Re-connect negative battery cable and then positive. 18. Install Access Panel Access Panel (2) Hardware Kit 400 Allen Wrench (5/32 and 7/32) a. Bolt access panel to fender frame using small button head screws. (Pic 18.1) b. Center panel and then snug screws. DO NOT over tighten. c. Insert 3 large button head cap screws on each fender frame
Rev. A Page 15 of 16 on the outside corners of the access panel. (Pic 18.1) 18.1 19. Install Hood Latches Stock Hood Latch (2) Stock Rubber Stop (2) Pliers 15mm Socket a. Insert rubber stops and pull snug with pliers. b. Mount and bolt down hood latches. Be sure to adjust before tightening. (Pic 19.1) 19.1
Rev. A Page 16 of 16 20. Clean Up Zip Ties 13mm Socket 5/8 Wrench a. Fasten all loose wires with zip ties as well as signal wires until signal kit is available. b. Tighten grill mounts. c. Find rock pile. d. Enjoy your bolt on, trail engineered body armor from Armored Works. e. Thank you for your purchase! 20.1