Thank you for the purchase of our JK Front Trail Doors. We have made these from 6061-T6 aluminum and reinforced them with stiffeners at the top that double as a comfortable armrest and support for Rugged Ridge uppers. Center supports have also been added to give you a design that combines high strength and light weight. These are the perfect solution for those times when you need a bit more comfort and would like to leave your OEM doors protected in a safe place. Rear latch doors are difficult to open and our solution mimics the OEM doors with the unique remote front lever handle and rear latch knob. The use of a quality rotary latch on the inside affords a rattle-free experience and protects them from trail damage with an uncluttered look. Enclosed you will find a set of instructions that will enable you to install the Trail Doors with a minimum of fuss and little more than basic hand tools. If you attempt the install and find yourself not understanding what needs to be done, please contact Savvy Off Road with your technical issue. Please take the time to read these instructions and familiarize yourself with the hardware parts list before attempting your installation. The instructions are lengthy, but are written to provide you with a step-bystep guide to install the Savvy Trail Doors with minimal issues. Parts and tools needed for installation- Outside of the parts supplied in the kit, you will need personal safety equipment, assorted hand tools, allen wrenches, and a phillips screw driver to complete the installation. Cleaning and Painting - Depending on your climate and environment you may choose to paint your Trail Doors. Cleaning with brake cleaner or mineral spirits is recommended to remove the material ink markings on door skins as well as good prep if painting. Should you choose to paint your Trail Doors, it is best to do so while fully disassembled. Page 1
Hardware Parts List Hardware Quantity 10-24 x 5/8" Flat Head Philips (A) 20 10-24 Flange Nuts (B) 20 1/4-20 x 1/2" Socket Head Cap Screw ( C ) 2 1/4-20 x 3/4" Socket Head Cap Screw (D) 4 1/4-20 x 3/4" Button Head Socket Screw ( E) 4 1/4-20 Nylock Nut (F) 4 1/4 Washer (G) 4 7/16-20 x 2" Stainless Bolts (H) 4 7/16-20 Nylock Nut (I) 4 1/4 Nylock Washer (J) 2 Cables (K) 2 8/32 x 1/2 Pan Head Philips (L) 2 8/32 Nylock Nuts (M) 2 12-24 x 3/4" Buttonhead Socket Screws (N) 8 12-24 Flange Nuts (O) 8 #8 Washer (P) 2 Black Door Knobs (Q) 2 Door Handles (Left & Right) ( R) 2 Door Handle Brackets (S) 2 Door Latches (Left & Right) (T) 2 Door Latch Brackets (Left & Right) (U) 2 Door Hinges (Left & Right) (V) 4 Door Hinge Backing Plate (W) 4 Door Skin (Left & Right) (X) 2 Upper Arm Support (Left & Right ) (Y) 2 Lower Arm Support (Left & Right) (Z) 2 Page 2
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Step 1: Starting on the Left Door organize the following components to assemble the Left Door. (1) Left Door Skin (X) (1) Upper and (1) Lower Left Arm Supports (Y & Z) (9) 10 24 x 5/8 Flat head Philips screws (A) (9) 10-24 Flange Nuts (B) Use a philips screwdriver and 3/8 wrench to assemble the upper and lower arm supports onto the door skin with the above listed screws and flange nuts making sure to align the middle hole in the upper and lower arms as this will affect installation of Rugged Ridge uppers, if used. Page 4
Step 2: Now gather the following components for the Left Door Handle Assembly. (1) Left Door Handle (R) (1) Left Door Handle Bracket (S) Assemble the Left Door Handle to the Left Door Handle Bracket with the attached pan head screws using a flat screwdriver as shown in the picture. Page 5
Step 3: Using the following components, assemble the left door latch as follows (1) Door latch (T) (1) Door latch bracket (U) (2) ¼ - 20 X ¾ socket head cap screw (D) Using a 7/16 wrench, attach latch to latch bracket. DO NOT TIGHTEN AT THIS TIME, adjustments will need to be made. Page 6
Step 4: Now attach the assembly to the door using (2) ¼ - 20 x ¾ button head socket screws (E), (2) ¼ - 20 nylock nuts (F) and (2) ¼ washers (G) with a 5/32 allen wrench and 3/8 wrench. The latch jaws should be facing the bottom of the door. DO NOT FULLY TIGHTEN as adjustments will need to be made. Step 5: Next, gather these components in order to attach the inner door knob and cable to the door latch and outer door handle. (1) Black door knob (Q) (1) ¼ - 20 x ½ socket head cap screw (C) (1) Cable (K) (1) Nylon washer (J) (1) 8/32 x ½ pan head screw (L) (1) 8/32 nylock nut (M) (1) #8 washer (P) Page 7
Place Nylon washer listed above (J) on screw (C) and insert through either loop of cable (K) then place bolt through outside hole and attach with door knob (Q) with knob on top. (see photo ). Next place washer (P) on screw (L) and insert through opposite end of cable and put through the arm of the outer door handle and attach using nylock nut (M). Step 6: At this time you are now ready to install hinges on the door using the components listed below (2) Door hinges (V) (2) Door hinge backing plates (W) (4) 12 24 x ¾ button head screws (N) (4) 12 24 x ¾ flange nuts (O) Page 8
Turn door panel so outer side is visible, align hinge plates (W) on upper and lower locations as indicated in photo and line up hinges (V) on top of plates (W). Slide screws (N) through holes on top of hinges and tighten with flange nuts (O) to back side of door panel until snug, adjustments will need to be made when aligning door onto vehicle. Page 9
Step 7: At this time you are ready to test fit door to Jeep using (2) 7/16 20 x 2 stainless bolts (H) and (2) 7/16 20 nylock nuts (I). Make adjustments necessary to have even spacing between door and surround, then tighten the (4) 12 24 x ¾ button head screws (N). Adjust the latch assembly so it closes securely and tightly to striker on the Jeep and tighten bolts. Once door is installed and all adjustments have been made, make sure all hardware is fully tightened. Repeat above steps on right door to assemble and install right side. You have now completed your Savvy JK Front door installation. Page 10