Front Runner FAJK002 Instruction Manual

ENG

180 min

Jeep Wrangler JKU 4 Door (2007-Current)

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.

FAJK002 / FAJK006

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

1 2 X Inner Roll Bar Clamp

2 2 X Outer Roll Bar Clamp

3 28 X M6 x 19 x 1SS Flat Washer

4 16 X Foam Seal Washer

5 16 X Aluminum Spacer

6 16 X M6 x 30 Hex Bolt

7 20 X M6 Nyloc Nut

8 8 X M6 x 20 Hex Bolt

9 20 X M6 Nut Cap

10 16 X M6 x 19 x 1SS Flat Washer

11 2 X Rear Support Bracket - 1LH + 1RH

12 2 X M8 x 75 Hex Bolt

13 2 X M8 Large Washer

14 2 X Middle Support Bracket - 1LH + 1RH

15 16 X Sealing Plug Assembly

IN THE BOX TOOLS NEEDED

T40

Torx Wrench

IN THE BOX

989

14L

14R

11R

11L

1GET ORGANIZED

FAJK002

13MM

10MM 10MM

13MM

6mm

22mm (7/8") Hole Saw

FAJK002 / FAJK006_REV_C00

17R

17L

1GET ORGANIZED

FIGURE 1.2

IN THE BOX

16 14 X M8 X 16 Hex Bolt

17 2 X Foot Rail - 1LH + 1RH

18 14 X M8 x 16 x 1.6SS Flat Washer

19 14 X M8 Nyloc Nut

20 14 X M8 Nut Cap

IN THE BOXIN THE BOX

FAJK006

FAJK002 / FAJK006_REV_C00

PREP FOR INSTALLATION OF INNER BRACKETS (FAJK002)

13mm

2.1

2.2

2.3

Loosen velcro, unzip and remove the

padding covering the roll bars.

Remove the wiring harness and plastic

clip from the roll bar.

Loosely attach the Rear Support Arms

(item 11) to the outside of the Roll Bar

Clamps using items M6 x 20 Hex Bolts,

M6 x 19 x 1SS Flat Washers and M6

Nyloc Nuts (Items 3, 7 & 8). Make sure

the foot faces the inside of the vehicle

and the contours of the foot match the

contours of the roof as shown.

Mark the position of the four holes in the

foot on the roof.

Once the holes have been marked

remove the Rear Support Arms.

Pilot drill the marked holes using a 6mm

drill bit.

Locate the two threaded holes on the

underside of the roll bar and fasten the

two halves of the Roll Bar Clamps (Items

1 & 2) to the roll bar using M6 x 19 z 1SS

Flat Washers and M6 x 20 Hex Bolts

(Items 3 & 8). Place the Outer Roll Bar

Clamp (Item 2) ﬁrst followed by the

Inner Roll Bar Clamp (Item 2).

10mm

6mm

FAJK002 / FAJK006_REV_C00

PREP AND INSTALLATION OF FOOT RAILS (FAJK006)

13mm

3.1

3.2

3.3

Locate the Foot Rail in position by lining

up the holes in the bracket with the

holes drilled in Step 2.3.

Place a M6 x 30 Hex Bolt (item 6) into

each hole to keep its location.

Once you are happy with your

measurements and alignment, mark the

four holes in the foot of the Foot Rail

onto the roof.

Remove the Foot Rail.

From outside the vehicle, using your

6mm drill bit, drill the four pilot holes

through the marks you just made.

Repeat Step 2.1 to 3.3 for the opposite

side.

Using a measuring tape and a rib in the

roof as a reference, adust the front of

the bracket so that the entire length of

the bracket is parallel with your

reference rib.

FRONT OF VEHICLE

SIDE VIEW OF FOOT RAIL

TOP VIEW OF FOOT RAIL

REAR FOOT

10mm

6mm

FAJK002 / FAJK006_REV_C00

FIT AND SECURE

13mm

3.4

3.5

3.6

Change from the 6mm drill bit to a

22mm hole saw. From the outside of the

vehicle drill all the 6mm holes (16 in

total) out to 22mm. Let the drill do the

work. You do not want to scratch or

damage your vehicle's roof. You may

wish to have a friend inside the vehicle

with a vacuum cleaner underneah where

you are drilling to catch all the dust and

keep your vehicle clean.

From the inside of the vehicle, in the

same position as where you just

inserted the bolt in Step 3.5, push the

Middle Support Bracket (Item 14)

through the hole in the roll bar padding

and loosely fasten it to the roll bar.

Please note that there is a left hand and

right hand bracket. The arrow on the

bracket must point to the rear of the

vehicle.

Pull back the padding around the roll bar

above the rear seats and insert an M8 x

75 Hex Bolt and M8 Large Washer (Items

12 & 13 from FAJK002 box) through the

hole as shown.

13mm

22mm

TIP - It is easier to do the next step if

you remove the roof.

FAJK002 / FAJK006_REV_C00

INSTALLATION OF REAR SUPPORT ARMS

13mm

4.1

Reﬁt and fasten the Rear Support Arms

as in Step 2.3

10mm

5PREP FOR RACK INSTALL (FAJK002)

5.1

5.2

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 4). Remove

the paper backing from the Foam

washer to expose the adhesive.

Insert the washer/spacer combination,

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.

NOTE: Use the worm slots to adjust the

height of the rear support brackets.

This will be important to create a

weatherproof Seal.

If not already assembled, assemble your

Tray as per the Universal Tray Assembly

Instructions (Document RRSTUNI)

NOTE: Before ﬁtting the Wind

Deﬂector, insert two M8 x 16 Hex

Bolts (Item 16 from FAJK006) or

(Item 1 from FAJK003) into the ﬁrst

slat (Combined Slat), using the

Machined slots. Slide a bolt to each

of the outer corners.

Half Rack Shown

80mm

FAJK002 / FAJK006_REV_C00

6.1

6.2

MOUNT YOUR TRAY

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 3, 6, 7 & 10

from FAJK002 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 9 from

FAJK002 box) provided over all the

exposed bolts and close up all the roll

bar padding.

11L

14L

13mm

PREP FOR RACK INSTALL (HALF RACK)5

5.3

After ﬁtting the wind deﬂectors, the tray

should still be upside down, loosely

mount the Foot Rails (Item 17L & 17R

from FAJK006 box) to the Tray using M8

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

Wahsers and M8 Nyloc Nuts (items 16,

18 & 19?. As before use the machined

slots to insert the hex bolts into the

Slats. The Foot Rail should be mounted

at the opposite end of the Tray to 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

FAJK002 / FAJK006_REV_C00

13mm

REMOVING YOUR RACK7

7.1

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.

12mm

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.

8.1

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

recommendations

FAJK002 / FAJK006_REV_C00

COMPLETION

INSTALL OTHER VEHICLE AND RACK ACCESSORIES

Now's the time to visit your favorite Front Runner Dealer in person or online.

9.1

Congratulations. You did it. Take a step back and admire your work!

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