Warn Rear Tire Carrier (66355).pdf

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Microsoft Word - 65805C0-pn65800.doc
INSTALLATION INSTRUCTIONS
For 65800, 65801, 66355, 69250, 69251 Rear
Bumper And Tire Carrier For Jeep XJ
Cherokee
Your safety, and the safety of others, is very important. To help you make informed decisions about safety, we have provided
installation and operating instructions and other information on labels and in this guide. This information alerts you to potential
hazards that could hurt you or others. It is not possible to warn you about all potential hazards associated with this product, you must
use your own good judgment.
CARELESS INSTALLATION AND OPERATION CAN RESULT IN SERIOUS INJURY OR EQUIPMENT DAMAGE.
READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND OPERATING INSTRUCTIONS BEFORE
INSTALLING AND OPERATING THIS PRODUCT.
This guide identifies potential hazards and has important safety messages that help you and others avoid personal
injury or death . WARNING and CAUTION are signal words that identify the level of hazard. These signal words
mean:
WARNING signals a hazard that could cause serious injury or death, if you do not follow
recommendations.
CAUTION signals a hazard that may cause minor to moderate injury, if you do not follow
recommendations.
This guide uses NOTICE to call attention to important mechanical information, and NOTE : to emphasize
general information worthy of special attention
NOTICE
Equipment Failure
Failure to observe these instructions could result in equipment failure.
Always Take time to fully read and understand this Installation Instruction and the related Warnings and
Cautions.
Always tighten all nuts and bolts securely, per the installation instructions.
Never exceed capacity of tire carrier. This tire carrier has a maximum tire carrying capacity of a 35” Tire.
Always periodically inspect bumper for damage or deformation. Any damage or deformation must be corrected
immediately.
NOTE
This installation requires cutting square holes to gain access to the sub-frame.
NOTE
This installation manual contains instructions for both 1984-1996 Cherokees and 1997-2001 Cherokees. Some steps are for
specific models and will be noted.
Read installation and operating instructions thoroughly.
PARTS LIST FOR 65800 (Rear Bumper For Tire Carrier)
PART NO.
QUANTITY
DESCRIPTION
65777
1
Bumper Center Section
65799
1
Left Hand Bumper End cap
65798
1
Right Hand Bumper End cap
65806
1
Bracket Kit
65770
1
LH Frame Bracket
65769
1
RH Frame Bracket
65768
1
Hardware Kit
1
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PARTS LIST FOR 65801 (Rear Bumper)
PART NO.
QUANTITY
DESCRIPTION
65777
1
Bumper Center Section
65809
1
Left Hand Bumper End cap
65810
1
Right Hand Bumper End cap
65806
1
Bracket Kit
65770
1
LH Frame Bracket
65769
1
RH Frame Bracket
65768
1
Hardware Kit
PARTS LIST FOR 66355 (Tire Carrier)
PART NO.
QUANTITY
DESCRIPTION
65780
1
Tube Assembly
62929
1
Tire Mount
65802
1
Shaft Support Bracket
65767
1
Hardware Kit
65786
1
Detent Pin
PARTS LIST FOR 69250 (Rear Bumper For Tire Carrier)
PART NO.
QUANTITY
DESCRIPTION
69246
1
Bumper Center Section
69244
1
Left Hand Bumper End cap
69245
1
Right Hand Bumper End cap
69249
1
Bracket Kit
69247
1
LH Frame Bracket
69248
1
RH Frame Bracket
65768
1
Hardware Kit
PARTS LIST FOR 69251 (Rear Bumper)
PART NO.
QUANTITY
DESCRIPTION
69246
1
Bumper Center Section
70131
1
Left Hand Bumper End cap
70132
1
Right Hand Bumper End cap
69249
1
Bracket Kit
69247
1
LH Frame Bracket
69248
1
RH Frame Bracket
65768
1
Hardware Kit
TORQUE SPECIFICATIONS
BOLT SIZE TORQUE
1/4 inch 8-10 ft. lbs.
3/8 inch 32-35 ft. lbs.
7/16 inch 50-54 ft. lbs.
1/2 inch
55-65 ft. lbs.
2
65805C0
5/8 inch
80-90 ft-lbs.
1. Remove the factory bumper and bumper brackets from vehicle. On 1997-2001 Models
with plastic side fender skirting behind the rear wheels, remove the plastic side fender
skirting when removing the bumper and keep the plastic side skirting for later
installation.
2. Using a hack saw blade, die grinder or saws-all, cut access holes in the back of the sub
frame to gain clearance for the frame brackets. See Figure 1 . Carefully trim the square
hole so the edge is flush with the inside of the sub-frame tubes. Be sure to only trim to
the inside edges of the sub frame walls. The bottom of the cutout must be flush to
insure the brackets fit properly. Once the sides and bottom are trimmed, the sheet metal
flap can be pushed in and bent upward into the sub-frame.
USE A SAWS-ALL, HACK SAW
BLADE, OR DIE GRINDER TO
CUT THE SHEET METAL TO
GAIN ACCESS TO THE INSIDE
OF THE SUB-FRAME
FACTORY NUT PLATE,
SOME MODELS.
Figure 1, Access Holes in Sub-frame
WARNING
Cutting operations can cause flying metal chips. WEAR SAFETY GOGGLES.
Flying metal chips can cause eye injury.
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3. Once the square holes are cut, remove the back three bolts on the bottom of the sub-
frame on the driver’s side and back four bolts of the sub-frame on the passenger’s side.
See Figure 2 . Some vehicles may not have the factory nut plates. If it does not have
them, use the ones supplied in the bracket kit. Use the three-nut plate for the driver’s
side and the four-nut plate for the passenger’s side.
FACTORY BOLTS. REMOVE BACK 3
ON DRIVERS’ SIDE AND BACK 4 ON
PASSENGERS’ SIDE.
Figure 2, Diagram of Sub-frame and Bolt locations
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4. After removing the bolts, pry up the nut plate located inside the sub-frame. This plate is
riveted to the bottom of the sub-frame. Use a chisel and hammer to break the rivet.
Install the frame brackets between the nut plate and the frame. Be sure that the
remaining part of the rivet is flush with the bottom of the sub-frame. See Figure 3 .
INSERT CHISEL UNDER NUT
PLATE AND HAMMER UNTIL
THE RIVET BREAKS.
Figure 3, Factory Nut Plates
5. Install the frame brackets. Loosen the upper shackle bolt on the rear leaf spring. This
bolt is attached to the sub-frame. Do not remove the bolt; loosening it is required for
installation of frame brackets. Slide the frame brackets into the sub-frame. Insert the
frame brackets into the sub frame tubes so that the nut plates are inside of the frame
bracket. Use a screwdriver to hold the nut plate down on the inside of the frame bracket
and re-install the factory bolts through the sub-frame, bumper bracket, and nut plate.
If you are not using factory nut plates, place the supplied nut plate inside the frame
bracket and use the supplied ½” hardware.
When all of the bolts are loosely installed in the bottom, install the factory bumper bolts
that go in the back panel of the uni-body through the frame bracket and into the factory
holes. Snug all of the bolts and measure from the outside of the passengers’ side to the
outside of the drivers’ side. See Figure 4 .
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