Installation Manual

ManualsBrandsBushwacker ManualsAutomotiveBushwacker 10916-07 Jeep Cut-Out Fender Flare - Set of 4

Jeep Cherokee ZJ

Bushwacker only approves installing the ﬂ ares according to these

written instructions with the hardware provided. WARNING: Failure

to install according to these instructions will invalidate the warranty.

This includes, but is not limited to using alternative installation

methods, hardware, or materials. DO NOT USE: Loctite, SuperGlue,

or similar products on the hardware or the ﬂ ares.

Fit: Verify the ﬁ t of the ﬂ ares to vehicle. (Some ﬁ ling, sanding, or

cutting may be necessary to ensure proper ﬁ t).

Painting: (Optional) if paint is desired it must be done prior to installing

ﬂ ares on the vehicle. Clean outer surface with a good grade degreaser.

DO NOT USE LACQUER THINNER OR ENAMEL REDUCER AS A

DEGREASER. Wipe outer surface thoroughly with a tack rag prior

to paint. Application of plastic adhesion promoter for TPO plastic as

per your paint system manufacturer’s recommendations is required.

Paint ﬂ ares using a high quality enamel, or polyurethane automotive

paint. If painting edge trim (not recommended), use a ﬂ ex additive.

Performance: Using larger Tires may increase the area required to

turn the vehicle. Some Tire/Rim combinations may require lowering

bump stops and or installing steering stops to prevent tire from

contacting ﬂ are.

Exhaust System: Modiﬁ cations may be necessary to maintain a

minimum 4” clearance between ﬂ ares and exhaust pipes. (Exhaust

gases should not vent directly onto ﬂ ares)

Metal Protection: All exposed fasteners and bare metal should

be treated with rust resistant paint BEFORE installing ﬂ ares. Spray

inner fender wells with undercoating AFTER ﬂ are attachments have

been completed.

Decals: Flares may interfere with existing decals on vehicle. If you

wish, remove decals prior to installation of ﬂ ares.

Grease Pencil or Scribe

Heavy Hammer

Reciprocating Saw

Pliers

Electric Drill

3/32”, 3/16” Drill Bits

#2 Phillips Driver Bit

Utility Knife

Putty Knife

Adhesive Remover Disk

Black Spray Paint

Palm Sander

Socket Wrench

3/8” Socket

Torque Wrench

Impact Wrench

Masking Tape

Partner (for part of rear installation)

Tuﬂ ock,

14 pcs

#45 Torx

Screw, 36 pcs

Mounting

Bracket, 4 pcs

#45 Torx Bit

Driver, 1 pc

Edge Trim

Tool, 1 pc

Washer,

16 pcs

Nut,

10 pcs

Edge Trim,

304 in.

3/4” Screw,

10 pcs

Rubber Grom-

met, 36 pcs

#8 Pan Head

Screw, 16 pcs

Set Part #10916-07

Rev-2 03-11-10

STEP 1 - PRIOR TO INSTALLATION

TOOLS FOR EASY INSTALLATION:

6710 N CATLIN AVE. • PORTLAND, OR 97203 • 503-283-4335 • 1-800-234-8920 (USA AND CANADA) • FAX 503-283-3007

•

To claim a warranty, you must provide Proof

of Purchase.

LIMITED LIFETIME WARRANTY AGAINST

ANY MANUFACTURING DEFECTS

THESE INSTRUCTIONS INVOLVE CUTTING THE

FENDERS OF THE VEHICLE. IT IS IMPORTANT TO

READ ALL INSTRUCTIONS PRIOR TO THE CUTTING

AND INSTALLATION OF THESE FLARES.

•

1. 8.

11.

6.3.

10.

5. 7.

Included in Hardware Kit

Summary of content (19 pages)

PAGE 1
Jeep Cherokee ZJ Set Part #10916-07 Rev-2 03-11-10 THESE INSTRUCTIONS INVOLVE CUTTING THE FENDERS OF THE VEHICLE. IT IS IMPORTANT TO READ ALL INSTRUCTIONS PRIOR TO THE CUTTING AND INSTALLATION OF THESE FLARES. STEP 1 - PRIOR TO INSTALLATION A) Bushwacker only approves installing the flares according to these written instructions with the hardware provided. WARNING: Failure to install according to these instructions will invalidate the warranty.
PAGE 2
STEP 2 - EDGE TRIM INSTALLATION (FRONT FLARE ONLY, SEE REAR INSTALLATION INSTRUCTIONS FOR REAR APPLICATION) A) If painting flares, see section C of Step 1 - Prior to Installation. Peel two to three inches of red vinyl backing away from edge trim tape. Applying the adhesive side of the edge trim to the inner side of the flare, affix the edge trim to the top edge of the flare (the portion that comes in contact with the vehicle).
PAGE 3
5 Remove one christmas tree fastener from bottom of lower side cladding. 6 Remove lower factory side cladding piece from front fender. 7 8 Splash Shield Spring Remove three christmas tree fasteners from wheel well splash shield. Fasteners are white in picture for visibility. 9 Pull the splash shield away from rear area of the fender and tuck it into the spring. 10 3 mm 40 mm Style Line Pinch Weld Remove and save sound dampening foam from inner wheel well.
PAGE 4
11 12 50 mm Remove and save factory bolt from bottom rear of front wheel well. 13 Install factory bolt saved during step 11 through the hole drilled in step 12. 15 Bend wheel well lip out with pliers to roughly match outer face of fender. Approximately 50 mm back from lip, predrill a hole through the pinch weld using a 3/16” drill bit. 14 Starting at the style line, cut along horizontal marks from wheel well to vertical line with reciprocating saw.
PAGE 5
17 Push splash shield back into place. 18 Attach wheel well liner by putting a tuflock through the two uppermost holes from which christmas tree fasteners were removed in step 7. 19 20 Vertical Line Starting at style line, use pliers to bend cut tabs into wheel well over the splash shield. The bend point of the tabs should be on the vertical line drawn in step 10. 21 Sand the chipped paint along bent edge of the wheel well.
PAGE 6
23 24 300 mm Mark fender flange 300 mm up from crease of pinch weld. Mark horizontal lines below 300 mm mark inbetween the spot welds on the pinch weld. Cut along horizontal lines in pinch weld using reciprocating saw. 25 26 Metal Inner Wheelhouse Flange Pound the fender flange back over to match the face of the metal inner wheelhouse with a heavy hammer. 27 Using spray paint, repaint the sanded edge of the wheel well flange.
PAGE 7
29 Hold flare in place on vehicle, mark hole locations onto fender through holes drilled in pockets of flare. 31 Using a stubby Phillips screwdriver, remove screw from rocker panel at forward side of rear wheel well. 33 Mark a line parallel with the forward edge of the rear wheel well from the door seam down to pinch weld along the rocker panel. Using a utility knife, make several cuts to cut off end of rocker panel along marked line. 30 Drill holes in fender at marks with a 3/16” drill bit.
PAGE 8
35 Put #45 Torx screw through hole in pocket of flare and secure with rubber grommet using supplied #45 Torx bit. The bit fits into a 5/16” socket with a 3-6” extension for drill or air ratchet. Drive screw into grommet until tight. Repeat for all pockets. 36 Hold flare in place on fender. Using the provided torx bit driver, start each screw into holes drilled in step 30. Once all screws have been started, snug screws to vehicle. 37 Torque to 24 in•lb (2 ft•lb).
PAGE 9
41 Completed front flare installation. Rear Flare Installation Procedures (Driver’s Side) Rear Main Flare 42 43 Screw Head Nuts & Washers Nut & Washer 3 Style Lines Screw Heads Bumper Piece Bolt rear main flare to bumper piece using 3/4” screws and nuts. Use supplied washers to sandwich plastic between screw and nut (three holes). Make screw direction as shown in picture. Parts are marked on the inside. Driver’s side: LR1 for main flare, LR2 for bumper piece.
PAGE 10
46 47 Possible Gapping There are three different styles of bumper for this vehicle. The bumper piece may not fit exactly. Gapping may occur. The bumper piece is made to accomodate all three styles. 48 Trace the wheel well edge of bumper flare onto bumper. 49 7 mm Trace a second line 7 mm offset from previous line toward rear of vehicle. 50 Using the reciprocating saw, cut bumper along offset line. Clean edge with a utility knife.
PAGE 11
52 Hold flare in place on vehicle, mark hole locations onto fender through holes drilled in pockets of flare. 54 53 Drill holes in fender and bumper at marks with a 3/16” drill bit. 55 Holes to Mark Hold the flare and bumper piece to the vehicle so that the bumper piece barely overlaps the cut bumper and mark the locations of the lowest hole and second highest hole on the bumper. Hole locations are white in picture for visibility. NOTE: See step 46 about gapping between bumper and bumper piece.
PAGE 12
58 Using a Phillips screw driver and a 3/8” socket wrench, tighten the nut and screw together. NOTE: Some adjustments may need to be made to the bracket for proper flare positioning so make sure it is not completely tightened. 60 Hold flare in place on fender. Using the provided torx bit driver, start each screw into drilled holes. 62 Put splash shield back in place and use a tuflock to secure to vehicle through hole near the shock in wheel well.
PAGE 13
64 Secure flare to fender with the #8 pan head screws through holes in flare and into predrilled holes. A drill with a #2 Phillips driver works well. 66 Remove rear tire using an impact wrench. Remove small factory side cladding piece from “dog leg” area of rear wheel well. 67 Hold factory side cladding to “dog leg” are of wheel well and trace a line at the top of the cladding on the vehicle.
PAGE 14
70 Bend wheel well lip out with pliers to roughly match outer face of fender. 72 Open door. Sand the chipped paint along bent edge of the wheel well. 74 Using spray paint, repaint the sanded edge of the wheel well. 71 Starting at style line, bend cut tabs into wheel well with a heavy hammer. The bend point of the tabs should be on the vertical line drawn in step 68. 73 With door open, run masking tape along door edge. Close the door and tape over the side cladding and rocker panel.
PAGE 15
76 Remove part and drill marked locations with 3/32” drill bit. 78 Close rear door. Hold door piece in place on door aligning it with rear main flare and trace outer edge of flare onto body side molding. Part is marked on the inside. Driver’s side: LR3 for door piece. 80 Remove the body side cladding from the vehicle. First, lift up by top edge to release top of cladding. Then pull bottom of cladding straight out from side of vehicle.
PAGE 16
82 Remove cladding clip closest to the rear wheel well. 84 Reinstall top portion of side cladding clip on vehicle. 86 Drill holes at marks in door with 3/16” drill bit. 83 Using a reciprocating saw, cut the cladding clip just below the top section. 85 Hold door piece in place on door aligning it with rear main flare and mark hole locations onto door through holes drilled in pockets of flare.
PAGE 17
88 Put screw through hole in pocket of door piece and secure with rubber grommet using supplied #45 Torx bit. Drive screw into grommet until tight. Repeat for all pockets. 89 Position door piece in place on door. Using the provided torx bit driver, start each screw into drilled holes. Once all screws have been started, snug screws to vehicle. 90 91 1/4” Gap Check the alignment of the door piece in relation to the main rear flare.
PAGE 18
94 Drill marked hole through rocker panel plastic and into sheet metal underneath with 3/16” drill bit. 96 Put screw through hole in pocket of rocker panel piece and secure with rubber grommet using supplied #45 Torx bit. Drive screw into grommet until tight. 98 Align rocker panel piece to bottom of door piece by hand and hold in position. Have a partner open the door. 95 For edge trim application on rocker panel piece, follow steps as listed at the beginning of this instruction set.
PAGE 19
100 Drill marked holes with 3/32” drill bit. 101 Fasten top of rocker panel piece to door sill with #8 pan head screws. Close door and verify alignment with door piece. Loosen screws and adjust if necessary. 102 Drill 3/32” holes through holes in bottom of rocker panel piece through factory plastic and sheet metal. 103 Fasten bottom of rocker panel piece with #8 pan head screws in holes drilled. A drill with a #2 Phillips driver works well. 104 Reinstall the tire using an impact wrench.