Manual

ManualsBrandsOR-Fab ManualsCar85209 JEEP WRANGLER JK SWING AWAY SPARE TIRE CARRIER WITH ROTOPAX CONTAINERS

3651 N Highway 89 • Chino Valley, AZ 86323

(928) 636-7080 • www.orfab.com

JEEP WRANGLER JK

SWING-A-WAY TIRE/CAN CARRIER

WITH ROTOPAX 3 GALLON CANS

2007-2012 JK Kits # 85209

NOTE

These instructions are for both the can and non-can

style carriers. Installation of both systems are identical

with the only difference being the shape of the main

carrier itself. All pictures in these instructions refer-

ence the Tire/Can carrier model.

WARNING

Read and understand all instructions, warnings, cau-

tions, and notes in this sheet and in your owners man-

ual before you begin the installation of this tire/tire-can

carrier kit.

CAUTION

Proper installation of a ORFab tire carrier kit requires

knowledge of the factory recommended procedures for

disassembly and assembly of original equipment com-

ponents. We recommend that the factory shop manual

and any special tools necessary to your vehicle be on

hand during the installation. Installation of this tire car-

rier lift kit without proper knowledge of the factory rec-

ommended procedures may affect the performance of

these components and the safety of your vehicle. We

strongly recommend that a certified mechanic familiar

with the installation of similar components install this

tire carrier kit.

ROTOPAX Swing-Away Tire/Can Carrier w/Gas Cans 1 Kit # 85209

Before starting installation

1. Carefully read all warnings and instructions com-

pletely before beginning.

2. Verify all parts have been received in this kit by

checking the parts list at the end of this document.

3. Only install this kit on the vehicle for which it is

specified. If anytime during the installation you

encounter something different from what is outlined

in the instructions, call technical support at (928)

636-7080.

4. Park the vehicle on a clean, dry, flat, level surface

and block the tires so the vehicle cannot roll in either

direction.

Tools needed:

1. Angle Drill

2. 1” hole saw OR Unibit 335

WARNING

The load rating for these tire-can/tire carriers is a

MAXIMUM of 175 lbs. Please be aware that some tire

and wheel combinations along with gas cans and hi-lift

jacks can exceed

this MAXIMUM rating.

WARNING

Some states require a center high-mount stop lamp by

law. OR Fab recommends that you consult your state

laws before you install this kit. If required you’ll need

optional (CHMSL) kit# 87017.

NOTE

Kit parts are prefaced by the word kit and appear in

bold print.

Summary of content (9 pages)

PAGE 1
Before starting installation WARNING The load rating for these tire-can/tire carriers is a MAXIMUM of 175 lbs. Please be aware that some tire and wheel combinations along with gas cans and hi-lift jacks can exceed this MAXIMUM rating. 3651 N Highway 89 • Chino Valley, AZ 86323 (928) 636-7080 • www.orfab.com JEEP WRANGLER JK WARNING Some states require a center high-mount stop lamp by law. OR Fab recommends that you consult your state laws before you install this kit.
PAGE 2
Prepare to install kit 3. Remove tail lights. a. Remove Tail lights from body. Only inner screws toward the tailgate on each light need to be removed. 1. Remove spare tire. 2. Remove 3rd tail light and prep tailgate. Tail Light a. Remove factory spacer tire/third brake light mount. Remove factory assembly Inner Screws Jeep Body Tailgate Jeep Body b. Remove grommet and wire harness from tailgate. Light Opening Grommet Harness Wiring Harness b. Unplug lights from Harness. Tailgate c.
PAGE 3
will no longer be able to to be used due to new tail gate position when tail gate is fully opened. . a. Mark and grind out area shown on factory tailgate hinges to allow clearance for kit bolt (8mm & tapered washer) and wrench during install. Remove Two T30 Bolts Clearance this area Door Guide Hinge a. Remove both upper and lower tailgate hinges with a T50 Torx bit. NOTE Die grinder and rotary file work best for this task. b. Hinge should open and close with clearance of bolt head and 13mm wrench.
PAGE 4
a. On inner two holes of hinge, Install using kit bolts (8mm-1.25 x 50mm) with taper washers (8mm). Do not tighten at this time. b. Find the center of the door chanel and measure from inner lower corner of body up 3 7/8” for first hole location and 10 7/8” for second hole location center punch and drill 7/16” hole on each as shown. (Note: Be sure to measure against flat sheet metal surface and not on top of body seam puddy.
PAGE 5
g. Tighten all installed hardware in previous steps. Use this hole 9. Drill and hole saw for landing block. a. From under-inside of body center punch remaining bracket hole on the rear inner body and drill a 1/8” pilot hole. Inner Left Rear Quarter Panel drill 1/8” hole d. Align foot of bracket to location shown here and install kit bolt (1/4” x 1”) with hardware. kit landing block mount bracket WARNING Careful to keep drilling straight through as you will drill two layers of body.
PAGE 6
10. Install kit landing block to new hole in body support bracket with kit bolt (1/2” x 2”), spacer (1/2” x1”), and hardware. Snug but do not tighten. wave washer “shim”, 1/2” sae washer, 1/2” lock nut, 1” spacer & 1.395” spacer) kit Wave Washer kit landing block kit Spacer kit Tire Carrier kit Bolt, (1/2” x 2”) kit Brass Washer kit Spacer NOTE NOTE Place washers and spacers in order shown below. If you have space or gap in the pivot washers use wave washers or extra washers included for shimming.
PAGE 7
c. Now open carrier rack and tailgate to tighten inner hinge plate bolts. f. Install on the back side of upper and lower hinge plate using kit nut (8mm flange) and tighten (exclude upper outer longer bolt for next step.) kit Hinge Plate Tighten kit 8mm flange nuts d. Tighten Landing block position so hook area of block just has enough clearance for landing bar of rack, block is slotted for this adjustment.
PAGE 8
c. From top side inside of body enlarge hole to 3/8” drill and install kit bolt (3/8” x 1”) with hardware and tighten. b. Use the location of the kit lower bump-stop on the tire carrier to position the kit 2” x 2” stainless steel stick pad on the tailgate. Kit Tire Carrier Drill to 3/8” and install kit 3/8” x 1” bolt Kit Lower Bump-stop Kit 2” x 2” Stainless Steel Stick Pad 15. Reinstall quarter panel inner foam liner and tail lights Tailgate 18. Install Kit Rotopax mount onto Kit carrier bracket. 16.
PAGE 9
NOTE After installing tire and cans to rack, carrier may seem to sag at latch end. Set pre-load to rack by adjusting hinge plate landing bar to landing block is just above center of landing area. This will set pre-load after weight is applied and will close properly.