AEV Roof Rack User manual

INSTALLATION GUIDE
Roof Rack
AEV30209AC
Last Updated: 07/02/18

PLEASE READ BEFORE YOU START
TO GUARANTEE A QUALITY INSTALLATION, WE RECOMMEND READING THESE INSTRUCTIONS
THOROUGHLY BEFORE BEGINNING ANY WORK. THESE INSTRUCTIONS ASSUME A CERTAIN
AMOUNT OF MECHANICAL ABILITY AND ARE NOT WRITTEN NOR INTENDED FOR SOMEONE NOT
FAMILIAR WITH AUTO REPAIR.
ii
This product is covered under the AEV Parts Limited Warranty, a copy of which can be found at aev-conversions.com/warranty.
INCLUDED PARTS QTY REQUIRED TOOLS
Aluminum Planks 5Basic hand tools
Right Side Rail 1Rivet gun
Left Side Rail 1
End Rails 2
Corners 4
Corner Closeout Plate 4
Corner End Rail Connectors 4
Aluminum Crossbars 5
Roll Bar Brackets 4
Satellite Antenna Bracket 1
Stantion Assemblies 4
AEV logo Decal 4
Alcohol Swab 1
Hardware
NOTE: roof rack may degrade satellite radio reception
Note: The included parts shown below are not necessary
for this application and may be discarded.

1
part i. Platform assembly
1Fit Corner T Mouldings to the Frame End extrusions. A
rubber mallet can be used to carefully tap the Moulding
in place.
M5x16mm Plastite Screws.
Fit the Plank Inserts into end of plank at both ends.
Orientation of inserts is critical. Carefully tap the Inserts
into place with a rubber mallet.
2
Nyloc Nuts must face up.
Holes face out.
Faces into Plank.
onto planks and fasten together using hardware supplied.
Do the same for the other end.
5
4
Place side extrusions upside down in position, slide corner mouldings onto T moulding and into extrusion simultaneously.
3
Fit all four cover plates to corner mouldings as shown.
M6x16mm Dome Socket
Head Screw.
M6 OD 12.5mm Flat Washer.
Corner Moulding.
Corner Moulding Cover.
M5x16mm Plastite Screw.
M5x16mm Plastite Screws.
6With the assembly still upside down, place the Crossbars in at an angle and rotate under the lip of the Frame Side
Extrusions. Note: Be sure to use the correct order of Crossbars for the installation as seen bellow ( the AEV Type 1
Before Rotation After Rotation
Cut corners
facing outside
of tray
Crossbar sitting
under bottom lip and
aligned with slot.
Crossbar Type 1 (clear bag)
Crossbar
Type 2
(green bag)
onto planks and fasten together using hardware supplied.
Do the same for the other end.
5
4
Place side extrusions upside down in position, slide corner mouldings onto T moulding and into extrusion simultaneously.
3
Fit all four cover plates to corner mouldings as shown.
M6x16mm Dome Socket
Head Screw.
M6 OD 12.5mm Flat Washer.
Corner Moulding.
Corner Moulding Cover.
M5x16mm Plastite Screw.
M5x16mm Plastite Screws.
6With the assembly still upside down, place the Crossbars in at an angle and rotate under the lip of the Frame Side
Extrusions. Note: Be sure to use the correct order of Crossbars for the installation as seen bellow ( the AEV Type 1
Before Rotation After Rotation
Cut corners
facing outside
of tray
Crossbar sitting
under bottom lip and
aligned with slot.
Crossbar Type 1 (clear bag)
Crossbar
Type 2
(green bag)

2
onto planks and fasten together using hardware supplied.
Do the same for the other end.
5
4
Place side extrusions upside down in position, slide corner mouldings onto T moulding and into extrusion simultaneously.
3Fit all four cover plates to corner mouldings as shown.
M6x16mm Dome Socket
Head Screw.
M6 OD 12.5mm Flat Washer.
Corner Moulding.
Corner Moulding Cover.
M5x16mm Plastite Screw.
M5x16mm Plastite Screws.
6With the assembly still upside down, place the Crossbars in at an angle and rotate under the lip of the Frame Side
Extrusions. Note: Be sure to use the correct order of Crossbars for the installation as seen bellow ( the AEV Type 1
Before Rotation After Rotation
Cut corners
facing outside
of tray
Crossbar sitting
under bottom lip and
aligned with slot.
Crossbar Type 1 (clear bag)
Crossbar
Type 2
(green bag)

3
7
8
9
Place channel nut within the crossbar as shown below and rotate 90 degrees. Place M8x15mm Flat Wahers on top of the
but do not tighten at this stage. Repeat this process for both ends of each crossbars.
M8 x15mm Flat Washer.
M8x20mm Dome Head Screw.
M8 Spring Washer.
M8 Flat Washer OD17.
M8 Channel Nut.
Align crossbars so that the washer sits centred over the slot, you may need to tap the crossbar into position with a rubber
mallet. Once the crossbar is in position tighten bolt with allen key provided.
Washer aligned with slot.
Install the Alloy Locking Tabs. Be aware of the orientation of the of the Single Alloy Tabs on the sides of the Platform.
M6x20mm Security Head Screw.
M6 Spring Washer.
M6 OD 16mm
Flat Washer.
Locking Alloy Tab
Single.
Locking Alloy Tab.
Note the orientations of the Single Locking Alloy Tabs.

4
7
8
9
Place channel nut within the crossbar as shown below and rotate 90 degrees. Place M8x15mm Flat Wahers on top of the
but do not tighten at this stage. Repeat this process for both ends of each crossbars.
M8 x15mm Flat Washer.
M8x20mm Dome Head Screw.
M8 Spring Washer.
M8 Flat Washer OD17.
M8 Channel Nut.
Align crossbars so that the washer sits centred over the slot, you may need to tap the crossbar into position with a rubber
mallet. Once the crossbar is in position tighten bolt with allen key provided.
Washer aligned with slot.
Install the Alloy Locking Tabs. Be aware of the orientation of the of the Single Alloy Tabs on the sides of the Platform.
M6x20mm Security Head Screw.
M6 Spring Washer.
M6 OD 16mm
Flat Washer.
Locking Alloy Tab
Single.
Locking Alloy Tab.
Note the orientations of the Single Locking Alloy Tabs.

5
Part ii. Installing roll–BAR brackets
1. Remove hard top.
2. Remove sound bar.
3. Unzip roll bar padding and pull back to expose factory brackets (g. 5.1 and 5.2). Remove bolts
(shown in gray) and save. On the front, right side, detach the satellite radio antenna (if equipped) from
it’s factory location and disconnect the wire connector. Be sure to save hardware.
Figure 5.1 front Figure 5.2 rear
satellite radio antenna
4. Replace roll bar padding.
5. Position AEV brackets over roll bar padding to align with the corresponding holes in the roll cage from
the bolts previously removed. Mark the hole’s position on the padding and cut through the pad using
a sharp awl or utility knife to allow access to them.
6. Place AEV brackets in position and secure loosely with the factory bolts removed previously (g. 7.1
and 7.2). DO NOT tighten until all adjustments are made in the following steps.
7. Use the measurements in Figure 8 to adjust the bracket positions.

6
Figure 7.1 front Figure 7.2 rear
Figure 8
43 inches
(109.22 cm)
32 1/4 inches
(81.92 cm)
Front of Vehicle

7
Part III. RELOCATING SATELLITE ANTENNA
1. Attach satellite radio antenna, using its original hardware, to the AEV provided bracket.
2. Remove all trim from passenger (right) side B-pillar and oor
3. Locate antenna wiring. and remove from B-pillar at all attachment points.
4. Relocate wiring up the A-pillar (windshield frame)
5. Once proper routing has been established, excess wiring will need to be secured out of harm’s way (g. 9).
Figure 9

8
6. Fasten AEV bracket with satellite radio antenna to the windshield frame with the supplied bolt, nut,
and washer through existing hole in the top of the A-pillar (g. 10). Pre-2013 JKs may or may not have
this existing hole. If your vehicle does not, you will need to drill a 5/16” hole. The remaining hole in
the AEV bracket should line up with the existing hole in the A-pillar for the plastic r-tree that secures
the A-pillar trim. You can use this hole to locate the bracket on the A-pillar for drilling location.
7. Reinstall factory trim.
Figure 10

9
Part IV. Attaching platform to hard top
a. Marking hard top
1. Reinstall Hard top on Vehicle. Top should be completely secured with all factory fasteners to ensure
proper position for drilling holes.
2. Press brackets up ush to the inside of the hard top and tighten all accessible fasteners.
3. Using the holes in the bracket, mark drilling positions on the inside of the hard top (8 holes).
b. drilling hard top
1. Remove hard top (you can now tighten any bracket fasteners that were not accessible before).
2. Drill pilot holes at marked locations with a small drill bit.
3. Using a 5/16” drill bit, drill nal holes through hard top.

10
C. assemble stantions
1. Pre-Assemble all four stantions as shown (g. 11) leav-
ing nger tight at this time. NOTE: Additional hardware is
included that is not required for this application. Adhere
the adhesive backed foam to the stantion foot, cut holes
for the bolts to pass through, and trim tight to foot. Adhere
the AEV Logo Decals to the stantions using the supplied
alcohol swab to rst clean the surface.
2. Reinstall Hard top on Vehicle. Top must be completely
secured with all factory fasteners.
3. Position stantions on hard top inserting bolts through the
newly drilled holes.
4. Working from the inside of the vehicle, fasten lock nuts
onto stantion bolts and nger tighten
D. Attach platform
1. Lift platform onto vehicle. Channel cutouts should be at
the rear of the vehicle.
2. Insert stantion channel nuts into platform cross bars.
Stantions connect to crossbars #1 and #4 if counting from
the rear of the vehicle.
3. Center platform Left and Right over vehicle.
4. Tighten all fasteners, leaving the saftey allen head screw
for last.
5. Reinstall sound bar.
adhesive foam
non-locking nuts
AEV logo decal
Figure 11

11
Important Information:
Maximum carrying capacity: AEV can not recommend a weight carrying capacity. Refer to
your Jeep owner’s manual.
It is essential that all bolt connections are checked after driving a short distance when you rst
install your AEV Roof Rack. Bolt connections should be checked again at regular intervals (proba-
bly once a week is enough, depending on road conditions, usage, loads, and distances travelled).
Make sure to fasten your load securely. Please ensure that all loads are evenly distributed and
that the center of gravity is kept as low as possible.
USE ONLY NON-STRETCH FASTENING ROPES OR STRAPS.
SENSITIVITY TO CROSSWINDS BEHAVIOR IN CURVES AND BRAKING.
The handling characteristics of the vehicle change when you transport a load on the roof. For
safety reasons, we recommend you exercise extreme care when transporting wind resistant
loads, special consideration must be taken into account when braking.
Note for dealers and tters. It is your responsibility to ensure instructions are given to the end
user or client.
comments or questions?
American Expedition Vehicles
www.aev-conversions.com
email: [e-mail]
ph: 248.926.0256
Be sure to visit our forum at: http://forum.aev-conversions.com