Fab Fours JTOR-02 User manual

Installation manual
Gladiator Overlanding Rack Extension
Product number: JTOR-02
Application: 2020 Jeep Gladiator

IMPORTANT SAFETY GUIDE | Your safety and the safety of others is very important.
SAFETY PRECAUTIONS
In order to help you make informed
decisions about safety, we have provided
the following warnings, safety precauons,
installaon instrucons, and other important
informaon to alert you to potenal hazards
that could hurt you or others.
Please do a job safety analysis before each
task to idenfy potenal hazards for your
situaon and remove/protect against them.
Use own good judgment and take your me.
• Failure to observe the following warnings
and instrucons provided in this manual
could lead to severe injury and/or death.
• For professional installaon only. Careless
installaon and/or operaon can result in
serious injury, death, and/or equipment
damage. All liability for installaon and use
rests with the user or consumer.
WARNINGS
• Always remove jewelry and wear eye
protecon.
• Always use extreme cauon when jacking
up a vehicle for work. Set emergency brake
and use re blocks. Locate and use the
vehicle manufacturers designated liing
points. Use jack stands.
• Always use appropriate and adequate care
in liing components into place.
• Always ensure components will remain
secure during installaon and operaon.
• Always wear safety glasses when installing
this kit. A drilling operaon will cause
ying metal chips. Flying chips can cause
serious eye injury.
• Always use extreme cauon when drilling
a vehicle. Always disconnect power before
welding. Thoroughly inspect the area to
be drilled (on both sides of material when
possible) prior to drilling, and relocate any
objects that may be damaged.
Check packaged materials immediately upon
arrival to ensure that all listed parts are included
and undamaged.
Read and understand all warnings, safety
precauons, and instrucons before installing
this product.
SENSORS FIELD OF VIEW MAY BE ALTERED WITH
USE OF THE REPLACEMENT BUMPER.
• Fab Fours, Inc. only approves installing this
product according to these wrien instrucons
with the hardware provided. Failure to install
according to these instrucons will invalidate
the warranty. This includes, but is not limited
to, using alternave installaon methods,
hardware, or materials.
• This product is for o road use only.
• Always use extreme cauon when welding
a vehicle. Thoroughly inspect the area to
be welded (on both sides of material when
possible) prior to welding, and relocate any
objects that may be a re hazard. When
welding in a cab, make sure the interior
surfaces are covered (e.g., welding blanket)
and a re exnguisher is at hand.
• Always use extreme cauon when cung and
trimming during ng.
• Always ghten all nuts and bolts securely per
installaon instrucons.
• Always route electrical cables carefully. Avoid
moving parts, components that become hot,
and rough or sharp edges.
• Always insulate and protect all exposed wiring
and electrical terminals.
• Perform regular inspecons and maintenance
on mounts and hardware.

Table of contents
SAFETY / DISCLAIMER
TABLE OF CONTENTS
A MESSAGE FROM THE OWNER
GETTING STARTED
PROVIDED MATERIAL
INSTALLATION
CONTACT
2
3
4
5
6
8
13

A message from the owner
Fab Fours’ was born out of a passion for customizing vehicles and a love of the outdoors. Our
engineering team uses the latest 3D design soware to turn new product ideas into reality. In our
factory, designs come to life with the combinaon of cung edge technology for metal cung
and forming and an American workforce that puts its’ heart and pride into every product.
From design and manufacturing, to quality and delivery, Fab Fours’ mission is to be the market
leader for steel truck and jeep accessories. We make sure a quality product is delivered on me,
more than expected, beer than expected to our customers.
Enjoy your new Fab Fours product. Welcome to the family!
Greg Higgs
Founder, Fab Fours

5
Before you begin the installaon process of your new Fab Fours product, we suggest
laying out all materials and parts on a pad or protecve surface.
Failure to fully account for all components before beginning installaon may leave vehicle
immobile unl part is acquired. Refer to the next pages as an inventory check.
Getting started

Provided materials
• 1/2” socket wrench
• 9/16” socket wrench
• 5/32” allen wrench
• 3/16” allen wrench
• T40 star-p socket
TOOLS REQUIRED
Disassemble the vehicle where you
can catalog and store everything.
We suggest labeling and bagging all
the OEM bolts when removing from
the vehicle. Failure to keep track of
parts could lead to an inability to
properly reinstall components.
Organization
We recommend two people
perform the installaon as items
are heavy and may need to be held
in place while installing.
Assistance
JTOR-02 IM
IM
50211-HW
HW
KIT
Hardware kit | 50211
Fab Fours
Identification
Component
Description
QTY
50211-HW M6 x 1.0 x 50mm Buon Head Cap Screw, Stainless
Steel
2
50211-HW M6 Lock Washer, Stainless Steel 2
50211-HW M8 x 1.25 x 35mm Buon Head Cap Screw, Stainless
Steel
4
50211-HW M8 Lock Washer, Stainless Steel 4
50211-HW 1/2” Tall Spacer, Aluminum 2
50211-HW 1/4” Tall Spacer, Aluminum 4
502110-HW 3/4” x 9/16” Adhesive Rubber Bumper 4
502110-HW 5/16”-18 Yellow Zinc Hex Head Bolt, Grade 8 4
50211-HW 5/16” Yellow Zinc Hex Nut, Grade 8 4
50211-HW
50211-HW
50211-HW
50211-HW
5/16” Yellow Zinc Flat Washer, Grade 8
5/16” Yellow Zinc Lock Washer, Grade 8
5/16”-18 Hex Head Bolt, Stainless Steel
5/16” Hex Nut, Stainless Steel
8
4
20
20
22075 22076
22077
21950 x2
Foam
Seal
61724 x2
22081 22080 22079 22078
22101

7
Fab Fours
Identification
Component
Description
QTY
50211-HW 5/16” Flat Washers, Stainless Steel 46
50211-HW 5/16” Lock Washer, Stainless Steel 20
50211-HW 3/8”-16 Yellow Zinc Hex Head Bolt, Grade 8 6
50211-HW 3/8” Yellow Zinc Hex Nut, Grade 8 6
50211-HW 3/8” Yellow Zinc Flat Washer, Grade 8 12
50211-HW 3/8” Yellow Zinc Lock Washer, Grade 8 6
502110-HW #8-32 Buon Head Bolt, Stainless Steel 4
502110-HW #8 Nylock Hex Nut, Stainless Steel 4
50211-HW #8 Flat Washer, Stainless Steel 8
Hardware kit | 50211

INstallation
1. Place with the JTOR-02 tube assemblies
(22075-22076) on top of the bed rail mounng
assemblies and use three (3) 5/16” buon
head bolts with at/lock washers and nuts to
aach them with a 1/2” socket wrench. Repeat
on opposite side. (Use hardware from the
JTOR-01 kit 50190-HW). Figure 1.
2. Use a 5/16” yellow zinc hex head bolt, at/
lock washers and nuts in the back of the tube
assemblies (50211-HW). Figure 2
Figure 1
3. Loosely install the center cross bar (22077)
using six (6) 5/16” stainless steel buon head
bolt, at/lock washer, and nuts with a 3/16”
allen and 1/2” socket wrench (50211-HW). Do
not ghten the bolts at this me. Figure 3.
NOTE: If assembling the JTOR-01 and
JTOR-02 at the same me: Follow Step 1-3
from the JTOR-01 Instrucon Manual. If
JTOR-01 is already installed: remove the
cross bars and tube assemblies from the
lower mounng structure.***
Figure 3
Figure 2

9
4. If you have or are going to install a Vicowl
onto your Gladiator skip steps 4-8 and
install the mounng arms (22080-22081)
to the vicowl using the #8 stainless steel
hardware (50211-HW) Figure 4.
5. Use a T40 star-p socket to remove three
(3) bolts on the cowl cover. Repeat on
opposite side. Figure 5.
Figure 4
Figure 5
6. Place the 1/2” aluminum spacer in the
upper bolt hole while placing two (2) 1/4”
aluminum spacers in the lower bolt holes
(50211-HW). Figure 6.
Figure 6

7. Take the two support arms (22078-22079)
and place two (2) rubber bumpers on the top
secon (50211-HW). Figure 7.
Figure 7
8. Cut the foam tape to t along the support
arm proles. Figure 7.
9. Place the support arm into place and use
a 6M buon head bolt with lock washer and
5/16” at washers on top and two (2) 8M
buon head bolts with lock washers and 5/16”
at washers on the boom. Fully ghten all
the bolts with a 5/32 socket wrench. Repeat
on opposite side. Figure 8.
10. Place the front tube assembly from the
JTOR-01 on the front support arm and loosely
aach it to the rear tube assembly using three
(3) 3/8” yellow zinc hex head bolts with at/
lock washers and nuts (50211-HW). Figure
9-10.
Figure 8
Figure 10
Figure 9

11
11. Loosely install the remaining six (6)
stainless steel buon head bolts in the
center crossbar to the front tube assembly
using a 3/16” allen wrench and 1/2”
socket wrench (50211-HW). Aline the tube
assemblies so that all faces are ush, then
use a 9/16” socket wrench to fully ghten
the 3/8” hardware installed in step 8.
Repeat on opposite side. Figure 11.
12. Use a 1/2” socket wrench to aach the
tube assembly to the front support arms
using a 5/16” yellow zinc hex head bolt with
at/lock washers and nuts (50211-HW).
Figure 12.
Figure11
Figure 12
13. Loosely install the front visor using
six (6) 5/16” buon head bolts with at/
lock washers and nuts from the JTOR-01
hardware kit using a 3/16” allen wrench and
1/2” socket wrench (50190-HW). Figure 13.
Figure 13

14. Loosely install the back-cross bar using
four (4) 5/16” buon head bolts with at/
lock washers and nuts from the JTOR-01
hardware kit using a 3/16” allen wrench and
1/2” socket wrench (50190-HW). Use two
(2) yellow zinc hex head bolts with at/lock
washers and nuts on the lower secon of
the back-cross bar. Figure 14-15.
Figure 14
Figure 15
15. Use the remaining 5/16” stainless steel
hardware to install the four (4) crossbars as
desired. Figure 16.
Figure 16
16. With all cross bars and assemblies
installed and in the desired posion, fully
ghten down all mounng hardware to
secure the rack in place.
16. When installing the crossbar closest to
the visor: install the visor support (22101)
between the visor and the cross bar using
the four (4) 5/16 stainless steel bolts, at/
lock washers and nuts with a 3/16” Allen
wrench and ½ socket wrench (50211-HW).
Figure 17.
Figure 17

13
Fab Fours Inc.
2213 Industrial Park Road
Lancaster, SC 29720
Phone: [phone]
Fax: [phone]
Email: [e-mail]
www.fabfours.com
Contact information

“If you’re looking for more of the same,
Then you’ve come to the wrong place.”
- Greg Higgs