Fab Fours Open Fender User manual

Installation Manual
Open Fender/Fender Flare
Product Number: TF4400 &
TF4410
Application:2019DodgeRamHD

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 PRECAUTIONS, AND INSTRUCTIONS
BEFORE INSTALLING THIS PRODUCT.
TIRE RUBBING MAY OCCUR AFTER
INSTALLATION OF THIS PRODUCT.
• 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.

Tableofcontents
SAFETY / DISCLAIMER
TABLE OF CONTENTS
A MESSAGE FROM THE OWNER
GETTING STARTED
PROVIDED MATERIAL
CHAPTER 1: DISASSEMBLY
CHAPTER 2: TEMPLATE APPLICATION/CUTTING
CHAPTER 3: INSTALLATION/ ROCKER CHANNEL
CHAPTER 3: INSTALLATION/ FENDER BASES
CHAPTER 3: INSTALLATION/ INNER FENDERS
CHAPTER 3: INSTALLATION/ FENDER FLARES
CONTACT INFORMATION
2
3
4
5
6
9
20
37
43
52
54
59

A message from the owner
Fab Fours’ was born out of a passion for customizing vehicles and a love for 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
This manual is meant to be a comprehensive companion to online video resources.
Our goal is to provide this manual in bite-sized videos that an individual will feel comfortable using
during the installaon process.
Visit youtube.com/FabFoursUSA for instruconal videos.
Instructional video

Provided Materials
21403-03
21402-02
21351-02 21402-01
21402-03 21403-01
21352-02
21402-04
21403-04
21977-01 21978-01

7
21954 21955
21956 21957
21453 21454
21455 21456
50192-HW
50121-HW
TF4400-IM
61728 Foam Seal Kit
61272 Rubber Seal x2

Hardware kit
•3-ton (or larger) jack
•3-ton (or larger) jack stands
(QTY 4)
•8mm, 10mm, 18mm, 22mm,
24mm, 3/8”, 1/2” socket
wrenches
•18mm & 1/2” open end
wrenches
•3/16” Allen wrench
•25/64” Transfer Punch
•Hammer
•Plasc panel pry tool
• Painters tape
•Duct tape
• Black and silver sharpies
• Impact driver
•Large reciprocang saw
•Small reciprocang saw
• Angle grinder
•4” ap disk wheel
•4” cut o wheel
•Die grinder
•2” cut o wheel
•Vise-grip C-Clamp (Qty 3)
•An-seize compound
•Deburring tool
•Razor blade
TOOLSREQUIRED

9
Disassembly
Disconnecng the baery terminals,
removing the res and raising the vehicle is
recommended at this me. We recommend
the use of an appropriately rated li for the
vehicle.
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 disassembly.
We recommend protecng any
painted surfaces that may come
in contact with the work area with
painters tape.
Assistance

1. Using an appropriately rated vehicle jack and jack stands or an appropriately rated vehicle
li raise the vehicle so that the res are o the ground.
2. Using a 22mm socket wrench remove the eight (8) lug nuts from each of the four (4) wheels and
set the factory wheels and res aside.
3. Disconnect the IBS sensor connecon from sensor on the negave baery terminal. Figure 1
Figure 1

11
Figure 2
4. Using a 10mm socket wrench, disconnect the negave terminal from the baery. Figure 1, #2
5. If applicable, disconnect the negave terminal from the auxiliary baery. Figure 2
Figure 1, #2

6. Using an 8mm socket wrench and plasc panel pry tool, remove the two (2) screws and one (1) push pin
from the rear splash shield trim. Figure 3
7. Using an 10mm socket wrench and plasc panel pry tool, remove the twelve (12) screws and two (2)
push pins from the inner fender and set aside. Figure 4 & 5
Figure 3
Figure 4

13
8. Disconnect the factory wiring harness from the inside of the driver side wheel well. Figure 6
Figure 6
Figure 5

9. With assistance, support the bumper from both sides of the vehicle. Using an 18mm socket wrench,
24mm socket wrench and 18mm open end wench, remove the three (3) factory bumper bolts that hold
the factory bumper to the frame rail. Figure 7
10. Remove the factory bumper from the vehicle and set aside. Figure 8
Figure 7
Figure 8
Note:
The factory tow hooks stay in the frame rail while extracng the front bumper from the frame rail ends.

15
Figure 9
Figure 10
11. Using an 8mm socket wrench, remove the screw in the splash shield forward of the bed wheel well.
Then using the plasc body panel pry tool, pull down and forward to remove the splash shield. Using
the plasc panel pry tool remove all the plasc clips le in the bed. Figure 9 & 10

13. Using an 8mm socket wrench, remove the four (4) screws aaching the forward rear inner fender to
the bed and remove it. Figure 12
Figure 11
12. Using an 8mm socket wrench, remove the two (2) screws in the splash shield rearward of the bed
wheel well. Then using the plasc body panel pry tool, pull down to remove the splash shield. Using the
plasc panel pry tool remove all plasc clips le in the bed. Figure 11
Figure 12

17
14. Using an 8mm socket wrench, remove the three (3) screws aaching the rearward rear inner fender
to the bed and remove it. Figure 13
Figure 13
Figure 14
15. Using a 10mm socket wrench, remove the two (2) screws at the boom of the front fender. Figure 14
Note: There are two (2) versions of rear inner fenders available. If your vehicle has the one (1) piece version
the process will be the same as explained in steps 13-14, but there will be addional screws to be removed.

16. Remove the foam ller panel from the inside of the fender along the door hinges. Figure 15
17. Using a plasc panel pry tool, carefully remove the body harness connector in the front wheel well
and secure it near the frame to keep it away from the cung area. Figure 16
Figure 16
Figure 15

19
18. Using a 10mm socket wrench, remove the screw aaching the support bar to the boom of the inner
bedside forward of the rear wheel. Figure 17
19. Repeat steps 6-17 on the passenger side of the vehicle.
Figure 17

Template Application/Cutting
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 cung process.
We recommend protecng any
painted surfaces that may come
in contact with the work area with
painters tape.
Assistance
1. Using painters tape, apply at least three (3 layers of tape to
the forward most part of the front door. Figure 1
Figure 1
Figure 2
2. Apply the DS FEN 1 template to drivers’ side front fender by
rst aligning the front secon with the blue dashed line to the
boom of the fender near the bumper. Then align the rounded
blue dashed line area of the template with the wheel well edge.
Finally nish applying the template by working the template
upwards away from the wheel well opening. If small bubbles
remain this is ne, it will not aect the funconality of the
template. Figure 2-4