Front Runner FAJK002 Instruction Manual

ENG
180 min
Jeep Wrangler JKU 4 Door (2007-Current)
inner brackets and Foot Rail
FAJK002 / FAJK006_REV_C00 © COPYRIGHT 2017 FRONT RUNNER VEHICLE OUTFITTERS
1
IMPORTANT WARNING!
Don’t be a hero and muscle through this without first reading these fitting instructions! Improper installation of this gear may void certain aspects of
your warranty.
Before you begin, take a moment and open all your Front Runner rack kit boxes and gather the assembly instructions for the various components.
A complete kit will contain:
1. A Front Runner Mounting System specific to your vehicle
2. A Front Runner Rack Tray or Load Bar Slats
This document will guide you through the assembly of the mounting system and assist you in fitting the roof rack tray or load bars to your specific
vehicle.
Please refer to the next page for a list of all the components, quantities and tools required.
FAJK002 / FAJK006
READ ME FIRST
START HERE!
FRONT RUNNER CAN NOT RECOMMEND A MAXIMUM LOAD CARRYING CAPACITY. PLEASE REFER TO YOUR VEHICLE MANUFACTURER'S RECOMMENDATIONS. IT IS CRITICAL
THAT ALL FRONT RUNNER PRODUCTS BE PROPERLY AND SECURELY ASSEMBLED AND ATTACHED TO YOUR VEHICLE. IMPROPER ATTACHMENT COULD RESULT IN AN
AUTOMOBILE ACCIDENT, AND COULD CAUSE SERIOUS BODILY INJURY OR DEATH. YOU ARE RESPONSIBLE FOR ASSEMBLING AND SECURING ALL FRONT RUNNER PRODUCTS
TO YOUR VEHICLE. CHECKING THE ATTACHMENTS PRIOR TO USE, AND PERIODICALLY INSPECTING THE PRODUCTS FOR ADJUSTMENT, WEAR AND DAMAGE. THEREFORE YOU
MUST READ AND UNDERSTAND ALL OF THE INSTRUCTIONS AND PRECAUTIONS SUPPLIED WITH YOUR FRONT RUNNER PRODUCT PRIOR TO INSTALLATION OR USE. IF YOU
DO NOT UNDERSTAND ALL OF THE INSTRUCTIONS AND CAUTIONS, OR IF YOU HAVE NO MECHANICAL EXPERIENCE AND ARE NOT THOROUGHLY FAMILIAR WITH THE
INSTALLATION PROCEDURES, YOU SHOULD HAVE THE PRODUCT INSTALLED BY A PROFESSIONAL INSTALLER OR OTHER QUALIFIED PERSONNEL.

FAJK002 / FAJK006_REV_C00 © COPYRIGHT 2017 FRONT RUNNER VEHICLE OUTFITTERS 2
IN THE BOX
FIGURE 1.1
1 2 X Inner Roll Bar Clamp
2 2 X Outer Roll Bar Clamp
3 28 X M6 x 19 x 1SS Flat Washer
4 16 X Foam Seal Washer
5 16 X Aluminum Spacer
6 16 X M6 x 30 Hex Bolt
7 20 X M6 Nyloc Nut
8 8 X M6 x 20 Hex Bolt
9 20 X M6 Nut Cap
10 16 X M6 x 19 x 1SS Flat Washer
11 2 X Rear Support Bracket - 1LH + 1RH
12 2 X M8 x 75 Hex Bolt
13 2 X M8 Large Washer
14 2 X Middle Support Bracket - 1LH + 1RH
15 16 X Sealing Plug Assembly
IN THE BOX TOOLS NEEDED
T40
Torx Wrench
IN THE BOX
9
8
3
12
3
3
7
989
4
6
10
5
14L
4
14R
11R
11L
3
7
13
12
15
5
6
10
1GET ORGANIZED
FAJK002
13MM
10MM 10MM
13MM
6mm
22mm (7/8") Hole Saw

© COPYRIGHT 2017 FRONT RUNNER VEHICLE OUTFITTERS
3 FAJK002 / FAJK006_REV_C00
17R
17L
1GET ORGANIZED
FIGURE 1.2
IN THE BOX
16 14 X M8 X 16 Hex Bolt
17 2 X Foot Rail - 1LH + 1RH
18 14 X M8 x 16 x 1.6SS Flat Washer
19 14 X M8 Nyloc Nut
20 14 X M8 Nut Cap
IN THE BOXIN THE BOX
16
18
19
20
FAJK006

© COPYRIGHT 2017 FRONT RUNNER VEHICLE OUTFITTERS
4 FAJK002 / FAJK006_REV_C00
4
PREP FOR INSTALLATION OF INNER BRACKETS (FAJK002)
2
13mm
2.1
2.2
2.3
Loosen velcro, unzip and remove the
padding covering the roll bars.
Remove the wiring harness and plastic
clip from the roll bar.
Loosely attach the Rear Support Arms
(item 11) to the outside of the Roll Bar
Clamps using items M6 x 20 Hex Bolts,
M6 x 19 x 1SS Flat Washers and M6
Nyloc Nuts (Items 3, 7 & 8). Make sure
the foot faces the inside of the vehicle
and the contours of the foot match the
contours of the roof as shown.
Mark the position of the four holes in the
foot on the roof.
Once the holes have been marked
remove the Rear Support Arms.
Pilot drill the marked holes using a 6mm
drill bit.
Locate the two threaded holes on the
underside of the roll bar and fasten the
two halves of the Roll Bar Clamps (Items
1 & 2) to the roll bar using M6 x 19 z 1SS
Flat Washers and M6 x 20 Hex Bolts
(Items 3 & 8). Place the Outer Roll Bar
Clamp (Item 2) first followed by the
Inner Roll Bar Clamp (Item 2).
10mm
10mm
10mm
6mm

© COPYRIGHT 2017 FRONT RUNNER VEHICLE OUTFITTERS
5 FAJK002 / FAJK006_REV_C00
4
PREP AND INSTALLATION OF FOOT RAILS (FAJK006)
3
13mm
3.1
3.2
3.3
Locate the Foot Rail in position by lining
up the holes in the bracket with the
holes drilled in Step 2.3.
Place a M6 x 30 Hex Bolt (item 6) into
each hole to keep its location.
Once you are happy with your
measurements and alignment, mark the
four holes in the foot of the Foot Rail
onto the roof.
Remove the Foot Rail.
From outside the vehicle, using your
6mm drill bit, drill the four pilot holes
through the marks you just made.
Repeat Step 2.1 to 3.3 for the opposite
side.
Using a measuring tape and a rib in the
roof as a reference, adust the front of
the bracket so that the entire length of
the bracket is parallel with your
reference rib.
FRONT OF VEHICLE
SIDE VIEW OF FOOT RAIL
TOP VIEW OF FOOT RAIL
REAR FOOT
10mm
10mm
6mm

© COPYRIGHT 2017 FRONT RUNNER VEHICLE OUTFITTERS
6 FAJK002 / FAJK006_REV_C00
4
FIT AND SECURE
3
13mm
3.4
3.5
3.6
Change from the 6mm drill bit to a
22mm hole saw. From the outside of the
vehicle drill all the 6mm holes (16 in
total) out to 22mm. Let the drill do the
work. You do not want to scratch or
damage your vehicle's roof. You may
wish to have a friend inside the vehicle
with a vacuum cleaner underneah where
you are drilling to catch all the dust and
keep your vehicle clean.
From the inside of the vehicle, in the
same position as where you just
inserted the bolt in Step 3.5, push the
Middle Support Bracket (Item 14)
through the hole in the roll bar padding
and loosely fasten it to the roll bar.
Please note that there is a left hand and
right hand bracket. The arrow on the
bracket must point to the rear of the
vehicle.
Pull back the padding around the roll bar
above the rear seats and insert an M8 x
75 Hex Bolt and M8 Large Washer (Items
12 & 13 from FAJK002 box) through the
hole as shown.
13mm
22mm
TIP - It is easier to do the next step if
you remove the roof.

© COPYRIGHT 2017 FRONT RUNNER VEHICLE OUTFITTERS
7 FAJK002 / FAJK006_REV_C00
4
INSTALLATION OF REAR SUPPORT ARMS
4
13mm
4.1
Refit and fasten the Rear Support Arms
as in Step 2.3
10mm
10mm
5PREP FOR RACK INSTALL (FAJK002)
5.1
5.2
Clean the area around all the 22mm
holes drilled in the roof with a rag and
methylated spirits/denatured alcohol.
Insert the Aluminum Spacers (Item 5)
into the Foam Washer (Item 4). Remove
the paper backing from the Foam
washer to expose the adhesive.
Insert the washer/spacer combination,
adhesive side down, into the 22mm
holes so that the spacer comes to rest
on the Rear Support Brackets
underneath.
Firmly press the foam washer all the
way around securing it to the roof.
NOTE: Use the worm slots to adjust the
height of the rear support brackets.
This will be important to create a
weatherproof Seal.
If not already assembled, assemble your
Tray as per the Universal Tray Assembly
Instructions (Document RRSTUNI)
NOTE: Before fitting the Wind
Deflector, insert two M8 x 16 Hex
Bolts (Item 16 from FAJK006) or
(Item 1 from FAJK003) into the first
slat (Combined Slat), using the
Machined slots. Slide a bolt to each
of the outer corners.

Half Rack Shown
80mm
© COPYRIGHT 2017 FRONT RUNNER VEHICLE OUTFITTERS
8 FAJK002 / FAJK006_REV_C00
4
6
6.1
6.2
MOUNT YOUR TRAY
With the help of a friend, flip the Tray
end over end so that it is in the upright
position. (The Tray is flipped end over
end so that bolts and brackets do not
slide left and right).
With one of you on either side of the
Tray, lift the Tray and walk it into
position above the vehicle, approaching
from either the front or the rear of the
vehicle.
The Foot Rail should still be loose
enough to move. Line the brackets up
with the holes on the roof and fasten
them into position using M6 x 19 x 1SS
Flat Washers, M6 x 30 (Items 3, 6, 7 & 10
from FAJK002 box). Centre the tray from
left to right. Use a tape measure to
double check. Once you are happy that
the Tray is in the correct position, fasten
all the nuts and bolts, both inside and
outside of the vehicle on all brackets
that were installed.
Fit the Plastic Nut Caps (Item 9 from
FAJK002 box) provided over all the
exposed bolts and close up all the roll
bar padding.
6
10
3
7
11L
14L
9
13mm
PREP FOR RACK INSTALL (HALF RACK)5
5.3
After fitting the wind deflectors, the tray
should still be upside down, loosely
mount the Foot Rails (Item 17L & 17R
from FAJK006 box) to the Tray using M8
x 16 Hex Bolts, M8 X 16 X 1.6SS Flat
Wahsers and M8 Nyloc Nuts (items 16,
18 & 19?. As before use the machined
slots to insert the hex bolts into the
Slats. The Foot Rail should be mounted
at the opposite end of the Tray to the
wind deflector.
The rear of the Foot Rail must mount
onto the very last Slat (Combined Slat)
and approximately 80mm in from the
outer edge of the side of the Tray. Do not
tighten the bolts yet.
13mm

© COPYRIGHT 2017 FRONT RUNNER VEHICLE OUTFITTERS
9 FAJK002 / FAJK006_REV_C00
4
13mm
REMOVING YOUR RACK7
7.1
Should you wish to remove your rack,
you will need to plug the holes you
drilled in the roof (Step 3.4), using the
supplied Sealing Plug Assemblies.
Remove the Tray, Front Uprights and the
Foot Rail, by reversing the instillation
procedure. Leave the Foam Washer and
the Aluminum Spacers in place. Screw in
the Sealing Plugs reusing the M6 Nyloc
Nuts and Washers that held the Foot Rail
in position.
12mm
TAKE A TRIP
8
After your first adventure, check that all nuts, bolts, screws and fittings are tight. Re-tighten where needed. You'll find a
small amount of settling has happened.
Go on many more adventures, periodically checking all nuts, bolts, screws and fittings.
8.1
Front Runner can not recommend a maximum load carrying capacity. Please refer to your vehicle manufacturer's
recommendations
15

© COPYRIGHT 2017 FRONT RUNNER VEHICLE OUTFITTERS
9 FAJK002 / FAJK006_REV_C00
4
COMPLETION
9
INSTALL OTHER VEHICLE AND RACK ACCESSORIES
10
Now's the time to visit your favorite Front Runner Dealer in person or online.
9
9.1
Congratulations. You did it. Take a step back and admire your work!