Front Runner FAJK010 Manual

ENG
Jeep Wrangler JKU 2 Door (2007-2018)
inner brackets and Foot Rail
FAJK010 / FAJK011_REV_A01 © 2020 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.
FAJK010 / FAJK011
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.

FAJK010 / FAJK011_REV_A01 © 2020 FRONT RUNNER VEHICLE OUTFITTERS 2
IN THE BOX
FIGURE 1.1
IN THE BOX TOOLS NEEDED
T40
Torx Wrench
IN THE BOX
2
9
8
4
6
3
5
8
9
3
7
10
1GET ORGANIZED
FAJK011
13MM
10MM 10MM
13MM
4mm
22mm (7/8") Hole Saw
1RH
1LH
1 2 X Inner Bracket 1LH + 1RH
2 2 X Inner Bracket Clamp
3 16 X M6 Nut Cap
4 8 X M6 x 30 Hex Bolt
5 8 X Spacer 19 x 12.58 x 15
6 8 X M6 x 19 x 1SS Flat Washer
7 8 X Foam Washer
8 24 X M6 x 12 x 1SS Flat Washer
9 24 X M6 Nyloc Nuts
10 1 X Seal Kit
Rear Of Vehicle

© 2020 FRONT RUNNER VEHICLE OUTFITTERS
3 FAJK010 / FAJK011_REV_A01
12R
1GET ORGANIZED
FIGURE 1.2
IN THE BOX
11 10 X M8 X 20 Hex Bolt
12 2 X Foot Rail - 1LH + 1RH
13 10 X M8 x 16 x 1.6SS Flat Washer
14 10 X M8 Nyloc Nut
15 10 X M8 Nut Cap
IN THE BOXIN THE BOX
11
13
14
15
FAJK010
Rear Of Vehicle

© 2020 FRONT RUNNER VEHICLE OUTFITTERS
4 FAJK010 / FAJK011_REV_A01
4
FIT AND SECURE
2
13mm
2.1
2.2
2.3
Remove the two T-top roofs.
Disconnect the power socket and water
pipe in the back left corner of the vehicle.
Using a T40 Torx Wrench, remove the six
torx bolts holding the rear roof to the
vehicle's body.
Remove the two torx bolts either side of
the front headrests holding the rear roof
the vehicle's body.
With the help of a friend, lift the roof off
the vehicle.
Drill 4mm pilot holes on the marks you
have made.
Change the 4mm drill bit to a 22mm hole
saw. Drill all the 4mm holes (8 in total)
out to 22mm.
Let the drill do the work. You do not
want to scratch or damage your
vehicle's roof. Have your friend hold the
vacuum cleaner underneath where you
are drilling to catch all the dust and
keep your vehicle clean.
After drilling, clean the area around all
the 22mm holes in the roof with a rag
and methylated spirits/denatured
alcohol.
Place the left and right Foot Rails (Item
12LH & 12RH) in position as shown. Mark
the position of the four mounting feet.
Remove the Rails. Using masking tape,
tape the marked area on the roof where
the mounting feet sat. This is done to help
protect your vehicle's roof when drilling in
2.3.
Place the brackets back in position,
making sure to align the Foot Rail with the
ribs on the roof.
Using a measuring tape, adjust the Rails
so the centre of the rear hole is 130mm in
from the rear edge of the roof and 3mm
from the edge of the outer rib as shown.
Mark the position of all the holes onto the
roof.
10mm
10mm
6mm
130mm
130mm

© 2020 FRONT RUNNER VEHICLE OUTFITTERS
5 FAJK010 / FAJK011_REV_A01
4
FIT AND SECURE
2
13mm
2.4
2.5
2.6
Remove the speaker box so that you have
access to the zips and padding that cover
the vehicles roll bars.
This is done by removing the six bolts that
hold it in place. Two bolts on the outside of
each speaker and one bolt either side of
the screw that hold the T-tops in place.
10mm
10mm
6mm
Loosen velcro, unzip and remove the
padding covering the roll bars. Remove the
foam shown.
Replace the roof, and fully tighten the
six torx bolts holding the rear roof to the
vehicle's body.
The two holes shown must be towards the
rear of the vehicle and the ribs of the
bracket must be on the inside of the roll
bar.
Align the holes in the Inner Brackets (Item
1LH & 1RH) with the holes drilled in 2.3.
Place the Inner Bracket Clamp (Item 2)
around the outside of the roll bar and
secure the Inner Bracket (Item 1) to the roll
bar using M6 Nyloc Nuts and M6 x 12 x 1
Flat Washers (Items 8 & 9) as shown.
Do this on both left and right side of the
vehicle.
Remove
Leave
Rear fo Vehicle
1RH
8
9
9
10mm

80mm
© 2020 FRONT RUNNER VEHICLE OUTFITTERS
6 FAJK010 / FAJK011_REV_A01
4
FIT AND SECURE
2
13mm
2.7
2.8
2.9
If not already assembled, assemble your
Tray as per the Universal Tray Assembly
Instructions (Document RRSTUNI)
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 7). Remove
the paper backing from the Foam
washer to expose the adhesive.
Insert the washer/spacer assembly,
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.
After fitting the wind deflectors, the tray
should still be upside down, loosely
mount the Foot Rails (Item 12L & 12R
from FAJK010 box) to the Tray using M8
x 20 Hex Bolts, M8 X 16 X 1.6SS Flat
Washers and M8 Nyloc Nuts (Items 11,
13 & 14). As before use the machined
slots to insert the hex bolts into the
Slats.
The Foot Rail should be mounted to the
tray with the product sticker at the
opposite end of 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
NOTE: Before fitting the Wind
Deflector, insert two M8 x 16 Hex
Bolts (Item 11 from FAJK010) or
if you are fitting a full rack (Item 1
from FAJK009) into the first slat
(Combined Slat), using the
Machined slots. Slide a bolt to each
of the outer corners.
5
7
For a Full Rack fitment refer to FAJK009
Fitment Guide.

© 2020 FRONT RUNNER VEHICLE OUTFITTERS
7 FAJK010 / FAJK011_REV_A01
4
2
2.10
FIT AND SECURE
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 4, 6, 8 & 9
from FAJK010 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 3 from
FAJK010 box) provided over all the
exposed bolts and close up all the roll
bar padding.
REMOVING YOUR RACK
10
13mm
3
3.1
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.
10mm
10mm
13mm
13mm
4
6
8
9
3

© 2020 FRONT RUNNER VEHICLE OUTFITTERS
8 FAJK010 / FAJK011_REV_A01
4
TAKE A TRIP
4
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.
4.1
Front Runner can not recommend a maximum load carrying capacity. Please refer to your vehicle manufacturer's
recommendations
COMPLETION
5
5.1
Congratulations! You did it. Take a step back and admire your work!
INSTALL OTHER VEHICLE AND RACK ACCESSORIES
6
Now's the time to visit your favorite Front Runner Dealer in person or online.
IMPORTANT!
Be sure to tag us. We love to see our gear in action! #FrontRunnerOutfitters #BornToRoam
Share your adventures on:
FRONT RUNNER RACK KITS OFTEN HAVE A HIGHER LOAD RATING THAN THE VEHICLES THEY ARE MOUNTED TO. PLEASE REFER TO YOUR SPECIFIC VEHICLE MANUFACTURER
FOR A RECOMMENDED ROOF RATING. FRONT RUNNER CANNOT BE RESPONSIBLE FOR IMPROPER LOADING BEYOND THE VEHICLE MANUFACTURER'S STATED LOAD CAPACITY.