Front Runner FAJL002 User manual

ENG
jeep wrangler jl (2018 -current)
inner brackets and Foot Rail
FAJL002 / FAJL003_REV_A00 © 2018 FRONT RUNNER VEHICLE OUTFITTERS
1
FAJL002 / FAJL003
READ ME FIRST
START HERE!
Don’t be a hero and muscle through this installation without reading these fitting instructions first! 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.
IMPORTANT WARNING!
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.
NOTE: Front Runner will not be responsible for any damage caused by the failure to install the product according to these instructions.
Please call us if you have any questions about the installation of this product.

FAJL002 / FAJL003_REV_A00 © 2018 FRONT RUNNER VEHICLE OUTFITTERS 2
TOOLS NEEDED
1GET ORGANIZED
FIGURE 1.2
IN THE BOX
1 2 X Foot Rail - 1LH + 1RH
2 14 X M8 X 20 Hex Bolt
3 14 X M8 x 16 x 1.6SS Flat Washer
4 14 X M8 Nyloc Nut
5 14 X M8 Nut Cap
IN THE BOX IN THE BOX
13MM
4MM
Allen Key
10MM 10MM
13MM
4mm
22mm (7/8") Hole Saw
FAJL002
2
1RH
3
4
5
1LH
- Vacuum Cleaner
- a Friend

© 2018 FRONT RUNNER VEHICLE OUTFITTERS
3 FAJL002 / FAJL003_REV_A00
IN THE BOX
FIGURE 1.1
6 2 X Rear Support Bracket - 1LH + 1RH
7 2 X Middle Support Bracket - 1LH + 1RH
8 16 X M6 Nut Cap
9 8 X M6 x 40 Hex Bolt
10 8 X M6 x 30 x 2 Laser Cut Washer
11 8 X PVC Washer M8 x 25 x 2.5
12 8 X Foam Seal Washer
13 8 X Aluminum Spacer
14 8 X M6 x 12 x 1SS Flat Washer
15 8 X M6 Nyloc Nut
16 6 X M8 x 16 x 1.6SS Flat Washer
17 6 X M8 SS Spring Washer
18 4 X M8 x 25 Button Head Bolt
IN THE BOX IN THE BOX
1GET ORGANIZED
FAJL003
6LH
7LH
21
16
17
20
19
8
9
10
11
12
13
14
15
8
6RH
7RH
8
9
10
11
12
13
14
15
8
16
17
18
22
IN THE BOX
19 2 X M8 Nut Cap
20 2 X M8 x 80 Hex Bolt
21 2 X M8 Cage Nut
22 1 X Seal Plug Kit
IN THE BOX IN THE BOX

© 2018 FRONT RUNNER VEHICLE OUTFITTERS
4 FAJL002 / FAJL003_REV_A00
4
FIT AND SECURE INNER BRACKETS AND FOOT RAIL
2
13mm
2.1
2.2
2.3
Looking at the rear roll cage, remove the
plastic trim covers located on the inside
of the roll bar as shown.
Do this on both the left and right side.
Open the rear passenger doors and locate
the hole shown.
Before fitting the Middle Support Brackets
(Item 7), assemble the Support Brackets
and M8 Cage Nuts (Items 7 & 21).
Refer to Figure 1.1 for positioning of the
Cage Nuts.
Fit the Middle Support Brackets (Items 7LH
& 7RH) on top of the roll bar and secure
them to the roll bar using M8 x 80 Hex
Bolts, M8 SS Spring Washers and M8 x 16 x
1.6 SS Flat Washers (Items 16, 17 & 20).
Refer to Figure 1.1 on page 3.
Do this on both left and right side.
Fit the Inner Support Brackets (Items 6LH
& 6RH) using the factory inserts in the roll
bar, using M8 x 25 Button Head Bolts, M8
SS Spring Washer and M8 x 16 x 1.6SS
Flat Washer (Items 16, 17 & 18).
Refer to Figure 1.1 on page 3.
Using the two top holes on the Inner
Support Bracket as a guide, mark the hole
positions on the roof. Do the same with
the opposite side Support Bracket.
You will drill these in Step 2.5
Remove the Brackets.
4mm
13mm
Rear Of Vehicle
4mm Pilot Holes

© 2018 FRONT RUNNER VEHICLE OUTFITTERS
5 FAJL002 / FAJL003_REV_A00
4
FIT AND SECURE INNER BRACKETS AND FOOT RAIL
2
13mm
2.4
2.5
2.6
Mark the two holes on both the brackets
onto the roof.
Remove the four brackets.
Have a friend hold a vacuum cleaner
with the nozzle attached, close the the
drill point.
Drill pilot holes using a 4mm drill bit on
the eight points marked on the roof.
Refit both LH and RH Inner Support
Bracket. Refer to Step 2.2.
Change the 4mm drill bit to a 22mm hole
saw. From the outside of the vehicle,
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.
4mm
4mm Pilot Holes
4mm
22mm

© 2018 FRONT RUNNER VEHICLE OUTFITTERS
6 FAJL002 / FAJL003_REV_A00
4
13mm
FIT AND SECURE INNER BRACKETS AND FOOT RAIL
2
13mm
2.7
2.8
2.9
Refit both the Middle Support Brackets.
Refer to Step 2.3 and 2.4.
Place the Foot Rail (Item 1) onto the
spacer and secure using M6 x 40 Hex
Bolts, M6 x 30 x 2 Flat Washers, PVC
Washers, M6 x 12 x 1SS Flat Washer and
M6 Nyloc Nuts (Items 9, 10, 11, 14 & 15)
as shown. Do this on both sides of the
vehicle.
Finish off by placing M6 Nut Caps
(Item 8) on all the nyloc nuts and bolt
heads.
Insert the Aluminum Spacers (Item 13)
into the Foam Washer (Item 12). 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 Inner and Middle Support
Brackets.
Firmly press the Foam Washer all the
way around, securing it to the roof.
13mm
8
9
10
11
12
13
14
15
8
1LH
10mm
12
13

© 2018 FRONT RUNNER VEHICLE OUTFITTERS
7 FAJL002 / FAJL003_REV_A00
4
13mm
REMOVING YOUR RACK 4
4.1
Should you wish to remove your rack,
you will need to plug the holes you
drilled in the roof (Step 2.5) using the
supplied Seal Plug Kit.
Remove the Tray and the Foot Rail by
reversing the installation 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.
TAKE A TRIP
5
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.
5.1
22
FIT AND SECURE ROOF RACK
3
3.1
3.2
4MM
3.3
Center the rack and tighten fully. Use M8 Nut Caps (Item 5) to finish off the nuts.
Fit your Roof Rack to the Foot Rails using
M8 x 20 Hex Bolts, M8 x 16 x 1.6SS Flat
Washers and M8 Nyloc Nuts (Items 2, 3 & 4).
Make sure that the wind deflector is installed
before you proceed to the next step.
Refer to Rack Fitment Guide (RRSTUNI).
13mm
2
4
5
3
10mm
4mm

© 2018 FRONT RUNNER VEHICLE OUTFITTERS
8 FAJL002 / FAJL003_REV_A00
4
COMPLETION
6
9
6.1
Congratulations! You did it. Take a step back and admire your work!
INSTALL OTHER VEHICLE AND RACK ACCESSORIES
7
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.