Front Runner FAJL004 User manual

ENG
Jeep Wrangler JL (2018-Current)
Front Bar Roof Rack Mount
FAJL004_REV_A01 © 2020 FRONT RUNNER VEHICLE OUTFITTERS
1
IMPORTANT WARNING!
FAJL004
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.
Thank you for purchasing a Front Runner Jeep Wrangler JL Front Bar Roof Rack Mount.
Before you start, take a moment to familiarize yourself with the Fitting Instructions and the components received.
Refer to Page 2 for a list of all the components, quantities and tools required.
READ ME !
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.

FAJL004_REV_A01 © 2020 FRONT RUNNER VEHICLE OUTFITTERS 2
IN THE BOX
FIGURE 1.1
1 1 X LH Front Support Arm
2 10 X M8 Flat Washer
3 6 X M8 Nyloc Nut
4 6 X M8 Nut Cap
5 4 X M8 x 30 Button Head Screw
6 4 X Spacer 19 x 12 x 15
7 4 X Spacer 19 x 12 x 12
8 4 X M8 x 16 Button Head Screw
9 2 X Pillar Bracket 1LH+1RH
10 1 X RH Front Support Arm
11 4 X M6 x 50 Button Head Screw
12 4 X M6 Flat Washer
13 4 X M6 Large Washer
14 2 X M8 x 20 Hex Head Bolt
IN THE BOX TOOLS NEEDED
IN THE BOX
4mm
Allen Key
5mm
13mm
Thread
Lock
1GET ORGANIZED
T40
Torx Wrench
1
2
3
4
5
2
6
7
8
11
12
13
10
4
3
2
14
10
9

© 2020 FRONT RUNNER VEHICLE OUTFITTERS
3 FAJL004_REV_A01
PREP FOR RACK INSTALL (FULL RACK)
2
13mm
2.1
2.2
2.3
Assemble the LH Front Support Arm
(Item 1) and the LH Pillar Bracket (Item 9)
using two M8x16 Button Head Screws, two
M8 Flat Washers and two M8 Nyloc Nuts
(Item 8, 2 & 3). Finish of by placing two M8
Nut Caps (Item 4) over the M8 Nyloc Nuts.
Do this with th RH Front Support Arm (Item
10) and the RH Pillar Bracket (Item 1).
Using a T40 Torx Wrench, remove the four
bolts holding the Corner Cover in place.
Place two Spacers 19x12x15 (Item 6) into
the two top recesses as shown.
Do this on both sides of the vehicle.
6
6
Apply a small bead of Thread Lock on
the thread around the tip of the M6x50
Button Head Screws (Item 11).
Carefully place the Front Support Arm
onto the two top Spacers (Item 6),
aligning the holes in the Pillar Bracket
with the holes on the vehicle.
Loosely assemble the Support Arm
assembly to the vehicle using M6x50
Button Head Screws, M6 Flat Washers
and M6 Large Flat Washers (Items 11, 12
& 13).
4
3
2
8
1
9
13mm
13mm
T40
11
12
13
6
Side Recess
Side Recess
4mm
Thread
Lock

© 2020 FRONT RUNNER VEHICLE OUTFITTERS
4 FAJL004_REV_A01
PREP FOR RACK INSTALL (FULL RACK)
2
13mm
2.4
2.5
2.6
Place two Spacers 19x12x12 (Item 7) into
the two side recesses shown in 2.2,
between the Front Support Arm and the
Corner Cover.
Apply a small bead of Thread Lock on the
thread around the tip of the M6x30 Button
Head Screws (Item 5).
Loosely assemble the Support Arm
assembly using two M8x30 Button Head
Screws and two M8 Flat Washers (Items 5
& 2).
Make sure the Support Arms are straight,
using the door shut line as a guide.
Fully tighten the M8 Button Heads (Item 5)
and then the M6 Button Heads (Item 11) on
top.
Before moving to the next step you need
to install the Inner and Middle Support
Brackets.
Refer to FAJL002 & FAJL003 Fitment
Guides.
If not already assembled, assemble your
Tray as per the Universal Tray Assembly
Instructions.
Make sure that the wind deflector is
installed before you proceed to the next
step.
Refer to Universal Tray Assembly
Instructions (Document RRSTUNI)
5
2
7
Thread
Lock
5mm

14
2
3
4
© 2020 FRONT RUNNER VEHICLE OUTFITTERS
5 FAJL004_REV_A01
PREP FOR RACK INSTALL (FULL RACK)
2
2.7
2.8
Fit your Roof Rack to the Inner and
Middle Support Brackets.
Refer to FAJL002 & FAJL003 Fitment
Guides.
Fit your Roof Rack to the Front Support
Arms using M8x20 Hex Head Bolts, M8
Flat Washers and M8 Nyloc Nuts (Items
14, 2 & 3) as shown.
Center the rack and fully tighten. Finish
off by placing M8 Nut Caps (Item 4) over
the M8 Nyloc Nuts.
INSTALL OTHER VEHICLE AND RACK ACCESSORIES
3
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.
13mm

ENG
jeep wrangler jl 2 door (2018 -current)
inner brackets and Foot Rail
FAJL005 / FAJL006_REV_A00
1
FAJL005 / FAJL006
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.
front runner
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.
© 2020 FRONT RUNNER VEHICLE OUTFITTERS

FAJL005 / FAJL006_REV_A00 2 © 2020 FRONT RUNNER VEHICLE OUTFITTERS
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
FAJL005
- Vacuum Cleaner
- a Friend
2
1RH
3
4
5

3 FAJL005 / FAJL006_REV_A00
IN THE BOX
FIGURE 1.1
6 2 X Rear Inner Bracket - 1LH + 1RH
7 2 X Middle Support Bracket
8 12 X M6 Nut Cap
9 8 X M6 x 40 Hex Bolt
10 8 X M6 x 30 x 2 Washer
12 8 X Aluminum Spacer
13 8 X Foam Seal Washer
14 4 X M8 x 25 Button Head Bolt
15 6 X M8 SS Spring Washer
16 4 X M8 x 16 x 1.6SS Flat Washer
IN THE BOX IN THE BOX
1GET ORGANIZED
FAJL006
IN THE BOXIN THE BOX IN THE BOX
© 2020 FRONT RUNNER VEHICLE OUTFITTERS
8
9
10
12
13
IN THE BOX
17 4 X M6 Nyloc Nut
18 4 X M6 x 12 x 1SS Flat Washer
19 2 X M8 x 25 x 2 Flat Washer
20 2 X M8 x 20 Hex Bolt
21 4 X M6 Cage Nut
22 4 X M6 SS Spring Washer
23 1 X Seal Kit
IN THE BOX IN THE BOX
SEAL PLUG KIT
23
7
20
15
19
21
14
15
16
9
10
22
12
13
8

4 FAJL005 / FAJL006_REV_A00
4
FIT AND SECURE INNER BRACKETS AND FOOT RAIL
2
13mm
2.1
2.2
2.3
Fit the Inner Support Brackets (Items
6LH & 6RH) to 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 14, 15 & 16).
Looking from the side ensure that the top
of the Inner Support Bracket is parallel
with the inside of the roof and looking
from the back must sit parallel with the
rib in the roof.
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.
Remove the brackets and drill a 4mm pilot
holes on all four marks you have made.
© 2020 FRONT RUNNER VEHICLE OUTFITTERS
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 remaining torx bolts either
side above the front headrests holding the
rear roof to the vehicle's body.
With the help of a friend, lift the roof off the
vehicle.
14
15
16
Roof
Holes
5mm
4mm
T40

5 FAJL005 / FAJL006_REV_A00
4
FIT AND SECURE INNER BRACKETS AND FOOT RAIL
2
13mm
2.4
2.5
2.6
Refit the roof, and fully tighten all six
torx bolts removed.
Reconnect the power socket and water
pipe in the back left corner of the vehicle.
Refit the Inner Support Brackets to the
roll bar.
5mm
4mm
22mm
© 2020 FRONT RUNNER VEHICLE OUTFITTERS
Working from the outside of the roof align
the rear two holes in the foot rails with the
holes drilled in 2.2.
Ensure that the foot rail runs parallel to the
rib on the roof before marking the two
front holes in the foot rail onto the roof.
Do this on both left and right side.
Remove the rails and drill 4mm pilot holes
on the marks you just made.
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 a vacuum cleaner
below where you are drilling to catch all
the dust.
After drilling, clean the area around all the
22mm holes in the roof with a rag and
methylated spirits/denatured alcohol.
13mm
14
15
16
Secure the Middle Support Brackets
(Items 7) onto the factory inserts in the
roll bar where shown, using M8 x 20 Hex
Bolts, M8 SS Spring Washer and M8 x 25
x 2 Flat Washer (Items 15, 19 & 20).
Make sure that the two M6 Cage Nuts
(Item 21) are assembled to the Middle
Support Bracket.
The angled edge of the bracket should
face to the outside of the vehicle.
20
15
19
7
21

6 FAJL005 / FAJL006_REV_A00
4
Fit the Front Support Bracket (Item 7) to
the vehicle using M8 x 20 Hex Bolt, M8
SS Spring Washers and M8 x 25 x 2 Flat
Washers (Items 15, 19 & 20) as shown.
13mm
FIT AND SECURE INNER BRACKETS AND FOOT RAIL
2
13mm
2.7
2.8
2.9
Place the Foot Rail (Item 1) onto the spacer
and secure using M6 x 40 Hex Bolts, M6 x 30
x 2 Flat Washers, M6 SS Spring Washers, M6
x 12 x 1SS Flat Washer and M6 Nyloc Nuts
(Items 8, 9, 10 & 22) as shown. Do this on
both sides of the vehicle.
Finish off by placing M6 Nut Caps (Item 8)
over all the bolt heads.
Insert the Aluminum Spacers (Item 12)
into the Foam Washer (Item 13). 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.
10mm
12
13
© 2020 FRONT RUNNER VEHICLE OUTFITTERS
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 11 from FAJL005) or
if you are fitting a full rack (Item 1
from FAJL004) into the first slat
(Combined Slat), using the
Machined slots. Slide a bolt to each
of the outer corners.
For a Full Rack fitment refer to FAJL004
9
10
22
8
10
Take note of the M6 SS Spring Washers
(Item 22) on the Middle Support Bracket.

7 FAJL005 / FAJL006_REV_A00
4
13mm
REMOVING YOUR RACK 4
4.1
Should you wish to remove your rack,
you will need to seal 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.
23
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
© 2020 FRONT RUNNER VEHICLE OUTFITTERS

8 FAJL005 / FAJL006_REV_A00
4
COMPLETION
5
4.1
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.
© 2020 FRONT RUNNER VEHICLE OUTFITTERS