JKS SuperNerfs OGS825 User manual

Installation
Instructions
Product: SuperNerfs™
JKS SuperNerf Installation PN OGS825 Page 1 of 3
Part Number: PN OGS825
Application: Jeep® Liberty KJ, 2002-07
Welcome
CONGRATULATIONS on your purchase of a
new JKS SuperNerf™ system! At JKS
Manufacturing, we are committed to providing
you with the best products available and your
satisfaction is our first priority.
PLEASE READ these Installation Instructions
carefully, and save them for future reference,
as they contain important installation and
maintenance information.
Important Safety Information
SUPERNERFS SHOULD BE WELDED
according to the installation instructions as this
will produce the strongest, most reliable
installation. However, a bolt-on installation is
possible for light to medium duty use.
Warning
INTENDED FOR VEHICLES WITHOUT
PRE-EXISTING DAMAGE to the rocker
panels or pinch welds. If damage already
exists in these areas, SuperNerfs may still be
installed as long as damage is not too severe
and pinch welds have been properly
straightened, or repaired if necessary.
Tools Required
Metric/Standard Socket Wrench Set
Torque Wrench *
Tape Measure
Razor Blade or Sharp Knife (for cutting
plastic fender flare)
Jack Stands
Bottle Jack (or similar hydraulic floor jack)
Reciprocating Saw or Die Grinder with
Cut-Off Wheel (for cutting pinch weld)
Hammer or Small Sledge *
Drill
5/16” Drill Bit
3/16” Drill Bit
3/8” Drill Bit *
1/2” Drill Bit *
3/8”-16 NC Tap *
Round or Rat-Tail File
Thread Lubricating Oil
Welder *
Satin Black Spray Paint
Factory Service Manual (recommended)
* Asterisk denotes tools that are not required for some
applications. Thoroughly read instructions first to
determine which tools will be required for your
application.
Parts Supplied
QTY DESCRIPTION
2 SuperNerfs
4 Chassis Mounting Arms
8 3/8” x 2-1/4” Bolts
8 3/8” Nylock Nuts
16 3/8” x 1” Self-Tapping Bolts
6 5/16” x 1” Bolts
6 5/16” Lock Washers
6 5/16” Flat Washers

JKS SuperNerf Installation PN OGS825 Page 2 of 3
Installation
REMOVE PLASTIC SILL MOLDING
A thin strip of plastic sill molding is attached to the pinch
weld beneath the rocker panel. These plastic pinch weld
covers must be permanently removed prior to SuperNerf
installation.
Remove the plastic sill molding from pinch weld
per the factory service manual for your vehicle.
Locate and remove the two (2) bolts that attach
the front fender to the pinch weld.
DETERMINE MOUNTING POSITION
HINT: Use jack stands to support and position
SuperNerfs during installation.
Identify the Driver-side and Passenger-side
SuperNerf by locating the corresponding “D” or
“P” stamped near the forward pre-threaded
mounting hole on square tube.
Position appropriate SuperNerf beneath rocker
panel so that the forward two (2) holes on the
square tube align with the front fender bolt
holes in pinch weld.
HINT: At this stage, the plastic fender flares will prevent
SuperNerf from fitting flush against pinch weld.
Using the SuperNerf as a guide, draw a “trim
line” on the plastic fender flares where they
prevent the square tube from fitting flush
against the pinch weld.
With SuperNerf in same position, mark the
location on the metal pinch weld where the front
and rear support legs intersect it. Set
SuperNerfs aside.
NOTCH PINCH WELDS
HINT: The Pinch Weld is the protruding body seam
located beneath the rocker panels – created where
adjoining layers of sheet metal are pinched together and
spot welded.
Using the marks from the previous step as a
guide, cut notches in the pinch weld to
accommodate the SuperNerf support legs.
Make your notches approximately 2” apart and
cut all the way to the top of the pinch weld (or
bottom of rocker panel).
HINT: A pneumatic reciprocating saw or die grinder with
cut-off wheel is useful for cutting pinch welds.
Remove the 2” long sections of pinch weld from
the vehicle by cutting flush with rocker panel, or
bend inboard until completely flat.
HINT: A hammer or small sledge is useful for bending
and flattening pinch welds.
TRIM PLASTIC FENDER FLARES
Cut the plastic fender flares along the “trim line”
to provide clearance for SuperNerf to fit flush
against pinch weld.
DRILL PINCH WELDS
Re-position SuperNerfs beneath rocker panels
and align with mounting location. Square tube
of SuperNerf should now fit flush against the
pinch weld.
Locate the pre-threaded mounting hole at rear
of square tube and mark its position on the
inboard side of pinch weld. Set SuperNerfs
aside.
Transfer your mark to the outboard side of
pinch weld using a vertical line to indicate
horizontal position.
Place a horizontal line across each vertical line
to indicate the vertical midpoint of pinch weld.
HINT: Before drilling holes in pinch weld, compare with
corresponding SuperNerf to ensure the locations of holes
are correct. Measure twice, drill once!
Drill a 3/16” pilot hole at each point in which the
vertical and horizontal lines intersect.
Enlarge all three (3) holes in each pinch weld –
including the original front fender bolt holes –
using a 5/16” drill bit.

JKS SuperNerf Installation PN OGS825 Page 3 of 3
MOUNT SUPERNERFS TO PINCH WELD
Identify the correct mounting position of the
Chassis Mounting Arms by locating the
corresponding letters stamped on the bottom of
flange.
DF = Driver Front PF = Passenger Front
DR = Driver Rear PR = Passenger Rear
Slip the proper Chassis Mounting Arms into
appropriate Support Legs of SuperNerfs.
Re-position SuperNerfs beneath rocker panels
and horizontally align with mounting holes in
pinch welds. It is unlikely that all mounting holes
will vertically align at this stage as additional
force may be necessary to raise the SuperNerfs
into position.
Place a bottle jack (or similar) beneath the
square tube of SuperNerf and carefully raise
assembly to minimize gap between rocker
panel. Closely monitor vertical alignment of
mounting holes in pinch weld. As holes align,
insert a 5/16” x 1” bolt through 5/16” lock
washer, 5/16” flat washer, and pinch weld
before threading into SuperNerf. DO NOT
tighten until all bolts have been successfully
inserted.
HINT: If any holes in pinch weld do not align with
SuperNerf, enlarge hole with a file until bolts can be
inserted without difficulty. This process is easiest with
SuperNerfs removed.
Once all bolts have been threaded into
SuperNerf, carefully tighten until SuperNerf is
secured to pinch weld. DO NOT over-tighten
bolts. Square tube should fit closely beneath
rocker panel and there should be no gap
between pinch weld.
MOUNT SUPERNERFS TO CHASSIS
Inspect vehicle chassis where Mounting Arm
flanges will attach and remove any
undercoating or debris. Flange must be flat
against the mounting surface and positioned as
high on the chassis as possible.
Fully extend Mounting Arms and rotate until
flanges are square with chassis. If necessary,
position a bottle jack beneath Mounting Arm
and raise the vertical position of flange on
chassis until square tube of SuperNerf is level.
HINT: A right-angle drill is useful for working in close
quarters. If unavailable, it is acceptable to drill holes and
insert bolts at slight angle due to limited space between
drill and support leg.
Using the flange as a guide, drill a 5/16” hole in
vehicle chassis. Insert a 3/8” x 1” self-tapping
bolt into the hole and carefully tighten until bolt
is snug. Repeat this step one at a time until all
bolts have been installed.
IMPORTANT: Use extreme care to avoid stripping
threads when tightening self-tapping bolts in
chassis. Lubricating oil will ease installation. If still
difficult, tap the holes with a 3/8”-16 NC tap.
SECURE CHASSIS MOUNTING ARMS
TO SUPERNERF SUPPORT LEGS
The Chassis Mounting Arms may be bolted or welded to
the SuperNerf support legs to complete the installation.
For best performance and the strongest connection, JKS
highly recommends the welded installation.
HINT: Before welding, remove any protective
powdercoat finish from area so that bare metal is
exposed.
Weld-On Installation
Enlarge pre-drilled holes located on SuperNerf
support legs to at least 1/2" diameter. DO NOT
drill through Chassis Mounting Arms.
Rosette weld support legs to Mounting Arms at
each hole.
Finally, weld the end of SuperNerf support legs
to Mounting Arms.
Bolt-On Installation
Using the pre-drilled holes located on the
support legs of each SuperNerf as a guide, drill
through the Chassis Mounting Arms using a
3/8” drill bit.
Insert supplied 3/8” x 2-1/4” cross bolts and
secure with 3/8” Nylock nuts. Tighten to 40 ft-lb.
using a torque wrench.
If possible, weld the end of SuperNerf support
legs to Mounting Arms for added security.
PROTECT ANY BARE METAL
Carefully inspect and locate any areas where
bare metal has been exposed due to cutting,
grinding, drilling, or welding. Paint unprotected
areas to prevent corrosion.
Maintenance
Surface of SuperNerfs may become scratched or
blemished under normal operating conditions. To
recondition the appearance and protect from corrosion,
satin black spray paint provides a close match to the
original powdercoat finish.
©2008 JKS Manufacturing, Inc & Aftermarketing, LLC
Revision Date 2/1/2008