Or-Fab 83241 User manual

421 MAIN STREET, RIVERSIDE CA, 92501 | UNITED STATES | (951)-680-9595 | WWW.ORFAB.COM
INSTALLATION INSTRUCTIONS
JEEP Cherokee XJ-MJ HD Front Winch
Bumper 2007-2017
Item Kit No.
1984-2001 83240
1984-2001 W/ HOOP 83241
1984-2001 ROCK-COMP 83248
WARNINGS/CAUTIONS
Before you install this kit, read and understand
all instructions, warnings, cautions, and notes in
this instruction sheet and in the vehicle owner’s
manual.
Proper installation of this kit requires knowledge
of the factory recommended procedures for removal
and installation of original equipment components.
We recommend that the factory shop manual and
any special tools needed to service your vehicle
be on hand during the installation. Installation of
this kit without proper knowledge of the factory
recommended procedures may affect the perfor-
mance of these components and the safety of the
vehicle. We strongly recommend that a certified
mechanic familiar with the installation of similar
components install this kit.
Many states and municipalities have laws
restricting bumper heights and "type". Consult
state and local laws to determine if the changes
you intend to make to the vehicle comply with
the law.
Always wear eye protection when operating
power tools.
Before you install this kit, block the vehicle tires
to prevent the vehicle from rolling.
OR-FAB Inc. recommends using the Loctite supplied
in the kit on the threads of all kit nuts and bolts
unless specified otherwise in these instructions.
If parts are missing from kit, please be prepared
to provide the following information:
1. Name of purchase location
2. Bar Code on side of box
3. Date above bar code
4. Date inside box cover
5. Inspector # from inside box cover
NOTE
Kit parts are prefaced by the word kit
and appear in bold print.
BEFORE STARTING INSTALLATION
1. Carefully read all warnings and instructions
completely before beginning.
2. Verify all parts have been received in this kit
by checking the parts list at the end of this
document.
3. Only install this kit on the vehicle for
which it is specified. If anytime during
the installation you encounter something
different from what is outlined in the
instructions, call technical support at the
number below.
4. Special tools needed:
a. Die grinder or similar tool capable of cut-
ting metal and plastic.
b. 7/32 drill bit
ENGINE COMPARTMENT
1. Disconnect both battery cables. Disconnect
negative cable first, then positive cable.
NOTE
OR-FAB HD front winch bumper will ONLY mount
8000lb (WARN M8000). “low profile“ remote winches.
9500lb. winches will fit with minor modifications to
the lower core support depending on size.

CHEROKEE XJ 2 HD FRONT BUMPER 1984-2001 - Kit 83240-241-248
Prepare to Install Kit
Front of Vehicle
1. Bumper
a. 1997-2001 Models: Remove push clips and pull
back wheel well liner from front bumper.
Wheel Well
Push Clip
Front
Bumper
b. 1997-2001 Models: Remove four bolts from
front bumper and two fenders.
Fender
Bolts
Front
Bumper
c. Disconnect vacuum line from vacuum reservoir.
Vacuum
Line
Vacuum
Reservoir
Front
Bumper
d. Remove six bolts and bumper from vehicle.
Front
Bumper
Bolts
e. Remove four c-clip fasteners from vehicle.
Unibody
C-Clips
f. 1984-1996 Models: Remove two bolts and vac-
uum reservoir from bumper.
Front
Bumper
Vacuum
Reservoir
Bolts
421 MAIN STREET, RIVERSIDE CA, 92501 | UNITED STATES | (951)-680-9595 | WWW.ORFAB.COM

CHEROKEE XJ 3 HD FRONT BUMPER 1984-2001 - Kit 83240-241-248
g. 1997-2001 Models: Remove two bolts, two
nuts, and bumper corner cover from bumper.
Front
Bumper
Bolts &
Nuts
Bumper
Corner Cover
h. 1997-2001 Models: Remove two torx bolts and
vacuum reservoir from bumper.
Front
Bumper
Torx
Bolts
Bumper
Corner Cover
2. Horns
a. Disconnect two wire harnesses from two horns.
Bracket
Horn
Wire
Harness
b. Remove two bolts, two brackets, and two horns
from vehicle.
3. 1984-1996 Models: Lower valence & fender flares
a. Remove five screws from lower valence and
core support.
Core
Support
Screws
Lower
Valence
b. Remove eight bolts and two lower valence sup-
ports from two fenders and core support.
Lower
Valence
Support
Bolts
Fender
c. Remove six nuts from two front wheel wells and
pull two fender flares away from front of fenders.
Fender Flare
Wheel Well
Nuts
421 MAIN STREET, RIVERSIDE CA, 92501 | UNITED STATES | (951)-680-9595 | WWW.ORFAB.COM

421 MAIN STREET, RIVERSIDE CA, 92501 | UNITED STATES | (951)-680-9595 | WWW.ORFAB.COM
CHEROKEE XJ 4 HD FRONT BUMPER 1984-2001 - Kit 83240-241-248
4. Remove three steering box bolts and washers from
driver side unibody and steering box.
Bolts &
Washers
Unibody
Steering
Box
Install Kit
Engine Compartment
1. Cruise Control Models: Vacuum lines
Check Valve
T-Connector
Vacuum Reservoir
AFTER
BEFORE
Intake Manifold
Cruise Control
Manifold Line
Fitting
Reservoir
Line
*Not To Scale
WARNING
Vacuum fittings and lines may have become brittle over
time. Use care when handling fittings and vacuum
lines. If necessary, use lengths of kit line (vacuum) in
place of cracked or damaged vacuum line.
a. Remove line from cruise control fitting and t-con-
nector.
b. Remove T-connector from reservoir line and
manifold line.
c. Trim manifold line, if necessary, and install onto
cruise control fitting.
d. Remove wiring harness and clips from driver
side inner fender.
Inner
Fender
Clips
Wiring
Harness
e. Install two kit bracket (2” step) onto driver side
inner fender with two kit bolts (5/16” x 3/4” self-
tapping). DO NOT TIGHTEN.
Vacuum
Reservoir
Kit Bracket
(2” Step)
Kit Bolt
(5/16” x 3/4”)

421 MAIN STREET, RIVERSIDE CA, 92501 | UNITED STATES | (951)-680-9595 | WWW.ORFAB.COM
CHEROKEE XJ 5 HD FRONT BUMPER 1984-2001 - Kit 83240-241-248
f. Install vacuum reservoir onto two kit brackets
(2” step) with two factory c-clips and bolts. DO
NOT TIGHTEN.
C-Clips &
Bolts
Vacuum
Reservoir
Kit Ties
(Zip)
g. Install wiring harness onto two kit brackets (2”
step) with two kit ties (zip).
h. TIGHTEN two kit bolts (5/16” x 3/4”) and two
factory bolts.
i. Remove manifold line and fitting from check
valve and intake manifold.
j. Install T-connector onto check valve.
k. Install manifold line into T-connector.
l. Install vacuum reservoir line into T-connector
and route vacuum reservoir line to vacuum res-
ervoir.
m. Trim vacuum reservoir line, if necessary. Install
vacuum reservoir line onto vacuum reservoir
with rubber fitting.
2. Non-Cruise Control Models: Vacuum lines
a. Repeat above steps, ignoring cruise control pro-
cedures.
Front of Vehicle
1. Air temp sensor
a. Remove bolt and sensor from core support.
Install bolt back into core support.
Bolt &
Sensor
Wiring
Harness &
Clip
Core
Support
b. Disconnect wiring harness from sensor.
c. Remove sensor wiring harness and clip from
core support.
d. Route wiring harness connector next to passen-
ger side horn.
e. Install sensor onto passenger side bracket with
kit bolt (1/4” x 1”), two kit washers (1/4” SAE),
and kit nut (1/4” Nylock).
NOTE
Drill 1/4” hole into bracket, if necessary.
Bracket
Kit Bolt
(1/4” x 1”),
Kit Washers
(1/4” SAE),
Kit Nuts
(1/4” Nylock)
Sensor &
Wiring Harness Kit Tie (Zip)
f. Connect wiring harness onto sensor.
g. Install wiring harness onto bracket with kit tie
(zip).

421 MAIN STREET, RIVERSIDE CA, 92501 | UNITED STATES | (951)-680-9595 | WWW.ORFAB.COM
CHEROKEE XJ 6 HD FRONT BUMPER 1984-2001 - Kit 83240-241-248
2. Gap guard
a. Install kit gap guard, dull side out, onto core
support with two kit clips (push) through top
driver and passenger holes of kit gap guard and
corresponding holes in core support.
Kit Clips
(Push)
Kit Gap
Guard
Core
Support
b. Drill four 7/32” holes into core support corre-
sponding to kit gap guard holes.
Kit Gap
Guard
Core
Support
Drill Here
c. Install 4 kit clips (push) into previously drilled
holes.
Kit Clip
(Push)
Kit Gap
Guard
Core
Support
3. 1984-1996 Models: Driver fenders
a. Position kit corner (driver) onto kit bumper
(center) and using kit corner (driver) as a guide,
mark fender approximately 1” below side
marker.
NOTE
For proper fender flare retention, attempt to cut fender
flare and bracket BELOW fender flare bracket stud.
NOTE
Further trimming of the fender and fender flare may be
required for desired fitment.
Mark Fender
Fender Flare
b. Cut fender along marked line.
Fender
Marked Line
c. Test fit kit corner (driver) onto kit bumper (cen-
ter).
Cut Fender
Kit Bumper
(Driver)

421 MAIN STREET, RIVERSIDE CA, 92501 | UNITED STATES | (951)-680-9595 | WWW.ORFAB.COM
CHEROKEE XJ 7 HD FRONT BUMPER 1984-2001 - Kit 83240-241-248
d. Mark and cut fender flare and fender flare
bracket along marked line for desired fit.
Remove lower valence along with cut portions of
fender flares.
Cut Fender
Flare
Fender Flare
Stud Hole
Cut Fender
Flare Bracket
e. Install fender flare and fender flare bracket onto
fender with nut, if possible.
f. Repeat above steps for kit corner (passenger)
4. Install winch
NOTE
OR-FAB Inc. HD front winch bumper will ONLY mount
8000lb. “low profile” remote winches. 9500lb. winches
will fit with minor modifications to the lower core
support.
Winch supplied mounting bolts may not be sufficient in
length.
a. Mount winch prior to installing bumper onto XJ.
Note: Be sure to mount winch with line feed on top
Mount Winch Example
Bumper
1. Installing bumper
a. Install kit bumper onto unibody with two kit
bolts (10mm x 40mm), and two kit washers
(10mm). DO NOT TIGHTEN.
Kit Bumper
(Center)
Kit Bolt
(10mm x
40mm),
Kit Washer
(10mm)
Unibody
b. Apply a small amount of kit Loctite® (6ml bottle)
onto threads of three kit bolts (7/16” x 4-1/2”)
and install kit bracket (steering box), kit
bumper, steering box, and steering box spacer
onto unibody with three kit bolts (7/16” x 4-1/2”)
and three washers. DO NOT TIGHTEN.
c. Install two kit bolts (1/2” x 1-1/2”), two kit wash-
ers (1/2” SAE), and two kit nuts (1/2” flange)
onto kit bumper and drivers side unibody.
NOTE
A spacer exists between unibody and steering box.
Ensure kit bolts (7/16” x 4-1/2”) are installed through
steering box spacer.
Kit Bolts
(7/16” x 4-1/2”),
Washers
Kit Bracket
(Steering
Box)
Kit Bolts
(1/2” x 1-1/2”),
Kit Washers
(1/2” SAE),
Kit Nuts
(1/2” Flange)

421 MAIN STREET, RIVERSIDE CA, 92501 | UNITED STATES | (951)-680-9595 | WWW.ORFAB.COM
CHEROKEE XJ 8 HD FRONT BUMPER 1984-2001 - Kit 83240-241-248
d. Install five kit bolts (1/2” x 1-1/2”), five kit wash-
ers (1/2” SAE), and five kit nuts (1/2” flange)
onto kit bumper and passenger side unibody.
Magnet may be used, through the front access
hole, to feed kit flange nuts (1/2”) into unibody.
DO NOT TIGHTEN.
Kit Bolts
(1/2” x 1-1/2”),
Kit Washers
(1/2” SAE),
Kit Nuts
(1/2” Flange)
Kit Bumper
2. Driver side horn
a. Remove nut and bracket from horn.
Bracket
Nut
Horn
b. Bend bracket tab as shown.
Bend Tab
Back
Horn
Bracket
c. Install bracket onto vehicle with bolt. DO NOT
TIGHTEN. Ensure bracket is positioned as
shown.
Bolt
Horn
Bracket
Vehicle
d. Install horn onto bracket with nut. TIGHTEN bolt
and bracket onto vehicle.
Wiring
Harness
Bolt
Nut
FRONTSIDE
BACKSIDE
Horn
e. Install wiring harness onto horn.
f. Repeat above steps for passenger side horn.

421 MAIN STREET, RIVERSIDE CA, 92501 | UNITED STATES | (951)-680-9595 | WWW.ORFAB.COM
CHEROKEE XJ 9 HD FRONT BUMPER 1984-2001 - Kit 83240-241-248
After Completing Installation
Engine Compartment
1. Connect both battery cables. Connect positive cable
first, then negative cable.
Positive
Cable
Battery
Negative
Cable
Miscellaneous
1. Check all fasteners to ensure they are tight.
2. Ensure all wires, hoses, cables, etc. are properly
connected and there is ample slack.
3. Check vacuum system for leaks.
Dynamic Vehicle Check
1. Check steering and suspension in all positions to
ensure that there is no bind and adequate clearance
between all moving, fixed, and heated members.
Check tire-to-bumper clearance and ensure no con-
tact in any position. Check battery connections and
electrical component operations. Test-drive vehicle.
Check cruise control, if equipped, and all vacuum
controlled vehicle systems. If vacuum leaks are
found, correct immediately.
NOTE
All warranty information, instruction sheets, and other
documents regarding the installation of this product
must be retained by the vehicle owner. Information
contained in the instructions and on the warranty card
will be required for any warranty claims. The vehicle
owner needs to understand the modifications made to
the vehicle and how they affect vehicle handling and
performance. Failure to provide the customer with this
information can result in damage to the vehicle and
severe personal injury.
CAUTION
OR-FAB Inc. does not recommend any particular
wheel and tire combinations for use with its bumpers
and cannot assume responsibility for the customer’s
choice of wheels and tires.

421 MAIN STREET, RIVERSIDE CA, 92501 | UNITED STATES | (951)-680-9595 | WWW.ORFAB.COM
CHEROKEE XJ 10 HD FRONT BUMPER 1984-2001 - Kit 83240-241-248
Kit Parts List
Qty. Description
Kit 83240 - 83241 - 83248
1Bracket (Steering Box)
1Bumper (Main)
1Gap guard
1Line (Vacuum)
1 ZH83240 (Hardware Bag Kit)
2Bracket (2” step)
2Bolt (10mm x 40mm)
1Bolt (1/4” x 1”)
2Bolt (5/16” x 3/4” self-tapping)
3Bolt (7/16” x 4-1/2”)
7Bolt (1/2” x 1-1/2”)
6Clip (push)
1Loctite® (6ml bottle)
1Nut (1/4” Nylock)
7Nut (1/2” flange)
4Tie (zip)
2Washer (10mm)
2Washer (1/4” SAE)
3Washer (7/16” USS)
7Washer (1/2” SAE)
NOTE
Depending on the vehicle configuration some parts
may not be used.
Rev. 01, Copyright 12/15
OR-FAB Inc.
www.orfab.com