Smittybilt 76716 User manual

Installation Instructions
Rock Crawler Roof Rack
(Part # 76716)
07-Up Jeep Wrangler J/K 2Door
For Technical Support/Warranty Information please call 310-762-9944
Smittybilt, 400 West Artesia Blvd, Compton, CA 90220

Page 1 of 9 6/3/09 Rev 1 (DP)
PARTS LIST:
1 Driver Front Leg (A) 6 Peel & Stick Foam Gaskets for Front Legs and Short Rear Mounting Brackets
1 Passenger Front Leg (B) 6 12mm Rubber Plug/Grommets
1 Driver Rear Top Leg (C) 4 12-1.75mm x 35mm Hex Head Bolts
1 Passenger Rear Top Leg (D) 4 12mm ID x 32mm OD x 3mm Flat Washers
1 Driver Rear Bottom Leg (E) 4 12mm Lock Washers
1 Passenger Rear Bottom Leg (F) 4 10-1.50mm x 35mm Hex Head Bolts
2 Short Rear Mounting Bracket (optional drill mount) (G) 4 10mm ID x 27mm OD x 3mm Flat Washers
2 Metal Plates (optional drill mount) (H) 4 10mm Lock Washers
6 Knobs with 8mm Nylon Locking Hex Nut (I) 6 8-1.25mm x 70mm Allen Bolts (
for Cross Rail
use only)
1 Front Cross Bar / Light Bar (J) 10 8-1.25mm x 65mm Allen Bolts
1 Rear Cross Bar / Light Bar (K) 12 8-1.25 x 35mm Hex Bolts Grade 10.9
1 Front Basket Holder Cross Rail (Short) (L) 8 8mm x 24mm OD x 2mm Thick Flat Washers
1 Front-Center Basket Holder Cross Rail (Mid Length)(L) 40 8mm x 16mm OD x 1.6mm Flat Washers
1 Rear Basket Holder Cross Rail (Long) (L) 8 8mm Lock Washers
2 Side Rails (M) 14 8mm Nylon Lock Nuts
2 12mm Double Nut Plates (N) 2 ST # 5 x 30mm Sheetmetal Screw
2 Rubber Bumpers 2 ST 9.8mm OD x 5.4mm ID x 1.1mm Flat Washers
2 2” Plastic caps for bottom of front legs
CAUTION: Recommended load rate is 350 lb. Too much weight will greatly reduce the stability of your
vehicle and increase the vehicle’s tendency to overturn. The manufacturer makes no representation or
warranty as to the amount of weight that your vehicle can safely carry. For guidance, we recommend that
you consult the vehicle manufacturer. Secure all payloads properly for safe transportation.
The Rock Crawler Roof Rack is NOT designed as a roll over roll bar.
NOTE: The "no drilling required, bolt-on" bottom rear leg mounts, (E & F), of your new Rock Crawler Roof
Rack are designed to work with aftermarket bumpers only and are not compatible with the factory bumper.

Page 2 of 9 6/3/09 Rev 1 (DP)
REMOVE CONTENTS FROM BOX. VERIFY ALL PARTS ARE PRESENT. READ INSTRUCTIONS
CAREFULLY BEFORE STARTING INSTALLATION. DRILLING IS OPTIONAL.
DO NOT TIGHTEN ANY HARDWARE UNTIL THE ROOF RACK IS FULLY ASSEMBLED.
(A) (B) (C) (D)
(E) (F)
(G)
(H)
(I)
(J) (K)
(L)
(M)
(N)
Rubber Bumper

Page 3 of 9 6/3/09 Rev 1 (DP)
Fig 2
Fig 3
DO NOT TIGHTEN HARDWARE UNTIL ASSEMBLY IS FINISHED
PROCEDURE:
1. Peel, stick and trim the self sticking Foam Gaskets
to the inside surface of the two mounting tabs on
each Front Leg. Remove the driver side (4) factory
outer windshield hinge bolts. Locate the driver side
Front Leg, (A) and attach it to the windshield hinge
using (4) 8-1.25mm x 35mm Hex Bolts, (4) 8mm
Lock Washers and (4) 8mm x 24mm OD x 2mm
Thick Flat Washers, (Figure 1).
2. Slide front Cross Bar into partially installed driver
side Front Leg and secure it with the included (1)
8mm x 65mm Allen Bolt, (2) 8mm Flat Washers
and (1) 8mm Nylon Lock Nut, (Figure 2).
3. Remove the passenger side (4) factory outer
windshield hinge bolts. Locate the passenger side
Front Leg, (B) and apply the Foam Gasket as
described in Step 1. Align the holes on the lower
section of the Front Leg with holes on the
windshield hinge and slide the tube into the Cross
Bar. Secure the Front Leg to the vehicle using (4)
8-1.25mm x 35mm Hex Bolts, (4) 8mm Lock
Washers and (4) 8mm x 24mm OD x 2mm Thick
Flat Washers. Proceed to secure upper section of
the Front Leg to Front Cross Bar using the
included (1) 8mm x 65mm Allen Bolt, (2) 8mm Flat
Washers and (1) 8mm Nylon Lock Nut, (Figure 3).
4. Remove the two bolts holding the aftermarket
bumper-if equipped, (Figure 4).
DO NOT TIGHTEN HARDWARE UNTIL ASSEMBLY IS FINISHED
Fig 1
Fig 4
Apply foam tape to the back of
these mounting tabs to protect
vehicle's finish.
Cross Bar pictured with tabs
facing forward (optional).
Recommended install is with
tabs facing to the rear.
(
4
) 8mm x
35
mm
Hex Bolts
(4) 8mm Thick
Flat Washers
(4) 8mm Lock
Washers

Page 4 of 9 6/3/09 Rev 1 (DP)
5. OPTIONAL: If you decide to bolt the Roof Rack
directly to the body of the vehicle, remove both
taillights from vehicle at this time, (Figure 5).
NOTE: Drilling required for "Bolt Direct to
Body" Installation. See Figures 14-On, Steps
18-On for detailed information.
6. NOTE: Cover the ends of the Side Rails facing
the rear of the vehicle with masking tape to
protect the vehicle from damage during
assembly. Slide both Side Rails, (with top holes
angled towards the outside of the vehicle), into
the previously installed Front Legs. Secure the
Side Rails to the Front Legs using the included
(1) 8mm x 65mm Allen Bolt, (2) 8mm Flat
Washers and (1) 8mm Nylon Lock Nut,
(Figure 6). Do not tighten hardware.
7. To better support the Roof Rack when loaded,
(2) Rubber Bumpers are included in the
installation kit. The Rubber Bumpers can be
installed at a point 29" up from the end of the
Rear Leg for vehicles with hard tops or at 6-3/8"
for vehicles with hard or soft tops, (Figure 7).
Once the location is determined and marked,
select the side of the Rear Leg (C,D) facing the
vehicle and mark the location. Remove the Rear
Leg. Place the Rear Leg on a stable work
surface with the side to be drilled facing up. Drill
an 1/8" hole into the Rear Leg. Drill only through
the side requiring the Rubber Bumper. Do not
drill through both sides of the tube. Secure the
Rubber Bumper to the Rear Leg with (1) #5 x
30mm Screw and (1) 5mm Flat Washer. Snug
but do not over tighten or the Rubber Bumper
will be deformed.
DO NOT TIGHTEN HARDWARE UNTIL ASSEMBLY IS FINISHED
Fig 6
Fig 5
6
-
3/8"
29
"
End of the tube
Fig 7
4
-
Door installation is pictured as an
example. 2 and 4-Door Rock Crawler
Roof Rack installation is identical

Page 5 of 9 6/3/09 Rev 1 (DP)
Fig 8
Fig 9
Fig 10
Fig 11
8. On a clean, stable work area, assemble the
rear section of the Roof Rack by attaching
both Upper Rear Legs to the Rear Cross Bar.
NOTE: The Rear Cross Bar can be installed
with the light tabs facing forward (preferred)
or rearward (optional). Secure this assembly
by using the included (2) 8mm x 65mm Allen
Bolts, (4) 8mm Flat Washers and (2) 8mm
Nylon Lock Nuts, (Figure 8). Do not tighten
hardware at this time.
9. With assistance, attach the assembled rear
top section of the Roof Rack to the already
inserted Side Rails. NOTE: Be careful not to
damage the vehicle when attaching the top
section. Use the included (2) 8mm x 65mm
Allen Bolts, (4) 8mm Flat Washers and (2)
8mm Nylon Lock Nuts to attach the Rear Top
Legs to the Side Rails, (Figure 9 & 10).
10.For "Bolt Direct to Body" installation, proceed
to Step 18.
11.With assistance, hold the rear section of the
Roof Rack up and attach the Rear Bottom Leg
section to the Rear Top Leg section using the
included (2) 8mm x 65mm Allen Bolts, (4) 8mm
Flat Washers and (2) 8mm Nylon Lock Nuts,
(Figure 11). IMPORTANT! Do not lay Roof
Rack on your vehicle to attach the Rear Bottom
Legs at any time. Damage to the vehicle may
occur.
(2) 8mm x 65mm Allen
Bolts
(4) 8mm Flat Washers
(2) 8mm Nylon Lock Nuts
(2) 8mm x 65mm Allen Bolts
(4) 8mm Flat Washers
(2) 8mm Nylon Lock Nuts
IMPORTANT! Do not lay Roof
Rack on your vehicle to attach the
Rear Bottom Legs at any time.
Damage to the vehicle may occur.
3pc. Rear Section
4
-
Door installation is pictured as an
example. 2 and 4-Door Rock Crawler
Roof Rack installation is identical

Page 6 of 9 6/3/09 Rev 1 (DP)
Fig 12B
Note:
Installation shown with aftermarket
bumper. Use the included Double Nut Plate,
(N), inside the rectangular frame tube as
required for installation on vehicles without
rear bumper or aftermarket bumpers that are
not threaded for mounting bolts. Also use the
following hardware included with this kit as
needed:
(4) 12-1.75mm x 35mm Hex Bolts
(4) 12mm Lock Washers
(4) 12mm x 32mm OD x 3mm Flat Washers
DO NOT TIGHTEN HARDWARE UNTIL ASSEMBLY IS FINISHED
12.Position the passenger Rear Bottom Leg
up to the frame and align the holes in the
Bracket with holes in the frame for the
bumper. Secure the rear holes in the
Mounting Bracket to the bumper using the
same bolts that came with your
aftermarket bumper. Attach the front of
the Bracket to the frame using the factory
bolts or the included hardware, (Figure
12A & 11B). Repeat this step for the
driver side installation.
13.NOTE: All Basket Holder Cross Rails are
different sizes with the shortest to the front,
mid length to the center and the longest to
the rear of the Roof Rack. Locate the
shortest Cross Rail and position it over the
mounting bolt holes toward the front of the
Side Rails, (Figure 13).
14.To secure the Basket Holder Cross Rail to
Side Rails, insert (1) 8mm x 70mm Allen
Bolt with (1) 8mm Flat Washer up through
the bottom hole in the Side Rail and
through Cross Rail. Place (1) 8mm Flat
Washer over the bolt and secure it with the
included Plastic Knob, (Figure 13).
15.Repeat steps 12 and 13 for the rest of the Basket Holder Cross Rails.
16.Align Roof Rack properly then tighten all hardware.
17.Do periodic inspections to the installation to make sure all hardware is secure and tight.
Fig 12A
Fig 13
(N)
(2) 8mm x 65mm
Allen Bolts
(4) 8mm Flat
Washers
(2) 8mm Nylon
Lock Nuts

Page 7 of 9 6/3/09 Rev 1 (DP)
OPTIONAL "BOLT DIRECT TO BODY" INSTALLATION INSTRUCTIONS
18.Select the (2) Short Bottom Brackets and apply
Peel and Stick Foam Gasket Material (G) to the
back of the 2-hole mounting tabs. With
assistance, hold the rear section of the Roof
Rack up and attach the Short Bottom Bracket to
the Rear Top Leg Section using the included (2)
8mm x 65mm Allen Bolts, (4) 8mm Flat Washers
and (2) 8mm Nylon Lock Nuts (Figure 14).
IMPORTANT! Do not lay Roof Rack on your
vehicle to attach the Rear Bottom Legs at any
time. Damage to the vehicle may occur.
19. Align the Side Rails parallel with the roof of the
vehicle, and then use the holes in the Short
Bottom Bracket as a template to mark the drilling
location on the vehicle, (Figure 15). NOTE:
Center of the holes must be 3/4” from body
seam, (Figure 16).
20.Once you have marked the drill locations on
both sides of the vehicle, remove the rear
assembly of the Roof Rack and set it aside.
NOTE: Do not remove the Short Bottom
Brackets from the Rear Legs.
21.Use a 3/8” drill bit to drill out the (4) marked
locations, (Figure 17). IMPORTANT: Any
cutting or drilling tool may break or shatter.
Government regulations require safety glasses &
equipment at all times when cutting or drilling.
Fig 14
Fig 15
Fig 16
Fig 17
(2) 8mm x 65mm
Allen Bolts
(2) 8mm Nylon
Lock Nuts
(4) 8mm Flat
Washers
Body seam
Mark location to drill
3/4" from seam-
toward rear of vehicle
Before installing the Short
Bottom Brackets, apply
foam tape to the back of
the mounting tabs to
protect vehicle's finish
WARNING: Before drilling into the vehicle, verify
that all parts of the Roof Rack are completely
clear of any top mechanisms, (soft and hard
tops), sunroofs and factory or added accessories
Body seam

Page 8 of 9 6/3/09 Rev 1 (DP)
22.Starting on the driver side, place adhesive
backed rubber gaskets between the body
and the Short Bottom Brackets,
(Figure 18).
23.With assistance, re-install the rear
assembly of the Roof Rack to the Side
Rails. Line up the holes in the Bottom
Bracket to previously drilled holes,
(Figure 18).
24.Insert (2) 8mm x 35mm Hex Head Bolts with (2) 8mm
Flat Washers through the Short Bottom Brackets and
body. Access the hardware through the opening for
the taillight and position the 2-hole Metal Plates over
the already inserted 8mm Hex Bolts, (Figure 19).
25. Secure the Metal Plates using the included (2) 8mm
Flat Washers and (2) 8mm Nylon Lock Nuts,
(Figure 19).
26.Repeat Steps 21-25 for the passenger side
installation.
27.Go to steps 13-14 to attach the Basket Holder Cross Rails.
28.Align Roof Rack properly and tighten all hardware.
29.IMPORTANT: Do periodic inspections to the installation to make sure all hardware is secure
and tight.
To protect your investment, wax this product after installing. Regular waxing is recommended to
add a protective layer over the finish. Do not use any type of polish or wax that may contain abrasives
that could damage the finish.
Fig 18
Fig 19
8mm x 35mm Hex Bolt
(2) 8mm x 35mm Hex
Bolts
(4) 8mm Flat Washers
(2) 8mm Nylon Lock nuts

Page 9 of 9 6/3/09 Rev 1 (DP)
LIMITED WARRANTY
Smittybilt (The Company) warrants to the original purchaser of this product that should the product or any
part thereof, under normal use and conditions, be proven defective in material or workmanship within the
warranty period of 5 years from the date of purchase, such defect(s) will be repaired or replaced (At the
Company’s option) without charge for parts or labor. To obtain repair or replacement within the terms of the
warranty, the product is to be delivered with proof of warranty coverage ( e.g. dated bill of sale, receipt),
specification of defect, freight pre-paid with Returns Good Authorization Number from Smittybilt to place of
purchase. Items returned to Smittybilt without a Returns Authorization Number will be refused and returned to
sender at the senders’ expense.
This warranty does not apply to any product or part thereof which, in the opinion of the Company, has
suffered or been damaged through altercation, improper installation, mishandling, misuse, neglect accident or
acts of nature. THE EXTENT OF THE COMPANY’S LIABILITY UNDER THIS WARRANTY IS
LIMITED TO THE REPAIR OR REPLACEMENT PROVIDED ABOVE AND, IN NO EVENT,
SHALL THE COMPANY’S LIABILITY EXCEED THE PURCHASE PRICE PAID BY THE
PURCHASER FOR THIS PRODUCT.
This warranty is in lieu of all expressed warranties and liabilities. ANY IMPLIED WARRANTIES,
INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY SHALL BE LIMITED TO THE
DURATION OF THIS WRITTEN WARRANTY. ANY ACTION FOR BREACH OF ANY WARRANTY
HEREUNDER INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY MUST BE
BROUGHTH WITHIN A PERIOD OF 90 DAYS FROM DATE OF ORIGINAL PURCHASE.IN NO CASE
SHALL THE COMPANY BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES FOR
BREACH OF THIS OR ANY OTHER WARRANTY, EXPRESSED OR IMPLIED,WHATSOEVER. No
person or representative is authorized to assume for the company any liability other than expressed herein in
connection with the sale of this product. Some states do not allow limitations on how long an implied warranty
lasts or the exclusion or limitation of incidental or consequential damage, therefore above limitations may not
apply to you. This warranty gives the purchaser specific legal rights. The purchaser may have additional rights,
which vary from state to state.
Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of
incidental or consequential damage, therefore above limitations may not apply to you. This warranty gives the
purchaser specific legal rights. The purchaser may have additional rights, which vary from state to state.