10912 09-07-06 REV-F

INSTALLATION INSTRUCTIONS 84-96 Jeep Cherokee 2-Door XJ 85-92 Jeep Comanche CUT OUT FLARE 10912-07
TOOLS REQUIRED FOR INSTALLATION: Hand Drill 5/32 Drill Bit # 2 Phillips Bit and Driver Cut off wheel Angle Grinder Bit extender (for Torx self tapping screw installation) Reciprocating saw 10mm Socket and Ratchet Scissors/utility knife 1/4" Tape
FLARE INSTALLATION PROCEDURES
NOTE: YOU WILL BE USING THE HOSE PROVIDED WITH THE KIT FOR SPACERS BETWEEN THE BACKSIDE OF THE FLARES AND THE SHEET METAL THROUGHOUT THE INSTALLATION. THESE SPACERS WILL BE OF VARYING LENGTHS, CUT BY HAND.
Step 1: Painting (Optional)
It is recommended that painting be done prior to installation. (A) Clean outer surface with a good grade degreaser. DO NOT USE LACQUER THINNER OR ENAMEL REDUCER AS A DEGREASER. Wipe outer surface thoroughly with a tack rag prior to painting. Sand outside of flares with 320 grit sand paper and wipe clean with a high-grade degreaser. Paint flare with adhesion promoter in two light coats; allow 5 minutes flash time between coats. Let second coat dry for 15 minutes before applying primer, sealer, or topcoat. If adhesion promoter is allowed to dry for more than 4 hours, reapply adhesion promoter. Paint flare with a high build primer. Flex additive must be added to prevent paint cracking Paint flares using a high quality enamel, or polyurethane automotive paint and clear coat.

(B) (C)

(D) (E)
Step 2: Preparing the Work Area (Front and Rear)
(A) Remove factory fender trim and mud flaps (when installed).

Illustration #1

Step 3: Edge Trim Installation (See Illustration #1)
(A) Peel two to three inches of red vinyl backing away from edge trim tape. Applying the adhesive side of the edge trim to the inner side of the flare, affix the edge trim to the top edge of the flare (the portion that comes in contact with the vehicle). See Illustration #1. Press edge trim into place along the top edge of the flare in one-foot increments, pulling red vinyl backing free as you continue to work your way around the top edge of the flare.
6710 N. CATLIN AVE. PORTLAND, OR 97203 503-283-4335 1-800-234-8920 (USA AND CANADA) FAX 503-283-3007

edge trim

Step 4: Front Fender Cutting
(A) (B) Remove factory flares. Mark a tapeline horizontally from bottom of headlight bezel to the inside of fender well opening. Remove the sheet metal below this line using a reciprocating saw. (SEE ILLUSTRATION # 3) Starting at bottom of headlight bezel, measure in 5 and mark a line on the fender. Run a tapeline from mark on fender to a point tangent to the wheel well opening. (SEE ILLUSTRATION # 3) Starting at bottom back edge of fender measure in 5-1/4, mark a line, then run a tapeline from mark on fender vertically to a point tangent to the wheel well opening. (SEE ILLUSTRATION # 3) Using the tapeline as a guide, starting at bottom of the fender cut along tapeline using a reciprocating saw. Trim inner plastic liner to match outer contour of wheel well opening. Deburr edges and Seal with primer or undercoating

(E) (F)

ILLUSTRATION # 2

Step 5:

(A) (B) (C) (D)

Front Flare Installation

(E) (F) (G)
Hold the flare up to vehicle, press firmly and mark the hole locations onto the vehicle fender using the 1/4 holes in the flare as a guide. Now remove the flare. Using 5/32 drill bit, drill each mark. Place a supplied washer on a supplied screw and place screw through hole in pocket. Place a 3/8 thick spacer on the screw from the back side of the pocket. Threads must protrude through spacer for proper attachment of flare. Repeat this step for all pockets. (SEE ILLUSTRATION # 2) Holding the flare into position on the fender, align the screws with the holes drilled in Step 5C. (Note: All spacers must be installed prior to installation of flare) Start each screw with kit provided Torx bit in each pocket but do not tighten until all screws have been started. Tighten each screw so that the flare is snug against the vehicle body. (Use Caution: Do not over tighten the screws) Over tightening will not allow the flare to expand and contract with temperature changes after the flare is installed, and may strip out the sheet metal.

Lines indicate old wheel well 5
Cut at the bottom of Headlight bezel

ILLUSTRATION # 3

NOTE THAT GREY ILLUSTRATION IS HOW SHEET METAL SHOULD LOOK AFTER CUTTING

Step 6:

(A) (B) (C) (D) (E)

Rear Fender Cutting

( CHEROKEE 2-DOOR XJ )
Remove factory flares. Make a mark 11-1/2 in from the back end of fender sheet metal. From that mark, run a tapeline to a point tangent to the wheel well opening. (SEE ILLUSTRATION # 4) Make a mark 10-1/2 back from the door edge opening. From that mark, run a tapeline to a point tangent to the wheel well opening. (SEE ILLUSTRATION # 4). Using the tapeline as a guide, starting at bottom of wheel well opening, cut along tapeline using a reciprocating saw. (SEE ILLUSTRATION # 4). Deburr edges and seal with primer caulking and undercoating.

Step 7:

Rear Flare Installation
Hold the flare up to the vehicle, press firmly and mark the hole locations onto vehicle fender using the 1/4 holes in the flare as a guide. Now remove the flare. Using 5/32 drill bit, drill each mark. Place a supplied washer on a supplied screw and place screw through hole in pocket. Place a 3/8 thick spacer on the screw from the back side of the pocket. Threads must protrude through spacer for proper attachment of flare. Repeat this step for all pockets. (SEE ILLUSTRATION # 2) Holding the flare into position on the fender, align the screws with the holes drilled in Step 7C. (Note: All spacers must be installed prior to installation of flare) Start each screw with kit provided Torx bit in each pocket but do not tighten until all screws have been started. Tighten each screw so that the flare is snug against the vehicle body. (Use Caution: Do not over tighten the screws) Over tightening will not allow the flare to expand and contract with temperature changes after the flare is installed, and may strip out the sheet metal.
Solid lines indicate old wheel well
Edge of door opening Cutting approximately 1 off

ILLUSTRATION # 4

Step 8:

Rear Bed Cutting

( COMANCHE ONLY )

(A) Remove factory flares. (B) Make a mark 26-1/2 in from the back end of bed on long bed. (On short bed 20). From that mark, run a tapeline to a point tangent to the wheel well opening. (SEE ILLUSTRATION # 5) (C) Make a mark 26 back from the front edge truck bed on long bed. (On short bed 20). From that mark, run a tapeline to a point tangent to the wheel well opening. (SEE ILLUSTRATION # 5). (D) Using the tapeline as a guide, starting at bottom of wheel well opening, cut along tapeline using a reciprocating saw. (SEE ILLUSTRATION # 5). (E) (Deburr edges and seal with primer and undercoating) (F) On Comanche long bed the gas filler door has to be cut. Hold the flare up to the vehicle, press firmly and mark on the outside of the flare over gas filler door. From this line, measure in and mark a line. Using the mark line as a guide, cut along mark line using a reciprocating saw.

Step 9:

(A) Hold the flare up to vehicle, press firmly and mark the hole locations onto the vehicle fender using the 1/4 holes in the flare as a guide. (B) Now remove the flare. (C) Using 5/32 drill bit, drill each mark. (D) Place a supplied washer on a supplied screw and place screw through hole in pocket. Place a 3/8 thick spacer on the screw from the back side of the pocket. Threads must protrude through spacer for proper attachment of flare. Repeat this step for all pockets. (SEE ILLUSTRATION # 2) (E) Holding the flare into position on the fender, align the screws with the holes drilled in Step 9C. (Note: All spacers must be installed prior to installation of flare) (F) Start each screw with kit provided Torx bit in each pocket but do not tighten until all screws have been started. (G) Tighten each screw so that the flare is snug against the vehicle body. (Use Caution: Do not over tighten the screws) Over tightening will not allow the flare to expand and contract with temperature changes after the flare is installed, and may strip out the sheet metal.
Cutting approximately 1 off
20 Short bed 20 Short bed 26 long bed

Front of bed

ILLUSTRATION # 5

26 long bed

Step 10: Seating Edge Trim
(A) Using supplied Edge Trim Tool, seat edge trim against vehicle by hooking curved end under edge trim at one end of flare. Next, slide around outer edge of flare to the other end. See Illustration #6. (B) Using flat end of supplied Edge Trim Tool, seat edge trim against flare by inserting straight end between edge trim and flare at one end. Next, slide around entire edge to the other end. See Illustration #7.

YEAR 1997-02 1984-96

cherokee xj
ARB DELUXE BULL BARS & WINCH BARS MODEL Winch Bar Winch Bar
FEATURES Airbag Approved, Recessed Indicators, Tow Points, Black Airbag Approved, Recessed Indicators, Tow Points, Black
WINCHES XD9000, M8000, M6000 XD9000, M8000, M6000
PART NO. 34500801 34500101
Minor modifications to bar may be required when fitting large diameter lamps.
ipf lighting & accessories year 1984-01 1984-02 recommended lighting 800XSD, 868CS, 968CSG, 820h1 (rectangular h4 headlamp conversion kit, bulbs not included) 800XSD, 868CS, 968CSG
IPF M002 headlight upgrade harness recommended when installing high performance H4 bulbs
safari snorkel year 2/95 to 12/01 to 1/95 recommended snorkel Inline six, 4.0 Litre, Left Side Mount Inline six, 4.0 Litre, Left Side Mount Refer to www.safari4x4.com.au for details. arb air locker locking differentials & accessories year Dana 44 Dana 30 Dana 35 description http://arbusa.com/New_Products/differential_cover.pdf http://arbusa.com/New_Products/differential_cover.pdf http://arbusa.com/New_Products/differential_cover.pdf
part no. SS1195HF SS1100HF
part no. 07500032 07500021,2 07500042
Will not work with stock height vehicles Internal diff cover modifications may be necessary with some R&P ratios if contact with cover occurs
arb roof racks year 1984-02 recommended roof racks 73 x 49" with Mesh Floor 73 x 49" without Mesh Floor Fitting Kit for 73 x 49" 1984-x 49" with Mesh floor 43 x 49" without Mesh floor Fitting Kit for 43 x 49" optional Wind Deflector for 49 wide Roof Rack optional Hi-lift Jack and Shovel holder for ARB Roof Rack thule roof rack system to suit arb rooftop tent year 1985-01 1985-01 description Thule roof rack system to suit ARB Rooftop Tent (W/Factory Rack) Thule roof rack system to suit ARB Rooftop Tent (W/O Factory Rack) part no. TA50010 TA50050 part no. 3800020M 3800030M 3700310 K6202
old man emu suspension systems model 1984-02 location Front description Stock/Light Load (0-110lbs) Nitrocharger Sport Nitrocharger 1984-02 Front Heavy Load (110-200lbs) Nitrocharger Sport Nitrocharger 1984-02 Rear light load Nitrocharger sport Nitrocharger 1984-02 Rear Medium Load Nitrocharger Sport Nitrocharger 1984-02 Rear required for Installation Heavy Constant Load Nitrocharger Sport Leaf Spring Bushings U Bolts T-Case Spacer Kit Steering Damper Optional Also Available
part no. *N35/N35C N35 cs034rb 60053 *N36/N36C CS034ra 60053 *N36/N36C CS035RA 60053 OE1
type Spring Shock Shock Spring Shock Shock spring Shock shock Spring Shock Shock Spring Shock

lift 1.75"

quantity 2

1.50"

2.25"

2.0"

OMEU60/572 XJGK01 OMESD40 OMEJGF10 D22XL3
Front 10mm Trim Spacer Rear Extra Leaf NITROCHARGER SPORT Front Extended Length Shocks NITROCHARGER SPORT Rear Extended Length Shocks 2 2

60052L4 60053L4

OE rubber leaf spring bushings are used to isolate road noise. Install original bushings from OE springs if they are in good condition, or source new OE bushings from dealership. OMEU60 suits Dana 35 type axle. OMEU57 suits Chrysler 8.25" type axle. Extra leaf can be fitted for heavier constant load carrying ability. Extended Length Shocks are for 3-5" suspension lifts only. Modified bump stop are required. Firmer Shock
arb air locker locking differentials & accessories year ALL axle Front description Dana 30 shaft 29.5 (1.16") 33.3 (1.31) ALL Rear Dana 35, C-clip, 29.5 (1.16") 29.5 (1.16) 33.3 (1.21) CHRYSLER 8.25 DANA 44

spline 30

ratio 3.73 & UP 3.54 & DN 3.73 & UP 2.73-3.31 3.54 & UP 3.54 & UP ALL 3.92 & UP 3.73 & UP
part no. RD100 RD101 RD104 RD103 RD1022 RD105 RD931 RD116 RD117

30.7 (1.21) 33.3 (1.31)

Pre 1997 - 8.25 axle assemblies w/27 spline shafts will accept newer 29 splines shafts if RD93 is fitted Some Dana 35s 4.10 gear sets,may require a high speed carrier air locker (RD103)