Tools: metric & standard socket set up to ¾", wrenches up to ¾" , and a large 1" socket are all that are needed

1 Expedition One Trail Series Rear Bumper W/ spindle

1 CNC cut threaded aluminum Hub (hinge) cap

1 Small tapered bearing (top bearing)

1 large tapered bearing (bottom bearing)

1 Grease seal

1 Large washer

1 Large Nylock Nut

2 L brackets with welded nut

1 rear door mounting plate

1 Coupling assembly

1 ¾" (large) Jam Nut for the coupling assembly

1 Package or 4 urethane bushings with grease

2 Rubber bump-stops

9 ½" large O.D. grade 5 washers

4 ½" grade 8 washers

3 ½" grade 5 washers

5 ½" x 2" grade 8 bolts

1 ½" x 4" grade 8 bolts

1 ½" x 4.5" grade 8 bolts

2 ½" grade 8 nylock nuts

2 M8x 30mm socket cap screws (these may be inserted into the Rubber bump-stops.

• Remove the Spare tire on the vehicle.
• Before removing the carrier make sure to un-plug the 3^rd break-light wire. This is done by opening the rear gate, popping of the plastic ventilation access panel on the driver’s side of the vehicle. Remove by pulling from the passenger side of the panel to the driver’s side. Inside you’ll see the wiring connection. Unclip and then pop the piece from the rear gate.
• Remove the stock tire carrier. 4 bolts on each side of the unit.

1. Insert the L shaped brackets in the rear frame facing outward, one in each frame rail respectively. The nut in the bracket should line up roughly in the center of the large oval shaped ¾" hole in the side of the frame.



2. THIS PART IS EASYER WITH ANOTHER PERSON HELPING YOU. You may now install the rear bumper. If you have a stock receiver hitch you are going to have to slide the bumper on wile lifting the back of the bumper up slightly to clear the hitch. 1 person on each side of the bumper will make this step quick and easy…
3. Put the OEM mounting bolt that were used on the outside mounting holes in place. Do not tighten down fully. You want to leave some room for adjustment.
4. Inside the bumper on the outer ends (directly back from the stock mounting position mentioned above) is the mounting position for the L-brackets that are inside the frame. Using the 2 ½ x 2" bolts and 1 ½" large O.D. washer (one for each bolt), install the bolts but again do not tighten all the way.

Using the supplied urethane bushings and grease install the urethane bushings into each end of the coupling.

Install the Jam nut on the coupling. This will require separating the coupling fully. When putting the Coupling back together collapse it down most of the way…

When installing the tire mount, the overall goal is to have the tire snug against the tire carrier. To do this the best thing is to fit the tire carrier up wile on the ground to avoid lifting a heavy tire and wheel over and over.

We recommend this method:

1. lie the tire and wheel face down. Set the tire mount on the backside of the hole pattern.
2. Slide the carrier in place and lay it on the tire.
3. Make a mark using a marker (or something that you can see) that give you an indication of the flush mounting point.
4. Install the tire mount on the carrier moving it back about ¼" from the marked position. Use the 3 supplied ½ x 2" bolts with washer and nylock nut. The tire should now fit snug on the carrier when installed.

1. Install the Rubber bump-stops on the rear Tale Gate of the vehicle utilizing the stock tire carrier bolt pattern and 8mm socket cap screws. The top most mounting point on the passenger side and the 3^rd mounting point down on the passenger side are the 2 locations for the rubber bump-stops.



2. Insert the large bearing pack on the spindle with the bearing tapering upward. Make sure the bearing has settled over the spindle and is on the bottom or near the bottom. We recommend not installing the grease seal until you are certain the hub assembly and bearings are postioned correctly.
3. You can now put the carrier assembly on loosely. You will want the top bearing ready to install at the same time as the carrier body. Put the hub over the spindle resting it on the bottom bearing, then insert the top bearing and seat the bearing so the carrier is now fee standing. Install washer and nylock nut and tighten until snug. DON’T WALK AWAY FROM THE CARRIER WILE ITS OPEN!!! IT COULD SWING INTO YOUR JEEP AND MAKE YOU SAD L . You can gently rest the carrier against the rear door bump-stops.
4. You can now install the rear gate mounting plate. You will have to adjust the mounting plate so before Installing you may want to put some masking tape on the gate to protect it from being scratched during adjustment. Utilizing the stock mounting points of the OEM tire carrier on the driver side of the tail gate, and the stock mounting bolts, install the mounting plate but do not tighten all the way….

 



5. Install the coupling on the carrier side using the ½ x 4.5" long bolt with corresponding nylock, 2 grade 8 washers (one on the bolt side and one on the nut side), and the other 7 flat grade 5 washers. The 7 Flat grade 5 washers should sit on the topside of the bushings of the coupling and act as spacer shims. Tighten until snug.

:::NOTE::: You may want to come back and check all the bolts in a few weeks or after a nice off road trip. The bolts can loosen a bit.

Tips for Fender well Plastic:

If you have any questions give me a call 801-726-4338