-- Expedition One

2007 + JK WRANGLER REAR BUMPER & TIRE CARRIER INSTALLATION INSTRUCTIONS

December2006

Revised February 4, 2009

 

Tools: metric & standard socket set up to ¾Ó, wrenches up to ¾Ó , and a large 1.5Ó socket are all that are needed

 

 

Parts list

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

2 L brackets with welded nut

1 rear door mounting plate

1 Coupling assembly

1 Package or 4 urethane bushings with grease

2 Rubber bump-stops

2 aluminum spacers

1 large bearing race (pre-installed into the bottom of the tire carrier hub assembly)

1 small bearing race (pre-installed into the top of the tire carrier hub assembly)

 

 

Hardware:

1 Large washer

1 Large Nylock Nut

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

7 ½Ó large O.D. grade 8 washers

2 5/8Ó grade 8 washers

2 5/8Ó x 2Ó grade 8 bolts

3 ½Ó x 2Ó grade 8 bolts

1 ½Ó x 4Ó grade 8 bolt

1 ½Ó x 4.5Ó grade 8 bolt

5 ½Ó grade 8 nylock nuts

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

We recommend watching our youtube install video: Expedition One JK Rear bumper install Video   

 

PREINSTALL NOTES:

 

¤         Keep all stock bolts and hardware. You will use some of it for the install.

¤         Be sure to check that races have been installed into the hub of the tire carrier. Comparison photos to assist in checking for the race installment can be found on the last pages of the install instructions (ref. pictures 7A,7B).

¤         Grease: We recommend using a Water resistant-high temp grease on all bearings, seals, and cap threads.

 

Remove stock rear bumper and tire carrier:

 

¤         Remove the spare tire on the vehicle.

¤         Before removing the carrier make sure to un-plug the 3rd brake-light wire. This is done by opening the rear gate and popping the plastic ventilation access panel on the driverÕs side of the vehicle. Remove by pulling from the passenger side of the panel to the driverÕs side. Inside you will see the wiring connection. Unclip the wire connector and then pop the piece from the rear gate.

¤         Remove the stock tire carrier. 4 bolts on each side of the unit. With the stock rear bumper and carrier removed you should now be ready to install your Expedition One rear bumper and tire carrier system.

 

Installing the Rear bumper:

 

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 ¾Ó hole in the side of the frame (ref picture 1).

                                                                                                                              Pic 1

 

2.       THIS PART IS EASIER 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 while 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 easyÉ

 

3.       Put the OEM mounting bolt that was 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 5/8Óx 2Ó bolts and 1 5/8Ó washers (one for each bolt),install the bolts but again, do not tighten all the way (ref picture 2).

 

Pic 2

Assembling the Coupling

 

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.

 

Installing the tire mount on the carrier:

 

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 while on the ground to avoid lifting a heavy tire and wheel repeatedly.

 

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.  (ref pictures 3A)

3.                   Make a mark using a marker (or something that you can see) that gives you an indication of the flush mounting point (ref picture 3B).

4.                   Install the tire mount on the carrier moving it back about ¼ to 3/8Ó from the marked position. Use the 3 supplied ½ x 2Ó bolts with washer and nylock nut. The tire should now fit snug on the carrier when installed.

 

 

    

Pic 3A                                                                                                                                Pic3B

 

                                                                              Pic4

 

 

 

Installing the Rear Tire Carrier:

 

Install the rubber bump-stops on the rear tail 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 3rdmounting point down on the passenger side are the 2 locations for the rubber bump-stops (ref picture 4). You may also use the bottom most hole for the lower bump-stop if so desired.

                                                                 

  

 

 

 

 

 

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. If everything is correct the carrier should  be able to stand up in correct position without being held. Install washer and nylock nut and tighten until snug. DONÕT WALK AWAY FROM THE CARRIER WHILE IT IS OPEN!!! IT COULD SWING INTO YOUR JEEP AND MAKE YOU SAD L. You can gently rest the carrier against the rear door bump-stops. The large spindle nut can now be tightened to snug.

 

                              Pic5

 

 

 

IMPORTANT NOTE: Installing the grease seal. The grease seal can be installed 2 ways. It can be put on the spindle and pushed in place while installing the carrier hub over the spindle. For some this way is easier, but we would recommend the 2nd method. This method requires putting the bearing in the hub  first and then putting on the grease seal. The following picture(s) show the proper configuration for the bearing assembly (ref pic 5)

 

 

 

 

 

 

 

 

 

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 (ref picture 6). Utilizing the stock mounting points and stock mounting bolts of the OEM tire carrier, on the driver side of the tail gate install the mounting plate but do not tighten all the way. NOTE: IF YOU HAVE A HEAVY TIRE AND WHEEL COMBINATION (OVER 150LBS) YOU MAY WANT TO INSTALL THE SPARE BEFORE ADJUSTING THE DOOR PLATE. THE EXTRA WEIGHT CAN SLIGHTLY ALTER  THE HEIGHT WHERE THE PLATE SITS ON THE DOOR.

 

 

                                                                                                                  Pic 6

 

Install the coupling on the carrier side using the 1Ú2 x 4.5Ó long bolt with corresponding nylock, 2 grade 8 washers (one on the bolt side and one on the nut side), the the 2 aluminum spacers. The 2 aluminum spacers usually sit on the topside of the bushings of the coupling and act as spacer shims there placement may vary depending on the vehicle and its spacing from the frame. The shims may have to be moved to the top or separated top to bottom depending on if you have an added body lift. (max body lift size is recommended at 1Ó).

 

Bumper and tire carrier alignment:

 

This part of the install is crucial to the function of the rear tailgate and carrier.  Pay attention!!!

 

 

With the rear gate and carrier in the closed position, you can now start the adjustment of the coupling. Overall, you want the carrier to be snug against the rear door. The coupling is the key to this, but it requires a balance. Adjust the coupling so the door is open and is 1 to 2 inches from closing when the carrier initially contacts the bump stops on the tail gate(this may need to be adjusted later when the spare tire is mounted to the carrier). Install the 4Ó bolt on tail gate side. over all you want the carrier to shut and be snug but not overly tight. DO NOT TIGHTEN THE BOLT WITHNUT! YOUÕLL PROBOBLY HAVE TO TAKE IT APART AGAIN.

 

With the carrier in the closed position and everything looking even, tighten the forward most bolt on the bumper DONÕT OVER TIGHTEN, you may need to undo them again to adjust the alignment.

There are 2 methods to getting proper pitch. 99% of the time the first method archives the correct pitch first thing. With the tire carrier installed with the door in the closed and/or almost closed position, you want the carrier to be contacting both bumpstops evenly. If the contact is even and the door swings with little or no binding the carrier pitch is good and the installation can now be completed. If it's tilting away from the vehicle, push in the top part of the carrier so that both bump stops hit evenly (you will most likely need help from another person in order to tighten the bumper bolt to keep the carrier in its correct position.) Once it is tight check the swing. If there is little or no binding you may move to the post install section and finish the install.

 

The 2nd method for getting proper pitch is described as follows: Now open the carrier until the door is perpendicular with the rear of the vehicle. You want the coupling to be sitting parallel to the ground. You also want there to be little or no binding on the coupling. If there is excessive binding on either side of the coupling you need to adjust it out by using the carrier as a lever to move the carrier up or down until the coupling sits level and/or there is no binding on the coupling. Getting it just right may require minor adjustments on each side of the bumper in the up and down position. Once it sits relatively level in both the closed and open position, and the carrier and door open and close as one unit, you can tighten the bumper bolts snug and adjust the coupling until it is at the desired tension.

 

Post installation

 

If the carrier is swinging properly free of binding on the door and coupling, you can now tighten down all bolts and install the cap.  

 

:::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.

 

We also recommend watching our youtube install video: Expedition One JK Rear bumper install Video 

 

If you have any questions email us at info@expeditionone.biz or call1-877-366-3099

 

Extra pictures for install help:

 

Top bearing race check:

                                                                              Pic7A

 

Bottom bearing race check:

                                                                  Pic 7B