American-expedition-vehicles Tummy Tucker – TJ Wrangler NON-Rubicon Manuel d'utilisateur télécharger pdf (Page 5)

Installation Instructions:Tummy Tucker™ – TJ Wrangler NON-Rubicon

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Fig. 6

Fig. 7

NOTE: We recommend applying anti-seize compound to the conical shoulder of the bolts (not just the

threads) to make them easier to remove later. Without this, the bolts can ‘bite into’ the powdercoat in

the countersunk holes of the TT and become difficult to remove.

NOTE: Frame Hole Alignment: Wrangler frame rails are naturally twisted inward at the bottom due to

the weight of the body pushing down at the body mounts – this causes the holes for the skid to shift

closer together than they were intended. The TT is designed to original Jeep CAD dimensions – and

so will hold the frame rails in place and keep your body mounts from sagging, but during installation, it

may appear that the skid is slightly too wide – this is normal.

models, there may be room for the hole to be forward

slightly from the original hole (about 1/8” forward is

ideal). Figure 6 shows a modified bracket for a ’97 TJ

with 4.0L/AX-15 manual trans. If there is not enough

material to locate the new hole forward, space the

bracket forward when reinstalling by placing one 3/8” ID

x 1/8” thick washer on each stud before the bracket.

- ‘03+ TJ’s

, The transmission bracket is made from round

stock with ‘smashed’ end tabs and a flattened area for

the green grommet. You should have been supplied with

a small plate and u-bolt that were included with the transmission adapter bracket. Remove the stock

bracket and grommet as described for ’97-02 TJ’s, then attach the plate to the stock bracket using

the supplied 7/16” bolt. The plate goes on the transmission side of the factory bracket; place the bolt

through the large round hole in the plate (the one with more material around the hole), then the

original grommet hole (from the non-trans side) and as shown in figure 7. Next place the small u-

bolt over the lower leg of the stock bracket and through the

two slotted holes in the plate – secure with washers and nuts

on the plate side. Install the green grommet into the new

hole on the plate from the non-trans side. Re-install the

bracket/plate assembly to the t-case bolts.

Snap the relay rod end into the green grommet. After installing

the TT skid in step 9, you should be able to confirm that the rod

is roughly horizontal again – this is the key to allowing the

linkage to work properly and be able to select all ranges without

binding or interference.

Step 9: Attach TT Main Skid Plate

. Elevate the powertrain all the way up against the floor for this step.

Confirm that you were supplied the correct fasteners laying the threaded portion of one against the

threads of an original bolt – they must ‘mesh’ exactly (’97-02 TJ’s use ½-13 SAE bolts; ’03-06 TJ’s use

M12 bolts). Some TT’s are made to fit multiple models of Wranglers, and have multiple sets of holes

along the frame rails. If your TT has two sets of holes, you must have an ’97-02 TJ - align the rearward

hole of each front pair to your first frame holes and the rest should line up (the right-rear will actually be

the forward hole for that pair - the other 6 holes are for YJ frames). Once the TT is positioned (make

sure the isolators didn’t hang up on the ribs) line up the countersunk holes with the frame holes and

hand-thread all six flathead bolts.

To make it easiest to get all six bolts started, do not set any of the bolts into their countersinks until they

are all started – then snug them up with a wrench. After the clearance check below, torque to 75 ft-lbs.

Clearance Check: Due to variations between vehicles, a few installations may need to ‘shim’ the

isolators to keep the transfer case from resting or bouncing on the TT. At this point, you can determine if

this is necessary by letting the jack under the t/case output down until the full weight of the powertrain is

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American-expedition-vehicles Tummy Tucker – TJ Wrangler NON-Rubicon Manuel d'utilisateur Page 5

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