installation instructions - jeep armor & 2009 poison spyder customs, inc. • 951-849-5911...

©2009 POISON SPYDER CUSTOMS, INC. • 951-849-5911 • WWW.POISONSPYDER.COM INST

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SThank you for purchasing a Poison Spyder Front RockBrawler Bumper for your Jeep JK. You now own the ultimate off-road bumper, which will give you many years of service. Installation is fairly simple with the right tools and good mechanical abilities. If you are not confident in your mechanical skills, please seek the help of a professional to perform the installation. Please read through these entire instructions before proceeding with installation.

PARTS LISTPlease check your packages immediately upon arrival to ensure that everything listed is included, and to check for damage during shipping. If anything is missing or damaged, call Poison Spyder at (951) 849-5911 as soon as possible.

(1) JKFrontRockBrawlerBumper(A)(1) Sub-FrameBracketRetainerPlate(B)(1) Sub-FrameBracket(C)(1) RemovableSkidPlate(D)(12) 3/8-16X1SSflatheadcapscrew(5) 3/8-16nyloninsertlocknut(5) 3/8flatwasher(11) 1/2-13nyloninsertlocknut(11) 1/2flatwasher

TOOLS NEEDED• Ratchet• 6”socketextension• 19mmdeepsocket• 3/4”deepsocket• Torquewrench(ft./lbs.)• 7/32”hexkey• Transferpunches:5/16”&15/32”• ShopHammer• Deadblowhammerorrubbermallet• Drillmotor• Drillbits:1/4”,3/8”&11/16”• Phillipsheadscrewdriver• Smallflatheadscrewdriver• Removal tool forpush-in retainerclips (see Figure1)orsmallprybar

• Abrasive cut-offwheel or othersuitable metalcuttingtool

• Touch-uppaintorclearcoat

BEFORE YOU BEGINThe JK Front RockBrawler bumper and associated components are shipped un-painted. You will want to paint or powder-coat these components prior to installation. If painting them

FIGURE 1

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JK FRONT ROCKBRAWLER BUMPER INSTALL

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SPoison Spyder Customs • JK FRONT ROCKBRAWLER BUMPER INSTALL

©2009 POISON SPYDER CUSTOMS, INC. • 951-849-5911 • WWW.POISONSPYDER.COM

yourself, we recommend starting with a quality etching primer and allowing sufficient cure/dry time between coats and before you apply color. Quality spray-can paints are fine, however be sure to thoroughly paint all of the inside corners and hard-to-reach areas of the bumper. A little extra time and attention to detail on your preparation and paint process will pay off in longer-lasting good looks and rust prevention.

INSTALLATION PROCEDURE1. Parkvehicleonalevelsurfaceandsetthe

emergencybrake.Youwillwanttoweareyeprotectionbeyondthispoint.

2. Removetheplasticlowerairdam.Useapush-inretainerremovaltooltopopouttheplasticpush-inretainersalongthefrontedgeand also underneath/behind the air damwhereitattachestothecrashbar.Ifyoudonothaveapush-inretainertool,aflat-edgescrewdriverorsmallpry-barmaybeused.

FIGURE 2

3. If your Jeep is equipped with factoryfog lamps, reach behind the bumper anddisconnectthewiringharnessplugsfromthesocketsatthebackofeachlamp.Asmallflathead screwdrivermaybeuseful to releasethetangsontheplug

4. Use a ratchet and 19mm deep socket toremove the eight (8) nuts that fasten thebumpertotheframe.Therearetwoofthesenutsontheinnerside,andtwoontheouterside, of each frame rail where it joins thebumper.

FIGURE 3

With these nuts removed, remove thebumperfromtheJeep.

FIGURE 4

5. If your Jeep is equipped with factory foglamps,thesemayberemovedfromthestockbumperandre-installedintotheRockBrawlerbumper.UseaPhillipsscrewdrivertoremovethefour(4)retainingscrewsfromeachlamp,onthebacksideofthebumper.

FIGURE 5

InstallthefactoryfoglampsintothefoglampmountsinthebacksideoftheRockBrawlerbumper. Re-use the OE retaining screws.Thesesheetmetalscrewswillformtheirownthreadsasyoudrivethemintotheretaining

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ringsontheRockBrawlerbumper,sopressfirmlyasyoutwistthescrewdriver.

FIGURE 6

6. Remove the plastic top bumper cover.Youmaybeable to remove the twoplasticscrewswithaPhillipsscrewdriver.Butitislikelythey’re“frozen”inplaceandwillhavetobepriedupwiththepush-inretainerremovaltool.

FIGURE 7

7. The factory “crash bar” is the semi-rectangular tube which runs from one sidetotheother,atthefrontoftheJeep’sframe,justbehindthebumper(thebumpershouldalready be removed at this point). Thelower cornerof the crashbarat eitherendmust be trimmed for proper fitment of theRockBrawlerbumper.Useanabrasivecut-offwheelorothersuitablecuttingtooltotrimofftheendofthecrashbar.Yourcutshouldbeadjacenttotheoutsideedgeofthefrontvertical support, or 7/8” inboard from theoutsideedgeoftheoutermostframebracketasshowninFigure8.

FIGURE 8

Dothisforbothendsofthecrashbar.Useafileordiegrindertode-burrthecutedge,thenapplytouch-uppaintorclearcoattotheexposed bare metal for protection againstcorrosion.

8. Pre-install theRockBrawlerbumperontothe frame. There are eight (8) threadedstuds located on the inside/backside ofthe bumper,whichwill correspondwith thebumper mounting holes on the frame. ItmaybeatightfitduetoslightmanufacturingvariancesfromJeeptoJeep,butthebumperwillfitwithsomegentlepersuasion.Youmayneedtousearubbermalletorsoftdead-blowhammer to tap the bumper into place. Becarefulnottomaryourpaintorpowdercoatfinish.

FIGURE 9

Locatethe1/2-13nyloninsertlocknutsand1/2”flatwashersthatcameinthehardwarekitwithyourRockBrawlerbumper.InstallaflatwasherandlocknutontothetwobumpermountingstudsattheoutsideoftheframerailoneithersideoftheJeep.Snugthesewiththe3/4”deepsocket,extensionandratchetbut do not over-tighten, as the bumperwill

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not properly seat into position yet. Do notinstalltheinboardnutsatthistime.

FIGURE 10

9. Observe the recessed area where theremovableskidplateistobeinstalledalongthe front lower surface of the RockBrawlerbumper. The lower-most hole in thisrecessed surface, on each side, is backedbyaweld-nutwhich interfereswith theOEcrash bar that is located directly behind it.Later,youwilldrillholesinthecrashbartoprovideclearance for theseweldnuts. Butfirst,useahammerand5/16”transferpunchinserted through this hole (and weld-nut)tomake a corresponding drill mark on thesurfaceofthecrashbar(seeFigure11).Dothisforthelower-mostholeonbothendsoftherecessedskidplatemountingsurface.

FIGURE 11

10.Loosen the four previously installedbumpermountinglocknutsandflatwashers,and remove theRockBrawler bumper fromtheJeep.

11.Useadrillmotorwith1/4”bittodrillthroughthe front surface of the crash bar at bothlocationsyoumarkedwiththetransferpunchinStep9.Switchtothe11/16”bittodrilleachholetoitsfinalsize.

FIGURE 12

De-burr the edges of the holes then applytouch-uppaintorclearcoat to theexposedmetal.

12.If your Jeep is equipped with the factoryelectric sway bar disconnect or the CurrieAnti-Rockswaybarsystem,pre-positionthesub-framebracketasshowninFigure12.

FIGURE 13

Useacoupleofzip-tiestotemporarilyholditinplaceagainstthecrashbar.

FIGURE 14

IfyourJeepisNOTequippedwiththefactoryelectricswaybardisconnectorCurrieAnti-Rock,youmayskipthisstepasyouwillbe

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abletoinstallthebracketlaterwithouthavingpre-positionedit.

13.Re-install the RockBrawler bumper ontotheJeep.Itshouldfullyseatthistime,withthe weld-nuts mentioned in Step 9 fittingthrough the clearance holes you drilled.Installandtightenalleight(8)locknutsandflatwashersontothebumpermountingstuds(twoinboardandtwooutboardofeachframerail).

14.Ifyou installed theOE fog lamps into theRockBrawler bumper, plug the harnessconnectorsbackintothesocketsinthebackof each lamp. Use the OE wire harnesspush-inretainerstosecuretheharnesstothethree (3) providedholesona flange insidetheRockBrawlerbumper. TheseholesareshowninFigure15,withthebumperofftheJeepforclarity.Youwillhavetolocatethemby feelas thearea ishard toseeoncethebumperisinstalled.

FIGURE 15

15.Pre-position the Sub-Frame BracketRetainer Plate. There are three slottedholesintheverticalflangeatthetop/rearofthebumper.Insertthethreecapturedstudson the retainer plate through these slots,from the inner side of the bumper (so thatthethreadsarepointedtowardtherearoftheJeep). Figure 16 illustrates this on an un-installedbumperforclarity.

FIGURE 16

16.Install theSub-FrameBracket,whichyoumayhavealreadypre-positionedinStep12(cuttheziptiesifyoudid).Thethreeslottedholesalongthetopofthebracketaretobeslipped over the three protruding threadedstuds of the Sub-Frame Bracket RetainerPlate (which was pre-positioned in theprecedingstep).TheloweredgeoftheSub-FrameBracket will fit against the backsideandundersideofthecrashbar.Wherethe90° flangefitsagainst theundersideof thecrash bar, it will fit between the crash barandthelowerlipofthebumperateitherend.Installa1/2-20locknutand1/2”flatwasherontoeachofthethree(3)threadedstudsoftheSub-FrameBracketRetainerPlate, butdonottightenthematthistime.

17.Pre-InstalltheRemovableSkidPlate.Usethree3/flatheadcapscrews to temporarilyholdit inplace,oneatthecenteralongthetopandonealong thebottomateachend.Ensurethattheskidplateisproperlyseatedinto its recess in thebumper,andsnug thethreeflatheadcapscrews.

FIGURE 17

18.The five countersunk holes along thebottom edge of the skid plate will require

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corresponding holes to be drilled into thebottomedgeof theJeep’scrashbar. Lookthrough the holes to ensure that the Sub-Frame Bracket does not interfere with anyoftheholelocations.Ifitdoes,thebracketcan be adjusted slightly in either directionbecauseyouhadleftthenutsun-tightenedinStep16.Useahammeranda15/32”transferpunch through each of the countersunkholestomarkthefivedrilllocationsalongthebottomofthecrashbar.Oncethesemarkshavebeenmade,removetheskidplate.

FIGURE 18

19.Usethedrillmotorand3/8”bittodrillthefiveholesalongthebottomofthecrashbarthatwere located andmarked in the precedingstep.

FIGURE 19

De-burr the edges of the holes then usetouch-up paint or clear coat to protect thebaremetal.

20.Re-installtheskidplatewiththe3/8-16X1SSflatheadcapscrews.Thesevenscrewswhich locate along the front surface of theskid platewill thread into pre-existingweldnuts.

FIGURE 20

For the five screws that install along thebottomedgeoftheskidplate,usea3/8flatwasher and 3/8-16 lock nut on the insideof the crash bar where the screw threadsprotrude.Torqueall11flatheadcapscrewsto30ft.-lbs.

21.Tightenthethree1/2-20locknutsatthetopof theSub-FrameBracketand torque themto70ft.-lbs.

22.Torque the eight (8) bumper mount locknuts(twoinboardandtwooutboardofeachframerail)to70ft.-lbs.

Congratulations, you have completed the installation of your Poison Spyder JK Front RockBrawler Bumper!

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WARRANTYPoison Spyder Customs™ warranties all of

the products we sell and distribute for one (1) year from the date of sale. These products will be free from defects in material and workmanship under normal installation, and use. Due to the intended use the powder coat finish is warranted for ninety (90) days. The finish warranty will not cover a product if it has been damaged in any way. Warranty is limited to repair or replacement. Poison Spyder Customs™ does not offer any type of labor or shipping allowance and all warranty claims are subject to inspection by Poison Spyder Customs™.At the discretion of Poison Spyder Customs™, the products in question can be repaired or replaced when found defective. Prior to any replacement or repair, written authorization must be obtained from Poison Spyder Customs™. Failure to contact us prior to having warranty work preformed will immediately void all applicable warranties; and it is then the sole responsibility of the customer to remit any payment incurred.The warranty expressed above is the sole warranty of Poison Spyder Customs™, and any other expressed or implied warranties are hereby specifically excluded and disclaimed.

HOLD HARMLESS AGREEMENT1. In purchasing a Poison Spyder Customs

Product™ I release, waive, discharge andcovenantnottosuePoisonSpyderCustomsofficers, servants, agents, or employees(hereinafter referred toasReleasees) fromanyandallliability,claims,demands,actionsandcausesofactionwhatsoeverarisingoutoforrelatedtoany loss,damage,or injury,including death, that may be sustained byme(oranyoneelse),anypropertybelongingtome(oranyoneelse),whethercausedbythenegligenceofthereleaseesorotherwise,whileworkingon,usingoranyactivityrelatedtothisproduct.

2. IamfullyawareofrisksandhazardsconnectedwiththeuseofathisproductandIelecttovoluntarilyengageinsuchuseofthisproductknowing that theusemaybehazardous tomeandmyproperty.Ivoluntarilyassumefullresponsibility forany risksof loss, propertydamageorpersonal injury, includingdeath,

that may be sustained by me (or anyoneelse), or any loss or damage to propertyownedbyme (oranyoneelse),asa resultofusingthisproduct,whethercausedbythenegligenceofreleaseesorotherwise.

3. Ifurtheragreetoindemnifyandholdharmlessthereleaseesfromanyloss,liability,damageor costs, including court cost and attorneyfees,thattheymayincurduetomyuseofathisproduct,whethercausedbynegligenceofreleaseesorotherwise.

4. ItismyexpressintentthatthisReleaseandHold Harmless Agreement shall bind themembers ofmy family and spouse, if I amalive, and my heirs assigns and personalrepresentative, if I amdeceased, and shallbedeemedasarelease,waiver,discharge,and covenant not to sue theabovenamedreleasees.IfurtheragreethatthisWaiverofLiabilityandHoldHarmlessAgreementshallbeconstruedinaccordancewiththelawsoftheStateofCalifornia.

By accepting this product, I acknowledge and represent that I have read the above Waiver and Liability and Hold Harmless Agreement, understand it and accept it voluntarily as my own free act and deed; no oral presentations, statements, or inducements, apart from the foregoing written agreement, have been made; I am at least eighteen (18) years of age and fully competent; and I execute this Release for full, adequate and complete consideration fully intending to be bound by same.If you do not agree with the preceding Hold Harmless Agreement, you may return the product and receive a full refund. Please, contact a Poison Spyder Customs™ sales representative and they will issue a call tag for the product in question. Once the product has been received by Poison Spyder Customs™ a full refund will be issued.

installation instructions - jeep armor & 2009 poison spyder customs, inc. • 951-849-5911...

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