OR-Fab 88002 User Manual

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3651 N Highway 89 • Chino Valley, AZ 86323

(928) 636-7080 • www.p-a-g.net

JEEP WRANGLER, RUBICON, UNLIMITED ROCK DOOR KIT INSTALLATION INSTRUCTIONS 1980-1986 CJ 1987-1995 YJ KIT# 88001 1997-2006 TJ KIT# 88000 2007 - 2012 JK KIT# 88002

2. Verify all parts have been received in this kit by

checking the parts list at the end of this document.

NOTE

If parts are missing from kit, please be prepared to provide the following information:

1. Name of purchase location

2. Bar Code on side of box

3. Date above bar code

4. Date inside box cover

5. Inspector # from inside box cover

3. Only install this kit on the vehicle for which it is

specified. If anytime during the installation you

encounter something different from what is outlined in the instructions, call technical support at (928) 636-7080.

4. Park vehicle on a clean, dry, flat, level surface and block tires so vehicle cannot roll in either direction.

Inside Cab

WARNING

Before you install this kit, read and understand all instructions, warnings, cautions, and notes in this instruction sheet and in the vehicle owner’s manual.

CAUTION

Proper installation of this kit requires knowledge of the factory recommended procedures for removal and installation of original equipment components. We recommend that the factory shop manual and any special tools needed to service your vehicle be on hand during the installation. Installation of this kit without proper knowledge of the factory recommended procedures may affect the performance of these components and the safety of the vehicle. We strongly recommend that a certified mechanic familiar with the installation of similar components install this kit.

WARNING

Always wear eye protection when operating power tools.

WARNING

Before you install this kit, block the vehicle tires to prevent the vehicle from rolling.

NOTE

The location of the interior door light switch fuse may vary; check the owner's manual.

1. Open glove box and remove interior door light switch fuse from fuse panel.

Prepare to Install Rock Doors

1. Driver door a. Remove two nuts from two O.E. door hinges.

O.E. Door

Nuts

Before Starting Installation

NOTE

Kit parts are prefaced by the word kit and appear in

bold print.

1. Carefully read all warnings and instructions com-

pletely before beginning.

CJ, YJ, TJ, JK Rock Door 1 Kit 88000, 88001, 88002

O.E. Hinges

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b. Open door and remove door restraint strap from

pin and vehicle.

b. JK Models: Install two kit hinges onto kit door

(driver) with four kit bolts (5/16 x 1” button head). Snug, but DO NOT TIGHTEN.

Restraint Strap

Door

c. JK Models: Unplug wire harness to each door. d. With door open, lift up and remove O.E. door

from two hinges and vehicle.

e. Repeat above substeps for passenger side door.

Install Rock Doors

1. Driver door a. CJ, YJ, TJ Models: Install kit hinge onto kit

door (driver) with kit bolt (3/8”-16 x 1”), kit washer (3/8” SAE) and kit nut (3/8”-16 flange).

Snug, but DO NOT TIGHTEN.

Kit Hinge

Kit Bolt

(5/16” x 1” button head)

c. Install kit cap onto kit door (driver).

NOTE

CJ, YJ, TJ models require one kit cap per door and JK models require two kit caps per door

d. Install kit plug onto kit door (driver).

CJ, YJ, TJ Models

Kit Door (Driver)

Kit Plug

Kit Hinge

Kit Bolt

(3/8”-16 x 1”), Kit Washer (3/8” SAE), Kit Nut (3/8”-16 Flange)

Kit Door (Driver)

Kit Cap

JK Models

Kit Plug

CJ, YJ, TJ, JK Rock Door 2 Kit 88000, 88001, 88002

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e. Install kit door (driver) onto two O.E. hinges with

two kit bolts and four kit washers (nylon)

NOTE

CJ, YJ, TJ models: kit bolts (3/8”-16 x 3-3/4”) and kit washers (3/8” nylon)

JK Models: kit bolts (7/16”-14 x 3-3/4”) and kit washers (7/16” nylon)

Kit Bolt (3/8”-16 x 3-3/4”)

Kit Door (Driver)

Kit Washers

(3/8” Nylon)

CJ, YJ Models:

h. Temporarily install kit latch (driver) onto kit door

(driver) with three kit bolts (1/4”-20 x 1”). DO NOT TIGHTEN.

Kit Door (Driver)

Kit Latch (Driver)

Kit Bolts (1/4”-20 x 1”), Kit Washers (1/4” SAE)

i. Position center of kit latch (driver) with door

catch on body. Space kit latch accordingly with

kit washers (1/4” SAE).

Kit Latch

(Driver)

Kit Bolt (3/8”-16 x 3-3/4”)

f. Install two kit washers and two kit nuts onto two

kit bolts. DO NOT OVERTIGHTEN.

NOTE

CJ, YJ, TJ models: kit washers (3/8” nylon) and kit nuts (3/8”-16 Nylock) onto kit bolts (3/8”-16 x 3-3/4”).

JK Models: kit washers (7/16” nylon) and kit nuts (7/

16”-14 Nylock) onto kit bolts (7/16”-14 x 3-3/4”).

Kit Bolt

(3/8”-16 x 3-3/4”)

Kit Washer (3/8” Nylon), Kit Nut (3/8”-16 Nylock)

Kit Washers

(3/8” Nylon)

Kit Bolts (1/4”-20 x 1”), Kit Washers (1/4”SAE)

YJ Models:

Kit Washers (1/4” SAE)

Catch

g. Adjust kit door (driver) and TIGHTEN kit bolts.

CJ, YJ, TJ, JK Rock Door 3 Kit 88000, 88001, 88002

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j. Install kit latch (driver) onto kit door (driver) with

three kit bolts (1/4”-20 x 1”), three kit washers (1/4” SAE) and any additional kit washers (1/4” SAE) to set kit latch to catch.

Kit Door (Driver)

Kit Latch (Driver)

Catch

JK Models:

n. Install kit latch (driver) onto kit door (driver) wit h

two kit bolts (1/4”-20 x 1”), two kit spacers, and two kit washers (1/4” SAE). DO NOT TIGHTEN.

Kit Bolts (1/4”-20 x 1”), Kit Washers (1/4”SAE)

k. Adjust kit latch (driver), TIGHTEN kit bolts (1/

4”-20 x 1”) and test kit door (driver). Readjust kit latch (driver) as necessary to obtain proper latch with catch.

TJ Models:

l. Install kit latch (driver) onto kit door (driver) with

two kit bolts (1/4”-20 x 1”) and two kit washers (1/4” SAE). DO NOT TIGHTEN.

Kit Door (Driver)

Kit Latch (Driver)

Kit Bolts (1/4”-20 x 1”), Kit Washers (1/4” SAE)

o. Adjust kit latch (driver), TIGHTEN kit bolts (1/

4”-20 x 1”) and test kit door (driver). Readjust kit latch (driver) as necessary to obtain proper latch with catch.

Kit Latch (Driver)

Two Kit Spac-

ers

All Models:

p. Open and close kit door (driver) ensuring proper

kit latch (driver) operation.

NOTE

Kit latches have two stages. The first stage will result in kit doors not seated completely against kit plug. The second stage will properly seat the kit doors against the body. Adjust kit latches and kit hinges if the second stage is not attainable.

Kit Bolts (1/4”-20 x 1”), Kit Washers (1/4” SAE)

m. Adjust kit latch (driver), TIGHTEN kit bolts (1/

4”-20 x 1”) and test kit door (driver). Readjust kit latch (driver) as necessary to obtain proper latch with catch.

CJ, YJ, TJ, JK Rock Door 4 Kit 88000, 88001, 88002

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q. Inst all kit weatherstrip onto kit door (driver).

Cut kit weatherstrip if necessary for proper fit- ment.

t. Install kit pad (cover, driver) onto kit pads.

Adjust as necessary.

J, YJ Model

Kit Door (Driver)

Kit

Weatherstrip

TJ Model

Kit

Weatherstrip

Kit Pad (Cover, Driver)

Kit Door (Driver)

u. Repeat above substeps for passenger door.

After Completing Installation

Miscellaneous

1. Check all fasteners to ensure they are tight.

2. Ensure all wires, hoses, cables, etc. are properly

connected and there is ample slack.

WARNING

r. Install kit pad (lon g) onto upper bar of kit door

(driver).

s. Install kit pad (short) onto lower bar of kit door

(driver).

Kit Pad (Long)

Kit Door (Driver)

Kit Pad (Short)

This product is for Off-Road use only. It is NOT intended as a safety restraint device. Always make sure all occupants are wearing seat belts at all times.

NOTE

All warranty information, instruction sheets, and other documents regarding the installation of this product must be retained by the vehicle owner contained in the instructions and on the warranty card will be required for any warranty claims. The vehicle owner needs to understand the modifications ma de to the vehicle and how they affect vehicle handling and performance. Failure to provide the customer with this information can result in damage to the vehicle and severe personal injury.

. Information

CJ, YJ, TJ, JK Rock Door 5 Kit 88000, 88001, 88002

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Kit Parts List

Qty. Description

1 Door (driver) 1 Door (passenger) 1 Label (logo) 2 Label (warning) 1 Pad (cover, driver) 1 Pad (cover, passenger) 2 Pad (long) 2 Pad (short)

1 ZH25 (Hardware bag, 88000)

4 Bolt (1/4”-20 x 1”) 2 Bolt (3/8”-16 x 1”) 4 Bolt (3/8”-16 x 3-3/4”) 2 Cap 2 Hinge 1 Latch (driver) 1 Latch (passenger) 2 Nut (3/8”-16 flange) 4 Nut (3/8”-16 Nylock) 2 Plug 4 Washer (1/4” SAE) 12 Washer (3/8” nylon) 2 Washer (3/8” SAE) 2 Weatherstrip

4 Sleeve 4 Washer (1/4” SAE) 8 Washer (7/16” nylon) 2 Weatherstrip

1 ZH26 (Hardware bag, 88001)

6 Bolt (1/4”-20 x 1”) 2 Bolt (3/8”-16 x 1”) 4 Bolt (3/8”-16 x 3-3/4”) 2 Cap 2 Hinge 1 Latch (driver) 1 Latch (passenger) 2 Nut (3/8”-16 flange) 4 Nut (3/8”-16 Nylock) 2 Plug 24 Washer (1/4” SAE) 12 Washer (3/8” nylon) 2 Washer (3/8” SAE) 2 Weatherstrip

1 ZH28 (Hardware bag, 88002)

4 Bolt (1/4”-20 x 1”) 8 Bolt (5/16” x 1” button head) 4 Bolt (7/16”-14 x 3-3/4”) 2 Cap (urethane) 4 Hinge 1 Latch (driver) 1 Latch (passenger) 2 Nut (7/16”-14 Nylock) 4 Plug (plastic)

CJ, YJ, TJ, JK Rock Door 6 Kit 88000, 88001, 88002