Revised 12.09.09
Installation Instructions:
(Part # SB76654)
87-06 Jeep TJ/YJ XRC Tire Carrier
NOTE: Carefully read entire instructions thoroughly before attempting to install this part.
Parts Included Qty
93-5642 TIRE CARRIER 1
93-2997 TIRE CARRIER PIVOT SHAFT 1
93-5650 TIRE CARRIER LATCH BRACKET 1
93-5652 WHEEL MOUNT: Adjustable Bracket 1
93-5655 WHEEL MOUNT: Stationary Bracket 1
90-5658 LATCH SHIM PLATE 2
90-5659 NUT PLATE: Latch 1
93-5661 LOCK OUT BRACKET ASSEMBLY 1
90-8000 SPACER TUBE 1
90-6712 HARDWARE PACK: Tire Carrier 1
3/8” X 1” GR. 8 HEX BOLT 5
3/8” X 1 1/4” GR. 8 HEX BOLT 6
3/8” X 2 1/2” GR. 8 HEX BOLT 2
3/8” HARDENED FLAT WASHER 20
Parts Included Qty
1/2" STOVER NUT 7
1/2” HARDENED FLAT WASHER 14
90-4214 HANDLE ASSEMBLY 1
90-6689 HARDWARE PACK: Handle 1
90-2940 NYLON WASHER 2
90-4218 CIRCLE CLIP 1
90-4219 LUG NUTS 3
90-4217 ZERK FITTING 1
93-5663 3rd BRAKE LIGHT BRACKET 1
90-6713 HARDWARE PACK: 3rd Brake Light 1
3/8" X 1" HEX BOLT GR. 8 2
3/8" STOVER NUT 2
3/8" SAE FLAT WASHER 4
5/16” X 1” HEX BOLT GR. 8 3
3/8" STOVER NUT 7
3/8” X 2 1/4” GR. 8 HEX BOLT: Jam Bolt 1
3/8" HEX NUT: Jam Nut 1
1/2" X 1 1/2" HEX BOLT GR. 8 4
1/2" X 3 1/4" HEX BOLT GR. 8: Support Plates 3
5/16” USS FLAT WASHER 6
5/16” NYLOCK NUT 3
93-5731 TJ SUPPORT PLATE 1
93-5845 YJ SUPPORT PLATE 1
90-5847 NUT PLATE: YJ Support Plate 1
7/16" X 1 1/2" GR. 8 HEX BOLT: YJ Support Plate 1
Tire Carrier Installation:
Step 1: Remove the stock spare tire from the vehicle.
Step 2:
housing from the vehicle.
Step 3:
taillight from the vehicle.
Step 4: Unbolt and remove the tire carrier pivot shaft block off plate.
Unclip the 3rd brake light wiring harness. Unbolt and remove the 3rd brake light
Unclip the passenger side taillight housing wiring harness. Unbolt and remove the
For Technical Support/Warranty Information please call 310-762-9944
Smittybilt, 400 W Artesia, Compton, CA 90220
Revised 12.09.09
Installation Instructions:
(Part # SB76654)
87-06 Jeep TJ/YJ XRC Tire Carrier
Step 5: Install the pivot shaft (93-2997) to the bumper using the supplied 3/8” X 1 1/4”
bolts and hardware. (Fig. A) Install the jam nut onto the 3/8” X 2 1/4” jam bolt. Insert the
jam bolt assembly into the bumper. (Fig. A) Tighten the jam bolt against the pivot shaft.
Tighten the jam nut against the bumper. Torque the bolts according to the chart on page 9.
Pivot Shaft
93-2997
3/8” X 1
1/4” bolts
Rear bumper
91-5417
3/8” X 2 1/4”
Jam bolt
3/8” Jam
Nut
Backside of Bumper
(Fig A)
Step 6: Install the latch plate (93-5650) to the bumper using the supplied 3/8” X 1 1/4” bolts
and nut plate (90-5659). (Fig. B) Leave the bolts loose at this time. NOTE: The wire on the
nut plate may need to be bent in order to properly fish it into place.
3/8” X 1
1/4” bolts
93-5650
Latch
Plate
90-5659
Nut Plate
(Fig B)
Step 7:
Place nylon washer onto the pivot shaft, then place tire carrier on top. Be sure to
install the tire carrier in the open position. (Fig. C1 & C2)
Step 8:
Install the tire carrier lockout mechanism (93-5661) and support plate (93-5731 TJ
model only or 93-5845 YJ model only) to the tire carrier (91-5642). Secure using the supplied 1/2” X 3 1/4” pinch bolts, hardware in the (2) pinch bolt holes. For TJ models only:
in the remaining support plate hole, insert the 1/2” X 3 1/4” bolt, sleeve (90-8000) and hard-
For Technical Support/Warranty Information please call 310-762-9944
Smittybilt, 400 W Artesia, Compton, CA 90220
Revised 12.09.09
Installation Instructions:
(Part # SB76654)
87-06 Jeep TJ/YJ XRC Tire Carrier
ware in the remaining hole. (Fig. C1). Leave bolts snug only. For YJ models only: in the
remaining tire carrier hole, insert the 7/16” X 1 1/2” bolt, nut plate (90-5847 inserted
through the upper or lower drain hole in the tire carrier) and 7/16” nut and 1/2” washer.
(Fig. C2). Leave bolts snug only.
Circle
Clip
Nylon
Washer
TJ Support
Plate
93-5731
90-5847
Nut Plate
Circle
Clip
93-5661
Lock Out
Bracket
1/2” X 3
1/4”
Pinch
bolts
90-8000
Spacer
Tube
Nylon
Washer
Pivot
Shaft
93-2997
93-5661 Lock Out Bracket
1/2” X 3
1/4” bolt
Tire Carrier
Brace
93-5642
(Fig C1) TJ
1/2” X 3 1/4” Pinch bolts
93-5661
Lock Out
Bracket
3/8” X 2
1/2” bolts
90-4214 Handle Assembly
93-5661
Lock Out
Bracket
Nylon
Washer
YJ Support
Plate
93-5845
Pivot
Shaft
93-2997
Nylon
Washer
7/16” X 1
1/2” bolt
& 1/2”
Washer
Tire Carrier
Brace
93-5642
(Fig C2) YJ
90-4214 Handle Assembly
3/8” X 2
1/2” bolts
For Technical Support/Warranty Information please call 310-762-9944
Smittybilt, 400 W Artesia, Compton, CA 90220
Revised 12.09.09
Installation Instructions:
(Part # SB76654)
87-06 Jeep TJ/YJ XRC Tire Carrier
Step 9: Install the handle assembly (90-4214) to the tire carrier using the supplied 3/8” X 2
1/2” bolts. (Fig. C1 & C2) Torque the bolts according to the chart on page 9.
Step 10:
bracket 93-5655) using the supplied (5) 3/8” X 1” bolts and hardware. Leave the bolts
loose at this time. Lay the spare tire face down on the ground and install the tire mount
bracket temporarily onto the spare tire. (Fig. D & E)
93-5655
Tire Mount
Stationary
Bracket
Assemble the tire mount bracket (adjustable bracket 93-5652 & stationary
3/8” X 1”
bolts
3/8” X 1”
bolts
93-5652 Tire
Mount
Adjustable
Bracket
(Fig D)
Step 11:
With the spare tire face down, lay a ruler or a flat bar across the tire and adjust the
tire mount bracket assembly until the base makes contact with the ruler or flat bar. (Fig. E)
Torque the tire mount bracket assembly bolts according to the chart on page 9. NOTE: The
assembled bracket may not line up perfectly with the straight edge.
Tire
Rim Face
Straight Edge
3/8” X 1”
bolts
(Fig E)
Tire Mount
Assembly
Bracket
Straight Edge
Tire
Rim Face
Step 12:
Install the tire mount bracket assembly onto the tire carrier using the supplied 1/2”
X 1 1/2” hardware. Install the spare tire to the mounting bracket. (Fig. F)
NOTE: The size of the spare tire will determine the mounting height of the bracket. If
possible, it is better to have the tire fit tighter against the straight edge/tire carrier to avoid
excess vibration.
For Technical Support/Warranty Information please call 310-762-9944
Smittybilt, 400 W Artesia, Compton, CA 90220
Revised 12.09.09
Installation Instructions:
(Part # SB76654)
87-06 Jeep TJ/YJ XRC Tire Carrier
Tire Carrier
Brace
93-5642
Handle
Assembly
Tire Mount
Bracket Assembly
1/2” X 1
1/2” bolts
(Fig F)
Step 13: Very carefully close the bumper and watch for tire carrier clearance over top of the
bumper. NOTE: Be careful not to scratch the top of the bumper.
Step 14: Adjust the height of the tire carrier by tightening or loosening the (2) 1/2” pinch
bolts on the pivot shaft. (Tightening = Higher / Loosening = Lower) Adjust the tire carrier
so it swings smoothly and latches correctly. The latch can also be adjusted by inserting the
supplied shims (90-5658) as well. Check that the tire carrier lock out mechanism fits properly into the lockout stop on the bumper by carefully swinging it backward. Once the lockout mechanism is aligned properly, tighten the (3) previously installed 1/2” bolts. (Fig. C)
IMPORTANT!: Over-tightening the pinch bolts will not allow the tire carrier to swing
freely.
Step 15: Once proper fitment is achieved install the nylon washer and snap ring onto the
pivot shaft. Install the Zerk fitting (90-4217) into the top of the pivot shaft (93-2997). (Fig.
C) NOTE: Do not over tighten the Zerk fitting.
90-4219
Lug Nuts
(Fig G)
For Technical Support/Warranty Information please call 310-762-9944
Smittybilt, 400 W Artesia, Compton, CA 90220
Revised 12.09.09
Installation Instructions:
(Part # SB76654)
87-06 Jeep TJ/YJ XRC Tire Carrier
Step 16: Torque all the tire carrier hardware (except the tire carrier pinch bolts) according to
the torque chart on page 9.
Step 17: Reinstall the passenger side taillight using the previously removed OE hardware.
Step 18: Installation of the tire carrier is now complete.
For Technical Support/Warranty Information please call 310-762-9944
Smittybilt, 400 W Artesia, Compton, CA 90220
Revised 12.09.09
Installation Instructions:
(Part # SB76654)
87-06 Jeep TJ/YJ XRC Tire Carrier
Third Brake Light Installation:
Step 1: Install the 3rd brake light bracket (93-5663) to the top of the tire carrier using the
supplied 3/8” X 1” bolts. (Fig. H) Torque the bolts according to the chart on page 9.
3/8” X 1”
bolts
(Fig H)
93-5663 3rd
Brake Light
Bracket
Tire Carrier
Brace
91-5642
Step 2:
Place the OE 3rd brake light plastic housing flush against the back of the 3rd brake
light bracket (93-5663). Using the bracket as a guide, scribe a line across the bottom of the
plastic light housing. Trim the plastic housing along the scribed line. (Fig. I)
NOTE: Depending on the size of the spare tire, the OE 3rd brake light plastic housing
may need additional trimming. Use the spare tire as a guide for any additional trimming.
Cut
Piece
(Fig I)
Cut
Line
OE 3rd
Brake Light
Housing
3rd Brake
Light
Bracket
93-5663
Step 3: Once the OE 3rd brake light plastic housing has been properly trimmed, place it
flush against the back 3rd brake light bracket (93-5663). Use the (3) holes in the bracket as a
For Technical Support/Warranty Information please call 310-762-9944
Smittybilt, 400 W Artesia, Compton, CA 90220
Revised 12.09.09
Installation Instructions:
(Part # SB76654)
87-06 Jeep TJ/YJ XRC Tire Carrier
guide to mark and drill the OE brake light plastic housing. Drill the plastic housing using an
11/32” drill bit. (Fig. J) NOTE: The 3rd brake light plastic housing will not sit flush
against the bottom of the 3rd brake light bracket (93-5663).
Step 4: Secure the OE plastic housing to the 3rd brake light bracket (93-5663) using the
supplied (3) 5/16” X 1” bolts and hardware. (Fig. J)
IMPORTANT!: Do not over tighten these bolts.
(Fig J)
OE 3rd Brake
Light Housing
93-5663 3rd
Brake Light
Bracket
11/32”
Drill Bit
Be sure the housing sits
flush against the back
of the bracket
5/16” X
1” bolts
Step 5: Reconnect the 3rd brake light wiring harness.
NOTE: It is recommended to extend the 3rd brake light wiring harness. This can simply
be done by splicing the wire and using some insulated butt splice connectors and 18 gauge
wire, extend the wire to the appropriate length. It is recommended to have this done by an
experienced electrical installer.
Step 6: Installation of the third brake light assembly is now complete.
For Technical Support/Warranty Information please call 310-762-9944
Smittybilt, 400 W Artesia, Compton, CA 90220
Revised 12.09.09
Installation Instructions:
(Part # SB76654)
87-06 Jeep TJ/YJ XRC Tire Carrier
Product cleaning and maintenance instructions
Stainless Steel Finish – Aluminum polish may be used to polish small scratches and scuffs on the finish. Mild
soap, window or glass cleaner may be used to clean the finish. Dual state powder coat finish – Mild soap, window or glass cleaner may be used to clean the finish. In order to protect the finish, you may wax your product on a
regular basis with pure carnauba automotive wax. Do not use any types of soap, polish or was that contains abrasive that could damage the finish. Textured coated finishes should be cleaned with a mild soap on a damp
sponge. Do not apply polish or was that requires to be removed by means of buffing. This type of wax is commonly used at car wash facilities. Chrome Finish – Mild soap, window or glass cleaner may be used to clean the
finish. In order to protect the finish you should wax your product on a regular basis with pure carnauba automotive
wax. Do not use any types of soap, polish or was that contains abrasive that could damage the finish.
For Technical Support/Warranty Information please call 310-762-9944
Smittybilt, 400 W Artesia, Compton, CA 90220
Revised 12.09.09
Installation Instructions:
(Part # SB76654)
87-06 Jeep TJ/YJ XRC Tire Carrier
Limited Warranties
Smittybilt’s products are covered under the following limited warranties only. Note that the duration of the limited
warranty differs according to the material and finish of the product purchased. Subject to the duration and conditions
of the limited warranty stated below, Smittybilt warrants to the original retail purchaser that its products are free from
defects in material and workmanship. All other warranties and representations express or implied, are hereby disclaimed, including fitness for merchantability and buyer’s intended use or purpose. All parts are sold “AS IS” except
for the limited warranties granted herein. Buyer assumes all risks as to the selection, suitability and performance of
all goods and products selected. This limited warranty does not cover damage or impairment in any part due to misuse, improper installation, accident or contact with on-road or off-road hazards, product modification, improper or
inadequate cleaning and/or maintenance. Smittybilt is not responsible for items damaged during shipping. This warranty is not transferable from the original buyer. For the orig inal Buyer to be eligible for the limited warranty coverage, the Buyer must provide proof of purchase. Smittybilt strongly recommends returning the warranty registration
card.
Customer’s remedy hereunder shall be limited only to repair or replacement (at Smittybilt’s option) of any defective
part(s) returned to Smittybilt at customer’s expense. The determination of whether or not a returned part is defective
or subject to coverage under the limited warranties stated herein shall be made at Smittybilt’s sole discretion.
Duration of Limited Warranty
Limited Lifetime Warranty on Stainless Steel Products -
Smittybilt stainless steel products carry the foregoing limited repair or replacement warranty against workmanship and defects in the material so long as the original purchaser retains the original stainless steel parts.
Limited Five (5) Year / 50,000 Mile Pro-Rata Warranty (whichever occurs first) on Dual-Stage Powder
Coating Products -
Smittybilt dual-stage powder coated products carry the foregoing limited repair or replacement warranty for a
period of (5) years or 50,000 miles (whichever occurs first) from date of purchase against workmanship and defects in the material, provided that any claim submitted after (2.5) years from date of purchase shall, if accepted,
be satisfied by Smittybilt offering customer a credit on the purchase of a replacement product equal to fifty percent (50%) of customer’s initial purchase price.
Limited Three (3) Year / 36,000 Mile Pro-Rata Warranty (whichever occurs first) on Chrome Products-
Smittybilt chrome products finished carry the foregoing limited repair or replacement warranty for a period of
three (3) years or 36,000 miles against workmanship and defects in the material (whichever occurs first) from the
date of purchase.
To assure product quality, Smittybilt reserves the right to change product design, material, specification and finishes
without prior notice to customers. This limited warranty gives you specific legal rights and you may also have other
rights, which may vary from state to state. Some states do not allow limitations on how long an implied warranty
lasts, so the above limitations may not apply as to you. Also, some states do not allow the exclusion or limitation of
incidental or consequential damages, so the above limitations or exclusions may not apply to you. Smittybilt reserves the right to discontinue product lines and substitute products, or provide other remedies than those listed in
this limited warranty for those discontinued products.
For Technical Support/Warranty Information please call 310-762-9944
Smittybilt, 400 W Artesia, Compton, CA 90220
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