Smittybilt SB76880 User Manual
Revised 02.08.11
Installation Instructions:
(Part # SB76880)
XRC Armor Front Fender Kit
WARNING: Check with Local and State laws
before installing this accessory!
NOTE: Carefully read entire instructions thoroughly before attempting to install this part.
Parts Included: Qty
93-5909 Front Fender: Drvr 1
93-5917 Front Fender:
93-5921 Fender Lip Guard:
93-5922 Fender Lip Guard: Pass 1
90-4275 Fender Liner: Drvr 1
90-4276 Fender Liner: Pass 1
93-5923 Outer Duct 2
93-5924 Inner Duct: Drvr 1
93-5925 Inner Duct: Pass 1
90-6745 Hardware Pack: Fender 1
3/8” X 1” SS Button Head Bolt 32
3/8” Flat Washer 32
3/8” Nylock Nut 32
Pass 1
Drvr 1
Parts Included: Qty
1/4”-20 SS Button Head Bolt 12
1/4”–20 SS Nylock Nut 12
10-24 X 3/4” Hex Bolt 3
10-24 SS Nylock Nut 3
90-6746 Hardware Pack: Inner Fender Liner 1
Plastic Retainers 28
90-6747 Hardware Pack: Nutcert 1
3/8” Nutcert 2
90-6774 Hardware Pack: Nutcert Installation 1
96-5951 Nutcert Tool 1
3/8” Star Washer 1
3/8” X 2” Socket Head Bolt 1
3/8” Gr. 8 Flat Washer 1
3/16” X 1” Self Tapping Screw 4
3/8” Gr. 8 Nut:
Un-plated 1
IMPORTANT!: In order to install these fenders the wiper cowl panel and the side cowl panels
must be removed from the vehicle.
OE Bolts
Windshield
Bracket
(Fig A)
For Technical Support/Warranty Information please call 310-762-9944
Smittybilt, 400 W Artesia, Compton, CA 90220
OE
Bolts
INSTALLATION:
Revised 02.08.11
Installation Instructions:
(Part # SB76880)
XRC Armor Front Fender Kit
Side
Cowl
Panel
1/4” Drill
Bit
Inner Fender Structure
Step 1: Working on one side of the vehicle at a time, unbolt and remove the windshield
brackets from the vehicle. Save hardware for reinstallation. (Fig. A)
Step 2: Remove the windshield wipers from the wiper cowl panel.
Step 3: Remove the wiper cowl panel to expose the fender bolts.
Step 4: Fold back the side cowl panel, as if it were hinged on the spot weld seam, to expose
the spot welds. Drill out the spot welds on the side cowl panel to fender seam using a 1/4”
drill bit. Remove the side cowl panel from the vehicle. (Fig. B)
NOTE: Once removed, clamp the cowl panel to a work surface and bend the panel
back to it’s original shape. Save for reinstallation.
Step 5: Unbolt the OE hood catch from the OE fender. Save catch and hardware for reuse.
NOTE: Steps 6 and 7 are for the passenger side fender Only!
Step 6:
Step 7:
for reinstallation. (Fig. I)
Step 8:
reinstallation.
Step 9:
ware for reinstallation.
NOTE: The fenders are spot glued and will require some persistence to remove them.
Step 10: Cut the OE fender bracket off the inner fender structure. It will no longer be
needed. (Fig. C)
Step 11:
place and installing a few OE bolts.
Step 12:
a guide and drill a hole through the inner fender structure. (Fig. D)
Step 13:
Unplug the antenna wiring. Loosen and remove the antenna mast. (Fig. I)
Pry the plastic cap off the base and unfasten the antenna base from the fender. Save
Remove the OE inner fender liners from the vehicle. Save The OE Hardware for
Unbolt the OE fender bolts and remove the fender from the vehicle. Save the hard-
Test fit the new fenders (93-5909 drvr and 93-5917 pass) by hanging them in
With the fender in it’s appropriate position, Use the lowest 3/8” wheel well hole as
Remove the fender from the vehicle.
(Fig B)
:
For Technical Support/Warranty Information please call 310-762-9944
Smittybilt, 400 W Artesia, Compton, CA 90220
Revised 02.08.11
Installation Instructions:
(Part # SB76880)
XRC Armor Front Fender Kit
Inner Fender Structure
OE
Fender
Bracket
(Fig C)
Step 14: Drill out the previously drilled hole in the inner fender structure from 3/8” to 1/2.”
Install the 3/8” nutcert into the 1/2” hole. (Fig. D)
NOTE: If you do not have a professional nutcert installation tool, use the 2 1/2” X
3/8” socket head bolt, 3/8” nut and washer. Install the nutcert into the 1/2” hole on the
vehicle. Thread the nut up as far on the 3/8” bolt as it will go and then follow that with the
washer. Thread the bolt, nut, washer, nutcert tool (96-5951) and star washer assembly
into the nutcert. (Fig. D) While holding the 3/8” bolt with an Allen wrench, tighten the
nut and washer down against the nutcert. Use the nutcert tool and star washer to keep the
nutcert body from spinning while tightening the 3/8” bolt. Once the nutcert is properly
installed into the vehicle remove the 3/8” bolt, nut, washer, nutcert tool (96-5951) and star
washer .
3/8”
Star
Inner Fender Struc-
3/8” X 2 1/2”
bolt, 3/8”
Rivet
Lowest
3/8” &
1/2”
3/8”
(Fig D)
For Technical Support/Warranty Information please call 310-762-9944
Smittybilt, 400 W Artesia, Compton, CA 90220
3/8” X
3/8” SS
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