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How to Install a Rugged Ridge Heavy Duty Solid Rocker Guards on your 2004-2006 Wrangler TJ Unlimited
Shop Parts in this Guide
1. Read all instructions before starting installation. Also, clean thoroughly any surfaces that will be covered Remove any side steps or panels before getting started. by the rocker panels.
2. Carefully hold a rocker panel up to the vehicle and position in by pushing it upward as far as it will go. It should fit snugly between the factory flares. If the fit is too tight, loosen the flares. After-market flares may also require loosening to ensure a proper fit. Once positioned, mark the six side holes using the rocker panel as a guide. Before drilling check inside the vehicle and move any wires that may be in the way. The 4 front most side holes should be drilled to 7/16" while the 2 rear most holes should be drilled to 9/16" Clean any metal chips of the side of the vehicle. NOTE: to prevent corrosion, use paint to cover exposed metal from drilling.
3. The two rear most mounting holes cannot be reached from the inside of the vehicle. For these holes use the supplied (4) 10mm rivet nuts. Insert the rivet nut into the hole and use the supplied rivet bolt tool to pass through the clearance nut tool and tighten into the rivet nut making sure the rivet nut stays flush against the vehicle. For the rivet nut to collapse, use a wrench and a ratchet placing the wrench on the clearance nut tool to keep it from spinning on the ratchet on the rivet bolt tool. Tighten until the rivet nut has fully collapsed. NOTE: These bolt holes will not require a flat washer, lock washer or standard nut.
4. After drilling the side holes, place the rocker panel against the side of the vehicle and use the 10mm black button head bolts with flat washers, and standard nuts on the inside of the vehicle. Do not use the lock washers yet as the rocker panel will be removed after marking the bottom holes. Hand tighten bolts evenly to secure the rocker panel in position.
5. To mark the three bottom holes, stick a black marker through each hole and mark the vehicle making sure the mark is aligned vertically with the hole. Remove the rocker panels after the three bottom holes are marked. Use a center punch to mark each bottom hole so that from inside the vehicle, you can tell where the hole will be located. Before drilling, pull carpeting back and remove anything that might get in the way of the drill. Drill the three bottom holes to 7/16" .
6. Locate the 4 mounting slots in the rocker panels that line up with the holes in the body mount tabs shown. Use the 6mm hardware to bolt the rocker panels to these 4 tabs being sure to use the small 6mm washer on top of the mounting tab and the large 6mm washer between the bolt head and the rocker panel.
7. Re-install the rocker panel by using the 10mm button head bolts with flat washers, lock washers, and standard nuts for the side mounting holes. For the bottom three mounting holes, use the three hex head bolts with washers, spacers and Nylock nuts. The 10mm medium bolt goes in the bottom front hole with the 25mm spacer and the 2 long bolts go in the bottom rear two mounting holes with the 45mm spacers. Make sure all bolts are tightened adequately before operating vehicle.
