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How to Install a Smittybilt 4 6 in. Wide Fender Flares on your 1997-2006 Wrangler TJ
Shop Parts in this Guide
Included in this Kit: (2) Front Flares, (2) Rear Flares, (2) Mud Guard
Hardware Bag: (28) Snap bases, (28) Snap Covers, (28) Rubber Spacers, (28) Washers (28) M5 x 32 bolt, (20’) Rubber Fender Trim, (28) M5 nuts with serrated washer
Prior to installation:
Pre-fit all flares before you attempt to install. If you plan on painting your Fender Flares it must be done prior to installation. All surfaces must be cleaned using a scouring pad such as Scotch Brite and prepped using an adhesion promoter. Follow all specifications required by the paint manufacturer. As you remove factory parts set them aside safely for later use.
Installation Instructions
Step One: Remove the Factory Flares from vehicle
1. Start with the rear fender flare. Remove the rear wheel well cowling by prying back the
Christmas tree fasteners.
2. Locate and remove the bolts holding the factory flares on the vehicle.
3. Repeat on the other side of vehicle.
4. Proceed to the front and remove the marker lights on the factory flare. Locate and remove the bolts holding the factory flare on the vehicle.
5. Repeat on the other side of vehicle.
Step Two: Install Rubber Trim
1. Locate the supplied rubber trim. Peel back approximately 1” of the backing away from the edge of the rubber trim. Starting at one end of the flare, push the trim onto the outer
edge of the flare (See: Fig A)
2. Continue pressing the rubber trim onto the flare. Push on approximately 4” then hold in place. (See: Fig B) Pull away the backing from backside. (See: Fig C) Continue on in this
manner until you have gone completely around the flare. This will take some time but once you master the technique it will precede quickly. Cut rubber trim to length as installed.
3. Repeat this process for the remaining flares.
Step Three: Install Flares and Mud Guards
1. Start with the front fender flares. Place a clear snap cap base on the screw and place the screw through the mounting hole in the flare. Place a 7mm spacer on the screw from the
backside of the flare. Repeat until all screws have been installed on the flare. (See: Fig D)
2. Hold the flare against the Vehicle and insert the screws through the factory holes in the fender. Place a flat washer and start the nuts on the screws. Do NOT tighten any nuts
until all nuts have been installed and the fender trim rubber has been properly aligned.
CAUTION: Do NOT over tighten the screws.
3. Reinstall the factory marker light into flare, using the factory hardware.
4. Repeat on the other side.
5. Proceed to install rear flares. Repeat Steps 1 & 2 above. Use the supplied nuts in positions that do not have a threaded insert in the vehicle body.
6. Attach Mud Guards to the vehicle using the factory hardware previously removed from vehicle.
7. Place the snap cap cover over the mounting screws and cap base and press firmly into place. Repeat process for the remaining caps.
