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Proudly Made In USA
Installation Instructions:
TJ & YJ Standard Rear Bumper
Part Number: TJ-YJ-20SRB(T)
Parts List
Qty:
1 Standard Rear Bumper
2 Left & Right Frame Tie-in
Brackets
2 Spacer Shims
8 7/16-20 x 1-3/4” Gr8 Bolts
8 7/16” Gr8 Flat Washers
8 7/16” Gr8 Lock Washers
4 7/16-14 x 3-1/2” Gr5 Bolts
4 7/16-14 Gr5 Hex Nut
8 7/16” Gr5 Flat Washers
4 7/16” Gr5 Lock Washers
Vehicle Fitment:
1987-2006 Jeep Wrangler &
Unlimited
Tools Needed
Ratchet
18mm Socket
5/8” Socket
Torque Wrench
18mm Wrench
5/8” Wrench
11/16” Wrench
Drill
7/16” Bit
Safety Glasses
Congratulations on your purchase of the Hyline Offroad Standard Rear Bumper. Our Bumpers are completely
manufactured in our facility located in Perkasie, PA. They are designed and engineered by Offroad enthusiasts just
like you to be rock solid at an affordable price. Hyline Offroad would like to thank you for your recent purchase
and look forward to serving you in the future.
OptionalOffroad
Winch Installation
Hyline
Staff
T:\Hyline Offroad, LLC\Installation Instructions\TJ-YJ-20SRB\TJ-YJ-20SRB Installation Instructions.doc
Page 1 of 1
REV 2 6/1/2010
PLEASE READ INSTRUCTIONS BEFORE BEGINNING INSTALLATION
Rear Bumper Installation
Step 1 – Remove the stock rear bumper by unbolting the two 18mm nuts from each side. It’s easier to use a
wrench to remove the top nut nearest the body mount. Next, remove the two bolts on the bottom of
the bumper that attach it to the frame. You’ll also need to remove any factory or aftermarket towing
hitch you may have installed. The stock bumper should be free to remove at this point.
***DO NOT THROW AWAY THE TWO BOTTOM BOLTS. YOU WILL REUSE THEM***
Step 2 – (1997-2006 TJ Rear Bumper Installation) **For 1987-1995 YJ Installations Skip to Step #3**
Each Hyline bumper we sell comes with Frame Tie-in
Brackets for the TJ Model Year only. To install these brackets
you will need to use a 7/16” Bit to drill a thru hole on
the inside of the frame, using the existing holes in the
frame as a guide. (SEE FIGURE 1)
After holes are drilled thru, Install the Frame Tie-in Brackets,
Using the supplied 7/16-14 x 3-1/2” Bolts. Install parts in the
Following order: Bolt, Flat Washer, Tie-in Bracket, Thru Frame,
Flat Washer, Lock Washer, Nut. ONLY HAND TIGHTEN
***THE NEXT STEP MAY REQUIRE TWO PEOPLE TO LIFT
AND HOLD BUMPER IN PLACE***
T:\Hyline Offroad, LLC\Installation Instructions\TJ-YJ-20SRB\TJ-YJ-20SRB Installation Instructions.doc
Figure 1
Drill these two existing holes through the inside frame. Be
sure to check for wires or any other lines before drilling. The
drill bit will exit close to the gas tank, so as an added
precaution, place a piece of wood or steel in between the gas
tank and inside of the frame to prevent any accident.
Page 2 of 2
REV 2 6/1/2010
Note: If installing a Tire Carrier you may need to keep the Gr8 Bumper
Mounting Bolts loose in order to install the Tire Carrier & Pivot Pin. Refer
to “NOTE” at Step 4 in Installation Instruction Packet for TJ-YJ-20STC.
Step 3 – Some TJ Models may have eight mounting holes in the rear cross member, but most will only have
four. All YJ Models should have eight mounting holes in the rear cross member. Our rear bumper
allows for installation of bolts through all eight mounting holes if applicable. For YJ Models you will not
be installing the Frame Tie-in Brackets.
For TJ’s you will install two bolts on each side using supplied
7/16-20 x 1-3/4” Bolts. Install parts in the following order:
Bolt, Flat Washer, Lock Washer, Tie-in Bracket, & Spacer Shim.
(SEE FIGURE 2) Re-install the two bolts you took out of from the
bottom of the stock bumper. BE CAREFUL NOT TO CROSS THREAD
THE 7/16-20 x 1-3/4” BOLTS WHEN THREADING INTO THE BUMPER.
Figure 2
For YJ’s you will install four bolts on each side using supplied
7/16-20 x 1-3/4” Bolts. You will not be installing the Frame Tie-in
Brackets on the YJ Model.
Install Spacer Shim in between rear cross
member and Frame Tie-in Bracket.
Step 4 – Tighten all bolts and torque to 75-78 ft/lbs. After about 50-100 miles of driving re-check all bolts and
torque to proper settings.
Send your OFFROAD pictures to [email protected] . If we choose any one of your pictures to be used on
our website, We send you a FREE Hyline Offroad T-Shirt.
Installation instructions provided must be read and followed exactly when installing
product. Failure to do so could potentially result in injury or death of any occupants
in the vehicle. WEAR SEAT BELTS AT ALL TIMES WHEN DRIVING!
Attention
Though our products are rugged, they are primarily designed and built to enhance the appearance of the
vehicle and will not protect from death or injury in the event of an accident. Adhere to all vehicle
manufacturers specifications
T:\Hyline Offroad, LLC\Installation Instructions\TJ-YJ-20SRB\TJ-YJ-20SRB Installation Instructions.doc
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REV 2 6/1/2010
Proudly Made In USA
Parts List
Qty:
1
1
1
1
1
1
2
5
5
5
2
4
2
2
2
1
1
1
1
1
Swingout Tire Carrier
Slide Adjustable Tire Mount
Black Tailgate Bracket Plate
Machined Pivot Pin
Short White Plastic Alignment Block
Long White Plastic Alignment Block
Brass Washers for Pivot Pin
½”-13 x 1-1/2 Gr. 8 Hex Head Bolts
½” Lock Washers Gr. 8
½” Flat Washers Gr. 8
5/16”-18 x 1-3/4” Gr. 5 Hex Head Bolts
5/16” Flat Washers Gr. 5
5/16”-18 Nylok Hex Nut Gr. 5
3/8” Flat Washers Gr. 5
3/8”-24 Nylok Hex Nut Gr. 5
3/8”-24 RH Thread Thin Hex Nut Gr. 5
3/8”-24 LH Thread Thin Hex Nut Gr. 5
Right Hand Thread Ball Joint Rod End
Left Hand Thread Ball Joint Rod End
1/8” PTF Stainless Steel Grease Fitting
1 Round Plastic Tube Plug
1
3
1
Aluminum Connector Rod
Wheel Studs
Black Rubber Stem Bumper
Installation Instructions:
TJ/YJ Gen II Swingout Tire
Carrier
Part Number: 250.200.120
Vehicle Fitment:
1987-2006 Jeep Wrangler &
Unlimited
Tools Needed
13mm Socket
¾” Socket
½” Socket
9/16” Socket
Torx Bit
½” Wrench
¾” Wrench
7/16” Wrench
Grease Gun
Lithium Grease
Wire Cutters
5 lb. Hammer
Or Heavy Duty Vise
Congratulations on your purchase of the Hyline Offroad Gen II Swingout Tire
Carrier. Our Products are completely manufactured in our facility located in
Perkasie, PA. They are designed and engineered by Offroad enthusiasts just like
you to be rock solid at an affordable price. Hyline Offroad would like to thank
you for your recent purchase and look forward to serving you in the future.
Hyline Offroad Staff
PLEASE READ INSTRUCTIONS BEFORE BEGINNING INSTALLATION
Generation II Swingout Tire Carrier Installation
Step 1 – If you have not already installed your Hyline Offroad Rear Bumper that accepts this tire carrier please do
so using the Installation Instructions for P/n 250.200.110.
***BEFORE INSTALLING TIRE CARRIER ON THE BUMPER COMPLETE STEPS 2 & 3***
Step 2 – Remove the stock tire carrier housing by unbolting the four bolts using the ½” socket. Then remove the 3 black
rubber mounts that the stock tire pressed against using the torx socket. Cut wire for third brake light as long as
possible for rewiring if desired.
Step 3 – Install the Stainless Steel Grease Fitting using the 7/16” Wrench.
The grease fitting has pipe threads which are tapered to obtain
a leak free seal. Because of the tapered threads you may not
be able to completely screw in the grease fitting. Note: Location of
fitting might vary from picture in Figure 1.
Brass Washers
& Grease Fitting
Step 4 – Install the supplied tailgate bracket using 3 bolts that were previously
removed from stock tire carrier (Do Not Tighten Yet). Install Rod End
Fitting using 3/8” flat washers & 3/8”-24 Locking Hex Nut & tighten.
Also install the white plastic Alignment block using two-5/16-18” bolts,
Figure 1
four-5/16” flat washers & two-5/16-18” hex lock nuts (Do Not Tighten Yet).
See Figure 2 – Photo May Vary By Model
Figure 2
Tailgate Bracket
Note: Two Plastic Alignment Blocks have been provided. Use whichever block works best to align swingout carrier parallel to the tailgate.
Typically all models will use the shorter block.
***INSTALL TIRE CARRIER ONTO BUMPER***
Step 5 – Apply a thin layer of quality white lithium grease onto the entire shaft of the Pivot Pin before
inserting into Tire Carrier. Insert the Pivot Pin through the Tire Carrier tube with the keyed end facing
down. Make sure you have installed the Brass Washers properly. (Refer to Figure 3). With the Pivot Pin
protruding through the Tire Carrier tube you can now slide the Pivot Pin down inside the bumper tube.
The keyed notch on the Pivot Pin will slide into the cutout in the bottom of the bumper tube. Once you
have the Pivot Pin seated properly you can now install the supplied ½”-13 Gr 8 Hex Head Bolt,
Lock Washer and Flat Washer up through the bottom of the bumper and thread into the Pivot Pin. This
will lock the pivot pin in place. You do not have to overtighten the ½”-13 Bolt… Tighten just enough so
that the Tire Carrier still opens and closes smoothly.
Figure 3
Step 6 – Install the other Rod End Fitting onto the Tire Carrier & tighten. (Fig. 3)
Step 7 – Now Install the 3 Wheel Studs into the Slide Adjustable Tire Mount.
Make sure you place wheel studs in the correct holes for your
wheel bolt pattern. You can use either a mechanical press, hammer or
bench vise to install the wheel studs. Install the Slide Adjustable Tire
Mount to Tire Carrier using the four supplied ½”-13 x 1-1/2” Gr 8 Hex
Head Bolts, Lock Washers and Flat Washers.
DO NOT TIGHTEN BOLTS YET.
Install your spare tire. With the tire installed you can now adjust the
sliding mount to the best position for your size tire. Once the position
is set, Tighten all four bolts. Note: Tire should be tight against swingout
base arm. This will help to keep the tire from vibrating.
Step 8 – Install the black rubber stem bumper onto plate on bumper. Work into hole
By twisting and pushing. (See Figure 4 For Location)
Rod End Fitting & Connector Rod..
Install on lower mounting point. Upper
mounting point is used if vehicle has a
body lift up to 2”.
Figure 4
Step 8 – Install the 3/8”-24 Thin Hex Nuts onto each Rod End Fitting & Assemble the
Aluminum Connector Rod to End Fittings. Note, the connector rod and end
fittings are machined with right and left hand threads. They can only be
assembled one way. Just start the threads into the connector rod in this step.
(See Figure 3)
Step 9 – With the tailgate in the closed and latched position, you can turn/tighten the
connector rod until the Tire Carrier draws in tight to the plastic alignment
block. You can adjust the alignment block up or down in order for it to align
with the round tube on the Tire Carrier. (See Figure 5 For Proper Tightening)
Figure 5
Step 10 – Tighten 5/16” bolts in Alignment Block & tighten 3/8” thin hex nuts
against the connector rod. This will keep the connector rod from
unthreading over time. You can also tighten the three Tailgate
Bracket bolts.
Step 11 – Use a Grease Gun with quality White Lithium Grease sold at almost
any automotive or hardware store. While pumping in grease,
continually rotate the tire carrier as far closed and open as possible.
This will help spread the grease evenly throughout the Pivot Pin.
From time to time you will need to re-grease the Pivot Pin. Doing so
will prolong the life of your tire carrier.
***After Driving a couple days, Check All Bolts and Connections
Re-tighten As Necessary***
Incorrect Adjustment
Connector Rod Should
Be Tightened
Correct Adjustment
Tightly Seated With
Alignment Block
Send your OFFROAD pictures to [email protected] . If we choose any one of your pictures to be used on our website, We send you a FREE
Hyline Offroad T-Shirt.