Mountain Off Road WCK200 - Manual (Page 2)

——— STEP BY STEP INSTRUCTIONS TO INSTALL THE TJ SPORT CAGE: ————
This Sport Cage can be installed with the top (hard or soft) on the Jeep®. However, M.O.R.E.™ recom-
mends removing the top for installation. All of the pictures in these instructions are with the top removed.
1. UN-zip padding from factory roll bar
2. Remove the factory horizontal bars that connect the roll bar to the windshield (W/S) frame. The simplest
way is to remove the stub from the roll bar (two #40 Torx head bolts per bar), then remove the two #40 Torx
head bolts from the W/S frame. See Figure 1.
3. Remove the factory stubs from the horizontal bars with the #50 Torx® bit (tamperproof) included with this
kit. Keep in mind that there is a left and right stub. See Figure 2.
4. If your Jeep® is equipped with carpet, pull it away from the sides of the body tub to expose the drain holes
in the floor. Do this on the drivers (left) and passenger (right) side. Remove the rubber plugs.
5. Enlarge the TOP of the drain hole to 1-1/4” (no need to enlarge the bottom part of the hole!). This can be
done with a round (rat-tail) file or a small grinding bit on a hi-speed grinder. It is very close to this size and not
much material needs to be removed. See Figure 3.
6. If you wish to retain the padding that was on the factory horizontal bars, cut about 4 inches from the front of
each piece and slide it over the Sport Cage side bars. Install the factory stubs into the L & R Sport Cage
bars. Using the factory #50 tamperproof Torx® head bolts, install the head on the inside, threads pointing
outward. Do not tighten yet, leave them snug only. See Figure 4.
7. Install the left Sport Cage bar in the drivers side of the Jeep®. There is a pre-welded stub on the bottom of
the floor plate that has threads in it. This stub inserts into the factory drain hole in the floor. Install the split-
lock washer on the 9/16”X1-1/2” bolt, then install the large flat washer on the same bolt. See Figure 5. Start
the bolt into the threaded stub in the bottom of the floor plate. See Figure 6. Do not tighten at this time. In-
stall the factory stub to the Jeep® roll bar with the factory # 40 Torx head bolts. See Figure 7. Do not tighten
at this time.
8. Install the cross bar on the pre-welded stub on the left side bar, (Use your rat-tail file to remove any burrs
from the inside of the crossbar). See Figure 8.
9. Install the right Sport Cage bar in the passenger side of the Jeep®. As you install it, insert the cross bar
over the pre-welded stub. See Figure 9. Follow the same procedure as in step 7.
10. Install the drivers side “L” bracket, and passenger side “L” bracket on the W/S frame using the factory #40
Torx head bolts. Snug tighten only.
11. Soft top installations: Install both door surrounds to the Sport Cage, W/S frame, and body tub. See Fig-
ure 10.
12. Close the doors against the surrounds. Make sure that they seal tight. You may have to push the Sport
Cage bars outward to help the doors seal against the surrounds. The pilot holes in the cross bar should be in
the center of the slot of the W/S brackets. If not, loosen the W/S bracket and move it until it lines up, and/or
rotate the cross bar. See Figure 11. With a 3/8” bit in a power drill, enlarge the pilot hole in the cross bar to
3/8”. Drill from the top downward first. Now drill the pre-welded stub to 3/8” (continue to push the side bars
against the door surrounds!). See Figure 12. Insert the 3/8”X2-1/4” bolt into the hole that you just drilled, to
hold all parts in place while you drill the bottom pilot hole and stub. See Figure 13. If you have a hard top,
and never plan on installing a factory style soft top, simply pull the two side bars together (crimping the cross
bar between them) and drill as described above.
13. Remove the bolt, and install it from the bottom with the threads pointing up, through the W/S bracket.
Install one flat washer and the 3/8” crimp-loc nut. Do not tighten at this time. See Figure 14.