American Expedition Vehicles Tummy Tucker – TJ Rubicon models - Manual (Page 4)

Installation Instructions: Tummy Tucker™ – TJ Rubicon models
Nth30116 v4.doc page 4 of 13 www.aev-conversions.com
was closer to the driver’s frame rail is for the rear axle – in the new orientation, the rear axle pump will be
to the rear of the Jeep. There are several separate steps to remounting the pumps:
Step 6a: Modify Locker Pump Bracket. (Skip ONLY this sub-step if you are installing this TT with an Nth°
long-arm suspension system – see the long-arm instructions for details).
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Depending on your available tools, it may be easier to completely remove this bracket from the Jeep
and perform the modifications on a bench. You do not have to remove the pumps from the bracket
however.
- Figure 5 shows the end of the bracket that was closest to the driver’s frame rail – it needs to be
‘unbent’ at the bend next to the mounting holes so that it will bolt to the TT rib later. Removing this
bend is somewhat difficult due to the ‘bead’ stamped into the bracket – it will go easier if you cut
through the bead at the bend with a die grinder or hacksaw.
- The other end of the locker bracket (now the ‘front’) has two mounting holes that are closer together
than the two that will go on the studs. The new mounting will use only the hole that is away from the
‘bead’ in the flange. It will be bolted to the countersunk hole to outboard side of the drive shaft cutout
on TT skid. Normally no modification of this end of the locker pump bracket is required. Once
installation is complete, if you have less than ½” of clearance to the drive shaft you may have to
slightly distort or trim the corner of the locker pump bracket. Operating with less than ½” clearance
will not result in any breakage, but a light scrap on the driveshaft may result.
Step 6b: ‘Dismantle’ Current hose/wire routing. Begin relocation of the pumps by separating all of the
electrical connectors from the bracket – they can be slid in one direction to disengage them from the two-
posted plugs that are pressed into the bracket holes (a large channel-lock pliers works well). Next,
unplug the two small diameter hoses from each pump – these are the ‘output’ hoses (the ones that go to
the axle differentials). CAUTION: The fittings for these hoses on the pumps are a molded part of the
pump housing and are fragile. If you break a nipple off a pump you need a new pump, and Jeep
currently only sells them as a complete assembly (two pumps and bracket). Do not twist the hoses on
the nipples to break the ‘bond’ between hose and nipple; instead gently pry the end of the hose free by
working around the end with a small screwdriver. Finally, remove the short section of larger diameter
hose that goes from the front pump to the plastic ‘T’ fitting at the far end of the bracket. The only thing
preventing moving the pumps to their new location now should be the speedometer wiring.
Step 6c: Rework Speedometer Wiring. In order for the wiring harness to reach the new location of the
locker pumps, the speedometer wires will be too short and the harness will want to lay directly in the
dimpled area above the t/case – do not leave it there! The t-case will move up/down and eventually
smash the wiring! To get the main harness fully in front of the t/case, untape the harness where the
speedometer wires come out and gently pull the wires out through the slit in the plastic ‘convolute’ tubing.
The speedometer wires will pull out back towards the top of the t-case – closer to the plug on the t/case
output. Once all of the inner and outer factory tape is removed, pull out about 6” of wire, this will give you
more than enough length to reroute the main harness - then retape the harness to keep the wires in their
new configuration (be sure to tape the exposed part of the speedometer wires). Now shift the main
harness to in front of the transfer case – only the speedometer wires should be crossing over to the back
(the connector can remain attached to the bracket on the t-case – it will be very close to the floor when
the install is done).
Step 6d: Reposition Locker Pumps. Now the bracket should be free enough that you can reposition the
bracket/pumps assembly to its new location along the driver’s frame rail. The bracket will still mount
‘shiny side up’ to the TT, but while the TT is not installed the two flanges that are now on the frame rail
side of the bracket can be hooked over the fuel lines on the frame rail (the flanges are just far enough
apart that they will straddle the plastic clip that holds the fuel lines – this is almost exactly straight above
the location where they will attach to the TT ) In order to do this, the one connector that was ‘by itself’
will need to be tucked ‘inside’ the bracket instead of mounted on top of it – to provide enough room to
hook the flanges over the top line (this is not necessary for some applications with body lifts). By
hanging the pumps on the fuel lines, it will be easier to complete the rerouting of wires and hoses – this
is also a convenient place to hang the pumps when you may remove the TT later for service work.