American Expedition Vehicles Tummy Tucker – TJ Rubicon models - Manual (Page 7)

Installation Instructions: Tummy Tucker™ – TJ Rubicon models
Nth30116 v4.doc page 7 of 13 www.aev-conversions.com
Figure 8 Figure 9
Figure 10
Figure 11
Figure 8 shows an auto bracket with a high-type exhaust extension in the Nth° long-arm (inboard
position) – Figure 9 shows a manual bracket with the low-type exhaust extension in the ‘standard’
position – other combinations will look similar.
Orient each isolator to roughly match the
orientation of the holes on the TT skid and leave
the bolts only finger tight for now as shown in
figure 10.
Step 10: Install the new Trans Mount Assembly
to the trans in the same manner that the original
one was removed. This will be easiest if you
increase the height of the jack under the transfer
case output so that the trans is higher relative to
the exhaust than it was stock. Start all bolts by
hand, then torque to 50 ft-lbs. Figure 11 shows a
mount installed on a TJ Rubicon with 4-speed
automatic.
Notes for specific transmissions
– 42RLE
Automatics re-use the original four
bolts.
– NV3550 (5-speed manual): Replace the
original four bolts with the supplied 7/16x1”L
flathead bolts.
– NSG-370 (6-speed manual): Replace the
original four bolts with the supplied
M10x25mm bolts – make sure to distinguish
these from the 7/16” flathead bolts that look
similar but will not fit!
Step 11: Attach TT Main Skid Plate. Confirm that you were supplied the correct fasteners by laying the
threaded portion of one against the threads of an original bolt – they must ‘mesh’ exactly (’97-02 TJ’s use
½-13 SAE bolts; ‘03+ TJ’s use M12 metric bolts). Elevate the powertrain all the way up against the floor
for this step. Before raising the TT into position, check the positioning of the exhaust. If the hanger at
the back of the muffler is no longer hanging (meaning the muffler is too high), loosen the two nuts on the
flange just ahead of the muffler until the rear portion of the exhaust again hangs from the rubber mounts
behind the muffler and at the tailpipe (you may need to bend the hanger rods slightly to get them to hang
fully). Next, confirm that the isolators are ‘clocked’ to roughly align with the holes in the skid. Before
raising the skid into position, install the two 5/16” bolts into the holes at the driver’s-side end of the main
(lateral) rib – these will be used to re-mount the locker pump bracket with two additional nuts later. The
bolts must go in from the front side of the rib and be secured with two nuts on the backside as shown in
figure 12 - it will be helpful to use lock-tite. Next raise the TT into position (make sure the isolators
didn’t hang up on the ribs) and line up the countersunk holes with the frame holes and hand-thread all six
flathead bolts.