American Expedition Vehicles TJ Highline Body Kit - Manual (Page 3)

Page 3 of 13
REMOVAL OF THE STOCK COMPONENTS
These instructions assume a certain amount of mechanical ability and are not written nor
intended for someone not familiar with auto body repair.
A. REMOVAL OF THE O.E. HOOD
1. Prepare the hood to be removed. Unplug the under hood lamp, washer nozzle
hose and remove the ground strap from the hood.
Remove the cowl cover. Remove the windshield wiper arms. Remove the four
screws under the windshield, one screw in the center vent area and two
screws under the hood to cowl seal. Carefully remove the cowl cover by
lifting up and pulling forward, some vehicles may need the hood lifted at
the same time to prevent the cowl cover from contacting the hood.
2. Remove the Hood. Use the T40 Torx bit to remove the hinges from the cowl.
Strip the O.E. hood of all hardware. Strip all latches, hinges, bolts, bumpers, prop rod
etc.
Using a small screwdriver remove the hinge backing plates from the rear cross-member
of the O.E. hood, re-install these in the AEV hood prior to paint.
B. REMOVAL OF THE O.E. FENDERS
1. Remove and temporarily relocate under hood components. Disconnect and
remove the fender flares, fender flare extensions, Sahara side moldings,
Rubicon Rocker guards, aftermarket rocker guards, battery, battery tray,
ABS tray, air filter box, washer fluid reservoir, rubber splash shields
and horn.
2. Using elastic cords or zip ties, temporarily relocate the PDC,
vacuum reservoir, emissions canister, TCM, speed control motor etc. Free
the wiring harnesses where attached to the fender as well as the hard AC
line on the right fender.
3. Undo the top shock mount and slide the shock downward so that the stud
does not protrude through the top of the shock tower.
4. Remove the bolt in the front body mount under the center of the grille.
5. Unbolt the fenders. Start by removing the six bolts that attach the
fender to the grille. Remove the four bolts that attach the inner fender
to the Fender Reinforcement Bracket. Remove the four bolts that hold the
fender to the cowl. Carefully remove the fenders.
6. Strip all hardware from the O.E. fenders.
Remove the fender reinforcement brackets, they are marked right and left on the bottom.