American Expedition Vehicles TJ Highline Body Kit - Manual (Page 9)

Page 9 of 13
D. INSTALL UNDER HOOD COMPONENTS
1. Replace all the under hood components in their stock location on the fenders and hood.
Most of the holes are in place, but depending on the particular year and model, some
minor holes may have to be drilled and painted. The hood updates the washer nozzle to
the newer 2003+ single nozzle system. Use Mopar #55156728AA if you have an earlier
model and need to upgrade.
2. Relocate your vacuum reservoir to the inside of the Reinforcement Bracket so that it does
not interfere with the Battery Temp Sensor or the Battery Tray.
3. Replace any harness retainers if they were damaged during removal. Use new retainers
to hold the splash shields in place if they were damaged during removal.
4. Using your stock hardware and the nuts and washers included in the kit, install the Front
Highline Flares. Tighten the bolts when you are satisfied with the alignment.
E. TRIMMING THE REAR FOR LARGE TIRES
1. If you plan on running large tires it is recommended that you install the wheels and tires
at this point. With the front swaybar connected to maximize rear suspension travel, use a
wheel jack or equivalent to lift one front tire in order to articulate the
suspension to see what needs to be “clearanced”. Follow normal safety procedures in
order to prevent the vehicle from unintentionally moving and causing an injury or
accident.
2. Remove the rear flares and wheelhouse liners.
3. Shown are a few normal trim operations, however you're vehicle may need more or less
trimming depending on the particular suspension, wheel offset, tire choice etc. These
diagrams should be used as a guideline only.
4. Once you are satisfied with the sheet metal trimming and bumpstop placement, trim the
inside flange of the rear fender flare to match the trimmed bodyside. These flares come
set up for a typical 35” install and will need to be trimmed for bigger or smaller tires.
5. Hold the flare in place and mark the hole positions for the hardware. Center punch and
drill the holes in the bodyside with a 5/16 bit.
6. Prep and paint anywhere the bodyside was trimmed or drilled. If you plan on blending
the bodysides to the fenders, this is an excellent opportunity to paint the trimmed and
drilled areas.
7. Mount the rear fender flares and undercoat the underside of the wheelhouse thoroughly.