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1999-2004 Jeep Grand Cherokee (WJ) Modular Recovery & Bull Bar Mounts Installation Manual
1) Examine the package contents to ensure you have all the items and hardware needed to install the recovery items you have purchased. You should have:
WJ Universal Mounting Brackets Quant. 2 Support plate Quant. 1 Left mounting bracket Quant. 1 Right mounting bracket Universal Mounting Bracket Hardware Quant. 6 -13 x 1.5 Grade 8 bolt with standard head Quant. 6 -13 Grade 8 locking flange nut Quant. 6 standard washer Bumper Fascia Reinstallation Hardware Quant. 6 captured push-pin fastener MiniMax Recovery Crosstube optional Quant. 1 MiniMax crosstube Quant. 8 -13 x 1.25 Grade 8 flange head bolt Quant. 1 Tube Loctite 242 medium strength thread locker Universal 5/8 Shackle Tabs optional Quant. 2 Shackle mount Quant. 8 -13 x 2.25 Grade 8 flange head bolt Quant. 8 -13 Grade 8 locking flange nut Universal Bull Bar Mounts optional Quant. 1 Left bull bar mounting tab Quant. 1 Right bull bar mounting tab Quant. 4 -13 x 1.25 Grade 8 flange head bolt (not present if MiniMax or shackle tabs ordered) Quant. 4 -13 Grade 8 locking flange nut (not present if MiniMax or shackle tabs ordered) If you are missing any of the items above or if you have questions at any time during the installation of our product PLEASE call us at 414-916-1781 so that we can take care of the problem/question.
2) Gather the tools you will need for installation. You should have:
A right angle drill, right angle die grinder, or a standard drill with a right angle adapter. A utility knife and cutoff wheel or Dremel-type rotary tool (1999-2003 WJs). A sheet of 220-400 medium/fine grit sand paper (1999-2003 WJs). A step drill bit or cone-type grinding burr or stone capable of enlarging holes to 9/16 diameter. A large ballpeen or small sledge hammer. drill bit or flat bladed screw driver and side cutters. A pair of needle-nose pliers. A drive ratchet, short extension, 7 and 10mm sockets. A drive ratchet and medium depth socket. A combination open and box-end wrench. A drive torque wrench capable of producing 120 foot pounds of torque. A jack, jack stand, or a helper capable of lifting and holding 45 pounds (for optional MiniMax crosstube installation).
3) Remove the front grill and bumper fascia from your Jeep WJ.
Step 1: Remove the three plastic rivets that attach the fascia to each wheel well liner and discard. Note: These rivets may be drilled out (carefully) using the bit. Alternately, you may pry them out with a flat blade screwdriver far enough to insert a pair of side-cutters and cut the rivet heads off. Use a rag or other protection under the screwdriver to prevent scratching the edge of the fender. Step 2: With a 10mm socket on the short extension, remove one bolt in each upper wheel well that attaches the fascia to the fender. Step 3: From inside the hood utilizing a 7mm socket, remove the four screws located along the top of the grille (2004 models skip this step). Step 4: Remove the three push-pin fasteners holding the bottom of the fascia to the drip pan and set aside. 2004 models have an additional five push-pin fasteners in the center of the fascia that must be removed. Note: These fasteners are removed by prying on the center rectangular head with a small flat blade screwdriver or pulling with needle-nose pliers enough to pop the center section out enough to remove the pin. The plastic holders must also be removed and are easily popped free by pulling the fascia edge down. Step 5: Remove the three screws in the front of the grille with a 7mm socket (2004 models skip this step). Step 6: If equipped with fog lights, unplug harness and slide the grill and fascia assembly forward. Carefully set the assembly aside.
Figure 1. Looking at the left side uniframe rail, from the bottom.
MiniMax Crosstube (optional) If you have purchased and are installing a MiniMax recovery crosstube: If you will be installing bull bar tabs, torque the four REAR -13 x 1.25 Grade 8 flange head bolts to 120 ft./lbs. of torque in 60 ft./lb. increments. Remove the four FRONT -13 x 1.25 Grade 8 flange head bolts from the crosstube and set them aside. . If you are not installing the optional bull bar mount tabs torque all eight -13 x 1.25 Grade 8 flange head bolts to 120 ft./lbs. of torque in 60 ft./lb. increments. 5/8 Shackle Tabs (optional) If you have purchased and are installing 5/8 shackle tabs: If you will be installing bull bar tabs, hold the shackle tab with the large hole in the lower position, and place it next to the inside of the mounting bracket. Insert the -13 x 2.25 Grade 8 flange head bolts from the outboard side, and thread two -13 Grade 8 locking flange nut on the REAR bolts. Torque the two REAR -13 x 2.25 Grade 8 flange head bolts to 120 ft./lbs. of torque in 60 ft./lb. increments. Remove the two FRONT -13 x 2.25 Grade 8 flange head bolts from the shackle tab assembly and set them aside. Repeat for the opposite side. . If you are not installing the optional bull bar mount tabs, hold the tab shackle tab with the large hole in the lower position, and place it next to the inside of the mounting bracket. Insert the -13 x 2.25 Grade 8 flange head bolts from the outboard side, and thread a -13 Grade 8 locking flange nut on each bolt. Torque the -13 x 2.25 Grade 8 flange head bolts to 120 ft./lbs. of torque in 60 ft./lb. increments. Repeat for the opposite side.
Figure 3. Remove the sections between the red lines (1999-2003 models only).
Step 3: Reinstall the three push-pin fasteners holding the bottom of the fascia to the drip pan. 2004 models have an additional five push-pin fasteners in the center of the fascia that must be installed. Step 4: From inside the hood utilizing a 7mm socket, reinstall the four screws located along the top of the grille (2004 models skip this step). Step 5: With a 10mm socket on the short extension, reinstall the bolt in each upper wheel well that attaches the fascia to the fender. Step 6: Reattach the fascia to each wheel well liner using the six new captured push-pin fasteners provided in place of the rivets you removed.