ASSEMBLY & MOUNTING for JK CONGO CAGE
5034150351HARDWARE KIT #
For TECHNICAL SUPPORT Call:
1-800-343-7486Monday- Friday 8:00 A.M. to 4:30 P.M. ( PACIFIC )
®
D
G
F
H
03
07
05
06
IJ
K
K
M
M
J
E
D
D
D
D
REAR “U” BAR is:
G
G
G
RED LOCKTITE
S
T
T
S
DG
04
C
B
AC
B
A
D G
5034150351HARDWARE KIT #
For TECHNICAL SUPPORT Call:
1-800-343-7486Monday- Friday 8:00 A.M. to 4:30 P.M. ( PACIFIC )
®HARDWARE KIT FOR
JK CONGO CAGEASSEMBLY
A
(2 ea.)1/2" x 1"Hex Bolt
C
(2 ea.) 1/2"
SAE Flat Washer
Shown Actual Size
(4 ea.)
F
5/16" Flat Washer
G
(12 ea.)5/16"
NyLock Nut
(8 ea.)5/16" x 2"
Button Head Bolt
D
B
(2 ea.) 1/2"
Lock Washer
K
(6 ea.) 3/8"
SAE Flat Washer
T
(6 ea.)8mm
Thick Flat Washer
M
(2 ea.)Mounting Bracket
Bushing
J(6 ea.)
3/8" Lock Washer
I (4 ea.)
3/8" x 1 1/2"Hex Bolt
H (2 ea.)
3/8" x 3 1/2"Hex Bolt
E (4 ea.)5/16" x 1"
Carriage Bolt
S(6 ea.)
8mm x 35mm Button Head
Bolt
Tighten down all nuts & bolts and THAT'S IT! You are now ready to use your rack.
SILICONE
SEALANT
Apply a healthy air tight bead of silicone around every swaged joint to prevent moisture from leaking into and out of the joint. If this is not done properly, the inside surface of the tubes can rust and rusty water can leak out. Maintain this joint seal throughout the life of your rack.
Rusty Joint
(WITHOUT SEALANT)
Remove existing bolts from the upper half of the windshield hinge plates. Put a small bead of silicone inside and around the countersunk bolt holes in the existing windshield hinge plates and place the thick washers T, (between the jeep and the bracket), then attach front leg mount plates with bolts D.
5034150351HARDWARE KIT #
For TECHNICAL SUPPORT Call:
1-800-343-7486Monday- Friday 8:00 A.M. to 4:30 P.M. ( PACIFIC )
®
Page 3
SEE PAGE 4 TO ATTACH BASKET RACK.
ASSEMBLY & MOUNTINGINSTRUCTIONS forJK CONGO CAGE
Remove existing bolts from bumper mounting bracket and place the rear mounting bracket between the bumper and the jeep body. After placing bushing M between bracket and chassis, attach bracket loosely with bolts I, lock washers J and flat washers K.
Put bolts E up through the foot of mounting bracket (between the bracket and the bumper). Tighten down the bolts at the chassis.
Place U-bracket onto mounting bracket (threads towards jeep), and attach with flat washers F and lock nuts G. Tighten down securely.
With bolts D and lock nuts G snug only the front legs 04 to the front U-bar 03 (narrow). Then attach rear legs to rear U-bar 05 (widest) with bolts D and lock nuts G.
Lift rack onto jeep and secure loosely front legs to front mounting brackets with bolts A, lock washers B, and flat washers C. Next attach loosely the rear legs with bolts H, lock washers J and flat washers K.
To remove and replace the soft top to the jeep, remove the front mount bolts and lift the front of the rack and prop it up with the prop rod while you work on the roof. On completion, lower rack back into postion and re-bolt.
Next, using bolts D and lock nuts G snug only the top cross bars 07 to front and rear U-bars.
#1=
#2=
#3=
#4=
#5=
#7=
NOTE:
IEJK
M
JEEP
BO
DY
REAR MOUNTING BRACKET
BUMPER BUMPERMOUNTING BRACKET
BUSHING
BOLTS, LOCK WASHERS,FLAT WASHERS
JEEPCHASSIS
PROP ROD
#6=
ASSEMBLY & MOUNTING for SAFARI RACK on CONGO CAGE
50561
Page 4
HARDWARE KIT #
For TECHNICAL SUPPORT Call:
1-800-343-7486Monday- Friday 8:00 A.M. to 4:30 P.M. ( PACIFIC )
®
HARDWARE KIT FORCONGO CAGE
MOUNT Q
5/16" Lock Washer
(8 ea.)
Shown Actual SizeShown Actual Size
(8 ea.)K
5/16" SAE Flat Washer
R(8 ea.)
5/16" x 3/4"Hex Bolt
O
(8 ea.)3/8" x 1"
Button Head
M
(8 ea.) 3/8"
SAE Flat Washer
N
(8 ea.) 3/8"
Lock Washer
Clamp Plate(inside)
Rack Cross Beam D
08same distanceeach bracket
DIAGRAM #1a
Cross Tube
Mount Plate
Mount Clamp Strap
10
CONGO CAGE 'U' Bars
0711
KMKMKMKM
D
08
07
K
R
Q
M
O
N
"Attach, Position and Sucure
these bolts FIRST"
"Finish with these bolts."
11
10
CONGO CAGE Cross Tube
