STOP!.

Read this FIRST!

Fawkes Manufacturing & Development LLC, D.B.A. Fawkes Off Road Fabrications (hereinafter "FMD") cannot and will not be responsible for any consequential or incidental damage to property (including the vehicle our product is installed on) or injury to persons deriving from the use, misuse, or abuse of the product provided to the customer, including any malfunction from negligence or defect. FMD specifically disclaims any damage that arises from the use of our products in any manner not related to off-road recovery use. The term Working Load Limits, while certified by a mechanical engineer and subject to numerous safety factors, are a guideline to product suitability only...don't do stupid things with our stuff and no one will get hurt. Customer understands that the installation and use of this product can cause injury or death to themselves or others and holds FMD, its agents and affiliates harmless from any liability arising out of or relating to the use or ownership of any product provided. Once a customer installs the enclosed product, that customer is releasing FMD of any and all responsibilities for the item such as stated above. We strongly recommend following the winching/recovery procedure "best practices" literature available free from Warn Winches, Pirate 4x4.com and the United States Army (FM 21-305) to assure the safety of the customer/operator and any observer during off road recovery operations. Failure to abide by these "best practices" isn't just a recipe for disaster, it subjects you and others to all sorts of dire consequences which we cannot and will not be responsible for.

By installing this product, you acknowledge that you have read, understood and agreed to the terms and conditions of this Agreement, and you represent that you are of legal age (age 18 or older) to enter this Agreement and become bound by its terms.

1999-2004 Jeep Grand Cherokee (WJ) Modular Recovery & Bull Bar Mounts Installation Manual

Revision 1.3: October 2, 2012

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.

4) Enlarge the mounting holes in the uniframe.

There are three holes now accessible on the bottom of each uniframe rail (on either side of the radiator support see Figure 1). Each of these holes must be opened up to at least 9/16 diameter with the step drill bit or die grinder. It is possible that you will need to flatten the pinch seam behind the inside front slot with your hammer before drilling. When enlarging this inboard front hole, try to use the center of the slot rather than the round, stamped hole outline as your starting point.

Figure 1. Looking at the left side uniframe rail, from the bottom.

5) Fasten the Universal Mounting Brackets to the uniframe rails.

Step 1: Locate the support plates in your installation kit and lay them on the inside of the frame rails so that the holes in the support plate line up with the holes in the uniframe. Step 2: Lift one angled bracket into position under the uniframe. Insert one -13 x 1.5 bolts with a washer preinstalled into the outermost hole from underneath, and hand tighten a flange nut on to the threads sticking above the support plate. Leave it at that position for now, and repeat the procedure on the other side. Step 3: Insert the remaining four -13 x1.5 bolts (with pre-installed washers) through the holes in the brackets from underneath and hand tighten a flange nut onto the portion of the threads sticking above the support plate for each of these inboard bolts, taking care to ensure that the clipped washer relief does not rotate. MiniMax Crosstube (optional) If you have purchased and are installing a MiniMax recovery crosstube: Remove the eight -13 x 1.25 Grade 8 flange head bolts from the crosstube and, using the included threadlocker, place a few drops of the liquid on the threads of four bolts. With the help of jack stands or a helper, raise the MiniMax crosstube into position and hand tighten the four bolts with threadlocker into the REAR two bolt holes on each side. If you will be installing the optional bull bar mount tabs, hand tighten the remaining four bolts in the FRONT two bolt holes without installing the bull bar tabs. If you are not installing the optional bull bar mount tabs, place a few drops of threadlocker on the threads of the remaining four bolts and hand tighten the remaining four bolts in the FRONT two bolt holes. Pull forward on the MiniMax to eliminate any play in the mounting brackets. Step 4: Making sure that your brackets are square and approximately 28.5 apart (unnecessary if youve installed the crosstube), tighten the flange nuts on top of the backing plate by holding the head of the bolts with your wrench, and turning the nuts on the inside of the uniframe rail with your socket using the pattern shown in Figure 2, torque the flange nuts to 120 ft./lbs. of torque in 60 ft./lb. increments.

Figure 2. Mounting bolt torque sequence.

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.

6) Trim the bumper fascia (1999-2003 MiniMax crosstube installation only).

Using a utility knife, die grinder cutoff wheel, or Dremel-type rotary tool, remove the six vertical sections of the lower radiator opening in the bumper fascia as shown in Figure 3. Use the utility knife to clean up any melted plastic, and the sand paper to smooth any rough edges.

Figure 3. Remove the sections between the red lines (1999-2003 models only).

7) Reinstall the front grill and bumper fascia.

Step 1: Slide the grill and fascia assembly over the MiniMax crosstube or shackle tabs, taking care to catch the two alignment pins just to the outside rear of the headlights. If equipped with fog lights, plug the harness in on both sides. Step 2: Reinstall the three screws in the front of the grille with a 7mm socket (2004 models skip this step).

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.

8) Universal Bull Bar Mount Installation (optional)

Step 1: Place the bull bar tabs next to the open bolt holes so that the tabs are angled outboard, and upwards away from the ground. Bull Bar Mount only With the tabs aligned, insert the -13 x 2.25 Grade 8 flange head bolts into the forward most holes from the outboard side, and thread the -13 Grade 8 locking flange nuts on each bolt hand tight. With MiniMax Crosstube Using the included threadlocker, place a few drops of the liquid on the threads of the four -13 x 1.25 Grade 8 flange head bolts you set aside when installing your MiniMax crosstube. With the tabs aligned, install the bolts into the front most holes on each bracket hand tight. With 5/8 Shackle Tabs With the tabs aligned, insert the -13 x 2.25 Grade 8 flange head bolts into the remaining holes from the outboard side, and thread the -13 Grade 8 locking flange nuts on each bolt hand tight. Step 2: Install the bull bar by threading the mounting bolts provided by the manufacturer through the oblong hole in the mounting tabs from the rear. Torque the bolts to the manufacturers specifications Step 3: Position the bull bar where you would prefer (there is some play built into the mounting tabs to allow for customer preference), and then torque all bolts threaded through the bracket to 120 ft./lbs. of torque in 60 ft./lb. increments.