Related Manuals for Fab Fours Open Fender
Summary of Contents for Fab Fours Open Fender
- Page 1 Installation Manual Open Fender/Fender Flare Product Number: TF4400 & TF4410 Application: 2019 Dodge Ram HD...
- Page 2 Use own good judgment and take your time. WARNINGS • Failure to observe the following warnings • Fab Fours, Inc. only approves installing this and instructions provided in this manual product according to these written instructions could lead to severe injury and/or death.
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Page 3: Table Of Contents
SAFETY / DISCLAIMER TABLE OF CONTENTS A MESSAGE FROM THE OWNER GETTING STARTED PROVIDED MATERIAL CHAPTER 1: DISASSEMBLY CHAPTER 2: TEMPLATE APPLICATION/CUTTING CHAPTER 3: INSTALLATION/ ROCKER CHANNEL CHAPTER 3: INSTALLATION/ FENDER BASES CHAPTER 3: INSTALLATION/ INNER FENDERS CHAPTER 3: INSTALLATION/ FENDER FLARES CONTACT INFORMATION... -
Page 4: A Message From The Owner
A message from the owner Fab Fours’ was born out of a passion for customizing vehicles and a love for the outdoors. Our engineering team uses the latest 3D design software to turn new product ideas into reality. In our factory, designs come to life with the combination of cutting edge technology for metal cutting and forming and an American workforce that puts its’... -
Page 5: Getting Started
Getting Started Before you begin the installation process of your new Fab Fours product, we suggest laying out all materials and parts on a pad or protective surface. Failure to fully account for all components before beginning installation may leave vehicle immobile until part is acquired. -
Page 6: Provided Material
Provided Materials 21351-02 21352-02 21402-01 21402-02 21402-03 21402-04 21403-01 21403-03 21403-04 21977-01 21978-01... - Page 7 21954 21955 21956 21957 21453 21454 21455 21456 50192-HW 61728 Foam Seal Kit 50121-HW TF4400-IM 61272 Rubber Seal x2...
- Page 8 Hardware kit TOOLS REQUIRED • 3-ton (or larger) jack • 3-ton (or larger) jack stands (QTY 4) • 8mm, 10mm, 18mm, 22mm, 24mm, 3/8”, 1/2” socket wrenches • 18mm & 1/2” open end wrenches • 3/16” Allen wrench • 25/64” Transfer Punch •...
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Page 9: Chapter 1: Disassembly
Disassembly Organization Disconnecting the battery terminals, removing the tires and raising the vehicle is recommended at this time. We recommend Disassemble the vehicle the use of an appropriately rated lift for the where you can catalog and store everything. We suggest vehicle. - Page 10 1. Using an appropriately rated vehicle jack and jack stands or an appropriately rated vehicle lift raise the vehicle so that the tires are off the ground. 2. Using a 22mm socket wrench remove the eight (8) lug nuts from each of the four (4) wheels and set the factory wheels and tires aside.
- Page 11 4. Using a 10mm socket wrench, disconnect the negative terminal from the battery. Figure 1, #2 Figure 1, #2 5. If applicable, disconnect the negative terminal from the auxiliary battery. Figure 2 Figure 2...
- Page 12 6. Using an 8mm socket wrench and plastic panel pry tool, remove the two (2) screws and one (1) push pin from the rear splash shield trim. Figure 3 Figure 3 7. Using an 10mm socket wrench and plastic panel pry tool, remove the twelve (12) screws and two (2) push pins from the inner fender and set aside.
- Page 13 Figure 5 8. Disconnect the factory wiring harness from the inside of the driver side wheel well. Figure 6 Figure 6...
- Page 14 9. With assistance, support the bumper from both sides of the vehicle. Using an 18mm socket wrench, 24mm socket wrench and 18mm open end wench, remove the three (3) factory bumper bolts that hold the factory bumper to the frame rail. Figure 7 Figure 7 Note: The factory tow hooks stay in the frame rail while extracting the front bumper from the frame rail ends.
- Page 15 11. Using an 8mm socket wrench, remove the screw in the splash shield forward of the bed wheel well. Then using the plastic body panel pry tool, pull down and forward to remove the splash shield. Using the plastic panel pry tool remove all the plastic clips left in the bed. Figure 9 & 10 Figure 9 Figure 10...
- Page 16 12. Using an 8mm socket wrench, remove the two (2) screws in the splash shield rearward of the bed wheel well. Then using the plastic body panel pry tool, pull down to remove the splash shield. Using the plastic panel pry tool remove all plastic clips left in the bed. Figure 11 Figure 11 13.
- Page 17 14. Using an 8mm socket wrench, remove the three (3) screws attaching the rearward rear inner fender to the bed and remove it. Figure 13 Figure 13 Note: There are two (2) versions of rear inner fenders available. If your vehicle has the one (1) piece version the process will be the same as explained in steps 13-14, but there will be additional screws to be removed.
- Page 18 16. Remove the foam filler panel from the inside of the fender along the door hinges. Figure 15 Figure 15 17. Using a plastic panel pry tool, carefully remove the body harness connector in the front wheel well and secure it near the frame to keep it away from the cutting area. Figure 16 Figure 16...
- Page 19 18. Using a 10mm socket wrench, remove the screw attaching the support bar to the bottom of the inner bedside forward of the rear wheel. Figure 17 Figure 17 19. Repeat steps 6-17 on the passenger side of the vehicle.
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Page 20: Chapter 2: Template Application/Cutting
Template Application/Cutting Organization 1. Using painters tape, apply at least three (3 layers of tape to the forward most part of the front door. Figure 1 Disassemble the vehicle where you can catalog and store everything. We suggest labeling and bagging all the OEM bolts when removing from the vehicle. - Page 21 Figure 3 Figure 4 3. Apply the DS FEN 2 template to the driver’s side front fender beginning with the puzzle piece section at the right side of DS FEN 1. Then work the blue dashed line along the wheel well opening continuing into the stamped body line running horizontal on the fender ending at the door jamb.
- Page 22 Figure 5 Figure 6 Figure 7...
- Page 23 4. Apply the DS FEN 5 template to the bed along the forward edge of the wheel well. Begin by aligning the hole in the template with the hole left from removing the bolt that attaches the stiffener to the bed side.
- Page 24 Figure 10 5. Apply the DS FEN 6 template to the bed along the rearward edge of the wheel well. Begin by aligning the two (2) slotted cutouts in the bottom of the template with the slotted holes in the bottom of the bed side.
- Page 25 6. Using a small reciprocating saw, cut along the red dashed line of the DS FEN 1 template. Then continue cutting onto the red dashed line of the DS FEN 2 template. Figure 13-14 Figure 13 Figure 14...
- Page 26 7. Using a flap disk wheel on an angle grinder remove any sharp edges along the cut area. Figure 15 Figure 15 8. Using a small reciprocating saw, cut along the inside of the red dashed line of the DS FEN 5 template leaving the red dashed line on the vehicle when the cut is finished.
- Page 27 9. Using a small reciprocation saw, cut along the inside of the red dashed line of the DS FEN 6 template leaving the red dashed line on the vehicle when the cut is finished. Figure 18-19 Figure 18 Figure 19...
- Page 28 10. Using a flap disk wheel on an angle grinder remove any sharp edges along the cut area. Figure 20 Figure 20 11. Remove all the templates now. Figure 21 Figure 21 12. Apply the DS BRKT 1 template to the front inner structure tubing aligning the u-shaped cutout outlined with the blue dashed line on the template to the oval hole stamped in the vehicle.
- Page 29 13. Using a 3/8” drill bit, make a hole in the indicated location on the DS BRKT 1 template. Then remove the template. Figure 23 Figure 23 14. Apply the DS CAB 1 template to the outside of the drivers’ side rocker channel. Start by aligning the two (2) notches in the bottom of the template with the two (2) holes in the pinch weld.
- Page 30 15. Apply the DS CAB 2 template to the front face of the rocker channel starting with aligning the oval cutout in the template with the oval hole in the rocker channel. Then, work the template up the rocker channel aligning the blue dashed line with the corner of the outer edge of the rocker channel. Figure 25 Figure 25 16.
- Page 31 17. Apply the DS CAB 4 template to the drivers’ side body mount on the frame aligning the blue dashed line profile with the outer edge of the body mount. Figure 27 Figure 27 18. Apply the DS CAB 5 template to the inboard side of the rocker channel above the DS CAB 3 template. Align the blue dashed line with the front edge of the rocker channel.
- Page 32 19. Using a sharpie scribe a straight line on the outside of the rocker channel that connects the red dashed lines. Figure 29 Figure 29 20. Using a large reciprocating saw, cut upward along the red dashed line of the DS CAB 1 template and previously made sharpie line until you reach the horizontal red dashed line.
- Page 33 Figure 30 Figure 31...
- Page 34 21. Using a small reciprocating saw, cut up along the red dashed line on DS CAB 1 and continue onto the horizontal red dashed line at the top of the DS CAB 2 template. Then cut up along the vertical dashed red line of the DS CAB 2 template to remove the rocker channel corner.
- Page 35 23. Using a large reciprocating cut upward along the red dashed line of DS CAB 5 connecting the end of all the cuts made previously. Figure 34 Figure 34 24. Using a large reciprocating saw, cut along the red dashed line of the DS CAB 4 template. Make sure the body control harness is clear before cutting.
- Page 36 25. Using a small cutting wheel, remove the second layer from the outside of the rocker channel to allow clearance for the provided rocker channel cover plate. Figure 36 Figure 36 26. Using a flap disk wheel on an angle grinder, remove any sharp edges created from previous cutting operations.
- Page 37 Installation | rocker channel plates 1. Using painters’ tape, cover the front fender eight inches up from the cut area. Figure 1 Figure 1 2. Using a drill and 1/2” bit, make a hole indicated by the template above the cut area on the rocker channel.
- Page 38 3. Loosely thread one (1) of the provided 5/16” stainless steel button head cap screws with bonded sealing washer (50192-HW) into the provided upper rocker channel cover plate (21977-01) through the previously drilled hole. The upper rocker channel cover plate should fit inside of the rocker channel. Figure 4 Figure 4 4.
- Page 39 5. Using an impact driver with a 3/8” socket, drill one (1) of the provided 5/16” self-tapping screws with bonded sealing washer (50192-HW) through the hole in the bottom of the lower rocker channel cover plate. Figure 6 Figure 6 6.
- Page 40 8. Loosely thread one (1) of the provided 5/16” grade 8 bolts, lock washers, and flat washers (50192-HW) through the provided horse-shoe shaped bracket (21402-02) into the previously installed nut plate. The nuts on the horse-shoe bracket should face up. Figure 8 Figure 8 9.
- Page 41 10. Using duct tape, cover any gaps or hole that may exist between the rocker channel cover plates and the rocker channel itself. Figure 10 Figure 10 11. Using the provided foam sealant and dispensing gun (61725), fill the cavity in the rocker channel with one (1) entire tube of foam from a gap at the highest point.
- Page 42 12. Give the foam sealant roughly five minutes to dry then use a razor blade to trim the excess away. Figure 12 Figure 12 13. Using an impact driver and 3/8” socket, bundle the body wiring harnesses together in the provided loop clamp (50192-HW) and then attached the loop clamp to the backside of the rocker channel.
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Page 43: Chapter 3: Installation/ Fender Bases
Installation | Fender Bases 1. Apply the provided rubber edge trim (61727) to the outer perimeter of the four (4) fender bases. Do not stretch the trim during application or it will not stay in place. Start at one end of the fender base and use a razor blade to cut off the excess at the other end. - Page 44 2. Using three (3) vise-grip c-clamps, hold the provided driver side front base (21954) up to the vehicle. Align the front edge with the bottom of the OEM fender below the headlight. Align the two (2) back to back bends below the farthest back hole with the profile on the door below the RAM logo. Figure 4 Figure 4 3.
- Page 45 4. Remove the fender base from the vehicle and using a drill with 3/8” bit, drill out the seven (7) previously marked locations. Figure 6 Figure 6 5. Remove the painters’ tape from the OEM fender. 6. Using a deburring tool, clean any sharp edges off the previously drilled holes in the OEM fender. 7.
- Page 46 9. Using three (3) c-clamps, attach the provided fender base to the OEM fender again aligning it with the previously drilled holes. Figure 8 Figure 8 10. Using a 3/16” Allen wrench, 1/2” socket wrench, and seven (7) of the 5/16”x1” stainless steel button head caps screws with bonded sealing washers (50192-HW), install the provided fender base to the OEM fender for the final time.
- Page 47 11. Using a 3/16” Allen wrench and one (1) of the provided stainless steel 5/16”x1” button head cap screws with bonded sealing washer (50192-HW), connect the fender base support bracket to the lower rocker channel cover plate. Figure 10 Figure 10 12.
- Page 48 13. Using a 1/2” socket wrench, tighten all the grade 8 hardware installed previously in the base fender support bracket. 14. Using painters’ tape, cover the bed side 10” around the wheel well. 15. Using three (3) vise grip c-clamps, mount the provided drivers’ rear base fender (21956) to the drivers’...
- Page 49 17. Remove the base fender from the vehicle and using a drill with 3/8” bit, drill out the 10 previously marked holes. Figure 14 Figure 14 18. Using a deburring tool, clean out any sharp edges in the previously drilled holes. 19.
- Page 50 21. Using a 3/16” Allen wrench and 10 of the provided 5/16”x1.5” stainless steel button head cap screws with bonded sealing washers, flat washers, lock washers, and nuts (50192-HW) through the previously drilled holes. Figure 17 Figure 17 22. Using a 10mm socket wrench, reinstall the OEM screw removed from the bed stiffener bar previously.
- Page 51 Figure 19 24. Using a 3/16” Allen wrench, install three (3) of the provided 5/16”x1” stainless steel button head cap screws with bonded sealing washers in the three (3) remaining holes with welded in nuts on the base fender. Figure 20 Figure 20...
- Page 52 Installation | I nner Fenders 1. The front OEM inner fenders can be reused with a little modification. Using a small reciprocating saw the plastic can be cut. The profile of the cut can be field determined based on the choice of front bumper, tire size, and lift options.
- Page 53 Figure 3 3. Finish reinstalling the modified inner fenders using an 8mm socket wrench to install the two (2) OEM screws and one (1) ribbed shank push pin. Figure 4 Figure 4...
- Page 54 Installation | Fender Flares 1. Apply the provided rubber edge trim (61727) to the outer profile of the four (4) provided fender flares (21453-21456) by starting at one end and working it across to the opposite end. Then use a razor blade to trim off the excess.
- Page 55 Figure 3 Figure 4...
- Page 56 4. Using a 1/2” open end wrench, install the provided driver’s side rear fender flare (21455) with three (3) of the provided 5/16”x1” grade 8 screws, flat washers, and lock washers. (50192-HW) Figure 5 Figure 5 5. Repeat steps 2-3 on passenger side.
- Page 57 Congratulations! You have completed the installation of the Fab Fours Open Fender Kit. We hope you enjoy your product and again, welcome to the family!
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Page 59: Contact Information
Contact Information Fab Fours Inc. 2213 Industrial Park Road Lancaster, SC 29720 Phone: (866) 385-1905 Fax: 866-574-1423 Email: support@fabfours.com www.fabfours.com... - Page 60 “If you’re looking for more of the same, Then you’ve come to the wrong place. ” - Greg Higgs...