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Smittybilt SB76410 Installation Instructions Manual

2007-2018 jeep jk tailgate
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NOTE: Carefully read entire instructions thoroughly before attempting to install this part.
Parts Included
93-112TU201 Tailgate
93-112TU204 Hinge Cover
35-112TU206 Hinge Pin
93-112TU208 Tailgate Hinge
93-112TU209 Nut Plate
93-112TU211 HD Tire Gate Hinge
93-112TU216 Spacer
93-356CA100 HD Tire Carrier Mount
93-9183 Stationary Bracket
93-9187 Adjustable Bracket
93-315TU001 Brake Light Mount
90-76410-0 Brake Light
90-76410-1 Hardware Pack
M5x.80x30 button head screw
5mm Flat washer
90-76410-2 Hardware pack
M4x.70x10 button head screw
4mm Split ring lock washer
4mm Flat washer
90-76410-3 Hardware Pack
M6x16mm button head socket cap screw
M6 Flat washer
90-76410-4 Hardware Pack Latch
M6x16mm Flat head socket cap screw
Tool Required:
Torque wrench's (in-lbs. & ft-lbs.)
Auto trim tool set/Plastic prybars
For Technical Support/Warranty Information please call 310-762-9944
Qty.
1
1
2
2
2
2
2
1
1
1
1
1
1
2
2
1
18
18
18
1
Exterior covers
8
8
1
3
Pliers
Metric Allen bit set
Smittybilt, 400 W. Artesia, Compton, CA 90220
Installation Instructions:
(Part # SB76410)
2007-2018 Jeep JK Tailgate
ID
Parts Included
1
90-76410-5 Hardware Pack
2
M8x25 Hex bolt GR 8.8
3
M8 Flat washer
4
90-76410-6 Hardware Pack
5
Snap rings
90-76410-7 Hardware Pack
6
M12x25 Hex bolt GR 8.8
7
90-76410-8 Hardware Pack
8
M12x25 Hex bolt GR 10.9
9
M12 Flat washer
10
M12 Nylock nut
90-76410-9 Hardware Pack
M10x25 Hex bolt GR 10.9
M10 Flat washer
M10 Nylock nut
90-76410-10 Hardware Pack
1/2x20 Serrated lug studs
1/2x20 Extended length lug studs
90-76410-11 Hardware pack
16mm Flat washer
90-76410-12 Hardware pack
Rubber gasket
24mm push in panel plug
401TU050B
Screwdrivers, flat and
Philips head
Metric socket & wrench set
Revised 10.22.18
Qty.
1
Tire carrier
8
8
1
Hinge
2
1
Hinge bracket
4
1
Carrier bracket
4
8
4
1
Tire carrier
5
10
5
1
Wheel studs
3
3
1
2
1
5
1
1
Torx bit set (S/B2830 or
similar)
Stud press
ID

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Summary of Contents for Smittybilt SB76410

  • Page 1 Torx bit set (S/B2830 or Torque wrench’s (in-lbs. & ft-lbs.) Pliers Philips head similar) Auto trim tool set/Plastic prybars Metric Allen bit set Metric socket & wrench set Stud press For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...

  • Page 2: Installation

    Be careful not damage the locating tabs on the opposing side (Fig. 2). Fragile locating tabs Fragile locating tabs Wiring cover Latch cover Fig. 2 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 3 (4) harness retainers, (Fig. 4) then r emove the wir ing har ness fr om the tailgate. Power locks harness Fig. 3 brake light harness brake light plug Harness retainer Fig. 4 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 4 Step 5 : Using a T20 Torx bit, remove the (4) Screws on the backside of the 3 brake light pillar (Fig. 6). Save these screws and carefully remove the 3 brake light assembly, set aside for re-installation. T20 screws Fig. 6 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 5 (Fig. 8). Pull Lift edge of cover Fig. 8 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 6 (Fig. 10). Next remove the (3 each) T50 Torx bolts holding the hinges to the body (Fig. 11). Remove T50 Remove bolts Fig. 10 Fig. 11 Torx bolts For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 7 (Fig. 12). Place the OE tailgate on a flat surface, in a position that allows easy access to the inside of the latch box. Fig. 12 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 8 Installation Instructions: (Part # SB76410) 2007-2018 Jeep JK Tailgate Step 11: Your Smittybilt tailgate is designed to re-use the OE latch, handle and lock from your vehicle. Perform the following steps on the inside of the latch, (Fig. 13) (Action A) : Only unclip the r etainer s secur ing the handle and lock cylinder connecting rods, leave latch assembly alone.
  • Page 9 (3) T30 Torx Screws (2) M6 Screws Fig. 14 Step 13: Unbox your new Smittybilt Tailgate (Fig. 15). Check all contents against the bill of materials list. If anything is missing, please call technical support immediately. Fig. 15 For Technical Support/Warranty Information please call 310-762-9944...
  • Page 10 OE M6 bolts with a 10mm socket wrench. Tighten the (3) T30 Torx screws and (2) M6 bolts to 8ft-lbs. or 96in-lbs. (Fig. 17). Tighten to 96 in-lbs. Fig. 17 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 11 (Part # SB76410) 2007-2018 Jeep JK Tailgate Step 16: On your new Smittybilt tailgate: Using Step 11 as a guide, note the orientation and install the OE lock cylinder with the OE horseshoe shaped spring clip. Install the OE handle, r e-using the OE nuts with an 8mm socket wrench (Fig 18). Tighten the nuts to 8ft-lbs.
  • Page 12 Latch access cover 1. Align holes to loosely install these screws Fig. 20 M4x.70 Allen, Split ring washer & Flat washer Fig. 20a For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 13 After these screws are installed, tighten to 10 in-lbs. Apply pressure, squeeze the two parts together to align screw holes M4x.70 Allen screw, Split ring washer & Fig. 21 Flat washer For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 14 (4 qty.) M12x1.5x25mm bolts & flat washers found in box (76410-09 hardware 01). Tighten finger tight at this time. M12 bolts and washers Hinges 112TU208 Nutplates 112TU209 Fig. 22 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 15 (Fig. 23a), these two will install in the upper locations on your new tailgate. Fig. 23a Slightly thicker carrier mounts Logo plate Slightly thinner carrier mounts Fig. 23 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 16 (Fig. 24b). Start and end at the middle of the bottom side of each part (Fig. 24c). Fig. 24a Fig. 24b Install gasket along the bottom edge Start and finish gasket in the middle of bottom edge Fig. 24c For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 17 (4) M6 screws to 4 ft-lbs. or 48 in-lbs. and (2) M5 bolts to 15 in-lbs. Rubber dust flap Fig. 25a Align mounting holes and Install M6 button head @ 4ft-lbs. Fig. 25 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 18 Step 24: Locate box (76410-04 hinge pair), Re-using the OE T50 Torx hardware (Use Step 9 as a guide) Install the (2) hinge mounts (112TU211) on the vehicle. Tighten finger tight at this time (Fig. 27). Fig. 27 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 19 When the pins ar e fully seated, install the (1 each) snap rings onto the bottom groove of the pin (Fig. 28a). Fig. 28 16 mm washer Fig. 28a Snap ring For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 20 (4) M12 hinge bolts to 78 ft-lbs. Adjusted just slightly higher than Center of center on striker striker Fig. 30 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 21 (76410-09 hardware-01). Install the cover over the hinges and tighten the M6 hardware to 6 ft-lbs (Fig. 31). M6 screws and washers Hinge cover plate Fig. 31 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 22 1/2x20 studs 3rd brake light assembly Tire carrier bracket (93- 9187) from Box (76410-03A) JK bolt pattern Fig. 33 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 23 Note: Use this as a starting point, depending on tire size, you can adjust the stationary mount to your personal preference. Stationary mount (93-9183) HD carrier (356CA100) M12 hardware Fig. 34 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 24 (93-9183), place your spare tire face down, lay a straight edge across the tire and measure from the rim face to the bottom edge of the straight edge (Fig. 36). Fig. 36 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 25 45 ft-lbs. Newer version Wiring through 24mm plug Meas. from Run 3 brake step 33 light wire through hole in tailgate 5 Qty. M10 hardware Fig. 37 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 26 (Part # SB76410) 2007-2018 Jeep JK Tailgate Step 35: Locate the Smittybilt tailgate rear cover from Step 14, (Fig. 16). Early Smittybilt tailgate models did not have an access hole for the OE wiring harness, it may be necessary to drill and/or notch a hole on the upper rear portion of the cover as shown (Fig.
  • Page 27 M4 hardware to 10 in-lbs. Tighten the M6 hardware to 7 ft-lbs. Tape wiring harness Fig. 39 Wiring Install M4 harness hardware through first notch M8 button head Fig. 40 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 28 Step 38: Close the tailgate and re-install the check strap with the OE Torx screws. See Step 6, (Fig. 7). Tighten these (2) Torx screws to 7 ft-lbs. For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 29 With a 90° drill and a short 0.20” drill bit, drill through the center of the semi-circle area of bare metal (Fig. 40). OE Tailgate Limit strap Drill through with 0.20’’ drill bit Fig. 40 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 30 Fig. 41 Step 42: Install one more rubber bumper (9541K901) on top with the cone shape pointing outwards (Fig. 42). 9540K901 cone shape facing outward Fig. 42 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 31 Step 43: Install this pin assembly into the hole previously drilled in the OE tailgate strap (Fig. 43). OE tailgate strap Pin assembly installed through drilled hole Fig. 43 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 32 Step 44: Install the remaining (2) bumpers (9541K901) onto the bottom portion of the installed pin, in the same fashion as before (Fig. 44). 401TU050 4 Qty. 9540K901 Fig. 44 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 33 When satisfied with operation of the tailgate, tighten the lug nuts to 50 ft-lbs. Your install is complete. Fig. 45 For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 34 Revised 10.22.18 Installation Instructions: (Part # SB76410) 2007-2018 Jeep JK Tailgate For Technical Support/Warranty Information please call 310-762-9944 Smittybilt, 400 W. Artesia, Compton, CA 90220...
  • Page 35 Customer’s remedy hereunder shall be limited only to repair or replacement (at Smittybilt’s option) of any defec- tive part(s) returned to Smittybilt at customer’s expense. The determination of whether or not a returned part is defective or subject to coverage under the limited warranties stated herein shall be made at Smittybilt’s sole dis- cretion.