Fab Fours Open Fender Installation Manual Download Page 8

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Hardware kit

•

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

•

Hammer

•

Plastic panel pry tool

• Painters tape
•

Duct tape

• Black and silver sharpies
• Impact driver
•

Large reciprocating saw

•

Small reciprocating saw

• Angle grinder
•

4” flap disk wheel

•

4” cut off wheel

•

Die grinder

•

2” cut off wheel

•

Vise-grip C-Clamp (Qty 3)

•

Anti-seize compound

•

Deburring tool

•

Razor blade

TOOLS REQUIRED

Summary of Contents for Open Fender

Page 1: ...Installation Manual Open Fender Fender Flare Product Number TF4400 TF4410 Application 2019DodgeRamHD...

Page 2: ...eye injury Always use extreme caution when drilling a vehicle Always disconnect power before welding Thoroughly inspect the area to be drilled on both sides of material when possible prior to drillin...

Page 3: ...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 C...

Page 4: ...on of cutting edge technology for metal cutting and forming and an American workforce that puts its heart and pride into every product From design and manufacturing to quality and delivery Fab Fours m...

Page 5: ...nstallation may leave vehicle immobile until part is acquired Refer to the next pages as an inventory check Getting Started This manual is meant to be a comprehensive companion to online video resourc...

Page 6: ...Provided Materials 21403 03 21402 02 21351 02 21402 01 21402 03 21403 01 21352 02 21402 04 21403 04 21977 01 21978 01...

Page 7: ...7 21954 21955 21956 21957 21453 21454 21455 21456 50192 HW 50121 HW TF4400 IM 61728 Foam Seal Kit 61272 Rubber Seal x2...

Page 8: ...3 16 Allen wrench 25 64 Transfer Punch Hammer Plastic panel pry tool Painters tape Duct tape Black and silver sharpies Impact driver Large reciprocating saw Small reciprocating saw Angle grinder 4 fl...

Page 9: ...vehicle where you can catalog and store everything We suggest labeling and bagging all the OEM bolts when removing from the vehicle Failure to keep track of parts could lead to an inability to proper...

Page 10: ...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 3 Discon...

Page 11: ...11 Figure 2 4 Using a 10mm socket wrench disconnect the negative terminal from the battery Figure 1 2 5 If applicable disconnect the negative terminal from the auxiliary battery Figure 2 Figure 1 2...

Page 12: ...remove the two 2 screws and one 1 push pin from the rear splash shield trim 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...

Page 13: ...13 8 Disconnect the factory wiring harness from the inside of the driver side wheel well Figure 6 Figure 6 Figure 5...

Page 14: ...and 18mm open end wench remove the three 3 factory bumper bolts that hold the factory bumper to the frame rail Figure 7 10 Remove the factory bumper from the vehicle and set aside Figure 8 Figure 7 Fi...

Page 15: ...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 remov...

Page 16: ...remove it Figure 12 Figure 11 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 t...

Page 17: ...3 Figure 13 Figure 14 15 Using a 10mm socket wrench remove the two 2 screws at the bottom of the front fender Figure 14 Note There are two 2 versions of rear inner fenders available If your vehicle ha...

Page 18: ...e of the fender along the door hinges 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...

Page 19: ...sing 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 19 Repeat steps 6 17 on the passenger side of the vehicle Fi...

Page 20: ...rea with painters tape Assistance 1 Using painters tape apply at least three 3 layers of tape to the forward most part of the front door Figure 1 Figure 1 Figure 2 2 Apply the DS FEN 1 template to dri...

Page 21: ...e 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 do...

Page 22: ...Figure 5 Figure 6 Figure 7...

Page 23: ...m removing the bolt that attaches the stiffener to the bed side Then work the template edge with the dashed blue line along the wheel well opening until you reach the other hole in the template Align...

Page 24: ...emplate with the slotted holes in the bottom of the bed side Then align the blue dashed line with the wheel well edge towards the hole in the top of the template Align the hole in the top of the templ...

Page 25: ...25 Figure 13 Figure 14 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...

Page 26: ...e grinder remove any sharp edges along the cut area 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...

Page 27: ...Figure 18 Figure 19 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...

Page 28: ...area Figure 20 Figure 20 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...

Page 29: ...he bottom of the template with the two 2 holes in the pinch weld Then work the template upwards aligning the blue dashed line with the front profile of the rocker channel Figure 24 13 Using a 3 8 dril...

Page 30: ...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 16 Apply the DS CAB 3 template to the inboar...

Page 31: ...ning 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 t...

Page 32: ...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 Cut horizontally through the rock...

Page 33: ...33 Figure 30 Figure 31...

Page 34: ...ed 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 Figure 32 Figure 32 Figure 33 22 Using a large r...

Page 35: ...shed 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 bod...

Page 36: ...ance for the provided rocker channel cover plate Figure 36 26 Using a flap disk wheel on an angle grinder remove any sharp edges created from previous cutting operations 27 Using the provided rust tra...

Page 37: ...es 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 c...

Page 38: ...eviously drilled hole The upper rocker channel cover plate should fit inside of the rocker channel Figure 4 Figure 4 4 Loosely thread one 1 of the provided 5 16 stainless steel button head cap screws...

Page 39: ...through the hole in the bottom of the lower rocker channel cover plate Figure 6 Figure 6 6 Using a 3 16 Allen wrench tighten the two 2 screws installed previously until the washer starts to flatten Fi...

Page 40: ...ed bracket 21402 02 into the previously installed nut plate The nuts on the horse shoe bracket should face up Figure 8 Figure 8 9 Loosely thread two 2 of the provided 5 16 grade 8 bolts lock washers a...

Page 41: ...nel itself Figure 10 Figure 11 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 Keep pum...

Page 42: ...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 Be sure to pull the co...

Page 43: ...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...

Page 44: ...dge 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 3 Using a 25 64 trans...

Page 45: ...deburring tool clean any sharp edges off the previously drilled holes in the OEM fender 7 Using the provided rust trap coating and brush 61725 apply a liberal coating to each drilled hole 8 Loosely i...

Page 46: ...OEM fender for the final time The two 2 center hole locations will thread into he previously installed intermediate bracket with weld nuts The remaining five 5 locations will get a stainless steel fla...

Page 47: ...washer 50192 HW connect the fender base support bracket to the lower rocker channel cover plate Figure 10 Figure 11 12 Using a 3 16 Allen wrench and three 3 of the provided 5 16 x1 stainless steel but...

Page 48: ...igure 12 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 side of the bed Figure...

Page 49: ...ing tool clean out any sharp edges in the previously drilled holes 19 Using the provided rust trap coating and brush 61725 apply a liberal amount to each of the previously drilled holes in the bed sid...

Page 50: ...nch Install one 1 of the provided 5 16 x1 5 stainless steel hex head cap screws bonded sealing washer flat washer lock washer and nut in the bottom most rear hole in the provided base fender This shou...

Page 51: ...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...

Page 52: ...sted cut profile has been included Figure 1 Installation Inner Fenders Figure 1 2 Four 4 5 16 stainless steel self tapping screws and stainless steel fender washers 50192 HW have been provided to aid...

Page 53: ...53 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 Figure 3...

Page 54: ...e excess Figure 1 2 Figure 1 2 Using a 3 16 Allen wrench remove the three 3 stainless steel button head cap screws per base fender installed previously in preparation for the fender flare hardware 3 U...

Page 55: ...55 Figure 3 Figure 4...

Page 56: ...n 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 5 Repeat steps 2 3 on passen...

Page 57: ...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...

Page 58: ...This page was intentionally left blank...

Page 59: ...59 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 Contact Information...

Page 60: ...If you re looking for more of the same Then you ve come to the wrong place Greg Higgs...

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Fab Fours Open Fender, Installation Manual

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