Assembly Instructions For

1984-2001 XJ Jeep Rear Bumper Kit

Thank you for your purchase at DIY Off Road Products!For more great products checkout our website, www.diyoffroadproducts.com or call us at 503-931-7069. If you have any questions or concerns please don’t hesitate to contact us.

Assembly Instructions For

1984-2001 XJ Jeep Rear Bumper Kit

TOO

LS N

EED

ED

Thank you for your purchase at DIY Off Road Products!For more great products checkout our website, www.diyoffroadproducts.com or call us at 503-931-7069. If you have any questions or concerns please don’t hesitate to contact us.

• MIG Welder w/ Solid Wire• Grinder• 4 1/2’’ Flapper Disk• 7’’ Sander for Finish

Mounting Bracket Assembly (L/R)• (1) Tabbed Mounting Bracket• (2) Slotted Mounting Bracket (Flat)• (3) Shackle Tab

Center Section Assembly• (4) Clenter Section• (5) Hitch Reinforcement Plate• (6) 2’’ Hitch

Wing Section Assembly• (7) Front Wing Section• (8) Side Wing Filler Plate• (9) Top Wing Cap

84 - 01 XJ REAR BUMPER KIT

“Do It Yourself ” weld your own 84-01 XJ Cher-okee rear bumper kitWelding and grinding required, fabricate your own off road rear bumperThis bumper is made from 3/16’’ thick hot rolled steelParts are pre-formed and ready for your weld-ing and grinding skillsIncludes mounting brackets

• No hardware included - Use existing bumper hardware

PART

S LI

ST

HARDWARE INCLUDED

1

4

5

7

9 28

36

7

3

82 9

Insert Tabbed Mounting Bracket (1) into Slotted Mounting Bracket (2).STEP

2

STEP

1

STEP

3

Place the Front Wing Section (7) on a flat surface with the top side facing down. Then place and tack weld the Side Wing Filler Plate (8) to the Front Wing Section (7). Repeat for the opposite side.

ATTENTION: REVIEW INSTRUCTIONS BEFORE INSTALLING 84-01 XJ REAR BUMPER KIT

Tack weld the Wing Assemblies to the Center Section (4)STEP

4

Remove the plastic bumper skin from the vehicle.

STEP

6

STEP

5

STEP

7

Tack weld Mounting Bracket Assemblies to the Center Section (4). There should be 31 inches between the inner bracket walls.

ATTENTION: REVIEW INSTRUCTIONS BEFORE INSTALLING 84-01 XJ REAR BUMPER KIT

Tack weld the Wing Assemblies to the Center Section (4)

Tack weld Top Wing Cap (9), Top Wing Front Cap and Top Wing Side Cap.

STEP

9

ATTENTION: REVIEW INSTRUCTIONS BEFORE INSTALLING 84-01 XJ REAR BUMPER KIT

Tack weld Receiver Hitch (6) to the Center Section (4). Make sure that the Receiver Hitch (6) is aligned with the Hitch Reinforcement Plate (5).

Tack weld Top Shackle Tabs (3) to the Center Section (4).

STEP

8

STEP

10

STEP

11TEST FIT

Bolt the bumper to the vehicle with wing sections attached to the center section.

ATTENTION: REVIEW INSTRUCTIONS BEFORE INSTALLING 84-01 XJ REAR BUMPER KIT

Once all tacked up, you may begin welding 6-8 inches at a time.STEP

12

Tack weld Hitch Reinforcement Plate (5) to Receiver Hitch (6) and Center Section (4).