rusty’s offroad sport cage 1997 2004 · rusty’s off-road sport cage 1997-2006 jeep...

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Warning:

Read and understand all instructions, warnings, cautions, and notes in this sheet and in the vehicle owner’s manual before

you install this kit.

Warning:

Use extreme caution when working near glass. Sharp objects in contact with glass could cause an explosion of glass resulting

in serious personal injury and property damage.

Warning:

The purpose of the Sport Cage is to enhance the appearance of the vehicle only. The Sport Cage is NOT intended to protect

the occupants of the vehicle in the event of a vehicle rollover.

Before Starting Installation:

1. Carefully Read all warnings and instructions completely before beginning.

2. Verify all parts have been received in this kit by checking the parts list at the beginning of this document.

3. Only install this kit on the vehicles for which it specified.

4. Park the Vehicle on a clean, dry, flat, level surface and block the tires so the vehicle cannot roll.

Prepare to Install Kit:

1. Remove top from vehicle. Refer to owners manual for removal instructions.

2. Remove the door surrounds.

A.) Loosen the two plastic knobs on each

door surround completely.

B.) Remove both door surrounds from the

vehicle.

Rusty’s Off-Road Sport Cage

1997-2006 Jeep Wrangler/Rubicon

2004-2006 Jeep Unlimited/ Unlimited Rubicon

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Prepare to Install Kit:

3. Windsheild Support Removal

A.) Remove padding from windshield supports

B.) Pull back padding from sport bar in area where the windshield supports are attached. This will

expose the hardware needed to be accessed in order to remove the windshield support bars.

C.) Remove Qty: 2 Torx Screws from the windshield

supports to the windshield on both sides.

D.) Remove the T50 Security Torx Bolts from each

windshield support. There should be one bolt per

windshield support. You can use a set of locking pli-

ers if you do not have access to a T50 Security Torx

Bit by grabbing the bolt on the outer diameter.

(These bolts will be replaced)

E.) Remove both of the sun visors from the windshield frame.

F.) Remove the screws and windshield molding from

the windshield.

G.) Remove the windshield wipers by first pulling the

wiper away from the windshield and out to the “lock”

position. Then, using a small flat tool such as a screw

driver, release the retaining clip. Lift the wipers off.




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H.) Remove the T30 Torx Screws from each side of

the windshield hinge as illustrated in this image.




I.) Lower the windshield gently until it contacts the

rubber hood bumpers

Dash Hardware Removal:

4. Remove six T30 Torx bolts from dash (three on each side)

These bolts will be re-used.

Figure #1

Remove Qty:6 - T30 Bolts circled

in the picture. These bolts will be

re-used later.

Install Sport Cage:

1. Cover ends of dash with heavy cloth or blue painters tape to prevent them from being scratched by kit

door bars during installation. Clean and apply some lubricant to the B-Pillar Tube adapter at this time.

2. Driver side: Kit door bar

A.) Insert the door bar over the factory B-Pillar tube adapter.

B.) Have an assistant the hold the door bar in the door frame opening.

C.) Install kit door bar on dash with the three torx bolts you removed from the dash.

DO NOT tighten.

E.) Fasten kit door bar to B-Pillar tube adapter with kit bolt (7/16” x 1” fine thread) and oval shaped

washer supplied in the kit. DO NOT tighten.

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3. Kit Crossbar

A.) Install kit crossbar on kit door bar with kit bolt (3/8” x 1” coarse thread) and kit washer (3/8” USS.

DO NOT tighten.

4. Passenger side: Kit door bar

A.) Insert the door bar over the factory B-Pillar tube adapter.

B.) Have an assistant the hold the door bar in the door frame opening.

C.) Install kit door bar on dash with the three torx bolts you removed from the dash.

DO NOT tighten.

D.) Fasten kit door bar to B-Pillar tube adapter with kit bolt (7/16” x 1” fine thread) and oval shaped

washer supplied in the kit. DO NOT tighten.

5. Kit brackets (windshield support)

A.) Install two kit brackets (windshield support) on windshield frame and kit door bars with four torx

bolts, two kit bolts (3/8” x 1-1/4”), and two kit washers (3/8”). Leave the torx bolts loose enough for a

little wiggle room for final adjustment later. Both Door Bars will have a preinstalled nut installed for the

windshield brackets to fasten to once the windshield is closed




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B.) Reinstall the sun visors to the windshield frame.

C.) Fold the windshield back into closed position.

D.) Reinstall the T30 Torx Screws from each side of

the windshield hinge as illustrated in this image.

E.) Reinstall the windshield wipers by reversing the

removal instructions.




Cross Over Bar

Driver Sid

e Do

or B

ar P

asse

nge

r Si

de

Do

or

Bar

Note the direction when installing by the notch

to allow for clearance around the door jam

sensors.

6. Windshield Molding Trimming

A.) It is usually necessary to trim the molding some in order to reinstall the molding. This can be

done by using a razor blade or rotary tool. We suggest carefully marking and lightly trimming the plastic. Test

fitting multiple times maybe needed in order to get the fitment just right. Reinstall the molding once you find

the best fitment.

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3. Soft top: door seal plates

A.) Install two door seal plates on two kit door bars with four release lever pins.

4. This completes the installation of this kit. You may now reinstall vehicle top. Refer to owners manual for

removal instructions.




Finish Installation

1. Tighten Everything

A.) Tighten torx bolts at kit door bar and dash.

B.) Tighten four torx bolts at two support feet and sport bar.

C.) Tighten two kit bolts (7/16” x 1” fine thread) at kit door bars and support feet.

D.) Tighten two kit bolts (3/8” x 1-1/4” coarse thread) at kit crossbar and kit door bars.

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2. Kit Contents List ( Please double check everything on list before beginning installation.)

QTY: DESCRIPTION:

4 BOLT, 3/8” X 1-1/4”

2 BOLT, 7/16” X 1 FINE THREAD

2 BRACKET, WINDSHIELD SUPPORT

1 CROSSBAR

1 DOOR BAR, DRIVER SIDE

1 DOOR BAR, PASSENGER SIDE

4 WASHER, 3/8” USS

Cross Over Bar

Driver Side Door Bar

Passenger Side Door Bar




Last Modified Date: 1-28-16

rusty’s offroad sport cage 1997 2004 · rusty’s off-road sport cage 1997-2006 jeep...

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