How to Install Bushwacker Flat Style Fender Flares (97-06 Wrangler TJ) on your Jeep Wrangler

Note: The edge trim for this application is double-tape edge trim so special care needs to be taken while installing. There is red vinyl backing on the inside of the edge trim where it will adhere to the flare and red vinyl backing on the outside where it will adhere to the vehicle. The following steps only concern where the edge trim will adhere to the flare. Additional edge trim installation instructions are included during the rest of the installation process. 

A. Peel two to three inches of red vinyl backing away from edge trim tape. Applying the adhesive side of the edge trim to the inner side of the flare, affix the edge trim to the top edge of the flare (the portion that comes in contact with the vehicle). Stop at tube feature of flare. Picture 1 for tube feature reference 

B. Press edge trim into place along the top edge of the flare in one-foot increments, pulling red vinyl backing free as you continue to work your way around the top edge of the flare. Picture 2 for additional edge trim orientation 

Unplug the factory installed side marker lamp by twisting the bulb housing in a counterclockwise direction. This is located at the front of the factory flare on the backside in the wheel well. 

Remove the factory installed fender flare and rocker guard screws with a 5/16” socket wrench. (13 locations on the backside of the flare.) 

Remove the factory installed fender flares. Thoroughly clean the exposed metal fender with a damp cloth and dry. 

Use wire cutters to cut the two wires at the base of the factory side marker lamp. 

Locate the flat flare front inner pieces. The driver side front inner pieces are marked D1 & D2. The passenger side front inner pieces are marked P1 & P2. 

Put an M5-.8 machine screw (SW1-0053) and washer (WA1-0003) through the top holes of the inner pieces and secure with a 1/4” rubber spacer (SP1-0011) on the underside of the inner piece. 

Push the rubber spacer (SP1-0011) and machine screw (SW1-0053) together until they are both tight against the inner piece. Spacer has been lightened in picture for visibility. 

Install a speed clip (CL1-0022) at each clip location on the inner pieces, centering them on the predrilled holes. (6 locations) NOTE: Clips slide out of place easily. Try pinching the metal tightly onto the inner piece with pliers. 

Use wire strippers to strip away approximately 3/8” of wire covering from the factory installed side marker lamp wires. 

Install a Female Bullet Connector (EC1-0007) to the end of each factory side marker light wires and secure by pressing firmly with a wire crimp. 

Seal with electrical tape or heat shrink tubing if desired. 

Secure inner piece D1 (and P1 for passenger side installation) to the sheet metal using the following Line up the M5-.8 machine screws (SW1-0053) with the factory hole locations and push them into place. 

As you line up the inner piece, feed the wire harness through the hole in the front of the bracket. 

Attach flange nuts (NU1-0010) to the threads on the M5-.8 machine screws and hand tighten. 

Fully tighten flange nuts using a 5/16” socket and wrench and use a #2 Phillips bit for the M5-.8 machine screws. 

Install inner pieces D2 (and P2 for passenger side installation) to the sheet metal by lining up the M5-.8 machine screws (SW1-0053) with the factory hole locations. 

While holding the inner piece in place, use a #2 Phillips bit to tighten the M5-.8 machine screws (SW1-0053) into the factory mounted nuts (NU1- 0010). 

Position the supplied side marker light (LT1-0003) onto the outer flare piece, threading the wires through the center predrilled hole. 

Secure the side marker light to the outer flare with 8-32 screw (SW1-0054), 8-32 nut (NU1-0018), and washer (WA1-0003) using a #2 Phillips bit and a 11/32” socket with 6” extension. (2 places) NOTE: If you are having trouble putting the washer and nut on the screw, use needle nose pliers. 

Before installing the outer flare, make sure that the speed clips on the inner pieces are centered over the predrilled holes. 

Use one supplied alcohol prep pad to clean the sheet metal above each inner piece in preparation to tape the edge trim to the sheet metal. This must be done for proper flare installation. 

Peel back 1-2” of red liner on each end of the edge trim and bend toward the outside of the flare. 

Connect the side marker light wires with the vehicle wires by attaching the male connectors to the female connectors. Test the connection by turning on the front turn signal. Switch connectors if necessary. 

Feed the ground wire back through the hole in the inner bracket and pull back under for attachment to sheet metal later. 

Place the outer flare over the inner pieces and push until snug against the sheet metal. Make sure that the side marker light wires are below the front inner piece. 

Use a scratch awl (or another pointed tool) to line up the speed clips with the outer flare holes (6 locations). If needed, use a flashlight to better locate the speed clips. 

Hold flare in place on fender and start a #8 pan head screw (SW1-0056) into each hole location and through speed clip on inner structure (6 places). Do not tighten. 

Tighten the #8 pan head screws by firmly pressing the flare toward the vehicle while tightening. 

Place the outer flare over the inner pieces and push until snug against the vehicle surface. Make sure splash shield is tucked behind flare. 

After the red liner is removed, firmly press the flare toward the vehicle for 10 seconds to adhere the tape to the vehicle surface. Repeat this process for the entire length of the flare. The vehicle surface temperature must be between 65-110° F for proper adhesion. Allow 24 hours for full adhesion. 

Attach the ground wire from the marker light with an M5-.8 machine screw (SW1-0053), washer (WA1- 0003), and flange nut (NU1-0010) using a Phillips head screw driver and 5/16” socket and wrench at the location shown. 

Starting at one end, use the flat edge of the supplied edge trim tool to further adhere the edge trim to the vehicle surface. Slide the tool along the edge trim while pressing it in toward the vehicle surface. 

Use the hooked end of the edge trim tool to check for full adhesion. Do this by sliding it along the top of the edge trim to visually verify that the tape is adhered to the vehicle surface. Repeat previous step if tape is not fully adhered to the vehicle surface. 

Attach one side reflex reflector to the side of the vehicle by peeling off the adhesive backing and pressing it firmly onto the cleaned vehicle surface. NOTE: Once reflector has adhered it cannot be repositioned. 

Optional Rocker Panel

Optional Rocker Installation: Peel back red tape liner approximately 2” from end of rocker piece and fold to the outside. Line up rocker along bottom edge of vehicle and 1/2” from edge of front flare. Remove tape liners while pressing onto vehicle surface. 

Press rocker piece onto vehicle to promote tape adhesion. 

Completed front driver’s side flare installation.