RED LOCKTITE

RED LOCKTITE

ASSEMBLY & MOUNTING for CONGO CAGE 50331

5030150311HARDWARE KIT #

For TECHNICAL SUPPORT Call:

1-800-343-7486Monday- Friday 8:00 A.M. to 4:30 P.M. ( PACIFIC )

®

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5031150311 front mountfront mount

platesplates

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When installing rear leg into

rear U bar, ensure that

hinge barrel is BEHIND the

leg as shown.

Detail for CONGO CAGERear Leg Hinge Joint

02

06

IMPORTANT:

Hinge Barrel BEHIND Leg.

JEEPJEEP

ETITKCOL DER

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503315030150311HARDWARE KIT #

For TECHNICAL SUPPORT Call:

1-800-343-7486Monday- Friday 8:00 A.M. to 4:30 P.M. ( PACIFIC )

®HARDWARE KIT FOR

CONGO CAGEASSEMBLY

A

(2 ea.)1/2" x 1 3/4"Cap Screw

C

(2 ea.) 1/2"

SAE Flat Washer

R(4 ea.)

1/2" Rubber Washer

M(10 ea.)

Shown Actual SizeShown Actual Size

(10 ea.)

G

5/16" Flat Washer

(4 ea.)

Q

5/16" ContouredFlat Washer

F

(12 ea.)5/16"

NyLoc Nut

E(2 ea.)

5/16" x 1 1/4"Hex Bolt

D(2 ea.)5/16" x 5"Hex Bolt

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1/4" SAE Flat Washer

(6 ea.)

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5/16" O Ring

(4 ea.)

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1/4" Lock Washer

(6 ea.)

5/16" -18 x 1"Button Head Bolt

I(4 ea.)

5/16" x 2 1/4"Button Head Bolt

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5/16" Lock Washer

(2 ea.)

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(6 ea.)1/4" x 20 x 1"

Thread Cutting Screw

(4 ea.)5/16" x 2"

Button Head Bolt

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B

(2 ea.) 1/2"

Lock Washer

Remove existing bolts from the upper half of the windshield hinge plates. Put a small bead of silicone inside and around the

countersunk bolt holes in the existing windshield hinge plates. Attach front LEG MOUNT PLATES with bolts , and

with lock washers , as shown. Attach the rear LEG MOUNT PLATES, by removing the tail lights and sliding the rear LEG

MOUNT PLATES in behind tail lights and secure with thread cutting screws , lock washers and flat washers .

Next, at the upper hole of the rear LEG MOUNT PLATES , drill a 5/16" hole through vehicle body. Secure with bolts , flat

washers , and nyloc nuts .

Assemble the cage on the ground. Cover entire swaged joint surfaces with silicone sealant (see page 5). Assemble FRONT 'U' BAR ( it's the wider one) to FRONT LEGS (they are the shorter ones) with button head bolts

and nyloc nut . IMPORTANT: Orient bolts so that nut is in front of leg (hood side) and bolt head is behind leg (cab side).HF

Now attach REAR 'U' BAR to the REAR LEGS , (see the detail drawing for the Rear Leg Hinge Joint), with button head

bolts and nyloc nuts . Cover entire swaged joint surfaces with silicone sealant (see page 5). .

Find CROSS TUBES . Cover entire swaged joint surfaces with silicone sealant (see page 5). Insert the CROSS TUBES

into the cups on the FRONT and REAR U BARS. Secure with bolt then (on top side only) place O-rings and

contoured washer , with lock nuts , (on the bottom side).

TIGHTEN UP ALL BOLTS.

THAT'S IT for the cage part. Lift the cage up onto the LEG MOUNT PLATES and secure with hex bolts , rubber washers

(see attached detail: Front Leg Shock Absorbers), lock washers , flat washers . for the front, and hinge bolts , flat

washers , and nyloc nuts for the rear.

THAT'S IT! YOUR INSTALLATION IS COMPLETE.

Align bolt holes of MOUNT PLATES with holes of CLAMP PLATES (inside rack cross beams ), and loosely attach

MOUNT PLATES with button head bolts , lock washers , and flat washers see DIAGRAM#1a. Position rack

to desired location front to back and confirm position of rack side to side with equal distance from all end caps to

mounting plates. After rack is centered, tighten bolts .

With rack in it's final spot, attach MOUNT CLAMP STRAP , around CROSS TUBES and secure into MOUNT PLATE ,

with bolts , lock washers , and flat washers . Tighten all bolts.

503315030150311HARDWARE KIT #

For TECHNICAL SUPPORT Call:

1-800-343-7486Monday- Friday 8:00 A.M. to 4:30 P.M. ( PACIFIC )

®

SEE PAGE 1

SEE PAGE 4 TO ATTACH BASKET RACK.

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“Any time an overhead rack is mounted on a vehicle, there will be some incremental wind noise. In the vast majority of cases, the additional noise is subtle and not objectionable. Sometimes, for reasons we cannot explain, customers complain that the wind noise is intolerable. For these customers, we offer this Optional Wind Deflector. Be sure to specify the Wind Deflector part number that is appropriated for your Congo Cage. #60141 for CJ Congo Cage #50301 and TJ Congo Cages #50311 & #50331.

NOTE:

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ASSEMBLY & MOUNTING for SAFARI RACK on CONGO CAGE

50561

Page 4

HARDWARE KIT #

For TECHNICAL SUPPORT Call:

1-800-343-7486Monday- Friday 8:00 A.M. to 4:30 P.M. ( PACIFIC )

®

HARDWARE KIT FORCONGO CAGE

MOUNT Q

5/16" Lock Washer

(8 ea.)

Shown Actual SizeShown Actual Size

(8 ea.)K

5/16" SAE Flat Washer

R(8 ea.)

5/16" x 3/4"Hex Bolt

O

(8 ea.)3/8" x 1"

Button Head

M

(8 ea.) 3/8"

SAE Flat Washer

N

(8 ea.) 3/8"

Lock Washer

Clamp Plate(inside)

Rack Cross Beam D

08same distanceeach bracket

DIAGRAM #1a

Cross Tube

Mount Plate

Mount Clamp Strap

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CONGO CAGE 'U' Bars

0711

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"Attach, Position and Sucure

these bolts FIRST"

"Finish with these bolts."

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SILICONE

SEALANT

Rusty Joint

(WITHOUT SEALANT)

Tighten down all nuts & bolts and THAT'S IT! You are now ready to use your rack.

Apply a healthy air tight bead of silicone around every swaged joint to prevent

moisture from leaking into and out of the joint. If this is not done properly, the

inside surface of the tubes can rust and rusty water can leak out. Maintain this

joint seal throughout the life of your rack.

503315030150311HARDWARE KIT #

For TECHNICAL SUPPORT Call:

1-800-343-7486Monday- Friday 8:00 A.M. to 4:30 P.M. ( PACIFIC )

®HARDWARE KIT FOR

CONGO CAGEASSEMBLY

DETAIL: Front Leg Shock Absorbers

DETAIL: Seal swage joints:

FRONT LEGS

(DRIVERS SIDE)RUBBER WASHERS

FLAT WASHER

EXTERNAL TOOTH LOCK WASHER

CAP SCREW

( TIGHTEN DOWN TO COMPRESS RUBBER TO 1/8” )

NOTE: When raising Congo Cage to install or remove top, DO NOT rotate the Cage

completely back as this will spring the rear hinge and/or damage the body of your

jeep. Rotate only to the extent necessary.

Hold the Congo Cage in the raised position by inserting the two support rods

(provided) into the hole of the front bracket and the hole in the bottom of the front leg.

For TECHNICAL SUPPORT Call:

1-800-343-7486Monday- Friday 8:00 A.M. to 4:30 P.M. ( PACIFIC )

®Page 6

SUPPORT RODS PROVIDED

YES NO