DO NOT LIFT THE SIDE ARMOR PANEL ASSEMBLY BY THE DOOR
ASSEMBLY'S CENTER LIFTING EYE. DAMAGE TO THE DOOR ASSEMBLY /
SIDE ARMOR PANEL ASSEMBLY COULD OCCUR DUE TO THE COMBINED
WEIGHT OF THE ASSEMBLIES.
The Side Armor Panel, Door Assembly, and numerous hardware items have
been pre-assembled at the factory (see the Armor Kit Parts List in Section 4.4).
c. Using the lifting strap and appropriate material handling equipment (hoist, forklift,
etc.), position the Side Armor Panel Weldment onto the door opening and secure the
A-Pillar Bracket (P/N 115503) using four bolts (3/8 - 16 x 1.750 LG), eight washers
(3/8 ID), and four locknuts (3/8 - 16). One bolt is used at the top of the Bracket, one
is used at the bottom of the Bracket, and two are used in the middle of the Bracket.
d. Secure the right side (upper aft) of the Side Armor Panel using one bolt
(7/16 14 x 4.000 LG), two washers (7/16 ID), one Attachment Plate
(P/N 113316-1), and one locknut (7/16 14) (see Figure 35).
e. Tighten the fasteners, as they provide positions for other fasteners.
Insert a drill bushing into the nine holes [marked with a check ( ) in Figure 35] and
match-drill a 3/16-in. pilot hole in each location (see Figure 35).
g. Remove the fasteners previously installed in Steps "c" and "d" above and remove the
Side Armor Panel Assembly from the vehicle using the two lifting eyes, a lifting strap,
and appropriate material handling equipment.
h. Using a drill and a 17/32-in. drill bit, drill through each of the nine 3/16-in. pilot holes.
k. Install nine rivnuts [3/8 16 (AVK)] into the nine 17/32-in. holes (use the Rivnut
m. Install the existing clearance light gasket onto the amber clearance light, feed the
clearance light wire through the appropriate hole in the Side Armor Panel. Secure the
amber clearance light onto the armor panel using four bolts (3/16 24 x 1.000 LG) and
p. Attach the amber reflector to the Side Armor Panel using two internal hex-head bolts
(1/4 28 x 0.750 LG) and two washers (1/4 ID).
Feed the amber clearance light wire through the Slit Grommet (P/N 111453-1) and
press the Grommet into the hole in the Side Armor Panel. Note: If the Grommet is not
already slit, create the slit from the outer edge of the Grommet into the center hole.)
s. Connect the amber clearance light lead inside the cab using the Extension Pigtail