Clean the vehicle's tubular frame and install (peel and stick) the Side Seal Gasket
(P/N X-103) (Item 14) around the perimeter of the door opening 1/2 in. away from the
u. Using the two lifting eyes, a lifting strap, and appropriate material handling
equipment, lift the Side Armor Panel into place on the side of the cab and secure it to
the previously installed A-Pillar Bracket (P/N 115503-1) using the hardware
described in Steps "c" and "d" that was removed in Step "g".
v. Secure the front and bottom edges of the side Armor Panel using nine bolts
(3/8 16 x 1.750 LG) threaded into the rivnuts installed in Step "k".
w. Place the Drill Guide (P/N 111489) into the three 0.75-in.-diameter holes along the
rear edge of the panel and drill a 0.31-in. diameter hole through the vehicle cab in
x. Secure the rear edge of the Side Armor Panel by inserting three bolts
(1/4 20 UNC x 2.000 LG) and three armor washers (P/N 111403-3), and three
washers (1/4 ID, SAE) into the drilled holes and securing them with three washers
(1/4 1.000 OD, USS) and locknuts (1/4 20) inside the cab (see Figure 37).
y. Reposition the Cab Entry Hand Hold on the second hole from the top of the rear edge of
the Side Armor Panel and secure the Hand Hold in place by threading two bolts
(7/16 14 x 4.000 LG), and two flat washers (7/16 ID) through the hand hold holes and
the cab holes and securing them with two Aft Plates (P/N 113316), two flat washers
(7/16 ID), and two locknuts (7/16 14) on the inside of the cab (see Figure 37).
(Optional: If the vehicles uses a two-point seat belt, use two bolts (7/16 14 x 4.500),
two washers (7/16 ID), and two locknuts (7/16 1/4) to fill the holes where the shoulder
strap mounts would be located, and use two alternate bolts (3/8 16 x 4.750 LG) for the
Cab Entry Hand Hold. These bolts are in the extra fastener kit, P/N 111444.
z. Torque the four locknuts (7/16 14) to 35 ft-lb and the three locknuts (1/4 20) to 9 ft-lb.
aa. Attach the Side-View Mirror to the blocks using three bolts (0.250 20 x 1.250 LG)
and washers (0.250 ID) at the top and three bolts (0.250 20 x 1.250 LG) and
bb. If required, adjust the door rotary latch position as follows:
1. Adjust the longitudinal position by removing shims between the latch and the
door. Locate the latch so that the striker pin's head is approximately centered in
the latch space.
2. Adjust the latch height to match the height of the striker pin. Tighten the screws
3. Adjust the ball joints on the rod to allow the latch mechanism to work properly.
Too short the latch will unlatch too easily. Too long the latch will not latch
smoothly. The length should be just short of "too long". Tighten the jam nuts to
lock the rod in place.
cc. Repeat Steps "a" through "bb" for the Side Armor Kit, P/N 115500-2, (passenger side).