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Johnny Express Spare Tire Rack Installation Notes

You have just obtained a reproduction Topper Johnny Express spare tire rack and now it is time to install it into your Johnny Express trailer unit. Even though great care has been exercised in making these parts, and a high quality plastic has been used – a procedure should be followed when installing the spare tire rack.

Prior to installing your spare tire rack, check the four trailer slot openings and make sure that they are clear of any dirt, debris or excess plastic flashing. If necessary, use a toothpick or Xacto knife to clean out the slot openings. It is best to heat up the spare tire rack tabs and the trailer slot openings with a hair dryer for a little while, this will make the plastic a bit more flexible and reduce the chance of the tabs breaking. Follow the original Johnny Express Spare Tire Rack instructions in the PDF file on the AEP site, see "The Johnny Express Original Instructions" page under the Media Tab.

On a Final Note – as with the original Johnny Express Spare tire rack – once you install a replication spare tire rack it is not advisable to ever attempt to remove it. The way the part is and the slot openings are – once you install a spare tire rack they can be extremely difficult to remove without breaking.

 

Johnny Express Mud flaps Installation Notes

A task oriented plastic has been used to make the reproduction mud flaps. Note that there are two different mud flaps. – a driver side mud flap and a passenger side mud flap Each installs onto the trailer bumper with the part number side on the rear of the bumper. Note that the slot is positioned differently on the driver side mud flap and the passenger side mud flap, this is so that one edge on each mud flap lines up along side of the trailer bumper edge (where the tail lights are). Follow the original Johnny Express Spare Tire Rack instructions in the PDF file on the AEP site, see "The Johnny Express Original Instructions" page under the Media Tab.

On a Final Note – be aware that the trailer bumpers are in some cases over 40 years old, and the tail lights mounted on them are likely very fragile. If you do not exercise care when snapping the mud flaps. onto the trailer bumper – you can break the tail lights on your bumper. Just take your time and install the mud flaps. with gentle pressure and the tail lights should survive.

 

Johnny Express Trailer Bumper Assembly Installation Notes

You have just obtained a reproduction Topper Johnny Express trailer bumper assembly and now it is time to install it into your Johnny Express trailer unit. Even though great care has been exercised in making these parts, and a high quality plastic has been used – a procedure should be followed when installing the bumper assembly.

Prior to installing your bumper, check the four trailer slot openings and make sure that they are clear of any dirt, debris or excess plastic flashing. If necessary, use a toothpick or Xacto knife to clean out the slot openings. Use a hair dryer to heat up the two bumper tabs that snap into the trailer unit, not the two pointed tabs that insert upward, but the two tabs that go in horizontally into the trailer. Heating up the tabs will make them more flexible during the installation process. After the tabs have been heated up, insert the pointed tabs in the upward direction first and gently exert pressure onto the horizontal tabs and they should snap into place. You might wish to use something like a Popsicle stick to help slide the horizontal tabs into place.

Note that there is a “graveyard” of original trailer bumper assemblies with broken tabs. Either because they were prone to breakage when installing, or because people tried to remove them once installed. After installation, do not attempt removal of the trailer bumper assembly.

 

Johnny Express Trailer Tail Lights Assembly Installation Notes

Installation of the tail lights into a trailer bumper assembly can be especially difficult. Prior to installing your tail lights, check the two trailer bumper openings and make sure that they are clear of any dirt, debris or excess plastic flashing. If necessary, use a toothpick or Xacto knife to clean out the slot openings. The geometries of the original parts don't line up to provide a lot of freedom when inserting the tail lights. It is critical that a hair dryer be used to heat up both the bumper slot openings and the tail light tabs prior to installation. Just snap them in. As with all of the installations, good luck.