Taking off those old TJ fender flares starts with locating the hidden fasteners beneath the plastic trim. If you are serious about removing jeep tj fender flares, you need to know that most of the bolts are not visible until you pop off the trim pieces. This guide will walk you through the entire process, from gathering tools to dealing with stubborn rusted nuts.
You do not need to be a professional mechanic. With some patience and the right approach, you can get those flares off in a couple of hours. The key is to work methodically and not force anything.
Why Remove Your Jeep Tj Fender Flares?
People remove flares for different reasons. Maybe you want to install aftermarket ones for a wider stance. Perhaps the old plastic is cracked and faded. Or you might be prepping the tub for a repaint. Whatever the reason, the process is mostly the same.
One common goal is to clean out the rust trap behind the flares. TJs are known for collecting mud and salt back there. Taking them off lets you inspect and treat the metal.
Tools You Will Need
Before you start, gather these items. It saves time and frustration.
- Torx bit set (T40 and T45 are common)
- 10mm and 13mm sockets or wrenches
- Flathead screwdriver or plastic trim tool
- Penetrating oil (like WD-40 or PB Blaster)
- Ratchet and extension bar
- Small pry bar (optional)
- Gloves and safety glasses
Safety First
Wear gloves. The plastic edges can be sharp. Safety glasses protect your eyes from falling debris or rust flakes. Work on a level surface.
Removing Jeep Tj Fender Flares
Now we get into the actual steps. This process works for both front and rear flares. The rear flares have a few extra bolts near the tailgate, but the concept is identical.
Step 1: Pop Off The Plastic Trim Covers
Look at the top edge of your flare. You will see a strip of plastic trim running along the top. This trim hides the main bolts. Use a flathead screwdriver or trim tool to gently pry it off. Start at one end and work your way along.
Be careful not to break the trim. If it is brittle from sun damage, it might crack. Go slow. Once the trim is off, you will see a row of Torx bolts.
Step 2: Remove The Torx Bolts
These bolts hold the flare to the tub. Use a T40 or T45 bit depending on your Jeep. Some TJs have a mix. Remove all the bolts along the top edge. There are usually 6 to 8 per flare.
If a bolt is stuck, spray penetrating oil and wait a few minutes. Do not strip the head. A little patience here prevents headaches.
Step 3: Access The Lower Fasteners
After the top bolts are out, you need to get the bottom ones. These are located under the flare, near the wheel well. You may need to turn the steering wheel to access the front ones. For the rear, you might have to remove the tail light or inner fender liner.
On some TJs, there are nuts on the inside of the tub. You need a 10mm or 13mm socket to reach them. Use an extension bar to get into tight spots.
Step 4: Wiggle The Flare Free
Once all fasteners are removed, the flare should come off. It might be stuck on with old adhesive or dirt. Gently pull it away from the tub. If it resists, check for missed bolts. Do not yank hard or you could crack the plastic.
For stubborn flares, use a plastic pry bar to break the seal. Work around the edges slowly.
Dealing With Rust And Stuck Bolts
Jeeps that have seen winters or off-road mud often have rusted fasteners. This is the most common frustration when removing flares. Here is how to handle it.
Use Penetrating Oil Generously
Spray every bolt and nut you can see. Let it soak for 10-15 minutes. For really stuck ones, apply more oil and wait longer. Heat from a small torch can also help, but be careful near plastic.
Bolt Extraction Tips
If a Torx head strips, you have options. Try a slightly larger bit. You can also use a screw extractor set. Worst case, drill the bolt head off. Then the flare will come off, and you can deal with the remaining stud later.
Broken Studs
Sometimes a stud breaks off inside the tub. Do not panic. You can drill it out and use a rivet nut or a self-tapping screw for reinstallation. Many aftermarket flare kits come with new hardware anyway.
Cleaning The Tub After Removal
With the flares off, you will see years of grime and possibly rust. Clean this area thoroughly before installing new flares or painting.
Remove Old Adhesive And Gunk
Use a scraper and some adhesive remover. Goo Gone or mineral spirits work well. Be gentle to avoid scratching the paint.
Treat Rust Spots
Sand down any surface rust with 80-grit sandpaper. Apply a rust converter or primer. If there are holes, you may need to patch them with fiberglass or weld in new metal. This is a good time to address body issues.
Installing New Flares (Quick Overview)
Once the old flares are off, putting new ones on is simpler. Most aftermarket flares use the same bolt holes. Some require drilling new ones.
Dry Fit First
Hold the new flare in place to check alignment. Mark any new holes with a marker. Drill slowly to avoid cracking the plastic or paint.
Use Stainless Hardware
If your kit does not include bolts, buy stainless steel ones. They resist rust much better than standard steel. Apply a little anti-seize compound to the threads for future removal.
Tighten Evenly
Do not overtighten. Snug is enough. Over-tightening can crack the flare or strip the threads. Work from the center outwards for even pressure.
Common Mistakes To Avoid
Even experienced DIYers make errors. Here are the ones to watch out for.
- Forgetting to remove the trim cover first. This hides the main bolts.
- Using too much force on stuck bolts. Patience and oil work better.
- Not labeling fasteners. Put bolts in a baggie or tape them to the flare.
- Skipping the cleaning step. Dirt left behind will cause rust later.
- Installing new flares without checking for hidden rust.
Time And Difficulty
Removing all four flares takes about 2-3 hours for a beginner. If you have rust issues, add an hour. The front flares are slightly easier than the rear because you have better access.
This is a moderate difficulty job. Anyone with basic tool skills can do it. The hardest part is dealing with corroded fasteners.
Frequently Asked Questions
Do I need to remove the tires to take off the flares?
Not necessarily. You can turn the steering wheel for front access. For the rear, you might need to jack up the Jeep to get clearance. Removing tires gives you more room but is not required.
Can I reuse the old hardware?
You can, but it is not recommended. Old bolts are often rusty and weak. New stainless hardware is cheap and prevents future problems.
Will removing flares affect my Jeep’s resale value?
It depends. If you install quality aftermarket flares, it can improve the look. Leaving the tub bare with holes might lower value. Keep the old parts if you want to return to stock.
What if my flares are cracked?
They are still removable. Just be careful not to break them further. You might need to remove them in pieces if they are very brittle.
How do I remove the rear flares without removing the tail light?
On some TJs, you can access the bolts through the tail light opening. Remove the tail light housing first. It gives you direct access to the nuts inside the tub.
Final Thoughts On This Project
Taking off those flares is a straightfoward job if you take your time. The biggest lesson is to be patient with stuck fasteners. Use oil, the right tools, and dont rush. Once the flares are off, you will have a cleaner Jeep and a better base for whatever comes next.
Whether you are upgrading to flat flares, painting, or just cleaning out the mud, the process is the same. Start with the trim covers, remove the bolts, and wiggle the flare free. Clean the area well before putting anything new on.
Your TJ will look different without flares. Some people like the bare fender look. Others prefer the protection flares offer. Either way, you now know how to get them off and on again. That is a usefull skill for any Jeep owner.
Remember to keep all your old hardware in case you need it later. And if you run into a stubborn bolt, step back, spray more oil, and try again. Every TJ has its quirks, but this job is very doable in a weekend afternoon.
Now you are ready to tackle this project. Grab your tools, pop that trim, and get those flares off. Your Jeep will thank you for the attention.