AEV 33” Tire Clearance Kit

1. Introduction

This manual provides essential information for the proper installation and maintenance of your AEV 33” Tire Clearance Kit. This kit is specifically designed to allow the fitment of 33-inch diameter tires on 2019-2022 Chevrolet Colorado ZR2 Bison models, enhancing off-road capability by increasing wheel well clearance. Adherence to these instructions is crucial for optimal performance and safety.

Image: A blue Chevrolet Colorado ZR2 Bison, equipped with the AEV 33” Tire Clearance Kit, showcasing the increased wheel well clearance for larger tires. The vehicle is positioned on a dirt path, highlighting its off-road readiness.

2. Safety Information

Warning: Installation of this product requires advanced mechanical skills and specialized tools. Improper installation can lead to vehicle damage, loss of control, and serious injury or death. If you are not confident in your ability to perform the installation, seek assistance from a qualified professional.

• Always wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
• Ensure the vehicle is securely supported on jack stands or a lift before working underneath it.
• Disconnect the vehicle's battery before beginning any electrical work.
• Exercise extreme caution when cutting or modifying vehicle body panels.
• Refer to the vehicle's factory service manual for additional safety precautions and torque specifications.

3. Package Contents

Verify that all components listed below are present and undamaged before beginning installation. If any parts are missing or damaged, contact AEV customer support immediately.

• Front Closeout Panels (Left & Right)
• Rear Closeout Panels (Left & Right)
• Support Brackets
• Trim Templates
• Installation Hardware (various fasteners, clips, etc.)

Image: The complete set of components for the AEV 33” Tire Clearance Kit, featuring precision-cut metal closeout panels and support brackets designed for vehicle modification.

4. Setup and Installation

The installation of the AEV 33” Tire Clearance Kit involves modifying the vehicle's fender wells and requires careful attention to detail. It is highly recommended to download and review the official AEV Installation Manual (PDF) for comprehensive, step-by-step instructions and diagrams.

Key Installation Considerations:

• Preparation: Thoroughly clean the work area on the vehicle. Remove wheels and any inner fender liners as necessary.
• Templating: Accurately apply the provided trim templates to the vehicle's body panels. Precision in this step is critical for a proper fit and finish.
• Cutting: Use appropriate cutting tools (e.g., air saw, Dremel, angle grinder) to carefully remove material from the fender wells according to the templates. Take precautions to protect painted surfaces and underlying components.
• Finishing Edges: Smooth all cut edges to prevent sharp points and apply rust-preventative coating as needed.
• Panel Installation: Install the closeout panels and support brackets using the supplied hardware. Ensure all fasteners are tightened to the manufacturer's specifications.
• Final Inspection: After installation, check for proper clearance with the new 33-inch tires through the full range of suspension travel and steering.

For detailed instructions, please refer to the official AEV Installation Manual (PDF).

5. Maintenance

Once installed, the AEV 33” Tire Clearance Kit requires minimal maintenance. However, regular inspection is recommended to ensure continued performance and safety:

• Periodically check all fasteners for tightness, especially after off-road use.
• Inspect the closeout panels and surrounding bodywork for any signs of damage, corrosion, or wear.
• Clean any accumulated dirt or debris from the newly cleared areas to prevent abrasion or premature wear.

6. Troubleshooting

While the AEV 33” Tire Clearance Kit is designed for precise fitment, some issues may arise during or after installation:

• Issue: Insufficient Tire Clearance.
  Solution: Re-verify that all cuts were made accurately according to the templates. Ensure the closeout panels are seated correctly and all hardware is tightened. Minor adjustments to the cut lines may be necessary in some cases, but proceed with caution.
• Issue: Misaligned Templates.
  Solution: Customer feedback indicates that some templates (specifically for the rear fender) may appear reversed. Always double-check template orientation against the vehicle and the official installation manual's diagrams before cutting. If unsure, contact AEV support.
• Issue: Rattling or Loose Components.
  Solution: Inspect all installed panels and brackets. Ensure all bolts, nuts, and clips are securely fastened. Apply thread locker where appropriate, following the installation manual's recommendations.

7. Specifications

8. Warranty and Support

For warranty information, technical support, or assistance with installation, please contact American Expedition Vehicles (AEV) directly. Refer to the official AEV website or the provided installation manual for contact details.

The official installation manual can be found here: AEV Installation Manual (PDF).