TJ Fender Flares — Replacing or Upgrading for Wider Tires

Running 33s on a stock TJ you need wider flares to stay legal — stock flares cover stock width. Budget flares from Smittybilt bolt straight to stock holes; tube fenders need drilling but look cleaner with big lifts.

Arizona, like most states, requires tires to be covered to the centerline. Stock TJ flares cover up to roughly 31-inch tires at stock width — move to 33s with any lift and the tire sidewall starts poking past the fender line. The fix is either wider replacement flares or tube fenders, depending on how aggressive the build is going.

For 33s and mild lifts (2.5 to 3 inches), a flat-style or extended OEM-style replacement flare adds 1 to 2 inches of coverage per side and installs in the factory clip holes. Bushwacker's Flat Style and Smittybilt's replacement flares are the common choices — both are OE-style ABS plastic, bolt on without drilling, and run $100 to $180 for the pair. They look stock enough to not draw attention.

For 35s and serious lift (4+ inches), tube fenders are the better answer. They add more coverage, they don't crack when a rock hits them like OEM-profile ABS flares do, and they clear the tire at full articulation rather than at ride height. The tradeoff is drilling into the body for mounting bolts. Rugged Ridge tube flares run $180 and are considered entry-level. Poison Spyder's tube fenders are sheetmetal, look right, and hold up to rock contact — closer to $400. If you're building a rock crawler, metal tube fenders are worth it.

• Replacement flares matched to TJ (OEM-style) or tube fenders
• 10mm socket and trim clip removal tool for stock flare removal
• Drill and step bit if installing tube fenders that require new mounting points
• Wire brush and touchup paint — the areas under the flares are usually surface-rusted on high-mileage TJs

1. Remove old flares. The stock TJ flares clip to the fender lip and secure with 10mm bolts at the wheel arch. Pop the clips with a trim tool, remove bolts, and lift flare off. It takes about 15 minutes per flare.

1. Clean the mounting surface. Scrub any rust with a wire brush and hit bare metal with rattle-can primer. You won't see this area again for years.

1. Install replacement OEM-style flares. Align over stock clip holes, press in clips, torque bolts. Test fit before final torque — misaligned flares look worse than old ones.

1. For tube fenders: Test fit and mark drill points before committing. Drill pilot holes, step up to final diameter, deburr and prime. Bolt through with stainless hardware and locking nuts.

1. Check clearance at full lock and full droop. Turn the wheel lock-to-lock with the Jeep on the ground. Check for rub points at full flex with a friend compressing the suspension by hand.

• Tube fenders require re-locating the turn signal. Budget an extra hour and a turn signal relocation harness ($20–$30).
• Inspect the inner fender area for rust before reinstalling any flare — this is a common rust accumulation zone on older TJs from wet climates.
• Not all "TJ flares" fit all years — check your year before ordering. A few flare kits fit either TJ or JK but not both.

OEM-style replacement flares: $90–$180 installed in under an hour with no drilling. Tube fenders: $180–$400 depending on material, plus 3–4 hours of work and a turn signal relocation. Sheetmetal tube fenders outlast plastic alternatives in rock use.

Tools required

• 10mm socket
• flat-blade screwdriver
• trim clip removal tool
• drill with bits (for tube flares)
• rivet gun (optional)

Parts

Part	Vendor	Est. price
Bushwacker Flat Style fender flares — TJ	Bushwacker	~$160
Smittybilt XRC replacement fender flares	Smittybilt	~$110
Rugged Ridge tube fender flare kit	Rugged Ridge	~$190
Poison Spyder tube fenders (sheetmetal)	Poison Spyder	~$380

Sources

• TJ Fender Flare Options and Tire Clearance Guide

Related

• TJ Soft Top Replacement
• TJ Battery Replacement and Upgrade Guide
• All Jeep Wrangler TJ guides & tools
• Browse the full DIY database

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Written and maintained by an AZ wheeler and driveway wrencher. Always cross-reference your factory service manual — modifications affect vehicle safety and warranty. Work at your own risk.

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