TONNEAU INSTALLATION GUIDE Warranty, Care & Maintenance EASY AS 1-2-3! NORMAL INSTALLATION TIME 30 MINUTES For Warranty Issues, Contact UnderCover Directly (866) 900-8800 www.undercoverinfo.com
Page 1 1 2 3 Be sure to use only cleaners, waxes, etc., which are labeled Safe for Plastics. Make sure that chemicals or substances, which are not labeled safe for plastics, do not come in contact with your Undercover. Failure to do so could cause discoloration and/or structural damage to your Undercover and will void your warranty. Paint rubbing of the truck is normally not a problem, but is always a possibility with any tonneau. To ensure less chance of possible paint rubbing of the truck, it is suggested to install a tailgate protector and adhere Cab Skin, Scotch Cal, or similar product to the truck bed. These products can provide added assurance against paint rubbing. Undercover Tonneaus are designed from trucks that do not have a bed liner (spray-in bed liners pose no problem). Trucks that do have under-the-rail or over-the-rail bed liners will require some minor trimming of the bed liner to ensure proper placement of the mounting brackets. Due to the wide variety of bed liner manufacturers, the modifications will vary slightly between different brands. Any modifications must be made to the bed liner and NOT to the Undercover mounting hardware. Modifications to the mounting hardware will result in improper installation and will void your warranty.
Page 2 Note: If your Tonneau has already been installed, skip to Page 11 for removal and reinstallation instructions.
Page 3 A B C D E FACT: UnderCover is the lightest hardshell tonneau in the industry. Only 58-pounds for full size trucks. Installing your Ford Sport Trac hardware is simple and easy to do. The Sport Trac comes with the mounting holes already in place. Our hardware mounts right to the existing holes. Page 4, Picture A shows what the rear bracket will look like once it is installed. Remove the plastic plugs with a pair of needle-nose pliers. Save these for future use if you ever remove the bracket system. See Page 4, Picture B. Install the rear bracket using two 6mm bolts and two washers threaded into the preset mounting holes. See Page 4, Picture C. Once you have tightened the bolts by hand, use a 10mm wrench or ratchet/socket to firmly secure the bolts to the bed. See Page 4, Picture D. BE SURE NOT TO OVER TIGHTEN, DOING SO COULD SHEAR OFF THE BOLT HEAD. The mounting holes on the rear bracket are slotted to allow for adjustment of the lock cams. The best position to start with is the bracket in the highest position. You can make further adjustments once the cover is mounted. See Page 4, Picture E. Repeat steps A through E for the other side. WARNING! Be sure not to over tighten the rear mounting bolts. Doing so could shear off the bolt heads, creating a difficult procedure to remove the remaining thread.
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Page 5 A Mounting the Ball Stud for your hydraulic strut is simple and easy. Page 6, Picture A shows what the finished install will look like. B In the center of the bed there are two torx bolts, you will need to remove the one towards the rear of the truck. You will need a Torx T-30 bit to remove this bolt. See Page 6, Picture B. Again, like the plastic tabs from the rear mounting bracket proceedure, you should save this bolt for removal of brackets in the future. C Once you have removed the torx bolt you can now hand thread the ball stud included with the hardware. Secure the ball stud with a 1/2" wrench or socket/ratchet. BE SURE NOT TO OVER TIGHTEN. DOING SO CAN SHEAR OFF THE BALL STUD AND CAUSE SERIOUS DIFFICULTY CORRECTING. D Once you UnderCover is installed you will be able to lift the cover up and clip the strut to the ball mount. See Page 6, Picture C. WARNING! Be sure not to over tighten the rear mounting bolts. Doing so could shear off the bolt heads, creating a difficult procedure to remove the remaining thread.
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Page 7 FACT: UnderCover's ABS-Composite material makes it the strongest and most durable tonneau on the market. A Installation of the front bracket is very similar to the rear. Remove the plastic plugs exposing the 3 preset bolt holes located at the front of the bed. Page 8, Picture A shows how the front bracket will look once it is fully installed. B Position the front bracket over the three preset bolt holes. See Page 8, Figure 1. Attach the bracket to the truck using the three 6mm bolts and washers. The measurement is just a starting point, the brackets are slotted to allow for adjustment. See Page 8, Picture B. Tighten the three bolts using a 10mm wrench or socket/ratchet. See Page 8, Picture C. BE SURE NOT TO OVER TIGHTEN OR YOU COULD SHEAR OFF THE BOLT HEAD CREATING A VERY DIFFICULT PROCEDURE TO REMOVE THE REMAINING THREAD. C D Repeat process for other side. Now you are ready to set your cover on the truck. The hinge that is attached to the cover has slots in it that fit over the mounting posts on the bracket you just installed. See Page 8, Figure 2. E With the hinge slot over the post, the cover will be sitting about 1-inch past the tailgate. See Page 9, Picture F. With the cover sitting all the way down on the truck bed, push the cover forward securing the 4 bar hinge to the mounting posts. See Page 9, Picture G. F With some assistance, have someone hold the cover up at the rear and reach inside the cover and screw in the two fastening knobs. See Page 9, Picture H. WARNING! Be sure not to over tighten the rear mounting bolts. Doing so could shear off the bolt heads, creating a difficult procedure to remove the remaining thread.
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Page 10 Not all truck beds are assembled 100% square, so it may be necessary to do some preliminary adjustments. The mounting holes in the front brackets are slotted to allow for adjustment. With your cover closed, take a quick inspection to make sure that it is not touching the bed on either side or the tailgate. If it appears square or close to square go on to Step 4, pages 11 and 12. If it is making contact with the side of the truck or the tailgate, you may wish to make some adjustments before going to the final step. To adjust the cover front to back evenly, move both of the front brackets forward or backward accordingly. To adjust one side or the other, move the front brackets forward or backward independently. Any questions you can call tech assistance Monday through Friday, 8 a.m. 5 p.m. Central Time (866) 900-8800. Very Important: Periodically check your truck for rubbing. Make slight adjustments when necessary.
Page 11 A B C D FACT: In less than one minute, you can both take on and off the Undercover tonneau. Fastest removal system in the industry. Install hydraulic struts making sure LARGE end of strut is attached to the tonneau, and SMALL or rod end is attached to the ball stud on rear bracket Page 10, Figure 7, Picture A. Be sure that the front flap seal hangs over the bulkhead of the truck and is not rolled under the tonneau after installation. If flap seal is rolled under the tonneau, open the tonneau, and from the inside push the flap seal out from under the tonneau and over the bulkhead Page 10, Figure 8, Picture B. Close tonneau and check length on the truck. There should be 1/8 -to- 3/8 gap between the tailgate and the tonneau. If this is not correct, adjust by moving front brackets forward or backward to achieve correct length. Front brackets may also have to be adjusted independently to square-up tonneau on some truck beds. Adjust lock strikes Page 10, Figure 9, Picture C. When adjusted properly you should be able to turn the key to the locked position without having to push down on the tonneau. There should be a very slight amount of play between the lock cam and lock strike. A good rule of thumb is to adjust the lock to have approximately 1/8 gap between the cam and lock strike with the truck tailgate down. This usually gives you the proper adjustment after the tailgate is shut Page 10, Figure 9, Picture D. WARNING: It is very important to be able to turn the key without any resistance. Do not try to force the lock cam to turn if you encounter resistance. This could result in a broken key or broken lock. Adjustment may be necessary to the lock strike plate to achieve a smooth turn without any resistance.
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Page 13 Congratulations! Your 30-minute installation job is now complete. Now, in less than one minute, you will be able to put on and take off your tonneau cover. STEP 1 Release strut off of ball stud Picture B. Holding tonneau up with one hand, place loose end of strut on storage clip Picture C. Repeat for the other side. STEP 2 Turn twist knobs until they release Picture A. STEP 3 Go to the rear of the truck and pull Tonneau cover back, releasing the post from the hinge slot, Picture D. You are now ready to lift the cover off. STEP 1 Place tonneau on the truck and follow instructions on Page 7. STEP 2 Be sure that the front flap seal is hanging over the bulkhead and not rolled under, see Picture E on this page. STEP 3 Reinstall struts as seen in pictures Pictures F and G on this page.
Page 14 STEP 1 Prior to removing the tonneau, mount the two J-Hooks provided on the garage wall. The hooks must have a minimum height from the floor of 84", and be 32 on center horizontally apart Picture A & B. STEP 2 Remove your tonneau from the truck bed according to instructions on Page 11. STEP 3 Hang tonneau vertically on the wall-mounted J-Hooks, with the underside against the wall inserting J-Hooks into the holes provided in Picture C & D.
TONNEAU INSTALLATION GUIDE Page 15 THANK YOU! Congratulations! You ve just installed the fastest-selling, highest-quality tonneau in the industry. Thank you very much for your purchase of UnderCover! David Wells President UnderCover, Inc. UnderCover, Inc. P.O. Box 620 Rogersville, MO 65742 (417) 753-8000 (866) 900-8800 www.undercoverinfo.com sales@undercoverinfo.com For any Warranty issues, contact UnderCover directly. 2010 UnderCover, Inc. All rights reserved.