HARD TRI-FOLD COVER SPECIAL BOLT ON SIDE RAIL INSTRUCTIONS 2016-ON TOYOTA TACOMA 6 BOX Read and follow these special instructions along with the standard instructions carefully before installing or using this cover. NOTICE TO INSTALLER: Even if familiar with product, read special instructions prior to installation as improvements may be made without notice. Always handle components with care. When done, these special instructions must be given to the consumer. NOTICE TO CONSUMER: Before using this product, read special instructions. Save these special instructions for future reference. NOTE TO OWNER AND INSTALLER: 1. Side rails in this kit mount to the deck rail system with special bolt on brackets instead of standard clamps as shown in standard instructions. 2. Cover may disable or limit use of some deck rail systems.
PREPARATION TOOLS NEEDED Protective eyewear Ratchet with 10 mm, 7/16 and 1/2 sockets Torque wrench! CAUTION: Over torquing hardware may damage components. Do not use impact tools. 1. INSTALLING WEATHER SEAL A. Clean vertical surface above deck rail system from bulkhead to tailgate with alcohol pad on both sides. NOTE: For best adhesion, ensure surface is clean and air along with surface temperatures are above 60 o F. B. Peel segment of paper backing from one end of D weather seal. At rear of truck, align top of weather seal with top of box rail then adhere weather seal segment without backing to vertical surface above deck rail system. NOTE: Ensure the top of seal is flush with box rail. C. From tailgate to bulkhead, continue peeling paper backing and adhering weather seal to vertical surface above deck rail system until bulkhead gap. Bulkhead Weather seal Bulkhead gap Area above deck rail Weather seal Truck rear Deck rail D. At bulkhead gap, pull seal section through at downward angle. TIP: Leave paper backing on section to allow for seal placement. Once seal is in place, carefully peel paper backing without removing seal from gap. Angle seal downward at bulkhead gap NOTE: Angling the seal, allows water to drain. E. Trim excess weather seal from both ends. 2
2. ASSEMBLING SIDE RAIL A. Locate two side rail sections for DRIVER S side by finding identifying arrow marks at seam of side rail sections. The remaining two side rail sections are for the passenger side. Arrow points toward the truck cab. NOTE: Be aware, side rails require multiple brackets for installation: front, middle and rear. Ensure to use the correct bracket that corresponds with its rail position. Front bracket Middle bracket Rear bracket NOTE: Each side rail assembly requires two different rail shapes: straight and contoured. B. Assemble side rail by mounting middle bracket to inner seams with (2) 1/4-20 x 3/4 bolts, (2) flat washers, (2) lock washers and (2) nuts. C. Align side rails, finger tighten and ensure brackets can be adjusted in or out. NOTE: Middle bracket attaches to side rail through square slots. Front straight side rail Align side rail seams Rear contoured side rail 1/4-20 x 3/4 Bolt Square slot 1/4 Flat washer 1/4 Lock washer 1/4-20 Hex nut 3
2. ASSEMBLING SIDE RAIL (Continued) D. Install front bracket to side rail with (1) 1/4-20 x 3/4 bolt, (1) flat washer, (1) lock washer and (1) nut. Finger tighten and ensure brackets can be adjusted in or out. NOTE: Front bracket attaches to side rail through square slots. E. Install rear bracket to side rail with (1) 1/4-20 x 3/4 bolt, (1) flat washer, (1) lock washer and (1) nut. Finger tighten and ensure bracket can be adjusted in or out. NOTE: Rear bracket attaches to side rail through square slot. 3. INSTALLING SIDE RAILS A. Remove deck rail system plug at end of channel near tailgate. Square slot 1/4 Flat washer 1/4 Lock washer 1/4-20 Hex nut Square slot Rear bracket 1/4 Flat washer 1/4 Lock washer 1/4-20 Hex nut 1/4-20 x 3/4 Bolt Side rail Front bracket 1/4-20 x 3/4 Bolt Remove plug 4
3. INSTALLING SIDE RAILS (Continued) B. Use 10 mm socket with ratchet to remove 6 mm bolt near end of truck. Save 6 mm bolt for reuse in Step 3G on page 6. 6 mm Bolt C. Slide carriage bolt bracket with 5/16 x 1-1/4 carriage bolt into channel of deck rail system, insert one set per front and middle bracket. D. Reinsert deck rail system plug at end of channel near tailgate. Weather seal Deck rail system E. For front and middle brackets, position side rail against inside lip of box. Align carriage bolts with brackets on side rails. Push side rail forward until rail touches front of box. NOTE: Ensure contoured portion of side rail is at rear of truck. 5/16 x 1-1/4 Carriage bolt and bracket Align slot in bracket with carriage bolt F. Secure with 5/16 serrated nuts. Leave finger tight for now. 5/16 serrated nut 5
3. INSTALLING SIDE RAILS (Continued) G. Attach rear bracket to box with 6 mm bolt (removed in Step 3B on page 5). Leave finger tight for now. 6 mm bolt H. For front and middle brackets, align side rail edge with bracket edge then tighten 1/4-20 nut. NOTE: Before tightening middle bracket nuts, ensure side rail is flush and aligned. Align edge of side rail with edge of bracket Tighten 1/4-20 nut I. At front and middle bracket, set height according to standard instructions. J. Position side rail and bracket against box rail and tighten 5/16 serrated nut. Hold side rail level while tightening Tighten 5/16 serrated nut 6
3. INSTALLING SIDE RAILS (Continued) NOTE: Before proceeding, ensure weather seal contacts side rail and creates a seal. Weather seal under side rail K. For rear bracket, align side rail edge with bracket edge then tighten 1/4-20 nut. Align edge of side rail with edge of bracket Tighten 1/4-20 nut L. Position side rail and bracket against box rail and tighten 6 mm bolt. Hold side rail level while tightening Tighten 6 mm bolt M. Repeat to install side rail on opposite side. N. Torque 5/16 nuts on 5/16 x 1-1/4 carriage bolts to 20 ft-lbs. O. Torque 1/4-20 nuts on 1/4-20 x 3/4 carriage bolts to 10 ft-lbs. P. Torque 6 mm bolts to 8 ft-lbs. Q. For remaining cover installation, refer to standard instructions. 7
Product subject to change without notice. 102517 2000125_INIT