| Installing a Roll-Top Bed Cover and Tailgate Lock |
From "Car Care & Repair"
episode CCR-107 |
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Installing the Roll-Top Cover A locking roll-top tonneau cover is a functional addition for a pickup, particularly if you use your truck as a daily driver. It protects your cargo from the elements and helps secure it against theft when you leave the vehicle parked. In keeping with the security function, a locking tailgate is a logical counterpart to this installation. In this demonstration, we install a locking tonneau along with a tailgate power lock on a 1998 Ford F-350. The cover installs and operates much like a rolled window shade. When not in use, it retracts into a rolled-up position (figure A). Once the cover is installed, you'll need to install a tailgate lock (figure B) in order to fully take advantage of the added security the cover offers. Important: Your tonneau cover will come with the necessary mounting hardware and detailed instructions for installation. Read and follow those instructions and diagrams carefully as there will be variations between installations depending on the particular cover you've selected and your specific vehicle. Following is a summary of the basic steps for installation as performed in our demonstration. Materials: Roll-top cover kit including mounting hardware
Electric drill
Clamps
Grease pencil - Follow the manufacturer's instructions for removing the tonneau cover, canister, lid and accessories from the packaging. During installation it helps to use a rag or soft piece of packing material to wedge into the rolled top to keep it from winding back into the canister. Install the lock arm assembly onto the underside of the tonneau handle according to the manufacturer's instructions. Once installed, when the lock is engaged, the locking arms will extend beyond the edges of the handle to secure the top. Using the key, test the lock to see that the arms extend and retract properly to engage and disengage the lock. Return the handle to the canister, being careful that the lock doesn't damage the sliding tonneau.
- Set the canister onto the rails of the truck in the position it will be mounted, but do not attach the canister yet. Remove the side channels and guide strips from the packing and check them to be sure they fit the side rails properly and are the correct length.
- As the cover unrolls, it slides back through channels that mount on both side rails of the truck bed (figure C). This holds the cover in position and prevents it from flapping or coming loose in the wind. The channels attach to the side rails with screws. Before installing the channels, measure the length of your bed and make certain that your channels are the right length. If they're too long, you may need to cut off some excess. Make certain that, once they are mounted, there's enough clearance for the tailgate to close.
- Clamp the track in place so that it's secure while you mark the location on the bed rails for the mounting screws. It may help to use wood blocks to assist in clamping the track in place.
- With the track clamped in position, mark the locations for drilling with a grease pencil (figure D).
- Remove the clamps and the track, and center-punch each mark for a good start for drilling the holes (figure E).
- Drill the holes at the marked locations.
- Using clamps once again to hold the track in place, install the track onto the bed rail with self-tapping screws.
- The next step is to install the lower guide-strip that runs along the inside of the channel (figure F). This is the piece that holds the edge of the cover as it slides along in the channel. The guide strip is attached inside the channel with screws that install in predrilled holes. With the guide strip situated in place (making certain not to confuse the left and right guide strips), insert the screws in the holes and tighten each one, but do not tighten them fully. Once they're all in, tighten them all down.
- Position the canister so that it is centered and will allow the cover to slide properly into the channels. With the canister positioned and the channels attached, test the cover to make certain that it rolls freely and smoothly in the channel.
- The roll-top cover is designed so that rainwater is channeled down into the canister, then out through a plastic tube (figure G) that permits water to drain out under the vehicle through holes in the bed floor. First, install the aluminum drain fittings into canister floor, pushing them down firmly until they are seated against the bottom of the canister. Next, slip the plastic drain tubes onto the drain fittings from underneath the canister and feed them down through the holes in the truck bed.
Note: In our example vehicle, we were able to make use of existing drain holes in the truck bed. If your truck does not already have drain holes in the bed, they must be drilled before installing the cover and canister. Use a 5/8" bit to drill holes large enough to accommodate the drain hose. Before drilling, check the underside of the truck at the site where you'll be drilling, making certain that you won't puncture brake lines, fuel lines, etc. The holes should be located near the sides and as far forward as practical. If you are installing the cover on a truck with a bed liner, it may be possible to channel the water through the bed liner and allow it to drain out without installing tubes. Check the manufacturer's instructions for complete information on installing the drain tubes. - With the drains installed and the canister and channels properly positioned, mark and drill the holes in the side rails so that you can attach the canister to the side rails with the screws provided (figure H).
- Install the plastic canister cover (figure I) with the screws provided. Don't overtighten the screws as this may cause the plastic to split.
Installing the Tailgate Lock The second part of this project is to install a tailgate lock. In our demonstration we install a tailgate power lock that is connected in with the power door-lock switch inside the cab. Important: Always disconnect the negative battery cable before you begin any electrical work on a vehicle. - With the tailgate open, remove the tailgate portion of the bed liner (if you have one) and the tailgate access panel to expose the existing lock mechanism.
- Remove the two nuts that hold the locking mechanism in place (figure J) and remove the old lock.
- Slip the new power lock into place to replace the old locking mechanism.
- Install the wiring harness following the manufacturer's wiring instructions and diagrams carefully. For our installation the wiring harness comes in two sections that plug together (figure K). That way, if the tailgate ever needs to be removed, it can be done without having to cut the wires. The wiring was run forward underneath the vehicle and attached to the frame with plastic fasteners (figure L).
- With the harness fastened underneath the vehicle, run the wiring into the engine compartment, then through the firewall and into the cab.
- Disconnect the negative battery cable and then follow the manufacturer's instructions to tap into the appropriate color-coded wires controlling the power door-locks. Consult your owner's manual or service manual for the best location to access the proper wires.
- Once the wiring is complete, reconnect the battery cable and test the power lock.
RESOURCES :
Vehicles provided by McNelly-Whaley Ford Lincoln Mercury
750 Dolly Parton Parkway
Sevierville, TN 37862
Phone: 865-453-2833
Web site: www.ford4u.com
Pace Edwards truck-bed roll-top cover
Truck-bed roll-top cover in this demonstration is from
Pace Edwards
2400 Commercial Blvd.
Centralia, WA 98531
Phone: 360-736-9991
Toll-free: 800-338-3697
Fax: 360-736-9992
Web site: www.pace-edwards.com
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