Page 1
INSTALLATIONSHEET
GasStruts(x2)
Lower
HingeRail
SpringBows
(x3-ShortBed)
(x4-LongBed)
“L”Bars
(LandR)
withclamps
included
Assemblyw/Tarpattached
MISSINGPARTS???
CallExtangat1-800-877-2588
Any and all needed parts will be shipped to you directly.
(DO NOT return whole kit to store)
PARTS INCLUDED IN YOUR KIT. You may want to lay them out in this manner for accessibility.
1 2
SideRails
(LandR)
UpperHingeRail
Allen Wrenchs
(3 sizes)
Tailgate
Rail
Corner
Braces(x4)
FoamhasNOadhesiveto
touchtruckfinish.
Wash truck bed.
3
ExtangCorporation
5400S.StateRoad
AnnArbor,MI48108
734677-0444,Fax:734677-8409
Insert “L” bars into the channel in the
lower hinge rail.
Donottighten.
0219
PLE ASE
DO NOT
LIT T E R
Remove paper tape from lower hinge rail. Discard properly.
Registeryourwarrantyat:
extang.com
Item No. 0035-1402 RH Pri nted i n U.S.A.
Page 2
Set assembly into the forward end of
4 5 6
payload bed. The forward channel of
the lower hinge rail centers over front
wall edge.
Adjust clamp for each side
Adjust front clamps as far
forward as possible.
Tighten both Allen bolts.
Adjust “L” bars out so that
neoprene pads rest on side
walls of payload bed.
bracket with two clamp bolts.
Set clamp in highest possible groove.
(Small bead of clamp fits groove in plate.)
Do not tighten.
7
Rotate upper hinge rail
assembly (at least 45°)
and fit into curved channel
of lower hinge rail.
Rotate upper hinge rail assembly
down so that deep channel engages
the ridge on the lower hinge rail.
Unroll tarp over truck cab.
8 9
Attach side rails to upper hinge rail
Assembly with brackets inside payload
bed, and locking levers to rear. Be sure
that ClickLock™ closures are fully secure.
10
The forward channel
11
of the lower hinge rail
should center over
front wall edge of the
payload bed.
Remove each pair of corner small Allen bolts on ends
of rails and insert diagonal bracket between them.
Do Not Tighten at this time.
Tighten front Allen bolts (x4) and side clamp bolts
(x8) with large and medium wrenches provided.
Connecting “L” bars firmly to the lower hinge rail
and the walls of the payload bed.
Square the tonno frame by aligning to side rails of
truck, or measuring diagonally, corner-to-corner,
and make sure that dimensions are equal. (This
can be done with frame detached from truck.)
Attach tailgate rail to side rails and
center entire assembly side-to-side,
leaving adequate clearance at
front with the truck cab.
With tonno frame
squared, retighten the
Note: Be sure that all corner members
corner Allen bolts.
are seated inside of
rails
Extang Corporation, 5400 S. State Road, Ann Arbor, MI 48108, 734 677-0444, Fax: 734 677-8409
Visit us at:
extang.com
Page 3
12
Frame locking lever must be
parallel to side rail when
opening and closing tonno.
Locking lever is secure when positioned at
right angle to, and engaged with side wall.
NOTE:
Model 8785 latches
will not turn
completely parallel
to side rails
ALWAYS latch tonno;
wind may open tonno, even when truck is stationary.
Locking levers come from the
factory ready to fit your truck.
If lever doesnʼt fit
snugly under side, you
can restack bushing
to get a better fit.
13
14
Insert bow onto top or bottom
peg, (Top peg for performance,
Bottom for good looks.)
Start at
Corners
Ends are spring loaded for
easy installation. Push and
hold on spring end and let
the other end slide on with
the spring action. NOTE:
Center bow provides
support to side rails and
may seem tight when
inserting between side
rails. It may be necessary
to pull out on side rails to
install the center bow.
Attach tarp by starting
at the corners, and
snap in place.
Studs Down
Upper
Peg
SPECIAL
FEATURE:
Two pegs
offer two
height
adjustments.
Note:
Bow End does not
fit between pegs.
SPECIAL FEATURE
Weather-adjustable Snaps
If it gets too cold, just bring the tonno inside!
Slides Off
TIGHT E R
TIGHT E R
LOOSE R
SUMMER SETTING
Takes up slack in tarp
caused by warm weather.
Rotate 180�
TIGHT E R
LOOSE R
LOOSE R
Allows more slack in tarp
Lower
Peg
Do Not
Place
Between
the Pegs
Studs Up
LOOSE R
TIGHT E R
WINTER SETTING
for cold temperatures.
15
Place sockets of gas strut over ball joints on each
bracket (cylinder-end attaches to truck). Cylinder
(round) socket should press easily over the lower
ball. Press retainer of upper socket into the ball to
lock securely in place. To remove cover from truck,
disengage gas strut at lower joint only.
NOTE: Round socket will release with hand
pressure. Do not remove strut from
tonno frame.
Push to
Lock
Extang Corporation, 5400 S. State Road, Ann Arbor, MI 48108, 734 677-0444, Fax: 734 677-8409
Pull to
Release
Visit us at:
extang.com
Page 4
Operating Your FullTilt™ Tonno
When in the proper position, the frame should freely
translate about 1/8”.
If not, raise the frame and seat it again.
When the upper hinge rail
Assembly is properly centered
side to side—the rail will rotate
easily. Be sure that steel rail end
plates are in place to keep rails
When replacing your FullTilt™
tonno be sure to seat the upper and
lower hinge rails properly. With the frame at a 30° angle,
shift the frame side-to-side to confirm that the curved ridge
on the lower hinge rail is located between the tonno frame
corner caps.
Quick Tips
• Do not overload your truck bed. Objects that press into t he
vinyl will wear a hole quite quic kly. If you need to carry larger
objects, remove t he entire tonneau frame, or roll the tar p to
the cab and secure. However when the tarp is rolled up the tail
rail must be attached to the framework.
• If t he load is too large to accommodate the tail rail, then t he
tonneau frame and tarp must be completely removed.
Reassemble when load is removed. The tonneau can be easily
stowed and reassembled for the return trip. It will improve your
fuel economy all t he way home!
• Do not attempt to carry the assembled tonneau loose in the truck bed,
even for a short distance, and even if tied down. The tonneau
will tr y to become airborne even at low speeds.
When tonno is
removed, stow the gas
shock against the shock
hold down stud.
from jamming.
Make sure that upper
hinge rail assembly
slides easily over ridge
on lower hinge rail.
If you need to tow your vehicle
backward, be sure to release the
cover and stow against the hinge
rail using Velcro® straps provided.
On a periodic basis, you should check the security
of
all t he fasteners on your tonneau system.
Trucks driven on bumpy roads or at high
speeds suffer vibration t hat can loosen all
elements of your tonneau system.
WARNING!
High winds may catch the tonno cover and cause it to open if not latched.
Be very careful raising tonno in windy conditions. Cover should always be latched when
down. Do not drive with cover raised or unlatched, even at slow speeds. When towing vehicle
backwards, cover must be removed or tarp fully rolled and secured with Velcro® straps.
Quick and Easy Removal
Step 1- Lift and hold cover while releasing the lower joint of the gas strut.
Step 2- Rotate the cover upward past 45° and lift out of the quick-hinge front rail system.
Step 3- Slide off the lower hinge rail.
Quick and Easy Reattachment
Step 1- Lift cover as a unit and drop front edge into the quick-hinge front rail system groove. Be careful that locking
tongue (vertical web) is between both corner pieces and rail end plates. There is about 1/8ʼ total clearance
on the ends. Slowly and gently rotate downward. DO NOT FORCE! IT SHOULD FALL INTO PLACE!! Note: Frame
should slide side-to-side about 1/8” freely, If hinge is tight, something is wrong, you are most likely not centered.
Step 2- Reattach the gas struts with body on bottom in open position. Drop cover and latch both sides securely.
Extang Corporation, 5400 S. State Road, Ann Arbor, MI 48108, 734 677-0444, Fax: 734 677-8409
Visit us at:
extang.com
Page 5
20161
Snap
Installing
Tool Kit
5xxx-*
P a r t s L i s t
See Part Descriptions on Back
NOTE: To order replacement parts, itʼs best to contact our
Customer Service Department for assistance, to ensure
getting the correct part for your vehicle application. When
ordering, xxx represents the 3 digit suffix, as referenced
on the sales receipt or vehicle application list.
Additional parts information can be found on our
website, at http://extang.com/how.html.
Customer Service: 800-877-2588
8xxx-31*
27005500
4208
26003300
27440200
1041
25001200
8xxx-1xS*
8xxx-35*
2001
33070100
8xxx-37*
2014
8xxx-55*
2014
8010
8xxx-32*
26000100
21221
8007
2002
26002700
27005100
28005100
8xxx-72*
8004
8xxx-45*
26002700
8xxx-71*
8xxx-73*
8003
26005000
8xxx-36*
8016
25000100
Extang Corporation
5400 S. State Road
Ann Arbor, MI 48108
734 677-0444, Fax: 734 677-8409
8xxx-74*
28001000
28001300
25001200
28001400
25000100
26005000
8xxx-75*
8xxx-70*
28005100
Specify: Year, Make, Model, Long-bed
*
or Short-bed, Driver or Passenger side.
Register your warranty at:
extang.com
I t e m N o . 0 1 0 6- 1 40 2 R H P r i n t e d i n U . S . A .
Page 6
P a r t s L i s t
NOTE: To order, xxx represents the 3-digit application # (vehicle type) following the 1- or 2-digit prefix, as referenced on the vehicle
application list or sales receipt. Or call our Customer Service Department at 1-800-877-2588 for assistance.
5xxx-* Black Replacement Tarp
8xxx-10S* Cab Bow w/Bow Ends (1)
8xxx-11S* Center Bow w/Bow Ends (S Bed) (1)
8xxx-12S* Cab Center Bow w/Bow Ends (L Bed) (1)
8xxx-13S* Tail Center Bow w/Bow Ends (L Bed) (1)
8xxx-14S* Tail Bow w/Bow Ends (1)
8xxx-31* Front Replacement Corner (2)
8xxx-32* Rear Replacement Corner (2)
4208 Replacement Corner Pads (4)
8xxx-35* Upper Pivot (Cab) Rail Assembly
2001 Cab Rail Foam Strip (30 ft.)
27005500 Cab Rail Hinge Lock (1)
8xxx-36* Lower Pivot Rail
8003 Pivot Rail Foam Pad (2)
8xxx-37* L Channel (for Toolbox Installation only)
2014 L Channel Seal
8xxx-45* Tailgate Rail Assembly
8xxx-71* Latch Assembly (1)
8004 Latch w/Sleeves
26002700 Weld Nut (1)8xxx-74*
Front Clamp Assembly (1)
25000100 5/16-18x13/4 SHCS (1)
26005000 1/4" Washer (1)
8xxx-75* Rear Clamp Assembly (1)
25000100 5/16-18x13/4 SHCS (1)
26005000 1/4" Washer (1)
1041 Corner Brace Assembly (1)
27440200 Corner Brace
26003300 Weld Nut (1)
25001200 1/4"-20x3/8" SHCS (1)
8007 Gas Shock (1)
8010 Pull-Down Strap w/Fasteners
Miscellaneous
28001000 3/16" Hex Key (1)
28001300 1/4" Hex Key (1)
2002 Tailgate Foam Strip (6 ft.)
8xxx-55* Side Rail Assembly (1)
2014 Side Rail Foam Strip (8 ft.)
21221 Bow Clip w/Screw (2)
25000800 1/4"-20x3/4" SHCS (1)
26002700 Weld Nut (1)
8xxx-70* "L" Rod (1)
8016 "L" Rod Bumper (1)
8xxx-72* Shock Stand-off Assembly (1)
27005100 Shock Stand-off Bracket (1)
26000100 5/16 Nylon Nut
28005100 10mm Ball Stud (1)
26002700 Weld Nut (1)
8xxx-73* Latch Stand-off Assembly (1)
28001400 3/32" Hex Key (1)
33070100 Metal Rail Snaps (1)
20161 Tarp Snap Tool Kit (w/4 Tarp Snaps)
Specify: Year, Make, Model,
*
Long-bed or Short-bed, Driver or
Passenger side.
Extang Corporation
5400 S. State Road
Ann Arbor, MI 48108
734 677-0444, Fax: 734 677-8409
Register your warranty at:
extang.com
Page 7
L
IFETIME FRAME & 10 YEAR TARP
READ CAREFULLY - KEEP IN A SAFE PLACE
PLEASE ATTACH AND SAVE YOUR SALES R ECEIPT.
CTIVATE YOUR wARRANTY ONLINEAT ExTANg.COm.
A
Maximum Strength Warranty - Lifetime frame & 10 year tarp
warranty covers the following tonneaus:
■ WARRANTY DURATION:
Lifetime Frame – Extang offers a lifetime warranty against defective materials or workmanship on all tonneau rails, aluminum components, clamps,
bows, hardware. 10 Year Tarp – Extang offers a 10 year warranty against defective materials or workmanship on the vinyl covering
■ WARRANTY CONDITIONS:
This warranty is against defective materials or workmanship. The warranty is void if the product has been damaged by accident, unreasonable
use, neglect, improper service/installation/removal, modifications, normal wear and tear or other causes not arising out of defective materials or
workmanship. Consequential and incidental damages are not covered under this warranty.
THE FOLLOWING CONDITIONS WILL ALSO VOID THE WARRANTY:
■ Wind whip damage - Tarps must be secured at all points when vehicle is in motion. An unsecured tarp will flap, resulting in damage to the fabric.
■ Improper cleaning - It is recommended to use the tested and approved Extang Tonno Tonic™ or clean with soap and water only. Do not use vinyl
conditioners (i.e. Armor All
■
Overloading of cargo - Cargo should not touch the tonneau’s tarp at any point. Protrusions in the tarp will stress the fabric. Cargo may shift
®
) because they will shrink the vinyl.
while traveling and cause it to push against the tarp fabric and damage it.
The warranty applies to the original consumer / purchaser. Warranty registration must be on file and/or proof of original purchase (detailed and dated
receipt) required for warranty to be effective. Warranty coverage starts from the date of purchase.
■ PERFORMANCE:
Provided all warranty conditions are met Extang will either repair or replace (at Extang’s option) the product or component. Extang may require
the original item to be returned postage prepaid for final determination. Extang reserves the right to substitute and offer the respective warranty
discount on an entire replacement system or provide other remedies than those listed in this warranty for discontinued products or other reasons.
A return authorization number must be obtained from our customer service department prior to returning any product. Shipping charges will apply
for any repair or replacement. This warranty gives you specific legal rights and you may also have other legal rights which vary from state to state.
.
HELPFUL ACCESSORIES REPLACEMENT PARTS
P R I C E S S U B J E C T T O C H A N G E
Snaps, Corners, Foam List Price
Sliding Rail Snaps (package of 28) $14.25
Sliding Rail Snaps (package of 4) 2.95
Snap Stopper (set of 4) 10.95
Corners (2) 17.55
Tarp Buttons (28) 14.25
Tool to Attach Tarp Buttons to Tarp with Buttons 19.95
Tailgate Ribbed Foam (6”) 10.95
Siderail/Cabrail Foam (30’ roll) 10.95
Extang has found through field experience and laboratory tests that most of the
popular “vinyl conditioners” actually
damage vinyl. After extensive testing, we
have developed Tonno Tonic, a product
that extends vinyl life and will keep your
tonneau looking clean and new.
List Price . . . . . . . . . . . . . .$9.95
(8 oz.)
Monster Bows
One Pair of Monster Bow Ends $10.95
One Monster Bow with plastic ends 19.75
Tuff Clamps
Clamps with Bolts (2) $19.75
Clamps with bolts (6) 37.35
Cab Rail Assembly (Rail, Snaps, Foam, Corners) 35.20
Tail Rail Assembly (Rail, Snaps, Foam, Corners) 35.20
Side Rail assembly (Rail, Snaps, Foam) 29.25
Replacement Tonneau Tarp $99.00
Order today, direct from our customer service department:
1- 80 0-877-2588
5400 S. STATE ROAD, ANN ARBOR, MI 48108
734-677- 0444 or 800-877-2588
VOICE:
FAX: 734-677-8409 EMAIL: [email protected]
WEB SITE:
extang.com
Item No. 0030- 11.13RRE
Print ed in U.S.A .
Page 8
SOMETHING DAMAGED? MISSING PARTS?
CALL US FIRST
WE CAN HELP YOU QUICKLY AND EASILY OVER THE PHONE
800-877-2588
Tonno Model: __________________________________
Purchase Date:_________________________________
Lot Code:______________________________________
Lot code can be found on underside of cover.
Part No.0032-1212RRE Printed in U.S.A.
SELLING TONNEAU
AMERICA’S
Experienced Customer Service staff
CUSTOMER SERVICE HOURS:
8:30 TO 5 EST, MONDAY - FRIDAY
to answer all your tonneau questions
1
#
Loading...