LUGGAGE CARRIER INSTRUCTION SHEET
EXPLORER
A90095 • A90096 • A90098
ASSEMBLY COMPONENTS
A
03347 • 2x 01315 • 1x 03807 • 2x 03808 • 2x 00841 • 2x 03810 • 2x 03396 • 2x
02943 04877 03918 • 4x 00017 00115 04103 01010 00764 00070 03948 03668
H I J K L M N O P Q R
4x 8x 4x 12x 8x 4x 4x 8x 4x 4x 1x
B C D E F G
TOOLS REQUIRED
S
10171
EXPLORER
A90095 • A90096 • A90098
PARTS LIST
Part Description Part Number Qty.
Hardshell Top
–
Hardshell Bottom
–
Master Parts Bag
–
Part Description
Snap
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
Latch
Foam Gasket
Camlock with Keys
Lock Locator
Bottom Lock Bracket
Support Assembly
Hinge
U-Bolt
Threaded Knobs
U-Bolt Plate
1/4” Flat Washer
1/4”-20 Plastic Insert Nut
1/4”-20 x 5/8” Screw
10-24 x 5/8” Screw
10-24 Plastic Insert Nut
Large Flat Washer
1/4”-20 Universal Drive Screw •
Small Flat Washer
Vinyl Hole Covers
––––––
––––––
05305
1
1
1
MASTER PARTS BAG
Part Number
03347
01315
03807
03808
00841
03810
03396
02943
04877
03918
00017
00115
04103
01010
00764
00070
03948
03668
10171
Qty.
2
1
2
2
2
2
2
4
8
4
4
12
8
4
4
8
4
4
1
CARGO BOX ASSEMBLY
EXPLORER
A90095 • A90096 • A90098
1
Attach foam
DO NOT CUT! Roll out in one piece and trim excess.
weather stripping (B) to inside of Carrier top.
TOP ASSEMBLY
2
Install lock assemblies (C).
NOTE: The locks must be in the “locked” position for assembly to the carrier top and for
Remove key to prevent movement of lock hook. Lock locator (D) tabs should be pointing toward the inside of the carrier.
assembly of the lock locators.
CUTAWAY OF HARDSHELL TOP
INSTALLED IN LOCKED POSITION
C
BOTTOM ASSEMBLY
3
Attach hinges (G) to carrier bottom with medium screws (M), medium washers (K) and large plastic insert nuts (L). DO NOT fully tighten at this time.
NOTE: Plastic insert nuts are meant to hold very securely. Screws cannot be tightened by hand but must be driven
through with a screwdriver and pliers or adjustable wrench.
D
TABS
EXPLORER
A90095 • A90096 • A90098
ASSEMBLING TOP TO BOTTOM
4
someone holds the top, align the slot in the hinges (G) on the Carrier bottom
While
with the Carrier top and attach medium screws (M), medium flat washers (K)
and large plastic insert nuts (L). DO NOT FULLY TIGHTEN AT THIS TIME.
5
While
someone holds the top in an open position, attach the suppor
with the 2 large screws (Q), 4 large flat washers (P) and 2 large plastic insert nuts (L).
Tighten screws until snug, (overtightening could cause binding).
Note: White plastic protectors in the center of the support assemblies
must be facing inwards.
t assemblies (F)
6
Attach front
flat washers (R) and small plastic insert nuts (O).
and back snap latches (A) to bottom with 4 small screws (N), small
7
Attach lock brackets (E) to Carrier bottom on passenger side with
medium screws (M) and large plastic insert nuts (L).
Use lower slots in lock
brackets. DO NOT FULLY TIGHTEN.
8
EXPLORER
A90095 • A90096 • A90098
Check for correct alignment of lock assembly by closing and locking the carrier
properly engages the bottom lock bracket, open the Carrier and tighten the hinge (G) hardware and
the lock bracket (E) hardware. If the lock does not align with the lock bracket and does not lock
properly, adjust the hinge and lock bracket hardware until they lock. Tighten hardware.
. If
the lock
9
To close Carrier, make sure the locks are in the open (horizontal) position with the key removed and pull Carrier top downward from both ends.
10
o lock Carrier, insert key, pull down
T
of snap latches down until they engage. FOR SAFETY, THE CARRIER LOCKS (C) MUST PROPERLY ENGAGE THE BOTTOM LOCK BRACKET (E) AND THE FRONT
AND REAR SNAP LATCHES MUST BE ENGAGED WHENEVER THE VEHICLE IS IN MOTION.
NOTE: Some deformation of the plastic top may occur in shipping. It may be necessary to reshape the hardshell bottom by pressing in on the top flange
against the bottom flange all around the Carrier and locking the Carrier. Within 48 hours the top and bottom will reshape and fit together more readily.
The Carrier may be used during this reshaping period.
on flange and turn key to the locked position (vertical). Place snap latches into top flange depressions and push front
OPEN LOCKED
CAUTION
Check that latches are engaging brackets. Top should not lift up when pulled.
All locking devices must be engaged (and keys removed) whenever the vehicle is
in motion.
11
EXPLORER
A90095 • A90096 • A90098
U-BOLT MOUNTING
I
J
E
H
When carrier is assembled, place on the cr
holes and U-bolt plates (J). Secure with threaded knobs (I). Recheck to see that your crossrails are securely locked into position.
For safety the hooks in the carrier locks must properly engage the lock brackets (E) whenever the vehicle is in motion.
ossrails, place U-Bolts (H) under cr
ossrails and
assemble U-bolts through Carrier bottom mounting
12
Periodically check all mounting hardware for tightness.
13
To help prevent water from entering your Carrier vinyl covers (8) are included
for any unused holes.
14
Cleaning: Clean with mild soap and water.
Storage: To prevent warping when storing, close and latch. Do not store items on top of
carrier.
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