TracRac TracTonnuea User Manual
P/N 1116240 Rev A
10/4/05, 200
Web Site : http://www.tracrac.com
Customer Service: 1-800-501-1587
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Phone: 1-508-677-4130 Fax: (508) 677-4136
994 Jefferson Street, Fall River, MA 02721
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T racRac, Inc. Limited W ARRANTY:
Thanks for purchasing a TracRac, Inc. product. We proudly make our products in the USA — and we stand behind them. We thoroughly inspect every
product before shipment, and warrant them to the original purchaser to be free from defects in materials and workmanship for a period of 24 months
from the date of purchase.
In the unlikely event that trouble develops during the warranty period, please: Contact TracRac for a return authorization number and instructions
If our inspection shows defective materials or workmanship, we will repair or replace the product (at our discretion) at no charge. We will return the
product to you at our expense.
Proof of purchase is required.
Certain restrictions apply:
This warranty does not apply to normal wear and tear.
Any damage caused by careless, unsafe, excessive use, improper handling, improper installation or alteration are not covered. Overloading beyond
rated capacity, accidents, or repairs attempted by anyone other than TracRac personnel or our Authorized Dealers are not covered.
This warranty applies in lieu of any other warranties, expressed or implied (including implied warranties of merchantability and fitness for a particular
purpose). Variations of its terms are not authorized.
The foregoing obligation is TracRac’s sole liability under this or any other implied warranty, and under no circumstances shall TracRac be liable for
any special, indirect, incidental or consequential damage, whether arising out of breach of warranty, breach of contract or otherwise.
Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitations of incidental or consequential damages, so the above
limitation or exclusion may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from state to state.
Purchased from:
Model (SKU) #:
Date of purchase:
This warranty is valid only in the United States of America
To activate your warranty — and to take advantage of our special promotions, new product releases, & product upgrades — please complete the
attached Customer Satisfaction Survey and submit it immediately to TracRac Inc.
Remember: Your Warranty is not in effect unless we receive your completed card within 10 days from your date of purchase. Thanks!
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TOOLS REQUIRED:
1. 9/16” Ratchet or Wrench
2. Large Flat Screwdriver
3. 1/8” Allen Wrench
*__ _ TracT onneau Replacement Cover
1 ___
2 ___*__ _ Black Header
*_ __ Header Seal, Notched
3 ___
4 11 15372 Header End Plugs (Set of Two)
5 1702602 Square Nut, 3/8"
6 11 15354 Header Insert Safety Clip
*__ _ Safety Strap
7 ___
8 11 14872 Header Guide
9 1703000 Cap Screw, 3/8" x 1 1/2"
10 11 15353 Header Safety Strap
11 1703344 Blind Rivet, 1/8" x 3/16"
12 1701595 End Plug, 1" OD
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TracTonneau_IM-F1-A01
TRACRAC REPLACEMENT PARTS
13 ___*___ Black Bow
14 1702992 Spring Plunger, 5/8" x 1.94"
15 1703260 Tension Control Bracket
16 1703345 Spring Pin, 1/8" x 5/16"
*_ _ _ Shur-Bond™ VELCRO® Fasteners
17 ___
18 1703332 Hitch Pin, 1/16" x 1 5/16"
19 1703643 Set Screw, 1/4” x 3/8”
*_ __ Side Rail, Passenger’s Side
20 ___
*_ _ _ Side Rail, Driver’s Side
21 ___
22 11 14773 Flat Spring, 5/8" x 3 7/8"
23 1703650 Latch Main Frame
24 1702610 Clevis Pin, 3/16" x 1 1/4"
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25 1703639 Toggle
26 1700419 Nylon Lock Nut, 5/16"
27 1703265 Toggle Cap
28 1702611 Cotter Pin, 3/64" x 19/32"
29 1702926 Cap Screw, 5/16" x 7/8"
30 1702801 Header Stop
31 1703301 Side Rail End Plug, Left
32 11 16263 Side Rail End Seal, 3”
33 1703300 Side Rail End Plug, Right
34 11 16265 Side Rail Cab Seal, 4 1/2”
35 11 16264 Side Rail Top Gap Seal, 2 5/8”
* Please specify length or make and model of vehicle.
SIDE RAIL & COVER INSTALLATION
bracket
spring
plunger
top gap seal
set
screw
end
plug
rubber
seal
STEP 1: Open tailgate and slide the side rails onto the inside
track of the TracRac rails.
tracrac rail
tractonneau
side rail
TENSION
CONTROL
driver’s
side rail
cover
assembly
passenger’s
side rail
safety
straps
cap screw,
3/8” x 1 1/2”
square nut, 3/8”
FRONT OF
TRUCK BOX
STEP 4: Install header guides
into front header with
3/8” x 1 1/2” cap
screws and 3/8”
square nuts as shown.
Nuts have been
pre-installed into
slot in header guide.
Finger tighten.
header
guide
bottombottom
bottom
bottombottom
viewview
view
viewview
cap screw,
3/8” x 1 1/2”
header guide
square
nut, 3/8”
LATCHING & UNLATCHING COVER
STEP 7: Unroll cover toward tailgate and rest bows on side
rails. Rotate header into header stops and press
down to lock toggle into header.
header
header seal
toggle
NOTE: If tailgate has a
header stop
cover
key lock, cover is secured until tailgate is
unlocked and opened.
header
seal
inside
tailgate
NOTE: In cold weather conditions or with some accessories, it may be
lock toggle into header
preferable to close the cover before closing the tailgate. Header seal
may be placed across top of tailgate if preferred.
COVER TENSION ADJUSTMENT
EVER-TITE™
AUTOMATIC
TENSION
CONTROL
front header
side rail
STEP 8: Secure Shur-Bond™ fasteners on one side rail,
by pressing along full length of rail. Pull cover
tight across pickup bed, and secure Shur-Bond™
fasteners on opposite side rail.
pull cover over rails
NOTE: Secure Shur -
Bond™ VELCRO
®
press edges
brand fasteners along
entire length of both
side rails before driving vehicle, to prevent
wind lift.
STEP 9: To release cover, pull back on toggle. Roll cover
toward cab to open. For best results, leave cover
fastened to side rails while opening.
STEP 10: Secure cover open by
hooking safety straps to
safety
straps
Spring plunger compensates for material expan-
•
sion and contraction caused by temperature
front loops.
cover secured open
changes.
open tailgate
end viewend view
end view
end viewend view
STEP 2: Locate cab seal between side rails and front of pickup
box. Peel backing and adhere cab seal to box.
front of
pickup box
cab seal
side rail
STEP 3: Press side rails
into cab seal,
compressing seal
1/4”. Install set
cab
seal
screws into clinch
nuts on side rails
1/4”
and tighten.
clinch nut
set screw
front header
STEP 5: Set cover assembly behind cab with header seal
on top of rail.
cover
side
rail
FRONT OF
TRUCK BOX
header
seal on top
of rail
side
rail
inside box rail
STEP 6: Slide header guides into side rail flanges on each
side of header. Tighten cap screws securely.
cover assembly
header guide
cap screw
side rail flange
spring plunger
Check cover tension after installation, seasonally ,
•
and after extreme temperature changes.
For best performance, adjust tension regularly
•
to protect your cover against wind wear.
STEP 11: Set tension during warmest part of day. With cover closed, release VELCRO® brand loop from both side rails near
cab. Check compression of both spring plungers against the front header per diagram. Roll cover open and make
adjustments. Close cover and recheck adjustment. Repeat until satisfactory tension has been achieved.
spring plunger
HERE HERE
adjust
HERE with
HERE HERE
flat screwdriver
NOTE: Adjust tension in small increments.
front header
COVER TOO LOOSE
ROTATE CLOCKWISE
CORRECT TENSION
DURING WARMEST
PART OF DAY
no less than 1/16”
Slight adjustments will gain significant results.
TROUBLE SHOOTING
Questions?
Call our friendly customer service staff
at TracRac T oll Free:
1-800-501-1587
HEADER WILL NOT LATCH:
Make sure the header seal is not caught between side rail and header.
FABRIC COVER IS TOO TIGHT OR TOO LOOSE: See Step 11 to adjust tension.
* VELCRO® is a registered trademark of the Velcro companies.
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