WEATHER GUARD 96142-3-01 User Manual
Bulkhead
Model Number 96141-3-01 and 96142-3-01
• Installing your ProMaster bulkhead is very clear cut following these instructions.
• Before cutting or drilling in the floor, verify the location of you gas tank, fuel lines and electrical cables
so you don’t accidentally cut something important.
• When mounting to the floor, make sure that the blind fasteners go into the sheet-metal floor and not the
composite floor. A hole saw will give you a nice, clean edge. Always wear eye protection when drilling
or cutting.
• When mounting to the B-pillar, you’ll need to cut through the plastic trim. A hole saw will give you a
nice, clean edge. Use the ½” spacers to ensure a solid mount to the van.
• Your ProMaster van bulkhead can be up-graded with a swing-door conversion kit, 96901-3-01. If you
think you might want to change to it in the future, put an extra nut between the driver's side panel and
the center panel to allow enough space.
• Electric Drill
• Electric Drill-driver or impact wrench
• Pencil or Marker
• Hammer
• Center Punch
• 1" Hole Saw
• Hack saw blade or sharp knife
• 7/16” and 1/2” Driver Bits and/or
Sockets
• Drill Bits: 1/8", 3/8", 1/2”, 13/32”
• Ratchet Drive for your sockets
• Level
• Carpenter’s Square
• Open End Wrenches: 7/16", 1/2",
9/16"
DESCRIPTION QTY
1/4-20 BLIND FASTENER 6
1/4-20 X5/8” HEX HEAD BOLT 15
1/4-20 NYLON LOCK NUT 24
5/16" FLAT WASHER 8
5/16-18 X2” HEX HEAD BOLT 4
¼” FLAT WASHER 44
5/16-18 BLIND FASTENER 4
5/16“ LOCK WASHER 4
5/16” FENDER WASHER 4
3/8” FLOOR MOUNTING SPACER 8
1/2” FLOOR MOUNTING SPACER 6
1/4-20x5/8 CARRIAGE BOLT 8
BLIND FASTENER INSTALL TOOL 1
1/4-20 x 2-1/4" HEX HEAD BOLT 1
5/16-18 x 2-1/4 HEX HEAD BOLT 1
1/4-20 x 1-1/4 HEX WSHR HD BOLT 6
SCREW, 1/4-14x3/4 DRILL 4
NUT, LOCK 5/16-18 NYLON 4
1
Part No. 24-0315 Rev 1 09/13
B
E
E
B
C
C
A
A
D
D
ASSEMBLY INSTRUCTIONS
STEP 1. Assemble the Door Pockets to either the
driver's side or cargo side of the Center Panel using
eight (8) 1/4-20 x 5/8" Carriage Bolts, 1/4-20 Nylon
Lock Nuts and 1/4" Flat Washers.
D
Bulkhead model 96141-3-01 has two
clear polycarbonate windows mounted
to panels A and C.
Bulkhead model 96142-3-01 has two
diamond mesh screens mounted to
panels A and C.
Available accessories:
Solid panel kit 96902-3-01
Hinge kit 96901-3-01
2
ASSEMBLY INSTRUCTIONS
STEP 2. Attach Driver Side Panel to Center
Panel with both panels flush to the bottom using
six (6) ¼-20 x 5/8" hex head bolts, ¼” flat
washers, and ¼-20 lock nuts.
STEP 3. Attach Passenger Side Panel
to Center Panel with both panels flush to
the bottom using five (5) ¼-20 x 5/8" hex
head bolts, ¼” flat washers, and ¼-20
lock nuts.
DO NOT FULLY TIGHTEN
FASTENERS AT THIS TIME, PARTS
MUST STILL MOVE IN SLOTS.
NOTE: Not all mounting holes will be
used on either of the vertical sides
of the Center Panel. Extra mounting
holes are for the swing door option
available for this Bulkhead.
3
Part No. 24-0315 Rev 1 09/13
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