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IMPORTANT!
By carefully following these written
instructions, installation of this kit should
be quick and easy. However, because
proper installation is greatly dependent
on the skill exercised in removing the rivets
from the door frame(s), THULE strongly
recommends installation by a qualified
professional. No warrant is given for
defects or vehicle damage resulting from
failure or inability to mount the load carrier
in accordance with written THULE
instructions.
For certain accessories such as a Combi
Box it is necessary to remove the factory
FORD Explorer 4-dr, 91–
x4
1
x4
2
18
90
3
x4
FORD Explorer 2-dr, 91–
MAZDA Navajo, 91–
x4
1
x4
18
2
90
x4
3
Thule System Kit 136
rack load bars (if applicable). Use a Torx-
20 screwdriver to remove the load bar.
Tools required: Electric drill, metal drill
bit 3/16" or 5 mm, pliers.
1/ Identify rivets to be removed in rubber
gasket. Plastic plugs must be removed
from the Explorer two door and Navajo.
2/ Place 3/16" or 5 mm drill bit into center
of rivet and very slowly and carefully drill
out the rivet. Always use protective
eyewear when using power tools. Only
drill in far enough to remove the rivet—do
not drill all the way into the rivet hole in
the roof.
800 mm/31,5 "
Rivet
Rive
Roof
Rive
Weather strip
Inne
r
wall
536•3DFK
CAUTION: Use very light pressure when
drilling the rivet. The material is very soft
and quite easily penetrated. Excessive
force will cause the drill bit to rapidly cut
through the rivet and strike the inside wall,
possibly breaking the bit. Use a pair of
pliers to remove the plastic plug from the
E x p l o re r t w o d o o r a n d N a v a j o .
3/ Place attachment clips behind rubber
gasket. Make sure to line up the hole in
the clips with the hole in the gasket and
roof. Using a screwdriver, secure
attachement clips tightly with screws
provided in kit.
6,5 Kg
1070 mm / 42
6,5 Kg
1070 mm / 42
/ 501-0136-04
Note: When threading the self-tapping
sheet metal screws into the door frames
it is recommended that a sealant (caulking
compound, silicone, pipe joint compound,
etc.) is applied to the threads to prevent
water from migrating through the threads.
The self-tapping screws and attachment
clips are designed to be permanently
installed on the vehicle. Do not remove
the screw after installation. Each time a
screw is removed and reinstalled, the
holding power of the fastener is reduced.
You can remove the load carrier and upper
mounting bracket with no effect on the
security of the system.
M A X
LOAD
60 Kg
mm/inch
Front
Rear
1
/
inch 1080 mm / 42
4
M A X
LOAD
75 Kg
4,5 Kg
mm/inch
Front
Rear
1
/
inch 1080 mm / 42
4
1
/
inch
2
1
/
inch
2
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