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Summary of Contents for Expedition One MULE-UR-TT22-CUTOUT
- Page 1 INSTALLATION GUIDE Toyota Tundra Mule Ultra Rack...
- Page 2 5 STARS EXPERT - Professional installation recommended. DISCLAIMER Expedition One is not responsible for any damages to vehicle or injury. We always recommend professional assistance when installing our vehicle products. Always follow safety procautions including the use safety gear and devices.
- Page 4 HARDWARE HARDWARE ITEM - Mounting Brackets - Mule Ultra Truck Hardware Kit 1/4”-20 X 1/2” Button Head Bolts 1/4”-20 X 3/4” Button Head Bolts 1/4”-20 Nylock Nuts 5/16”-18 X 3/4” Hex Cap Bolts 5/16”-18 X 3/4” Button Head Bolts 5/16”-18 X 2 1/2” Button Head Bolts 5/16”-18 Nylock Nut 5/16”...
- Page 5 RACK ASSEMBLY ATTENTION When assembling the Mule Ultra Rack, remember to hand-tighten all bolts relatively loose until the very end of the install. This allows everything to fit into place before everything is tightened down. OEM ROOF RACK REMOVAL Remove the OEM roof rack from the vehicle by undoing the hardware located at each mount. FRONT AND SIDE BRACES MOUNTING Lay out the front and side braces as shown.
- Page 6 REAR BRACE AND SIDE FASCIA MOUNTING Attach the rear brace using the provided 1/4” hardware. Mount the side fascis with 5/16” hardware on both sides as shown below.
- Page 7 SIDE FASCIA CONTINUED REAR FASCIA MOUNTING Attach rear fascia as shown with 5/16” bolts and nuts.
- Page 8 FRONT FASCIA MOUNTING Attach the front fascia using 1/4” bolts. Use the provided round spacers to adjust the front fascia to match the curve of the roof when test fitting the roof rack during mounting. NOTE: IF YOU HAVE A FASCIA WITH A LIGHT BAR CUTOUT, WE RECOMMEND INSTALLING THE LIGHT BAR PRIOR TO MOUNTING THE ROOF RACK.
- Page 9 SEAM JOINERS Mount both front and rear seam joiners with 5/16” hardware as shown top and bottom.
- Page 10 REINFORCEMENT SPACERS Attach reinforcement spacers as shown on all 6 hole locations (3 each side) with the provided hardware.
- Page 11 LOAD BAR ASSEMBLY Assemble the load bars with the provided mounts using 1/4” bolts and nuts. Repeat for all load bars. LOAD BAR INSTALLATION Flip roof rack over and attach load bars as shown. Using provided nuts and bolts, you may begin tightening down each load bar with two bolts and nylocs for each side.
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Page 12: Mounting Area
ROOF RACK MOUNTS MOUNTING AREA Start by removing the roof trim on each side as shown. Towards the back of the trim ,you’ll need to re- move it from the separate trim piece that runs along the back end of the vehicle MOUNTING BRACKET LOCATIONS REFERENCE DIAGRAM SAFE ZONE... - Page 13 MOUNTING BRACKET LOCATIONS - CONTINUED With the trim removed, start marking the mount locations by placing the tape measure at the end of the trim piece at the rear of the cab (circled below). From this point measure forward to the speficied dimensions below for placing the mounting brackets.
- Page 14 MOUNTING BRACKET LOCATIONS - CONTINUED FRONT MOUNTS - ( F marking ) Measurements for the front mounts are as follows 42” & 48” This the safe zone for drilling. Drilling outside of this area with cause damage. Mark these locations for reference. (see bottom tape marks). 42”...
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Page 15: Mounting Holes
DRILLING HOLE LOCATIONS MOUNTING HOLES With the hole locations marked, drill each hole to roughly 3/8” in size. Next, add some caulk sealant to riv nut as shown. (this will help seal the nut into the roof from the elements).with two wrenches, begin twisting your riv nut down into the roof until you feel it ‘sit’... - Page 16 REPLACING ROOF TRIM Once all bracket are secure, place the rubber trim strims back into position. You will need to mark off the areas around the mount brackets with a sharpie. With a box cutter or sharp blade, slice down- wards as shown below half way down and then cut horizontally.
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