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Vehicle Model & Year: FORD RANGER/RAPTOR MY22+
PART NUMBER : RT040552ML
LOWER TUB
REINFORCEMENT KIT
Installation time: 120 minutes (without tubliner)
Caution
• Do not attach EGR RollTrac in a location or by a method not specified.
• Do not use this product for any vehicle make or model, other than those specified in this document.
• Do not remove the plaque or label from this product.
• Do not modify the structure of the EGR RollTrac in any way.
General Notes
• Read through the fitting instructions before installation of EGR RollTrac.
• Always install the accessory following the fitting instructions. Failure to do so may cause damage to the vehicle or the accessory.
• Ensure all recyclable discarded vehicle accessory components and packaging are recycled following local recycling regulations.
• It is always recommended that this accessory is fitted by a qualified Technician.
• Safely store and protect any removed vehicle components.
• Ensure all bare metal surfaces are protected using Automotive Bare Metal Primer and touch-up paint.
• Remove all metal swarf and dust from all vehicle surfaces if surface is used for accessory installation.
Safety Notes
• Check that all work practices comply with safety standards.
• Please wear appropriate clothing and use safety equipment.
ISSUE 1: 2/08/24
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EGR Document ID#123700 v4
INSTALLATION INSTRUCTIONS
IF THE EGR ROLLTRAC IS FITTED TO THE VEHICLE WITH ANY ACCESSORY
LOADED WITH MORE THAN 45KG, A LOWER TUB REINFORCEMENT KIT MUST
BE FITTED. THE LOWER TUB REINFORCEMENT KIT CAN BE PURCHASED FROM
YOUR LOCAL DEALER OR DIRECTLY FROM EGR (PART NUMBER : RA039842).
2024-11-16 09:38:14
MANUAL
IMPORTANT:
Page 1 of 25
chaumont --
RT0402
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Summary of Contents for EGR Rolltrac RT040552ML
- Page 1 Installation time: 120 minutes (without tubliner) Caution • Do not attach EGR RollTrac in a location or by a method not specified. • Do not use this product for any vehicle make or model, other than those specified in this document.
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Page 2: Installation Process
STEP 1-12 EGR ROLLTRAC EGR ROLLTRAC ASSEMBLY INSTALLATION SECTION B SECTION C STEP 1-9 STEP 1-7 LOCKING, LUBRICATION OPENING & FINISH GUIDE CLOSING GUIDE UNPACKING ISSUE 1: 2/08/24 Page 2 of 25 RT0402 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --... - Page 3 LHS RAIL QTY: 1 RHS RAIL QTY: 1 MNT BAR MNT BAR TGAT0032-RH TGAT0032-LH QTY: 1 QTY: 1 EGR EGR ROLLTRAC CLAMP KIT IN BAG H-BAR CRN BRK REAR SUPP BRK FR MNT BRK FR MNT BRK MNT BRK CLIP4106 CLIP4110-LH...
- Page 4 EGR EGR ROLLTRAC MBAR HARDWARE KIT IN BAG M8x25 BUTTON HEAD SCREW END PAD M6x20 HEX HEAD M6x50 HEX HEAD M6x15 HEX DRIVE HEX DRIVE MISC5812 SCRW0997 SCRW0967 SCRW0974 SCRW0973 QTY: 8 QTY: 10 QTY: 8 QTY: 14 QTY: 6...
- Page 5 Place the Front Reinforcement Bracket (34) underneath the tub liner (if applicable) and secure with 3x screws (36) and washers (37). Torque to 20Nm. Repeat for the LHS. ISSUE 1: 2/08/24 Page 5 of 25 RT0402 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --...
- Page 6 Using hole saw drill 60mm hole in the tubliner only, With a 38mm hole saw, drill hole in the tub following the pilot hole use 10mm stop. Deburr both holes and apply rust inhibitor to the metal. Repeat for LHS. ISSUE 1: 2/08/24 Page 6 of 25 RT0402 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --...
- Page 7 Centre punch the locations and drill 5.5mm pilot hole through the tub. Using hole saw drill 29mm hole in the tub. Use 10mm stop. Repeat for LHS. ISSUE 1: 2/08/24 Page 7 of 25 RT0402 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --...
- Page 8 Fit the rear drain tubes from the inside of the tail lamp cavity up through the drilled hole. Spray tubes with soapy water to help with fitment. Repeat for LHS. CONTINUE ON NEXT PAGE RT0402 ISSUE 1: 2/08/24 Page 8 of 25 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --...
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Page 9: Section View
LHS. Apply the front rail seal (17) along the top of the h-bar as shown and ensure ends touch the endcap. Apply Silicone in the gap between the rail seal, bracket and tub rail as shown. NOTE: Seal all holes in the tub as required. ISSUE 1: 2/08/24 RT0402 Page 9 of 25 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --... - Page 10 Fit the 4 screws (19) into the RHS mounting rail (6) and fit the end pads as shown. Set the screws height as shown in detail. Repeat for the LHS mounting rail. NOTE: Screws will be adjusted in later stage once fitted to the tub. ISSUE 1: 2/08/24 Page 10 of 25 RT0402 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --...
- Page 11 NOTE: Level the bar by pushing it up till it contacts the tub (see section view). Turn the screw (19) up until the cap (18) contacts the inner tub sheet metal (see section view). Do not overtighten. ISSUE 1: 2/08/24 Page 11 of 25 RT0402 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --...
- Page 12 Connect the front drain tubes (8) to the tub. Make sure that both tubes engage over the wall of the tub. Leakage will occur if they are not properly installed. RT0402 ISSUE 1: 2/08/24 Page 12 of 25 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --...
- Page 13 IMPORTANT: Carefully align and slide the rail over the handrail and canister endplate taking particular care to ensure that the siderails are slid straight and no undue force is applied to the rail. Details in following steps. ISSUE 1: 2/08/24 RT0402 Page 13 of 25 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --...
- Page 14 CHECK SEAL IS IN POSITION AND NOT DAMAGED Carefully lay the assembly over onto a protected surface. Remove the tape holding the rubber seal and check the seal position as shown. Page 14 of 25 ISSUE 1: 2/08/24 RT0402 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --...
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Page 15: Side View
Spray the ENTIRE Side Rail and Seal with soapy water. Slide the side rail seal (16) into the side rail from the front rearwards and trim as illustrated. NOTE: Trim seal backing to aid assembly, see detail. Page 15 of 25 ISSUE 1: 2/08/24 RT0402 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --... - Page 16 Using one screw removed in Step 4, secure the Front Cover (2) to the Canister Assembly (1) as shown and torque to 5.5 Nm. ISSUE 1: 2/08/24 Page 16 of 25 RT0402 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --...
- Page 17 Fit the RHS water duct (30) over the bottom of the RHS endcap and secure with 3 screws (26) as shown. Important: Hand torque screws (26) until fully seated (contact water duct surface). Repeat for LHS. ISSUE 1: 2/08/24 Page 17 of 25 RT0402 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --...
- Page 18 NOTE: Brace is equipped with locators at the bottom and those must be fitted into the side rails. Tighten the wing bolt (finger tight only). Page 18 of 25 ISSUE 1: 2/08/24 RT0402 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --...
- Page 19 Note: The front mounting brackets (7&8) must engage with the header bar corner bracket (9) as shown in detail. Join the two rear brackets (12&14) using the nut plate (15) and two screws (22). Do not torque at this stage. Page 19 of 25 RT0402 ISSUE 1: 2/08/24 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --...
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Page 20: Height Adjustment
Place the setup jig (27) on top of the tailgate as shown and move the Rolltrac up or down till the endcap touches the jig (27), (target offset is 34mm). RT0402 ISSUE 1: 2/08/24 Page 20 of 25 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --... -
Page 21: Side Rail
Align taped plates (inside the M-BAR) with holes in brackets using a scribe or small screwdriver. Install and torque all screws to the specified settings in the order shown. Repeat for LHS. RT0402 ISSUE 1: 2/08/24 Page 21 of 25 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --... - Page 22 1.5-2.0mm side to side free-play of slat assembly within side rails. If there are any tight spots, then re-adjust side rail width as described in previous steps. Remove the setup brace. Page 22 of 25 RT0402 ISSUE 1: 2/08/24 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --...
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Page 23: Cable Tie
Repeat for LHS. Connect the front drain tubes to the canister. Use soapy water solution to help rubber slide over the fitting. ISSUE 1: 2/08/24 RT0402 Page 23 of 25 EGR Document ID#123700 v4 2024-11-16 09:38:14 chaumont --... - Page 24 SILICONE SPRAY Close the inspection covers and secure with retained screws. Open and close the EGR Rolltrac to distribute lubricant and check operation. Allen Key 2.5mm INSPECTION COVER...
- Page 25 2. Open the rubber cap covering the lock and using the provided key turn LEFT (CCW) to lock and RIGHT (CW) to unlock the hand rail. 3. Check latch engagement by opening the tailgate, if lock does not engage recheck EGR RollTrac installation. Ensure the lock cap is pushed down to seal the lock.
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