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EGR ROLLTRAC Installation Instructions Manual

Ford f-150 6.5ft bed rhd&lhd - compatible with boxlink 2018 onwards
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INSTALLATION INSTRUCTIONS
Vehicle Model: Ford F-150 6.5Ft Bed RHD&LHD - Compatible with Boxlink®
Year of manufacture:
Part Number: RT040032E
FORD AU P/N: AMNL3J501A34BA
Installation time: 180 minutes
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.
RT0082
ELECTRIC
2018
onwards
Page 1 of 37
*RT0082*
Issue 2: 01/08/24

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Summary of Contents for EGR ROLLTRAC

  • Page 1 Installation time: 180 minutes 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.
  • Page 2 BED PREP ELECTRICAL START SECTION A SECTION B STEP 1-15 STEP 1-14 EGR RollTrac ASSEMBLY EGR RollTrac SECTION C INSTALLATION STEP 1-11 SECTION D STEP 1-5 OPERATIONS CALIBRATION FINAL NOTES SECTION E FINISH RT0082 Page 2 of 37 Issue 2: 01/08/24...
  • Page 3 CANISTER ASM. QTY: 1 FRONT COVER QTY: 1 LHS RAIL QTY: 1 LHS RAIL QTY: 1 LHS MOUNT EXTRUSION QTY: 1 RHS MOUNT EXTRUSION QTY: 1 EGR RollTrac M-Bar Assy Hardware Kit SETUP JIG MISC5622 MISC5512 CLIP3989PC MISC5691 CLAMP PLATE...
  • Page 4 EGR RollTrac FITTING KIT COMPONENTS IN BAGS PANEL CLIP QTY: 1 BLADE FUSE T-PATCH CABLE TIE QTY: 20 MAIN HARNESS CABLE TIE QTY: 2 EGR RollTrac FITTING KIT ADDITIONAL ITEMS INSTALLATION OWNERS INSTRUCTIONS MANUAL RUBBER RUBBER EXTRUSION EXTRUSION QTY: 1...
  • Page 5 SECTION A BED PREPARATION Carefully remove any accessories (Sports Bars, Cabin Guards, etc.) attached to the bed of the vehicle. Thoroughly wash the vehicle and bed and ensure that all dirt and grease is removed. Allow to dry. Clean the top surfaces of the bed and tailgate and allow to dry.
  • Page 6 Ø29mm (11/8”) 95mm (3.74’’) ANTI RUST 95mm (3.74’’) HOLE FOR MAIN HARNESS LHS ONLY ! ATTENTION Ensure that the diameter of the hole does not exceed Ø29mm (11/8”) Larger hole size will lead to water ingress into the bed On the front LHS of the bed, mark the position for the Main Harness grommet and drill with holesaw.
  • Page 7 Ø29mm (11/8”) 130mm (5.1”) ANTI RUST HOLES FOR REAR DRAIN TUBES RHS & LHS 40mm (1.57’’) ATTENTION Ensure that the diameter of the hole does not exceed Ø29mm (11/8”) Larger hole size will lead to water ingress into the bed Mark the position of the rear drain tubes holes in the bed rear panel and drill with holesaw.

  • Page 8: Section View

    Remove Tape TRIM AS REQUIRED Liner 50/50 Isopropyl Alcohol/Water 3M Primer 94 (preferred) or equivalent RHS BED TOP & INSIDE RHS BED FRONT CORNER FILL GAPS AS REQUIRED FILL GAPS AS REQUIRED Clean the front top of the bed using Isopropyl Alcohol/Water mix and apply primer to the top area. Allow to dry. Place the extrusion (19) on front of the vehicle bed, check the length and trim to full width if required.
  • Page 9 LHS MOUNT EXTRUSION ASSEMBLY SPACER SPACER SPACER SPACER SECTION VIEW Check if the plastic spacers are in place, if they have fallen out during transport, please refit. RHS MOUNT EXTRUSION ASSEMBLY LOOSE SECTION VIEW Fit the side brackets (7) to the mount extrusion (6) as shown. Do not torque the screws at this stage. Attention: Fit screws only two rotations into the plates.
  • Page 10 LHS MOUNT EXTRUSION ASSEMBLY LOOSE SECTION VIEW Fit the side brackets (7) to the mount extrusion (5) as shown. Do not torque the screws at this stage. Attention: Fit screws only two rotations into the plates. SECTION VIEW VEHICLE MOUNT CLAMP EXTRUSION PLATE...
  • Page 11 Note: Trucks without factory supplied cargo hooks may need to be threaded/tapped M6xPitch:1.0 Hold the assembly in position and fit screws (12). Do not torque the screws. Fit the setup jigs, to set up the RH mount extrusion first. Adjust the mount extrusion front position to the bed cap and rear position to the top of the tailgate using the setup jigs as a guide.
  • Page 12 TOP VIEW FRONT POSITION TAILGATE POSITION 2.8mm(0.1’’) SETUP JIG SETUP JIG 2.8mm(0.1’’) 10mm(0.4’’) MOUNT EXTRUSION TAILGATE SETUP JIG SETUP JIG Set front/back position of the mount extrusion relative to the tailgate 10mm(0.4’’) gap as shown in top view. Set the vertical position of mounting extrusion by adjusting the extrusion relative to the bedcap (ensuring parts are held level).

  • Page 13: Main Harness

    ELECTRICAL LOOM INSTALLATION SECTION B WHILE ROUTING THE VEHICLE HARNESS AVOID ANY VEHICLE COMPONENTS THAT HEAT UP, SUCH AS EXHAUST AND ENGINE COMPONENTS. DO NOT ATTACH HARNESS TO MOVING PARTS, FUEL LINES, BRAKE LINES, MOVING PARTS AND AVOID PINCH POINTS. ENSURE VEHICLE PARTS ARE AT AMBIENT TEMPERATURE BEFORE PERFORM- ING FITMENT.
  • Page 14 Trim Removal Tool SCUFF PLATE Remove the RHS front scuff plate as shown. Trim Removal Tool TRIM COVER Remove the RHS B-pillar trim cover as shown. RT0082 Page 14 of 37 Issue 2: 01/08/24...
  • Page 15 CLIP PUSH DOWN CONNECTOR Locate the connector on the outside of the B-pillar and disconnect as shown. FRONT FLOOR PLUG Locate the rubber floor plug on the front RHS of the vehicle as shown. Remove the plug and feed the B-connector from the main harness to the inside of the cabin.
  • Page 16 LIFT CARPET FRONT SECURE TO EXISTING VEHICLE HARNESS On the front RHS lift up the carpet and pull in the vehicle harness connector B inside the foot well until the rubber grommet on the harness is secured in the floor hole. Feed the harness towards the rear to the B-pillar as shown. IMPORTANT: FOR 2018-19 VEHICLES (INCLUDING RAPTOR) FEMALE CONNECTOR ON THE T-PATCH (E) NEEDS TO BE MODIFIED TO FIT THE VEHICLE HARNESS CONNECTOR (SEE DETAIL)
  • Page 17 Run the harness connector (B) along the floor and up to the T-Patch and connect to the (G) connector joining T-patch and Rolltrac harness as shown. IMPORTANT: Secure the harness by using cable ties to the original vehicle harness and panel clip cable tie to the body on the B-pillar to keep away from the seat belt retractor.
  • Page 18 F150 GAS ONLY MODEL BATTERY CONNECTION STEPS USE DRAW WIRE TO PULL VEHICLE HARNESS INTO THE ENGINE BAY TUCK THE HARNESS BEHIND THE SHIELDING KEEP CLEAR OF STEERING COLUMN Feed the harness into the engine bay along the RHS fire wall from underneath the vehicle. Use draw wire first by pushing it down from the engine bay behind the fuse box as shown.

  • Page 19: Side Panel

    F150 LIGHTING EV MODEL BATTERY CONNECTION STEPS SIDE PANEL Remove front drivers side panel. All fixings can be released without the use of tools as shown. BATTERY In the trunk, remove the battery cover to gain access to the positive terminal. RT0082 Page 19 of 37 Issue 2: 01/08/24...
  • Page 20 F150 LIGHTING EV MODEL BATTERY CONNECTION STEPS USE DRAW WIRE TO PULL VEHICLE HARNESS INTO THE ENGINE BAY Feed the harness into the trunk along the RHS fire wall from underneath the vehicle. Use draw wire first by pushing it down from the trunk. Attach the harness terminals (D) using tape and pull gently into the trunk. Run the harness along the top towards the battery as shown.
  • Page 21 REAR From underneath the vehicle, route the Vehicle Harness connector A towards the rear of the vehicle, following outside the chassis rail. Use the supplied cable ties and retain the harness every 200mm (8’’) to the chassis rail using holes already present on the chassis rail. REAR From underneath the vehicle, route the Vehicle Harness connector A towards the rear of the vehicle, following outside the chassis rail.
  • Page 22 Run the vehicle harness to the cross beam as shown in detail (1). Use long zip tie to secure it. Follow the cross beam to the other side of the vehicle. Keep the harness on top of the beam and away from the muffler and moving parts.

  • Page 23: Installation Step

    IMPORTANT BULLETIN HAND RAIL ATTACHMENT PARTS: Hand Rail QTY-1 INSTALLATION STEP: Place hand rail onto slat assembly by turning approximately 45 degrees down and inserting it as shown. ° ALIGN ENDS...
  • Page 24 EGR RollTrac ASSEMBLY SECTION C DURING ASSEMBLY PROCEDURE SUPPORT AT CENTER OF CANISTER ONLY, PLACE ON TOP AND BASE CARTON (OR SIMILAR), COVER WITH FOAM BLANKET. TO AVOID SCRATCHING POWDERCOATED SURFACES. DO NOT LOAD ELECTRICAL CONNECTORS OR MOTOR COVER. FIT RHS 4mm(5/32’’)
  • Page 25 CAUTION 90° FIT FIRST ALIGN HOLES FIT SECOND SLIDE INTO POSITION ALIGN HOLES INSERT SCREWS AND TIGHTEN LOOSELY GENTLY WIGGLING THE PART INTO THE FINAL TUCK LOOM TO THE SIDE POSITION MAY HELP Pull hand rail to expose 3 slats. Slide the RHS Rail over slat ends and onto endcap location pins. Align the holes and secure loosely with two screws (15).
  • Page 26 REMOVE TAPE SECURING THE RUBBER CORNER SEAL CAUTION DO NOT DAMAGE ATTENTION: Remove foam tape end from the side rail before fitting into front cover Slide the Front Plate (2) over the canister and into the side rail channels ensuring that the foam side rail tape is pulled out of side rail and the small rubber corner seal on the RHS and LHS of the front plate are not damaged.
  • Page 27 LHS SHOWN CAUTION DO NOT DAMAGE While sliding the front cover ensure the cast connectors are align. 5.5Nm (4ft-lb) 4mm(5/32’’) REAR VIEW INSERT SCREWS AND TORQUE TO 5.5Nm (fft-lb) Using 5 screws (15), secure the Front Plate (2) to the Canister Assembly (1) and torque to 5.5Nm (4ft-lb). Page 26 of 37 RT0082 Issue 2: 01/08/24...
  • Page 28 5.5Nm (4ft-lb) 4mm(5/32’’) SIDE VIEW Carefully flip the assembly over onto a flat protected surface which will not damage the cover or scratch the paint work. Install the 2 screws (15) on each side through the canister and side rail into front cover. Torque all screws in order shown to 5.5Nm (4ft-lb).
  • Page 29 CONNECT PUSH CLICK PULL CONNECT PUSH CLICK PULL SECURE ALL CABLES TO PREVENT PINCHING Connect side rail harness connectors to the connectors on the canister on the LHS and RHS. Connect the lamp connector as shown next to the motor on the RHS. Secure the harness to the canister using cable ties and pads as shown.
  • Page 30 Setting Brace comes pre-assembled. Fit the T-Nuts with washers and wing screws as shown to both ends of the Setting Brace. Place the Setting Brace over the rear of the Rolltrac and slide the T-Nuts into the slots as shown. Once in position, slide the brace backwards till the plastic part of the brace comes to contact with the edge of the rear End Cap.
  • Page 31 SECTION D EGR RollTrac INSTALLATION FRONT SEAL HEAVY CONNECT PUSH CLICK PULL PULL THE CONNECTORS NOT THE CABLE Spray the top surface of the bed liberally with a soapy water solution to enable the Cover to slide easily. Using two people to lift the cover from both sides and carefully lower it onto the bed.
  • Page 32 FIT FIRST Secure the rear of the Rolltrac side rail to the mount extrusion with one screws (17) on each side as shown. Secure the side rail with 7 screws (16) on each side. Work from RHS to LHS to avoid one side lifting up.

  • Page 33: Rear View

    PERFORM FITMENT CHECK Perform width check (using canister end as reference) and diagonal fitment check (mounting bolts may need loosening for adjustment). Open and close the cover by hand, checking for smooth operation and consistent 1.5-2.0mm(0.05-0.07”) side to side free-play of slat assembly within side rails. If there are any tight spots, then check side rail position and re-adjust side rail width as required.
  • Page 34 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 4mm INSPECTION COVER...

  • Page 35: Calibration Procedure

    WARNING: Keep obstructions clear of cover during calibration mode. 5 SECONDS PULL • Cover will CLOSE and OPEN once automatically. • The EGR RollTrac internal LED light will pulse slowly during calibration and stop pulsing when calibration is complete. 2 SECOND PULSE START OF CALIBRATION...
  • Page 36 NOTE: EGR RollTrac should open and close smoothly. If cover does not lock or open correctly, please refer to the trouble shooting section in the Owners Manual. If the EGR RollTrac closing is slow, clean the siderails and ensure that no dirt or debris is inside the drive rail.
  • Page 37 UTILITY HOOKS REFIT (OPTIONAL) RHS MOUNT EXTRUSION ASSEMBLY 7.5Nm (5.5ft-lb) OPTIONAL: Remove the screws holding the side brackets (7). Fit the utility hook brackets (if provided - removed in step 1) and fit over the support brackets using same screws. Torque to 7.5Nm (5.5lb-ft). RT0082 Issue 2: 01/08/24 Page 36 of 37...

  • Page 38: Key Fob Operation

    If pause is activated by the fob whilst auto closing, the RollTrac can be closed and paused using the • RollTrac close button. Reactivate both Rolltrac buttons by unlocking the vehicle. If the RollTrac is open and the lock button is only pressed once, the vehicle and the RollTrac will lock. • RT0082...

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Rt040032e