BAK bakFlip Manual

OVERVIEW

1. Hard Folding Cover
2. RH, passenger side rail
3. LH, driver side rail
4. Prop rod
5. Prop rod clip
6. Buckles
7. Buckle mounting inserts
8. Buckle mounting screws
9. Bulkhead seal
10. Drain hoses
11. Cover mounting elevator bolts
12. Cover mounting rubber washers
13. Cover mounting washers
14. Cover mounting lock washers
15. Cover mounting knob

1. 16. Well nuts
   17. Washers, oversize #10
   18. Screws, buttonhead
   19. Screw and washers, truss head
2. 20. Well nuts
   21. Washers, flat
   22. Washers, oversize #10
   23. Screws, buttonhead
   24. Jack nuts
   25. Washers, flat
   26. Bolts 1/4-20
   27. Allen wrench
   28. Washers, retainer
   29. Spacers
   30. Screw & washers, M6
   31. Cab bumpers
   32. Jack nut installer wrench

TOOLS RECOMMENDED
7/8", [0.875", (22mm)] drill bit & drill (optional)
Philips screwdriver
1/8" Hex head
T50 Torx drive
NOTE: The rail installation will require identifying the bulkhead hole configuration of your truck. This will determine which hardware package, A or B, is used. This is in step 6.

INSTALLATION

1. BULKHEAD SEAL STRIP INSTALLATION
   NOTE: Installations with a drop-in bed liner will NOT require the bulkhead seal.
   NOTE: Wipe the surface with isopropyl alcohol before applying.
   Remove the paper backing and apply the seal strip to the top of the bulkhead. Trim the ends to tightly fit to the sides of the bed. Apply along the radius of the bulkhead back edge.
   
2. DROP IN LINER TRIMMING
   If the truck has a drop in bed liner, the top corners at the bulkhead, and the top corners of the tailgate liner need to be trimmed to allow for the bed cover rails.
   
   Move the bed liner away from the truck sheet metal, or remove the liner from the truck so that the truck bed is not damaged.
   Locate the necessary cuts by starting with the top left corner edge of the liner (1), then measure a distance of 0.18", 4.8mm, outboard to establish point A.
   The first cut is down from A 2.5", 63.5mm, to point B. The next cut is from point A, inboard horizontally 2.6", 66.7mm, to point C.
   Cut from point C to D, then finish with a cut from B to D.
   The cut is done on the right hand side as a mirror image, Figure 5.
   
3. Locate the necessary cuts for the tailgate liner by starting with the outside corner of the liner, measure a distance of 0.375", 9.5mm inboard, then 0.875", 22.2mm, down.
   The cut is done on both sides, as a mirror image.
   
   Move the tailgate liner away from the truck sheet metal, or remove the liner from the truck so that the truck bed is not damaged.
   
4. Holes are necessary in the drop in liner for the bed cover rail drain tubes. A 7/8",[0.875", (22mm)], diameter hole needs to be centered on the first rib from the edge. The hole will be 2.875", 73mm, up from the floor. The hole is cut on both sides, as a mirror image.
   
   Move the tailgate liner away from the truck sheet metal, or remove the liner from the truck so that the truck bed is not damaged.
   
5. If the bed rail caps are not trimmed in the rear /tailgate section, cut using the scribed lines as a guide to expose the area shown. Perform this operation on both sides of the pickup box.
   
6. Identify your truck bulkhead mounting hole configuration. Follow that letter through the next steps.
   
   1. an open hole on top, a threaded hole underneath.
   2. an open, hex shaped hole on top; an open hole underneath.

1. 7. For vehicles with a sprayed on bed liner, the threaded area in the bulkhead must be cleared of liner material.
      
   8. Thread the buttonhead screw through the #10 oversize washer, through the top hole in the bracket and into the well nut. One for each side.
      
      Note: Assemble just until contact is made, do not tighten the well nut.
   9. Insert the M6 screw & washer into one of the rear rail mounting holes as shown. Slide a spacer then a retainer washer onto the threaded portion of the screw. Repeat for the second rear mounting hole, and repeat with the opposite rail.
      
   10. Place the cover rail onto the bed rail and slide it forward, using the well nut as a guide into the bulkhead opening.
       
   11. At the rear/tailgate, thread the M6 screw & washers, installed in step 9, into the threaded inserts in the bed wall. Tighten with the 90 degree Torx key. Leave the bolts loose until the front/ cab bolts have been installed and tightened.
       The Torx key is included in the hardware kit.
       
       
   12. Thread the truss head screw & washer through the bottom hole of the cover rail bracket, and tighten to 17.5 Nm/12.9 ft/lbs on both sides. Snug up the upper buttonhead screw in the well nut.
       
   13. Tighten the rear/tailgate M6 screw & washers, on both sides. While tightening the bolts, lift up on the rear/ tailgate end of the rail.
       
2. 7. Install the jack nut into the truck bulkhead, one on both sides. Insert the jack nut into the upper, hexagonal hole. Insert the 1/4-20 bolt through the install wrench and into the jack nut. Use the install wrench to hold the jack nut from turning while tightening the bolt with a wrench or socket. This will pull and collapse the jack nut. Once the bolt has stopped turning, remove it for later installation.
      
   8. Thread the buttonhead screw through the #10 oversize washer, through the bottom hole in the bracket, through the flat washer and into the well nut. One for each side.
      
      Note: Assemble just until contact is made, do not tighten the well nut.
   9. Insert the M6 screw & washer into one of the rear rail mounting holes as shown. Slide a spacer then a retainer washer onto the threaded portion of the screw. Repeat for the second rear mounting hole, and repeat with the opposite rail.
      
   10. Place the cover rail onto the bed rail and slide it forward, using the well nut as a guide into the bulkhead opening.
       
   11. At the rear/tailgate, thread the M6 screw & washers, installed in step 9, into the threaded inserts in the bed wall. Tighten with the 90 degree Torx key. Leave the bolts loose until the front/ cab bolts have been installed and tightened.
       The Torx key is included in the hardware kit.
       
       
   12. Thread the 1/4-20 bolt through the flat washer, into the top hole of the cover rail bracket into the jack nut, tighten to 17.5 Nm/ 12.9 ft/lbs on both sides.
       Snug up the lower buttonhead screw in the well nut.
       
   13. Tighten the rear/tailgate M6 screw & washers, on both sides. While tightening the bolts, lift up on the rear/ tailgate end of the rail.
       

14. To mount the strap buckles to the top of the coverpush a threaded post (1) up from the bottom into the pre-drilled hole (2) in the cab panel. Place the buckle (3) over the holes and with a screw driver thread the screw (4) through the buckle and into the post.
    Securely hand tighten only, DO NOT use a screw gun.
    Repeat on both sides.
    
15. Place the folded cover on the mounted rails at the front/cab end of the bed. The cab panel holes will align with the slotted brackets of the cover rails.
    
    NOTE: The bottom edges of the cover and the top rubber surfaces of the rails should be periodically cleaned of dirt and debris for best performance.
    
16. Insert the elevator bolt through a large rubber washer, into the cab panel hole and down through the slotted rail bracket. One on both sides.
    
17. Rotate the cab panel down and thread on to the cover mounting bolt the large rubber washer, the large metal washer, the lock washer and thread on the cover mounting knob.
    
18. Unfold the cover toward the tailgate. Make sure the cover fits squarely between the rails. If it is not square adjust the cover side to side. Then carefully fold the cover and tighten the cover mounting knobs.
    
    NOTE: When the cover is adjusted correctly and sitting square with the truck bed, the latch pall will make the proper contact with rail as shown (9) on both sides. Not as shown in (10).
19. Fold the cover up to the cab, install the three cab bumpers along the top edge of the cover where it meets the truck cab.
    
20. The cover's aluminum frame will fit just inside the tailgate when the forward and backward adjustment of the cover is correct. With proper alignment the first two fins of the tailgate seal will be engaged with the tailgate.
    
    The rear edge of the cover and tailgate seal will rest on top of the tailgate.
    If this needs adjustment, loosen the cover mounting knobs and move the cover forward or backward. Be sure to maintain the side to side adjustments made in step 16.
    Re-tighten the cover knobs.
21. Insert one end of the drain hose onto the cover rail drain nozzle.
    
22. The other end of the drain hose must route out of the truck bed, drilling a hole in the bulkhead plug provides a route outside of the bed.
    Install drain hoses on both sides.
    

Tonneau Cover Tail Panel Operation

TO CLOSE THE TAIL PANEL
The tail panel can be closed with the tailgate either up or down. Assure that both latches engage. The tailgate can be closed with the tail panel opened or closed.

TO OPEN THE TAIL PANEL
Open the tailgate and reach under the panel for the release cable (1) at either side of the panel housing.
Pull down on either cable to release both rear latches and lift the panel open.

NOTE: DO NOT ATTEMPT TO DRIVE WITH THE TAIL PANEL IN A PARTIALLY OPEN POSITION.

Safe operation and use

While driving, the cover must be secured- either completely closed/flat with all of the latches engaged; or in the completely folded position with the latches engaged and tie down straps attached for the hard top and convertible top use; or folded open with both prop rods engaged for use ONLY with the hard top.
DO NOT DRIVE with the cover partially opened.

Tonneau Cover Positions While Operating Vehicle

Prior to vehicle operation, tonneau cover MUST be properly secured.

CLOSED POSITION
All panels must be closed and FULLY LATCHED to tonneau side rail. All panels must be layed flat and latches engaged.

COMPLETELY FOLDED POSITION
To drive with your cover in the completely folded position, engage the provided tie down straps and buckles provided with your cover. Ensure that BOTH buckle clips are fully inserted into the buckle ends located on the front header panel of the cover and adjust the straps to ensure the cover is secure during vehicle operation. The clips should be secured in the storage, position as shown in Figure 1, when not in use.

Do not drive with your BAKFlip in the flipped up and secured position without the hard top installed on your Jeep.

FLIPPED UP POSITION
For use with hard top ONLY
Fold the cover open and lift it until its vertical or past 90 degrees toward the truck cab. Then release the prop rod that is attached to the cover rail. Fold the prop rod over and position it firmly against the vertical plate on the underside of your cover. Then slide the prop rod lock down and tighten the knobs to lock the prop rod into position.
Do this on both sides of the cover.
The cover should be firmly in position with little to no movement once the prop rods are locked

Additional Important Operating Tips

• The bed cover MUST be free of foreign material including snow and ice before opening panels.
  
• Do NOT tow your vehicle from the rear with the bed cover on your truck.
  
• Do NOT operate vehicle with objects on top of cover.

FAILURE TO FOLLOW THESE CAUTIONS MAY RESULT IN SEVERE DAMAGE AND WILL VOID YOUR WARRANTY!

CARE AND MAINTENANCE

BAK Flip tonneaus are made from durable materials and require simple care to ensure a long life of performing well and looking great.

Cleaning the Top (Washing)
Standard automotive soap and water with a soft sponge or cloth is recommended for cleaning. Shammy dry to keep the finish polished and brilliant. Wax is NOT recommended as it tends to fill in cracks and crevices, which may affect the textured panel finish. Do NOT use any harsh cleaners or abrasives.

Treating the Vinyl Top
3M 303 Aerospace Protectant may be used to keep the vinyl surface clean and protected from the elements and will also remove any water spots that may have developed. 303 Aerospace not only protects against fading, discoloration and cracking from harmful UV rays, but repels dust and stains. Simply spray on and wipe dry for a beautiful, matte finish that protects your cover from road grime and dust.

Maintenance
It is recommended that you periodically check your cover is securely attached to your truck bed. Inspect the clamps and front mounting bolts to ensure they were properly installed and have not come loose or knocked out of adjustment during operation. Covers that are used with high frequency or that are subject to the vibrations and impact from rough roadways can cause the cover to require adjustment.

Lubricating the Latches
It is recommended that you periodically inspect and service the latches on each panel. Clean away any excess dirt or grime and lubricate with silicone spray. Ensure the latches move freely in and out to properly engage the side rail and provide proper performance with optimum security. Be careful not to overspray the cover. Wipe away any excess around the latch location.

Any damaged or missing parts?
Parts will be shipped to you directly.
Call 818-365-9000 Mon - Fri 8:30 am - 7 pm EST
or email support@bakindustries.com

BAK Industries
1100 N. Glenstone Ave. Suite 140, Springfield, MO 65802
bakindustries.com