upTOP 2005-2015 NISSAN Xterra Roof Rack Instruction Manual

upTOP 2005-2015 NISSAN Xterra Roof Rack

Product Information: NISSAN Xterra

Thank you for choosing upTOP as your go-to adventure gear provider. Our products are designed, developed, tested, and manufactured in Colorado along the front range of the Rocky Mountains.
Product Name: Nissan Xterra 2G 2005-2015

What’s in the Box

Product Usage Instructions

• Step 1
  Identify the Xterra 2G 2005-2015.

• Step 2:
  Refer to the Factory Mounting Area Diagram.

• Step 3:
  Place the Rack Foot according to the following part numbers: 2305 D, 2305 P, 2306.2, 2307, and 2308.

• Step 4:
  Follow the instructions for attaching the Front Brace.

• Step 5:
  Attach the Driver Side Front Foot and Passenger Side Front Foot.

• Step 6:
  Attach the Load Bar Clamp Foot 2.

• Step 7:
  Attach Ambi-Driver/Passenger Foot 3 and Ambi-Driver/Passenger Foot 4.

• Step 8:
  Attach the Ambi-Driver/Passenger Cross Bar 50.00 2×1.

• Step 9:
  Attach the Adaptive Wind Screen.

• Step 10:
  Attach the No Cut Insert.

• Step 11:
  Complete the following tasks before installing the front wind screen:

  • Verify rack is centered on the vehicle. Adjust as needed.
  • Tighten all of the Rack to Roof hardware with 4mm Allen.
  • Tighten all of the feed to load bar hardware with 5/32 Allen.
  • Tighten the 1371 bolts/nuts with 3/16 Allen and 1/2 wrench
  • Tighten the front load bar support bolts with 5/32 Allen
  • Verify that you have sealed up un-used factory mounting locations.

• Step 12:
  Attach the Splitter design wind screen. You can install lights in the front of your roof rack by removing the upper trim panel. We offer brackets for all industry leading lighting companies. If you ordered your roof rack for a specific type of light, the brackets are included in your kit. Refer to our lighting and electrical guide on our website for more information.

• Step 13:
  After completing all installation steps, ensure that all bolts are tightened and secure.

Contact Information
If you have any questions or concerns, please contact us at:
upTOP Overland
2278 Manatt Court Unit C11
Castle Rock, Colorado 80104
720.730.6381
support@uptopoverland.com

NISSAN Xterra

• 2005-2015
• No Drilling Required

Thank you for trusting upTOP™ as your choice for adventure gear. We proudly design, develop, test, and manufacture our products along the front range of the Rocky Mountains in Colorado.
A lot of thought has gone into this product design so that you can install and maintain the product yourself. Browse these instructions to familiarize yourself with the process and required tools prior to beginning your installation. If at any time you do not feel confident completing the installation yourself we recommend professional installation of this product through our network of authorized resellers all over the globe. You can find more information about authorized retailers and installation centers under our dealer locator tab located on our website.

TOOLS REQUIRED

• T30 Torx (Factory roof rack removal)
• 5/32 Allen
• 3/16 Allen
• 1/2 wrench
• 4mm Allen
• Silicon and dispenser
• Tape Measure

Nissan Xterra 2G 2005-2015

NOTES ABOUT INSTALLATION

• This roof rack takes the place of your factory roof rack. The factory roof rack will need to be removed prior to installation of your new roof rack.
• Factory threaded inserts on the Nissan Xterra are prone to spinning or coming un-clinched from the factory mounting locations. DO NOT USE POWER TOOLS TO REMOVE THE FACTORY BOLTS.
• Your hardware kit ships with replacement threaded inserts for the factory locations as well as a tool kit to install them in any locations that may become damaged during factory roof rack removal. It is critical to the load capacity of your new roof rack that all indicated locations are utilized during installation.
• Inspect the areas around your mounting locations once the factory roof rack is removed. If you notice any metal fatigue, corrosion, or damage around the factory mounting locations you will need to repair those areas prior to installing your new roof rack.
• Any factory mounting locations not used for installation of the new roof rack will need to be sealed/plugged to prevent water damage to the interior of vehicle.

What’s in the box:

Additional brackets and hardware may be provided with kit depending on lighting options selected at checkout. For additional information on lighting installation for the front wind screen please refer to the “Lighting/Electrical Guide” located on our website under the instructions tab.

STEP 1

• Use a T30 Torx Driver to remove the factory roof rack wind screen, storage box (if equipped), and side rails.
• Thoroughly clean the roof of the vehicle around all of the mounting locations and inspect the factory inserts for corrosion or metal fatigue. Repair or replace the factory threaded inserts as needed BEFORE you install your new roof rack.
• If your factory roof rack is equipped with the OEM lighting option you will need to unplug the connector from the wind screen before removing it completely from the truck. This wiring can be used to power additional aftermarket lighting if desired. Please refer to vehicle owners manual for electrical limitations pertaining to factory installed wiring.

STEP 2
Factory Mounting Area Diagra

• The locations shown in GREEN are areas where a foot will directly contact the roof of the vehicle with NO SPACER in between.
• The locations shown in ORANGE are areas where you will place a spacer between the roof of the vehicle and the under side of the mounting foot in that location.
• The locations shown with a RED X are factory locations that will NOT be re-used with the installation of the new roof rack.
• Go ahead and dispense your silicone sealant in all areas as shown.
• In the RED areas install one of the provided “Rack to Roof” bolts and washers into the threaded inserts to close them up.
• In the ORANGE areas place one of the provided spacers in your hardware kit over each location. You can just sit it down right into the sealant.

STEP 3
Rack Foot Placement

• Place the feet as shown.
• All locations will use the same hardware included in your kit. They are NOT specific to each location.
• The locations shown in ORANGE should have the supplied spacers in between the bottom of the foot and the roof of the vehicle to level the feet.
• In areas shown in GREEN the foot will be in direct contact with the roof with NO spacer installed.
• For now, DO NOT install the hardware at the very front of the vehicle on feet labeled 2305 D (Driver) and 2305 P (Passenger). You will be adding the 2305 B (Braces) in these locations later.

4mm Allen

STEP 4 Foot to Load Bar Hardware Assembly
All of the feet shipped in your kit will assemble with the same hardware set as shown above.

• Before assembly please apply the included VC3 thread compound to the threads of each bolt included in the “Foot to Load/Cross Bar” hardware bag. Allow the compound to air dry for 30 minutes prior to installation of the hardware.
• Add the hardware to each of the feet as shown above. There will be no lock washers for the following feet, and there are two (2) each:
  • 1308.2
  • 1307
  • 1306.2
  • 1371

When all of the feet have the hardware installed you are ready to install the first three (3) cross bars onto the vehicle.

STEP 5 First Three Cross Bars

• Align the cross bars as shown and slide them from one side of the vehicle to the other.
• Center the cross bars on the vehicle by measuring the distance from the end of each cross bar to the side of the foot at each location. That area is shown above on the rear cross bar in PINK.
• Adjust and center all three (3) cross bars.
• Snug the hardware in place to hold the cross bars in the proper location. Do not fully tighten to allow minor adjustments once the rack sides are installed.

STEP 6

• 3/16 Allen
• 1/2 Wrench
• 5/32 Allen

1371 Cross Bar Clamps & 4th Load Bar 

• The included 1371 cross bar clamps, shown here in ORANGE, will attach to your 2305 (D & P) at the front of the vehicle as pictured above.
• You will use the lowest hole location and install the clamps aligning the holes in the 1371 to the slots in 2305. Use the provided bolts and nylon locking flange nuts to attach the clamps to the bases (2305). Use the
• Because of how the 1371 cross bar clamps are produced they will be facing opposite directions as pictured. This is normal.
• Install your cross bar inserts and hardware to each clamp.
• Align and slide the cross bar across the vehicle like with the previous three (3) load bars.
• Center the load bar on the vehicle but DO NOT tighten any hardware.

STEP 7
5/32 Allen

Rack Body Side Installation

• Apply the VC3 thread locking compound to all of the bolts in the bag labeled “Load Bars/Cross Bars”. Allow to air dry for 30 minutes prior to installation.
• Align the rack body (2020.3 passenger side shown) and use the slots highlighted in PINK to hang the rack body onto the cross bars. These four positions will be fixed, or non-adjustable, once the rack is fully installed because they are attached to feet on the roof of the vehicle.
• Each location will get two (2) bolts and two (2) flat washers. Start the hardware but leave it loose enough for the rack body to slide back and forth by hand.
• Repeat the process with the 2019.3 driver side.

STEP 8 Remaining Cross Bars

• Install the remaining cross bars.
• Do not fully tighten any hardware. You should still be able to move the cross bars with your hands.

STEP 9

Front Cross Bar Threaded Inserts

• Slide the two threaded inserts into the FRONT of the front load bar. You want them in the channel indicated above by the PINK line.
• You can slide them into place later but for now just put them into the load bar channel and attach the front load bar into the rack on both sides of the vehicle.
• Leave the hardware loose enough that you can move the load bar back in forth in the slot by hand.

STEP 10

• 5/32 Allen
• 4mm Allen

Front Rack Support

• You will attach one 2305 B bracket at each side of the rack.
• Align the bracket by installing the lower hardware first. This is the left over “Rack to Roof” hardware you have in your bag. Leave the hardware loose.
• Slide a threaded insert into place behind the 2305 B near the front cross bar and install the hardware. At these locations you will use the provided lock washers and flat washers due to the thickness of the bracket material. Failure to use the lock washer will cause the hardware to bottom out in the cross bar channel and give you a “false tight” situation that will cause noise and vibration.
• Repeat the process on the opposite side of the vehicle with the remaining bracket and hardware.

STEP 11
Before you assemble and install the front wind screen you will go ahead and finalize the rack installation. Follow this chart and complete each step before installing the wind screen to allow yourself adequate tool and hand clearance at the front of the roof rack:

STEP 12

• Great care has been taken in the design of the wind screen for your rack. Our Splitter design cuts through oncoming headwind and deflects air around the roof rack as well as gear loaded upTOP.
• The adaptive design of your windscreen gives you the choice between installing lights in at the front of your roof rack or not by simply removing the upper trim panel at any time to install a variety of lighting.
• We offer product specific brackets on our website that can be used with all the industry leading lighting companies. If you ordered your roof rack for a specific type of light from the drop down menu the brackets are included with your kit. If you need to some brackets after your initial purchase you can always add them at any time.
• Please refer to our lighting and electrical guide on the web site for an in depth look at how to install a wide range of lighting options into your new upTOP roof rack.
• The following page provides a diagram for wind screen assembly and installation.

STEP 12 Wind Screen Mounting Hardware

• Your wind screen will attach to the last cross bar that you have left over after your rack is assembled.
• Insert three (3) threaded inserts into each of the channels as shown. If you are installing lighting into your roof rack only install the inserts into the channel shown with the PINK line.
• All wind screen mounting hardware needs the VC3 thread locking compound applied.

Wind Screen Mounting Hardware

• Slide the threaded inserts along the channel to align with the holes in the main part of the wind screen as shown above.
• Use a 5/32 Allen wrench to install a bolt and washer at each location. The wind screen is the exact same width as your cross bar. Center it and fully tighten the three (3) bolts.

5/32 Allen

STEP 12 No Cut Blank

• If you won’t be installing lighting into the front of your roof rack you will need to install the no cut blank provided with your kit.
• Using the same hardware align the threaded inserts and tighten the hardware into place.
• The blank can always be removed at a later time to install a variety of lighting at the front of your roof rack.
• If you remove the blank you will want to also remove the threaded inserts from the cross bar. If left loose they will slide and rattle when underway.

5/32 Allen

STEP 13 Mounting the wind screen into the roof rack

• The hardware is the same as used for all other load bars with the exception of flat washers. You will not use washers for this step.
• Apply VC3 thread locking compound to the bolts.
• Align the wind screen as shown and install the hardware. Once you have both sides of the wind screen mounted to the rack you can fully tighten the hardware.
• The wind screen should fit tight to the roof of the vehicle but should not come into contact with it at all.

5/32 Allen upKEEP and General Information

• Periodically inspect the roof rack and hardware to ensure it is in good working order. Repair or replace worn components as needed.
• Be sure that cargo loads are evenly distributed across the roof rack with heavier loads situated closer to the rear of the vehicle than the front.
• NEVER exceed the recommended weight capacity for the vehicle or the roof rack. For the Nissan Xterra the recommended cargo loads are: 350 pounds Dynamic (Moving) and 850 pounds Static (Stationary).
• Improperly secured loads can shift on uneven terrain and may result in damage to persons or property.
• It is the responsibility of the end user to ensure that the product is maintained in working condition and the end user assumes all risk for cargo loads and operation of the vehicle with the product installed.

Contact Information

upTOP Overland
2278 Manatt Court
Unit C11
Castle Rock, Colorado 80104
720.730.6381
support@uptopoverland.com
Do your part. Our company is founded and staffed by outdoor enthusiasts that understand how fragile our planet really is. The most important message that we can impart to you about enjoying our open spaces is to leave them better than you found them. Don’t be a dick. Pick up after yourself. Pick up after others that don’t and when possible educate them as to why they should. Stay on designated trails, camp sites, and pathways. If you take it with you, bring it back with you. There are no excuses.
Manufacture responsibly. We strive to produce an American made product that will perform as intended for many years and we try very hard to do that with locally sourced materials from other small businesses because relationships matter to us. When absolutely necessary we will import components for our products from other countries and we maintain strict guidelines for the companies we work with to ensure that their employees are treated with dignity and respect.
Lifetime warranty. As over-engineered as some of our products can be eventually something will break. When that happens you can rest assured that we will repair or replace the items for the life of the product to the original purchaser. Content sharing. We love to see all the pictures and videos of our stuff in action on your rig. You can share the content via email and/or social media 24/7 and if we share it with our audience we will credit the photographers and vehicle owners whenever possible. upTOP Overland is a US based manufacturer of off road products operating out of Colorado. All information contained in this material is the intellectual property of Relic Automotive Design, dBA upTOP Overland. Duplication, alteration, or distribution of this material without express written permission from upTOP Overland is forbidden. Just. Don’t.

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>