TOYOTA PT954-34220-02 Tundra Tonneau Cover Instruction Manual

TOYOTA PT954-34220-02 Tundra Tonneau Cover

Kit Contents

Hardware Bag Contents

Additional Items Required For Installation

Conflicts

Recommended Tools

Personal & Vehicle

Protection

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Special Tools| Notes
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Installation Tools| Notes
Philips Screwdriver|
T-30 Torx Driver|
3/8” Drive Short extension|
Ratchet Wrench|
Scissors|
Alcohol Wipe|
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Special Chemicals| Notes
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General Applicability

Recommended Sequence of Application

Vehicle Service Parts (may be required for reassembly)

Legend

STOP: Damage to the vehicle may occur. Do not proceed until the process has been complied with.
OPERATOR SAFETY: Use caution to avoid risk of injury.
CAUTION: This a process that must be carefully observed in order to reduce the risk of damage to the accessory/vehicle and to ensure a quality installation.
TOOLS & EQUIPMENT: Used in Figures calls out the specific tools and equipment recommended for this process.
REVISION MARK: This mark highlights a change in installation with respect to the previous issue.
SAFETY TORQUE: This mark indicates that torque is related to safety.
REGULATORY MARK: This mark indicates the component is related to regulatory compliance.

Care must be taken when installing this accessory to ensure damage does not occur to the vehicle. The installation of this accessory should follow approved guidelines to ensure a quality installation. These guidelines can be found in the “Accessory Installation Practices” document.

This document covers such items as

• Vehicle Protection (use of covers and blankets, cleaning chemicals, etc.).
• Safety (eye protection, rechecking torque procedure, etc.).
• Vehicle Disassembly/Reassembly (panel removal, part storage, etc.).
• Electrical Component Disassembly/Reassembly (battery disconnection, connector removal, etc.).

Please see your Toyota dealer for a copy of this document.

Install Tonneau Cover Rails

• Remove the cargo rail fasteners and the rail. Keep both for later reinstallation (Fig 1-1).
• Install foam block filler with adhesive end up as far forward as possible against the cab end bed wall/bulkhead (Fig 1-2).
• Push upward into place as far as possible. Do this for both RH and LH sides (Fig 1-2).
• Align the S clamps with the bed rail slot and insert them into the rail.
  1. If the vehicle is equipped with an electrical outlet at the right rear corner of the bed, the right rearmost clamp will look different than the rest of the clamps, as shown in Figure 1-3 and Figure 1-4.
• Using fasteners from Step 1, mount the bed cover rail into the holes in the truck bed (Fig. 1-4). Torque fasteners to 9 Nm (6.6 ft-lbs).
  1. Before tightening, adjust the rail to ensure it is pushed all the way up against the headrail and clears the tailgate.

Install Accessory Rails

• Mount the cargo rail to the S clamps utilizing the lower holes in the clamp and the Torx screws (Fig 2-1). Torque screws to 8Nm (5.9 ft-lbs).
• Before proceeding, ensure both bed cover rails are pushed up tight against the bulkhead (Fig 2-2).

Install Drain Tube

• Slide the drain hose onto the small end of the drain hose adapter until it stops sliding (Fig 3-1).
• Push the drain hose adapter with the drain hose onto the cap until it stops. Once installed there should be a 5mm gap between the top of the drain adapter and the bottom of the drain cap (Fig 3-2).
• Install the drain hose on the bottom of the truck bed, going through the hole nearest the center of the bed. Trim the end of the drain tube such that it extends 80mm into and below the hole in the truck bed (Fig 3-3).
  1. Repeat for both LH and RH sides.

Install Tonneau Cover

• Place the tonneau cover in the folded position on the bed cover rails toward the front of the bed near the cab (Fig 4-1).
• Raise the front panel to install the two buckles into the pre-drilled holes with the provided machine screws and threaded posts. Do not use a screw gun but tighten securely by hand with a screwdriver (Fig 4-2).
• The front panel folds down over the slotted rail brackets. Fold the panel down and align it so it sits squarely on the rails and align the mounting holes with the slotted rail brackets (Fig 4-3).
• Insert the elevator bolt through a rubber washer, through the front panel, and the slotted bracket (Fig 4-4).
  1. Complete for both LH and RH sides.
• Assemble the washers from underneath. On the elevator bolt, install the hardware in this order: large rubber washer, large flat washer, lock washer, and knob (Fig 4-5). Do this for both LH and RH sides.
• Unfold the cover toward the tailgate. Make sure that the cover fits squarely between the rails and ensure the seal along the edge does not fold up under itself (Fig 4-6).
• Ensure the latches for opening the tonneau cover are properly engaged with the side rails (Fig 4-7).
  1. If necessary, adjust the tonneau cover from left to right to confirm side rail engagement. Once the tonneau cover is fully engaged, ensure the knob is hand-tightened and secure (Fig 4-8).
• Confirm the rear edge of the cover and seal rest on top of the tailgate (Fig 4-9).

Install Tonneau Cover Bumpers

• Install the three cab bumpers along the top edge of the cover where it meets the truck cab when folded and propped up with the prop rods (Fig 5-1).

1. The center bumper should be installed at the very center of the tonneau cover near aligned with the taillight.
2. The two outside bumpers should be no closer than 25.4mm (one inch) from the outside edges.

Confirm Tonneau Cover Operation

• Open the tailgate and reach under the panel to the cable at either end of the panel. Pull the cable down to release both latches while lifting the panel (Fig 6-1).
• Fold the tonneau cover and then unfold it latching the tonneau cover securely. Close the tailgate confirming the tonneau cover fin lays on top of the tailgate.
• Place graphic symbol stickers on both sides of the emergency release handle. (Fig 6-2).

Checklist these points MUST be checked to ensure a quality installation.

Check

Accessory Function Checks

• Confirm cover operation
• Confirm tailgate operation

Vehicle Function Checks

• Confirm tailgate operation

Vehicle Appearance Check

• After accessory installation and removal of protective cover(s), perform a visual inspection.

Look For

• Confirm tonneau cover opens, closes, and folds properly.
• The tailgate should open and close without interference.
• Ensure no damage (including scuffs and scratches) was caused during the installation process. (For PPO installations, refer to TMS Accessory Quality Shipping Standard.)

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