Orion Motor Tech V20231023 Tailgate Assist Instruction Manual

V20231023
Tailgate Assist
Instruction ManualRead Carefully Before Use
Keep for Future Reference

Safety Information

Warning!

• The instructions provided herein are only for general information. ALWAYS use this product in full compliance with your vehicle’s service manual.
• DO NOT allow children or those unfamiliar with this product and its compatible vehicle models to use it. Do not use while under the influence of alcohol, drugs, or any medication that negatively affects your judgment or reflexes. Keep children and bystanders away during use.
• Dress properly for automotive servicing. Do not wear loose clothing or jewelry and keep hair, lothing, gloves, hoses, and tools away from any moving parts during use.
• Do not overreach. Keep proper footing and balance at all times.
• DO NOT use excessive pressure with this product and do not force it or its attachments.
• Maintain this product. Check for misalignment, binding, wear, or other damage before use.
  If any damage is detected, repair or replace the problematic components before further use.
  In a large shop, mark such tools DO NOT USE until they have been repaired. Only replace components with identical parts.

Specifications

2003–2009 RAM 2500 & 3500
Net Weight| 8.1 oz.| 230 g

Parts List

Included but Not Pictured
Mylar Sheet| Required but Not Included
10 mm Open Ended Wrench
13 mm Open Ended Wrench
17 mm Open Ended Wrench| Flat End Screwdriver
M5 Hex Wrench
Pliers
Tape Measure
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Operation

Note: This product can only be installed on the driver’s side.

1. To install the M10 blind nut (E) at the tailgate pivot point, use an M5 hex wrench and a 10 mm wrench (not included). Apply a small amount of threadlocker (H) to the threads of the blind nut before tightening it by at least nine full 360° turns, while marking one side of the nut and counting the number of revolutions to ensure the correct number of turns. If after the nine turns, the blind nut can still move or rotate, continue tightening it for an additional 1 or 2 turns. Exercise caution to avoid overtightening the nutsert as this can strip the threads and render the nutsert unusable. Check the blind nut again and repeat the process if necessary. Once the installation is complete, remove the nutsert tool.

2. Use a 13 mm wrench or socket (not included) to install the lower ball mount (F) into the nutsert.
   Apply a small amount of threadlocker to the threads of the ball mount before torquing it to 8 ft-lbs.

3. Remove the tailgate cable and use the T45 torx wrench (D) to remove the cable bolt.

4. Use a 17 mm open ended wrench (not included) to install the upper ball mount (C) and washer (B) where the factory bolt was removed in the previous step. Apply a small amount of threadlocker to the threads of the bolt before tightening it.

5. Install the tailgate cable onto the upper ball mount by sliding the cable end onto the mount until it snaps into place.

6. Remove the motion limiter from the other end of the tailgate cable with the T45 torx and remove the flat retaining nut to take off the limiter.

7. Pry up one edge of the flat nut with a flat end screwdriver (not included), hold this edge with a pair of pliers (not included), and spin the bolt out of it to remove the limiter. Once the limiter is removed, reinstall the cable mount to the tailgate.

8. Measure down from the top of the cable 3½ in. (8.9 cm) and press the cable clip (G) onto the cable with a pair of pliers. Failure to remove the limiter and to install the cable clip will cause the cable to bind or become caught between the shock and truck bed, which may lead to vehicle damage.

9. Cut the provided Mylar sheet to the required size using scissors. Apply the Mylar to the truck bed and tailgate where tailgate assist components will be in close proximity during opening and closing. The red lines show the area where the Mylar has been installed. The vehicle shown is an example of how the Mylar can be installed. Your vehicle may differ from the vehicle shown.

10. Install the larger part of the shock on the upper ball mount and the narrow end of the shock on the lower ball mount.

Maintenance

• Clean these tools with a dry brush or cloth after use. If rinsing is necessary, dry all parts completely before storage. Clean the tailgate assist as needed. Never use abrasive cleaners or caustic chemicals with any part.

• Check the tailgate assist and these tools periodically for any looseness, wear, or damage.
  Tighten, repair, or replace any problematic parts before further use.

• If the assist will not be used for an extended period of time, remove and store in a cool dry place inaccessible to children.

Contact Us

Thank you for choosing our products! If you have any questions or comments, contact us at support@orionmotortech.com and we’ll resolve your issue ASAP!
For a .pdf copy of the latest version of these instructions, use the appropriate app on your smartphone to scan the QR code to the right.

https://sp9c.com/CRQBV
TAS-0300-BK Rev. 23 Oct. 2023

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