Enclosed Partition Installation Instructions

Transcription

1 Nissan NV1500/2500/3500 High Roof Partition Kit Part #: DTC V

2 IMPORTANT INSTALLATION STEPS ARE DENOTED USING A STOP SIGN. THESE STEPS MUST BE PERFORMED IN THE SPECIFIED ORDER TO ENSURE PROPER INSTALLATION AND MUST BE FOLLOWED IN ORDER TO MAINTAIN YOUR PRODUCT WARRANTY! CRITICAL INFORMATION PERTAINING TO USER AND/OR VEHICLE SAFETY IS DENOTED USING A CAUTION SIGN. SAFETY ITEMS MUST BE STRICTLY ADHERED TO IN ORDER TO ENSURE A SAFE WORKING ENVIRONMENT! WARNING THE USE OF DRILLS WITH INTEGRAL DRILL STOPS ALONG WITH PROPER INSPECTION FOR GAS TANK, GAS LINES, BRAKE LINES AND ELECTRICAL LINES PRIOR TO DRILLING ANY MOUNTING HOLES IS STRONGLY RECOMMENDED TO ENSURE THAT VEHICLE DAMAGE IS AVOIDED! THE USE OF AIR OR ELECTRIC IMPACT TOOLS FOR THE ASSEMBLY OF FASTENERS COULD CAUSE FASTENER FAILURE! THE USE OF NON STANDARD FASTENERS AND/OR DEVIATING FROM THE FASTENERS SPECIFIED IN THESE INSTRUCTIONS MAY VOID YOUR PRODUCT WARRANTY! ALL DRILLED HOLES IN THE VEHICLES SHOULD HAVE THE RAW METAL EDGES SEALED WITH A SELF ETCHING PRIMER TO RESIST CORROSION AND POTENTIAL FASTENER POINT FAILURE!

3 TOOL LIST Safety glasses MUST be worn at all times! Drill TOOLS Drill Bits Drill 11/32, 5/16, 1/2, 7/16 Drill Stop 7/16 & 13mm Socket; with Misc. Extensions RECOMMENDED TOOLS: 1/2 Inch-pound Torque Wrench Pneumatic Plus Nut Gun Impact Gun Screwdriver 1 Hole Saw

4 Step 1: Mark Hole Locations A. Make markings on the roof of the locations of the area where the pre-threaded OEM holes are on the roof pillar. This is so you know where the holes are once the partition is up. B. Place the partition into the vehicle flush up against the plastic trim. Remove rubber trim from around side door if you need to. C. Mark the hole locations for the sides of the partition: - 1 st hole: 12 from floor - 2 nd hole: 28 from floor - 3 rd hole: 42.5 from floor - 4 th hole: from floor - All holes should be a 1/2 in from the edge of the partition Same hole locations on both the Roadside and Curbside of the partition.

5 Step 1: Mark Hole Locations, CONT d D. Mark the holes at the top of the partition, about a 1/2 down from the edge of the partition at the locations marked for the pre-threaded holes. Notice hole markings on the roof. E. Remove the (2) most outer OEM M8 bolts on the floor. Make a mark of where the pre-thread holes are located. Picture shows the Curbside. F. From the photo below, mark the hole locations at the center of the rib where the bolt is located at. Roadside hole is about 14-3/16 away from pre-threaded hole, while Curbside hole is about 17-7/8 away from pre-threaded hole. Holes should be about 1 in from the edge. OEM Pre-Threaded Holes Newly Added Holes

6 Step 1: Mark Hole Locations, CONT d G. With all (16) holes marked on the partition, you can begin drilling through. For the top holes, start drilling through the partition with a 1/4 drill bit. Do it slowly and carefully in order to see if your hole is lining up with the OEM hole behind it. While drilling, adjust the drilling location so that your drilled hole is truly over the OEM holes. Do this for (4) holes. Use drill stop when drilling. H. For the sides, start drilling through the marked locations with a 1/4 drill bit. You are going to want to drill through the partition just enough to the point where it leaves a drill bit mark on the plastic trim behind it. Do this for (8) holes. I. For the bottom, start drilling through the partition with a 1/4 drill bit. Do it slowly and carefully in order to see if your hole is lining up with the OEM hole behind it. While drilling, adjust the drilling location so that your drilled hole is truly over the OEM holes. Do this for (2) holes. For the other (2) holes, You are going to want to drill through the partition just enough to the point where it leaves a drill bit mark on the floor. Use drill stop when drilling. Step 2: Drill Through Marked Holes A. Drill through the holes on the top and bottom of the partition and open them up using an 11/32 drill bit. B. Drill through the holes on the sides of the partition and open them up using a 5/16 drill bit. C. Now that all (16) holes are drilled through the partition, make the holes in the vehicle. For the (2) bottom holes, drill through the marked locations using a 1/2 drill bit. Verify that you are not drilling into the gas tank before drilling through floor. Use drill stop when drilling into vehicle. D. On the sides, use a 1 hole saw to cut the plastic trim. This will be needed to later insert spacers. When drilling through with the hole saw, you should make a drill bit mark on the sheet metal of the vehicle pillar. E. Take the marks you just made with the hole saw on the sides and drill through those marks using a 7/16 drill bit. Use drill stop when drilling into vehicle.

7 Hardware: FAS M PLUS NUT(QTY: 2) AUST EQFLATWASHER164 SPACER, 3/8 THICK, 1 O.D. X.4375 I.D. (QTY: 36) GRA 25DD50 M HEX BOLT, 40mmL (QTY: 8) FAS /16 LOCK WASHER (QTY: 8) FAS /16 FLAT WASHER (QTY: 8) FAS / 4-20 PLUS NUT (QTY: 8) FAS /4-20 X 3.5 L HEX BOLT (QTY: 4) FAS /4-20 X 1.5 L HEX BOLT (QTY: 4) FAS /4 LOCK WASHER (QTY: 8) FAS /4 FLAT WASHER (QTY: 8) Step 3: Mount the Partition in the Vehicle A. Install (8) 1/4-20 plus nuts on the sides of the vehicle in the holes that you drilled through. Install (2) M8 plus nuts in the bottom in the holes you drilled through. Use rust blocker or any other form of rust protection spray on drilled out holes. Refer to the next page on how to install plus nuts. B. Cover all of the edges of the partition that are going to be mounted up against the vehicle with the Butyl Tape. C. Place spacers over the holes where they are needed. The top doesn t get any spacers. The bottom gets (2) spacers over each mounting point, (8) total on the bottom. The Curbside gets (1) spacer over each mounting point, (4) total on the Curbside. The Roadside gets (6) spacers over each mounting point, (24) total on the Roadside. Taping spacers together and then taping them to mounting surface can make process easier.

8 Step 3: Mount the Partition in the Vehicle, CONT d Before drilling check all mounting locations to prevent penetration of: Gas Lines, Gas Tanks, Break Lines, Wiring or any other vehicle structure. There are 2 methods for installing the Plus Nuts: Manual & Automatic (They are both listed below) D. First Method: Manual The Plus Nut is Pre-bulbed for easy installation. 2. The Plus Nut is pre-assembled with hex cap and hex bolt, then inserted into predrilled hole. 3. As the bolt is tightened the Plus Nut expands holding in place. 4. Full tightened Plus Nut provides reliable nut plate for fastening. Second Method: Automatic (Requires Pneumatic Plus Nut Gun) 1. Thread Plus Nut onto Plus Nut Gun. 2. Screw Plus Nut into Hole. 3. When Plus Nut is fully tightened remove Plus Nut Gun.

9 Step 3: Mount the Partition in the Vehicle, CONT d E. Now place partition in vehicle, removing film on the Butyl Tape and stick it up against the vehicle in its proper position. Use a screwdriver or something similar to properly lineup the holes in the partition with the holes in the vehicle. F. On the top, fasten the partition at the (4) OEM pre-threaded holes using (4) M8x1.25 X 40mm long hex bolts. Include flat and lock washers when fastening GRA 25DD50. G. On the bottom, fasten the partition at the (2) OEM pre-threaded holes and (2) M8 plus nuts using (4) M8x1.25 X 40mm long hex bolts. Include flat and lock washers when fastening GRA 25DD50. H. On the Curbside, fasten the partition in the (4) 1/4-20 plus nuts using (4) 1/4-20 X 1.5 long hex bolts. Include flat and lock washers when fastening FAS I. On the Roadside, fasten the partition in the (4) 1/4-20 plus nuts using (4) 1/4-20 X 3.5 long hex bolts. Include flat and lock washers when fastening FAS

10 Bill of Material ITEM NO. PART NUMBER DESCRIPTION QTY. 1 DTC ENCLOSED PARTITION, NV2500 DSB, HR 1 2 AUST EQFLATWASHER164 SPACER, 3/8" THICK, 1" OD, 7/16" ID 36 3 GRA 25DD50 M HEX BOLT, 40mm L 8 4 FAS M8 PLUS NUT 2 5 FAS WASHER, FLAT, 5/16" 8 6 FAS WASHER, LOCK, 5/16" 8 7 FAS /4-20 HEX BOLT, 1.5 L 4 8 FAS WASHER, LOCK, 1/4" 8 9 FAS FLAT WASHER, 1/4 X 5/8 O.D FAS /4-20 PLUS NUT 8 11 FAS /4-20 HEX BOLT, 3.5 L 4 12 MCMA 75875A661 BUTYL TAPE, 1/8 X 3/8 23FT