Aluminess Products Inc 9402 Wheatlands Ct. #A Santee, CA 92071 619-449-9930 TIRE RACK INSTALLATION INSTRUCTIONS 07-11 Dodge Sprinter Please read before beginning Stainless steel hardware may bind together when tightening It is recommended that you apply an anti-seize assembly lubricant to the threads of each bolt before assembly This installation requires two people Required tools Drill and drill bits (1/4, 5/16, 3/8 ) ¼-20 drill and tap set Standard wrench set Center punch or scribing tool Pre-Assembled components hardware Quantity 70056 Nylock 7/16-14 1 70022 - BOLT, Hex head SS, 5/16-18x1 1 70020 Flat Washer, SS, 5/16 ID x ¾ OD 6 70019 Nylock, SS, 5/16-18 3 70023 - BOLT, Hex head 5/16-18x1 ½ 2 400528 3 Piece Dovetail rotary latch assembly 1 300245 Dodge Sprinter Delrin Bearing 2 Included hardware for installation Quantity 70183 - BOLT, Hex head cap screw ¾-10 x 7 (if not shipped assembled) 1 o 70048 - WASHER, ¾ (if not shipped assembled) 1 70058 - BOLT, Hex head cap screw 7/16-14 x 5 4 o 70057 - WASHER, 7/16 8 o 70056 - NUT, Nylon insert locking 7/16-14 4 70029 - BOLT, Hex head cap screw 3/8-16 x 1 ¼ 1 o 70028 - WASHER, 3/8 2 o 70024 - NUT, Nylon insert locking 3/8-16 1
o 70027 - WASHER, 3/8 2 300416 - SUPPORT BRACKET 1 70022 - BOLT, Hex head cap screw 5/16-18 x 1 2 o 70020 - WASHER, 5/16 4 o 70019 - NUT, Nylon insert locking 5/16-18 2 70059 - U-BOLT, 3/8-16 x 2 1 o 70028 - WASHER, 3/8 2 o 70024 - NUT, Nylon insert locking 3/8-16 2 400527 - RUBBER CONTACT 1 70011 - BOLT, Hex head cap screw ¼-20 x ¾ 1 2
Assembly instructions 1. The tire rack needs to be assembled before installation Figure 2: Tire rack swing arm Figure 1: Tire rack base 2. Align the ¾ holes on the left side of the swing arm and base (as shown above) 3. Place the ¾ washer on the ¾ bolt and insert it through both the swing arm and base, threading it into the base until securely fastened 4. The tire rack should resemble figure 3 below and is now ready to install Installation Instructions: 1. The tire rack mounts underneath the vehicle on the driver s side, using the four mounting bolt positions shown in Figure 4 remove these bolts from the vehicle Figure 3: Assembled tire rack 3
2. Have one person hold the tire rack up so that the bent bracket is underneath the vehicle and held against the frame on the driver s side Figure 4: View of four mounting bolt positions on rear driver side frame Figure 5: Bent mounting bracket installed on vehicle 3. Install the backing plate on the passenger side of the frame so that it makes contact with the bent mounting bracket on the lower flat surface as shown in Figure 6 4
Figure 6: Bent mounting bracket and backing plate 4. Insert the four 7/16 bolts (#70183) through the holes in the frame with a washer on each side and install a locking nylon nut on each 5. Install the 3/8-16 x 1 ¼ hex bolt (#70029) with washers and a nylock nut through the hole in the bent mounting plate that lines up with the hole in the backing plate ( this is the only other hole in the mounting plate that does not line up with the four holes on the frame) Support Bracket Installation 6. In order to mount the support bracket, first remove the circular plastic insert so that a hole is exposed as shown in Figure 7 to the right 7. Put the support bracket (black rectangular piece seen in image to the right) up against the rectangular 2 x2 steel tube on the tire rack base 8. Put the U-Bolt around the 2 x2 steel tube and through the holes in the support bracket with washers and hand tighten the nuts on as shown in Figure 8 9. Bolt a tire onto the rack in order to make adjustments in the next steps 10. Slide the support bracket against the side of the vehicle toward the driver s side of the van. 11. Have one person hold the tire rack in position by pushing it toward the vehicle so the rubber contact is compressed on 5
against the magnet on the door as shown in Figure 9 12. If needed use a hydraulic floor jack to push up on the 2 x2 square tube and keep it located to the door magnet Figure 7: Support bracket installed on vehicle 6
13. While holding the tire rack so the contact is against the magnet, use a small drill bit to drill a pilot hole through the two holes already in the support bracket and through the sheet metal on the side of the van, then use a 5/16 drill bit for the final hole 14. Install the 5/16-18 x 1 bolts with washers and fasten with nylon locking nuts facing toward the center of the vehicle 15. With the rubber contact still pressed firmly against the magnet, tighten down the four bolts that go through the frame, the two bolts in the Figure 8: U-bolt installed on 2x2" tube support bracket, and the U-bolt 16. Tighten the 3/8-16 x 1 ¼ hex bolt which runs through the bent mounting bracket and the backing plate 17. If you have a hitch and/or a step, drill a 1/4 pilot hole through the lower hole already cut in the bent mounting bracket and through the side of the hitch, then use a 3/8 drill bit for the final hole 18. Install a 3/8-16 x 11/4 bolt with a washer on both sides and fasten with a nylon locking nut 19. If there is a gap between the bent mounting bracket and the step or hitch use the supplied 3/8 thick washers as a spacer Figure 9: Rubber contact located to door 20. With the tire rack fully mounted, magnet tightened down, and the swing arm closed hold the rubber contact in place as shown in Figure 9, taking care to insure that the rubber contact is aligned with the door magnet 21. Holding the rubber contact in place, open the swing arm 22. Punch through the hole in the center of the rubber contact onto the flat part of the swing arm 23. Drill and tap a ¼ -20 threaded hole at the location of the center punch mark. 24. Insert the ¼ -20 x ¾ bolt through the hole in the rubber and thread it into the flat piece of aluminum that is on the back of the swing arm 7