ACCESS COVER INSTALLATION INSTRUCTIONS (Kit #601 for 2006 Honda Ridgeline) NOTE TO INSTALLER: IMPORTANT READ BEFORE ATTEMPTING INSTALLATION. Allow extra time, up to 2 hours to install this cover. Disassembly of the box wall panels and drilling is required. When assembly is complete, the roll-up cover will set recessed down from the top of the box sides. This allows the cover to match with the height of the box behind the cab and at the tailgate. These instructions replace all of Step 1 and Step 2A of the instructions in the Access owners manual. Torx bolts T-50 remove all hooks (6 total) ILLUSTRATION 1 (passenger side) TOOLS NEEDED: a. T-50 Torx f. 1/8 Bit b. T-40 Torx g. 1/4 Bit c. Flat head screw driver h. Inch pound torque wrench d. #2 Phillips head screw driver i. 10 MM Socket e. Electric Drill j. 3/8 Socket/Wrench front box wall panel Torx bolts T-40 REMEMBER TO WEAR PROTECTIVE EYEWEAR 1. Look-up the anti-theft code for the radio on the vehicle audio system card kept with the owners manual and write down the radio station pre-sets. Disconnect the negative cable from battery. 2. Remove the tie down hooks (6 total) starting at front passenger side and driver side. Then at rear passenger side and driver side (T-50). SEE ILLUSTRATION 1. ILLUSTRATION 2 (front wall) remove screw cover at rear of bed caps with flat head screw driver Phillips screw 3. Remove the 6 torx bolts on the front box wall panel (T-40) and remove. (The top three bolts will not be reused when reassembling panel). SEE ILLUSTRATION 2. 4. Remove passenger bed rail cap. Use flat head screw driver to remove screw cover at rear of bed cap. Use #2 Phillips screw driver to remove screw, then slide bed rail cap back to release clips, and lift up. SEE ILLUSTRA- TION 3. Repeat procedure on driver side bed cap. ILLUSTRATION 3 (passenger side) Part No. 40616 REV:B Page 1 of 6 090905
5. Remove passenger side box wall panel, (5 torx bolts) (T-40). SEE ILLUSTRATION 4. remove the 5 torx bolts that hold side panel to box 8. Pull panel away from steel box wall and unplug light connector. SEE ILLUSTRATION 7. unplug connector ILLUSTRATION 4 ILLUSTRATION 7 6. Next, pull gently on lower portion of inside pillar until one clip lets loose. SEE ILLUSTRATION 5. 9. Pull on inside pillar trim and hold - then gently lift wall panel out of box. SEE ILLUSTRATION 8 & 9. ILLUSTRATION 5 pull inside pillar trim away from steel body - then gently lift rear of side wall panel up and out ILLUSTRATION 8 7. On passenger side only, locate spare tire clip. Push center of clip and pull out on panel to free clip. SEE ILLUSTRATION 6. 10. Repeat procedure on driver side box wall panel. (driver side does not have spare tire clip). ILLUSTRATION 6 lift rear up and away ILLUSTRATION 9 Page 2 of 6
(Kit #601 Cont.) NOTE: Length dimensions given are approximate. Use them to locate the 3 locations for drilling holes. drill 1/8 pilot holes 3 locations only - exactly 1/2 up from mold marks. 11. With passenger side wall panel laying backside facing up, mark three new hole locations as shown (1/2 inch above center of existing mold marks) and drill three 1/8 pilot holes into panel. SEE ILLUSTRATION 10. Repeat procedure for driver side wall panel. 28 1/ 4 14 3/ 16 12. Now, open the Roll-Up Cover kit and find the metal Z brackets (6 pcs), the flat washers, lock washers, and 6mm x 40mm hex head bolts. Install these brackets to the existing holes on the box wall with a 10mm wrench. Slotted hole in bracket should point up - insert bolt with washers in bottom hole first. NOTE: Two brackets with 2 3/8 leg belong at front of box. Attach all 6 brackets. Tighten all bolts to 100 inch pounds. SEE ILLUSTRATION 11 & 12. 1/ 2 existing marks on panel mark center location of new hole 1/2 up from center in line with existing mold marks ILLUSTRATION 10 rear - tailgate end passenger side shown with wall panel back side facing up Z bracket flat washer lock washer install end with slotted hole up 2 3 /8 front Z bracket 6mm x 40mm hex head bolt (10mm wrench) center Z bracket rear Z bracket ILLUSTRATION 11 ILLUSTRATION 12 Page 3 of 6
13. Re-install both sidewall panels, reconnect light plug connectors. Re-connect the negative cable to the battery and check that the cargo lights work. SEE ILLUSTRATION 13. Then insert bolts and tighten. On passenger side, push spare tire clip on. reconnect light plug Now, re-install bed caps (if bed rail caps do not align properly you may need to loosen torx bolts on wall panel and shift panel for better fit, then re-tighten bolts). push panel in and down 14. Next, set front box wall panel in position with the 3 bottom torx bolts only and tighten them. Then re-install all 6 tie-down hooks. ILLUSTRATION 13 15. Locate header bar and 6mm x 40mm hex head bolts in the kit. Align holes in header bar with upper three open holes on front box wall panel. Insert replacement Hex head bolts. Tighten outer bolts to 60 inch pounds. Tighten center bolt to about 20 inch pounds. (10mm socket) SEE ILLUSTRATION 14. header bar ILLUSTRATION 14 16. With a 1/8 drill bit, use previously drilled holes in sidewall panels as a guide to drill a 1/8 pilot hole into the Z brackets (that are now behind the sidewall panels) and through the sheet metal of the box wall. SEE ILLUSTRATION 15. Then drill 1/4 enlargement holes in composite layer of the wall panel. DO NOT DRILL 1/4 hole into steel Z brackets. This avoids chipping the composite panel when mounting side rails with self drilling screws. use previously drilled holes in panel (3 per side) as guide to drill pilot holes into Z brackets ILLUSTRATION 15 Page 4 of 6
17. Locate the cover siderails, nylon spacers and screws used to mount the rails to the box and sort them by size as shown. Align holes in the cover rail with previously drilled holes in box wall. Match the screws and spacers with the proper location. SEE ILLUSTRATION 16. passenger side rail shown nylon spacer FIRST FASTEN FRONT - use 2 1 /2 long screw with 3/4 long spacer THIRD FASTEN CENTER - use 2 1 /2 long screw with 7/8 long spacer SECOND FASTEN REAR - use 2 1 /2 long screw with 1 long spacer 18. Back of rail should rest on top of pillar at rear of box. Note nylon spacer attached to bottom of rail helps stabilize rail during install. (Leave attached to rail permanently). SEE ILLUSTRATION 17. ILLUSTRATION 16 back of rail resting on box pillar 19. First, begin at front of rail - Align pre-punched holes in rail with drilled holes in wall panel. Insert 2 1 /2 screw, use 3/4 long spacer positioned behind rail and drill screw into pilot hole of metal Z bracket. Use 3/8 socket. SEE ILLUSTRATION 16 &18. ILLUSTRATION 17 Second, go to rear of rail - install a 2 1/ 2 screw with 1 long spacer positioned behind rail and drill screw into pilot hole on Z bracket. SEE ILLUSTRATION 16 & 18. 3/8 socket Third, finish at center of rail with another 2 1/ 2 screw and a 7/8 spacer behind the rail. REPEAT PROCEDURE for driver side rail. Tighten all screws until spacer is tight -then check with torque wrench and tighten to about 40 inch pounds. Now - refer to the owners/installation manual and continue on beginning with Step 2B - Element Seal TM instructions. tighten screws until spacer is tight (approx. 40inch pounds) ILLUSTRATION 18 Page 5 of 6
20. Reset the clock, and reset the radio station presets. NOTE: Whenever the battery is disconnected, the driver s window AUTO function is disabled. 21. Start the engine. Push down on the driver s window switch until the window is fully open. 22. Check that the cargo lights are working. 23. Pull up on driver s window switch to close the window completely, then hold switch for two seconds or more. 24. Lower and raise window to check the operation of the driver s window AUTO function. 25. Now - refer to the Access owners/installation manual and continue on beginning with Step 2B - Element Seal TM instructions. Shown here are some helpful hints when closing the cover. Use these in conjunction with the procedures in the Access owners manual (page 5). When sealing the sides, push down on vinyl next to rail... grip and pull it snug by the edge... then push it down to seal along rail from front to back. NOTE: For best results always keep valley between box and cover clean of debris NOTE: The Honda Ridgeline is equipped with a trunk-like lid on the bed floor. The lid remains functional - although slightly restricted from fully opening with the cover. Avoid forcing the lid beyond its limit. floor storage lid open Page 6 of 6