Expedition One MULE User manual

INSTALLATION GUIDE
LEXUS GX MULE ROOF RACK

2
CONTENTS
SKILL LEVEL - 3 STARS
1 STAR EASY - No tools required
2 STARS BASIC - Requires standard tools, basic mechanical knowledge and understanding
3 STARS MODERATE - Requires standard tools. Some drillling and/or cutting.
4 STARS ADVANCED - Requires speciality tools. Drilling, cutting, and/or welding
5 STARS EXPERT - Professional installation recommended.
DISCLAIMER
Expedition One is not responsible for any damages to vehicle or injury.
We always recommend professional assistance when installing our vehicle products.
Always follow safety procautions including the use safety gear and devices.
CONTENTS
Page 3 Rack Assembly Drawing
Page 4 Hardware
Page 5 Front and Side Braces
Page 6 Rear Brace and Side Fascia
Page 7 Rear Fascia
Page 8 Front Fascia
Page 9 Seam Joiners
Page 10 Spacers
Page 11 Load Bars
Page 12-13 Roof Mounts
Page 14 Roof Rack Installation

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1
2
B
A

4
1
2
HARDWARE
ITEM QTY
Lexua GX Mule Ultra Roof Rack
Front Brace 1
Le Rail 1
Right Rail 1
Rear Brace 1
Front - Cutout or No Cutout 1
Le Side 1
Right Side 1
Rear 1
Front Le Seam Joiner 1
Front Right Seam Joiner 1
Rear Le Seam Joiner 1
Rear Right Seam Joiner 1
Spreader 10
Spreader Bracket 20
A- Mule Ultra SUV Hardware Kit
1/4”-20 X 1/2” Button Head Bolts 80
1/4”-20 X 3/4” Button Head Bolts 22
1/4”-20 Nylock Nuts 102
5/16”-18 X 3/4” Hex Cap Bolts 8
5/16”-18 X 3/4” Button Head Bolts 38
5/16”-18 X 2 1/2” Button Head Bolts 6
5/16”-18 Nylock Nut 44
5/16”-18 Clip Nut 8
5/16” Flat Washer 16
Roof Mount Hardware Kit
M8-1.25 X 30mm 12
5/16” - USS Washers 12
B- Spacer Kit
Round Spacer 10
Tube Spacer 6
Med Rectangular Spacer 6
ick Rectangler Spacer 12
C- Roof Mounts
Front Mounts ( F ) 2
Middle Mounts ( M ) 2
Rear Mounts ( R ) 2
D - Weather Stripping - 63” 1
Foam Stripping - 18” 1
HARDWARE
B
A
B
C
D

3
RACK ASSEMBLY
ATTENTION
When assembling the Mule Ultra Rack, remember to hand-tighten all bolts relatively loose until the
very end of the install. is allows everything to t into place before everything is tightened down.
FRONT AND SIDE BRACES MOUNTING
Lay out the front and side braces as shown. Mount the braces together using the 5/16” bolts and nuts.
2
5
OEM ROOF RACK REMOVAL
Remove the OEM roof rack from the vehicle by undoing the hardware located at each mount.
1

6
3
REAR BRACE AND SIDE FASCIA MOUNTING
Attach the rear brace and side fascias shown using 1/4” and 5/16” bolts on both sides as shown below.
3

7
3
3
SIDE FASCIA CONTINUED
REAR FASCIA MOUNTING
Attach rear fascia as shown with 5/16” bolts and nuts.
4

8
3
FRONT FASCIA MOUNTING
Attach the front fascia using 1/4” bolts. Use the provided round spacers to adjust the front fascia to
match the curve of the roof when test tting the roof rack during mounting.
NOTE: IF YOU HAVE A FASCIA WITH A LIGHT BAR CUTOUT, WE RECOMMEND
INSTALLING THE LIGHT BAR PRIOR TO MOUNTING THE ROOF RACK.
5
Install the weather stripping to the bottom of front
fascia as shown and trim any excess.

SEAM JOINERS
Mount both front and rear seam joiners with 5/16” hardware as shown top and bottom.
6
99

7REINFORCEMENT SPACERS
Attach reinforcement spacers as shown on all 6 hole locations (3 each side) with the provided hardware.
10

3
LOAD BAR INSTALLATION
Flip roof rack over and attach load bars as shown. Using provided nuts and bolts, you may begin
tightening down each load bar with two bolts and nylocs for each side.
9
LOAD BAR ASSEMBLY
Assemble the load bars with the provided mounts using 1/4” bolts and nuts. Repeat for all load bars.
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11

12
3
ROOF RACK MOUNTS
MOUNTING AREA
In preperation for attaching the roof mounts cut a foam strip to lenght of mount area and attach. It is
recommended that you place 2 of the large (thicker) spacers over each the mounting location. Extra spac-
ers are provided to level and shim the rack mounts as needed. Repeat this step for the other mounts.
e Medium (thin) spacers are optional and my be used to level or adjust the rack height if desired.
10
ROOF MOUNTS
Attach all roof mounts to the vehicle using the M8 bolt and washer hardware. Leave loose to provided
adjustment as needed. e location and placement are shown on the next page. Once completed add the
provided clip nuts to the top of each mount for attaching the roof rack.
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13
3
PASSENGER SIDE
DRIVER SIDE
ROOF MOUNTS CONTINUED

3
14
ROOF RACK MOUNTING
Place the roof rack onto vehicle with help of a friend and align with each bracket. Use the provided
5/16” bolts and washers for each mount hole location and tighten down roof rack to each bracket as
shown below. Spacer kit may be used to level and adjust the roof rack. Tighten all hardware once
completed.
12
ROOF RACK INSTALLATION