Kargo Master 40649TL Manual

Kargo Master
Rancho Cordova, CA 95742
800-343-7486
[e-mail]
20200608R1 DATE: ________________
Instruction Guide
40649TL

Installation Instructions –40649TL
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 1
*PLEASE READ ALL INSTRUCTIONS AND WARNINGS PRIOR TO ASSEMBLING, INSTALLING,
AND USING THIS PRODUCT.*
Warning
Always check for wires, fuel tanks and lines, brake lines and other important vehicle
functionality items prior to drilling and installing all products.
Tools Needed
3/8” Wrench and Socket
7/16” Wrench and Socket
Drill
25/64” Bit
Phillips Driver
10mm Wrench and Socket
1/2” Wrench and Socket
9/16” Wrench and Socket
Table of Contents
Parts List............................................................................................................................................................ 2
Hardware .......................................................................................................................................................... 3
Step 1 –Attaching Side Wings .......................................................................................................................... 4
Step 2 –Attaching Top Panel............................................................................................................................ 5
Step 3 –Attaching Bottom Plate....................................................................................................................... 5
Step 4 –Attaching Roof Support ...................................................................................................................... 6
Step 5 –Installing Handle Mount ..................................................................................................................... 6
Step 6 –Installation Preparation ...................................................................................................................... 7
Step 7 –Installing Partition to Floor ................................................................................................................. 8
Step 8 –Installing Partition to Floor ................................................................................................................. 9
Step 9 –Installing Driver Side Wing to Van Siding.......................................................................................... 10
Step 10 –Installing Roof Support to Van Siding ............................................................................................. 11
Step 11 –Installing Handle to Handle Bracket ............................................................................................... 11
Step 12 –Installing Wing to “B” Pillar............................................................................................................. 12
Before You Begin
Read all instructions prior to installing any Kargo Master product.
Be sure to have 40640 partition assembled and ready to be installed before continuing.

Installation Instructions –40649TL
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 2
Parts List

Installation Instructions –40649TL
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 3
Hardware

Installation Instructions –40649TL
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 4
Step 1 –Attaching Side Wings
Using four 1/4” x 5/8” flanged bolts and four
1/4” flanged lock nuts, bolt passenger side (PS)
side wing to partition.
Snugly tighten.
Using four 1/4” x 5/8” flanged bolts and four
1/4” flanged lock nuts, bolt driver’s side (DS)
wing to partition.
Snugly tighten.

Installation Instructions –40649TL
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 5
Step 2 –Attaching Top Panel
Using six 1/4” x 5/8” flanged bolts and a 1/4” flanged lock nuts, bolt top wing to partition.
Snug tighten.
Step 3 –Attaching Bottom Plate
Using four 1/4” x 1/2” hex head bolts, four 1/4” lock washer, and four 1/4” washers, bolt through the
partition panels into the bottom panel.
Snug tighten.

Installation Instructions –40649TL
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 6
Step 4 –Attaching Roof Support
Using a 1/4” x 5/8” flanged bolt and
a 1/4” flanged lock nut and the
previously installed 1/4” x 5/8”
flanged bolt and 1/4” flanged lock
nut, LOOSELY bolt the roof support
to partition.
Step 5 –Installing Handle Mount
Remove handle from slider doorway as shown below.

Installation Instructions –40649TL
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 7
Using a M6 x 25mm hex head, 1/4” lock washer and a 1/4” split lock washer, install handle mount where
handle was previously removed.
Snug tighten.
Step 6 –Installation Preparation
Remove the D-rings from
both the driver’s side and
passenger side “B” pillars.
If wall liner is installed on
driver-side sidewall behind
the driver’s seat, remove wall
liner and wall liner holding
clips nearest the driver’s
seat. Wall liner can be
reinstalled later on during
installation.

Installation Instructions –40649TL
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 8
Step 7 –Installing Partition to Floor
Place assembled partition with wings into van
with the flanged side of partition facing to the
rear and wings bent towards the front.
Push the partition firm against the passenger
side “B” pillar.
Align holes in passenger side wing with
previously installed handle mount.
On the driver’s side, the holes in the outside
edge of the wing should line up with three
existing holes on the side of the van.
Holding the partition in place, use a straight
edge to ensure the bottom of the partition is
straight and square with van.
Be sure this is the desired location to install the
partition.
Mark all holes and slots along floor.
Remove partition with wings.
Based upon lack of obstructions and ease of installation, determine which four locations on each partition
panel to drill into floor.
DO NOT drill beyond depth of
floor. Always check that each
location is clear of wires, fuel tanks
and lines, brake lines and other
important vehicle functionality
items prior to drilling and installing
any product.
Use a drill stop to avoid
unnecessary damage.
Drill hole at each marked location using
25/64” drill bit and appropriate sized drill-bit
stop collar. If 25/64” drill bit is not available, a
3/8” drill bit can be used, although it may be
necessary to tap in the plus nuts.
Insert a 1/4” x 2-1/4” hex head bolt through a 1/4” washer and the plus nut installation tool, and then
screw the bolt into plus nut. Knurled end of plus nut tool must be directed away from bolt head and
contacting plus nut.
Insert and press plus nut, with tool still attached, into hole.

Installation Instructions –40649TL
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 9
Using the 9/16” box wrench, hold the plus nut tool stationary and then tighten hex head bolt until plus
nut is tightly gripping and does not spin when hex bolt is loosened.
DO NOT overtighten plus nut.
Step 8 –Installing Partition to Floor
Place assembled partition with wings
back into van. Align with previously
installed plus nuts.
Along the floor, at each plus nut, bolt
through partition panels using
1/4" x 1-1/4” hex head, 1/4" lock
washer, and a 1/4" flat washer.
Insert nylon spacer underneath
partition if needed.
Snug tighten.

Installation Instructions –40649TL
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 10
Step 9 –Installing Driver Side Wing to Van Siding
On the driver’s side of van, the driver’s wing should
line up with three (3) factory holes in the van siding.
There are two options for installing the wing to the
driver’s side van siding.
oThe first option is to bolt through the wing
and the hole in the side of the van using a
1/4" x 1-1/4”hex bolt, a 1/4” lock washer, a
1/4” washer, and a 1/4" flanged lock nut.
oThe second option is to install a plus nut into
the existing holes in the van siding, and then
bolt through the wing into each plus nut
using a 1/4" x 1-1/4” hex bolt, a 1/4” lock
washer, and a 1/4" washer.
oNOTE: If wall liner was removed, it may be
desirable to install the three plus nuts and
then reinstall the wall liner by sandwiching
it between the driver side wing and the van
siding.
Snug tighten.

Installation Instructions –40649TL
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 11
Step 10 –Installing Roof Support to Van Siding
On the driver’s side of van, the roof
support should line up with a factory
hole high in van siding.
Install a plus nut into the existing
hole in the van siding.
Bolt through the roof support into
the plus nut using a
1/4" x 1-1/4”hex bolt, 1/4” lock
washer, and a 1/4" washer.
Snug tighten.
Step 11 –Installing Handle to Handle Bracket
From the backside, using two
5/16” x 1-1/4” carriage bolts, two
5/16” flat washers, and two 5/16” lock
nuts, bolt through the rectangular slots
in the previously installed handle
mount, the passenger side wing, and
then through factory handle.
Snug tighten.

Installation Instructions –40649TL
For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 12
Step 12 –Installing Wing to “B” Pillar
Always check that each location is clear of wires, fuel tanks and lines, air bags, and
other important vehicle functionality items prior to installing screws into “B” pillar.
Screw passenger side wing into “B” pillar using four #14 x 3/4” sheet metal screws.
Reinstall D-rings through large holes in the
bottom panel.
GO BACK AND TIGHTEN ALL BOLTS.
YOUR INSTALLATION IS NOW COMPLETE.