Let's Go Aero GearDeck 17 Installation instructions

The GearDeck™17 Cargo Carrier is a highly versatile, modular system for multi-use purposes. The TwinTube®
UBI hitch rack is the structural foundation for the GearDeck capsule. Assembly consists of the TwinTube® UBI
installation on the hitch receiver, followed by installation of the GearDeck™ 17 capsule on the TwinTube® UBI.
Installation Tips:
•Keep this manual for future reference.
• TheGearDeck™17systemtsa2"sizereceiverstylehitchandrequiresaminimum
ofaClassIItowrating.IfyourvehiclehasaClassII,1.25"sizehitch,anadaptermay
be used.
•Keep in mind that the TwinTube® UBI is a precision built product and some consideration
of“alignment”isnecessarywhenrstassemblingthesystem.TheTwinTube®UBI
uses “symmetry” in a balanced manner, so when bolting the system together for the
rsttime,tightenallhardwareinatwostepprocess-rsttightentheassemblytoset
the components in position and then, when the TwinTube® UBI is installed, securely
tighten all hardware.
If this product was purchased from a dealer, all documentation MUST be furnished to the customer.
Part One
TwinTubeUBI®InstallationPage2
Part Two
GearDeck™ 17 Installation Page 7
GearDeck™ 17 carGo carrier
TelescopinG sysTem
iTem no. HDk796 / HDk802 (aka GD 4117-WB / GD 4117-BB)
User Assembly and Operation Manual
Part Three
Safe Use and Operation Page 9
U.S. And International Patent Numbers: 6,409,203; 6,609,725; 6,945,550;6,910,609; Patents Pending
HDK796/HDK8020415

parTs iDenTificaTion
Parts List
Item Description Quantity
Tools Needed
3/4"Wrench
3/4"Socket
1/4"WrenchorSocket
7/16"Wrench
Two Silent Hitch Pins are included with TwinTube® UBI
to prevent the inherent rattle that occurs when placing an
accessory device (in this case, TwinTube® UBI) into the
receiver hitch. The installation process is the same for
both Silent Hitch Pins, the Hexhead Silent Hitch Pin® (J)
secures the TwinTube® Assembly to the receiver hitch and
the Hand Tighten Silent Hitch Pin® (K) secures the Frame
Assembly to the Spine Assembly.
1. OrienttheShank(A)withthetwo5/8"holestoward
the receiver hitch on the vehicle. Insert the spring nut
from the Hexhead Silent Hitch Pin® Assembly (J) into
the Shank and line it up with the second hole from the
end of the Shank (A).
silenT HiTcH pin® insTallaTion
TheSilentHitchPins®mustbermlytightenedtowork
properly. Make sure you use the Hexhead Silent Hitch
Pin® (J) to attach the Shank to the receiver hitch and
use a wrench to securely tighten it.
WARNING
Note: Use the bolt hole in the Shank that places the
TwinTube® as close to your vehicle as possible. If
more clearance is needed use the last hole in the
Shank.
Spring Nut
Shank (A)
Use Second Hole
unless more clear-
anceisrequired
1
2. Slide the Shank with the spring nut installed into the
vehiclehitchandlineuptheShank’sboltholeswith
the hole in the hitch.
Make sure the washer is on the Hexhead Silent
Hitch Pin® (J) and thread it into the threaded spring
nut. Use a wrench to securely tighten the Hexhead
SilentHitchPin®(J)to30ft.lbs–60ft.lbs.oftorque
(equivalenttotighteningalugnutonacarwheel).
Install the pin clip from the assembly.
2
Shank (A)
Receiver
Hitch
Hexhead Silent
Hitch Pin
Washer
Pin Clip
spine assemBly
3. The V-Plate (B) with the Safety Cable hole goes on
the passenger side of the Shank (A). Orient both
V-Plates (B) so that they angle up and away from
the Shank (A) and the lower holes in the plates line
upwiththe1/2"holesintheShank.Installa1/2"
ShoulderBolt(P),two1/2"Washers(Q)anda1/2"
LockingNut(R)ineachhole.Usea3/4"Wrenchand
a3/4"Sockettopositiontightenthebolts.
Note: V-PlatesMUSTbeattachedangledAWAYfromthe
vehicle for product to install properly.
3
parT one: insTall TWinTuBe® uBi on HiTcH receiver
If you are missing any items, contact your sales agent if the product was assembled by them.
If not, or if purchased from Let’s Go Aero, please contact us at 1-877-GO-4-AERO (464-2376).
A Shank 1
B V-Plates 2
C Top Plate 1
D TelescopeTubes 2
E FixedTubes 2
F Wings(44"CChannel) 2
G TopHatBrackets 4
H 1/4-20U-Bolts 4
J Hexhead Silent Hitch Pin® Assembly 1
K Hand Tighten Silent Hitch Pin® Assembly 1
L SafetyCablewith2QuicklinkConnectors 1
M EndCaps 2
N EndCap&ReectorAssembly 2
P 1/2"ShoulderBolts 6
Q 1/2"Washers 12
R 1/2"LockingNuts 6
S 1/4"Washers 16
T 1/4"LockingNuts 12
U Safety Cable Retainer 1
V Center Plate 1
W 1/4-20x3/4"Bolts 4
X SlideBumpers 2
 ParafnStarterWax 1
Item Description Quantity
The TwinTube® UBI system features separate components that extend and enhance the load carrying
capabilities of a receiver style hitch.
• TheSpineassembly,whichprovidesUBI’sstructuralstrengthandtelescopesupport.
• TheFrameassemblywhichprovidesUBI’scarrier,platformorboxmountinginterfaceand
telescoping function.
• SafetyCableQuickLinksallowtheFrameandSpinesystemcomponentstobeseparated,
therebydividingtheUBI’sweightinhalf.Thisprovidesease-of-usewheninstallingorremoving
and storing the system.
C
MM
P
Q
A
J
P
Q
B
T
T
T
V
W
SQ
R
B
R
Q
L
E
E
X
X
Q
P
N
G
N
T
TS
S
KG
K
KT
G
D
F
H
D
F
H
U
S
G
H
Frame Assembly
Spine Assembly
4. Place the Center Plate (V) between the V-Plates.
Installa1/4-20x3/4"Bolt,two(2)1/4"Washersanda
1/4"LockingNutineachhole.Thentightenthebolts
on the Center Plate.
1/4-20x
3/4"Bolts
1/4-20x
3/4"Bolts
1/4"Locking
Nuts
1/4"
Washers
1/4"
Washers
V-Plates (B)
Safety Cable Hole
Receiver
Hitch
1/2"Shoulder
Bolts (P)
1/2"Washers(Q)
1/2"Washer(Q)
1/2"Locking
Nut (R)
4
Page2of9 Page 3 of 9

5. Place the Fixed Tubes (E) between the top of the V-
Plates (B) and place the Top Plate (C) on top. Install
a1/2"ShoulderBolt(P),two1/2"Washers(Q)anda
1/2"LockingNut(R)ineachhole(2perTube).Usea
3/4"Wrenchanda3/4"Sockettopositiontightenthe
bolts.
5
10
8
Fixed Tubes (E)
Top Plate
1/2"Shoulder
Bolts (P)
1/2"Washers(Q)
1/2"Locking
Nuts (R)
1/2"Washers(Q)
1/2"Shoulder
Bolts (P) 1/2"Washers(Q)
6. Securely tighten the bolts that attach the V-Plates (B)
to the Shank (A). Make sure that the bolts are so tight
thatitisdifculttotightenthemfurtherusinghand
tools. Then snug tighten the bolts on the Center Plate
to12ft.lbs.
Periodically check that the bolts are tight to ensure
TwinTube® performs as designed.
Caution
8. Insert the spring nut from Hand Tighten Silent Hitch
Pin Assembly (K) into the Telescope-Safety pin hole
on one of the Fixed Tubes (E). Line up spring nut hole
with the Telescope-Safety Pin hole.
Note: It does not matter which Fixed Tube is used.
9. Securely tighten the bolts that attach the Fixed Tubes
(E) to the V-Plates (A). Make sure that the bolts are
sotightthatitisdifculttotightenthemfurtherusing
hand tools.
Spring Nut from Hand
Tighten Silent Hitch Pin
Either Fixed Tube
may be used
Telescope Safety Pin Hole
10. Rubthetop,sidesandcornersoftheSpine’s
FixedTubes(E)withtheenclosedbarofParafn
Wax.Thisreducesfriction,providestelescope
smoothness, and protects the powder coated paint
fromwear.YouwillndthatTwinTube’sParafnWax
is a great solution to clean, hassle-free operation.
Once applied, it stays put and stays clean.
Rub top, sides and corners
withParafnWax
frame assemBly
11.Locate the Telescope Tubes (D) and orient them to
the Spine Assembly with the weld seam down and
with the hole away from the Spine. The hole in each
Telescope Tube (D) must line up with the hole in the
Fixed Tube (E).
Telescope Tubes (D)
Holes must align
11
Fixed Tubes (E)
12
14
12. Thetwo44"Wings(F)formthemountingsurfaceof
theTwinTubeUBI®.TheWingsareadjustablefor
different platform widths, but they must be at least
12”aparttosupportaloadproperly.
 TherstWing(F)shouldbemountedasclose
to the Top Plate (C) of the Spine Assembly as
possible, depending on spare tires or ladders on
the vehicle.
 TomountthisWing,placetwo1/4x20U-Bolts(H)
in the pre-drilled mounting holes in the bottom of
theWingchannelandpositiontheWingonthe
Telescope slide tubes. Place the Safety Cable
Retainer (U) on the passenger side and a Top-Hat
Bracket (G) over the U-Bolt threads. Secure the
Bracketswitha1/4"Washer(S)anda1/4"Locking
Nut (T) on each leg of each Bracket.
13. Check that the Telescope Tubes (D) are as
far toward the vehicle as possible and that the
Telescope Pin holes in the rear of the Spine and
TelescopeTubes(D)arealigned.Wheneverything
isaligned,tightenthe1/4x20LockingNuts(T)on
theU-Bolts(H).Tightenthe1/4x20LockingNuts
alternating from side to side so each side of the
Top-HatBracketisequallycompressedaroundthe
TelescopeTube(D).Usea7/16"wrenchtosnug
tightenthenutsto12ft.lbs.
Slide the Frame back and forth on the Spine to
check the alignment. If any binding is observed,
check to be sure that the Telescope Tubes (D) both
come to rest against the Top Plate on the Spine and
thattheWingismounted“squarely”.Ifnot,loosen
the Top Hat Bracket fasteners and reposition the
Wing(F).
14. RepeatSteps9and10withtherearWing(F).
Leave the U-Bolts (H) and Locking Nuts (T) loose
enoughsotheWingcanmoveforwardorbackas
neededtottheboltholepatternoftheplatform
youintendtomountonUBI.Youmayadjust
bothWingsalongtheFrametubeasneededto
accommodate your platform of choice, as well as
for additional clearance to accommodate spare
tires, etc. on the back of your vehicle.
Note: AfterinstallingyourplatformofchoicetotheWings,
thelaststepistormlytightenallthe1/4x20
NutssecuringtheTop-HatBracketstotheWings.
Tighten these in a balanced fashion until securely
snug. Between uses, periodically re-check these
fasteners for proper tightness.
TheWingsmusttsquarelyontheTelescopeTubes
for the U-Bolts to tighten correctly and for the telescope
feature to operate freely. Tighten the Top Hat Brackets so
thattheearsdeectintoaslightbend.
Caution
44"Wing(F)
1/4x20U-Bolts(H)
1/4"Washers(S) 1/4"Locking
Nuts (T)
Top-Hat Bracket (G)
Safety Cable
Retainer (U)
Top Plate (C)
1/4"Washers(S)
and1/4"Locking
Nuts (T)
Top-Hat
Bracket (G)
1/4"Washers(S)and
1/4"LockingNuts(T)
Top-Hat Bracket (G)
44"Wing(F)
1/4x20U-Bolts(H)
1/4"Washers(S)
and1/4"Locking
Nuts (T)
Top-Hat
Bracket (G)
9
13
The44"Wingsmustbeatleast12"aparttosupporta
load properly.
WARNING
7. Place a Slide Bumper (X) over each Fixed Tube and
slide them back against the Top Plate.
7
Slide Bumpers (X)
Page4of9 Page5of9

17
16. InstalltheEndCaps(M)withoutreectorsintothe
ends of the Fixed Tubes (D) closest to the vehicle
andtheEndCapandReectorAssemblies(N)
into the ends of the Telescope Tubes at the rear
of TwinTube® (farthest from vehicle for view from
behind).
17. The Hand Tighten Silent Hitch Pin® (K) with the
handleisforsecuringTwinTube’sFrametothe
Spineduringuse.Whenthispinisengaged,it
helpspreventcarriermovementorwobble.Whenin
transit, it prevents the Frame from sliding rearward
ontheSpine.Besuretousethe1/4"x5/8"nylon
bushing on the Silent Hitch Pin® assembly to
prevent any scratching or marring of the powder
coatednishontheTelescopeTube(D).Toinstall,
thread the Hand Tighten Silent Hitch Pin® (K) into
the spring nut that was installed in Step 6. Install
the pin clip from the assembly.
WARNING
TheHandTightenSilentHitchPinMUSTbermlysecured
in Telescope-Safety pin hole location before transit. Failure
to do so may result in potential hazards from improper
operation,includingpropertydamageandbodilyinjury.
15. Attach the Safety Cable (L) to the passenger side
V-Plate (B) and the Safety Cable Retainer (U) on
theFrameusingtheQuick-Linksattachedtothe
cable. This will ensure that the Frame cannot slide
off the Spine inadvertently. To remove the Frame
andcarrierfromtheSpine,simplyundooneQuick
Link. This allows TwinTube® to be separated into
its two component parts to ease the installation,
removal and storage of the system. 15
16
16
Safety Cable (L)
V-Plate (B) -
Passenger Side
Safety Cable
Retainer (U)
End Caps (M)
EndCapandReector
Assemblies (N)
Hand Tighten Silent
Hitch Pin (K)
Nylon Bushing
Pin Clip
Never move your vehicle with the TwinTube™ UBI ex-
tended in the telescoped position. It must always be prop-
erly secured before transit. Failure to do so may result
inpotentialhazardsfromimproperoperation,including
propertydamageandbodilyinjury.
WARNING
parTs iDenTificaTion
Parts List
Item Description Quantity
Tray Assembly
A Tray 1
B D-RingTieDowns 4
C 1/4-20Bolts 10
D 1/4-20NylockNuts 10
E 1/4"FlatWashers 10
F 1/4"x1-14"FenderWashers 10
G DrainPlugs 4
Lid Assembly
H Lids 2
J AluminumAngles 2
K 1/4-20x1"StainlessSteel
 ButtonSocketHeadCapBolts 4
L 1/4"x1"StainlessSteelFenderWashers 4
M 1/4"Washers 4
N 1/4-20NylockNuts 4
P AllenWrench 1
If you are missing any items, contact your sales agent if the product was
assembled by them. If not, or if purchased from Let’s Go Aero, please
contact us at 1-877-GO-4-AERO (464-2376).
Tools Needed
7/16"SocketWrench
Rubber Mallet
HexWrench(included)
Install the TwinTube® UBI on your hitch receiver rst.
The GearDeck ™ 17 Cargo Carrier should be installed as close to your vehicle as possible. There are two hitch receiver
boltholesettingsfromwhichtochoose.YoumayalsoadjustthepositionofthewingsalongtheFrameTubeforupto6"
ofaddeddistancefromyourvehicleforatotalof15-1/4"ofinstalledclearanceasneeded.
A
L
HK
H
B
C
D
E
J
N
G
Telescope
Rear Clearance
Installed
6-3/4"
9-1/4"
Range of Motion along Tube
toAdjustRearClearance
6"
parT TWo: insTall GearDeck™ 17 capsule
TheGearDeck™17systemiscompletedwiththeassemblyoftheGearDeck™17capsule’strayandlids.
Page 6 of 9 Page 7 of 9

WARNINGS
Failure to adhere to these recommendations may result in potentialhazardsfromimproperoperation,includ-
ingpropertydamageandbodilyinjury.
• Engage Silent Hitch Pins®
Both pins MUST be securely engaged before transit. A wrench MUST be used to tighten the Hexhead
Silent Hitch Pin® at the hitch receiver location.
• Secure the GearDeck™ 17 Cargo Carrier as close to vehicle as possible
AlwayssecureGearDeck™17asclosetoyourvehicleaspossible,minimizingthedistanceofthis
structureanditsloadfromyourvehicle.Therearetwoboltholesettingsfromwhichtochoose.You
mayalsoadjusttheWingsforupto6"ofrearinstalledclearancefromyourvehicleasneeded.See
Step10ofthisUserManualforWingadjustment.
• Verify that the Safety Cable is Secured
The Safety Cable prevents the Frame from sliding off the Spine when telescoping the GearDeck™ 17
Cargo Carrier. It should always be engaged for this reason, and to prevent the cable from dragging on
the ground while in transit.
• Never move your vehicle with the GearDeck™ 17 extended in the telescoped position.
The GearDeck™ 17 must always be properly secured before transit.
• Secure the GearDeck™ 17 Latches before Transit.
Always secure the lids together before transit by pulling the draw latch over the receiver end.
1. Place the Tray over the wings of the TwinTube®
UBI and line up the holes in the tray with the
holes in the wings. Place the D-Ring Tie Downs
over the outer most set of holes on each end of
thetray.Installa1/4-20Boltanda1/4"x1-1/4"
FenderWasherineachholeinthebottomofthe
Tray through the wings. Secure each bolt to the
TwinTubeWingwitha1/4"FlatWasheranda1/4-
20NylockNut.
2. Locate the Lid with the latches on the side. Place it
on the side of the Tray nearest the vehicle. Align the
four(4)holesinthesidesoftheLidwiththeholes
intheTray.Placea1/4"x1"StainlessSteelFender
Washerovera1/4-20x1"StainlessSteelButton
Socket Head Cap Bolt and insert the bolt into the
holefromtheoutside.Threada1/4"Washerand
1/4-20NylockNutovertheboltfromtheinsideand
tightenwithanAllenWrenchand7/16"socket.
Repeatatallfour(4)locations.
4. Locate the two Aluminum Angles in the parts kit.
Theyprovideadditionalsidewallrigidityforthexed
Lid and will be installed inside the lid between the
plastic and the heavy-duty weatherstripping.
Peel the weatherstripping away from the vertical
edge of the Lid. Place the Aluminum Angle on the
insideoftheLidushwiththebottom.Reinstall
the weatherstripping over the edge of the Lid
and the Aluminum Angle. Use a rubber mallet
to tap it into place if necessary. Crimp the lip of
the weatherstripping over the Lid and Aluminum
Angle to provide a tight grip that cannot easily be
removed.
5. If you wish to install a license plate on the
GearDeck,alocationisprovidedontheTray.We
recommendthatyouinstalltheplateonthedriver’s
side. Use the license plate as a template to drill two
holes in the tray.
1
2
3
3. Slide the hinges on the Pivoting Lid over the hinge
posts on the fixed Lid and close it.
54
D-Ring Tie Downs
Tray
TwinTube™
UBI
1/4-20Bolts
1/4"x1-14"
Fender
Washers
1/4"Flat
Washers
1/4-20Nylock
Nuts
1/4"x1"Stainless
Steel Fender
Washer
1/4-20x3/4"Stainless
Steel Button Socket
Head Cap
1/4-20Nylock
Nut (Inside)
Aluminum Angle - Place
along edge under
Weatherstripping
Drill Holes for License Plate
if desired
safe use & operaTion
Be sure to follow these guidelines to prevent possible hazards from misuse.
Vehicle and Hitch Receiver Compliance
ThisGearDeck™17CargoCarrierts2"sizehitchreceiversandisratedforaClassIItowcapabilityorhigher(ClassII,
IIIandup).Whenoperatingatowaccessory(anyiteminsertedintothehitchreceiver),youmustcomplywiththevehicle
andhitchreceiver’stowingparameters.Consultyourvehicleandhitchreceiverownermanual(s)fordetailsonyourtow
andtongueweightparameters.BesurethattheyarecompatiblewithGearDeck™17’sweightspecications.
Tongue Weight Compliance
The GearDeck™ 17 and its cargo creates a combined weight that creates direct downward pressure on the hitch receiv-
er’stongue.Thisdownwardpressureisthetongueweight.Tongueweightisoneofthetwocriticalweightratingfactors
ofyourtowrating’sclassication(ClassI,II,III,IV,V).Never exceed your vehicle and hitch receiver’s tongue weight
specication.
GearDeck™ 17 Weight and Load Parameters
TheGearDeck™17weighs72lbsunloaded.Todetermineyouravailableloadweightinaccordancewithyourvehicleand
hitchreceiver’stongueweightrating,subtractGearDeck™17’s72lbsfromyouridentiedtongueweightrating.Thedif-
ferencerepresentsyourvehicleandhitchreceiver’savailableloadweight.
TheGearDeck™17isratedforupto300lbsofcargoweightcarryingcapacity.Whentransportingcargo,placeheavy
loads in the center and lighter cargo to the outside.
Telescoping GearDeck™ 17 Cargo Carrier
To telescope the GearDeck™ 17, remove the Hand Tighten Silent Hitch Pin® from the Telescope Safety pin hole. Verify
that the Safety Cable is secured and then slide the frame to the rear.
Locking Up GearDeck™ 17
ApadlocklocationisprovidedforalockinthecenteroftheLid’slipontheside.Werecommendalockwitha1"shankhook.
1/4"Washer
(Inside)
We warrantthis product to therst consumerto befree from defect in materialand workmanship for oneyear (Pleaseretain your salesslip for yourrecords).
Any product or part thereof found to be defective within that period will be replaced without charge provided that: (1) the product was not misused; (2) no
alterations or modications were made; (3) its failure resulted from a defect in material or workmanship and not from normal wear expected in the use of
the product; (4) the product or part is delivered, freight prepaid, to Let’s Go Aero. Please contact Let’s Go Aero, toll free, at 877-464-2376 to get a return
authorization number prior to return. Manufacturers only obligation shall be to replace such products or parts proved to be defective.
Copyright©2006-2012Let’sGoAero,Inc.
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