Let's Go Aero GearDeck H00604 User manual

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GearDeck®
17 cu ft. Enclosed Slide-out Cargo Carrier
Part No. H00604
Revision Date: 12/12/19GDH00604-121219Rev
For More Information & Accessories, Visit our Website - www.LetsGoAero.com
For Technical Support & Product Questions Contact Us at 877-464-2376 or 719- 630-3800
Email: [email protected]
Installation & Safe Use Operation Highlights
For 2in Receivers Hitches and Class II Minimum Tow Rating.
Weighs 80 lbs empty. Rated for up to 300 lbs of cargo payload.
NOTICE: All Manual information is subject to change without notice. Revised editions
will be available for free download at LetsGoAero.com. Manual information is considered
factual until made obsolete by a revised version.
Follow this QR-Code or visit
LetsGoAero.com/manuals to check for an updated version:
Copyright© 2019, Lets Go Aero, Inc., All rights reserved. Patent Numbers 6,409,203; 6,609,725; D717718 Patents Pending
PRODUCT MANUAL
For product updates and to register your product, visit the LetsGoAero.com/registration

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A
B
C
D
E
F
G
H
K
L
M
N
P
Q
R
S
T
U
V
W
X
Y
Z
AA
BB
CC
DD
EE
FF
GG
JJ
KK
LL
MM
NN
PP
QQ
RR
SS
TT
UU
VV
WW
XX
YY
ZZ
1
2
1
1
1
1
1
2
1
2
2
2
4
8
1
2
8
8
1
10
10
10
10
4
1
1
1
4
4
4
4
8
6
2
8
2
2
2
2
1
2
2
4
4
4
2
TWINTUBE SPINE
RETAINER CLIP
5/8” SILENT HITCH PIN®
5/8” SILENT HITCH PIN WITH HANDLE
5/8” LOCK WASHER
5/8” FLAT WASHER
5/8” PLASTIC BUSHING
5/8” SPRING NUT
WAX
RUBBER BUMPER
SLIDE TUBES
WING
HAT BRACKETS
5/16” X 1” CARRIAGE BOLTS
SAFETY CABLE (W/ QUICK LINK)
REFLECTOR END CAPS, 2 1/4”
5/16” WASHERS
5/16” NYLOCK NUTS
TRAY
1/4-20 HEX BOLTS
1/4-20 NYLOCK NUTS
1/4” FLAT WASHER
1/4” X 1 1/4” FENDER WASHER
DRAIN PLUGS
FIXED LID
PIVOT LID (W/ LOGO)
HANDLE
1/4-20 X1” BUTTON-HEAD CAP BOLTS
1/4 X 1” FENDER WASHER
1/4” FLAT WASHER
1/4-20 NYLOCK NUTS
10X24-1 PHILLIPS PAN SCREW
#10 WASHER
3/16 X 1 FENDER WASHER
10-24 NYLOCK NUT
RUBBER LATCH
ANGLES
LATCH KEEPER
LED LIGHT
WIRE HARNESS
LED LICENSE PLATE BRACKET
LED MOUNT BRACKET
HEX BOLT
NYLOCK NUT
FLAT WASHER
K-LATH TEX SCREWS
QTY. DESCRIPTION QTY. DESCRIPTION
PARTS LIST
PARTSPARTS
STEP 1
Remove Spring Nuts [H] from Silent Hitch
Pins and install two Spring Nuts into the
TwinTube Spine [A] as shown. [Fg.1-3]
The TwinTube [A] shank
end contains two mounting
holes. [Fg.2] Use the second
hole in from the end. If more
clearance is needed, you
may use the rst hole in from
the end.
A
H
H
[Fg. 2]
[Fg. 3]
[Fg. 1]
H
AH
A
1ST HOLE
2ND HOLE
STEP 2
Slide the TwinTube [A] shank into the
receiver with the 6 inch rise positioned
above the hitch as shown. Align the
mounting hole (with the Spring Nut [H])
with the hole in the receiver hitch. [Fg.4]
Insert the Silent Hitch Pin [C] with a
5/8in Lock Washer [E] & 5/8in Flat
Washer [F] into the receiver hole and
thread through the Spring Nut [H] as shown. Tighten rmly with
wrench and secure with Retainer Clip [B]. [Fg. 5]
REQUIRED TOOL: 7/8” WRENCH
B
E
A
H
C
F
Hitch Receiver
[Fg. 5]
A
[Fg. 4]
THIS END INTO
VEHICLE
HITCH RECEIVER
POSITION WITH
RISE AS SHOWN

Page 3 of 11
STEP 3
Rub the Wax Block [K] all over
along the all four sides of the
TwinTube [A] Spine’s dual tubes.
[Fg. 6 & 8]
Install two Rubber Bumpers [L],
with one onto each xed tube of
the TwinTube [A]. [Fg. 6 & 7]
L
L
A
[Fg. 6] [Fg. 7]
K
[Fg. 8]
A
STEP 4
Slide the female Slide Tubes [M] all the way onto the xed
tubes of the TwinTube [A] Spine. [Fg. 9]
Be sure that the mounting holes on the TwinTube [A] and
Slide Tubes [M] align. AM
Mounting Hole
Mounting Hole
[Fg. 9]
STEP 5 REQUIRED TOOL: 1/2” WRENCH
M
P
T
U
QN
Set the one (1) Wing [N] on top of the Slide Tubes [M].
Bring two (2) Hat Brackets [P] up from underneath the Slide Tubes [M] so the
Hat Brackets wrap around the Slide Tubes and align with the holes located along
the Wing [N].
Using two (2) 5/16in Carriage Bolts [Q], two (2) 5/16in Carriage Washers
[T], and two (2) 5/16in Nylock Nuts [U] per Hat Bracket [P], connect the Hat
Brackets to the Wing [N] as shown. [Fg. 10]
[Fg. 10]
Hand tighten only at this time, further adjustment will be required before
nal assembly.
WARNING:
Silent Hitch Pin must be secured in hitch with wrench before transit.

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STEP 6 REQUIRED TOOL: 1/2” WRENCH
P
Q
T
ZZ
M
R
N
[Fg. 11]
U
On the side of the base that is closest to the
vehicle, in the same manner as STEP 5, attach
the remaining Wing [N] to the Slide Tube [M]
using two (2) Hat Brackets [P] along with two
(2) 5/16in Carriage Bolts [Q], two (2) 5/16in
Carriage Washers [T], and two (2) 5/16in Nylock
Nuts [U] on each side, adding the “looped end”
of the Safety Cable [R] between the Hat Bracket
and Wing [N] on one side only. [Fg.11]
IMPORTANT: The Safety Cable [R] must be
placed on the interior of the Slide Tube [M] and
on the side of the Wing [N] that is closest to the
vehicle.
STEP 7
STEP 8
Slide the 5/8 Plastic Bushing [G] onto the Silent Hitch Pin with Handle [D].
In the same manor as STEP 2, insert and thread the Pin [D] with the Plastic
Bushing [G] through the aligned holes of the Slide Tubes [M], the TwinTube
Spine [A] and the Spring Nut [H] (note that either tube end shown may be
used for the Spring Nut/Silent Hitch Pin with Handle engagement, your choice).
Tighten threaded engagement rmly. Secure with Retainer Clip [B]. [Fg. 12]
NOTE: The Silent Hitch Pin with Handle [D] controls the slide-out function of the
platform. Once installation is complete, the Hand-Tighten Silent Hitch Pin may
be removed in order to slide the carrier rearward for rear hatch access when the
vehicle is stationary.
D
B
M
HG
[Fg. 12]
[Fg. 13]
Install the Reector End Caps [S] over both ends of each Slide Tube
[M] and secure with one (1) #10 K-Lath Tex Screw [ZZ] each. [Fg.13]
TIP: Reector End Caps are a tight t. Use a rubber mallet as a
dampener to carefully but rmly install.
S
M
WARNING:
Never operate the vehicle without the Silent Hitch Pin with Handle fully secured. Failure to follow proper procedures
may result in bodily injury and property damage.
Hand tighten only at this time, further
adjustment will be required before nal
assembly (see STEP 10).

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STEP 10: REQUIRED TOOL: 10MM SOCKET OR WRENCH
Z
Y
N
STEP 9
[Fg.14]
Never operate the carrier’s slide-out function without the Safety Cable [R] fully secured. Failure to follow proper
procedures may result in bodily injury and property damage.
WARNING:
R
Attach the carabiner to the Safety Cable [R] (if not
already pre-installed). From underneath the carrier,
connect the carabiner end of the Safety Cable [R] to
the “1st Position” hole in the frame of the TwinTube
[A]. [Fg.14]
NOTE: The Safety Cable [R] can be secured in two
positions. Secure the Safety Cable to the rst position.
For maximum installed clearance needs, the second
position may be used.
A
W
2ND POSITION
1ST POSITION
Place the Tray [V] over the 41”
Wings [N] and line up the holes
in the tray with the holes in the
Wings.
Install a 1/4-20 Hex Head Bolt [W]
and a 1/4" x 1-1/4" Fender Washer
[Z] in each hole in the bottom of
the Tray [V] through to the Wings
[N]. Secure each bolt to the Wing
with a 1/4" Flat Washer [Y] and a
1/4-20 Nylock Nut [X]. [Fg. 15]
NOTE: The larger 1/4” x 1-1/4”
Fender Washer [Z] must be
installed inside of the carrier while
the smaller 1/4” Flat Washer [Y]
must be installed from underneath
the carrier. [Fg. 16 & 17]
X
V
W
N
Y
X
Z
V
[Fg.16]
[Fg.15]
[Fg.17]
Position side of Tray
with two holes closet to
vehicles.

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STEP 11
With the Hat Brackets [P] from STEP 5 & 6 still loosely secured, slide the carrier back and forth along the Slide Tubes [M]
to adjust for required vehicle clearances (user discretion). Once the nal clearance adjustments have made, conrm the
aligned Slide Tubes are slid all the way back against the Rubber Bummers [L] and then fully secure all Hat Brackets [P]
and hardware from Steps 5 & 6.
NOTE: Users wanting less clearance between the tow vehicle and carrier should position the Hat Brackets [P] closer to
the vehicle on the Slide Tubes [M] [Figure 18].
NOTE: Users wanting more clearance between the tow vehicle and carrier should position the Hat Brackets [P] further
away from the vehicle on the Slide Tubes [M] [Figure 19].
NOTE: Be sure to allow room for the Hand-Tighten Hitch Pin [D] to turn and operate as required.
DO NOT ALLOW HAT BRACKETS [P] TO OVERLAP THE 3.5” WARNING LABEL LOCATED
ON ON THE SLIDE TUBE. Failure to do so will permit over-extension of the safety cable allowing
the capsule to slide off and cause damage or personal injury.
WARNING:
MIN INSTALLED CLEARANCE MAX INSTALLED CLEARANCE
M
MPP D
DWARNING
WARNING
[Fg. 18] [Fg. 19]
STEP 12
Using the Supplied Hardware pre-attached to both LED Lights [SS] mount each LED Light onto a LED Mount Bracket
[VV] in the order shown. [Fg.
20]
OPTIONAL:On the LED
Light [SS] marked LEFT only,
optional License Plates Brackets
[UU] may also be included
in-between the Small Washer
(supplied with the LED Lights)
and the LED Mount Bracket
[VV] as shown for the mounting
of a (user supplied) license
plate. [Fg. 21]
REQUIRED TOOL: 1/2” WRENCH
REQUIRED TOOL: 7MM WRENCH & PHILLIPS HEAD SCREW DRIVER
[Fg.20] [Fg.21]
VV VV
UU
SS
SS

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USER-SUPPLIED
LICENSE PLATE
USER-SUPPLIED
LICENSE PLATE
USER-SUPPLIED
LICENSE PLATE
[Fg.22]
[Fg.23]
[Fg.24]
STEP 13 OPTIONAL
STEP 14
WW
WW
YY
XX
UU
UU
YY
This step is for the OPTIONAL installation of a (user
supplied) license plate. If you did not install the License
Plate Brackets [UU] onto your LED Light kit during Step
12, you may skip this step and continue onto Step 14.
Attach a (user supplied) License Plate to the License
Plate Brackets [UU] using two (2) Hex Bolts [WW], two
(2) Flat Washers [YY], and two (2) Nylock Nuts [XX] as
shown. [Fg. 22]
Install the LED Lights Kits onto the Tray [V]
using two (2) Hex Bolts [WW], two (2) Flat
Washers [YY], and two (2) Nylock Nuts [XX]
(one for each light) to mount the LED Light
Bracket [VV]. [Fg. 23 & 24]
NOTE: Be sure the LED Light [SS]
marked LEFT (yellow wire) is installed
on the DRIVERS SIDE of the vehicle. The
LED Light marked RIGHT (green wire)
must be installed on the PASSENGER
SIDE of the vehicle.
V
XX
REQUIRED TOOL: TWO (2) 7/16 WRENCH OR SOCKET
REQUIRED TOOL: TWO (2) 7/16 WRENCH OR SOCKET
Connect the Wire Harness [TT] to the in-line plug ends of each LED Light [SS]
wire. [Fg. 25]
NOTE: Be sure the LED Light [SS] marked LEFT with the Yellow Wire is connected
to the Wire Harness in-line end that also has a Yellow Wire and the LED Light
market RIGHT (green wire) is connected to the Wire Harness end that also has
Green Wire.
TIP: Wrap the connections with electrical tape to increase the longevity of the
LED Lights [SS], especially when the LED Lights are subjected to poor weather
conditions.
Connect the 4-at end of the Wire Harness [TT] to a 4-at wire plug connection on the vehicle. Secure with zip ties.
Check and conrm the LEDs are installed and wired properly by preforming a full test on each brake light, left turn signal,
right run signal, and hazard signal.
TT
SS
[Fg.25]
STEP 15

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STEP 17
[Fg. 26]
STEP 16
Place the Fixed Lid [BB] on the
side of the Tray [V] nearest the
vehicle. Align the four (4) holes
(two holes on the back of the
tray, one hole on each side)
of the Lid with the holes in the
Tray.
Using two (2) 1/4-20 x 1” Button
Socket Head Cap Bolt [EE],
two (2) 1/4” x 1” Stainless Steel
Fender Washer [FF], two (2) 1/4" Washer
[GG] and two (2) 1/4-20 Nylock Nut [JJ]
secure the holes locations located in the back
of the carrier. [Fg. 26]
NOTE: The larger 1/4” x 1” Stainless Steel
Fender Washer [FF] must be installed on
top of the Fixed Lid [BB]
while the smaller 1/4” Washer
[GG] must be installed from
underneath the Tray [N] edge.
[Fg. 27 & 28]
NOTE: Remove the Hand-
Tighten Silent Hitch Pin [D]
and slide the carrier out for
more access to hole locations
if necessary.
Using two (2) 1/4-20 x 1”
Button Socket Head Cap
Bolt [EE], two (2) 1/4” x
1” Stainless Steel Fender
Washer [FF], two (2) 1/4"
Washer [GG] and two (2)
1/4-20 Nylock Nut [JJ]
secure the holes locations
located on the sides of the
Tray [V]. [Fg. 29 & 30]
NOTE: The larger 1/4” x
1” Stainless Steel Fender
Washer [FF] must be
installed on the outside of the Fixed Lid [BB] while
the smaller 1/4” Washer [GG] must be installed
from inside the Tray [N] edge.
REQUIRED TOOL: 7/16” SOCKET & 5/32” ALLEN WRENCH
REQUIRED TOOL: 7/16” SOCKET & 5/32” ALLEN WRENCH
EE
FF
BB
GG
JJ
V
[Fg. 27]
[Fg. 28]
[Fg. 29]
[Fg. 30]
EE
GG
FF JJ
BB
V

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STEP 18
STEP 19
[Fg. 31] [Fg. 32]
BB BB
Pull the weather-stripping away from the
vertical edges of the Fixed Lid [BB].
Position and align the Angles [QQ] on the
inside of the Fixed Lid [BB] as shown. [Fg. 31]
Working from the top of the Angle [QQ],
reinstall the weather-stripping over the edge of
the Angle held against the lid (be sure to hold
the angle completely ush with the edge of the
carrier until fully installed). [Fg. 32]
Crimp the lip of the weather-stripping over the
Fixed Lid [BB] and Angle [QQ] to provide a
tight grip.
Install all four (4) Drain Plugs [AA] into the large holes in the bottom
of the Tray [V]. [Fg. 33]
WEATHER
STRIPPING
WEATHER
STRIPPING
QQ
QQ
[Fg.33]
AA
V
STEP 20
Install one (1) Rubber Latch [PP] onto each
side of the Fixed Lid [BB] using two (2) 10x24-1
Phillips Pan Screw [KK], two (2) #10 Washers
[LL] and two (2) 10-24 Nylock [NN] on each
side. [Fg. 34]
NOTE: Though only one bolt is shown in Fg. 34
for clarity. Two (2) Phillips Pan Screw [KK] per
latch are needed.
BB PP
KK
LL
NN
[Fg.34]
REQUIRED TOOL: 3/8” WRENCH & PHILLIPS SCREW DRIVER
Weather Stripping may disengage from lid during transit due to unnatural pressure from tightly nested lid
during shipping. Simple follow procedures to re-apply.

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STEP 21
Install Handle [DD] onto the Pivot Lid
[CC] (with the GearDeck Logo) where
holes have been pre-drilled using 10x24-
1 Phillips Pan Screws [KK] secured on
the inside with 3/16” x 1” Fender Washers
[MM], and 10-24 Nylock Nuts [NN]. [Fg.
35]
[Fg.35]
[Fg.36]
DD
CC
KK
MM
NN
STEP 22
Install one Latch Keeper
[RR] onto each side of
the Pivot Lid [CC] where
holes have been pre-drilled
using 10x24-1 Phillips Pan
Screws [KK] secured on
the inside with one (1) #10
Washer [LL] and one (1)
10-24 Nylock Nuts [NN].
[Fg. 37]
NOTE: The Latch Keeper [RR] must be
installed so that the Latch Keeper points
toward the large GearDeck logo on the
front of the lid as shown. [Fg. 36]
KK
RR
LL
NN
CC [Fg.37]
STEP 23
Slide hinges on the
Pivoting Lid [CC]
over the hinge posts
on the xed Lid [BB]
and close the lid. [Fg.
38 & 39]
NOTE: A slight offset is provided on the Driver Side
hinge as an alignment aid to attaching and removing
the pivoting lid to the xed lid.
CC
BB
[Fg. 39][Fg. 38]
REQUIRED TOOL: 3/8” WRENCH & PHILLIPS SCREW DRIVER
REQUIRED TOOL: 3/8” WRENCH & PHILLIPS SCREW DRIVER

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Always check and conrm all bolts and connections are tight and fully secure before each transit. Always conrm the GearDeck
Lid is closed and the Rubber Latch is fully secured over the Pivoting Lid of the carrier. Failure to follow proper installation and
equipment checks before transit may result in damage to carrier, damage to property, bodily injury or death.
WARNING:
Vehicle and Hitch Receiver Compliance
This GearDeck Cargo Carrier ts 2" size hitch receivers and is rated for a Class II tow capability or higher. Before using
this product, consult your vehicle and hitch receiver owner manual(s) for details on your tow and tongue weight parame-
ters. Be sure that they are compatible with GearDeck’s weight specications. Never exceed vehicle or hitch weight limits.
GearDeck Weight and Load Parameters
The GearDeck weighs 80 lbs unloaded. To determine your available load weight in accordance with your vehicle and
hitch receiver’s tongue weight rating, subtract GearDeck’s 80 lbs from your identied tongue weight rating. The difference
represents your vehicle and hitch receiver’s available load weight.
The GearDeck is rated for up to 300 lbs of cargo weight carrying capacity for a combined weight of 380 lbs when fully
weight loaded.
Sliding Out GearDeck Cargo Carrier & Clearance Adjustability
To telescope the GearDeck, remove the Hand Tighten Silent Hitch Pin® from the Slide Tube’s Safety pin hole. Verify that
the Safety Cable is secured and then slide the frame to the rear. When adjusting the position of capsule clamps for added
clearance needs, be sure to adhere to NO USE AREA distance of 3.5 inches rearward from Spine’s vertical plate along
the frame tubes.
Closing Lid & Lock Up
Always secure draw latches on both sides of GearDeck before transit. A hole is tapped on the Pivot Lid and Tray for use of a
lock (not included). A padlock works well.
Limited Lifetime Warranty
Car vehicle exhaust can cause a hazard. As a precaution, position carrier clear of exhaust.
CAUTION:
If a Let’s Go Aero bike rack is found to have a defect in workmanship or material over the lifetime of the original purchaser, Let’s Go
Aero will repair or replace the defect free of charge. This warranty terminates if a purchaser transfers the product to any other person.
The warranty does not cover damage or wear which occurs as a result of day to day use or general wear and tear. No warranty is given
for defects caused by normal wear and tear, cosmetic rust, scratches, accidents, unlawful vehicle operation, or modication of, or any
types of repair of, a load carrier system other than those authorized by Let’s Go Aero.
No warranty is given for defects resulting from conditions beyond Let’s Go Aero’s control including, but not limited to, misuse, overload-
ing, or failure to assemble, mount or use the product in accordance with Let’s Go Aero’s written instructions or guidelines included with
the product or made available to the purchaser.
Subject to the limitations and exclusions described in this warranty, Let’s Go Aero will remedy defects in materials or workmanship by
repairing or replacing any parts diagnosed to be at issue without charge for parts or labor. In the event that a product is defective, the
purchaser should contact the Let’s Go Aero dealer from whom the product was purchased. If the dealer is not able to correct the defect,
the purchaser should contact Let’s Go Aero in writing to [email protected] or by phone at 877-464-237 or 719-630-3800.
In the event that a product needs to be returned to Let’s Go Aero, a Let’s Go Aero technician will provide the purchaser with the appro-
priate mailing address and any additional instructions. Proof of purchase in the form of an original purchase invoice or receipt, and a
detailed description of the defect must be provided. Please note that a Return Merchandise Authorization (RMA) from Let’s Go Aero is
required for any returns.
DISCLAIMER OF LIABILITY REPAIR OR REPLACEMENT OF A DEFECTIVE PRODUCT OR THE ISSUANCE OF A REFUND OR
CREDIT (AS DETERMINED BY LET’S GO AERO) IS A PURCHASER’S EXCLUSIVE REMEDY UNDER THIS WARRANTY. DAMAGE
TO A PURCHASER’S VEHICLE, CARGO AND/OR TO ANY OTHER PERSON OR PROPERTY IS EXCLUDED.
THIS WARRANTY IS EXPRESSLY MADE IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING
THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
LET’S GO AERO’S SOLE LIABILITY TO ANY PURCHASER IS LIMITED TO THE REMEDY SET FORTH ABOVE. IN NO EVENT WILL
LET’S GO AERO BE LIABLE FOR ANY LOST PROFITS, LOST SALES, OR FOR ANY CONSEQUENTIAL, DIRECT, INDIRECT, INCI-
DENTAL, SPECIAL, EXEMPLARY, OR PUNITIVE DAMAGES OR FOR ANY OTHER DAMAGES OF ANY KIND OR NATURE.
SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE
ABOVE LIMITATIONS MAY NOT BE APPLICABLE. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO
HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.