PUTCO Boss Headache Rack User manual

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Putco guarantees its Stainless Steel and Aluminum products against defects in workmanship and material for as long as you own your vehicle. All
painted products have a 90 day warranty on the painted surface. Any defects resulting from faulty material or workmanship will be warranted by
Putco and repaired or replaced at our discretion. Putco assumes no extra labor costs. Damages caused by freight carriers, improper installation,
misuse, collision, or neglect will not be warranted by Putco.
Boss Headache Rack Installation Instructions
Congratulations on your purchase of a high quality PUTCO product. Should you need any application
or technical assistance, feel free to call us at: 1-800-247-3974
Monday-Friday 8:00 a.m. - 5:00 p.m. (Central Standard Time)
Contact your PUTCO dealer for other quality accessories.
Please read all instrucons before installaon and check to see that all parts are included.
KIT CONTENTS:
Description Qty.
Boss Headache Rack 1
Mounting Brackets 2
Threaded Plates 2
5/16” x 3.25” Bolt 2
5/16” x 1.25” Bolt 2
3/8” x 1.5” Bolt 2
5/16” Flange Locknut 2
5/16” Washers 4
Oval or Flat Washer (GM / RAM use oval washer,
others use Flat Washer)
2
Rubbers Bands 4
Tools Needed:
− X-Acto Knife/Razor Blade
− Measuring Tape
− Ratchet
− 9/16” Socket
− 3/16” Hex Socket or Key
− Drill and Drill Bits (Optional)
Installation Instructions:
1. Use X-Acto knife/razor blade to cut open stake pocket (if
not already exposed).
2. Use 2 rubber bands to hold threaded plate to mounting
bracket. Make sure threaded hole is not obstructed (see
Figure 1).
3. Thread the 3.25” long bolt into the bracket assembly,
and lower it into the stake pocket. NOTE: Some brack-
ets are driver/passenger side specific! Make sure nut
clip is facing into the bed of the truck, and is centered in
hole of bed wall (Figure 2).
Figure 1: Bracket and threaded plate.

890xxI
PT — 9/27/18 Page 2 of 2 890xxI
Putco guarantees its Stainless Steel and Aluminum products against defects in workmanship and material for as long as you own your vehicle. All
painted products have a 90 day warranty on the painted surface. Any defects resulting from faulty material or workmanship will be warranted by
Putco and repaired or replaced at our discretion. Putco assumes no extra labor costs. Damages caused by freight carriers, improper installation,
misuse, collision, or neglect will not be warranted by Putco.
4. Loosely thread 3/8” bolt with oval washer (flat washer on Ford)
through bed wall into bracket. Temporarily remove 3.25” bolt
from top of bracket.
5. Repeat steps 1-4 on other stake pocket.
6. Place Boss headache rack on bed caps, aligning slotted holes on
the rack with threaded hole on mounting bracket.
7. Insert 3.25” long bolt into slot and finger tighten in threaded plate
(Figure 3). Repeat on other side.
8. Align headache rack, making it flush with the front of bed cap.
Use tape measure to make the gap between mounting feet and
edge of bed cap equal on both sides (Figure 4).
9. Using a 9/16” socket, tighten 3/8” bolts inside bed of truck. Next,
tighten the 3.25” long bolts using a 3/16” hex key or socket.
10. Optional step: For extra rigidity, use drill and 5/16” drill bit to drill a hole in bed cap. Make sure
headache rack is properly aligned before drilling. Use 5/16” x 1.25” long bolt and flange locknut to fas-
ten rack to bed cap (Figure 4).
Enjoy your new Putco Boss Rack!
Figure 2: Lowering bracket into pocket.
Nut clip facing into bed (touching bed
wall) and centered in opening.
Figure 3: Threading 3.25” bolt.
3/8” bolt and washer
Figure 4: Aligning headache rack. Oponal mounng
point circled.
Oponal mounng
locaon