Ranger design 1525-TCX User manual

INSTALLATION GUIDE
1525-TCX Combination Ladder Rack
Transit Connect ( Aluminum )

QUICK START GUIDE
REQUIRED ITEMS
2
PERSONS
NOTE: Use Sawhorses if possible, or use the box as a at protective surface on the ground or table.
qCordless Impact
qRatchet
qTape Measure
qMallet
qMarker
qLadder
qCutter
q1/2" Socket
qSawhorse ( Optional )
qBox
qKnife
q1/2" Wrench
q7/16" Socket
qSilicone
q1.1 Setup...............................................................................................................................................
q1.2 Ladder Rack Assembly....................................................................................................................
3 - 5
5 - 14
q2.1 Mounting Tracks Installation............................................................................................................
q2.2 Ladder Rack Installation..................................................................................................................
q2.3 Note.................................................................................................................................................
15
16 - 20
21
Phase 1 - Assembly
Phase 2 - Installation

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PHASE 1 – ASSEMBLY
1.1 SETUP
1.1.1 Unpack components; compare with the bill of materials.
1.1.2 Verify all parts are present.
Item No. Description Qty.
10-149 Clamp Handle Support 2
10-461 “V” Foot 4
10-545 Ski Plastic Plug 4
10-548 Hook Protector ( 4 - 3/8" L ) 2
10-722 Mounting Track 2
15-2581 Front Crossbow 2
15-2591 Rear Crossbow 1
15-2596 Third Crossbow 1
15-3003 Ladder Clamp Lock 2
15-3004 Ladder Clamp Rear Hook 2
15-3005 Ladder Clamp Bar ( Driver Side ) 1
15-3006 Ladder Clamp Bar ( Passenger Side ) 1
15-3010 Ski ( Left ) 1
15-3011 Ski ( Right ) 1
15-4290 Front Hook 2
94-1011 Assembly Fastener Kit 1
96-1015 Install Fastener Kit 1
BILL OF MATERIALS
15-300615-3005
15-3011
15-3010
15-3004 15-4290
15-3003
10-545
10-149
10-548
10-722
15-2591 15-259615-2581
10-461

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94-1011 Fastener Kit Fastener Assembly
1.1.3 Fastener kits.
4×
#90-487 Carriage Bolt 5/16" × 3/4"
#98-123 Lock Washer
#94-105 Hex Nut
#98-117 Flat Washer
28×
#90-491 Carriage Bolt 5/16" × 1"
#98-123 Lock Washer
#94-105 Hex Nut
#98-117 Flat Washer
4×
#98-123 Lock Washer
#94-105 Hex Nut
#98-117 Flat Washer
2×
#90-491 Carriage Bolt 5/16" × 1"
#98-123 Lock Washer
#94-105 Hex Nut
#98-117 Flat Washer
#98-160 Spacer
# 90-487
4×
Carriage Bolt
5/16"-18 × 3/4"
SS304
# 90-491
30×
Carriage Bolt
5/16"-18 × 1"
SS304
# 98-117
Flat Washer
5/16", O.D 3/4"
SS18-8
38×
# 98-123
Lock Washer
Regular 5/16"
SS304
38×
# 94-105
Hex Nut
5/16"-18
SS316wax
38×
# 98-160 Spacer
SS18-8
2×

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PHASE 1 – ASSEMBLY
1.2 LADDER RACK ASSEMBLY
1.2.1 Peel the backer off of the adhesive on the hook protector, then attach the hook protector
to the upper rear hook.
TOOLS
qKnife
REMOVE
2×
Fastener Assembly96-1015 Fastener Kit
# 98-117
16×
Flat Washer
5/16", O.D. 3/4"
SS18-8
8× # 98-123
Lock Washer
5/16"
SS304
8× # 94-150 Channel Nut
5/16"
# 90-209
Hex Bolt
5/16"-18 × 1"
SS304
16×
8× # 94-116
Serrated Nut
5/16"-18
ZINC
8×
#90-209 Hex Bolt 5/16" × 1"
#98-123 Lock Washer
#98-117 Flat Washer
#94-150 Channel Nut
8×
#90-209 Hex Bolt 5/16" × 1"
#98-117 Flat Washer
#94-116 Serrated Nut
#98-149 Neoprene Spacer
# 98-149
Spacer
0.290" ID × 1.375" OD × 0.125" L
NEOPRENE
8×

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1.2.2 Attach the rear hooks to the ladder clamps, with the pre-assembled hardware on the pivot bars.
TOOLS
qCordless Impact
q1/2" Socket
q1/2" Wrench
#90-225 Hex Bolt
5/16" - 18 × 2" SS304
#98-117 Flat Washer
#98-117 Flat Washer
#94-111 Lock Nut
HARDWARE USED
4× hardware is pre-assembled.

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1.2.3 Slide carriage bolts on the bottom face of the crossbows.
TIPS: Use tape to keep the bolts from sliding off.
NOTE: The track plug must be removed from the underneath of the crossbow, and reinstalled after
the feet have been installed in the nal position.
Third crossbow
• Slide 4 pcs. of 1" carriage bolts.
DRIVER SIDE
8×
#90-491 Hex Bolt
5/16" × 1" SS304
Rear crossbow
• Slide 2 pcs. of 3/4" carriage bolts.
• Slide 4 pcs. of 1" carriage bolts.
HARDWARE USED
2×
#90-487 Carriage Bolt
5/16" × 3/4" SS304
PASSENGER SIDE
8×
#90-491 Hex Bolt
5/16" × 1" SS304
Rear crossbow
• Slide 2 pcs. of 3/4" carriage bolts.
• Slide 4 pcs. of 1" carriage bolts.
Third crossbow
• Slide 4 pcs. of 1" carriage bolts.
HARDWARE USED
2×
#90-487 Carriage Bolt
5/16" × 3/4" SS304

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HARDWARE USED
16× hand-tighten the nuts.
Carriage bolts are already on
the crossbows.
#98-123 Lock Washer
#98-117 Flat Washer
#94-105 Hex Nut
1.2.4 Install the feet on the third, and rear crossbows.
NOTE: The more slanted side of the V foot should be closer to the center of the crossbow.

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1.2.5 Fasten the left and right ladder clamp assemblies to the rear crossbow.
HARDWARE USED
4×
Carriage bolts are already on
the crossbows.
#98-123 Lock Washer
#98-117 Flat Washer
#94-105 Hex Nut
TOOLS
qCordless Impact
q1/2" Socket
qTape Measure
qMarker
12-3/4"

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8.5"
Tighten the nuts just to hold the front
hook for adjustment.
HARDWARE USED
4× hardware is pre-assembled.
#98-123 Lock Washer
#98-117 Flat Washer
#90-491 Carriage Bolt 5/16" × 1"
#94-105 Hex Nut
TOOLS
qMarker
qCutter
1.2.6 • Pull out the 14.5" track plug on the passenger side of the rst front crossbow and
the driver side of the adjustable front crossbow.
• Loosen the pre-assembled hardware on the front hooks and slide the hooks onto the
front crossbows to the position shown below.
• Cut the track plug, then attach it back to the crossbows.

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1.2.7 Install the left and right Skis to the end brackets of the front crossbow.
HARDWARE USED
4×
Carriage bolts are already on
the ski.
#98-123 Lock Washer
#98-117 Flat Washer
#94-105 Hex Nut
TOOLS
qCordless Impact
q1/2" Socket

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1.2.8 Install the third crossbow to the left and right Skis.
1.2.9 Install the adjustable front crossbow to the left and right Skis.
NOTE: Tighten the nuts just to hold the 2nd front crossbow for adjustment.
TOOLS
qCordless Impact
q1/2" Socket
HARDWARE USED
4× hand-tighten the nuts.
#98-123 Lock Washer
#98-117 Flat Washer
#90-491 Carriage Bolt 5/16" × 1"
#94-105 Hex Nut
HARDWARE USED
4× hand-tighten the nuts.
#98-123 Lock Washer
#98-117 Flat Washer
#90-491 Carriage Bolt 5/16" × 1"
#94-105 Hex Nut
8.456"

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1.2.10 Loosen the pre-assembled hardware on the ladder clamp hasps, slide the hasps on the skis to the
position shown below, and tighten the nuts.
1.2.11 Slide 3pcs. of carriage bolts on the rear end of the each ski, then attach end plugs on
both ends of the skis.
HARDWARE USED
4× hardware is pre-assembled.
#98-123 Lock Washer
#98-117 Flat Washer
#90-487 Carriage Bolt 5/16" × 3/4"
#94-105 Hex Nut
TOOLS
qCordless Impact
q1/2" Socket
qTape Measure
qMarker
HARDWARE USED
6×
#90-491 Carriage Bolt
5/16" × 1" SS304
TOOLS
qMallet
end plug
end plug end plug
15 - 1/2"

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1.2.12 Install the Rear Crossbow to the skis with the clamp handle supports, aligning the rear surface of the
crossbow brackets to the rear surface of the skis.
TOOLS
qCordless Impact
q1/2" Socket
HARDWARE USED
4×
#98-123 Lock Washer
#98-117 Flat Washer
#94-105 Hex Nut
2×
#98-123 Lock Washer
#98-160 Spacer
#98-117 Flat Washer
#94-105 Hex Nut
Carriage bolts are already on
the ski.
Carriage bolts are already on
the ski.

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PHASE 2 – INSTALLATION
2.1 MOUNTING TRACKS INSTALLATION
2.1.1 • Pull the plugs off, then apply a bead of silicone around the each hole.
• Install the mounting tracks on the roof.
FRONT
NOTE: The ends of the mounting tracks with the half-circles go to the front of the vehicle.
#90-209 Hex Bolt 5/16" × 1"
#98-117 Flat Washer
#94-116 Serrated Nut
#98-149 Neoprene Spacer
TOOLS
qCordless Impact
q1/2" Socket
HARDWARE USED
8×
use use use use

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PHASE 2 – INSTALLATION
2.2 LADDER RACK INSTALLATION
2.2.1 Position the Ladder Rack ( minimum two persons ) on the vehicle so that the feet are on the tracks.
NOTE: If you do not have a hoist, lift the ladder rack onto the roof manually.
Ladder Rack

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2.2.2 While making sure the crossbows are parallel to each other, slide the rack to the appropriate position,
then attach all the “V” feet to the mounting tracks.
distance < A >
distance < A >
distance < B >
distance < B >
distance < foot to end of track >
TOOLS
qRatchet
q1/2" Socket
qTape Measure
HARDWARE USED
8×
#90-209 Hex Bolt 5/16" × 1"
#98-123 Lock Washer
#98-117 Flat Washer
#94-150 Channel Nut

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2.2.3 Center the crossbows on the vehicle, then tighten all the “V” feet to the crossbows.
TOOLS
qRatchet
q1/2" Socket

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2.2.4 Ladder Rack adjustment for extention ladder.
1"
TOOLS
qCordless Impact
q1/2" Socket
front hook
rear hook
NOTE: The ladder cannot extend beyond the rear bumper of the vehicle.
When the rear hook touches the ladder,
the handle should be 1" below the ladder
clamp hasp.
Now adjust the front hook to be snug against
the ladder rung and tighten the bolts on the
front crossbow.

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2.2.5 Ladder Rack adjustment for step ladder.
NOTE: • The same procedure applies to the hook located on the adjustable front crossbow. The position
of the adjustable front crossbow must be adjusted according to the length of the stepladder.
•The ladder cannot extend beyond the rear bumper of the vehicle.
NOTE: Make sure all the bolts are
tightened after adjusting.
The inner ladder side support must
be adjusted according to the width
of the step ladder.
Be sure that the extrusion of the
step ladder is on the ladder side
support.
IMPORTANT: • After installation is complete, cut the track plug underneath the crossbow to ll all the
unused space.
• Place the ladder rack warning label on a visible area, recommended on a partition.