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

For technical support, contact us at 1-800-565-5321 1525-TCX Installation Guide |REV. D2 | Page 3
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

For technical support, contact us at 1-800-565-5321 1525-TCX Installation Guide |REV. D2 | Page 4
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×

For technical support, contact us at 1-800-565-5321 1525-TCX Installation Guide |REV. D2 | Page 5
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×

For technical support, contact us at 1-800-565-5321 1525-TCX Installation Guide |REV. D2 | Page 6
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.

For technical support, contact us at 1-800-565-5321 1525-TCX Installation Guide |REV. D2 | Page 7
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

For technical support, contact us at 1-800-565-5321 1525-TCX Installation Guide |REV. D2 | Page 8
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.

For technical support, contact us at 1-800-565-5321 1525-TCX Installation Guide |REV. D2 | Page 9
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"

For technical support, contact us at 1-800-565-5321 1525-TCX Installation Guide |REV. D2 | Page 10
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.