Remora 004-A263A User manual
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
rev100 - 2021-11-03
Product : Modular Roof Rack
Part # : 004-A263A
Application : Dodge RAM Promaster 159-X HR (2014+)
Difficulty : 1 2 34 5
Installation time : 3 to 4 hours (without solar panels)
4 to 6 hours (with solar panels)
Make the road your home.
www.remoraco.com
Reference Manual - Installation
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
rev100 - 2021-11-03
Index
P2 INDEX
P3 PRECAUTIONS ET RECOMMENDATIONS
P4-5 WARNINGS
P6 REQUIRED TOOLS
INSTALLATION STEPS
P8 ROOF MOUNT INSTALLATION
P9-10 ROOF MOUNT POSITIONING LAYOUT - RAM PROMASTER 159X-HR
P11-13 SIDE PLATE & JOINER PLATE INSTALLATION
P14-17 SOLAR PANEL & CROSSBAR INSTALLATION
P18-19 WIND FAIRING BRACKET INSTALLATION (ON FRONT CROSSBAR)
P20 CROSSBAR TIGHTENING
P21 ALIGNMENT & FINAL TIGHTENING
P22 T-NUT INSTALLATION ON CROSSBARS
P23 WIND FAIRING INSTALLATION
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
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Preparation
Precautions & recommendations
A few precautions for a smooth installation
* We recommend that you protect the roof of your vehicle with a blanket or large cardboard box, to
prevent from scratching your roof with free moving parts during installation.
* Be careful; you will perform tasks from 8’+ heights. Be supervised at all times or secured with a
harness during installation. An 8’ or higher stepladder is necessary.
* We recommend that you securely place all the necessary components and tools on the (protect-
ed) roof of your vehicle. This will make it much easier to install directly on the roof with everything
at hand.
* In order to considerably reduce installation time, we recommend the use of two good quality 8’+
stepladders, placed on each side of your vehicle.
* At any time, if you have any doubts about the installation, stop immediately and contact our cus-
tomer service department.
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
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Preparation
Warnings
Warnings
!Some components of the product have sharp edges. Please handle with care and remain aware of your surround-
ings to avoid any scratching or damage to your vehicle.
!Tighten all hardware by hand using a torque wrench or torque adaptor.
Since the components are made of aluminum, the use of an “impact”, battery or electric screwdriver could damage
the threads of the components and render the product unusable.
!Perform the nal tightening of the roof anchor hardware at the very end of the installation. Since this hardware is
made up of “NyLock” type nylon lock nuts, it is not recommended to tighten and loosen these nuts more than once,
as this may crack or cut the bolts. These nuts are of single use. The nal tightening must therefore be done only
once, at the very end of your installation.
!For any hardware that does not use “NyLock” type nylon lock nuts, apply a drop of blue Loctite (provided in your
hardware box) on the bolt threads. (Wind fairing hardware for deector & crossbar hardware)
!To avoid the appearance of scratches or premature wear of the paint under the wind fairing, caused by using the
vehicle in sandy “off-road” environments, or by insufcient cleaning of the sand, dirt, dust or abrasive elements
under the deector, it is important to apply the protective paint lms (supplied) to the suitable places on your body,
under the wind fairing rubber edge trims. Regular inspection of the product and the underside of the deector is
necessary to ensure the correct positioning of the fairing and protective paint lms.
!Under road, wind and pothole vibration, the product and its components may slightly move and self-adjust. Per-
form a regular check once every season change to ensure the good condition and correct positioning of the com-
ponents. Check the anchoring hardware and installation hardware after the rst 20 and 200 kilometers traveled and
adjusting the hardware torque if needed. Also perform a routine check of all product hardware.
!Installation and removal of the roof rack and its components should always be performed by two or more people.
...
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
rev100 - 2021-11-03
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Warnings (part 2)
!As it is difcult to predict the thousands of different congurations with the hundreds, if not thousands of com-
ponent choices currently available on the market, installing a modular rack, roof fans and other components on the
roof of your vehicle can cause or accentuate in certain cases, noises, whistles, turbulence or vibrations. We strive
throughout the product development and prototyping phases to minimize the sound and sensory impacts of adding
such components. However, the aerodynamics, fuel consumption and noise tests of your vehicle manufacturer were
performed with a “bare” vehicle, without any roof components. We are therefore not responsible for noises, whis-
tles, vibrations, or turbulence caused by the addition of your roof components, nor for the increased fuel consump-
tion of your vehicle.
!Do not overload your vehicle roof. Refer to your vehicle manufacturer’s load specications for the maximum
weights and heights to be respected. Overloading the manufacturer’s load limit will impact the center of gravity of
your vehicle and might result in a change of the vehicle’s driving attitude, or in loss of control.
!Do not put more than 40lbs of weight directly over an unsupported part; for example at the rear end of the rack
which is not supported by any roof mounts on the Ford Transit 148-X.
!Remora Modular Roof Racks are adaptation supports for recreational vehicle components (solar panels, cargo
boxes, lighting components, etc.) or in some cases, for sports equipment. Any other use including the handling and
moving of heavy objects at roof height, the installation of products or components not intended for these purposes
or any leisure or maintenance operations made on your roof or roof rack is at your own risk.
!The design, manufacturing, installation and use of one or more supporting surface(s), nishing surface(s) or roof
platform(s) that do not come from Remora co is at your own risk and may void the product warranty.
!Any modication or alteration of the Modular Roof Rack not approved by Remora co, or addition of components
not designed or manufactured by Remora co may void the product warranty.
!At any time, if you have any doubts about the installation, stop immediately and contact us or an authorized
installer.
Preparation
Warnings
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
rev100 - 2021-11-03
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Preparation
Required tools and supplies
Recommended supplies for installation
- Large blanket or large carton to protect the roof
- 8’+ stepladder
Tools required for installation (not included)
- Measuring tape
- “Sharpie” felt pen or lead pencil
- Ratchet torque wrench (5Nm to 25Nm), extension & 1/2 ”& 9/16” deep sockets
- 3/16 ”& 7/32” “Allen” (Allen socket) bits for ratchet wrench
- Otherwise, “Allen” keys 3/16 ”& 7/32”
- Electric drill
- 1/8 ”metal pre-drill bit
- 11/32 ”metal bit
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
rev100 - 2021-11-03
Installation steps
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
rev100 - 2021-11-03
Installation steps
Roof Mounts
A. Roof mount installation
A1. Insert (2X) carriage bolts in the square openings of the
“U-shaped” adaptors, with the round bolt heads facing downwards.
Slide the “U-shaped” adaptors from the center of the vehicle, out-
ward. (“U” facing upwards)
* Promaster 136 HR : 6 mounts
* Promaster 159 HR : 8 mounts
* Promaster 159”-X HR : 10 mounts
A2. Inser the roof mount top adaptors on the “U-shaped” bottom
adaptors, making sure the slotted holes are centered with the car-
riage bolts and that the adaptor visual openings are on the same
side, facing outwards of the vehicle.
WARNING !
Make sure that the roof mount top adaptors have rubber edge trims
applied on the lower sitting edges. If no rubber edge trims are pres-
ent, stop installation immediately and contact Remora co customer
service. Fig. A1
Fig. A2
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Outside of vehicle
Outside of vehicle
Center of vehicle
Center of vehicle
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
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Roof mount positioning diagram - RAM Promaster 159-X HR
2014 ProMaster Design Recommendations
•Main Menu
•Index IN
+
OUT
-
ALL
•ProMaster Home
FITTING A ROOF RACK
The roof rack must be fitted using the attachments on the roof, following the instructions
of the roof rack manufacturer; maximum admissible load condition (including roof rack)
must in any case be respected.
Short wheelbase - 150 Kg
Medium wheelbase - 150 Kg
Long wheelbase - 150 Kg
NOTE: The limit of 25 kg for each attachment on the roof must not be exceeded. The
maximum permitted weight of 150 kg is an absolute limit, even if the wheelbase is
lengthened.
NOTE: The load must be distributed evenly on the luggage rack and it must not
exceed the width of the mounting tabs.
Diagram of roof rack attachment
7. Top exterior. –8. roof –9. roof rack pin –10. roof rack attachment reinforcement –
X0. front wheel axis
02/25/2014
Installation steps
Roof Mounts
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
rev100 - 2021-11-03
2014 ProMaster Design Recommendations
•Main Menu
•Index IN
+
OUT
-
ALL
•ProMaster Home
ATTACHMENT POSITIONING
07/08/2013
Floor/Wall Tie Down Rings
•The rings on the floor are tested to support 225 lbs. static load
•The rings on wall are tested to support 70lbs. Static load
136
159
159-X
Roof mount positioning diagram - RAM Promaster 159-X HR
Installation steps
Roof Mounts
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
rev100 - 2021-11-03
B. Side plate installation
B1. Place the side panels on the roof anchors previously installed in steps A, starting with the front panels and working your way towards the rear. Refer to
the “Positioning Diagram” on the next page or to the diagram provided by Remora for your custom project. The side panels are identied with a label on the
inside.
WARNING !
Loosely-tted side panels can slip, fall and damage your vehicle. Do not leave them unsecured.
B2. Add the washers and nuts provided and tighten lightly on the anchor bolt threads, by hand. Stop tightening before the nylon inserts of the nuts reach
the bolt threads. At this point we just want to secure the panels to prevent them from falling. ** DO NOT TIGHTEN THE NYLOCK NUTS - These nuts are for
one time use only; it is necessary to avoid tightening and loosening them. **
* It is important to leave some slack in the nuts at this time, to allow the cross members to be inserted from the top of the roof rack later on.
** The nal tightening will be done later.
Fig. B1 Fig. B2
Installation steps
Side Plates
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
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Side plate positioning diagram - RAM Promaster 159-X HR
JOINTS JOINTS
(Passenger side plates in transparency here.)
FRONT REAR
Installation steps
Side Plates
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
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Fig. B4
B. Joiner plate installation
B3. Repeat with the front and rear side panels on other side, if not already done.
* Quantity and length of panels may vary depending on your format.
B4. Install the joiner plates inside the rack, at the joints of the various side panels, using the
bolts, nuts and washers included. Allow a gap of 1/16 ”to 1/8” between two adjacent panels.
You can wait until the very end to do the nal tightening. This will give you a little more exibility
during the installation of the crossbars and solar panels.
Fig. B3
(Mercedes Sprinter 170 shown here)
Installation steps
Side Plates
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
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Fig. C2
Installation steps
Solar panel & crossbar installation
C. Solar panel & crossbar installation
NOTE : If you’re not installing solar panels at this moment, you can skip to page 18.
C1. Determine the position of your roof components and solar panels beforehand. We do offer 3D analysis and roof layout
design services to help you with the positioning of your roof components. Don’t hesitate to contact us for more details.
C2. Calculate and drill 2 holes per short side on a 100W panel or 4 holes per long side on a 300W panel for width assem-
bly. In order to install your solar panels “ush-mount” with the top of your crossbars, calculate 3/4” from the top of your
solar panel (side with the cells) for the positioning of the holes. Pre-drill with a 1/8 ”drill bit and then with an 11/32” drill bit.
CAUTION !
Some panels have a thicker top cell layer than others. Take the necessary measurements inside of the panel and precau-
tionnary measures while drilling to make sure you do not drill too close to the cells. You must have space inside your panel
to install the 5/16 “x 3/4” long bolts and washers included in the “Solar Panel Hardware” kit.
→
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
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Fig. C3 Fig. C4
C. Solar panel & crossbar installation
C3. Apply a drop of Loctite Blue on the end of the 5/16-18 x 3/4 bolts and screw the “T-Nuts” onto the bolt thread protruding
outside of the solar panel(s), installed in step C2. Do not tighten them all the way. Leave about 3/16 “to 1/4” clearance between the
outside of the panel and the “T-Nuts”.
C4. Slide a crossbar on each side of your panel(s), making sure the “T-Nuts” slide into the crossbar grooves.
Installation steps
Solar panel & crossbar installation
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
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C. Solar panel & crossbar installation
C5. If needed, measure the required spacing between your panels according to the positioning and clearance of your different roof components. (Maxxfans,
antennas, etc.)
C6. Once the positioning and alignment of your panels is complete, tighten (by hand) the 5/16” x 3/4” long bolts located inside the solar panels.
* Perform a nal tightening for this step - you will not have access to this hardware afterwards.
Tightening torque : Torque to 7Nm / 4 pi-lb for double-sided aluminum wall solar panels, with a minimal wall thickness of 0.042”.
(Do not forget to apply a drop of Blue Loctite on the tip of these screws).
For panels with walls thinner than 0.042”, contact your solar panel manufacturer to validate the installation method.
C7. Lay the solar panels (tted with crossbars) and unused crossbars on the vehicle roof, being careful not to scratch your roof.
CAUTION !
Depending on the size of your panel(s), we recommend asking help during this step. Some panels or panel assemblies can be very heavy.
Fig. C5 Fig. C6
Installation steps
Solar panel & crossbar installation
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
rev100 - 2021-11-03
Fig. C8 Fig. C9
Installation steps
Solar panel & crossbar installation
C. Solar panel & crossbar installation
C8. Apply a drop of Loctite Blue to the end of the 3/8 ”x 1” bolts provided for the installation of the crossbars (“Crossbar ends hardware” kit) as well as on
the 5/16 ”x 5/8” bolts provided for the installation of the deector brackets. (“Wind fairing hardware” kit).
* No need to apply a large amount of Loctite. One medium-sized drop per bolt is sufcient.
C9. Identify the right position for your solar panel(s) and place them on the inside of the side panels. It is preferable to have a partner for this step.
Use the 1 1/2” thick cardboard blocks at the extremeties of the rack packaging box to temporarily set your panel(s) on. These will raise the panels at the
height needed for their installation.
C10. Use the 3/8 ”x 1” bolts and washers from the “Crossbar ends hardware” kit and torque down the crossbars. Refer to page 21. Torque to 19Nm.
CAUTION !
When adding or repositionning crossbars, clean the bolt threads and add a drop of Loctite Blue before reinstallation.
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
rev100 - 2021-11-03
Fig. D1 Fig. D2
Installation steps
Wind fairing brackets
D. Wind fairing bracket installation
D1. Place an unused crossbar on a worktable or level ground. Place your deector on top, centered lengthwise with the crossbar, the slotted holes
directly located on the edge of the crossbar.
D2. Once properly centered, make a line using a pencil or felt-tip pen in the center of the slotted holes on your crossbar. These lines will determine the
centers of your fairing brackets.
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
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Fig. D3
Fig. D4
D. Wind fairing bracket installation
D3. Place 4X “T-Nuts” in the groove of the crossbar and line up the “T-Nut” hole with your marks made at step D2.
D4. Place the 4X fairing brackets on the at surface of the crossbar and assemble using the bolts and spacers provided for this purpose.
(“Wind fairing hardware” kit). Make sure the brackets are centered with your marks / lines. Apply a drop of Loctite Blue on the tip of the screws.
* Perform nal tightening for this step - however, you will be able to adjust this hardware later, during nal tightening. Torque to 15Nm.
Installation steps
Wind fairing brackets
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Doc # : Remora_004-A263A_RAM Promaster_159X-HR_eng
rev100 - 2021-11-03
Fig. E1
Fig. E2
E. Crossbar tightening
E1. Once your crossbars are on the roof of the vehicle, position them according to your roof layout planned in advance.
E2. Secure them at both ends using the 3/8 “x 1” bolts and washers provided for this purpose, to which Loctite has been applied in step C8.
* It is normal for the side panels to straighten out when tightening the cross members. A nal alignment and tightening of the side panels on the roof
mounts will be performed next.
Installation steps
Crossbars
Table of contents
