SMARTCAP FORD RANGER EDITION NEW GENERATION 2023 Manual

FORD RANGER EDITION
NEW GENERATION 2023-2024
PREPARE A CLEAN WORK AREA.
WE RECOMMEND A MINIMUM OF 2 PEOPLE FOR ASSEMBLY AND
4 PEOPLE FOR INSTALLATION
ENSURE THE REQUIRED TOOLS ARE PRESENT AND ALL HARDWARE
CONTENTS ARE ACCOUNTED FOR.
NEVER USE ACETONE OR THINNERS ON PAINTED PARTS.
READ THROUGH THE ENTIRE INSTRUCTION GUIDE BEFORE STARTING THIS
PROCEDURE AND FOLLOW THE STEPS CAREFULLY TO AVOID ANY DAMAGE
TO THE COMPONENTS OR THE VEHICLE.
INSTRUCTION GUIDE
I-SHEET-SA-R2
SMARTCAP.COM
[e-mail] - REST OF WORLD
[e-mail] - NORTH AMERICA/CANADA

IT IS A REQUIREMENT FROM FORD THAT ANY 2024 NEXT GEN RANGER WITH ACCESSORIES
EXTENDING ABOVE THE BEDRAILS, AND WEIGHING IN EXCESS OF 99LBS, BE FITTED WITH
THEIR LOAD BOX REINFORCEMENT BRACKETS (AKA J-BRACES) PRIOR TO INSTALLATION,
TO AVOID NEGATIVELY IMPACTING YOUR VEHICLE'S FACTORY WARRANTY. PLEASE CONSULT
YOUR OWNER’S MANUAL OR SELLING DEALER FOR MOR INFORMATION.
PG. 2
TOOLS REQUIRED
COMPONENTS
FRONT FLANGE
REAR FLANGE
ROOF PANEL
LEFT PANEL
RIGHT PANEL
13mm Socket
Socket
Wrench
10mm Socket
13mm Socket
Torque
Wrench
Scissors
Utility
Knife
10mm
Combination
Wrench
IMPORTANT
!
!DISCLAIMER
USE ONLY THE TOOLS RECOMMENDED ABOVE.
USE ONLY THE HARDWARE PROVIDED IN THIS KIT.
ASSISTANCE WILL BE NEEDED FOR THIS INSTALLATION.
FOUR PEOPLE ARE RECOMMENDED TO LIFT THE SMARTCAP ONTO THE VEHICLE.
AVOID PINCHING OR CRUSHING HANDS AND FINGERS.
INSPECT ALL KIT COMPONENTS FOR DAMAGE BEFORE ASSEMBLY.
NEVER USE ACETONE OR THINNERS ON PAINTED PARTS.
I-SHEET-SA-R2
Allen Key
5mm Allen Key
5mm Hex Socket

PG. 3
ASSEMBLY HARDWARE
FITMENT KIT
PRE-FASTENED TO ROOF PANEL
M6 LOCK
NUT
M6 FENDER
WASHER
D - RUBBER
M6 LOCK
WASHER
M6 x 10mm BOLT FASTENER
BLOCK CLAMP
FASTENER
BLOCK
30X 30X
30X
10X
28X
30X
28X
30X
30X
28X
30X
30X
30X
28X
1X
10X
SPARE PARTS
2X
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PG. 4
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PLACE THE ROOF PANEL WHERE YOU
PLAN TO ASSEMBLE THE CAP. REMOVE THE
LID FROM THE PACKAGING AND PLACE IT
NEXT TO THE ROOF PANEL.
USE LID AS
WORK SURFACE
IMPORTANT
BE SURE TO REMOVE ALL FIVE PANELS FROM
THEIR PACKAGING AND INSPECT THE PAINTED
SURFACES PRIOR TO ASSEMBLY, AS SMARTCAP
WILL NOT ACCEPT WARRANTY CLAIMS AFTER
ASSEMBLY IS COMPLETED. IF MANUFACTURING
IMPERFECTIONS OR SHIPPING DAMAGES
ARE FOUND, DO NOT CONTINUE WITH THE
ASSEMBLY PROCESS AND CONTACT
[e-mail] - REST OF WORLD
[e-mail] - NORTH AMERICA/CANADA
LOGO SIDE UP
!
1
2

PG. 5
I-SHEET-SA-R2
RIGHT PANEL
LOCATE THE RIGHT PANEL IN THE SMARTCAP
PACKAGE AND BRING IT TO YOUR WORK AREA.
SLANTED EDGE INDICATES REAR
USE A 10MM COMBINATION WRENCH TO REMOVE
ALL HARDWARE FROM THE ROOF PANEL AND
SAVE FOR REUSE.
FRONT EDGE
ROOF PANEL
!
AIR VENT INDICATES REAR
!
10mm
10X
3
4
AIR VENT

PG. 6
I-SHEET-SA-R2
SLANTED EDGE
TOWARDS REAR
RIGHT PANEL
FRONT EDGE
REAR EDGE
ROOF PANEL
M6
LOCK NUT
M6
FENDER
WASHER
INSERT PANEL TABS INTO
NARROW SLOTS JUST ABOVE
FOAM PADDING ON ROOF PANEL.
TAP FIRMLY WITH PALM OF HAND
UNTIL THERE IS A 2-3MM GAP.
PANEL TABS
5X
5
6
HAND TIGHTEN M6 LOCK NUT WITH
M6 FENDER WASHER TO ALL ROOF STUDS.
AIR VENT
5X 5X

PG. 7
I-SHEET-SA-R2
LEFT PANEL
ROOF PANEL
SLANTED EDGE
TOWARDS REAR
LEFT PANEL
AIR VENT
FRONT EDGE
REAR EDGE
LOCATE THE LEFT PANEL IN THE SMARTCAP
PACKAGE AND BRING IT TO YOUR WORK AREA.
SLANTED EDGE INDICATES REAR
INSERT PANEL TABS INTO
NARROW SLOTS JUST ABOVE
FOAM PADDING ON ROOF PANEL.
TAP FIRMLY WITH PALM OF HAND
UNTIL THERE IS A 2-3MM GAP. PANEL TABS
!
7
8

PG. 8
I-SHEET-SA-R2
M6
LOCK NUT
M6
FENDER
WASHER
PUSH THE SMARTCAP TO EXPOSE A FEW INCHES OF
STYRAFOAM UNDERNEATH THE ROOF PANEL TO
PROVIDE SUPPORT FOR THE FRONT FLANGE.
5X
9
10
HAND TIGHTEN M6 LOCK NUT WITH
M6 FENDER WASHER TO ALL ROOF STUDS.
5X 5X
STYRAFOAM

PG. 9
I-SHEET-SA-R2
FRONT FLANGE
FRONT FLANGE
REAR EDGE
AIR VENT
PLACE FRONT FLANGE AS SHOWN BELOW.
11
12
RETRIEVE THE NECESSARY HARDWARE
FROM THE FITMENT KIT.
LOCATE THE FRONT FLANGE IN THE SMARTCAP
PACKAGE AND BRING IT TO YOUR WORK AREA.
14X
14X 14X
14X

PG. 10
I-SHEET-SA-R2
1 23 4 6
8
9
13
12
5
7
10
11
14
INSTALL HARDWARE ALONG FRONT FLANGE WITH
M6 BOLT ON INSIDE.
ADJUST LEFT AND RIGHT PANELS TO ALIGN
FASTENER BLOCKS 6-15 FOR ASSEMBLY.
START WITH ASSEMBLING FASTENER BLOCKS 1-5.
PUSH THE SMARTCAP TO EXPOSE A FEW INCHES OF
STYRAFOAM UNDERNEATH THE ROOF PANEL TO
PROVIDE SUPPORT FOR THE REAR FLANGE.
14X
FASTENER
BLOCK
BLOCK CLAMP
M6 BOLT
M6 LOCK WASHER
FRONT FLANGE
SIDE PANEL
ROOF PANEL
BE SURE PANELS ARE FLUSH
!
13
14
HAND TIGHTEN IN THE
SEQUENCE SHOWN.

PG. 11
I-SHEET-SA-R2
REAR FLANGE
REAR FLANGE
PLACE REAR FLANGE AS SHOWN BELOW.
15
16
RETRIEVE THE NECESSARY HARDWARE
FROM THE FITMENT KIT.
LOCATE THE REAR FLANGE IN THE SMARTCAP
PACKAGE AND BRING IT TO YOUR WORK AREA.
14X
14X 14X
14X

PG. 12
I-SHEET-SA-R2
5X 5X
14X
14X
INSTALL HARDWARE ALONG REAR FLANGE WITH
BOLT ON INSIDE.
ADJUST LEFT AND RIGHT PANELS TO ALIGN
FASTENER BLOCKS 6-15 FOR ASSEMBLY.
START WITH ASSEMBLING FASTENER BLOCKS 1-5.
TIGHTEN ALL HARDWARE WITH
TORQUE WRENCH AND 10MM
SOCKET TO 3.7 FT. LBS.
(5 NEWTON METERS)
1 23
5
7
9
11
13
46
8
10
12
14
FASTENER
BLOCK
BLOCK CLAMP
M6 BOLT
M6 LOCK WASHER
FRONT FLANGE
SIDE PANEL
ROOF PANEL
BE SURE PANELS ARE FLUSH
!
17
18
HAND TIGHTEN IN THE
SEQUENCE SHOWN.
14X
(3.7 ft. lbs)/(5 Nm)
10mm

STAY WITHIN 1/8 INCH
FROM THE SMARTCAP’S
OUTER EDGES.
PEEL AWAY ADHESIVE BACKING
IN SHORT LENGTHS AS YOU
WORK AROUND THE EDGES.
REMOVE EXCESS
WITH A STRAIGHT CUT.
20
1/8 INCH
FROM EDGE
START END
PG. 13
LOCATE RETENTION TAB
19
BE SURE THE
SURFACE IS CLEAN
FIRMLY PUSH THE TAB
BACK DOWN TO SECURE
THE D-RUBBER IN PLACE.
PEEL AWAY A SMALL PORTION
OF THE ADHESIVE BACKING
FROM THE D-RUBBER.
SMARTCAP
BOTTOM
LIP FACES
OUTWARDS
B
A
C D
LOCATE THE D-RUBBER
RETENTION TAB NEXT TO
THE REAR DOOR GASKET.
BEND THE TAB UPWARDS
AT A 45 DEGREE ANGLE.
REAR
DOOR
D-RUBBER
D-RUBBER
REAR FLANGE
RETENTION
TAB
INSERT THE TAB INTO THE D-RUBBER
UNTIL THE D-RUBBER LIGHTLY BUTTS
UP AGAINST REAR DOOR GASKET.
CORRECT D-RUBBER
ORIENTATION
D-RUBBER
REAR
FLANGE
INCORRECT D-RUBBER
ORIENTATION
XD-RUBBER
REAR
FLANGE
I-SHEET-SA-R2

PLATE STRIPS
(RIGHT)
(LEFT)
IMPORTANT
ASSISTANCE WILL BE NEEDED FOR THIS INSTALLATION. FOUR PEOPLE ARE
RECOMMENDED TO LIFT THE SMARTCAP ONTO THE VEHICLE.
AVOID PINCHING OR CRUSHING HANDS AND FINGERS.
!
MOUNTING BRACKETS
2X
2X
2X
M8 x 20mm BOLT M8 LOCK
WASHER
M8 FENDER
WASHER
M8 x 20mm
BUTTON BOLT
M8 LOCK
NUT
LOAD
SPREADER
25mm x 25mm
FOAM SEAL TAPE
20X 14X
8X 10X
38X
4X
1X
REAR
BRACKETS
(LEFT AND
RIGHT)
(LEFT AND
RIGHT)
FRONT
BRACKETS
INSTALLATION HARDWARE
READ THROUGH THE ENTIRE PROCEDURE BEFORE STARTING.
VEHICLE INSTALLATION
PG. 14
I-SHEET-SA-R2

BED-RAIL
CAP INSERT
PLATE STRIP
PEEL AWAY
ADHESIVE BACKING
BED-RAIL CAP
BIN RAIL
PLATE STRIP
21
22
PG. 15
REMOVE THE PLASTIC BED-RAIL CAP
INSERTS AND BED-RAIL CAPS.
REMOVE THE ADHESIVE BACKING
FROM THE PLATE STRIP AND APPLY
TO THE BIN RAIL, ALIGNING THE
FRONT OF THE PLATE STRIP TO
THE FRONT OF THE BIN.
REPEAT ON THE OPPOSITE
SIDE OF THE VEHICLE.
REPEAT ON THE OPPOSITE
SIDE OF THE VEHICLE.
I-SHEET-SA-R2

M8 BOLT
M8 LOCK
WASHER
M8 FENDER
WASHER
2X 6X
6X6X
3X
FULLY SEAL
AT BOTH ENDS
25MM x 25MM FOAM SEAL TAPE
PEEL AWAY
ADHESIVE
BACKING
CUT TO LENGTH
NEEDED
FOAM SEAL TAPE
REMOVE THE FRONT TIE DOWN
HOOK FROM THE INNER
WALL OF THE TRUCK BED.
POSITION THE RIGHT SIDE
FRONT MOUNTING BRACKET IN
THE FRONT CORNER OF THE
TRUCK BED AS SHOWN.
SECURE THE BRACKET WITH
THE FASTENERS AS INDICATED,
HAND TIGHTEN ONLY.
REPEAT ON THE OPPOSITE SIDE
OF THE VEHICLE WITH THE LEFT
FRONT MOUNTING BRACKET.
INSPECT THE TRUCK BED. IF FRONT EDGE IS
LOWER THAN THE SIDES, ADD FOAM SEAL TAPE
TO THE FRONT EDGE OF THE BED.
FRONT MOUNTING
BRACKET
TIE DOWN
HOOK
1X
23
24
PG. 16
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M8 BUTTON
BOLT
M8 FENDER
WASHER
M8 LOCK
WASHER
PG. 17
2X 4X
4X4X
2X
2X
2X
2X
REMOVE THE REAR TIE DOWN
HOOK FROM THE INNER
WALL OF THE TRUCK BED.
POSITION THE RIGHT SIDE
REAR MOUNTING BRACKET IN
THE BACK CORNER OF THE
TRUCK BED AS SHOWN.
SECURE THE BRACKET WITH
THE FASTENERS AS INDICATED,
HAND TIGHTEN ONLY.
REPEAT ON THE OPPOSITE SIDE
OF THE VEHICLE WITH THE LEFT
REAR MOUNTING BRACKET.
REPEAT ON THE OPPOSITE SIDE
OF THE VEHICLE WITH THE LEFT
FRONT MOUNTING BRACKET.
M8 BOLT
M8 LOCK
WASHER
M8 FENDER
WASHER
REAR MOUNTING
BRACKET
TIE DOWN
HOOK
PLATE STRIP
25
26
USE A 5MM ALLEN KEY TO FASTEN
THE FRONT RIGHT MOUNTING BRACKET
TO THE TOP OF THE TRUCK BED.
SECURE THE BRACKET WITH
THE FASTENERS AS INDICATED.
I-SHEET-SA-R2
5mm

M8 BUTTON
BOLT
M8 FENDER
WASHER
M8 LOCK
WASHER
LOAD SPREADER
FOAM STRIP
PEEL AWAY
ADHESIVE BACKING
PG. 18
2X
2X
2X
4X
2X
REPEAT ON THE OPPOSITE
SIDE OF THE VEHICLE.
REPEAT ON THE OPPOSITE SIDE
OF THE VEHICLE WITH THE LEFT
FRONT MOUNTING BRACKET.
PLATE STRIP
27
28
USE A 5MM ALLEN KEY TO FASTEN
THE REAR RIGHT MOUNTING BRACKET
TO THE TOP OF THE TRUCK BED.
SECURE THE BRACKET WITH
THE FASTENERS AS INDICATED.
REMOVE THE ADHESIVE BACKING FROM LOAD
SPREADER
APPLY LOAD SPEADERS TO THE TOP OF PLATE
STRIP. USE THE SLOTS TO ALIGN
I-SHEET-SA-R2
5mm

TO AVOID DAMAGE TO THE D-RUBBER,
DO NOT SLIDE THE SMARTCAP INTO PLACE.
IT’S IMPORTANT THAT THE
SMARTCAP IS NOT PUSHED
TOO FAR FORWARD, LEAVING
A GAP BETWEEN THE SMARTCAP
AND THE CAB.
USE 4 PEOPLE TO LIFT THE ASSEMBLED
SMARTCAP ONTO THE TRUCK BED.
CHECK THAT THE SMARTCAP
IS PROPERLY POSITIONED AND
CENTERED ON THE TRUCK BED.
30
29
31
WALK AROUND THE TRUCK BED TO MAKE SURE THE D-RUBBER FITMENT IS CORRECT
AND THAT THE RUBBER LIP IS FLUSH WITH THE EXTERIOR OF THE TRUCK BED.
INCORRECT D-RUBBER
ORIENTATION
X
REAR FLANGE
TAILGATE
D-RUBBER
CORRECT D-RUBBER
ORIENTATION
D-RUBBER
TAILGATE
REAR FLANGE
PG. 19
I-SHEET-SA-R2

6X
6X
12X
4X
4X
4X
M8 BUTTON
BOLT
M8 FENDER
WASHER
M8 SPRING
WASHER
M8 BOLT
M8 FENDER
WASHER
M8 FENDER
WASHER
M8 LOCK
NUT
PG. 20
2X
3X
SECURE THE SMARTCAP TO THE RIGHT
FRONT MOUNTING BRACKET WITH THE
FASTENERS AS INDICATED, HAND
TIGHTEN ONLY.
REPEAT ON THE OPPOSITE SIDE
OF THE VEHICLE WITH THE LEFT
FRONT MOUNTING BRACKET.
SECURE THE SMARTCAP TO THE RIGHT
REAR MOUNTING BRACKET WITH THE
FASTENERS AS INDICATED, HAND
TIGHTEN ONLY..
REPEAT ON THE OPPOSITE
SIDE OF THE VEHICLE.
SMARTCAP
32
33
WITH A 5MM ALLEN KEY, LOOSELY TIGHTEN
THE SMARTCAP RIGHT SIDE PANEL TO THE
TOP OF THE TRUCK BED USING M8 BUTTON
HEAD BOLT, M8 LOCK WASHER, AND M8
FENDER WASHER AS SHOWN BELOW.
I-SHEET-SA-R2
5mm