UnderCover 2110 User manual

TONNEAU INSTALLATION GUIDE
Warranty, Care & Maintenance
EASY AS 1-2-3! 30 MINUTESNORMAL INSTALLATION TIME
For Warranty Issues, Contact Undercover Directly
[phone] www.undercoverinfo.com
FORM # IG2110
Modified January 2007
Model 2110 Ford Sport Trac 2007

PRE-INSTALLATION NOTES
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TONNEAU INSTALLATION GUIDE
INSTALLATION KIT CHECKLIST
E
H
I
D
G
J
F
A: Hydraulic Struts
B: Front Mounting Brackets
(mounted to Bedrail)
C: 4-Bar Hinge with Twist Knobs
(mounted to the Cover)
D: Ball Studs
E: J-Hook Wood Screws
F: Rear Mounting Bracket
G: Wall-Mounting J-Hooks
H: 6mm Bolts
I: Lock Washers
J: Washers
B
C
A
Be sure to use only cleaners, waxes, etc., which are labeled ‘Safe for Plastics’. Make sure that chemicals or substances,
which are not labeled ‘safe for plastics’, do not come in contact with your Undercover. Failure to do so could cause
discoloration and/or structural damage to your Undercover and will void your warranty.
Paint rubbing of the truck is normally not a problem, but is always a possibility with any tonneau. To ensure less chance of
possible paint rubbing of the truck, it is suggested to install a tailgate protector and adhere Cab Skin®, Scotch Cal®, or
similar product to the truck bed. These products can provide added assurance against paint rubbing.
Undercover Tonneaus are designed from trucks that do not have a bed liner (spray-in bed liners pose no problem). Trucks
that do have under-the-rail or over-the-rail bed liners will require some minor trimming of the bed liner to ensure proper
placement of the mounting brackets. Due to the wide variety of bed liner manufacturers, the modifications will vary slightly
between different brands. Any modifications must be made to the bed liner and NOT to the Undercover mounting hardware.
Modifications to the mounting hardware will result in improper installation and will void your warranty.
1
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FORM # IG2110
Modified January 2007
Page 1
Model 2110 Ford Sport Trac 2007

NORMAL INSTALLATION TIME MINUTES
30
TONNEAU INSTALLATION GUIDE
[phone] www.undercoverinfo.com
UNDERCOVER INSTALLATION TOOLS NEEDED
QUICK REMOVAL & REINSTALL REVIEW
UnderCover makes tonneaus for most makes and models of trucks.
Note: If your Tonneau has already been installed, skip to Page 9 for removal
and reinstall instructions.
Off your truck and on your wall in less than one minute!
10mm WRENCH OR SOCKET, TORX BIT T-30, NEEDLE-NOSE
PLIERS, 1/2-INCH WRENCH.
FORM # IG2110
Modified January 2007
Page 2
Model 2110 Ford Sport Trac 2007

TONNEAU INSTALLATION GUIDE
[phone] www.undercoverinfo.com
UNDERCOVER INSTALLATION INSTRUCTIONS
EASY AS 1-2-3
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Installing your Ford Sport Trac hardware is very simple and easy to do. The Sport Trac comes with
the mounting holes already in place. Our hardware mounts right to the existing holes. Page 4, Picture A is
what the final rear bracket will look like once it is installed.
Remove the plastic plugs with a pair of needle-nose pliers. Save these in a plastic bag for future
use if you ever remove the bracket system. Page 4, Picture B.
Take your rear-mounting bracket and thread your 6mm bolts and washers through the bracket
into the preset threads. It will take two bolts and a set of washers. See Page 4 Picture C. Once you have
hand-tightened down the bolts use a 10mm wrench to firmly secure the bolts to the bed. BE SURE AND
DO NOT OVER TIGHTEN, YOU COULD SHEAR-OFF THE BOLT HEAD. See Page 4 Picture D.
To adjust this bracket so that the lock cams will slide under the lock plate, there are two slots that
will allow the rear bracket to slide up or down. The best position to start with is the bracket in its highest
position. If necessary you can adjust after you mount the cover to the bed. See Page 4, Picture E.
Repeat steps A through D for the other side.
FACT:
Undercover is the
lightest hardshell
tonneau in the industry.
Only 58-pounds for full
size trucks.
A
B
C
D
E
WARNING! Be sure and do not over-tighten the rear-mounting bolts. Doing so can shear-off the
bolt heads, creating a difficult procedure to remove the remaining thread.
FORM # IG2110
Modified January 2007
Page 3
Model 2110 Ford Sport Trac 2007

TONNEAU INSTALLATION GUIDE
UNDERCOVER INSTALLATION INSTRUCTIONS
[phone] www.undercoverinfo.com
A
B C
D E
10
MINUTES
FORM # IG2110
Modified January 2007
Page 4
Model 2110 Ford Sport Trac 2007

TONNEAU INSTALLATION GUIDE
[phone] www.undercoverinfo.com
UNDERCOVER INSTALLATION INSTRUCTIONS
EASY AS 1-2-3
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Mounting the Ball Stud for your hydraulic strut is simple and easy. Page 6 Picture A demonstrates what
the finished hook-up will look like.
In the center of the bed is a Torx Bolt # T-30. You will need a Torx T-30 to remove this bolt. Again,
like the plastic tabs from the rear mounting bracket you should save this bolt for future needs. See Page 6,
Picture B.
Once you have removed the Torx Bolt you can now hand thread the Ball Stud included with your
hardware. Secure the Ball Stud with a 1/2" wrench or socket set. BE SURE AND DO NOT OVER-TIGHTEN
DOWN. DOING SO CAN SHEAR-OFF THE BALL STUD AND CAUSE SERIOUS DIFFICULTY CORRECTING.
Once your UnderCover is installed you will be able to lift the cover up and clip on the strut and mount it
to the ball stud. See Page 6, Picture C.
A
B
C
D
WARNING! Be sure and do not over-tighten the rear-mounting bolts. Doing so can shear-off the
bolt heads, creating a difficult procedure to remove the remaining thread.
FORM # IG2110
Modified January 2007
Page 5
Model 2110 Ford Sport Trac 2007

TONNEAU INSTALLATION GUIDE
UNDERCOVER INSTALLATION INSTRUCTIONS
[phone] www.undercoverinfo.com
A
B
C
10
MINUTES
Ball Stud that goes
in place of Torx Bolt
that comes with
your truck.
Torx Bolt
Torx Bit
FORM # IG2110
Modified January 2007
Page 6
Model 2110 Ford Sport Trac 2007

TONNEAU INSTALLATION GUIDE
[phone] www.undercoverinfo.com
UNDERCOVER INSTALLATION INSTRUCTIONS
EASY AS 1-2-3
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Like the rear-mounting bracket installing the front bracket is much the same. Remove the plastic studs exposing
the 3 preset bolt holes located at the front of the bed. See Page 8, Picture A for a complete look at how the front
bracket will look when completely installed.
Place the front bracket included in your hardware kit in place over the 3 preset bolt holes. See Figure 1. Hand
screw in three 6mm bolts with washers. Tighten down using 10mm socket or wrench. BE SURE TO NOT OVER-TIGHTEN
OR YOU COULD SHEAR-OFF THE BOLT HEAD CAUSING A SERIOUS REPAIR ISSUE TO REMOVE THE REMAINING THREAD.
See Page 8 Picture B. On Page 8 Figure 2 shows how your 4-bar hinge will fit on the bracket you just installed.
Repeat this process on the opposite side. Once completed you will will have the front mounting bracket firmly in
place and ready to install the cover.
Now you are ready to set your cover on the truck. Look at Page 9 Picture F. You must slide the 4-Bar Hinge
Bracket attached to the cover over the mounting post. Look again at Page 8 Figure 2, as to how the 4-Bar Hinge fits
over the post.
With the hinge slot sitting over the post the cover will be sitting about 1-inch over the tailgate Page 9 Picture
F. From this position you can now push the cover firmly into position securing the 4-Bar Hinge to the post. See Page 9
Picture G.
Now with someone assisting, lift cover up keeping the pressure pushing the cover forward. Reach inside the
cover and screw in the 2 fastening knobs. Only hand tighten down. See Page 9, Picture H.
Your cover is now ready for Step 4.
FACT:
Undercover’s
ABS-Composite
material makes
it the strongest
and most
durable tonneau
on the market.
A
B
C
D
E
F
G
FORM # IG2110
Modified January 2007
Page 7
Model 2110 Ford Sport Trac 2007

Figure 2
TONNEAU INSTALLATION GUIDE
UNDERCOVER INSTALLATION INSTRUCTIONS
[phone] www.undercoverinfo.com
B
A
C
Figure 1
MOUNTING POSTS
FRONT BRACKET
20
MINUTES
MOUNTING POST
HINGE SLOTS
4-BAR HINGE
PRE-MOUNTED TO COVER
TWIST KNOB
FRONT BRACKET
MOUNTED TO BED RAIL
FORM # IG2110
Modified January 2007
Page 8
Model 2110 Ford Sport Trac 2007

TONNEAU INSTALLATION GUIDE
UNDERCOVER INSTALLATION INSTRUCTIONS
[phone] www.undercoverinfo.com
G
H
F
Slots on 4 bar hinge should be
sitting on mounting post ready to
be pushed into position.
Push 4-bar hinge slots into
mounting post securing
hinge system.
20
MINUTES
Unsecured
Secured
FORM # IG2110
Modified January 2007
Page 9
Model 2110 Ford Sport Trac 2007

[phone] www.undercoverinfo.com
TONNEAU INSTALLATION GUIDE
TEST FIT COVER PROPERLY BEFORE FINAL
SECURING OF KNOBS AND CLAMPS.
With your cover installed, including Hydraulic Struts (see Step 4) leave your tailgate open and cover closed.
Check locks to see if they line-up properly and the strike cams slide under lock plate without any resistance. If
there is resistance, you can adjust lock plate with 10mm wrench.
If your cover is not square with the bed, the locks will look out of position with each other. If this is the case you
will need to adjust only the front brackets.
Depending on which side is not hitting the lock plate properly, you will need to slide that side's Front Bracket
either forward or backward slightly, to bring the cam into proper position with the lock plate. If this does not
work, go to the opposite side and move front bracket back until the lock lines up.
Any questions you can call tech assistance Monday through Friday, 8 a.m. – 5 p.m. [phone].
Once locks line-up properly, close tailgate. You can then feel around the outer edge of the cover, as it should
have a similar gap all the way around your truck and should NOT be touching anywhere. If this is good, go back
and tighten all clamps and knobs.
If you have any Warranty questions, call: 866-900-8800.
Very Important: Periodically check your truck for rubbing. Make slight adjustments
when necessary. More information on Step 4.
FORM # IG2110
Modified January 2007
Page 10
Model 2110 Ford Sport Trac 2007

TONNEAU INSTALLATION GUIDE
[phone] www.undercoverinfo.com
UNDERCOVER INSTALLATION INSTRUCTIONS
EASY AS 1-2-3
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FACT:
In less than one minute, you can both take on and off the
Undercover tonneau. Fastest removal system in the industry.
Install hydraulic struts making sure LARGE end of strut is attached to the tonneau, and SMALL or rod end
is attached to the ball stud on rear bracket Page 12, Figure 7, Picture A.
Be sure that the front flap seal hangs on the bulkhead plate and is not rolled under the tonneau after
installation. If flap seal is rolled under the tonneau, open the tonneau and from the inside use a yardstick or
something similar to push the flap seal out from under the tonneau and over the bulkhead.
Close tonneau and check length on the truck. There should be 1/8” -to- 3/8” gap between the tailgate
and the tonneau. If this is not correct, adjust by moving front brackets forward or back to achieve correct length.
See Page 10 for further instructions. Front brackets may also have to be adjusted independently to “square-up”
tonneau on some truck beds.
Adjust lock strikes Page 12, Picture B. When adjusted properly you should be able to turn the key to
the locked position without having to push down on the tonneau. There should be a very slight amount of play
between the lock cam and lock strike. A good rule of thumb is to adjust the lock to have approximately 1/8” gap
between the cam and lock strike with the truck tailgate down. This usually gives you the proper adjustment after
the tailgate is shut Page 12, Figure 9, Picture C.
WARNING: It is very important to be able to turn the key without any resistance. Do not try to
force the lock cam to turn if you encounter resistance. This could result in a broken key or
broken lock. Adjustment may be necessary to the lock strike plate to achieve a smooth turn
without any resistance.
A
B
C
D
FORM # IG2110
Modified January 2007
Page 11
Model 2110 Ford Sport Trac 2007

UNDERCOVER INSTALLATION INSTRUCTIONS
Figure 7
Figure 8
Figure 9
TRUCK BED RAIL
LOCK STRIKE
LOCK
LOCK CAM
#10-24
WIZ NUT
TRUCK BED RAIL
REAR BRACKET
BED LIP
CLAMP
5/16"-18 X 1-1/4"
HEX HEAD BOLT
5/16" LOCK WASHER
5/16" WASHER
TRUCK BULKHEAD
TONNEAU
UNDERCOVER
FRONT FLAP SEAL
CORRECT PLACEMENT
OF FRONT FLAP SEAL:
FLAP HANGS OVER
BULKHEAD
INCORRECT
PLACEMENT
OF FRONT
FLAP SEAL
TONNEAU INSTALLATION GUIDE
[phone] www.undercoverinfo.com
HYDRAULIC STRUT
(LARGE END)
ATTACHES TO TONNEAU
HYDRAULIC STRUT
(ROD END)
REAR BRACKET
B
C
A
30
MINUTES
NOTE: Sport Trac Strike Plate is mounted to bracket as
shown in Picture C. There is no clamp system.
NOTE: Sport Trac stud attaches
as shown in Picture A.
FORM # IG2110
Modified January 2007
Page 12
Model 2110 Ford Sport Trac 2007

TONNEAU INSTALLATION GUIDE
[phone] www.undercoverinfo.com
1Minute
Removal
1Minute
Re-Install
A
CB
F
UNDERCOVER REMOVAL & REINSTALATION INSTRUCTIONS
D
G
HYDRAULIC STRUT
(LARGE END)
HYDRAULIC STRUT
(ROD END)
E
TONNEAU
UNDERCOVER
INCORRECT
PLACEMENT
OF FRONT
FLAP SEAL
Your 30-minute installation job is now complete. Now, in less than one
minute, you will be able to put on and take off your tonneau cover.
Congratulations!
Release strut off of ball stud.
Holding tonneau up with one hand,
place loose end of strut on storage
clip Picture C. Repeat for the other
side Picture A.
Turn twist knobs until they
release, Picture B.
Go to back of truck and pull
Tonneau cover back, releasing the
post from the hinge slot, Picture
D. You are now ready to lift the
cover off. Just pull the cover back
releasing it from the mounting post.
Place tonneau on the truck.
Follow instructions on Page 7,starting
at Section D.
Be sure that the front flap
seal is hanging over the bulkhead,
not rolled under the tonneau after
installation Picture E.
Reinstall struts Page 11,
Section A, Figure 7, also Page 13
Picture G.
STEP 1
STEP 2
STEP 3
STEP 1
STEP 2
STEP 3
FORM # IG2110
Modified January 2007
Page 13
Model 2110 Ford Sport Trac 2007

TONNEAU INSTALLATION GUIDE
[phone] www.undercoverinfo.com
UNDERCOVER WALL HANGING INSTRUCTIONS
A
C
D
B
32”
84”
Prior to removing the tonneau,
mount the two J-Hooks provided on
the garage wall. The hooks must have
a minimum height from the floor of
84”, and be 32” on center horizontally
apart Picture A & B. Mount hooks onto
2x4 board that is mounted into drywall
studs.
Remove your tonneau from the
truck bed according to instructions on
page 9, 1-Minute Removal.
Hang tonneau vertically on
the wall-mounted J-Hooks, with the
underside against the wall inserting
J-Hooks into the holes provided in
Picture C.
STEP 1
STEP 2
STEP 3
FORM # IG2110
Modified January 2007
Page 14
Model 2110 Ford Sport Trac 2007

TONNEAU INSTALLATION GUIDE
Congratulations! You’ve just
installed the fastest-selling,
highest-quality tonneau in the
industry. Thank you very much for
your purchase of UnderCover!
Steve Brallier
President
E.D. Industries/UnderCover
© 2007 E.D. Industries, Inc. All rights reserved.
E.D. Industries/UnderCover
P.O. Box 620
Rogersville, MO 65742
[phone]
[phone]
www.undercoverinfo.com
[email protected]
UNDERCOVER SERIAL NUMBER LOCATION
THANK YOU!
For any Warranty issues, contact UnderCover Directly.
Page 15
Model 2110 Ford Sport Trac 2007