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 # IG2110HH
Modified Mar 2009
Model 2110 Ford Explorer Sport Trac 2007-Current

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
2
3
FORM # IG2110HH
Modified Mar 2009
Page 1
Model 2110 Ford Explorer Sport Trac 2007-Current

Note: If your Tonneau has already been installed, skip to Page 11 for removal
and reinstallation instructions.
FORM # IG2110HH
Modified Mar 2009
Page 2
Model 2110 Ford Explorer Sport Trac 2007-Current

FACT:
UnderCover is the
lightest hardshell
tonneau in the
industry. Only
58-pounds for full
size trucks.
A
B
C
D
E
Installing your Ford Sport Trac hardware is 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 shows what the rear bracket will look like once it is installed.
Remove the plastic plugs with a pair of needle-nose pliers. Save these for future use if you
ever remove the bracket system. See Page 4, Picture B.
Install the rear bracket using two 6mm bolts and two washers threaded into the preset
mounting holes. See Page 4, Picture C. Once you have tightened the bolts by hand, use a 10mm
wrench or ratchet/socket to firmly secure the bolts to the bed. See Page 4, Picture D. BE SURE
NOT TO OVER TIGHTEN, DOING SO COULD SHEAR OFF THE BOLT HEAD.
The mounting holes on the rear bracket are slotted to allow for adjustment of the lock
cams. The best position to start with is the bracket in the highest position. You can make further
adjustments once the cover is mounted. See Page 4, Picture E.
Repeat steps A through E for the other side.
WARNING! Be sure not to over tighten the rear mounting bolts. Doing so could shear
off the bolt heads, creating a difficult procedure to remove the remaining thread.
FORM # IG2110HH
Modified Mar 2009
Page 3
Model 2110 Ford Explorer Sport Trac 2007-Current

FORM # IG2110HH
Modified Mar 2009
Page 4
Model 2110 Ford Explorer Sport Trac 2007-Current

Mounting the Ball Stud for your hydraulic strut is simple and easy. Page 6, Picture A shows
what the finished install will look like.
In the center of the bed there are two torx bolts, you will need to remove the one towards
the rear of the truck. You will need a Torx T-30 bit to remove this bolt. See Page 6, Picture B.
Again, like the plastic tabs from the rear mounting bracket proceedure, you should save this bolt
for removal of brackets in the future.
Once you have removed the torx bolt you can now hand thread the ball stud included
with the hardware. Secure the ball stud with a 1/2" wrench or socket/ratchet. BE SURE NOT TO
OVER TIGHTEN. DOING SO CAN SHEAR OFF THE BALL STUD AND CAUSE SERIOUS DIFFICULTY
CORRECTING.
Once you UnderCover is installed you will be able to lift the cover up and clip the strut to
the ball mount. See Page 6, Picture C.
A
B
C
D
WARNING! Be sure not to over tighten the rear mounting bolts. Doing so could shear
off the bolt heads, creating a difficult procedure to remove the remaining thread.
FORM # IG2110HH
Modified Mar 2009
Page 5
Model 2110 Ford Explorer Sport Trac 2007-Current

FORM # IG2110HH
Modified Mar 2009
Page 6
Model 2110 Ford Explorer Sport Trac 2007-Current

FACT:
UnderCover's
ABS-Composite
material makes
it the strongest
and most
durable tonneau
on the market.
Installation of the front bracket is very similar to the rear. Remove the plastic plugs exposing the 3
preset bolt holes located at the front of the bed. Page 8, Picture A shows how the front bracket will look
once it is fully installed.
Position the front bracket over the three preset bolt holes. See Page 8, Figure 1. Attach the bracket
to the truck using the three 6mm bolts and washers. The measurement is just a starting point, the brackets
are slotted to allow for adjustment. See Page 8, Picture B. Tighten the three bolts using a 10mm wrench
or socket/ratchet. See Page 8, Picture C. BE SURE NOT TO OVER TIGHTEN OR YOU COULD SHEAR OFF THE
BOLT HEAD CREATING A VERY DIFFICULT PROCEDURE TO REMOVE THE REMAINING THREAD.
Repeat process for other side.
Now you are ready to set your cover on the truck. The hinge that is attached to the cover has slots in
it that fit over the mounting posts on the bracket you just installed. See Page 8, Figure 2.
With the hinge slot over the post, the cover will be sitting about 1-inch past the tailgate. See Page 9,
Picture F. With the cover sitting all the way down on the truck bed, push the cover forward securing the 4
bar hinge to the mounting posts. See Page 9, Picture G.
With some assistance, have someone hold the cover up at the rear and reach inside the cover and
screw in the two fastening knobs. See Page 9, Picture H.
A
B
C
D
E
F
WARNING! Be sure not to over tighten the rear mounting bolts. Doing so could shear
off the bolt heads, creating a difficult procedure to remove the remaining thread.
FORM # IG2110HH
Modified Mar 2009
Page 7
Model 2110 Ford Explorer Sport Trac 2007-Current

FORM # IG2110HH
Modified Mar 2009
Page 8
Model 2110 Ford Explorer Sport Trac 2007-Current

FORM # IG2110HH
Modified Mar 2009
Page 9
Model 2110 Ford Explorer Sport Trac 2007-Current

Very Important: Periodically check your truck for rubbing. Make slight
adjustments when necessary.
Not all truck beds are assembled 100% square, so it may be necessary to do some preliminary
adjustments. The mounting holes in the front brackets are slotted to allow for adjustment.
With your cover closed, take a quick inspection to make sure that it is not touching the bed on either
side or the tailgate. If it appears square or close to square go on to Step 4, pages 11 and 12. If it is making
contact with the side of the truck or the tailgate, you may wish to make some adjustments before going
to the final step.
To adjust the cover front to back evenly, move both of the front brackets forward or backward
accordingly. To adjust one side or the other, move the front brackets forward or backward independently.
Any questions you can call tech assistance Monday through Friday, 8 a.m. – 5 p.m. Central Time [phone].
FORM # IG2110HH
Modified Mar 2009
Page 10
Model 2110 Ford Explorer Sport Trac 2007-Current

FACT:
In less than one minute, you can both take on and off
the Undercover tonneau. Fastest removal system in the
industry.
A
B
C
D
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 10, Figure 7, Picture A.
Be sure that the front flap seal hangs over the bulkhead of the truck and is not rolled
under the tonneau after installation. If flap seal is rolled under the tonneau, open the
tonneau, and from the inside push the flap seal out from under the tonneau and over the
bulkhead Page 10, Figure 8, Picture B.
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 backward to achieve correct length. Front brackets may also have to be adjusted
independently to “square-up” tonneau on some truck beds.
Adjust lock strikes Page 10, Figure 9, Picture C.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 10, Figure 9, Picture D.
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.
FORM # IG2110HH
Modified Mar 2009
Page 11
Model 2110 Ford Explorer Sport Trac 2007-Current

FORM # IG2110HH
Modified Mar 2009
Page 12
Model 2110 Ford Explorer Sport Trac 2007-Current

Release strut off of ball stud
Picture B. Holding tonneau up with
one hand, place loose end of strut
on storage clip Picture C. Repeat for
the other side.
Turn twist knobs until they
release Picture A.
Go to the rear of the truck
and pull Tonneau cover back,
releasing the post from the hinge
slot, Picture D. You are now ready
to lift the cover off.
STEP 1
STEP 2
STEP 3
Place tonneau on the truck
and follow instructions on Page 7.
Be sure that the front flap
seal is hanging over the bulkhead
and not rolled under, see Picture E
on this page.
Reinstall struts as seen in
pictures Pictures F and G on this
page.
STEP 1
STEP 2
STEP 3
Congratulations! 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.
FORM # IG2110HH
Modified Mar 2009
Page 13
Model 2110 Ford Explorer Sport Trac 2007-Current

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.
Remove your tonneau
from the truck bed according to
instructions on Page 11.
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 & D.
STEP 1
STEP 2
STEP 3
FORM # IG2110HH
Modified Mar 2009
Page 14
Model 2110 Ford Explorer Sport Trac 2007-Current

Page 15
Model 2110 Ford Explorer Sport Trac 2007-Current