Weather guard 96111-3-02 User manual

1 ®2019 WernerCo Part No. 24-0340 REV. C 11/2019

Before drilling into the van, check for electrical wiring and air-bag system components.

INSTALLATION MANUAL

Models 96111-3-02 & 96511-3-02

Bulkheads for 2014 and Later

Ford Transit Connect Vans

ATTENTION: PLEASE READ AND UNDERSTAND ALL INSTRUCTIONS AND WARNINGS

BEFORE ASSEMBLING, INSTALLING OR USING THIS PRODUCT.

PLAN YOUR VAN (TIPS FOR FASTER INSTALLATION)

PARTS LIST

Description Qty.

1/4-20 x 3/4˝ Bolts 17

1/4-20 x 1-1/2˝ Bolts 8

1/4-20 x 2-1/4˝ Black Bolt 1

1/4-14 x 3/4˝ Self-Tapping Screws 4

1/4” Flat Washers 21

1/4” Lock Washers 4

1/4” Nylon Retaining Washers 4

1/4-20 Nylon Lock Nuts 15

1/4-20 Blind Fasteners 4

Blind Fastener Installation Tool 1

1/2” Spacers 4

3/4” Spacers 4

TOOLS REQUIRED

HARDWARE KIT

This “-02” bulkhead is only intended for a 2014 model year and later Ford Transit Connect Vans. If you have a 2013 or

earlier Transit Connect van, a different bulkhead (either an 96111-3-01 or 96511-3-01) must be used.

Header Panel

Base Panel

Panel Top

(Screen—96111-3-02 only)

Panel Top

(Window—96511-3-02 only)

B-Pillar Brackets (2)

96111-3-02 Screen Bulkhead

96511-3-02 Window Bulkhead

• 3/8˝and 7/16˝ Sockets

• Electric Drill/Driver

• Ratchet Handle

• 7/16˝Wrench

• 9/16˝Wrench

• Floor Hole Locator Template (page 3&4)

• Marker

• 1/8˝Drill Bit

• 7/32˝Drill Bit

• 3/8˝ Drill Bit

• 1-1/8˝Hole Saw

• 1/4-20 Thread Tap

• Utility Knife

®2019 WernerCo Part No. 24-0340 REV. C 11/20192

Figure 3

Figure 5

Figure 4

Figure 6

Figure 1 Figure 2

STEP 1. Assemble Bulkhead

Bolt panel top to base panel using nine each 1/4-20

3/4˝bolts, 1/4˝flat washers and 1/4-20 nylon lock

nuts as shown in figure 1. For the purposes of this

instruction sheet, the screen version of the

bulk-head will be shown but the window version

of the bulkhead installs in the same manner.

STEP 2. Loosely Assemble B-Pillar Brackets to the

Panel Top

Loosely bolt a B-pillar bracket to each side of the

panel top to base panel using two each 1/4-20 3/4˝

bolts, 1/4˝flat washers and 1/4-20 nylon lock nuts

as shown in figure 2. Do not tighten the hardware

at this time.

STEP 3. Locate Existing Mounting Holes in Floor of Van

The four mounting holes at the bottom of the base

panel line up with four pre-punched holes in the

floor of the Transit Connect located directly behind

the seats and under the floor mat (see figure 3).

Position the floor hole locator template (page 3 of

these instructions) as shown in figure 4 using the

front edge of the floor and the center of the tie-down

bolt (see figure 5) as reference points on either side.

Mark the hole locations on the floor mat and then

drill a 1/8˝pilot hole to confirm the exact location for

each of the four holes.

STEP 4. Drill 1-1/8˝ Holes in the Floor Pad Directly Above

the Four Floor Mounting Holes

With the hole saw and using the pilot holes drilled

in step 3, drill a 1-1/8˝hole in the floor pad directly

above each of the four floor mounting holes. See

figure 6. Be careful not to drill through the van

floor with the hole saw!

®2019 WernerCo Part No. 24-0340 REV. C 11/20193

EHTROFEGAPEHTFOEDISSIHTESU EDISREGNESSAP NAVEHTFO

MOUNTING HOLE MOUNTING HOLE

CENTER OVER

TIE-DOWN BOLT

FLOOR MOUNTING HOLE

ETALPMETROTACOL

snaVtcennoCtisnarTdroFretaldna4102

Line up this edge of the template parallel

with the edge of the ﬂoor mat.

EHTROFEGAPEHTFOEDISSIHTESU EDISREVIRD NAVEHTFO

MOUNTING HOLEMOUNTING HOLE

CENTER OVER

TIE-DOWN BOLT

FLOOR MOUNTING HOLE

ETALPMETROTACOL

snaVtcennoCtisnarTdroFretaldna4102

Line up this edge of the template parallel

with the edge of the ﬂoor mat.

®2019 WernerCo Part No. 24-0340 REV. C 11/20195

Push top of header panel up through

slot in headliner

Figure 7

Figure 8

Figure 10

Figure 11

STEP 5. Install Blind Fasteners and/or Spacers in

Floor of Van

2014-2017 – Widen the existing four floor mounting

holes by drilling them with a 3/8˝ drill bit. Install a blind

fastener in each of these holes following the instruc-

tions on page 7. Position a 3/4˝ floor spacer on top

of each installed blind fastener.

2018 & newer – Drill holes to 7/32˝ and tap to 1/4-20

thread. Position a 3/4˝ floor spacer on top of each

threaded hole.

STEP 6. Attach Bulkhead in Van

Position the bulkhead in the van with the decals

facing the rear of the van. Using the 7/32˝ bit, drill out

the two B-Pillar Holes nearest the B-Pillar brackets

and tap them to 1/4-20 thread. Using two each 1/4-20

x 3/4˝ bolts and 1/4˝ flat washers, attach the B-pillar

brackets on either side to the B-pillar of the van

through the existing holes punched into the B-pillar

(see figures 7 & 8). The hardware attaching the

B-pillar brackets to the bulkhead should remain loose

at this time. Secure the bottom of the bulk-head to the

van floor using four each 1/4-20 x 1-1/2˝ bolts and

1/4˝ lock washers into the blind fasteners

(see figure 7).

STEP 7. Modify the Headliner to Accommodate the Header

Panel

2014-2017 – Using a utility knife, cut a slot along the

headliner ridge as shown in figures 9 and 10. The slot

should be centered left-to-right and just long enough to

allow the top part of the header panel to slip above the

liner and attach to the roof rib in the van (Figure 11). Cut along here

Figure 9

®2019 WernerCo Part No. 24-0340 REV. C 11/20196

2018 & newer – Pull out the four grey plastic clips at

the back of the headliner (Figure 12). While holding

the center black foam piece up, pull down on the back

of the headliner until the white plastic pin (shown in

Figure 13 with foam piece already removed) clears

the bottom of the foam piece and remove the foam

piece. Cut the foam piece along the corner edge at

the back (Figure 14). Place the front portion of the

foam back into the van between the headliner and the

roof rib and replace the four plastic clips (Figure 15).

Figure 12

Figure 13

Figure 14

Figure 15

Cut along

corner edge

Discard

back poron

Keep front

poron

®2019 WernerCo Part No. 24-0340 REV. C 11/20197

Figure 17

Figure 19

INSTALLATION PROCEDURE

FOR BLIND FASTENERS

Figure 16

STEP 8. Position Header Panel to Panel Top and Loosely

Bolt on Place

Slip the top of the header panel through the slot in the

headliner as shown in figure 11 (2014-2017 only) and

then loosely bolt the header panel to the panel top

using four each 1/4-20 x 3/4˝ bolts, 1/4˝ flat washers

and 1/4-20 nylon lock nuts as shown in figure 16.

STEP 9. Attach Header Panel to Roof Rib

2014-2017 – See figure 17. Pull down slightly on the

rear edge of the headliner in order to give you access

to the van’s roof rib and then, using a drill/driver,

attach the header panel to the roof rib through the

four tabs using four each 1/4-14 self-tapping screws

and 1/4˝ flat washers.

2018 & newer – Use header panel as template to

mark hole locations in the roof rib, drill 3/8˝ holes,

and install blind fasteners. Attach the header panel

to the roof rib using 1/4-20 x 1-1/2˝ bolts, washers,

1/2˝ spacers, and retaining washers

(see Figure 18).

STEP 10.Tighten Loose Hardware

Tighten the loose hardware from the header panel

to the panel top and from the B-pillar brackets to the

bulkhead on both sides of the van (Figure 19).

Tighten the

two bolts

securing the

B-pillar brackets

to the panel top.

Tighten the

four bolts

securing the

header panel

to the

panel top.

Before drilling for blind fasteners, check to make sure that you won’t be damaging wiring,

fuel lines, brake lines or other crical vehicle systems.

Place a drop of oil on the threads of the black oxide bolt before assembling as shown

on le.

Place the blind fastener in the mounng hole unl just the top head of the blind fastener is

visible above the sheet metal of the vehicle. Use a 7/16˝ socket driver to ghten the black

oxide bolt unl the blind fastener is fully seated.

The ﬁrst few turns of the black oxide bolt will be require some force but as the blind

fastener “bulbs” out under the sheet metal it will get easier unl the blind fastener

booms out or sets.

The 9/16˝ wrench and installaon tool will make sure that the blind fastener does not turn

during the installaon.

Figure 18

®2019 WernerCo Part No. 24-0340 REV. C 11/20198

WEATHER GUARD®Products — Limited Lifetime Warranty (Purchased on or after 1/1/2009).

———————————————————————————————————————————————————————————————————————————

WERNER CO. (the “Manufacturer”) warrants to the original purchaser only that WEATHER GUARD®Truck and Van Products

(the “WEATHER GUARD®Product ”) will be free from defects in material and workmanship from the date of purchase and continuing for the expected

lifetime of the WEATHER GUARD®Product. A copy of the original sales receipt must be supplied to the Manufacturer at the time a warranty claim is

made. This warranty terminates if the original purchaser transfers the WEATHER GUARD®Product to any other person.

What is Covered

All WEATHER GUARD®Products identified above that are purchased on or after January 1, 2009.

What We Will Do to Correct Problems

Subject to the limitations and exclusions described in this limited warranty, the Manufacturer will remedy defects in materials or workmanship by

providing one of the following remedies at its option and without charge tothe original purchaser for parts or labor: (a) repairing the defective portion

of the WEATHER GUARD®Product or (b) replacing the entire WEATHER GUARD®Product. In addition, the manufacturer may elect at its option,

not to repair or replace the WEATHER GUARD®Product, but rather issue to the original purchaser a refund equal to the purchase price paid for the

WEATHER GUARD®Product or a credit to be used toward the purchase of new WEATHER GUARD®Product.

What is Not Covered

This limited warranty expressly excludes:

• Defects caused by normal wear and tear, cosmetic rust, scratches, accidents, unlawful vehicle operation, or modification to the

product, or any types or repair of a WEATHER GUARD®Product other than those authorized or provided by the Manufacturer.

• Defects resulting from conditions beyond the Manufacturer’s control including, but not limited to misuse, overloading, or failure to

assemble, mount or use the WEATHER GUARD®Product in accordance with the Manufacturer’s written instructions or guidelines

included with the WEATHER GUARD®Product or made available to the original purchaser.

• Damage to the contents of the box or vehicle.

• TO THE EXTENT PERMITTED BY LAW, IN NO EVENT SHALL THE MANUFACTURER BE LIABLE FOR ANY INCIDENTAL,

SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES, INCLUDING ANY ECONOMIC LOSS, WHETHER RESULTING FROM

NONPERFORMANCE, USE, MISUSE OR INABILITY TO USE THE WEATHER GUARD®PRODUCT OR THE MANUFACTURER’S

NEGLIGENCE.

No Other Express Warranty Applies

This Limited Lifetime Warranty is the sole and exclusive warranty for WEATHER GUARD®Products. No employee, agent, dealer, or other person is

authorized to alter this warranty or make any other warranty on behalf of WERNER CO.

Notification Procedures

If the WEATHER GUARD®Product does not conform with the terms of this limited warranty, the original owner must promptly notify the Manufacturer

in writing upon discovery of the nonconformity. In order to receive the remedies underthis limited warranty, the warranty claim must describe the na-

ture of the nonconformity, and a copy of the original sales receipt, invoice, bill or other proof of purchase must accompany the claim. Repairs or modi-

fications madeto the WEATHER GUARD®Product by otherthanthe Manufacturer or its authorized agent will nullify this limited warranty. Coverage

underthis limited warranty is conditioned at all times upon the owner’s compliance with these required notification and repair procedures. Warranty

claims must include reciprocal contact information and may be made via certified mail to:

WERNER CO. ATTN: Warranty Claims

420 E. Terra Cotta Avenue Crystal Lake, IL 60014

If you have any questions, please call toll free at 1-800-456-7865.

WERNER CO. LIMITED LIFETIME WARRANTY FOR WEATHER GUARD®PRODUCTS

Any modification or unintended use of this product shall immediately void all manufacturer’s warranties. Manufacturer disclaims all liability for

injuries to persons or property resulting from any modification to, or unintended use of this product.

- NOTICE -

This product can reduce the driver’s ability to clearly see roadways, vehicular or pedestrian traffic and other objects through the rear and side

windows of the vehicle, which can cause an accident. Extra precautions should be taken when driving a vehicle with this product. Make all

adjustments necessary to ensure maximum visibility, including but not limited to, changing mirror and seating positions. State and local laws

may prohibit obstruction of windows in a moving vehicle.

These instructions are to be followed using the parts and fasteners supplied for proper installation. Any modifications or improper installation of this