Wilco Off-road ADV Trail Boss User manual

This guide will show you how to install
your new Wilco Off-road ADV Trail Boss
Complete Kit.
To complete this installation, you will
need the following tools. 10, 15, 17, and
19 millimeter Box Wrenches, Adjustable
Wrench, Socket Wrench with 10, 15, 17
and 19 millimeter Sockets, Safety glasses
and a Torque Wrench. It is recommended
that you lay out all the parts and tools
prior to beginning.

Unscrew the (5) M10 by 60 Button Screws
and remove the factory Bed Cross
Member. Attach the Bed Rail with the
screws you just removed.
Remove the factory Bed Rail End Caps and
set them aside.
Place (5) Bedrail Clamp Plates in the
passenger side Bed Rail, (5) in the driver
side Bed Rail, and (4) in the forward, or
cab, Bed Rail. Place the Passenger Bedrail
Weldment onto the bed and align it with
the Bedrail Clamp Plates.

Using a Socket Wrench, (3) M10 by 25
Bolts and an M10 by 35 Bolt attach the
Bedrail Weldment as shown. Torque the
bolts to 45 foot-pounds.
Attach the Driver Bedrail Weldment as
shown and torque the bolts to 45 foot-
pounds.
Place a Rack Adjustment Assembly on the
Driver Bedrail Weldment as close to the
cab as you can, making sure the screw
head is accessible. Now place the Driver
Riser Weldment onto the Rack
Adjustment Assembly.

Insert a Half by 13 by 12 Bolt, (2) Half Inch
Washers, and a Half Inch Nut. Tighten the
nut down only slightly. This will be
torqued in a later step.
Screw the Rack Adjustment Assembly
clockwise to adjust upwards, and counter-
clockwise to adjust downwards.
Install the Rack Adjustment Assembly on
the passenger side, and the Passenger
Riser Weldment. Do not fully tighten at
this point.

Attach the passenger side Corner Brace by
first mounting it to the cab Bedrail Clamp
Plate and then to the Passenger Side Riser
Weldment. Do not fully tighten the nuts
and bolts at this point.
Attach the driver side Corner Brace the
same way. Do not fully tighten the nuts
and bolts at this point.
You may want to place a Blanket or some
other protective cover over the roof of
your truck to prevent any damage.

Place the Driver Side Frame Weldment to
the Driver Side Riser Weldment. Attach
the top M10 by 1.5 by 90 Hex Screw,
M10 Washers and M10 Lock Nut first.
Next, attach the lower bolt, washers and
nut. Do not fully tighten the nuts at this
point.
Attach the Passenger Side Frame
Weldment to the Passenger Side Riser
Weldment the same way. Insert the top
bolt and washers first, and then the lower
bolt and washers. Do not fully tighten the
nuts at this point.
Place the Tire Support Rack between the
Frame Weldments as it will not fit once
they are connected. Place the Horizontal
Connecting Tube over each of the Frame
Weldments. There should be enough play
in each of the Riser Weldments and
Frame Weldments to fit the Horizontal
Connecting Tube with ease.

Place the Fairing onto the Horizontal
Connecting Tube and insert the (4)
Carriage Bolts.
Place the Light and Hooking Bracket to
the underside of the Horizontal
Connecting Tube ensuring the correct
orientation. Attach the brackets using (4)
M10 Lock Nuts and M10 Washers.
Attach the Bumper to the Driver Side
Frame Weldment.

Attach the Bumper to the Passenger Side
Frame Weldment.
Slide the Racking Tube into position on
the foremost holes on the Frame
Weldments.
Attach the Racking tube using an M10 by
25 Bolt.

Attach the other side of the Racking tube
using an M10 by 25 Bolt.
Install the remaining Rack Tubes using the
same method and hardware. Install the
Tire Support Rack in the same way. You
may now remove the protective Blanket.
Attach the Angle Plugs to the Driver side
and Passenger Side Lowrider Weldment.

Place the Driver Side Lowrider Weldment
onto the Driver Bedrail Weldment and
Driver Riser Weldment. Attach to the
Bedrail Weldment with (2) M10 by 35
Bolts. Do the same on the Passenger Side
Lowrider Weldment.
Attach the Driver Side Lowrider
Weldment to the Driver Side Riser
Weldment using an M10 by 25 Bolt. Do
the same on the Passenger Side Riser
Weldment.
Assemble both Highrider Tubes by
attaching Angle Plugs to the end of the
straight tube. Then, attach Straight Plugs
to the curved tube.

Place a Highrider Tube assembly onto the
Driver Side Lowrider Weldment and the
Driver Side Riser Weldment. Attach it to
the Lowrider Weldment using an M10 by
60 Screw, (2) M10 Washers and an M10
Lock Nut. Do the same for the Passenger
Side Lowrider Weldment.
Attach the Highrider Tube to the Driver
Riser Weldment using an M10 by 25 Bolt.
Do the same for the Passenger Side Riser
Weldment.
Place the Driver Expedition Panel
between the Driver Side Riser Weldment
and the Driver Side Highrider Tube. Attach
to the Riser Weldment using (2) M10 by
1.5 by 30 Screw, an M10 Washer and an
M10 Lock Nut. Do the same for the
Passenger Side Expedition Panel.

Attach the Expedition Panels to the
Highrider Tubes using (2) M10 by 80
Screws, (4) M10 Washers and (2) M10
Lock Nuts.
The passenger's side should be completed
along with the driver's side
Hook one of the Turnbuckles into the hole
on the Passenger Bedrail Weldment as
shown. Adjust the Turnbuckle by turning
the body of the Turnbuckle. Once set with
moderate pressure on the D hook of the
truck bed, tighten both Jam Nuts on the
Turnbuckle.

Place the Turnbuckle on the Driver Bedrail
Weldment in the same way.
There are numerous locations to mount
the Racking Tubes onto your ADV Trail
Boss Complete Kit.
To attach the Racking Tubes, first place a
Crossbar Clamp Assembly onto a Tube as
shown.

Insert the Clamp bolts into the Racking
tubes end and slide them inward. Position
the Clamp Bolts back into the Crossbar
Clamp Assembly and set it down. Ensure
that the Racking Tube is centered side to
side.
Attach the mounting hardware to the
Crossbar Clamp Assembly. Tighten down
when Racking Tubes are in the desired
positions.
Add other Racking Tubes if applicable.

Make sure that the rack is straight and
everything is properly placed. Check all
the connections to make sure everything
is tight. Torque the remaining bolts in
order:
Riser Bolts/Nuts: 80 foot-pounds.
Corner Braces: 45 foot-pounds.
Crosstube, Rear: 45 foot-pounds.
Clamp Blocks: 35 foot-pounds.
Crosstube, Front: 40 foot-pounds.
Racking Tubes: 40 foot-pounds.
Your new Wilco Off-road ADV Trail Boss
Complete Kit is now ready for adventure!