Installation Instructions Van: VNFD92ECXT65 FORD ECONOLINE EXT 138” WHEELBASE 1992-2014 TOOLS REQUIRED Adjustable wrench (that opens to about 1”), 1/2” open end wrench, Phillips screwdriver, 3/8” socket, 7/16” socket, 7/32” Allen wrench, electric drill, 5/16” drill bit Watch short installation videos at www.decked.com/video | Register your system at www.decked.com/warranty follow us : VERSION 1 DECKED.COM | SERVICE@DECKED.COM | 208.806.
This product BE INSTALLED in a This product MUSTMUST BE INSTALLED in conjunction with conjunction with a bulkhead wall, and/or bulkhead wall, and/or adequate structural framework adequate structural framework to prevent to prevent injury as a result of a traffic accident. injury as a result of a traffic accident.
▼ READ BEFORE YOU INSTALL DECKED ▼ DON’T use power tools to assemble or install the DECKED system. Impact wrenches and other power tools can over tighten and damage components (aside from drilling drain holes in ammo cans). DON’T over tighten J-hooks during installation. J-hooks need to be snug to keep system from moving around, but should NOT be cranked down. DON’T over torque any bolts, particularly the bolts attaching the center vert to the deck halves.
PREPARE VAN: INSTALL SHIMS There are 2 shims provided: 1) If your vehicle is equipped with a rubber floor mat in the cargo area, you will need to remove the screws securing the plastic trim pieces at the base of the rear door and side door openings, and remove and set aside the plastic trim pieces. If no mat is installed, follow step 3 on this page. 2) At the rear door opening, lift the floor mat and fold it forward so it is clear of the floor area where the shims will be placed.
PREPARE VAN: INSTALL TIE-DOWN BRACKETS STEP 1: Locate bracket locations along fore-aft body ledge per dimensions shown in detail views A-D. Note: the three large holes of each bracket will be pointing upwards. STEP 2: Use marking pen to mark outermost bracket hole locations according to detail views A-D. Invert bracket to mark, as shown in detail B. NOTE: In detail B, you may need to temporarily remove jack tools to mark and drill holes. STEP 3: Drill 5/16” clearance holes where marked.
STEP 1: DRIVER SIDE DECK ASSEMBLY • Loosely bolt C-channel to the ledges on the inside of the two ammo cans. Make sure bolt head is on the C-channel side, not inside ammo can; bag 1A. NOTE: The small rectangular slot in the C-channel indicates the rear end. • Line up the deck (sticker indicates driver side deck half) on top of the C-channel/ammo can assembly and the vert bosses. NOTE: Rear side of vert has an axle hole at the bottom (see below).
STEP 2: INSTALL AXLES 1). Install the driver side rear ammo can axle; bag 2A. • Rotate the axle from its inbound side using a wrench on the “flat” end. Nut is included in bag and can be held with adjustable wrench while tightening. NOTE: Axles should be tight enough that the axle end is difficult to spin with a 1/2” wrench. 2). Repeat on passenger side rear ammo can; bag 2A. 3). Install vert axle; bag 2B.
STEP 3: INSTALL DRIVER SIDE DECK HALF • Get a buddy to help you place the driver side deck assembly into your van and slide it up against the driver side wall. • Insert the J-hook through the hole shown on the driver side front ammo can and loosely affix it to tie-down bracket (hook on bottom); bag J5. • Insert the J-hook through the center hole on the driver side rear ammo can and loosely affix it to the bracket with J-hook (hook on bottom); bag J5.
STEP 4: PASSENGER SIDE DECK ASSEMBLY • Loosely bolt C-channel to the ledges on the inside of the two ammo cans. Make sure bolt head is on the C-channel side, not inside ammo can; bag 4A. NOTE: The small rectangular slot in the C-channel indicates the rear end. • Line up the deck (sticker indicates passenger deck half) on top of the C-channel/ammo can assembly and the vert bosses. NOTE: Rear side of vert has an axle hole at the bottom.
STEP 5: INSTALL PASSENGER SIDE DECK HALF • Wake up your buddy to help you place the passenger side deck assembly into the van so it overlaps the driver side deck section. Slide until inside edge of the deck rests on the round bosses of the vert. • Insert the J-hook through the hole shown on the passenger side front ammo can and loosely affix it to tie-down bracket (hook on bottom); bag J5.
STEP 5.5 INSTALL SIDEBOARDS • Identify driver side ‘L’ shaped plastic sideboard. • Center the sideboard front to rear on the deck panel. • Push vertical leg of sideboard up against the interior side panel of van. • Using the holes in the sideboard as a guide, install-self-tapping screws; bag 5.5. • Repeat the process for the passenger side of the system.
STEP 6: INSTALL DRAWER WHEELS • There is a left and a right corner bracket for each drawer–bolt brackets in place. (use the 2” bolts for the upper back wall bracket hole); bags 6A and 6B. • Use tube brace with two bolts to connect the two corner brackets; bag 6C. • Insert axle through wheel and affix to drawer bracket; bag 6D. Do this for each wheel (4 times). • Turn drawer upside down and align the holes in the L-braces (loose in system box) with the drawer holes.
4 2 STEP 7: INSTALL DRAWER HANDLES 6 5 3 ZONE REV. • Save yourself the headache, watch this short installation video: decked.com/videohandle • From the underside of drawer, place the springs between the holes, red spring=right spring; bag 7A. NOTE: each spring arm should point inward, not outward. • Install clevis pin through each drawer hole and through spring; bag 7B. • With DECKED logo facing outward, insert the handle ends behind the spring arms.
STEP 8: INSTALL DRAWERS • Save yourself the headache, watch this short installation video: decked.com/videotailgatewheels. • Install optional drawer braces (instructions included in bag); bag 8A. • Install drawer by sliding wheels into their two channels (C-channel and vert). • Install remaining tailgate side wheels onto their axles; bag 8B. NOTE: Placing a spacer under the drawer to raise it into position makes this easier (ammo can lids work well).
STEP 9: THE FUN STUFF Caution: These are small gauge screws–light, hand-tightening is all that is required. • Center and screw on the edge guard/ruler; bag 9A. • Screw on the bottle opener; bag 9A. • Using your favorite beverage, test the bottle opener, and think about how jealous your buddies are going to be.
