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ASSEMBLY INSTRUCTIONS FOR HAULER RACK

II - UNIVERSAL TRUCK SERIES RACKS

T11U2863-1 shown above

HAULER RACKS, INC. Toll Free: 1-800-843-5445

7109 31

Avenue North Phone: 763-546-5620

Minneapolis, MN 55427-2848 Fax: 763-546-0933

Page 1 of 14 WWW.HAULERRACKS.COM

Package Contents:

HARDWARE KIT PARTS

(4) 3/8”-16 x 3” CARRAIGE BOLTS (1) RAIL DRIVER’S SIDE ASSEMBLY

(20) 3/8”-16 x 2” CARRAIGE BOLTS (1) RAIL PASSENGER’S ASSEMBLY

(2) 3/8”-16 x 1-3/4” CARRAIGE BOLTS (1) FRONT RECTANGLULAR CROSSBAR

(12) 3/8”-16 x 1-1/4” HEX BOLTS (1) MIDDLE CROSSBAR ASSEMBLY WITH ‘H’ & ‘T’ BRACKETS

(12) 3/8”-16 x 1-1/4” HEX LAG BOLTS (1) REAR CROSSBAR WITH ‘T’ BRACKETS

(38) 3/8”-16 NUTS (2) FRONT LEG ASSEMBLY

(38) 3/8” SPLIT LOCK WASHERS (2) REAR LEG ASSEMBLY

(4) HD BRACES

Before you begin:

Remove all components from the shipping carton.

The rack should be assembled on a padded surface such as carpet to prevent scratching of aluminum surfaces. Remove bands

securing components together.

Read the instructions thoroughly to familiarize yourself with the assembly sequence.

Note that you DO NOT tighten any nuts and bolts until the completed rack is installed on the vehicle unless specified. This allows for

minor adjustments to the rack during the installation process.

Gather the following tools used to assemble and install the rack.

9/16” Sockets or open end wrenches

1/4”, 3/8” Drill bits and drill

Pencil or marker

Tape measure

Center punch and hammer (optional)

Level (optional)

2 Clamps (optional)

Boards (optional)

Summary of content (14 pages)

PAGE 1
ASSEMBLY INSTRUCTIONS FOR HAULER RACK II - UNIVERSAL TRUCK SERIES RACKS T11U2863-1 shown above Package Contents: HARDWARE KIT (4) 3/8”-16 x 3” CARRAIGE BOLTS (20) 3/8”-16 x 2” CARRAIGE BOLTS (2) 3/8”-16 x 1-3/4” CARRAIGE BOLTS (12) 3/8”-16 x 1-1/4” HEX BOLTS (12) 3/8”-16 x 1-1/4” HEX LAG BOLTS (38) 3/8”-16 NUTS (38) 3/8” SPLIT LOCK WASHERS PARTS (1) RAIL DRIVER’S SIDE ASSEMBLY (1) RAIL PASSENGER’S ASSEMBLY (1) FRONT RECTANGLULAR CROSSBAR (1) MIDDLE CROSSBAR ASSEMBLY WITH ‘H’ & ‘T’ BRACKETS (1) REAR CROSSB
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NOTE: If you have a 97-09 Chevrolet or GMC fullsize truck, you will need to change the feet with p/n SPBKIT-1 due to possible stake pockets interference. 1. Connect front and rear sections Each side rail side contains a front and rear section preassembled for easier assembly. The front and rear sections are banded together. Remove the banding and separate the front and rear rail sections from packaging.
PAGE 3
1. (Continued) Connect front and rear sections Note the orientation of the other carriage bolts on rail assemblies. For the top round tube, use a 3/8”-16 x 1-3/4” carriage bolt, 3/8” split lock washer and a 3/8”-16 nut, install hardware finger tight. Repeat for other side rail. For the lower rectangle tube, use (2) 3/8”-16 x 3” carriage bolts, (2) 3/8” split lock washers and (2) 3/8”16 nuts, install hardware finger tight. Repeat for other side rail. HAULER RACKS, INC.
PAGE 4
2. Install front Crossbar. The front crossbar is the smooth rectangle tube with the round bolt holes in each end. Secure the front cross bar to the ‘H’ brackets mounted on the side of the front rail sections using (4) 3/8”-16 x 2” carriage bolts, (4) 3/8” split lock washers and (4) 3/8”-16 nuts. Finger tighten only. HAULER RACKS, INC. st 7109 31 Avenue North Minneapolis, MN 55427-2848 Page 4 of 14 Toll Free: 1-800-843-5445 Phone: 763-546-5620 Fax: 763-546-0933 WWW.HAULERRACKS.
PAGE 5
3. Set middle crossbar assembly in place. The middle crossbar assembly is the ribbed rectangle extrusion with a slotted bottom with ‘H’ brackets attached to each end and ‘T’ brackets attached to the slotted bottom. Orientate the crossbar so the ribbed bottom is facing down. Position the middle crossbar assembly on the front side rails forward of the 5” bracket and about halfway between the 5” bracket and the next support bracket.
PAGE 6
4. Install rear crossbar. The rear crossbar is the rectangular extrusion with a ribbed bottom and square bolt holes in each end and ‘T’ brackets attached to the bottom of the crossbar. Using (4) 3/8”-16 x 2” carriage bolts, (4) 3/8” split lock washers and (4) 3/8”-16 nuts, secure the rear crossbar to the ‘H’ brackets mounted at the ends of the rear rails sections. Finger tighten hardware only. HAULER RACKS, INC.
PAGE 7
5. Install rear legs Turn the rack over so the round tubes are on the bottom. Place the rear legs (legs with un-notched feet) so the ribbed portion faces inwards. Use (2) 3/8”-16 x 2” carriage bolts, (2) 3/8” split lock washers and (2) 3/8”-16 nuts to secure the leg to the ‘T’ bracket. Finger tighten hardware. Repeat for other side. Note the orientation of the carriage bolts so they face inwards. HAULER RACKS, INC.
PAGE 8
6. Install front legs The front legs can be indentified by the notches in the mounting brackets attached to the bottom of the legs. Driver’s side Passenger’s side Place the front legs into the ‘T’ brackets so the notches are facing towards the front of the rack. Use (2) 3/8”-16 x 2” carriage bolts, (2) 3/8” split lock washers and (2) 3/8”-16 nuts to secure the leg to the ‘T’ bracket. Finger tighten hardware. Repeat for other side. Note the orientation of the carriage bolts so they face inward.
PAGE 9
7. Adjust leg span to fit truck bed Some truck beds vary in width in the front and rear of the bed. Performing the following will help in a quicker setup and centering of the rack on the crossbars without having to readjust the ‘T’ brackets and HD braces. Measure the truck bed span (width) at the front and rear of the bed and record in the boxes below.
PAGE 10
8. Install HD braces Remove the 3/8”-16 nuts and 3/8” split lock washers from the floating 3/8” bolts in the legs and crossbar. Loosely attach the HD brace to the leg using one of the previously removed 3/8” split lock washers and 3/8”-16 nuts. Slide the HD brace along the leg to the crossbar. Align the floating bolt in the crossbar so that the floating bolt goes though the open hole on the HD brace. Continue to slide HD brace to the crossbar. Install 3/8” split lock washer and 3/8-16 nut.
PAGE 11
9. Drill and attach middle crossbar / leg assembly Turn the rack upright and place the rack on the vehicle. The rear legs should be positioned as far back on the bed edge as possible. Avoid placing attachment bolt holes in brackets over stake pockets. Check to make sure the tailgate can open and close properly. Temporarily clamp the rear legs in place (optional but suggested).
PAGE 12
9. (Continued) Drill and attach middle crossbar / leg assembly Mark the location of the square holes in the ribbed middle crossbar end brackets on the underside of the rectangle side rail tube. For best results use a pencil or marker and trace the outline of the square holes onto the rail. Repeat for other side. Slide the front leg / middle crossbar assembly backwards enough to gain clearance to drill. With a pencil or marker, draw lines from corner to corner on square outlined on the rail.
PAGE 13
10. Drill and attach rack brackets to truck bed. Ensure legs and rack are square and rack is positioned correctly on the truck bed rails. Mark the hole positions on all four legs (3 holes per leg bracket – 2 on top and 1 on the inside) Examine the truck bed underneath the marked areas to see if access is available to attach nuts to bolts. If no access is available, drill 1/4” dia holes and use 3/8” hex lag bolts with lock washers. If access is available, drill 3/8” holes in all locations where marked.
PAGE 14
Customer Limited Warranty and Standard Return Policy Hauler Racks, Inc. offers to preferred customers a special limited warranty. It is our goal to provide effective service for any warranty or standard return. This statement of warranty and return policy is divided into two sections: Warranty Returns of Defective Product and Standard Returns of Unused Product. Warranty Returns of Defective Product Hauler Racks, Inc.