Ladder Tray Installation Instructions Must Be Installed With Side DuraRac Ford Transit Low/Med/High Roofs - 148” WB Ladder Tray Part #: DTC 0804-002 V1.0.10.24.18 1.877.335.2621 www.DEJANA.com IMPORTANT INSTALLATION STEPS ARE DENOTED USING A STOP SIGN. THESE STEPS MUST BE PERFORMED IN THE SPECIFIED ORDER TO ENSURE PROPER INSTALLATION AND MUST BE FOLLOWED IN ORDER TO MAINTAIN YOUR PRODUCT WARRANTY! CRITICAL INFORMATION PERTAINING TO USER AND/OR VEHICLE SAFETY IS DENOTED USING A CAUTION SIGN. SAFETY ITEMS MUST BE STRICTLY ADHERED TO IN ORDER TO ENSURE A SAFE WORKING ENVIRONMENT! WARNING THE USE OF DRILLS WITH INTEGRAL DRILL STOPS ALONG WITH PROPER INSPECTION FOR GAS TANK, GAS LINES, BRAKE LINES AND ELECTRICAL LINES PRIOR TO DRILLING ANY MOUNTING HOLES IS STRONGLY RECOMMENDED TO ENSURE THAT VEHICLE DAMAGE IS AVOIDED! THE USE OF AIR OR ELECTRIC IMPACT TOOLS FOR THE ASSEMBLY OF FASTENERS COULD CAUSE FASTENER FAILURE! THE USE OF NON‐STANDARD FASTENERS AND/OR DEVIATING FROM THE FASTENERS SPECIFIED IN THESE INSTRUCTIONS MAY VOID YOUR PRODUCT WARRANTY! ALL DRILLED HOLES IN THE VEHICLES SHOULD HAVE THE RAW METAL EDGES SEALED WITH A SELF‐ETCHING PRIMER TO RESIST CORROSION AND POTENTIAL FASTENER POINT FAILURE! 1.877.335.2621 www.DEJANA.com Ladder Tray Installation Instructions – TOOL LIST Safety glasses MUST be worn at all times! TOOLS Drill Drill Bits Drill Stop Ratchet Wrench 5/16”, 7/16”, 11/32” 1/2” Drill 10” Drift Punch Box End Wrench Rubber Mallet/ Steel Hammer 7/16”, 1/2” Socket; (Used in aligning bolt 7/16”, 1/2”, 9/16” T45, T30, T27 TORX Bit holes) with Misc. Extensions RECOMMENDED TOOLS: Inch-pound Torque Wrench Impact Gun Leveling Gauge 1.877.335.2621 www.DEJANA.com Ladder Tray Installation Instructions Hardware: FAS 37708 FAS 10051-12025 FAS 33078 FAS 0195543 FAS 0197057 FAS 0195544 ACORN NUT, T27 TORX HEAD FLAT WASHER, T30 TORX HEAD 1/4”-20 T30 TORX HEAD 1/4”-20 SCREW 1/4”-20 X 1/4” X 5/8” SCREW 1/4”-20 X T-NUT,1/2”L SCREW 1/4”-20 X (QTY: 8) 5/8”L (QTY: 8) O.D. (QTY: 8) 1/2”L (QTY: 5) (QTY: 7) 11/16”L (QTY: 2) Step 1: Assemble Ladder Tray Subassemblies Notes: If pre-assembled from manufacturer proceed to Step 2. A. Begin by assembling the front section of the ladder tray with the rear section, and then the back section with the end stop. Bolt the three assemblies together using the 1/4”-20 T27 Torx screws, flat washer, and acorn nuts. 1.877.335.2621 www.DEJANA.com Ladder Tray Installation Instructions Step 1: Assemble Ladder Tray Subassemblies, CONT’d. Notes: B. With ladder tray assembled, mark the (7) hole locations shown. Once marked, disassemble the sections you just put together, and then drill through marked holes in FRP with an 11/32” drill bit. C. Now that holes are drilled through FRP, repeat step A, and assemble the sections again using The (2) outer 1/4”-20 T27 Torx screws, flat washers, and acorn nuts. Next insert T-nuts on the top of the ladder screws seen tray using your hands, pushing the T-nut in the hole as much as you can. Then use a hammer to in ‘Detail D’ fully insert T-nut until T-nut is flush to the surface. Once T-nuts are in, fasten 1/4”-20 T30 Torx are part screws into T-nuts. number FAS 0195543. The other (5) screws used are part number FAS 0195543. 1.877.335.2621 www.DEJANA.com Ladder Tray Installation Instructions Hardware: FAS 37018 FAS 19903 FAS 33078 NYLOCK NUT, SERRATED FLANGE FLAT WASHER, 1/4”-20 (QTY: 4) BOLT, 1/4”-20 X 1/4” X 5/8” 3/4” (QTY: 4) O.D. (QTY: 4) Step 2: Install Strut and Base Tab Notes: Rear DuraRac or Rear Mount and Side Durarac Must Already Be Installed to Continue Installation A. Remove (1) bolt and accompanied washers from the Streetside baseplate. B. Insert additional strut channel and align holes in the strut channel with the holes in the transverse mounting angle of the Side DuraRac. Fasten the two together with 1/4”-20 bolts, washers, and nuts. 1.877.335.2621 www.DEJANA.com Ladder Tray Installation Instructions Step 2: Install Strut and Base Tab, CONT’d. Notes: C. With strut now fastened to transverse mounting angle, insert base tab at the bottom of the additional strut, so that the hole in the tab is over the hole in the baseplate. Then re-fasten the 5/16” bolt down to fasten the tab and baseplate. D. Mark (2) hole locations onto the additional strut. Remove 5/16” bolt from base plate yet again, along with the base tab. Drill through strut and baseplate using a 5/16” drill bit. Then re-insert base tab, fasten 5/16” bolt back down, and then fasten the base tab to the strut using (2) 1/4”-20 bolts, washers, and nuts. 1.877.335.2621 www.DEJANA.com Ladder Tray Installation Instructions Hardware: FAS 37341 FAS 10140022 SERRATED T45 TORX HEAD FLANGE NUT, SCREW 3/8”-16 X 3/8”-16 (QTY: 12) 3/4”L (QTY: 12) Step 3: Install Ladder Tray in Vehicle Notes: A. Install the (3) ladder tray straps at the pre-drilled holes in the ladder tray angle. Fasten 3/8”-16 Bolts to go T45 Torx screws and serrated nuts. Make sure that the straps are aligned straight up and leveled on inside of before fully tightening bolts. ladder tray and the nuts will be on the outside. 1.877.335.2621 www.DEJANA.com Ladder Tray Installation Instructions Step 3: Install Ladder Tray in Vehicle, CONT’d. Notes: B. Insert ladder tray into the vehicle, we typically place it about 13” from the floor mat of the vehicle, but you can set it to whatever height you would prefer. Using two people at least, put the ladder tray flush up against the rear durarac and additional strut at the side durarac, and clamp ladder tray up against them. Once clamped you can begin adjusting to the preferred height. Be sure that the height is consistent the whole way down by measuring at multiple points and using a leveling gauge. C. With ladder tray in proper position and clamped in place, mark a total of (9) holes onto the struts that the ladder tray is clamped to. 1.877.335.2621 www.DEJANA.com Ladder Tray Installation Instructions Step 3: Install Ladder Tray in Vehicle, CONT’d. Notes: D. Take clamps off and set ladder tray out of the way. Drill through the (9) marked holes with a 7/16” drill bit. Then place ladder tray back up and fasten ladder tray to struts using 3/8”-16 T45 Torx screws and serrated nuts. 1.877.335.2621 www.DEJANA.com Ladder Tray Installation Instructions – Bill of Material ITEM PART NUMBER DESCRIPTION QTY. NO. 1 DTC 0804-002 [FWD SECTION] LADDER TRAY, FRONT SECTION 1 2 DTC 0804-002 [BACK SECTION] LADDER TRAY, REAR SECTION 1 3 DTC 0813-006 LADDER TRAY STRAP 3 4 DTC 0213-075 LADDER TRAY END STOP 1 5 AUST TB9002 STRUT CHANNEL, 47.75”L 1 6 DTC 0213-076 UNISTRUT BASE TAB 1 7 FAS 0197057 1/4”-20 T-NUT, 1/2”L 7 8 FAS 33078 FLAT WASHER, 1/4” X 5/8” O.D. 12 9 FAS 10051-12025 T27 TORX HEAD SCREW 1/4”-20 X 5/8”L 8 10 FAS 37708 1/4”-20 ACORN NUT 8 11 FAS 10140022 T45 TORX HEAD SCREW 3/8”-16 X 3/4”L 12 12 FAS 37341 3/8”-16 SERRATED FLANGE NUT 12 13 FAS 19903 SERRATED FLANGE BOLT, 1/4”-20 X 3/4” 4 14 FAS 37018 NYLOCK NUT, 1/4”-20 4 15 FAS 0195544 T30 TORX HEAD SCREW 1/4”-20 X 11/16”L 2 16 FAS 0195543 T30 TORX HEAD SCREW 1/4”-20 X 1/2”L 5 1.877.335.2621 www.DEJANA.com Ladder Tray Installation Instructions – Technical Drawing 1.877.335.2621 www.DEJANA.com Ladder Tray Installation Instructions – Inspection Dimensions 1.877.335.2621 www.DEJANA.com .