Extang Solid Fold 2.0 Tonneau Cover Hinge Seal Repair Instructions Written Out

Published 09/26/2018

Question:

I’m trying to re attach the panel of my Extang Solid Fold 2.0 Tonneau Cover closet to the tailgate but I cannot get it to snap together. It doesn’t appear that anything is broken. I just cannot get it snapped back together. I saw this post below from someone else with the same issue see image but it’s hard to read the words. Could someone email this pdf to me so that I can print it off. Thank you.

asked by: Danny

Expert Reply:

I found the picture you mentioned and while I wasn't able to find a better version that has easier to read text I can retype out the text of each step to make it easier to understand.

Step 1. With the cover supported and laying flat, remove the three T20 Torx screws from the hinge and caps on one side.

Step 2. With the panel angled at about 45 degrees slide it free of the hinge towards the missing end cap.

Step 3. Rotate the hinge slightly and slide it free of the carrier panel. Repeat for the middle panel and second hinge.

Step 4. The seals can move back and forthe in the extrusion slots. The next step is to make sure that both seals are centered with the hinge extrusions. When centered each seal should extend past both ends of the hinge extrusion by approximately 1/8 inch or 3 mm. (smaller square on left of step) On the end cap side should be no gap between the end cap and seal. The seal extends into the end cap.

Step 5. With the seals positioned place the hinge extrusions upside down on a solid surface. The surface should be firm but also be careful not to damage hinge sirface. Using safety glasses, a hammer and a center punch, strike the edge of the extrusion to create a dent that will stop the seal from sliding in the groove. Do this in 4 places. two on each side.

Step 6. Reassembly is a reverse of the disassembly. Sliding the panels and hinges back together and reattaching the end caps. (left picture) When sliding the panels and hinges together make sure they are flush before attaching the end caps. IMPORTANT When tightening the screws only hand tighten to ensure not to over torque.

expert reply by: Jameson C