Carpet Bed Install
Just installed the Carpet Kit in the bed last night. Did (almost all) by myself. Here are a few comments or tips:
- I removed the Cargo Area Cover by myself. I'm a big guy and I was just barely able to do this... and I won't ever do it again. It really takes two people. I did get assistance to re-install it.
- The Torx in the tailgate are a different size than the Torx in the cargo rails in the bed. The Torx in the 'box' under the drivers rear fender, which are very hard to see, are the same size as the TAILGATE. Torx can be deceptive, don't strip one by using the wrong size.
- I started by removing the cover and just removing every Torx I could see in the plastic bedliner. No problems getting the Torx out. There is some adhesive below the ones in the side rails. Also remove the plastic push rivets; these WILL BE reused, so remove carefully: Pull the center out, then the big ring.
- Then I put gloves on and just started working on "bending" the plastic liner out. The wiring harness for the power outlet became an obvious sticking point; it disconnects below the passenger rear fender.
- You must remove the drivers side cargo area bracket to access the wiring harness. MAKE NOTE of where the bracket 'fits' on the studs; this will make re-align much easier when putting it back. Do remove the rubber 'donut' protecting the harness at the bed wall; do not allow the harness to fall in the hole... I taped it.
- Then open the 'box' under the drivers rear fender. It's the same one that has the emergency release for the cover (see owner's manual). Use a small screwdriver to push the catch, then open the cover (partway - its blocked).
- Remove the two Torx (same size as tailgate) at the front of the box. This allows the box to be 'pried' out of the way while dealing with the wire.
- I used woven Dacron fishing line to help with the wire. Tied to the upper end of the old harness. Pulled that out (thus pulling in the string) and continued to pull the string till I had a piece longer than the harness. Tied to this 'mid-point' of the string to the upper end of the new harness and used it to pull the new harness in place. That way, if anything went wrong, the string was still in place. I did it this way because I was working alone... worked great, first time, and once the wiring harness was in place (and secure at both ends!!) I cut and removed the string.
- Put torx back in box; I used a mirror to help. Hook up harness and secure all clips.
- Put bracket back with wiring harness, etc.
- At this point, I'd HIGHLY RECOMMEND a test fit of the cargo cover. I did not, and my bracket was off a tiny bit... and once the carpet is installed, the bracket screws are covered... Yikes!
- Carpet install is easy and obvious and quick. Mine came with "every other" hole in the rails populated with a new Torx; I re-used some of the ones removed from the old liner. Plastic Rivets are re-used.
- TEST THE LIGHT in the top piece at this point!
- I put two layers of duct tape over the little "circuit board" on the top piece... just insurance.
- Invert the cargo cover onto blankets. The Air-Struts must go through the slits on the carpet piece. Use a small screwdriver to PARTIALLY pull the clip on the outside of the end-piece... once partially pulled, the end piece will pop off of the ball very easily. I removed the ones FURTHEST from the cargo cover (i.e. on the bracket) just because they are easiest to get to. Carpet on... struts snapped back on balls... align and use plastic push pins. The 'rivet' ones go just by the light... the long spiny ones every where else. I was two short of being able to fill every hole.
- Tailgate last; it's done with double stick velcro. Before doing the sticky stuff, note that two Torx that were NOT part of the plastic bedliner line up with holes in the carpet; remove them, and replace through the carpet holes with longer Torx that have bigger washers; these were removed from the plastic bedliner .
Put the cargo cover back on and CAREFULLY CHECK ALIGNMENT; I had to move it a FRACTION and then tighten the two grey bolts.
Works Great! I really, really, really like the carpet for my use of the truck (hauling radio control helicopters).