river_rat has a post about checking to make sure the yellow "Emergency Release" cable is all the way into its housing! Search thread "Bed cover won't unlatch" with river_rat post.
8-2-17 Wasn't trying to tease or keep anyone in suspense earlier, but my phone battery was dying. Anyway, what the problem was on both Ray's and Kathy's (nj6969) trucks was that the emergency release cable was not fully retracted. The emergency release cable actually functions two ways. If pulled lightly, it closes a micro switch in the actuator box which in turn energizes the relay in the underhood fuse box and thus energizes the actuator solenoid releasing the cargo cover. If you pull harder on the release cable, it will then mechanically release the cargo cover. I would imagine the secondary mechanical release was designed this way in case of battery failure.
Anyway if the emergency release handle gets pulled and it does not retract completely when released, it can keep the relay and actuator powered which will prevent the cargo cover from opening as well as drain the battery. What I cannot explain at this time is if the actuator is energized then why weren't the cargo release latches always released the entire time. Ray did mention that he was occasionally getting a cargo cover ajar warning and also did find that he randomly found the cargo cover released. He was also experiencing excessive battery drain when parked.
On Ray's truck, we found the emergency release cable kinked just above the handle which was causing the cable to not retract completely when you let go. The emergency handle should only be pulled downward, NOT sideways nor upward as either of those movements can cause cable damage.
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