Body - Tonneau Cover Latches/Locks/Struts Inoperable

Article No.
03-23-1

11/24/03

BODY - TONNEAU COVER LATCH AND STRUT
DIAGNOSTICS - CUSTOMER INSTRUCTIONS FOR
REMOVAL/INSTALLATION

FORD:
2001-2003 RANGER

ISSUE

Some 2001-2003 Ranger vehicles equipped with a Hard Tonneau Cover may exhibit inoperable Latches, Locks and/or Lift Struts.

ACTION

This article describes the proper diagnostic and repair procedures for the Tonneau Cover Latches, Locks and Lift Struts. Refer to the following Service Procedure to aid in diagnosing and repair.


























NOTE
FIGURES 8 THROUGH 15 OF THIS ARTICLE MAY BE DETACHED AND PROVIDED TO THE CUSTOMER, TO AID IN THE PROPER OPERATION OF THE TONNEAU COVER.

SERVICE PROCEDURE

TONNEAU COVER LATCH OR LATCHES INOPERATIVE





1. Lift up Tonneau Cover and check for lock retainer clip (Figure 1). If the lock retainer clip is not damaged and is properly in place, proceed to Step 2. If the lock retainer clip is missing or damaged replace with new and recheck for normal operation. If corrected, return the vehicle to the customer. If not, proceed to Step 2.

2. Check the ferrules on the end of the latch cable for proper installation and/or for breakage. If all ferrules are properly installed and undamaged proceed to Step 3.





a. If a ferrule is not snapped into the bracket (Figure 2) and is not broken, snap the ferrule back into the bracket and recheck for normal operation. If corrected, return the vehicle to the customer. If not, proceed to Step 3.

b. If a ferrule is broken, replace the latch cable and recheck for normal operation. If corrected, return the vehicle to the customer. If not, proceed to Step 3.





3. Open the Tonneau Cover. Close both latches by hand (Figure 3). Unlock the Tonneau with the key.

a. If the latches do not operate normally with the Tonneau Cover open, proceed to Step 5.

b. If the latches operate normally, close and latch the Tonneau Cover to the pickup box and reopen. If the Tonneau Cover latches function properly, return the vehicle to the customer. If the latches do not operate normally, proceed to Step 4.





4. If the Tonneau Cover does not close and latch/unlatch normally, adjust the strikers on the pickup box (Figure 4). After adjustment, recheck for normal operation. If corrected, return the vehicle to the customer. If not, proceed to Step 5.











NOTE
THE TONNEAU COVER MAY HAVE SHIFTED FORWARD OR BACKWARD ON THE PICKUP BOX. THIS CAN BE DETERMINED BY CHECKING WHERE THE LATCHES HIT THE STRIKER. THE LATCHES SHOULD HIT THE CENTER OF THE STRIKER (FIGURE 5). IF THE LATCHES ARE SET TOO FAR TO THE FRONT OR REAR OF THE STRIKER (FIGURE 6), THE CENTER-MOUNTING BRACKET MAY ALSO NEED TO BE ADJUSTED SO THE LATCH HITS THE MIDDLE OF THE STRIKER (FIGURE 7).

5. If the latches do not operate normally with the Tonneau Cover open, replace the latch cable (IF NOT PREVIOUSLY REPLACED PER THIS TSB) and recheck for normal operation. If corrected, return the vehicle to the customer. If not corrected, lubricate the latches with Multi-Purpose Grease (XGA). Cycle latches to work-in the grease and check for normal operation. If corrected, return the vehicle to the customer. If not, replace the non-functional latch or latches. Verify fix and return to customer.

TONNEAU COVER SUPPORT STRUT REPAIR

Inspect all Tonneau Cover support struts and determine the area of damage. The entire support strut assembly should not be replaced unless it is broken or bent. Broken upper or lower support strut ends can be replaced separately. The center-mounting bracket ball studs and the upper bracket & ball stud assemblies are also serviced as separate components.





Parts Block

OTHER APPLICABLE ARTICLES: NONE

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage





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