Buzz
Tonneau covers are available in various types and numerous specific models. While these general instructions typically suffice, an unconventional model or troubleshooting scenario may necessitate contacting the manufacturer. Soft covers are notably easier to install than hard covers and can usually be installed by someone without expertise in about an hour. Hard covers are heavy and challenging to install, so it's advisable to seek assistance from a friend or two.
Instructions
Installing the Cover Rails
Confirming Compatibility with Other Components. Bed liners, bed rail caps, and other additions may not be compatible with certain covers. If needed, consult the tonneau cover manufacturer or adhere to these guidelines:
- If a bed liner obstructs installation, simply create a notch where necessary to accommodate a clamp or other cover component.
- If the bed liner extends over the rails and the tonneau cover fits between the rails (rather than over them), both components might not be suitable for your truck.
- Most bed rail caps typically do not affect installation, but diamond plate bed rail caps may prevent some covers from fitting properly or forming a weatherproof seal.
Ensure the tailgate is open. Installation can be obstructed by a closed tailgate.
Position one side rail loosely onto the bed rail. Most tonneau covers are equipped with two side rails, which attach to the top or side of the truck's bed rails. Align a side rail flush with the front of the bed rail, near the cab. Temporarily secure it in place with a spring clamp or have someone hold it.
- If your cover lacks rails, it should have clamps that swing down from the underside once installed. While these covers are less stable and not weatherproof, they are easy to remove and reinstall.
- If you have a retractable tonneau cover stored in a canister, you may need to position it before attaching the rails. Place the canister on the bed rail edge, near the cab, ensuring it is centered before connecting the rails to the canister.
Secure the side rail next to the cab with a clamp. Your installation kit should include several toothed clamps. Attach one of these to the underside of the side rail, close to the cab. Align the clamp's teeth with the grooves, then hand-tighten. Use a wrench or socket wrench to tighten a few more times until it presses against the bed rail.
Use shims if needed. Examine the underside of the rail. If there is any gap between the truck, place shims evenly along the bed rail to eliminate it. These shims are plastic or rubber spacers that adhere directly to the bed rail.
- If there is a significant gap (more than approximately ⅜ inches / 10mm), you may require shim brackets. Loosen the rail, slide the shim brackets onto the end, space them evenly, then reattach the rail. Your kit might not include shim brackets, or they may feature a slightly different attachment design.
Install additional clamps. Most installation kits contain eight clamps (four per side), though a short bed may only need six (three per side). Attach these clamps similarly to the first one, spacing them evenly along the rails.
- Some soft tonneau cover instructions suggest postponing this step until the end for easier final adjustments. However, for a hard cover, it's essential to firmly secure
Proceed with the second rail. Install the second rail using the same method.
Align rails to be centered and level. Ensure both rails are perfectly parallel to each other, aligned with the bed rails, and pushed back as far as possible. If needed, slightly loosen the clamp to adjust the rails, then tighten it again. If one rail is tilted, adjust the clamp position or apply pressure to the raised end while securing the clamp. This step requires careful attention as improper rail positioning can hinder cover installation.
- If there's a gap between your bed rails and the cab, the side rails should not extend into it.
- The rails may not align precisely with the closed tailgate.
Fully tighten all clamps. Once you've ensured proper rail alignment, use a wrench to firmly tighten the front clamp of each rail. Repeat this process for the remaining clamps, working towards the back of the truck.
Installing the Cover
Attach rubber seals if provided. Weather-resistant covers typically include a rubber seal to fill the gap between the cover and the cab. Clean this area with rubbing alcohol to ensure good adhesion. Remove the backing paper from the seal and apply it between the two side rails, starting from the driver's side. Trim any excess seal material.
- Some tonneaus may include extra seals for the sides or tailgate, as well as larger corner plugs to enhance weatherproofing in the rear corners.
Inspect for additional components. Certain installation kits may contain components that are easier to install before positioning the cover. Verify your kit for the following items:
- Storage straps, threaded through cover holes.
- Tension adjuster screws, used for manually tightening the cover. These typically attach to the side rails and may come pre-installed.
- Hinged covers and some hard folding covers include a rod to support the cover when open. This rod should snap or screw into place somewhere on one of the side rails, with the opposite end resting on a small cradle.
Place the cover over the rails. Having two or more people will make this task easier, especially if the cover is hard or if your truck is lifted. Position the rolled or folded cover at the end of the rails, adjacent to the cab. It should fit snugly onto the rails, although you may need to apply some pressure to align it. Ensure it is perfectly centered and inserted onto the side rails before proceeding.
- If centering the cover is challenging, place it back on the ground and readjust the rails.
- Hinged hard covers (single solid pieces without folds) are exceptionally heavy and should not be installed by a single person for safety reasons. Utilize a forklift or enlist the help of multiple individuals.
Unroll or unfold the cover. Close the tailgate. Gently unroll or unfold the cover until it reaches the tailgate, ensuring it remains within the rails along its entire length. Make minor adjustments to the cover's positioning until it sits flush with the tailgate and the end of the side rails near the cab.
- Look for a small hand-tightened screw on the rail to adjust cover tension. It should be taut across your bed, fully covering it.
Secure the cover to the rails. Depending on your model, the cover may have already snapped onto the rail during unfolding. Additionally, most covers come with elevator bolts or other large bolts for further securing. Align the bolt holes on the cover with those on the side rails, and firmly tighten them using the washers and nuts provided in your kit.
- Some covers feature clamps or levers on the underside, which lower to brace the cover against the bed side.
Ensure all clamps are tightened. Inspect all clamps on the cover rails and securely tighten them. Verify all other attachment points to confirm that the cover is securely in place and cannot shift or become loose.
Complete installation with final components. Certain tonneau covers may include drainage tubes to redirect rain, bump stops to shield your cab from dents when a hard cover is opened, or other optional components. If you encounter any unidentified parts in your installation kit, reach out to the manufacturer or a mechanic for assistance.
Helpful Tips
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Weatherproof seals may slightly bulge after installation. Exposure to heat can help them flatten out, so consider parking in sunlight or using a heat gun or hairdryer to warm them up.
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If your cover is either too tight or too loose, adjust it using the tension adjusters. These are small screws located on the rail or cover that can be tightened manually.
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Clean the bed of your truck thoroughly before installing the tonneau cover.
Essential Tools
- Wrench
- Spring clamps
- Scissors
- Tonneau cover installation kit
- Assistant (recommended)
