ACCESS® COVER INSTALLATION INSTRUCTIONS(Kit #601 for 2006 Honda Ridgeline)

TOOLS NEEDED:a. T-50 Torx f. 1/8” Bitb. T-40 Torx g. 1/4” Bitc. Flat head screw driver h. Inch pound torque wrenchd. #2 Phillips head screw driver i. 10 MM Sockete. Electric Drill j. 3/8” Socket/Wrench

REMEMBER TO WEAR PROTECTIVE EYEWEAR

1. Look-up the anti-theft code for the radio on the vehicle audio system card kept with the owners manual and write down the radio station pre-sets. Disconnect the negative cable from battery.

2. Remove the tie down hooks (6 total) starting at front passenger side and driver side. Then at rear passenger side and driver side (T-50). SEE ILLUSTRATION 1.

3. Remove the 6 torx bolts on the front box wall panel (T-40) and remove. (The top three bolts will not be reused when reassembling panel). SEE ILLUSTRATION 2.

4. Remove passenger bed rail cap. Use flat head screw driver to remove screw cover at rear of bed cap. Use #2 Phillips screw driver to remove screw, then slide bed rail cap back to release clips, and lift up. SEE ILLUSTRA-TION 3. Repeat procedure on driver side bed cap.

Part No. 40616 REV:B Page 1 of 6 090905

ILLUSTRATION 1 (passenger side)

ILLUSTRATION 2 (front wall)

ILLUSTRATION 3 (passenger side)

remove all hooks(6 total)

Torx bolts T-50

front boxwall panel

Torx boltsT-40

remove screw cover atrear of bed caps withflat head screw driver

Phillipsscrew

NOTE TO INSTALLER: IMPORTANT READ BEFORE ATTEMPTING INSTALLATION. Allow extra time, up to 2 hours to install this cover. Disassembly of the box wall panels and drilling is required. When assembly is complete, the roll-up cover will set recessed down from the top of the box sides. This allows the cover to match with the height of the box behind the cab and at the tailgate. These instructions replace all of Step 1 and Step 2A of the instructions in the Access owners manual.

(Kit #601)

5. Remove passenger side box wall panel, (5 torx bolts) (T-40). SEE ILLUSTRATION 4.

6. Next, pull gently on lower portion of inside pillar until one clip lets loose. SEE ILLUSTRATION 5.

7. On passenger side only, locate spare tire clip. Push center of clip and pull out on panel to free clip.

SEE ILLUSTRATION 6.

Page 2 of 6

ILLUSTRATION 4

ILLUSTRATION 6

remove the 5 torx bolts that hold side

panel to box

ILLUSTRATION 5

8. Pull panel away from steel box wall and unplug light connector. SEE ILLUSTRATION 7.

9. Pull on inside pillar trim and hold - then gently lift wall panel out of box. SEE

ILLUSTRATION 8 & 9.

10. Repeat procedure on driver side box wall panel.

(driver side does not have spare tire clip).

ILLUSTRATION 7

ILLUSTRATION 8

ILLUSTRATION 9

unplugconnector

pull inside pillar trim away from steel body - then

gently lift rear of side wall panel up and out

lift rearup and away

(Kit #601 Cont.)

11. With passenger side wall panel laying backside facing up, mark three new hole locations as shown (1/2 inch above center of existing mold marks) and drill three 1/8” pilot holes into panel. SEE ILLUSTRATION 10. Repeat procedure for driver side wall panel.

12. Now, open the Roll-Up Cover kit and find the metal “Z” brackets (6 pcs), the flat washers, lock washers, and 6mm x 40mm hex head bolts. Install these brackets to the existing holes on the box wall with a 10mm wrench. Slotted hole in bracket should point up - insert bolt with washers in bottom hole first.

NOTE: Two brackets with 2 3/8” leg belong at front of box. Attach all 6 brackets. Tighten all bolts to 100 inch pounds.

SEE ILLUSTRATION 11 & 12.

Page 3 of 6

ILLUSTRATION 11 ILLUSTRATION 12

passenger side shown with wallpanel back side facing up

ILLUSTRATION 10

rear - tailgate end

rear “Z” bracket

center “Z” bracket

front “Z” bracket

2 3/8”

3 5/8”

existing markson panel

mark center location of new hole 1/2” up from center in line with existing mold

marks

3 5/8”

NOTE: Length dimensions given are approximate. Use them to locate the

3 locations for drilling holes.

install end with slotted hole up

“Z” bracket

flat washer

lock washer

6mm x 40mm hex head bolt

(10mm wrench)

1/2”

3 5/8”

28 1/4”

14 3/16”

3 5/8”

drill 1/8” pilot holes3 locations only - exactly 1/2”

up from mold marks.

(Kit #601)

13. Re-install both sidewall panels, reconnect light plug connectors. Re-connect the negative cable to the battery and check that the cargo lights work. SEE ILLUSTRATION 13. Then insert bolts and tighten. On passenger side, push spare tire clip on.

Now, re-install bed caps (if bed rail caps do not align properly you may need to loosen torx bolts on wall panel and shift panel for better fit, then re-tighten bolts).

14. Next, set front box wall panel in position with the 3 bottom torx bolts only and tighten them. Then

re-install all 6 tie-down hooks.

15. Locate header bar and 6mm x 40mm hex head bolts in the kit. Align holes in header bar with upper three open holes on front box wall panel. Insert replacement Hex head bolts. Tighten outer bolts to 60 inch pounds. Tighten center bolt to about 20 inch pounds. (10mm socket)

SEE ILLUSTRATION 14.

16. With a 1/8” drill bit, use previously drilled holes in sidewall panels as a guide to drill a 1/8” pilot hole into the “Z” brackets (that are now behind the sidewall panels) and through the sheet metal of the box wall. SEE ILLUSTRATION 15.

Then drill 1/4” enlargement holes in composite layer of the wall panel. DO NOT DRILL 1/4” hole into steel Z brackets. This avoids chipping the composite panel when mounting side rails with self drilling screws.

Page 4 of 6

ILLUSTRATION 15

use previously drilled holes in panel (3 per side) as guide to drill pilot holes

into Z brackets

ILLUSTRATION 13

push panelin and down

ILLUSTRATION 14

header bar

reconnect light plug

(Kit #601)

18. Back of rail should rest on top of pillar at rear of box. Note nylon spacer attached to bottom of rail helps stabilize rail during install. (Leave attached to rail permanently). SEE ILLUSTRATION 17.

19. First, begin at front of rail - Align pre-punched holes in rail with drilled holes in wall panel. Insert 21/2” screw, use 3/4” long spacer positioned behind rail and drill screw into pilot hole of metal Z bracket. Use 3/8” socket. SEE ILLUSTRATION 16 &18.

Second, go to rear of rail - install a 21/2” screw with 1” long spacer positioned behind rail and drill screw into pilot hole on Z bracket. SEE ILLUSTRATION 16 & 18.

Third, finish at center of rail with another 21/2” screw and a 7/8” spacer behind the rail. REPEAT PROCEDURE for driver side rail. Tighten all screws until spacer is tight -then check with torque wrench and tighten to about 40 inch pounds.

Now - refer to the owners/installation manual and continue on beginning with Step 2B - Element SealTM instructions.

Page 5 of 6

ILLUSTRATION 17

ILLUSTRATION 18

back of rail resting on box pillar

tighten screws until spacer is tight (approx.

40inch pounds)

nylon spacer

passenger side rail shown

FIRST FASTEN FRONT - use 21/2” long screwwith 3/4” long spacer

THIRD FASTEN CENTER - use 21/2” long screwwith 7/8” long spacer

SECOND FASTEN REAR - use 21/2” long screwwith 1” long spacer

ILLUSTRATION 16

17. Locate the cover siderails, nylon spacers and screws used to mount the rails to the box and sort them by size as shown. Align holes in the cover rail with previously drilled holes in box wall. Match the screws and spacers with the proper location. SEE ILLUSTRATION 16.

3/8” socket

(Kit #601)

Shown here are some helpful hints when closing the cover.Use these in conjunction with the procedures in the Access owners manual (page 5).

Page 6 of 6

NOTE: The Honda Ridgeline is equipped with a trunk-like lid on the bed floor. The lid remains functional - although slightly restricted from fully opening with the cover. Avoid forcing the lid beyond its limit.

When sealing the sides, push down on vinyl next to rail...

grip and pull it snugby the edge...

then push it down to seal along rail from front to back. NOTE: For best results always keep valley between box and cover

clean of debris

floor storage lid open

20. Reset the clock, and reset the radio station presets. NOTE: Whenever the battery is disconnected, the driver’s window AUTO function is disabled.

21. Start the engine. Push down on the driver’s window switch until the window is fully open.

22. Check that the cargo lights are working.

23. Pull up on driver’s window switch to close the window completely, then hold switch for two seconds or more.

24. Lower and raise window to check the operation of the driver’s window AUTO function.

25. Now - refer to the Access owners/installation manual and continue on beginning with Step 2B - Element SealTM instructions.