LAZERBACK INSTALLATION INSTRUCTIONS Ssangyong Musso, 2004 – Current

Part Number: 650Z

BASIC TOOLS REQUIRED Drill, Phillips Head Drill Bit, Tape Measure, Marking Pencil/Pen, Silicone, Methylated Spirits, Clean Rag

CONTENTS � 16 X Self-drilling Screws & Springs � 2 X Keys � 2 X Gas Strut Brackets With Base Plates � 2 X Key Rings � 2 X Gas Struts � 1 X Length of Foam Sealing Tape � 2 X Female Hinges � 1 X Tailgate Lock Bracket Checked by_________________________ Date______________________

All fitting kits are weighed to ensure accurate quantities. INSTALLATION PROCEDURE

Before fitting Ensure that your Lazerback fitting kit is complete and your keys open the new lock. Please read fitting instructions carefully and completely before attempting to fit your new lid. If any parts are missing, do not return product to place o f purchase. Instead, call our toll free customer care line on 1800 656 820 for replacement parts within two working days.

1. The hinges must always be fitted first, directly onto the vehicle body. The hinges must never be fitted over the Ute liner. Before fitting the Lazerback, the front top edge of the ute liner must be cut off.

2. Using the tape measure, and with a marking pencil, mark the centre of the tub at the front. Similarly, find and mark the centre of the Lazerback at the front. Place the Lazerback on the body of the vehicle being very careful to not mark the paintwork. Hint: Place 2 soft cloths on the side rim of the vehicle’s tub, underneath each of the locking rods.

3. Put a mark on the body where the male hinges on the Lazerback are located. Line up the female hinges on the body with the marks and attach them with the self drilling screws and spring washers supplied (3 per hinge). Do not over tighten the screws as the metal can be thin on some models. See Figure 1

4. We recommend that you now remove the hinges so that you can clean away any swarf or metal filings, and apply a bead of sealant to the underside of the hinges and the 6 holes that you have drilled to prevent water seepage, then refit the hinges.

5. With a clean rag and methylated spirits, clean the front top of the tub before applying the foam sealing tape. Start applying the foam sealing tape from a position on the inside edge of the tub, 80mm from the front of the tub. Apply the foam sealing tape from this point working your way back along the inside edge of the front of the tub stopping at the hinge and then starting again on the other side of the hinge. Repeat procedure for the other hinge and continue around the corner until you finish 80mm along the inside edge of the other side of the tub. Apply foam tape to the top of the hinges. Ensure that where the foam tape meets the foam tape on top of the hinge, you have a good tight join. You can apply a small bead of silicon at these joins to ensure that you have an uninterrupted seal from one side of the vehicle to the other side. This will prevent water from seeping into the tub. Note : If installing in cold weather the foam sealing tape may need be heated to assist adhesion. See Figure 1

6. Take the Lazerback, and carefully lift vertically. Insert hinge tongues on the lazerback into the female

hinge slots on the tub. Carefully lower the Lazerback, ensuring that the tongues are fully inserted into the slots. BEWARE not to lower the Lazerback completely as the locking bars on the Lazerback might need cutting to length and can scratch the paint work on the vehicle’s body. With a marking pencil, make a mark on the vehicle body adjacent to the gas strut bracket on the Lazerback. Remove the Lazerback, and measure 330mm towards the rear of the vehicle, and make a mark on the top edge of the vehicle. Attach the gas strut bracket 20mm down from the top edge using 2 self drilling screws and spring washers supplied. Reattach the Lazerback, and attach the cylinder end of the gas struts onto the brackets on the lid. See Figure 2 Important: now attach the key ring to the small hol e at the end of the male hinge. This prevents accidental release. The gas struts may be removed at any time by inserting a small screwdriver under the metal spring clip on the gas strut end and gently easing it out. You can then pop the strut off the ball. Never completely remove the spring from the gas strut end. Remembe r, when removing and refitting your Lazerback, ensure that the hinges are fully engaged to avoid damaging or bending them and the key rings are attached to each male hinge to avoid them releasing accidentally.

7. Close the Lazerback and check to see if the Lazerback fits evenly around the sides and the back. The Lazerback can be adjusted forward and back by loosening the screws on the male hinges, which are located under the carpet tongues, and sliding the hinge back or forward. Retighten the screws after adjustment.

8. To fit the lock brackets you will need to lie down inside the tray with a torch and close the lid. Make a mark where the locking rods and center cam line up with the body and install lock brackets with the self-drilling screws supplied, allowing for adjustment up or down See figure 3. You will also need to cut the locking rods to the correct length. To do this you need to have the lock in the unlocked position, mark and cut the bars to fit just inside the locking brackets. Once you have fitted the tailgate locking bracket you might need to adjust the locking tag underneath the lid. Making sure that when you close the lid the tag goes through the hole on the tailgate locking bracket. (This stops tailgate being opened when lid is closed). When correctly adjusted you might need to apply slight pressure to the lid in order to operate the key. See Figure 4

9. Your vehicle should now look fantastic with its new Lazerback fitted. Remember when removing and refitting your Lazerback ensure that the hinges are fully engaged to avoid damaging or bending them.

NEVER DRIVE WITH LID OPEN OR IN AN UNLOCKED POSITIO N

Having trouble? Call us toll free for assistance on 1800 656 802.

Figure 1 Placement of aluminum hinges and foam tape. Foam tape must stop either side of the hinge and not run under the hinge. A separate piece of foam must cover the hinge. Figure 2 Placement of gas strut brackets. Figure 3 Placement of lock side brackets Placement of tailgate locking bracket

330mm