Promaster Partition Installation Instructions€¦ · uol-v|;u -u om Installation Instructions...

MASTERACK Headquarters2400 Mellon CourtDecatur, GA 30035

800-222-8785

Promaster Partition Installation Instructions

Before starting installation,review this document to ensure thatall parts and hardware are includedin the package. In the event that parts are missing, please contact MASTERACK at 1-800-222-8785 to re-ordermissing parts.

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MASTERACK.COM

2MASTERACK.COM


!Before starting installation,review this document to ensure thatall parts and hardware are includedin the package. In the event that parts are missing, please contact MASTERACK at 1-800-222-8785 to re-ordermissing parts.

■ Recommended Tools

• 7/16" Air Wrench or Socket Ratchet• 10mm Air Wrench or Socket Ratchet

(only required to replace OEM partition)• 7/16" Box End/Open End Wrench• Torque Wrench• Electric Drill with 3/8" Drill Bit

(drill stop recommended)

2400 Mellon Court, Decatur, GA 30035 Phone: 1-800-222-8785 www.masterack.com

RM470279 Rev 2.2

Page 1 of 11


RM470279 Rev 2.2

Page 1 of 11

Attention: If replacing an OEM partition or if there are threaded HEX mounting nuts already installed in the B-pillar and Roof Bow, please skip pages 5 & 6 of this installation guide.

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■ Components


RM470279 Rev 2.2

Page 2 of 11

Item Part # (Individual) Description1 02H220 PROMASTER PARTITION TOP ATTACHMENT PANEL2 02H221 PROMASTER PARTITION CS ATTACHMENT PANEL3 02H222 PROMASTER PARTITION SS ATTACHMENT PANEL4 02J158 HIGH/MID ROOF SLD PNL TYPE 25 02J159 HIGH/MID ROOF PRF PNL TYPE 26 02J160 HIGH/MID ROOF SLD CS TYPE 27 02J161 HIGH/MID ROOF PRF CS TYPE 28 02J162 HIGH/MID ROOF SLD HGD TYPE 29 02J163 HIGH/MID ROOF PRF HGD TYPE 2

NOT HINGED02J176KP = #4 + #4 + #602J177KP = #4 + #5 + #702J178KP = #5 + #5 + #7

HINGED02J179KP = #4 + #6 + #802J180KP = #4 + #7 + #902J181KP = #5 + #7 + #9

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■ Hardware

Partition Panels HardwarePart # Description Qty

RM442002 BAG POLY 6X8 3 MIL 1

RM510107 BOLT CARRIAGE 1/4-20X3/4 ZINC 20

RM511458 SCREW 1/4-20X3/4 7/16 HEX WSHR 10

RM511471 SCREW 1/4-20X1-1/4 HEX WHD 4

RM520111 PLUS NUT #S25-PB-280 PRE-BULB 14

RM520112 PLUS NUT TOOL #C500-25 1

RM520312 NUT 1/4-20 E-STOP 20

RM541039 WASHER SPLIT LOCK 1/4 GALV 14

RM541061 WASHER 1/4 USS FLAT ZINC 20

Partition Attachment Panels HardwarePart # Description Qty

RM541039 WASHER LOCK-SPLIT 1/4” ZINC 19

RM511603 SCREW SOCKET HEAD CAP M6X1X18 BLK OX 12.9

15

RM510107 BOLT CARRIAGE 1/4-20X3/4 18

RM520312 NUT ESTOP 1/4-20 18

RM541061 WASHER 1/4” USS FLAT 37

RM520111 PLUS NUT #SRT25PB280 PRE-BULB 19

RM520112 PLUS NUT TOOL #C500-25 1

RM511477 SCREW 1/4-20X1-1/4 HWH G8 1

RM511428 SCREW 1/4-20 X 1” HEX HD G8 19

Cab Divider Door Hardware (Where Applicable)Part # Description Qty

RM580030 PLASTIC LATCH COVER PLATE 2004 1

RM580314 HANDLE #H-17003C INSIDE CHROME

1

RM580365 HANDLE RND FLSH MNT PRTN DOOR

1

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■ Plusnut Installation

BEFORE DRILLING - CHECK ALL MOUNTING LOCATIONS TO PREVENT PENETRATING GAS LINES, GAS TANKS, BRAKE LINES, WIRING OR ANY OTHER STRUCTURE OF VEHICLE

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Page 12 of 13

RM470447

BEFORE DRILLING CHECK ALL MOUNTING LOCATIONS TO PREVENT PENETRATING

GAS LINES, GAS TANKS, BRAKE LINES, WIRING OR ANY OTHER STRUCTURE OF VEHICLE

CHECK EACH BOLT LOCATION to ensure they are tightened to the specified

torque setting.

TORQUE SETTING:Size – 1/4 GRD 5 = 7- 9.6 Ft.-Lbs.Size – 1/4 GRD 8 = 10- 13.5 Ft.-Lbs.

The Plusnut® is pre-bulbed for easy installation

1

The Plusnut® is pre-assembled with hex cap and hex bolt. Then it is inserted into a pre-drilled hole

2

As the bolt is tightened, the Plusnut® upsets and provides outstanding

blind fastening holding power

3

C-500 tool tightens bolt thru hex head cap into Plusnut® A ratchet, open-end or closed –end wrench can be used.

4

Fully upset Plusnut® provides a reliable nut plate for fastening.

5

USE DRILL STOP TO PREVENT DAMAGING VEHICLE

DRILL CHUCK

DRILL STOP

DRILL BIT



Page 12 of 13

RM470447




torque setting.



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DRILL CHUCK

DRILL STOP

DRILL BIT


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DRILL STOP

DRILL BIT


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DRILL STOP

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DRILL STOP

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■ Installation


RM470279 Rev 2.2

Page 5 of 11

Cut out a section of the plastic trim on both B-Pillars, locate the OEM hex-holes, and install 10x Plusnuts. Refer to page 4 for Plusnut installation.

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■ Roof Bow Plusnut Installation

Locate the OEM hex-holes along the front roof bow (marked with a star in the image below), and install 5x Plusnuts*. Refer to page 4 for Plusnut installation.Hardware: (5x) Plusnuts


RM470279 Rev 2.2

Page 6 of 11


RM470279 Rev 2.2

Page 6 of 11

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■ Floor Plusnut Installation

Drill 3/8” holes at the four locations (specified in the image below) on the floor of the vehicle, and install 4x Plusnuts*. Refer to page 4 for Plusnut installation.Hardware: (4x) Plusnuts


RM470279 Rev 2.2

Page 7 of 11


RM470279 Rev 2.2

Page 7 of 11

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■ Partition Assembly Installation2400 Mellon Court, Decatur, GA 30035

Phone: 1-800-222-8785 www.masterack.com

RM470279 Rev 2.2

Page 8 of 11

TORQUE SETTING: 1/4-20 Grade 5 = 7 – 9.6 Ft. Lbs.

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■ Hinged Door Handle Assembly


RM470279 Rev 2.2

of 11

TORQUE SETTING: 1/4-20 Grade 8 = 10 – 13.5 Ft. Lbs. M6 Grade 10.9 = 10.9 – 11 N-m

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■ Attaching Partition


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RM470066 Rev. 2.2

8

Properly align partition using a straight edge and square. Mark through the slots in the bottom flange onto the floor, and Left and Right Panels [2, 4] onto B-Pillars.STRAIGHT

EDGE

SQUARE

SLOT LOCATIONS

ALWAYS CHECK BEFORE DRILLING ANY HOLES TO MAKE SURE NO WIRING OR FUEL LINES WILL BE DAMAGED.

SERIOUS INJURY CAN RESULT

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■ Attaching Partition


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RM470066 Rev. 2.2

9

With partition properly aligned and positioned, using a 17/64drill bit, drill out existing hole in B-pillar and secure with (12) 1/4 Monobolts

With partition properly aligned and positioned, drill(7) 17/64 holes, and secure with (7) 1/4 Mono Bolts



NOTE: 1/4-20 Plusnuts and 1/4-20 Screws have been included as an alternative installation option.

1/4-20 x 1-1/4Hex WHD

1/4-20Flat washer

1/4-20Lock washer

Plusnut

RM470066 Rev. 2.2

9

With partition properly aligned and positioned, using a 17/64drill bit, drill out existing hole in B-pillar and secure with (12) 1/4 Monobolts

With partition properly aligned and positioned, drill(7) 17/64 holes, and secure with (7) 1/4 Mono Bolts



NOTE: 1/4-20 Plusnuts and 1/4-20 Screws have been included as an alternative installation option.

1/4-20 x 1-1/4Hex WHD

1/4-20Flat washer

1/4-20Lock washer

Plusnut

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■ Attaching PartitionRM470066

Rev. 2.2

10

Attach Left and Right Panels [2, 4] to floor as shown here.

5/16-18 x 1 1/4HEX HEAD GRD 5

BOLT

5/16-18FLAT WASHER

FLOOR MAT

FLOORMOUNTING

WASHER

FENDERWASHER

5/16-18PREVAILINGTORQUE NUT

3/8HOLE

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■ Attaching PartitionRM470066

Rev. 2.2

11

Using a 1-1/8 Hole saw made for mat cutting, and hole saw out

hole in the composite floor

At this location, drill a 1/2 hole using a drill stop to prevent penetrating the fuel tank.

Assemble 1/4 Plusnut, using1/4 x 1-1/4 Hex Head Grd 5 screw

and (1) 1/4 Flat washer

Insert Plusnut assembly into hole, holding the Plusnut Tool with a wrench, tighten screw with a wrench or a

ratchet until screw is tight. While still holding the Plusnut Tool securely, remove the screw.

5/16-18 x 1 1/4HEX HEAD GRD 5

BOLT

5/16-18FLAT WASHER

1/2 SPACER

Plusnut

Fully Set Plusnut

RM470066 Rev. 2.2

11

Using a 1-1/8 Hole saw made for mat cutting, and hole saw out

hole in the composite floor

At this location, drill a 1/2 hole using a drill stop to prevent penetrating the fuel tank.

Assemble 1/4 Plusnut, using1/4 x 1-1/4 Hex Head Grd 5 screw

and (1) 1/4 Flat washer

Insert Plusnut assembly into hole, holding the Plusnut Tool with a wrench, tighten screw with a wrench or a

ratchet until screw is tight. While still holding the Plusnut Tool securely, remove the screw.

5/16-18 x 1 1/4HEX HEAD GRD 5

BOLT

5/16-18FLAT WASHER

1/2 SPACER

Plusnut

Fully Set Plusnut

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■ Attaching Partition - Hinged Center Door Panel

RM470066 Rev. 2.2

12

Make sure the handle is in the Locked position and insert it, cam first into the octagonal hole in the front of the door as shown. Slide the cam through the slot in the side of the door and snap handle into place.The cam will rotate up to disengage, otherwise the handle has been assembled in the open position and will need to be removed and locked to repeat this step.

Remove backing from tape on the latch cover plate and assemble as shown. Place latch handle over square shaft and secure with the set screw provided.

FOR PARTITIONS WITH HINGED CENTER DOOR PANEL

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■ Plusnut Installation


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Page 12 of 13

RM470447




torque setting.



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DRILL CHUCK

DRILL STOP

DRILL BIT



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DRILL STOP

DRILL BIT


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DRILL STOP

DRILL BIT


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DRILL STOP

DRILL BIT


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DRILL STOP

DRILL BIT


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DRILL CHUCK

DRILL STOP

DRILL BIT

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■ Securing Top Panel

Replace assembled partition and secure using:(4) 1/4-20 x 3/4 HWH Screws(4) 1/4 Split Lock Washers

Page 13 of 17

RM470028 Rev 3.2


SECURING TOP PANEL Replace assembled partition and secure using:(4) 1/4-20 x 3/4 HWH Screws(4) 1/4 Split Lock Washers

INSTALLEDPLUSNUTS

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■ Securing To Floor

Replace assembled partition and secure using: (4) 1/4-20 x 1-1/4 HWH Screws Grd 8(4) 1/4 Split Lock Washers

Page 14 of 17

RM470028 Rev 3.2


SECURING @ FLOOR Replace assembled partition and secure using:(4) 1/4-20 x 1-1/4 HWH Screws Grd 8(4) 1/4 Split Lock Washers

INSTALLEDPLUSNUTS

INSTALLEDPLUSNUTS

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■ Securing B-Pillars

Replace assembled partition and secure using: (6) 1/4-20 x 1-1/4 HWH Screws Grd 8(6) 1/4 Split Lock Washers

Page 15 of 17

RM470028 Rev 3.2


SECURING @ B-PILLARS Replace assembled partition and secure using:(6) 1/4-20 x 1-1/4 HWH Screws Grd 8(6) 1/4 Split Lock Washers

RIGHT PANEL (PASSENGER’S SIDE)

INSTALLEDPLUSNUTS

INSTALLEDPLUSNUTS

LEFT PANEL (DRIVER’S SIDE)

Page 15 of 17

RM470028 Rev 3.2


SECURING @ B-PILLARS Replace assembled partition and secure using:(6) 1/4-20 x 1-1/4 HWH Screws Grd 8(6) 1/4 Split Lock Washers

RIGHT PANEL (PASSENGER’S SIDE)

INSTALLEDPLUSNUTS

INSTALLEDPLUSNUTS

LEFT PANEL (DRIVER’S SIDE)

Right Panel (Passenger’s Side) Left Panel (Driver’s Side)

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■ B-Pillar Trim

Passenger B-Pillar (Shown with Trim) Driver’s B-Pillar (Shown with Trim)

Page 16 of 17

RM470028 Rev 3.2


@ PASSENGER’S B-PILLAR (SHOWN WITH TRIM)

@ DRIVER’S B-PILLAR (SHOWN WITH TRIM)

NOTE: IT WILL BE NESSARY TO CUT TRIM IN THIS AREA

B-PILLAR TRIM

Page 16 of 17

RM470028 Rev 3.2


@ PASSENGER’S B-PILLAR (SHOWN WITH TRIM)

@ DRIVER’S B-PILLAR (SHOWN WITH TRIM)

NOTE: IT WILL BE NESSARY TO CUT TRIM IN THIS AREA

B-PILLAR TRIM

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MASTERACK® 3 Year / 36,000 Mile Limited Warranty

MASTERACK® commercial van and pickup equipment is warranted to be from defects in material and workmanship, under normal use and service for a period of one (1) year from date of purchase. Factory installations, and products installed in new vehicles by an authorized MASTERACK® installer are warranted for (3) years or 36,000 miles (60,000KM), whichever comes first. This warranty covers only repairs, or at MASTERACKS’ discretion, replacement to correct any defects related to materials and workmanship.

This warranty does not apply to:

• Additions, alterations, or installations made by persons including dealers,other than MASTERACK® and it’s authorized distributors, made in accordance with MASTERACK® specifications and / or instructions, nor to defects arising out of attribute to such additions, alterations or installations.

• Defects attributable to abuse or misuse of the product, misapplication, negligent accident, modification or tampering.

• Damage resulting from failure to promptly notify and comply with the instructions of the dealer or manufacturer about defects when noted.

• Any incidental or consequential damages connected with a defect, either while under warranty or afterward, including the cost of a rental truck and / or loss or revenue.

THE WARRANTY IS THE ONLY WARRANTY APPLICABLE TO A MASTERACK PRODUCT PURCHASE. ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE ARE DISCLAIMED. MASTERACK® AND ITS SUBSIDIARIES, SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUR OF

ANY BREACH OF THIS WARRANTY, NOR SHALL THE DAMAGES EXCEED THE RETURN AMOUNT OF THE PURCHASE PRICE PAID BY THE ORIGINAL PURCHASER.

Warranty claims must be submitted to either your sales representative or a customer service representative at 816-455-0218. The vehicle must be delivered to the original MASTERACK® authorized dealer for inspection and any warranty service. Any warranty service to be performed by a source other than MASTERACK® location or an approved MASTERACK® distributor must be authorized in advance of the repairs by the MASTERACK® Warranty Administrator and a purchase order issued by MASTERACK®

in advance or repairs for the authorized repairs.

PROMASTER_PARTITION_INSTALL_REV1212020

Promaster Partition Installation Instructions€¦ · uol-v|;u -u om Installation Instructions...

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