Assembly & Installation Instructions

Save as PDF

Time Required

Approximately 1 hour to assemble. (Approximately 5 minutes to install or remove).

Tools Required

Roberston (Red) screwdriver

Assembly and Installation Video

Inquiries

Please contact the Sosco team at 1-877-748-29241-877-748-2924 or e-mail customerservice@ezpactrucktray.ca

Components / Pieces

There are 2 main components.

The Sub-frame consists of:

• (1) Main beam
• (2) Braces (Front and Rear brace)
• (2) Roller banks (Each roller bank comes with 12 pre-installed rollers)
• (2) Angle (“L”) brackets
• (2) Compression arms (with foam)
• (2) Threaded rod assembly (fits onto "L" brackets)

The Tray consists of:

• (4) panels: (1) Rear panel, (2) middle panels, and (1) Front panel with hand cut-outs and an adjustable underside
• (2) Side walls
• (1) Back wall

 

Hardware

Qty. 4	Qty. 25	Qty. 32	Qty. 4	Qty. 4	Qty. 2

	Qty. 4
	Qty. 25
	Qty. 32
	Qty. 4
	Qty. 4
	Qty. 2

Accessories (if purchased)

• Custom Divider(s)
• Custom fit rubber liner

Important

1. When the truck is in motion always ensure the lock-out is engaged, and the tailgate is closed.
2. Ensure all stoppers are firmly affixed to the unit before operation.
3. Do NOT overload the unit. Ensure the weight of your load is evenly dispersed. Maximum 300lbs of evenly distributed weight.
4. Do NOT stand or sit on the unit.

Assembly

Step 1

: Assemble the

Sub-frame.

1. Overlay the left and right roller banks onto the main beam. Insert 3/4" machine screws
2. Insert the front and rear braces between the roller banks. Secure with 3/4" machine screws and tighten
3. Tighten machine screws in step i. to secure the roller banks to the main beam.
4. Affix slide lock on the top surface of the left (or right) roller bank using black tap screws.
   
   
5. Choose the pair of rivnuts on the "L" bracket which allows the compression arm to i) clear the sidewall lip of your truck, and ii) provides enough threaded rod travel to ensure the compression arm is secured underneath the sidewall. Attach the threaded rod assembly to the "L" bracket using two 3/4" machine screws.
6. Insert the left and right angle ("L") brackets into the main beam. Insert both "L" brackets all the way into the main beam. Temporarily insert one 3/4" machine screw through the main beam and into the "L" bracket to stop bracket from sliding out. Note: The "L" brackets will be adjusted once the sub-frame is positioned in the bed of the truck.
7. Affix the compression foam to each of the compression arms.
8. Insert the compression arms into the "L" brackets. Ensure the threaded rod is fully reversed allowing the compression arm to sit down in the "L" bracket channel. Insert two 3/4" machine screws through the compression arm and into the "L" bracket - do not tighten.
   
   

The sub-frame is now ready to be placed into the bed of your truck.

Step 2

: Installing the

Sub-frame

into the bed of your truck:

Aligning the sub-frame in the bed of your truck:

1. Place the sub-frame into the bed of your truck.
   Note: You may need to insert the sub-frame on a slight angle to get around any obstruction at the back of the bed.
2. Line up the front of the roller bank with the end of the truck bed, inset approx. 1/2" - 1".
   Note: ensure the tailgate closes without making contact with the front of the roller bank.
3. Check the distance from the outside of the roller bank and the wheel well - make sure it is the same on both sides.
   (ie. Centre the sub-frame between the wheel wells)
   
   

Securing the sub-frame in the bed of your truck:

1. Remove the screw that was temporarily inserted into the "L" bracket (refer to Step 1, vi).
2. Pull out "L" bracket an equal distance on both sides until the angle of the "L" bracket allows the compression arm to fully extend under the side rail. When the right position has been found, secure the "L" bracket to the main beam with two 3/4" machine screws.
3. Extend the threaded rod by turning the knob clockwise until the compression foam touches the underside of the sidewall rail. Note: If there are plastic plugs holding down the sidewall cap, ensure the compression arm is behind the plugs before compressing.Do not fully tighten at this point. Repeat on the other side.
4. Once the sub-frame is aligned properly / symmetrically, apply full compression on both sides until the sub-frame is fully secured.
   Important: To ensure the unit is secure, pull back on the "L" bracket until it does not move when pulled upon.
5. Once the "L" bracket is secured under the side rail, tighten the two 3/4" machine screws through the compression arm, and into the "L" bracket.
   
   
   
   

Step 3

: Assembling the

Tray.

Connect 4 tray sections and secure with tap screws:

1. Turn panels upside down (careful not to scratch the surface) and lay panels laterally, from front to back.
2. Place the 2 middle sections side to side and secure with 3 tap screws under panel lip.
3. Secure the rear panel to the back-middle panel with 4 tap screws, noting the overlapping lip.
4. Secure the front panel (with hand cut-outs on the top surface) to the front-middle panel with 3 tap screws.
   
   

   (Underside view of Panels)

   
5. The front panel has an adjustable support panel underneath with 3 settings. An upper, middle and lower setting.
   
   

   (Underside view of Panels)

   

   Important: Choose the setting that provides the smallest amount of clearance (gap) between the bottom of the support panel, and the surface of the tailgate when the tray is fully extended. Ensure the support panel does not rub the tailgate when the tray is fully extended with no load.

   

   Note: The tray was designed to allow the support panel to make contact with the surface of the tailgate under load. This helps to distribute the weight and reduce the strain on the rollers/roller banks when the tray is fully extended.

Side and back wall assembly:

1. Connect the left and right sidewalls to the tray surface. Secure with eight ¾” machine screws provided. Note: The first threaded opening on each side wall is for the front tray stopping post.
   i)b: The last threaded opening one each side wall is for the rear tray stopping post which is not inserted until Step 4, ii).
2. Insert the 2 front tray stopping posts using the 1 ¾” machine screws and spacers.
   (Do not install back tray stoppers at this time).
3. Insert the back wall into the last side wall slot. (The back wall can be removed to accommodate larger items)
   

   Note: the additional rear side wall slots can be used to store dividers (dividers purchased separately).

   

Step 4

: Insert the

Tray

into the

Sub-Frame.

1. Carefully insert the Tray into the roller banks.
   Note: The tray will rest on the surface of the bottom rollers and be guided by the roller shoulder.
   Push the tray all the way in until the front tray stopper makes contact with the front rubber roller bank stopper.
   Note: This is the fully retracted position.
2. Pull the Tray forward and stop when the front of the tray is flush with the end of the tailgate.
   • Insert the two rear tray stopping posts (1 ¾” machine screw and spacer) into the last threaded opening at the back of each side wall.
3. Pull the tray out until the stopping post makes contact with the rear roller bank stopper.
   Note: This is the fully extended position.
   You can engage the slide lock at the fully extended position to stop the tray from rolling back into the roller bank.
4. Fully retract the Tray and engage the slide lock.
   
   
   

Removing the Unit

Step 1:

1. Remove the 2 rear tray stopping posts.
2. Carefully pull out the tray.

Step 2:

1. Loosen the two 3/4" machine screws which go through the compression arm and into each "L" bracket.
2. Decompress the compression arms until the compression foam is below the side wall rail.
3. Remove the Sub-frame.

 

Congratulations - You are now ready to enjoy your new EZ-PAC Truck Tray™!

Thank you for your business.

Sosco Ltd.