Body/Accessories - Bed Extender Component Replacement

Body and Accessories

09-005/04

2001-2004 B-SERIES - BED EXTENDER
COMPONENT REPLACEMENT AND REMOVAL /
INSTALLATION INSTRUCTIONS

APPLICABLE MODEL(S) / VINS

2001-2004 B-Series

DESCRIPTION

If service should become necessary on a bed extender, separate components are available which enable repairs without replacement of the entire unit. Replacing the entire bed extender assembly, when it is only necessary to replace the defective or damaged parts, is considered an over repair.





Prior to replacing an entire bed extender assembly, examine it closely and determine if repairs can be made utilizing the components and replacement instructions listed in this TSB. Determine also whether the complaint condition may be the result of an impact or customer abuse, as repairs for these reasons may not be covered under warranty. Refer to the following service procedures.

REPAIR PROCEDURES

Bed Extender Pin Lock Assembly Replacement:

1. Remove bed extender from vehicle.

2. Remove metal nut retaining the pin assembly to the upper tube support.

3. Slide the pin assembly out of the tube support.

4. Install a new pin assembly to the upper tube support.

5. Install the retaining nut and torque to 3-4 Nm (26-35 lb-in).

6. Reinstall bed extender to vehicle.

Bed Extender Support & Bracket Tube Assembly Replacement:

1. Remove bed extender from vehicle.

2. Remove the three tube caps from the stainless steel tubes on the affected side. Save these for reinstall ation.

3. Remove the pin assembly by removing the metal nut.

4. Remove two screws attaching support to tubes.

5. Use a soft hammer to tap the support tubes off

6. Slide the new support over the tubes, use a soft hammer if needed.

7. Reinstall the tube caps.

8. Note the position of the latching side of the support for installation, it must face the pivot pin.

9. Attach the new support with two screws and nuts, torque to 4-5 N.m (35-44 lb-in).

10. Insert the pin assembly through the upper support hole.

11. Attach the pin assembly to the support with metal nut and torque to 3-4 N.m (26-35 lb-in).

Bed Extender Rubber Bumper Replacement:

1. Remove the four screws that attach the tube support using a T-25 Torx driver.

2. Note the bumper position (facing up or down with the extender deployed).

3. Separate the two halves of the support and remove the bumper.

4. Insert a new bumper into the cavity formed by the two support halves.

5. Position the two halves onto the tube with the new bumper trapped by the supports.

6. Install the support halves to the tube with screws and nuts.

7. Torque the screws to 4-5 N.m (35-44 lb-in).





PART(S) INFORMATION