Installation Instructions for Direct Mount Adapter Kit System (DMK-R)

Part Number:

• 59754

Compatible Products:

• For use on sheet metal surfaces
• Compatible with ROLA APE and APX crossbar kits

Tools Required:

• Masking Tape
• Fine Tip Marker
• Center Punch
• 8mm Wrench
• 10mm Wrench
• Tape Measure
• Hammer
• Drill Motor
• Safety Glasses
• Drill Bits:
  • 3.6mm (0.125”)
  • 0.290” Diameter ("L" Drill Bit)

Hardware List:

1. Button Head Bolt (M5 - 0.8 x 20mm) - QTY 8
2. Nylon Washers - QTY 8
3. Plus-Nut Inserts - QTY 8
4. Phillips Head Screw (M6 x 20mm) - QTY 1
5. ROLA Covers - QTY 4
6. Direct Mount Adapter Bases - QTY 4
7. Rubber Mounting Gaskets - QTY 4
8. Brass Nut (M6) - QTY 4
9. Hex Bolt (M5 - 0.8 x 30mm) - QTY 1
10. Hex Nut (M6) - QTY 1
11. Flat Washer (Steel) - QTY 1
12. Star Washer (M5) - QTY 8
13. Hex Key (3mm) - QTY 1
14. Silicone Sealant - QTY 1

Step-by-Step Instructions:

Pre-Installation:

1. Prepare Vehicle Surface:

   • Clean and dry the sheet metal surface where the adapters will be mounted.
   • Verify that all kit components are included.

2. Placement of Adapters:

   • Align the crossbars to the desired width and attach them to the adapter bases.
   • Position the assembly on the vehicle's roof, considering accessory spacing and underside clearance.

3. Marking Hole Locations:

   • Once aligned, tape the adapters to the surface and carefully remove the crossbars.
   • Use a fine tip marker or pencil to mark the mounting holes.

Installation Steps:

1. Drill Pilot Holes:

   • Drill 3.6mm pilot holes at the marked locations.
   • Expand the holes to 0.290” diameter using the specified drill bit.
   • Important: Do not drill deeper than ¼”. Use drill stops or masking tape to limit depth.

2. Seal Holes:

   • Clean away debris and apply a small amount of silicone sealant into each hole to prevent corrosion.

3. Install Plus-Nut Inserts:

   • Assemble the M6 hex nut, M5 x 30mm bolt, steel flat washer, star washer, and Plus-Nut as shown in the instructions.
   • Insert the Plus-Nuts into the drilled holes.
   • Use the wrench assembly to tighten the bolts until the Plus-Nut collapses. Remove the hex bolt, nut, and washer assembly.

4. Attach Adapter Bases:

   • Place the rubber gaskets on the adapter bases.
   • Secure the bases to the Plus-Nut inserts using button head bolts and nylon washers.

5. Reinstall Crossbars:

   • Attach the crossbars to the adapter bases and tighten all hardware securely.

Safety Notes:

• Load Limitations:
  • Do not exceed the vehicle's load rating or the crossbar system's capacity, whichever is lower.
• Driving Precautions:
  • Loads will affect vehicle handling, especially in crosswinds or during cornering. Drive with caution.
  • Ensure all doors and sunroofs operate correctly after installation.
• Regular Maintenance:
  • Periodically check the tightness of bolts and ensure the system is secure.
  • Distribute loads evenly and secure them properly to prevent movement.

Warranty:

• Coverage:
  • Limited warranty for repair or replacement of defective products.
  • Excludes damage caused by improper installation, overloading, or misuse.

For complete warranty instructions, please download the full installation PDF.

For technical support and assistance, our team of experts is available to help. You can reach our tech support by visiting www.trailerjacks.com or calling 877-869-6690.

Additional Notes:

• When crossbars are not installed, use the ROLA covers to protect the adapters from debris.
• Always wear safety glasses when drilling or working with tools.

Installation Instructions for APE Cross Bar Kits for Track & Direct Mounting Systems

Part Numbers:

• 59773

Carrying Capacity:

• 75 Kgs / 165 Lbs

Tools Required:

• Phillips screwdriver
• Scissors or blade
• L wrench (security key)
• 13mm or adjustable wrench

Hardware List:

• Cross Bars x 2
• End Support x 4
• Track Mount Bolt (M6 x 16mm) x 4
• Direct Mount Bolt (M6 x 24mm) x 4
• Clamp Plate x 4
• M8 Hex Nut x 4
• M8 Bolt (M8 x 20mm) x 4
• M8 Washer x 4
• M8 Spring Washer x 4
• Cross Bar End Caps x 4
• Under Cover x 2

Step-by-Step Instructions:

Pre-Installation:

1. Verify the kit contains all necessary parts.
2. Determine if the system is a Track or Direct Mounting System.
   • For Track Mounting Systems, follow Steps 2 and 3.
   • For Direct Mounting Systems, follow Steps 4 and 5.

Track Mount Installation:

Step 2: Assembling the Cross Bars

1. Locate the hardware bag labeled “Track Mount Hardware.”
2. Assemble M6 x 16mm bolt into End Support and thread the M6 brass nut onto the bolt. Repeat for other End Supports.

Step 3: Installing to Vehicle

1. Insert the End Support with the M6 brass nut into the track channel and position as required.
2. Tighten the bolt with the L wrench security key (2–3 turns). Repeat for other End Supports.

Direct Mount Installation:

Step 4: Assembling the Cross Bars

1. Locate the hardware bag labeled “Direct Mount Hardware.”

Step 5: Installing to Vehicle

1. Use a Phillips screwdriver to remove the top screw and cover from the mounting block.
2. Attach the End Support with the logo facing out using the M6 x 24mm bolt. Tighten with the L wrench security key (2–3 turns). Repeat for all End Supports.

Attaching the Cross Bars:

Step 6:

1. Place the Cross Bars onto the End Supports, ensuring proper alignment with the “FRONT” labeled bar at the front.
2. Insert M8 Hex Nut into the Clamp Plate and align it with the End Support bolt hole.
3. Secure with M8 x 20mm bolt, washer, and spring washer using a wrench. Fully tighten to 5Nm (44 in/lbs) or firm hand tightness.

Additional Installation Steps:

Step 7: Installing Under Cover Strips

1. Mark the required length of Under Cover strips on the underside of the bars.
2. Cut Under Cover strips to size and attach to the Cross Bars before final assembly.

Step 8: Installing End Caps

1. Attach End Caps to the ends of the Cross Bars. Lock the caps and store the keys safely.
2. For accessories, remove End Caps, cut Buffer Strips to fit, and reinstall the End Caps.

Safety Notes:

• Ensure Cross Bars are parallel and secure with tightened bolts.
• Use non-stretch tie-down straps to secure loads.
• Regularly check bolt tightness and ensure all loads are evenly distributed.
• Check the functionality of doors and sunroof before driving.
• Drive cautiously, particularly in crosswinds or corners.

Warranty and Support:

• For technical support and assistance, our team of experts is available to help. You can reach our tech support by visiting www.trailerjacks.com or calling 877-869-6690.
• For complete warranty instructions, please download the full installation PDF.