How to Install and Operate Undercover Tonneau Covers

Pre-Installation Notes

Before diving into the installation process, it's crucial to prepare your truck and understand some key points:

1. Paint Protection: While paint rubbing is generally not an issue with Undercover tonneau covers, the tight clearance around the tailgate can cause minor rubbing. To prevent this, consider installing a standard tailgate protector. Many truck owners prefer a sprayed-in bedliner that covers the tailgate's top edge. Alternatively, a plastic, rubber, or thin chrome tailgate protector will suffice. For side rails, thin plastic smooth side rail covers or protective films like 3M Scotch Cal or CabSkin can be used to prevent paint damage. Consult your dealer for specific recommendations.

2. Bed Liner Compatibility: Undercover tonneau covers are designed for trucks without a plastic over-the-rail bed liner. If your truck has a bed liner, you may need to trim it slightly to ensure proper placement of the installation brackets.

Installation Instructions

Step-by-Step Guide

1. Rear Bracket Placement:

   • Place the rear bracket against the truck stake pocket.
   • Use two unobstructed holes in the rear bracket (there are three to choose from). Preferably, use the two holes that are further apart for a more secure fit.
   • Insert a bolt with a washer through the hole. Place an aluminum clamp on the backside of the bracket behind the bed lip of the truck. Thread the bolt into the clamp, ensuring the clamp remains straight while tightening. Ensure the bracket is tightly held against the truck rail and in the correct position before fully tightening.

2. Repeat for Opposite Side:

   • Follow the same steps to install the rear bracket on the opposite side.

3. Front Bracket Positioning:

   • Position the front bracket along the inside of the side rail closest to the front corner of your truck bed. This bracket should sit on the top rail of the truck to provide a mounting location for the front of the cover.
   • Using pre-drilled holes in the front bracket, install clamps as you did with the rear brackets. Ensure the bolts are very tight. You may need to make minor adjustments due to slight variations in truck beds.

4. Repeat for Opposite Front Bracket:

   • Follow the same steps to install the front bracket on the opposite side.

5. Tonneau Cover Placement:

   • Position the female hinges on the tonneau cover over the tangs of the front brackets. Install split rings to secure the cover. These rings are designed to hold the cover in place until it needs to be removed.

6. Hydraulic Struts Installation:

   • Attach the large end of the strut to the tonneau and the small end to the ball stud on the rear bracket. The strut should snap into place and be held by a pre-installed retaining clip.

7. Front Flap Seal:

   • Ensure the front flap seal hangs over the bulkhead (the front edge of the truck bed). This flap provides additional weather resistance. If the flap seal is rolled up under the tonneau, use a yardstick or similar tool to push it out from under the tonneau and over the front edge of the truck bed.

8. Final Adjustments:

   • Close the tonneau and check the length on the truck. There should be a ¼ inch gap between the tailgate and the rear overlapping edge of the tonneau. Adjust the front brackets as needed to achieve the correct clearance. Ensure the lock strikes are properly adjusted for easy locking without having to push down on the tonneau.

Removal Instructions

Fast and Easy Steps

1. Open Tonneau:

   • Use a small screwdriver to gently pry out the retaining clip on the hydraulic lift strut about 1/8 inch. Gently strike the strut with the palm of your hand to remove it from the ball stud. Do not completely remove the retaining clip. Place the loose end of the strut into the strut storage clip under the cover. Repeat on the opposite side.

2. Remove Split Rings:

   • Remove the split rings from the tangs on the front brackets. Ensure you complete the first step before removing the split rings.

3. Tonneau Removal:

   • The tonneau is now ready for removal.

Re-Installation Instructions

Quick Re-Installation Steps

1. Position Tonneau:

   • Place the tonneau on the truck, positioning the female hinges over the tangs on the front brackets. Install split rings into the holes in the male tang on the front brackets.

2. Attach Hydraulic Struts:

   • Lift the tonneau with one hand and firmly push the strut over the ball stud of the rear bracket with the other hand. You do not need to pry out the retaining clip when re-installing the hydraulic struts.

3. Front Flap Seal:

   • Ensure the front flap seal hangs over the bulkhead of the truck and is not rolled up under the tonneau. If it is, use a yardstick or similar tool to push it out from under the tonneau and over the front edge of the truck bed.

Interesting Stats

• Fuel Efficiency: Installing a tonneau cover can improve your truck's fuel efficiency by up to 10% by reducing aerodynamic drag (source).
• Cargo Security: According to a survey by the Specialty Equipment Market Association (SEMA), 60% of truck owners cite cargo security as the primary reason for purchasing a tonneau cover (source).
• Market Growth: The global tonneau cover market is expected to grow at a CAGR of 7.5% from 2021 to 2028, driven by increasing demand for pickup trucks and aftermarket accessories (source).

By following these detailed instructions, you can ensure a smooth installation and operation of your Undercover tonneau cover, enhancing both the functionality and aesthetics of your truck.