Kargo Master 40649TL Manual

Kargo Master

Rancho Cordova, CA 95742

800-343-7486

CustomerService@KargoMaster.com

20200608R1 DATE: ________________

Instruction Guide

40649TL

Installation Instructions –40649TL

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 1

*PLEASE READ ALL INSTRUCTIONS AND WARNINGS PRIOR TO ASSEMBLING, INSTALLING,

AND USING THIS PRODUCT.*

Warning

Always check for wires, fuel tanks and lines, brake lines and other important vehicle

functionality items prior to drilling and installing all products.

Tools Needed

3/8” Wrench and Socket

7/16” Wrench and Socket

Drill

25/64” Bit

Phillips Driver

10mm Wrench and Socket

1/2” Wrench and Socket

9/16” Wrench and Socket

Table of Contents

Parts List............................................................................................................................................................ 2

Hardware .......................................................................................................................................................... 3

Step 1 –Attaching Side Wings .......................................................................................................................... 4

Step 2 –Attaching Top Panel............................................................................................................................ 5

Step 3 –Attaching Bottom Plate....................................................................................................................... 5

Step 4 –Attaching Roof Support ...................................................................................................................... 6

Step 5 –Installing Handle Mount ..................................................................................................................... 6

Step 6 –Installation Preparation ...................................................................................................................... 7

Step 7 –Installing Partition to Floor ................................................................................................................. 8

Step 8 –Installing Partition to Floor ................................................................................................................. 9

Step 9 –Installing Driver Side Wing to Van Siding.......................................................................................... 10

Step 10 –Installing Roof Support to Van Siding ............................................................................................. 11

Step 11 –Installing Handle to Handle Bracket ............................................................................................... 11

Step 12 –Installing Wing to “B” Pillar............................................................................................................. 12

Before You Begin

Read all instructions prior to installing any Kargo Master product.

Be sure to have 40640 partition assembled and ready to be installed before continuing.

Installation Instructions –40649TL

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 2

Parts List

Installation Instructions –40649TL

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 3

Hardware

Installation Instructions –40649TL

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 4

Step 1 –Attaching Side Wings

Using four 1/4” x 5/8” flanged bolts and four

1/4” flanged lock nuts, bolt passenger side (PS)

side wing to partition.

Snugly tighten.

Using four 1/4” x 5/8” flanged bolts and four

1/4” flanged lock nuts, bolt driver’s side (DS)

wing to partition.

Snugly tighten.

Installation Instructions –40649TL

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 5

Step 2 –Attaching Top Panel

Using six 1/4” x 5/8” flanged bolts and a 1/4” flanged lock nuts, bolt top wing to partition.

Snug tighten.

Step 3 –Attaching Bottom Plate

Using four 1/4” x 1/2” hex head bolts, four 1/4” lock washer, and four 1/4” washers, bolt through the

partition panels into the bottom panel.

Snug tighten.

Installation Instructions –40649TL

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 6

Step 4 –Attaching Roof Support

Using a 1/4” x 5/8” flanged bolt and

a 1/4” flanged lock nut and the

previously installed 1/4” x 5/8”

flanged bolt and 1/4” flanged lock

nut, LOOSELY bolt the roof support

to partition.

Step 5 –Installing Handle Mount

Remove handle from slider doorway as shown below.

Installation Instructions –40649TL

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 7

Using a M6 x 25mm hex head, 1/4” lock washer and a 1/4” split lock washer, install handle mount where

handle was previously removed.

Snug tighten.

Step 6 –Installation Preparation

Remove the D-rings from

both the driver’s side and

passenger side “B” pillars.

If wall liner is installed on

driver-side sidewall behind

the driver’s seat, remove wall

liner and wall liner holding

clips nearest the driver’s

seat. Wall liner can be

reinstalled later on during

installation.

Installation Instructions –40649TL

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 8

Step 7 –Installing Partition to Floor

Place assembled partition with wings into van

with the flanged side of partition facing to the

rear and wings bent towards the front.

Push the partition firm against the passenger

side “B” pillar.

Align holes in passenger side wing with

previously installed handle mount.

On the driver’s side, the holes in the outside

edge of the wing should line up with three

existing holes on the side of the van.

Holding the partition in place, use a straight

edge to ensure the bottom of the partition is

straight and square with van.

Be sure this is the desired location to install the

partition.

Mark all holes and slots along floor.

Remove partition with wings.

Based upon lack of obstructions and ease of installation, determine which four locations on each partition

panel to drill into floor.

DO NOT drill beyond depth of

floor. Always check that each

location is clear of wires, fuel tanks

and lines, brake lines and other

important vehicle functionality

items prior to drilling and installing

any product.

Use a drill stop to avoid

unnecessary damage.

Drill hole at each marked location using

25/64” drill bit and appropriate sized drill-bit

stop collar. If 25/64” drill bit is not available, a

3/8” drill bit can be used, although it may be

necessary to tap in the plus nuts.

Insert a 1/4” x 2-1/4” hex head bolt through a 1/4” washer and the plus nut installation tool, and then

screw the bolt into plus nut. Knurled end of plus nut tool must be directed away from bolt head and

contacting plus nut.

Insert and press plus nut, with tool still attached, into hole.

Installation Instructions –40649TL

For Technical Support Call: 800-343-7486 Monday-Friday 7AM - 4 PM (PST) Page 9

Using the 9/16” box wrench, hold the plus nut tool stationary and then tighten hex head bolt until plus

nut is tightly gripping and does not spin when hex bolt is loosened.

DO NOT overtighten plus nut.

Step 8 –Installing Partition to Floor

Place assembled partition with wings

back into van. Align with previously

installed plus nuts.

Along the floor, at each plus nut, bolt

through partition panels using

1/4" x 1-1/4” hex head, 1/4" lock

washer, and a 1/4" flat washer.

Insert nylon spacer underneath

partition if needed.

Snug tighten.

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