1. Using a large crescent wrench, twist end cap so its point is directl...
01Bent.JPG 181 hits | 74.51 KB | Posted: 4/25/07 This cover was mangled & then abandoned in a junkyard for at least a year. It's severly sunburned, ...
02CapWrench.JPG 124 hits | 69.76 KB | Posted: 4/25/07 The best place to start disassembly is by removing the colored end caps from the black torque plates...
03CapLoose.JPG 148 hits | 73.53 KB | Posted: 4/25/07 There are 4 short pins that lock into holes in the torqe plate, so it takes some effort to pop them ...
04CapLoose.JPG 98 hits | 71.48 KB | Posted: 4/25/07 If the slots are aligned inside, the cap slides straight off.
05CapOff.JPG 105 hits | 74.08 KB | Posted: 4/25/07 Here, the slot, pins, & mating holes are visible.
06SlotAlign.JPG 118 hits | 63.53 KB | Posted: 4/25/07 With both end caps off, the cover can be unwrapped. Align the torque plate slot with the drum slot ...
07SlideOff.JPG 154 hits | 64.81 KB | Posted: 4/25/07 The plastic might be adhered to the drum, so it may be necessary to flex it to break it loose.
08Cover.JPG 180 hits | 29.63 KB | Posted: 4/25/07 After the cover is stripped, wash it & put in on a flat surface in the sun to relax mild wrinkles. ...
09LEnd.JPG 105 hits | 26.92 KB | Posted: 4/25/07 After driving out the LEFT roll pin (use a 3/32" drift), the torque plate, bearing, spring, and caps...
10REnd.JPG 105 hits | 19.94 KB | Posted: 4/25/07 Pull the torque rod out of the drum & remove the RIGHT roll pin. Then disassemble & clean everythin...
11SpringRivet.JPG 132 hits | 43.95 KB | Posted: 4/25/07 The torque spring is riveted to the rod - don't remove it. The rattle-mesh slides off easily.
12SpringEnd.JPG 101 hits | 33.89 KB | Posted: 4/25/07 The bearing pops loose from the spring, but be sure to replace it in this direction.
13SpringSleeve.JPG 82 hits | 32.18 KB | Posted: 4/25/07 There's a black plastic rattle sleeve under the spring that can't be removed.
14EndBearing.JPG 91 hits | 48.3 KB | Posted: 4/25/07 The large black bearings support the weight of the cover, and should slide freely inside the drum
15RodBearing.JPG 94 hits | 34.57 KB | Posted: 4/25/07 The bearings at the L end inside the drum is usually jammed onto its stops due to the spring pressur...
16Handle.JPG 96 hits | 77.62 KB | Posted: 4/25/07 Remove the 2 phillips screws from below the handle.
17HandleOff.JPG 91 hits | 77.33 KB | Posted: 4/25/07 Remove the handle & work the draw rod to free it from the plastic so it slides.
18DrawRod.JPG 100 hits | 79.5 KB | Posted: 4/25/07 Slide the draw rod far enough to expose one rivet, and turn it to the flared end. Use a small file ...
20DrumSection.JPG 81 hits | 36.9 KB | Posted: 4/25/07 Cross-section of the drum tube. There are 6 tabs punched in to locate the white torque rod bearings...
19DrawRodEnd.JPG 88 hits | 86.75 KB | Posted: 4/25/07 Work the catch pin out without tearing the O-rings, and slide the draw rod out of the cover. Then r...
21Date.JPG 98 hits | 35.68 KB | Posted: 4/25/07 The date is printed on both sides of a Tyvek tag near the R end of the cover, at the seam on the dru...
Greases.JPG 174 hits | 75.94 KB | Posted: 4/25/07 Use silicone grease on the O-rings, and teflon (PTFE) on the bearings.
22DrumVise.JPG 102 hits | 86.92 KB | Posted: 4/25/07 By slightly crushing the drum, rotating a few degrees, & repeating, most dents can be pushed back ou...
28Roll Pin.JPG 92 hits | 38.96 KB | Posted: 4/25/07 It's possible to remove the roll pins with the end caps in place, but it's much more difficult.
22DrumBent.JPG 66 hits | 42.77 KB | Posted: 4/25/07 This drum is severely bent in several places, as are its torque rod & draw rod.
23DrumStraighter.JPG 86 hits | 62.44 KB | Posted: 4/25/07 After some work, the drum is much better, but still not good enough to be used. The draw rod & torq...
24DrumBuilt.JPG 101 hits | 64.27 KB | Posted: 4/25/07 The roller assembly is ready to have the colored parts added, beginning with the cover. Slide it in...
25Assembled.JPG 165 hits | 63.26 KB | Posted: 4/25/07 Since I don't have a truck with the right bedwalls, I can't actually test it, but it's rolled up fla...
BedwallPanelFront.JPG 481 hits | 42.11 KB | Posted: 1/8/05 The front of the bedwall panel is the same for all '92-96, but the rear of '92-93 doesn't have slots...
12.JPG 205 hits | 51.61 KB | Posted: 11/29/04 These pics are for adding slots to a panel not originally molded with them.
01.JPG 248 hits | 30.1 KB | Posted: 11/29/04 These pics are for adding slots to a panel not originally molded with them.
07.JPG 205 hits | 54.17 KB | Posted: 11/29/04 These pics are for adding slots to a panel not originally molded with them.
04.JPG 186 hits | 40.94 KB | Posted: 11/29/04 These pics are for adding slots to a panel not originally molded with them.
02.JPG 205 hits | 52.1 KB | Posted: 11/29/04 These pics are for adding slots to a panel not originally molded with them.
13.JPG 236 hits | 52.79 KB | Posted: 11/29/04 These pics are for adding slots to a panel not originally molded with them.
03.JPG 198 hits | 54.18 KB | Posted: 11/29/04 These pics are for adding slots to a panel not originally molded with them.
11.JPG 208 hits | 47.64 KB | Posted: 11/29/04 These pics are for adding slots to a panel not originally molded with them.
05.JPG 291 hits | 45.32 KB | Posted: 11/29/04 These pics are for adding slots to a panel not originally molded with them.
06.JPG 239 hits | 40.98 KB | Posted: 11/29/04 These pics are for adding slots to a panel not originally molded with them.
Cover01.JPG 116 hits | 29.51 KB | Posted: 2/4/08 Cargo Cover (repaired) from '94-96 Eddie Bauer Bronco
Actual dimensions: 5 lbs 61x3x2"
Cover02.JPG 90 hits | 41.38 KB | Posted: 2/4/08 Cargo Cover (repaired) from '94-96 Eddie Bauer Bronco
Cargo Cover Specs
