Cargo Cover Reassembly Tutorial

4Runner-Dan

New member
Recently I purchased a "new" cargo cover from another member to replace my missing one. The seller and I both agreed that the end caps needed to be shipped separately. We both had bad experiences in the past with them being damaged or broken, and I didn't want to have another broken one. So....here we go.

(A side note: [MENTION=102813]SURF RUNNER[/MENTION] is a stand up seller and I would absolutely do business with him again. Very professional and upfront with price and information. His packing skills are also top notch. Mine could have survived a nuclear war by the way it was packed.)


Anyway, so you get your box. I think this was after I removed it.


Roll it out and look for damage, cracks, whatever. Mine was in great shape.


Mine was shipped with the end caps disassembled from the cover itself. SURF RUNNER and myself both agree that this is the best way to have them transported. The caps are way too easily broken, chipped or damaged by the "professionals" shipping them.

The end caps....



With the end caps should be 6 screws (3 per side) and two pins which have a smooth side and a notched side.


The notched end will slide into the end cap and "catch" the spring, allowing you to place tension on it when you spin it.

In this next picture, I have removed the silver cover on the end cap (two phillips screws) and you can see the spring inside.


Placed the notched end of the pin in way that catches the spring and you can rotate it. See below....


Replace the silver cover with the 2 phillips screws.

Now comes the tricky part. ***This is my method which did work. If anyone else has tried a different way, please reply and critique. I'm sure there's a million other ways to do this.***

I removed the actual cover from the guide, rolled it up as tight as I could, and replaced it. (The end caps are still removed)


Take the end cap and insert it, GENTLY, into the slot on the cover. You want it just enough so that the pin engages the slot, but not so much that the two plastic pieces touch each other. This will allow you to spin the end cap and place tension on the spring.

You will have to mess with it a bit to find the right amount of tension. (I placed some tension on it, put the plastic pieces together, and tested it a few times) Once that is done, spin the end cap so it lines up with the guide and sandwich them together. Sorry, I don't have pictures of this. I can get some for those who are visual learners.

Finally, use the 6 screws to secure everything together. The holes are on the bottom and back side.


Enjoy your new cargo shade!


Also, pay no mind to my interior. It's a project! Haha
I hope everyone enjoys this write-up (first one!) and that it will help someone else in the future. It's a little extra work, but I think it's worth it to not have broken end caps.
 
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i appreciate this write up.... the thing i was struggling with when putting mine back together was (had to take it apart because glass was in the metal area where the cover gets rolls up) because i had no idea how many times i needed to twist the spring.... its hard to know exactly how many turns it needs to get the correct tension... too little and it doesn't roll back good.. too much and it rolls up too fast and flies away into the cabin somewhere....
 
Great write-up! Thanks for doing this.

As far as I know all of the 1996-2000 cargo covers have the square end caps. The 2001-2002 cargo covers have the round end caps. The square end caps are suceptible to damage during shipping. I've not heard of a single one of these arriving undamaged. The cargo covers with the round end caps are less likely to be damaged as compared to the square ones.
 
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Terrific tutorial. I was having problems trying to figure out why the cover I ordered online wouldn't retract. After watching your tutorial I realized that the cover sent to me was missing the "pins". Thank you.
 
I am returning the cover to the seller since he cannot find the pins. He is going to send me a different intact cargo cover. I asked him to send the replacement to me without removing the rounded endcaps. Hoping he packs it well.
 
The 2001-2002 cargo cover with the rounded end caps don't seem to be as prone to damage during shipping as much as the 1996-2000 version with the square end caps are.

If I were you I would generalize and let the seller know that a lot of 3rd Gen owners have had these damaged with the end caps on so that he packs it with lots of styrofoam anyway.
 

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