INSTALLATION GUIDE
SPRINTER VAN STANDARD ROOF RACK - 170"
Model: SP0115B
TOOLS REQUIRED (NOT INCLUDED)
- MEASURING TAPE
- 7/32" ALLEN WRENCH
- 3/16" ALLEN WRENCH
- 5/32" ALLEN WRENCH
- 7/16" WRENCH OR SOCKET
INSTALL INFO
TIME TO INSTALL THIS PRODUCT: 1-2 HOURS
Additional help is suggested for a few of the install steps.
BEFORE YOU START
Please inspect the product and packaging upon delivery to ensure there are no issues and that all parts and hardware are accounted for.
Contact Flatline Van Co ASAP if anything is missing at: support@flatlinevanco.com
All Flatline Van Co products must be properly assembled and secured before attaching to your vehicle. Improper attachment could result in an automobile accident, and could cause serious bodily injury or death to you or to others involved. You are responsible for assembling and securing Flatline Van Co products to your vehicle, checking the mounting points and attachments prior to use, and regularly inspecting the products for wear and or damage. Flatline Van Co recommends using a professional to install any aftermarket accessories to your vehicle. If you have no mechanical experience and are not thoroughly familiar with the installation procedures, you must have the product installed by a professional installer or other qualified persons. The responsibility is yours and must be taken seriously for everyone's safety.
PACKAGE CONTENTS
Description of main product image: A black metal roof rack system designed for a Sprinter van, featuring multiple crossbars and side rails.
- DRIVER FRONT SIDE RAIL (QTY: 1)
- DRIVER CENTER SIDE RAIL (QTY: 1)
- DRIVER REAR SIDE RAIL (QTY: 1)
- PASSENGER FRONT SIDE RAIL (QTY: 1)
- PASSENGER CENTER SIDE RAIL (QTY: 1)
- PASSENGER REAR SIDE RAIL (QTY: 1)
- CROSSBAR (QTY: 9)
- SIDE LADDER ACCESS COVER (QTY: 1)
- REAR SPOILER (QTY: 1)
- FRONT FAIRING (QTY: 1)
- DRIVER SIDE FAIRING BRACKET (QTY: 1)
- PASSENGER SIDE FAIRING BRACKET (QTY: 1)
- CENTER FAIRING BRACKET (QTY: 1)
- CROSSBAR FAIRING BRACKET (QTY: 1)
- FAIRING GASKET TRIM (QTY: 1)
- SIDE RAIL COUPLER PLATE (QTY: 4)
HARDWARE
- 3/8-16 X 0.75 BUTTON HEAD HEX DRIVE SCREW (QTY: 20)
- 3/8 SCREW BELLEVILLE SPRING LOCK WASHER (QTY: 20)
- SPRINTER RAIL NUT (QTY: 20)
- 1/4-20 X 0.75 FLANGED BUTTON HEAD HEX DRIVE SCREW (QTY: 69)
- 1/4-20 NYLON LOCKNUT (QTY: 25)
- 1/4-20 X 0.5 BUTTON HEAD HEX DRIVE SCREW (QTY: 16)
- 1/4 SCREW BELLEVILLE SPRING LOCK WASHER (QTY: 16)
- 1/4 SCREW FLAT WASHER (QTY: 41)
- 1/4-20 TNUT (QTY: 16)
- THREADLOCKER (QTY: 1)
STEP | 01 LAYOUT AND INSTALL PREP
TOOLS REQUIRED FOR THIS STEP: MEASURING TAPE
1.1 Install Rail Nuts: Slide (9) Rail Nuts into the passenger side factory roof rail (refer to FIG 1), and (11) into the driver side rail. The extra two Rail Nuts will be for either your Side Ladder or Side Ladder Access Cover.
1.2 Layout Rail Nuts: Space out the Rail Nuts close to their final positions as roughly laid out in FIG 3.
Description of FIG 1: Illustration showing a square-shaped 'Rail Nut' being slid into the channel of a Sprinter van's factory roof rail.
Description of FIG 2: Close-up view of a 'Rail Nut' fitting into the extruded channel of a van's roof rail.
Description of FIG 3: Overhead schematic of a Sprinter van roof, indicating reference points and precise measurements (0", 20.5", 50", 53", 68", 71.125", 91.88", 95", 98", 120.16", 141.83") for positioning the rail nuts.
STEP | 02 SIDE RAIL INSTALL
TOOLS REQUIRED FOR THIS STEP: 7/32" ALLEN WRENCH
2.1 Install Side Rails: Beginning with the forward section of the rack (see FIG 5 for layout), start loosely attaching the side rails to the roof rails using the 3/8-16” Button Head Screws & 3/8" Lock Washers, but do not tighten them all the way down yet (refer to FIG 4). If you are not installing a Side Ladder at this time, install the Side Ladder Access Cover in the location shown in FIG 5.
Description of FIG 4: Detail showing a side rail being attached to a roof rail using a 3/8-16" Button Head Screw and a 3/8" Lock Washer.
Description of FIG 5: Layout diagram of the side rails on the van roof, with an arrow indicating the front and a callout for the "SIDE LADDER ACCESS COVER" placement. A note emphasizes positioning the rail as far forward as possible.
2.2 Side Rail Connecting Plates: Install the Side Rail Connecting Plates to the locations shown in FIG 6 using (4ea) 1/4-20 x 0.75 Flanged Button Head Screws, Flat Washers and Nylon Locknuts to loosely join the Side Rails together (refer to FIG 7).
Description of FIG 6: Diagram illustrating the placement of the Side Rail Connecting Plates on the side rails.
Description of FIG 7: Close-up view of the Side Rail Connecting Plates being fastened with 1/4-20 x 0.75 Flanged Button Head Screws, Flat Washers, and Nylon Locknuts.
STEP | 03 CROSSBAR INSTALL
TOOLS REQUIRED FOR THIS STEP: 3/16" ALLEN WRENCH
3.1 Layout Crossbar Locations: Position the crossbars in your desired locations, loosely threading in the 1/4-20" Flange Head Screws to hold in place (refer to FIG 8).
NOTE: Save a crossbar for Fairing Assembly in the next step.
NOTE: Keep in mind the layout of your roof top array (solar panels, fans, tents, etc.). You can mount crossbars in the set pair of holes (FIG 9), or you can place them in the slots which provides you more freedom of layout.
Description of FIG 8: Illustration showing crossbars being positioned on the side rails, with 1/4-20" Flange Head Screws indicated for temporary attachment.
Description of FIG 9: Close-up view of the side rail showing the pre-drilled holes and slots where crossbars can be mounted.
STEP | 04 FAIRING ASSEMBLY
TOOLS REQUIRED FOR THIS STEP: 5/32" ALLEN WRENCH
4.1 Crossbar Fairing Bracket: Stack a 1/4-20” x 0.5 Button Head Screw, 1/4" Belleville Lock Washer and 1/4" Flat Washer as shown in FIG 10 and insert into the six available front holes of the Crossbar Fairing Bracket. Loosely assemble using a T-Nut. You'll only want to screw the T-Nuts on a little in order to provide clearance for the next step.
4.2 Crossbar Install: Now, slide the Crossbar onto the Crossbar Fairing Bracket. You'll have to straighten each T-Nut as you go to get it to feed into the crossbar correctly (refer to FIG 11).
Description of FIG 10: Shows the components (screw, washer, washer) being stacked and inserted into the Crossbar Fairing Bracket, with a T-Nut shown for assembly.
Description of FIG 11: Illustration depicting a crossbar being slid onto the Crossbar Fairing Bracket, with a T-Nut visible.
STEP | 04 FAIRING ASSEMBLY (Continued)
TOOLS REQUIRED FOR THIS STEP: 3/16" ALLEN WRENCH, 5/32" ALLEN WRENCH, 7/16" SOCKET OR WRENCH
4.3 Center Fairing Bracket: Slide in the Center Fairing Bracket into place along the two center-most 1/4-20” Button Head Screws of the Crossbar Fairing Bracket as shown in FIG 12.
4.4 Tighten Assembly: After sliding in the Center Fairing Bracket, tighten all six (6) of the 1/4-20” Button Head Screws in the Assembly.
4.5 Attach Front Fairing: Attach the Front Fairing to the Assembly using 1/4-20 x 0.75 Flanged Button Head Screws, Flat Washers and Nylon Locknuts (refer to FIG 13).
Description of FIG 12: Shows the Center Fairing Bracket being slid into position on the Crossbar Fairing Bracket.
Description of FIG 13: Depicts the Front Fairing being attached to the assembly using screws, washers, and locknuts.
4.6 Driver and Passenger Side Fairing Brackets: Attach the Driver and Passenger Side Fairing Brackets to the Assembly using 1/4-20 x 0.75 Flanged Button Head Screws, Flat Washers and Nylon Locknuts (refer to FIG 14).
4.7 Fairing Gasket Trim: Attach the Fairing Gasket Trim to the Front Fairing in the orientation shown in FIG 15. Make sure the "bulbed" side is facing inward.
Description of FIG 14: Shows the Driver and Passenger Side Fairing Brackets being attached to the assembly.
Description of FIG 15: Illustrates the Fairing Gasket Trim being applied to the Front Fairing, with the "bulbed" side indicated.
STEP | 05 FAIRING INSTALL
TOOLS REQUIRED FOR THIS STEP: 3/16" ALLEN WRENCH
5.1 Fairing Install: Now you're ready to attach the fairing to the roof rack. Slide it in from the front and into the location shown in FIG 16. Tighten down using (8) 1/4-20" Flange Head Screws (refer to FIG 17).
Description of FIG 16: Shows the fairing being slid into its final position on the roof rack from the front.
Description of FIG 17: Close-up of the fairing attachment points on the roof rack.
STEP | 06 REAR SPOILER INSTALL
TOOLS REQUIRED FOR THIS STEP: 3/16" ALLEN WRENCH, 5/32" ALLEN WRENCH
6.1 Spoiler Assembly: Stack a 1/4-20” x 0.5 Button Head Screw, 1/4" Belleville Lock Washer and 1/4" Flat Washer as shown in FIG 18 and insert into the ten available top holes of the Rear Spoiler. Loosely assemble using a T-Nut. You'll only want to screw the T-Nuts on a little in order to provide clearance for the next step.
6.2 Crossbar Install: Now, slide the Crossbar onto the Rear Spoiler. You'll have to straighten each T-Nut as you go to get it to feed into the Crossbar correctly (refer to FIG 19). After sliding the Rear Spoiler and Crossbar together, tighten all fasteners.
6.3 Fairing Install: Now you're ready to attach the Rear Spoiler to the roof rack. Slide it in from the back and into the location shown in FIG 20 and tighten down using (8) 1/4-20" Flange Head Screws.
Description of FIG 18: Shows the components (screw, washer, washer) being stacked and inserted into the Rear Spoiler, with a T-Nut shown for assembly.
Description of FIG 19: Illustration depicting a crossbar being slid onto the Rear Spoiler, with a T-Nut visible.
Description of FIG 20: Shows the Rear Spoiler being attached to the roof rack from the back.
STEP | 07 FINAL ADJUSTMENTS
TOOLS REQUIRED FOR THIS STEP: 3/16" ALLEN WRENCH, 7/32" ALLEN WRENCH, 7/16" WRENCH OR SOCKET
7.1 Tighten Crossbar Fasteners: Tighten all crossbar bolts using the 3/16" Allen Wrench.
NOTE: Do not overtighten! If you are concerned about the bolts backing out, you can put a dab of blue loctite on the bolts before tightening down completely.
7.2 Tighten Rail-to-Rail Fasteners: Now tighten Side Rails to Roof Rail using the 7/32" allen key.
7.3 Tighten Rail Connecting Plates: Tighten all Rail Connecting Plates using the 3/16" Allen Wrench and a 7/16" Socket.
Description of FIG 21: Close-up view of the assembled roof rack, highlighting various fasteners and connection points.
Description of FIG 22: Close-up view of the Rail Connecting Plates and their fasteners.
GET OUT AND EXPLORE!
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