Flatline Van Co. Installation Guide

Tools Required

• Impact Driver
• Drill
• 3/8" Driver Bit
• 3/16" Drill Bit
• 17/32" Drill Bit
• 7/32" Allen Key
• 5/32" Allen Key
• Rivet Nut Tool
• 9/16" Socket
• 7/16" Socket
• Ratchet
• Blue Loctite
• Tape Measure
• Marker
• Power Drill

Install Info

Time to Install This Product: 2 Hours

Additional help is suggested for a few of the install steps.

Before You Start

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 always 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.

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

Package Contents

Weldments

• Passenger Step Weldment - Front (QTY: 1)
• Passenger Step Weldment - Rear (QTY: 1)
• Driver Step Weldment - Front (QTY: 1)
• Driver Step Weldment - Rear (QTY: 1)

Hangar Brackets

• Short Hangar Bracket (QTY: 5)
• Tall Hangar Bracket (QTY: 3)

Braces

• Driver Side Brace D1 (QTY: 1)
• Driver Side Brace D2 (QTY: 2)
• Passenger Side Brace P1 (QTY: 1)
• Passenger Side Brace P2 (QTY: 2)

Other Components

• Bayonet (QTY: 2)
• Joining Bracket (QTY: 2)
• Bracket Spacer - Double (QTY: 8)
• Bracket Spacer - Single (QTY: 6)

Hardware

• 1/4-20 x 0.75 Hex Head Drilling Screw (QTY: 80)
• 3/8 x 1 Serrated Flanged Hex Head Screw (QTY: 32)
• 3/8 Bonded Sealing Washer (QTY: 14)
• 3/8-16 x 0.027-0.15 Heavy Duty Rivet Nut (QTY: 6)
• 3/8-16 x 0.75 Button Head Hex Drive Screw (QTY: 14)
• 1/4-20 x 0.75 Flanged Button Head Hex Screw (QTY: 10)
• 1/4 Flat Washer (QTY: 2)
• 1/4 Nylon Locknut (QTY: 2)
• Threadlocker (QTY: 1)

Step 01: Weldment Assembly

1. Assemble Driver's Side Step: Insert a Bayonet into the tubing of the Front Driver Side Step Weldment. Align the first two holes of the Bayonet to the holes of the weldment and attach using two (2) 1/4 x 0.75 Flanged Button Head Screws with Loctite. Slide the Rear Driver Step Weldment onto the protruding Bayonet and attach using the same hardware and method.
2. Install Joining Bracket: Attach the Joining Bracket across from the bayonet joint using two (2) 3/8-16 X 1 Flanged Hex Head Screws with Loctite.
3. Assemble Rear Passenger's Step: Repeat Steps 1.1 and 1.2 for the Passenger Step using the same hardware and method.
4. Tighten All Step Screws: Once aligned, fully tighten all fasteners.

NOTE: The Joining Bracket is used to help with alignment of the two weldments and can be clamped in place while tightening to ensure alignment.

Diagrams illustrate the assembly process for both passenger and driver sides, showing the placement of bayonets, weldments, and joining brackets.

Step 02: Sealing Weldments

1. Reveal the bottom-most set of mounting holes by turning the assembled steps upside-down. These will need to be plugged using 3/8-16x0.75 Button Head Hex Drive Screws and 3/8 Bonded Sealing Washers to protect them from the elements. The graphic depicts the locations for the Passenger Side Weldment.
2. Affix a Bonded Sealing Washer to the screw and apply Loctite to the threads before tightening it down into the weldment with a 7/32" Allen Key. The screw should be turned to the point where the conical sealing washer flattens and the black rubber is set tight against the weldment.
3. Repeat this process for the Driver's Side Weldment.

Diagrams show the process of installing the sealing screws and washers into the bottom-most mounting holes.

Step 03A: Assemble Side Steps - "Solo Install Method"

This guide demonstrates an alternate mounting method that doesn't require measuring under the van. Ideal for solo installers.

1. Attach Sandwich Plates to Steps: Position the Double and Single Sandwich Plates to the Side Step Weldments in the locations shown, using masking tape. This will make installing the Hangar Brackets and Side Step Braces easier in the next steps.

Diagrams illustrate the placement of single and double sandwich plates on the side step weldments.

Step 03A: Assemble Side Steps

1. Identify Bracket Types: Notice that there are “Tall” and “Short” Hangar Brackets. The Driver Side Step features one (1) Short Hangar Bracket and three (3) Tall Hangar Brackets, while the Passenger Step has only four (4) Short Brackets.
2. Attach Hangar Brackets to Steps: Attach Hangar Brackets to the locations shown using two (2) 3/8-16 x 1 Flanged Hex Head Screws.

Diagrams show the identification of tall and short hangar brackets and their attachment to the side steps.

Step 03A: Assemble Side Steps

1. Identify Brace Types: Notice that there are different types of Braces on each side of your Side Steps. The Driver Side Step features one (1ea) “D1” and two (2ea) “D2” Braces, while the Passenger Step has one (1ea) “P1” and two (2ea) “P2” Braces.
2. Attach Braces to Steps: Attach Hangar Brackets to the locations shown using one (1) 3/8-16 x 1 Flanged Hex Head Screw.

Diagrams illustrate the different types of braces (P1, P2, D1, D2) and their attachment points.

Step 04A: Install Side Steps

1. Position Step Under Van: Carefully lift up your Side Step Assembly with a floor jack or helper. Ensure the Pinch Weld slips into the gap in the Hangar Bracket.

Diagrams show the side step assembly being lifted into place under the van and the pinch weld engaging with the hangar bracket.

Step 04A: Install Side Steps

1. Mark Brace Mounting Locations: Use a Marker to mark hole positions under each brace. Lower your Step and proceed to drill out mounting holes.
2. Drill Mounting Holes: Drill a pilot hole using a 3/16" Drill Bit and expand using a 17/32" Drill Bit. Clean up the drill hole using a file or countersink.
3. Install Rivet Nut: Using a Rivet Nut Tool, install your Rivet Nut into the drilled hole.
4. Repeat for All Mounting Holes: Repeat this process for all mounting holes.

NOTE: To ensure proper placement of Side Step Braces, cross reference your marks to those on Pages 17 and 18 of this guide.

NOTE: We recommend using a pneumatic or electric drill adapter rivet nut tool for this, although a manual rivet nut tool can work if you have enough ground clearance. The Astro Tools ADN38 XL model is recommended for a drill adapter.

Diagrams illustrate marking mounting locations, drilling pilot holes, expanding holes, and installing rivet nuts.

Step 04A: Install Side Steps

1. Lift Step Back into Place and Hand-Tighten: Attach each Brace to the Van using one (1ea) 3/8-16 x 1 Flanged Hex Head Screw.
2. Secure Hangar Brackets: Drive two (2ea) 1/4-20 x 0.75 Hex Drive Self Tapping Screws through the lower mounting surface of the Hangar Bracket to secure them to the van.

NOTE: Check to make sure you are happy with the alignment of your Side Step at this time. At this point, you should still have back-and-forth and left-to-right adjustment.

Diagrams show attaching braces to the van and securing hangar brackets using self-tapping screws.

Step 04A: Install Side Steps

1. Secure Hangar Brackets: Move to the outside of the van and drive two (2ea) 1/4-20 x 0.75 Hex Drive Self Tapping Screws through the exterior mounting surface of the Hangar Bracket to further secure them to the van.
2. Secure Hangar Brackets: Back under the van, drive at least three 1/4-20 x 0.75 Hex Drive Self Tapping Screws through the upper mounting surface of the Hangar Bracket to finish the install of the Hangar Brackets.

NOTE: You'll need an extension to reach this area of the van.

Diagrams show securing hangar brackets from the exterior and interior of the van using self-tapping screws.

Step 04A: Install Side Steps

1. Final Side Step Alignment: Check to make sure you are happy with the alignment of your Side Step at this time. At this point, you should still have up-and-down adjustment.
2. Tighten All Fasteners: Go back through and tighten all fasteners.
3. Attach Step Weldments Together: Finalize the install by joining the Passenger Rear and Front Step together using two (2) 1/4-20 x0.75 Flanged Button Head Screws, 1/4" Flat Washers and Locknuts.

NOTE: You'll need an extension to reach this area of the van.

Diagrams show final alignment checks and the process of joining the passenger side step weldments.

Step 04B: Install Side Steps

Now we will begin to measure and mark the locations of where to mount each Hangar Bracket along the welded pinch seam of your van body.

For 3rd generation Sprinters (VS30 chassis) [2019+]

1. Using the front jack point as your reference, layout the bracket locations according to the dimensions listed on the right.

For 2nd generation Sprinters (NCV3 chassis) [2007-2018]

1. Using the body seam as your reference, lay out the bracket locations with an inch added to each of the dimensions listed. The body seam is where the front door meets the front wheel well panel. There is an indent on the undercarriage where this seam lies.

NOTE: These are centerline dimensions. Your mark on the pinch seam will align with the centerline notch cut into the Hangar Bracket. Also note the labels next to the brackets in the diagram; the short brackets are labeled “S” and the tall brackets are labeled “T”. The two tall brackets go to the rear of the van on the driver side as shown.

NOTE: Ensure that your marks are accurate. While there is a small amount of adjustment built into the bracket mount holes for tolerance, labeling your marks for each bracket type as you go is a good way to avoid placing the wrong bracket in the wrong location.

Diagrams show reference points and measurements for bracket placement on both 3rd and 2nd generation Sprinters, indicating short (S) and tall (T) brackets.

Step 04B: Install Side Steps

1. Seat the Hangar Bracket: Seat the Hangar Bracket into place along the pinch seam and line up your mark with the center of the bracket.
2. Mark and Drill Holes: Mark the center of each hole as pictured in the first illustration and drill out your pilot holes using a 3/16" Drill Bit. Be sure to drill from the outside of the van.
3. Attach Brackets: Replace the Hangar Bracket and drive four 1/4x0.75 Hex Head Drilling Screws into the pilot holes using an Impact Driver and 7/16" Socket.

NOTE: The four mounting holes used in this step are slotted to allow for a small amount of lateral adjustment if necessary.

NOTE: There is a notch cut out into the upper portion of the bracket to aid in this alignment. It is recommended that you dry fit each bracket to make sure that they won't conflict with any existing units installed on your van (i.e. heaters, a/c units, water tanks).

NOTE: For more information about how to modify the hangar bracket layout to accommodate varying types of undercarriage configurations, please refer to our Help Center of the webpage.

Diagrams illustrate seating the hangar bracket, marking and drilling holes, and attaching the bracket with screws.

Step 04B: Install Side Steps

You can now attach the side step assemblies to the Hangar Brackets. This step will require some help from another person or the assistance of a floor jack to keep the side step assembly up off the ground and aligned to the Hangar Brackets.

1. Place Spacer Plate and Loosely Thread Screws: Place a Double Bracket Spacer Plate between the side step assembly and the Hangar Bracket as shown. Apply Loctite to two 3/8-16x1 Serrated Flanged Hex Head Screws and loosely thread them into place, sandwiching the Spacer Plate between the weldment assembly and the Hangar Bracket.
2. Tighten Bolts: Repeat this process for all Hangar Brackets on each side of the van and proceed to tighten down the bolts using a 9/16" Socket. The steps should now be hanging freely from the sides of your van, but will need reinforced by installing the remaining braces.

Diagrams show placing a spacer plate and loosely threading screws to attach the side step assembly to the hangar brackets.

Step 04B: Install Side Steps

1. Install Rivet Nuts (Passenger Side): Start by installing 3/8 Rivet Nuts into the passenger side of the van undercarriage using a Rivet Nut Tool with a 3/8-16 Mandrel.
2. Attach Passenger Side Braces: Once you've installed the Rivet Nuts, you can attach the Passenger Side Braces. There are two styles of Passenger Braces; P1 & P2. Refer to the first image on the right for locations. Fit the P1 Side Brace to the Rivet Nut and loosely thread a 3/8-16x1 Serrated Flanged Hex Head Screw, again applying Loctite.
3. Sandwich Spacer Plate: Sandwich a Single Bracket Spacer Plate between the brace and step assembly while threading another 3/8 Screw loosely into place.
4. Repeat for P2 Braces: Repeat the process for the P2 Side Braces and once complete, tighten down all the screws before moving on to the driver's side.

NOTE: We recommend using a pneumatic or electric drill adapter rivet nut tool for this, although a manual rivet nut tool can work if you have enough ground clearance. The Astro Tools ADN38 XL model is recommended for a drill adapter. Pictured for reference.

NOTE: The locations for these Rivet Nuts are circled in the first image to the right. It is always a good idea to double check your Rivet Nuts once installed to ensure they do not fall out or spin.

NOTE: Unlike the Passenger side, installing braces for the Driver's side will first require you to drill some holes before you can proceed to the application of Rivet Nuts.

Diagrams show the installation of rivet nuts on the passenger side, attachment of P1 and P2 passenger side braces with spacer plates, and a reference image of the rivet nut locations.

Step 04B: Install Side Steps

There are two styles of Driver Side Braces; D1 & D2. Refer to the first image on the right for locations.

1. Mark Locations for Drilling (D1 Brace): To mark the locations for drilling, fit the D1 Brace to the side step assembly and thread in a 3/8-16x1 Serrated Flanged Hex Head Screw firmly in place. Then, pressing the brace up against the van body, mark the center of the upper mounting slot to drill your hole. Repeat this process for both D2 Braces.
2. Drill and Install Rivet Nuts: Once your spots are marked, remove the braces and drill a pilot hole using a 3/16" Bit. Continue by drilling out your rivet nut hole using a 17/32" Bit. Clean drill holes (rust preventative paint is recommended) and install your Rivet Nuts using a Rivet Nut Tool.
3. Attach Driver Side Braces: Once you've installed the Rivet Nuts, you can attach the driver side braces just like the passenger side, sandwiching the Single Bracket Spacer Plate between the brace and weldment assembly before tightening it together using Loctite and 3/8-16 Hex Head Screws.

Diagrams illustrate marking locations for driver side braces, drilling holes, installing rivet nuts, and attaching the driver side braces.

Get Out and Explore!

Leave Us a Review

Happy with your new FVC product? We would love to hear (and see) from you! Head to the product page and click "Leave Review." Add a short review and upload a few photos to be showcased on the product page.

Share Your Pics

We love seeing how our customers use their FVC products and following along with your adventures. Tag us in your photos with: @flatlinevanco or send them to us via email. We love posting customer pictures in our feed!

Need Any Help?

If you are having any issues with your product, please reach out, and Flatline Van Co will make it right. Flatline Van Co is a company of van and outdoor enthusiasts that design and use their own products, so they want you to be as stoked on your new parts as they are!

Social media icons for Facebook, Instagram, and YouTube are present.