Unaka Gear Co. Installation Instructions

Overview

This set of instructions is a basic guideline on how to install your Ford Transit 8020 Roof Rack Brackets. If you have questions or issues with our product do not hesitate to contact us at info@unakagearco.com.

Rack Overview

Van Roof Load Rating

Even though the Unaka Gear Co rack mounts can support more weight per point, we DO NOT recommend that anyone to exceed the vehicle manufacturer's specifications. Ford publishes the maximum loads per roof attachment points as well as the max allowable load for any rack. Go to their website here at https://fordbbas.com/publications. From this page you can find the Body and Equipment Mounting manuals for your specific van year. This document contains many design recommendations including the roof rack mount point dimensions and loading for that specific year.

Check the link above to confirm the load ratings for your specific year. The van roof load ratings for the 2020 transits state each van mounting location can hold up to 79.3 kg (174.8 lbs.) with a max load of 190Kg (418.8 lbs) per van roof no matter what size or the number of attachment points are used. Figure 1 shows the 2020 Ford Transit rack load ratings per the 2020 Transit Body and Equipment Mounting Manual which can be found by clicking HERE.

Figure 1: A diagram excerpt from the 2020 Ford Transit Body and Equipment Mounting Manual illustrates load ratings for roof attachment points. It includes a warning to refer to the owner's manual for load carrying information and maximum roof loads, and notes that the number of load retaining fixtures may vary. It also specifies that roof racks may be fitted to various Transit variants provided load limits are met, referencing specific load capacities per attachment point and total roof structure durability.

Roof Rack Terminology

Figure 2 shows a high-level overview of the components that make up most roof racks. This image shows a rack made using 8020 side rails and cross bars, but other materials can be used as well. Table 1 outlines the main parts that make up a roof rack highlighted in Figure 2.

Figure 2: A diagram provides an overview and terminology for a roof rack, showing side rails, cross bars, and mounting points.

Safety

Working with tools involves inherent risks that could result in injury or in extreme cases death. It is important to know how to perform the job and perform it safely. Always use the correct tools for the job and wear the required personal protective equipment (PPE) necessary for the job. If you are unsure of how to complete a task safely consult a friend or a professional. Below are some suggestions for PPE to help stay safe but as individuals may approach a job differently, they may need to adjust the required PPE accordingly.

Suggested PPE:

• Safety Glasses
• Gloves
• Hearing Protection

Ladder Safety: Installing a roof rack will require the use of a ladder. Any ladder used should follow the manufacturer's guidelines with respect to proper usage.

Required Tools

The following tools or a combination of these tools should be used for this installation.

Tools Required for Unaka Ford Transit Rack Brackets

• Standard Allen Wrench Set (must include 3/16" Allen Key)
• Metric Allen Wrench Set (must include 5mm Allen Key)
• Metric Wrench and Sockets (must include 13mm)
• Torque Wrench (Must go up to 180 in-lbs or 15 ft-lbs and be compatible to use with 3/16" Allen Key)
• Torque Wrench (Must go up to 180 in-lbs. or 15 ft-lbs. and be compatible to use with 5mm Allen Key)

Required Materials

• Dicor RV Roof Lap Sealant or similar UV resistant sealant
• Blue 242 Loctite
• Minimum of 2 Sets of Roof Rack Brackets
  • Most installs require more than one set to build a rack.
• Rail or Rack Materials (8020, Aluminum Angle, Etc.)

Figure 3 shows a detailed breakdown of the parts that make up a set of Unaka mounting brackets. Note each Set of brackets that you order from Unaka comes with two complete mounting brackets and associated hardware.

Figure 3: An image displays the components of an Unaka rack bracket set, detailing the Hex Bolt (M8-1.25 x 30mm Lg, 18-8 SS), Washer (1" OD, 18-8 SS with Rubber), Unaka Ford Transit Bracket, Adhesive Backed Rubber Pad (already installed), and 5/16-18 Flanged BHCS & T-Nut.

Roof Rack Bracket Locations

148" WB Roof Rack Bracket Locations

The mounting locations on the standard transit are straight forward but are highlighted below.

Figure 4: A diagram illustrates mounting locations for 148" WB Ford Transit roof rack brackets, showing positions 1 through 4.

148" WB Extended Length Roof Rack Bracket Locations

The Ford Transit 148” WB Ext. Length van has five standard mounting locations, and one rear mounting position which uses a slightly different bracket, Figure 4. The installation of this rear bracket is covered at the end of this manual. We recommend using all the mounting locations on every van with some exceptions based on design and loads. If you plan to extend your side rails to the back of the van, we recommend using a set of our Ford Transit Rear Brackets as without these you would have to much overhang past the fifth bracket to correctly support your rails. Our 8020 Ford Transit Rack kits use mounting points 1, 2, 3, 5, and the rear bracket. We skip the fourth position as it is so close to the fifth position which better distributes the load.

Figure 5: A diagram provides a detailed view of the rear mounting positions for the 148" Extended Length rack, highlighting the 3rd, 4th (skipped), 5th, and Rear Bracket locations.

Roof Rack Bracket Installation Steps

Important: Read all the directions below before beginning your installation!

Transit Standard Roof Rack Bracket Installation

These instructions do not cover how to install your specific rack but only how to connect our brackets to your Ford Transit and your main rails.

1. Un-wrap your roof rack brackets and remove the hex bolts and washers.
2. Place a bracket and its hardware at each mounting point you plan to use on the van roof.
3. Carefully remove rack mounting hole covers at mounting pad locations

   Note: Other hole covers may be present on the roof, only remove the hole covers at the rack mounting pad locations.

   • A plastic scraper or putty knife can be used to pry up and pull off the covers over the holes.
   • Light heat can be applied to the hole cover if needed to help loosen up any adhesive.
4. Enlarge any holes in the van roof as needed
   • This should not be required on every hole, but it is common to have to enlarge 1 to 2 mounting hole locations that were not aligned correctly at the Ford factory.
   • If any of the bolt locations are covered up by the sheet metal of the van roof use a file, tin snips, or a small Dremel to open the hole to allow access to the bolt hole. Protect the rest of the van roof from metal shavings as needed.
   • Remove any metal shavings from the roof of the van and clean the area completely.
   • After cutting, apply primer and paint to any bare metal after cutting is complete.
5. Loosely install each rack bracket at the desired mounting locations
   • Center the lower slot over the bolt hole.
   • Loosely tighten the M8 bolt using the 5mm Allen key to keep the bracket in place. Do not fully tighten at this time so that the brackets can be aligned to each other using your side rails.
   • Helpful Tip: Do NOT fully tighten this hardware yet, leave it slightly loose. Check the alignment of all brackets along the length and the spacing from one side rail to the other. As you get things in place slowly snug up a few pieces of hardware to hold it in place. If you are using 8020 cross bars you may want to hold up or temporarily bolt it in place to check the alignment. Re-check and once everything are in place and parallel go back and tighten all the hardware.
6. After the initial fit up and before final installation of any hardware, apply LOCTITE 242 to the hardware per their directions.

   An image displays a bottle of Loctite 242 threadlocker next to installation hardware, including a bolt and washer.

Transit 148" Ext. Length Rear Roof Rack Bracket Installation

To better utilize more of the roof on the Ford Transits, we designed a unique bracket to help extend and support your rack side rails. The installation process of this bracket is very similar to the standard bracket with a few small differences.

1. Steps 1 through 4 are identical to those for the standard bracket
   • During step 4, there is no threaded insert underneath the cap area.
2. Loosely install each rack bracket at the desired mounting locations
   • Center the lower slot over the bolt hole.
   • Insert the M8 bolt through the sealing washer, and the rear bracket, and into the van as shown in Figure 8.
   • From inside the van, insert the provided square or second large round washer onto the bolt, and the M8 Nyloc nut. Apply anti seize to the end of the bolt before installing the nut.
   • With one person on the outside, and one person on the inside, do not fully tighten at this time so that the brackets can be aligned to each other using your side rails.
   • Helpful Tip: Do NOT fully tighten this hardware yet, leave it slightly loose. Check the alignment of all brackets along the length and the spacing from one side rail to the other. As you get things in place slowly snug up a few pieces of hardware to hold it in place. If you are using 8020 cross bars you may want to hold up or temporarily bolt it in place to check the alignment. Re-check and once everything are in place and parallel go back and tighten all the hardware.
3. With all the bracket in place, you can proceed to the next step and install your 8020 side rails.

8020 Side Rail Installation

1. At this point all the roof rack brackets and 8020 adapters should be in place but with the hardware still slightly loose or barley snug.
2. Place your 8020 side rail on the roof of your van on the inside of the rack brackets. You may want to put a towel or rags down on each end to help protect your van roof from the ends of the extrusion.
3. Pick a t-slot in the extrusion (typically the top or the side closest to the adapters. Slide 2 x T-nuts into the extrusion for each 8020 adapter you will be bolting to. Space the T-nuts so they are 2” to 3" outside of the 8020 adapter profile on each side, Figure 11. This will allow you to slide them into place when you are ready to insert the hardware. We typically place the long end of the t-nut towards the center of the bracket.
4. Once all the hardware for one side rail is in place and spaced on both sides of the Unaka 8020 adapters, the rail can be bolted to the adapters. Start at one end of the 8020. Place the 8020 against the rack bracket, slide one of the 2 nuts so that it lines up with the hole in the Unaka Adapter, then insert the Flanged Button Head Cap Screw and tighten it using a 3/16" Allen Key. Do not fully tighten, leave this loose.
5. Go to the opposite end of your side rail and repeat the previous step of aligning the nut, and loosely inserting the bolt.
6. Now go through and repeat this process for all the nuts along the length of the side rail. Leave all bolts loose until you get all the bolts in place on both side rails.
7. Verify side rail alignment from one to the other along the full length. Make slight adjustments as needed until rails are positioned as desired and are parallel to each other.
8. Tighten up the M8 BHCS using the 5mm Allen key to secure the transit brackets to the roof of the van. Torque to 14 ft-lbs. (168 in-lbs.)
9. Once both side rails are positioned with respect to each other as desired, go back and snug up all the side rail hardware using your 3/16" Allen Key.
10. Once all the 8020 hardware is snug, torque to 13 ft-lbs. (156 in-lbs.).
11. After the entire rack bracket installation is complete, we highly recommend sealing the lower perimeter of the bracket where it meets the van roof as well as covering the edge of the washer and flanged BHCS with Dicor RV roof sealant or a similar UV resistant adhesive sealant.

    Note: The EPDM rubber pad on the bottom of the rack bracket and the washer should minimize the chance of water finding its way into your van but even after testing other competitor rack brackets which use similar features Unaka concluded that the only way to truly keep water from finding its way into your van is to fully seal the perimeter and the hardware with sealant. After the sealant is applied and has cured per the manufactures recommendations a leak check should be conducted and more sealant applied until all leaks are eliminated.

Figure 6: Illustrates the hardware locations for a Transit bracket, showing the M8-1.25 x 30mm Lg Hex Bolt, 1" OD Washer with Rubber, Unaka Ford Transit Bracket, and Adhesive Backed Rubber Pad, along with the 5/16-18 Flanged BHCS & T-Nut.

Figure 7: Shows a Transit bracket secured to a van roof.

Figure 8: Details the hardware for a rear Transit bracket, showing an M8 Nyloc Nut, M8x1.25 Thread x 30mm Lg Hex Bolt, Large Sealing Washer with Rubber Gasket, and Square Washer or 1.25" OD Washer.

Figure 9: Compares a standard versus a rear transit bracket.

Figure 10: Shows the location of a rear bracket on a van roof, with annotations indicating recommended sealing points with Dicor sealant for the main cavity, outside edges, and the M8 bolt head.

Figure 11: Illustrates the installation of Unaka 8020 adapter hardware, showing T-nuts positioned on either side of the adapter.

Figure 12: Shows the correct orientation for a 8020 T-Nut, with the boss facing the center of the extrusion.

An image shows a tool (likely an Allen key) being used to tighten hardware on a roof rack bracket installed on a van roof.

Figure 13: Shows where to apply Dicor RV Roof Sealant around the lower edge of the rack bracket, M8 Bolt, and washer.

Figure 14: Displays a tube of Dicor RV Roofing Lap Sealant.

Figure 15: Illustrates the final Dicor sealant locations for a rear bracket, covering all four sides, the main gap, and the bolt head.

Legal Disclaimer

Unaka Gear Co. makes no warranties whatsoever, expressed, or implied, oral, or written to any purchasers, except the limited warranty described on our website. Unaka Gear Co. is hereby specifically excluded from any implied warranty of incidental, secondary, or consequential damages of any kind whatsoever. All purchasers and users of products manufactured by Unaka Gear Co. agree to hold harmless and indemnify Unaka Gear Co from any and all claims arising from their use. Failure to receive notice of any limitations or the limitations contained in this disclaimer shall not serve to extend liability to Unaka Gear Co. for any claims arising out of use of its products.

An image of the Unaka Gear Co. logo featuring mountains and the brand name.