Small but potentially useful maintenance item for three-fold rigid tonneau cover

For those of you running an OEM three-fold rigid tonneau cover on a 3rd gen (or possible earlier versions as well, not sure if it's different), this might be a useful maintenance tip for. I had arrived at job (photographer) around 5.00pm and was getting my gear out of the back of the truck, and as usual, it was a fairly tight window to get in, get done and get out. Reached for the middle handle to flip the second section of cover back and... it came free in my hand. Of course it was getting dark, I didn't have time to f*** with it, etc... made do, looked like an idiot wriggling around trying to get stuff that was right up against the rear of the cab... I called the dealer to enquirer about the warranty and got a whole bunch of, "Well... it depends on whether we installed it" (I installed it), whether you bought it with the truck (I did, but it was back-ordered for a couple of months)... anyway, I quickly decided unless it was catastrophic, the dealer was more hassle than it was worth.
I pulled the cover off the release handle mechanism, and quickly discovered the problem. The metal rod that connects the handle to the release mechanism under the cover had pulled through the push-nut because the push-nut had rusted through due to prolonged exposure to trapped moisture.


A quick trip to the local hardware store netted me push nuts with an identical OD, and slightly larger ID; two taps with a hammer and flat punch closed the ID to spec. To put things in perspective, the cover has been installed for about 20 months.

This is the mechanism for the first "flip" - it hadn't failed yet, but looked
imminent


The handle with the new push nut installed (if you're going to do this, note the order that the spring and washer go in; it's a PIA if you get the handle pushed into the push-nut and don't get this right... or so I've heard). Once I had the handles in the new push-nuts I covered everything with a liberal coating of spray lithium.
Hope someone finds it useful...

 

Thanks for the write-up

 

Good to know.

 

I've had the latch that's actually attached to the cable come off. So only one side was unlocking and couldn't open the cover.
I found pinching it tighter with a pair of pliers helped. Just something to consider for you guys with OEM cover.
Mine was the driver side but can happen to other side to.

As soon as you unscrew the cover over the cable near where it latches you'll see what I mean. I don't have a picture

 

Well done write up.

 

This is useful information, especially in southeast Louisiana where we have so much rain and humidity.
But maybe I'm the only one that doesn't understand..Are you saying that this picture is incorrect?

 

No, that photo is provided for reference and shows the correct order/positioning of the spring, washer, etc.... the first time I assembled it, I got the spring & washer on the wrong side of that block nearest the handle, and then had to sacrifice a push nut in order to disassemble and correct things.

 

I just went through the same thing shit dealer was such a pain. I did exactly what you did

 

I just pulled my covers and gave them a shot of WD-40, didn’t appear to be any rust. Good preventative maintenance though once or twice a year to give that entire assembly under there a squirt.

 

Do you remember the size of the push nut? This JUST happened to me and my local Home Depot does not have anything close to this in stock.

 

Go to harbor freight. They have small plastic containers of o-rings in different sizes. Right next to them are other containers with maintenance parts in them. Split pins cotter pins ands some of these. Might be some in there if the right size. I keep a container of those in the truck to have just in case.

 

Alright guys. I ordered a push nut assortment kit from Amazon. The M3 sized push nut fits perfectly. Spray some white lithium on all moving parts/steel and call it a day. Link is below for the kit:

$13 HELIFOUNER 360 Pieces 9 Sizes Internal Tooth Star Lock Washers, Quick Speed Locking Washers, Push Nuts, Speed Clips Retaining Clips Fasteners Assortment Kit

Amazon.com: HELIFOUNER 360 Pieces 9 Sizes Internal Tooth Star Lock Washers, Quick Speed Locking Washers, Push Nuts, Speed Clips Retaining Clips Fasteners Assortment Kit : Industrial & Scientific