'94-96 Bronco Cargo Cover
IF THE IMAGE IS TOO SMALL, click it.
Actual dimensions: 5 lbs 61x3x2"
I've never found any Ford documentation about this cover, so I created the diagram above & wrote this after finding a damaged one in a JY, and repairing it.
DISASSEMBLY
1. Using a large crescent wrench, twist the end cap so its point is directly over the slot in the torque plate; slide the end cap off the torque plate; repeat for the other end cap. Note the direction that the torque plate rotates, so that it can be re-wound the opposite direction during assembly.
2. Unroll the cover from the drum and mark the drum L & R for proper reassembly; align the drum slot with the torque plate slot; slide the cover off the drum
3. Compress the LEFT (driver's) torque plate slightly & drive the LEFT roll pin out of the torque rod using a 3/32" drift; remove the torque rod from the RIGHT end of the drum; drive out the RIGHT roll pin
4. Remove, clean, & lube all the hardware from the torque rod with teflon (PTFE) grease
5. Remove the handle
6. Slide the draw rod to expose one rivet; file the flare off rivet #1 (DO NOT remove rivet #2); compress the catch pin slightly & drive the rivet out using 3/32" drift; remove the catch pin; slide the draw rod out of the cover
7. Remove the other catch pin; clean & lube the O-rings with silicone grease
ASSEMBLY
See the other photos in this album, and their captions. Gently peen rivet #1 with a center punch to re-flare it slightly.
Only the drum, torque rod, cover, & handle must be oriented L/R; all other parts are interchangeable. The rod bearing that the torque spring pushes against must be installed the correct direction.
