Tonneau (Cargo Cover) Repair

Two weeks ago my left quarter window was smashed by a thief, sending bits of glass everywhere. I just finished cleaning glass out of the last place: The cargo cover. I'm writing this for anyone who might disassemble their cargo cover in the future.

It's easy to disassemble the cargo cover: Remove two Philips screws from either end cap, remove the cap, and slide the rolled up cover out of the aluminum shell which houses it. In my case, that's when you shake all the glass out. The rolled up cover is spring-loaded, kind of like a window blind which rolls up and down.

When I reassembled the cover, it had no spring tension: The cover would no longer retract into its aluminum shell. Oh no! Here is what I learned.

The two end caps are different. One cap has a small hole, in which the round shaft of the cover fits. The other cap has a star pattern, into which the other side of the cover fits. Older Prius' used a flat shaft instead of the star-shape, and the flat shafts tended to wear out.

At any rate, you first roll up the cover and slide it inside the aluminum housing, with both end caps removed. You'll need an assistant. With the cover protruding an inch from the end with the star shape, you fit the star-shaped end cap over the cover, and then you slowly spin it clockwise to wind up the spring. Once I wound it enough to pull the cover in snugly, I turned it fourteen full rotations. This was my guesstimate; it's not a spec but it worked. If you don't tighten the spring enough, the cover won't fully retract. If you over-tighten, the spring can snap when you extend the cover.

Anyway, after you turn the end cap about fourteen full rotations, gently slide the end cap over the aluminum housing and secure it using the two Philips screws. Make sure they're tightened; the cap must be fully in place over the aluminum.

Next, you'll need to fit the other end cap over the round shaft of the cover. You might need needlenose pliers to get the shaft into the hole in the cover. Once in place, make sure the second end cap is fully in place and tighten the two Philips screws on the second end cap. You're done. Put the cover in the vehicle and test it.

 

Only break-in in thirty years living here. And the boneheads didn't manage to steal anything.

 

Yes, if you have nothing in the hatch area, leave it visible so crooks can see there's nothing to steal