Installation Instructions for Lock Core and Key Set

Part Numbers:

• 59315 (4 Lock Cores)
• 59316 (8 Lock Cores)

Tools Required:

• Control Key (included)
• Standard Key (included)

Safety Notes:

• Warning:
  • Proper installation is critical to the performance and safety of this product.
  • Always read and understand the instructions and warranty information before installation.
  • Damage to the vehicle, cargo, or personal property caused by improper installation is not covered under warranty.
  • Installation is the end user's responsibility.

Step-by-Step Instructions:

Installing New Lock Cores

1. Insert the control key into the lock core.
2. Orient the key with the housing in the unlocked position.
3. Slide the lock core into the housing until it is fully seated.
4. Hold the lock core in place with your finger and remove the control key.

Note:

• If installing into an accessory like a crossbar end cap that is removed, the lock core can be installed in either the locked or unlocked position.
• If the accessory is already installed or if it is a different type (e.g., a bike carrier), the lock core must be inserted in the unlocked position.

Replacing Existing Lock Cores

• If the supplied control key does not fit:

  1. Access the back side of the lock core.
  2. Insert the current key halfway into the lock.
  3. Depress the exposed lock blade using a small tool (see Fig. 1).
  4. Push the key in fully to keep the lock blade depressed.
  5. Slide the old lock core out of the housing.

• If the supplied control key fits:

  1. Ensure the lock core is in the unlocked position.
  2. Fully insert the control key into the lock core.
  3. Carefully pull out the lock core.

Maintenance:

• Lubricate lock cores regularly to ensure smooth operation.
• Clean housing areas of any dirt or debris before inserting lock cores.

Hardware List:

• (4) or (8) Lock Cores (depending on part number)
• (2) Standard Keys
• (1) Control Key

Warranty:

• The warranty is limited to repair or replacement of defective parts.
• Damage caused by improper installation, misuse, or neglect is not covered.

For technical support and assistance, our team of experts is available to help. You can reach our tech support by visiting www.trailerjacks.com or calling 877-869-6690.

Installation Instructions for Part #R5017
Roof Rail Kit System with Cross Bars, ACBC Components, and RE1350-53 Rails

Supported Vehicles:

• Volkswagen Golf V, 5-door Hatchback, 2004–2007
• Volkswagen Golf VI, 5-door Sedan, 2010–Present
• Volkswagen Rabbit, 5-door Sedan, 2006–2009
• Volkswagen GTI V, 5-door Sedan, 2006–2009
• Volkswagen GTI VI, 5-door Sedan, 2010–Present

Part Numbers:

• RE1350-53: Roof Rails
• 59970: Cross Bar System
• ACBC: Buffer and Cover Components

Tools Required:

• Torque Wrench (18 ft-lbs and 8 ft-lbs for fasteners)
• Measuring Tape
• Pliers
• Marker or Pencil
• Cleaning Cloth

Hardware List:

RE1350-53 Rails

• (2) Rails
• (4) End Caps
• (4) Quarter Turn Plugs
• (4) Position Sliders

ACBC Components

• (2) Buffer Strips
• (4) Outer Under-Covers

59970 Cross Bar System

• (2) Cross Bars (included)
• (4) Lock Cores (optional, sold separately for additional security)

Step-by-Step Instructions:

Step 1: Prepare Your Work Area

• Park your vehicle on a level surface.
• Clean the roof of your vehicle with a cleaning cloth to remove any debris or dirt.
• Verify all components listed in the parts and hardware section are present before starting.

Caution: Always wear gloves and safety glasses during installation.

Step 2: Apply Positioning Stickers

• Refer to the End Support Instructions for exact sticker placement.
• Affix the provided positioning stickers to the roof at the designated measurement points for your specific vehicle model.

Step 3: Assemble and Attach Rails

• Attach the End Caps to the ends of the RE1350-53 Rails.
• Insert the Quarter Turn Plugs into the Position Sliders and adjust to fit your vehicle’s roof dimensions.
• Position the rails on the roof at the following measurements:
  • Front Rail Position (W): 8.25 in (210 mm) from the windshield edge.
  • Rear Rail Position (Z): 28 in (710 mm) from the windshield edge.
• Use the torque wrench to tighten the quarter turn plugs to 8 ft-lbs.

Warning: Ensure the rails do not extend past the vehicle's side mirrors.

Step 4: Install Buffer Strips and Covers

• Slide the Buffer Strips into the grooves on the rails to provide protection.
• Attach the Outer Under-Covers to the underside of the rails to safeguard the vehicle's roof paint.
• Double-check that all components are securely seated and aligned.

Step 5: Attach Cross Bars

• Secure the Cross Bars (59970) to the rails by aligning them with the Position Sliders.
• Tighten the fasteners with a torque wrench to 18 ft-lbs.
• Apply force in all directions to test the stability of the cross bars.

Caution: Overtightening can damage the cross bars, rails, or roof.

Step 6: Load and Secure Cargo

• Ensure the combined weight of the rails, cross bars, and cargo does not exceed 110 lbs (50 kg).
• Use non-stretch straps to secure the cargo firmly.
• Tie down any long items (e.g., kayaks, surfboards) to both front and rear bumpers in addition to the cross bars.

Warning: Improperly secured cargo can cause accidents, damage, or void your warranty.

Maintenance:

Before Each Trip:

• Check all bolts, straps, and locks to ensure they are tight and undamaged.
• Verify that the cargo is evenly distributed and securely fastened.

Monthly Maintenance:

• Clean the rails and cross bars with a damp cloth to remove dirt and debris.
• Lubricate screws, nuts, and lock cores (if installed) to prevent rust and ensure smooth operation.

Winter Maintenance:

• Remove salt and road debris promptly to prevent corrosion.
• Inspect the buffer strips and under-covers for wear or damage.

Safety Notes:

• Avoid speeds over 50 mph (80 km/h) when the roof rail system is in use.
• Do not use the cross bars or rails for off-road driving or on trailers.
• Remove the system when not in use or before entering an automatic car wash.
• Adjust driving behavior to account for the increased height and load of the vehicle.

Warning: Failure to follow these instructions may result in injury, property damage, or voided warranty.

Specifications:

• Maximum Weight Capacity: 110 lbs (50 kg) combined (rails, cross bars, and cargo)
• Recommended Speed Limit: 50 mph (80 km/h)

Caution: Exceeding weight or speed limits can result in instability and potential accidents.

Installation Instructions for Part #R5017
Roof Rail Kit System with Cross Bars, ACBC Components, and RE1350-53 Rails

Supported Vehicles:

• Vehicle 1, 5-door Hatchback, 2004–2007
• Vehicle 2, 5-door Sedan, 2010–Present
• Vehicle 3, 5-door Sedan, 2006–2009
• Vehicle 4, 5-door Sedan, 2006–2009
• Vehicle 5, 5-door Sedan, 2010–Present

Part Numbers:

• RE1350-53: Roof Rails
• 59970: Cross Bar System
• ACBC: Buffer and Cover Components

Tools Required:

• Torque Wrench (18 ft-lbs and 8 ft-lbs for fasteners)
• Measuring Tape
• Pliers
• Marker or Pencil
• Cleaning Cloth

Hardware List:

RE1350-53 Rails

• (2) Rails
• (4) End Caps
• (4) Quarter Turn Plugs
• (4) Position Sliders

ACBC Components

• (2) Buffer Strips
• (4) Outer Under-Covers

59970 Cross Bar System

• (2) Cross Bars (included)
• (4) Lock Cores (optional, sold separately for additional security)

Step-by-Step Instructions:

Step 1: Prepare Your Work Area

• Park your vehicle on a level surface.
• Clean the roof of your vehicle with a cleaning cloth to remove any debris or dirt.
• Verify all components listed in the parts and hardware section are present before starting.

Caution: Always wear gloves and safety glasses during installation.

Step 2: Apply Positioning Stickers

• Refer to the End Support Instructions for exact sticker placement.
• Affix the provided positioning stickers to the roof at the designated measurement points for your specific vehicle model.

Step 3: Assemble and Attach Rails

• Attach the End Caps to the ends of the RE1350-53 Rails.
• Insert the Quarter Turn Plugs into the Position Sliders and adjust to fit your vehicle’s roof dimensions.
• Position the rails on the roof at the following measurements:
  • Front Rail Position (W): 8.25 in (210 mm) from the windshield edge.
  • Rear Rail Position (Z): 28 in (710 mm) from the windshield edge.
• Use the torque wrench to tighten the quarter turn plugs to 8 ft-lbs.

Warning: Ensure the rails do not extend past the vehicle's side mirrors.

Step 4: Install Buffer Strips and Covers

• Slide the Buffer Strips into the grooves on the rails to provide protection.
• Attach the Outer Under-Covers to the underside of the rails to safeguard the vehicle's roof paint.
• Double-check that all components are securely seated and aligned.

Step 5: Attach Cross Bars

• Secure the Cross Bars (59970) to the rails by aligning them with the Position Sliders.
• Tighten the fasteners with a torque wrench to 18 ft-lbs.
• Apply force in all directions to test the stability of the cross bars.

Caution: Overtightening can damage the cross bars, rails, or roof.

Step 6: Load and Secure Cargo

• Ensure the combined weight of the rails, cross bars, and cargo does not exceed 110 lbs (50 kg).
• Use non-stretch straps to secure the cargo firmly.
• Tie down any long items (e.g., kayaks, surfboards) to both front and rear bumpers in addition to the cross bars.

Warning: Improperly secured cargo can cause accidents, damage, or void your warranty.

Maintenance:

Before Each Trip:

• Check all bolts, straps, and locks to ensure they are tight and undamaged.
• Verify that the cargo is evenly distributed and securely fastened.

Monthly Maintenance:

• Clean the rails and cross bars with a damp cloth to remove dirt and debris.
• Lubricate screws, nuts, and lock cores (if installed) to prevent rust and ensure smooth operation.

Winter Maintenance:

• Remove salt and road debris promptly to prevent corrosion.
• Inspect the buffer strips and under-covers for wear or damage.

Safety Notes:

• Avoid speeds over 50 mph (80 km/h) when the roof rail system is in use.
• Do not use the cross bars or rails for off-road driving or on trailers.
• Remove the system when not in use or before entering an automatic car wash.
• Adjust driving behavior to account for the increased height and load of the vehicle.

Warning: Failure to follow these instructions may result in injury, property damage, or voided warranty.

Specifications:

• Maximum Weight Capacity: 110 lbs (50 kg) combined (rails, cross bars, and cargo)
• Recommended Speed Limit: 50 mph (80 km/h)

Caution: Exceeding weight or speed limits can result in instability and potential accidents.

Important Notes:

• Attention: This is a summary of the installation procedure. For complete installation instructions, including diagrams and detailed information from the manufacturer, please download the full installation PDF.
• Warranty Information: For complete warranty instructions, please download the full installation PDF.
• Technical Support: For technical support and assistance, our team of experts is available to help. You can reach our tech support by visiting www.trailerjacks.com or calling 877-869-6690.