GROUP

NUMBER

BODY

Technical Service Bulletin
SUBJECT:

25-BD-011H

DATE

MODEL(S)

AUGUST 2025

SANTA CRUZ (NXT)

TONNEAU COVER FUNCTION: INSPECTION & REPAIR

This TSB supersedes 24-BD-004H to remove tonneau cover realignment and replacement
information, add the Tonneau Cover Repair Kit to the Description (page 1), Parts Information
(page 2), and Warranty Information (page 3), and add the Tonneau Cover Repair procedure
(pages 8-15).
Description: Certain Santa Cruz (NXT) vehicles may exhibit a condition where the tonneau cover does
not retract properly and/or a V-Gap is present when closed. This may be due to a broken or missing
clip on the underside of the tonneau cover. Follow the instructions in this TSB to inspect and, if
necessary, repair the tonneau cover function using the Tonneau Cover Repair Kit.

Applicable Vehicles:
Model Year

Model

Equipped with

Production Dates

2022 - 2024

Santa Cruz (NXT)

Tonneau Cover

06/15/2021 – 08/09/2023

Circulate To: General Manager, Service Manager, Parts Manager, Warranty Manager, Service
Advisors, Technicians, Body Shop Manager, Fleet Repair

TONNEAU COVER FUNCTION: INSPECTION & REPAIR

SUBJECT:

Parts Information:
Model

Part Name

Part Number

Santa Cruz
(NXT)

Tonneau Cover
Repair Kit

828A0-K5000ASQQH

Figure

Remarks

Qty: 1 kit
per vehicle

Kit contents listed below:

Rubber Strap

Qty: 3

Axle Clip

Qty: 3

Right Lamella Clip

Qty: 20
Marked with
“R”

Left Lamella Clip

Qty: 20
Marked with
“L”

End Cap Screw

Qty: 6

Lid Screw

Qty: 2

Tension Lock

Qty: 1

TSB #: 25-BD-011H

Page 2 of 16

TONNEAU COVER FUNCTION: INSPECTION & REPAIR

SUBJECT:

Required Equipment/Supplies:
Name

Figure

T10 Socket Wrench

Remarks
8 mm
3 mm
T10

•
•
•

8 mm Socket
3 mm Hex Bit
T10 Torx Bit

Box Knife

Silicone Oil
Standard shop supply

Shop Vacuum

Warranty Information:
Model

Santa Cruz
(NXT)

Op. Code

Operation

Op.
Time

30DA18I0

Inspection of Tonneau
Cover Functions ONLY

0.2
M/H

Repair of Tonneau Cover
30DA18R3
using Repair Kit

0.6
M/H

Causal Part

Nature
Code

Cause
Code

A35
828A0-K5000

ZZ1
I21

NOTE 1: Submit claim on Claim Entry Screen as “Campaign” type.
NOTE 2: This TSB includes repair justification photos. Op times include VIN, mileage, and repair
justification photo(s) as outlined in the Digital Documentation Policy.
NOTE 3: The incident parts are subject to callback through the normal Warranty Technical Center
(WTC) parts return process. Claim is subject to debit if the part is not returned.
NOTE 4: If a part is found in need of replacement while performing this TSB and the affected part is
still under warranty, submit a separate claim using the same repair order. If the affected part is out of
warranty, submit a Prior Approval request for goodwill consideration prior to performing the work.
NOTE 5: Op code 30DA18R3 will reimburse $0.50 for use of silicone oil.

TSB #: 25-BD-011H

Page 3 of 16

SUBJECT:

TONNEAU COVER FUNCTION: INSPECTION & REPAIR

Service Procedure:

DIGITAL DOCUMENTATION
This TSB includes repair justification photos. Refer to the latest Warranty Digital Documentation
Policy for requirements.

NOTICE
Applying the recommended torque to all fasteners is essential to reduce potential issues from
occurring after the service procedure.

NOTICE
If tonneau cover repair is needed, have a clean table ready to lay the cover on during
disassembly.

Table of Contents
•

Service Procedure Flowchart ................................................................................................... 5

•

V-Gap Inspection ..................................................................................................................... 6

•

Retraction Inspection................................................................................................................ 7

•

Tonneau Cover Repair ............................................................................................................. 8

•

Proper Tonneau Cover Operation .......................................................................................... 16

TSB #: 25-BD-011H

Page 4 of 16

SUBJECT:

TONNEAU COVER FUNCTION: INSPECTION & REPAIR

Service Procedure Flowchart

TSB #: 25-BD-011H

Page 5 of 16

SUBJECT:

TONNEAU COVER FUNCTION: INSPECTION & REPAIR

V-Gap Inspection
1.

Open the tailgate and use the pull strap (A) to
close the tonneau cover.
Ensure that the latch pins on both sides lock
securely at the end of the bed rails.
A

2.

3.

Close the tailgate.
•

PASS: If NO V-gap is present, this
inspection is complete.
Proceed to the Retraction Inspection
procedure on the next page.

•

FAIL: If a V-gap (B) is present, go to the
next step to take a photo for Digital
Documentation, then proceed to the
Tonneau Cover Repair procedure on
page 8.

No V-Gap (PASS)

DIGITAL
DOCUMENTATION

V-Gap Present (FAIL)

Using STUI, take a photo of the V-gap
condition with the last 6 digits of the
VIN and the date of repair on a piece
of paper.
Upload the photo to STUI.
B

4.

Proceed to the Retraction Inspection
procedure on the next page.

TSB #: 25-BD-011H

Page 6 of 16

SUBJECT:

TONNEAU COVER FUNCTION: INSPECTION & REPAIR

Retraction Inspection
1.

Put the tonneau cover latch (A) into the open
position.

A
2.

Retract the tonneau cover.
If the tonneau cover retracts easily or needs a
gentle push to retract, this inspection is
complete. Continue to the next step.
If the tonneau cover does NOT retract or
requires excessive effort while pushing to
retract, proceed to the Tonneau Cover Repair
procedure on the next page.

3.

Use the pull strap (B) to close the tonneau
cover.

B

4.

If the tonneau cover requires excessive effort
to close, then proceed to the Tonneau Cover
Repair procedure on the next page.
If the tonneau cover closes easily with minimal
binding, no further action is necessary.
Proceed to the Proper Tonneau Cover
Operation procedure on page 14.

TSB #: 25-BD-011H

Page 7 of 16

TONNEAU COVER FUNCTION: INSPECTION & REPAIR

SUBJECT:

Tonneau Cover Repair
1.

Remove the two 3 mm bolts (A) and then
open the tonneau cover lid (B).

i

A

A

Information

Refer to the QR code or link below for a
summarized demonstration of the
tonneau cover repair procedure:
Santa Cruz Tonneau
Cover Repair
Demonstration

B

2.

Remove the end caps from the tonneau cover
at the rear of the vehicle by first removing the
2 screws (C) in each end cap.
Bend the rubber cover (D) outward and
remove the 3rd screw (E). Then remove the
end cap.

C

Repeat on the other side of the tonneau cover.

i

Information

D