GROUP

NUMBER

BODY

Technical Service Bulletin

25-BD-011H-1

DATE

MODEL(S)

DECEMBER 2025

SANTA CRUZ (NXT)

TONNEAU COVER INSPECTION & REPAIR GUIDE

SUBJECT:

This TSB supersedes 24-BD-003H & 25-BD-011H to combine service procedures for tonneau
cover related repairs.
Description: Some Santa Cruz (NXT) vehicles may have a tonneau cover that does not latch or
unlatch, retract properly, and/or have a v-gap is present when closed. This may be due to a broken or
missing clip on the underside of the tonneau cover. This bulletin provides instructions to inspect and, if
necessary, repair the tonneau cover function using the Tonneau Cover Repair Kit or replacing the
tonneau handle & latch assembly.

Applicable Vehicles:
Model Year

Model

Equipped with

ALL

Santa Cruz (NXT)

Tonneau Cover

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

TONNEAU COVER INSPECTION & REPAIR GUIDE

SUBJECT:

Parts Information:
Model

Part Name

Part Number

Figure

Remarks
Qty: 1

Tonneau
Handle & Latch
Assembly

828C7K5000QQH

Santa Cruz
(NXT)

(order only
if latch
replacement is
necessary)
Qty: 1 kit per
vehicle

Tonneau Cover
Repair Kit

828A0K5000ASFFF

(order only if
repair kit is
necessary)

Tonneau Cover Repair 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-1

Page 2 of 17

TONNEAU COVER INSPECTION & REPAIR GUIDE

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

Op. Code

Operation

Op.
Time

Causal Part

Nature
Code

Cause
Code

828C7FF0

Tonneau Handle & Latch
Replacement

0.3
M/H

828C7-K5000

I11

ZZ3

828A0FF0

Repair of Tonneau Cover
(Repair Kit)

0.6
M/H

828A0-K5000

I21

ZZ1

Santa Cruz
(NXT)

NOTE 1: Normal warranty applies.
NOTE 2: This TSB includes repair justification photos. Op times include VIN, Mileage, and repair
justification photos 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 any part(s) not subject to this TSB are found in need of replacement while performing the
repair procedure, and the affected part(s) are still under warranty, the dealer may submit a separate
claim using the same repair order. If the part(s) not subject to this TSB are out of warranty coverage,
the dealer has the option to submit a PA Request for goodwill consideration on a case-by-case basis.
NOTE 5: Submit claim on Claim Entry Screen as "Warranty" type.

TSB #: 25-BD-011H-1

Page 3 of 17

SUBJECT:

TONNEAU COVER INSPECTION & REPAIR GUIDE

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, place the tonneau cover on a clean table during disassembly.

Table of Contents
•

Latch & Tonneau Cover Conditions...................................................................................... 5

•

Tonneau Cover Latch Replacement...................................................................................... 6

•

Tonneau Cover Repair ........................................................................................................... 9

•

Proper Tonneau Cover Operation ....................................................................................... 17

TSB #: 25-BD-011H-1

Page 4 of 17

SUBJECT:

TONNEAU COVER INSPECTION & REPAIR GUIDE

Latch & Tonneau Cover Conditions
Condition
Handle does NOT open
the tonneau cover

QR Code/Link/Figure

Remedy

Link
Tonneau Cover
Latch Replacement

Handle does NOT latch
when the cover is closed

Link

Tonneau cover does NOT
retract

Link

Tonneau cover binds and
hard to close

Link

Tonneau Cover Repair

V-Gap between the cover
and tailgate when closed
and latched

TSB #: 25-BD-011H-1

Page 5 of 17

TONNEAU COVER INSPECTION & REPAIR GUIDE

SUBJECT:

Tonneau Cover Latch Replacement
1.

Remove 2 screws (A) then remove 2 end caps
from the rear of the vehicle.
Lift the rubber cover (B) to access the 3rd end
cap then remove the 3rd screw (C) and end
cap.

i

Information

A

Do NOT remove rubber cover (B) from
the tonneau cover assembly.
Repeat this step for the other side of the
tonneau cover.
B

C

2.

Pull out the tonneau cover until the latch
assembly (D) passes the rear combination
lamp.

D

TSB #: 25-BD-011H-1

Page 6 of 17

TONNEAU COVER INSPECTION & REPAIR GUIDE

SUBJECT:

3.

Clamp one side of the tonneau cover to
prevent it from retracting.

NOTICE
Use a rubber or plastic clamp. Do NOT
use a metal clamp on the tonneau cover
to prevent damage.
4.

Visually inspect the plastic guide rails (E)
under the tonneau cover for displacement.
Reinsert the plastic guide rail(s) into the
track(s) if needed.
E

5.

Tilt the latch assembly downward then slide it
out of the tonneau cover.

TSB #: 25-BD-011H-1

Page 7 of 17

TONNEAU COVER INSPECTION & REPAIR GUIDE

SUBJECT:

6.

DIGITAL
DOCUMENTATION

Using the STUI camera function, take a
photo of the original latch assembly next
to the replacement latch assembly.
Upload the photo to STUI.
NOTE: If the STUI camera function is
NOT used, write the last 6 digits of the
VIN and date of repair on a piece of
paper to include in the photo.
7.

Slide the new latch assembly into the tonneau
cover.

8.

Reinstall all parts in the reverse order of
removal.

9.

Confirm the end caps seals are properly
reassembled.

i

Information

The lower seal MUST overlap the end
cap, not be underneath.
The upper seal MUST be completely
flush with the end caps.

10.

INCORRECT

INCORRECT

CORRECT

CORRECT

Confirm the latch properly operates.

TSB #: 25-BD-011H-1

Page 8 of 17

TONNEAU COVER INSPECTION & REPAIR GUIDE

SUBJECT:

Tonneau Cover Repair
1.

Remove the two 3 mm bolts (A) 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