NHTSA ID Number: 11027055
Manufacturer Communication Number: 25-BD-011H-1 TSB
TSB/Document Date: 2026-01-06
Summary
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.
Cover Repair
Demonstration
B
2.
Remove 2 screws (C) then remove 2 end caps
from the rear of the vehicle.
Lift the rubber cover (D) to access the 3rd end
cap then remove the 3rd screw (E) and end
cap.
i
C
Information
Do NOT remove rubber cover (B) from
the tonneau cover assembly.
D
Repeat this step for the other side of the
tonneau cover.
E
TSB #: 25-BD-011H-1
Page 9 of 17
TONNEAU COVER INSPECTION & REPAIR GUIDE
SUBJECT:
3.
Pull out the tonneau cover until the 1st two
lamellas are hanging off from tracks.
4.
Rotate the axle (F) toward the rear of the
vehicle then engage the metal tension lock (G)
between the axle and the canister to lock the
axle in place.
i
Information
Ensure the side of the axle where the
rubber straps are installed is facing up
and accessible.
i
F
Information
Locking the axle in place will maintain
spring tension for the rest of the
disassembly procedure.
G
TSB #: 25-BD-011H-1
Page 10 of 17
TONNEAU COVER INSPECTION & REPAIR GUIDE
SUBJECT:
5.
While the spring is under tension, cut the
rubber straps (H) flush with the axle.
6.
Remove the tonneau cover (I) then place it on
a clean flat surface, such as a table.
i
H
I
Information
Ensure the sides of the tonneau cover
should hang over the edge of the table to
provide access to the lamella clips for
steps 9 & 14.
7.
Remove any debris from the canister with a
shop vacuum.
8.
Lubricate the side profile flocking strip (J) with
silicone oil.
J
TSB #: 25-BD-011H-1
Page 11 of 17
SUBJECT:
9.
TONNEAU COVER INSPECTION & REPAIR GUIDE
Remove the 2 clips (K) from the front lamella.
K
10.
Remove and discard the old rubber straps
from the tonneau cover.
11.
Slide the 3 axle connector clips (L) onto the
3 new rubber straps (M).
M
L
12.
Slide the new rubber straps (N) into the front
lamella.
TSB #: 25-BD-011H-1
N
Page 12 of 17
TONNEAU COVER INSPECTION & REPAIR GUIDE
SUBJECT:
13.
Evenly space the rubber straps (O) on the
lamella.
i
8 in.
8 in.
Information
O
The center rubber strap should be within
~2 inches from the center.
O
2 in.
24 in.
Center
14.
Remove the remaining old clips and replace
ALL removed clips with new clips (P).
i
Information
Install 20 clips (40 total) on each side.
The right clips are marked with “R”, and
the left clips are marked with “L”.
i
P
Information
Right Side
The circular end of the clip should be
oriented towards the rear of the vehicle.
Rear
Left Side
Rear
15.
Reinstall the tonneau cover but leave the first
two lamellas outside of the track.
TSB #: 25-BD-011H-1
Page 13 of 17
TONNEAU COVER INSPECTION & REPAIR GUIDE
SUBJECT:
16.
Evenly space the new rubber straps (Q) on the
axle adjacent to the removed rubber straps.
Q
Q
Old Rubber Straps
17.
Press the connector down onto the axle until it
snaps into place.
i
Information
Old Rubber Strap
An audible “click” should be heard when
the connector snaps onto the axle.
18.
DIGITAL
DOCUMENTATION
Using the STUI camera function, take a
photo showing the 3 straps with metal
connectors installed on the axle.
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.
19.
Carefully release the metal tension lock (R)
between the axle and canister, allowing the
cover to return to its tensioned position.
i
Information
The rear profile should NOT roll all the
way into the canister.
TSB #: 25-BD-011H-1
R
Page 14 of 17
TONNEAU COVER INSPECTION & REPAIR GUIDE
SUBJECT:
20.
Slide the remaining section of the tonneau
cover back into the tracks.
21.
Reassemble the end caps on both sides of the
vehicle.
Tightening Torque:
lb-ft
1.1
lb-in
13
N.m
1.5
i
Information
Slide the rubber cover into the slot to
cover the 3rd screw.
i
Information
The lower seal MUST overlap the end
cap, not be underneath.
The upper seal MUST be completely
flush with the end caps.
TSB #: 25-BD-011H-1
INCORRECT
INCORRECT
CORRECT
CORRECT
Page 15 of 17
TONNEAU COVER INSPECTION & REPAIR GUIDE
SUBJECT:
22.
Close the tonneau cover lid (S) then tighten
the two 3 mm bolts (T).
T
Tightening Torque:
23.
lb-ft
1.3
lb-in
16
N.m
1.8
S
Confirm the tonneau cover properly operate.
NOTICE
Ensure the cover does NOT retract too
fast and slam into the canister.
24.
If necessary, adjust the tension of the spring
by pressing and turning the knob, right to
tighten (increase speed), and left to loosen
(decrease speed).
NOTICE
Ensure the cover does NOT retract too
fast and slam into the canister.
NOTICE
Do NOT use a power tool for this
adjustment.
NOTICE
U
Make sure the tension knob (U) is pushed
all the way in to prevent damaging the
plastic teeth when turning.
U
FAIL
25.
PASS
Verify proper tonneau cover operation and that
NO V-gap exists (if applicable).
TSB #: 25-BD-011H-1
Page 16 of 17
SUBJECT:
TONNEAU COVER INSPECTION & REPAIR GUIDE
Proper Tonneau Cover Operation
i
Information
Inform the customer how to properly operate the tonneau cover using the tips below.
•
ONLY use the pull strap or center handle to
close the tonneau cover.
•
The tonneau cover should ONLY be closed by
pulling from the center.
•
Do NOT pull from the sides.
•
Alignment / retraction problems may occur if the
tonneau cover is repeatedly improperly closed.
NOTICE
Do NOT slam the tonneau cover closed
with excessive force. This may cause
damage to the cover.
•
Secure the pull strap (A) to either side of the
bed when NOT in use.
•
Pulling the strap to the left will reset the latch
center handle position.
TSB #: 25-BD-011H-1
A
Page 17 of 17
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TSB/Document ID: 25-BD-011H-1 TSB
Replacement Service Bulletin Number:
MFR Communication Date: 2026-01-24
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: STRUCTURE:BODY
MFR Component System:
MFR Component Subsystem:
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