423-ULLDEF – Defender Load Lugga Installation Guidelines.
The load lugga is a bolt in accessory which does not require any modification to
the vehicle.
The instructions for fitment detail vehicles with interior trim fitted in the rear,
Installation time approx. 1-1/2 hour’s max.
If your vehicle has no rear interior trim fitted, installation will be simpler and
quicker. ALL tasks are the same on BOTH sides of the vehicle
First task is to unclip the ends of the upper grab handles and remove the bolts
securing the handles on both sides of the vehicle.
Remove the 4 bolts and keep the bolts / handles safe.
Next is to remove the rear speaker trims (if fitted), these are held in place by 3
x plastic rivets, 2 on the rear door shut face and one under the carpet (if fitted)
You do not need to remove the trim completely, ie disconnecting speakers as
the speaker trims are only removed to allow the upper quarter trims to be
removed.
Next step is to remove the quarter window trims…these are held in place by 2
x spring steel clips at the door latch side of the back door. Indicated below…
The rear quarter window trims need to be removed carefully as possible as the
clips retaining them can easily break. Once the quarter trims are removed,
then remove the fur tree trim plugs retaining the side trims….one at the rear
door latch area shown below…..
And the remaining 2 indicated below…
Now you have to release the top of the interior trim. The trim is held into the
interior “gutter” by spring steel clips. The trim must be flexed “up and out”
over the gutters. DO NOT apply excessive force to do so. If you feel behind the
trim you will be able to feel the clips.
Clips located as indicated by red circles, “some” vehicles may have additional
clips indicated by the yellow circle.
NOTE :If you vehicle has additional accessories fitted like the window guards below, or
a dog guard….these must be removed prior to load lugga installation.
Once the trim is released, you should be able to see the bolts that hold the
roof panel to the vehicle body side panels.
The load lugga inner brackets are secured with at least 2 of the roof panel
bolts, on some vehicles 3 bolts may well line up with the slots in the brackets.
The image above is taken from below looking up. The roof panel bolts have
built in washers and are installed from below and screwed up to the roof
panel. You need to loosen 2 of the bolts as a minimum by 3-4 turns only.
The bolts are only needed to be loosened to allow the inner load lugga
brackets to be slipped underneath the bolts.
The inner brackets can then be fed behind the trim, NOTE :- the brackets are
handed with the small holes towards the front end, these 2 holes line up with
the grab handle holes in the inner trim.
Slip the brackets under the loosened roof bolts and tighten the roof bolts.
Once the inner brackets are installed, refit the removed trim panels and grab
handles in the reverse order of removal.
1. Side trims
2. Grab handles
3. Speaker trims (if fitted)
4. Quarter window trims
Next install the second bracket from the kit onto this bracket using 3 x M6
bolts and washers from the kit.
Repeat this bracket install again on the other side of the vehicle. Finally fit the
shelf itself onto the brackets and secure into place with the threaded plastic
thumbwheels in the kit. Install all the thumbwheels loosely first.
Finally, tighten the plastic handles HAND TIGHT only and fit the plastic nut caps
onto the M6 bolts holding the second set of brackets.