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How do I repack/rewind tonneau after repairing end cap

Discussion in 'Gen 2 Prius Main Forum' started by Maureen G., May 23, 2021.

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  1. Maureen G.

    Maureen G. Junior Member

    Joined:
    Jul 31, 2019
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    Location:
    Waikoloa, Hawaii
    Vehicle:
    2005 Prius
    Model:
    N/A
    Aloha,

    My tonneau recently stopped retracting, so I pulled it apart and found the plastic holding the metal rod that the fabric wraps around had cracked on one of the end caps, allowing the rod to move out of alignment. I MacGyvered a solution, hammering metal discs into the voids in the molded plastic so the plastic is now back in alignment and the rod fits securely.

    My issue: Now I need to put the tension back into the rod and re-attach the caps while that rod is under tension so the tonneau wants to roll up on its own.

    Has anyone ever done something like this? How might I accomplish this task?

    TIA,
    Maureen
     
    #1 Maureen G., May 23, 2021
    SFO likes this.
  2. Mendel Leisk

    Mendel Leisk EGR Fanatic

    Joined:
    Oct 17, 2010
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    Location:
    Greater Vancouver, British Columbia, Canada
    Vehicle:
    2010 Prius
    Model:
    Touring
    I have no clue, but did get some interesting results googling:

    rewind roller blind

    Might be a similar mechanism.
     
    #2 Mendel Leisk, May 23, 2021
  3. Moses Bruh

    Moses Bruh Member

    Joined:
    Dec 20, 2018
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    Location:
    California
    Vehicle:
    2008 Prius
    Model:
    Four
    I remember i followed this video as a reference to assembling back the internals together. Im not 100% sure what i did, but i do remember i used a plier to turn the spring to load it up and holding it in place until you can put the cover onto the end to lock it in place. Exactly how many turns I dont think the video specifies and it was more or less trial and error. MAKE SURE not to over twist, it is safer to under twist and keep adding a few turns and testing it over and over a few times, than twisting too much and breaking the spring or the plastic hold that the spring seats into.
     
    #3 Moses Bruh, May 23, 2021
    Last edited: May 23, 2021
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