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I can think of two things that might give you some wiggle room. The vents on my '08 crew cab will almost come out. (I took one out so I could put a subwoofer behind the rear seat. I popped it out and it is still between the bed and cab but has moved slightly.)
1. Use a floor jack or a lift and lift up on the frame right under the rear of the cab. Try to get as much weight off of the rear wheels as you can. I doubt you would want to actually lift them off the ground.
2. Use a couple of ratchet straps and hook them to the hooks at the rear of the bed and then hook the top of the front wall of your bed and add tension, not so much though, just a little "stress". You might be able to gain some room and slide them out.
Now installing new ones? Seems like they press in from behind. I don't know about that......Just thinking out loud here.
yup. that be the problem. i can get them out without much effort. and if they complain coming out, i just break them apart. the pain in the azz part is getting them back in without breaking them or ripping the gaskets.
it is looking like i am just going to have to seam sealer weld a patch panel over the vent holes to shut them tight.
Some of the guys that have done the harpoon mod, jack the front of the bed up to access the fuel tank. Maybe that would allow you to get to the vents. It doesn't look like it was too difficult to do.
of the 32 bolts on the 4 beds i have had to remove, i have only sucessfuly take one bolt out. the other 31 had to be cut with a torch.
they are cut bolts. the nuts are a hair softer than the bolts and have no threads in them. when you run the self-tapping bolts in, they cut threads into the nuts, and the heat generated makes them almost welded together.
Sounds like it might be easier to take the back seat out (if you have one), measure the vent, look at it real good (if you have not already). Then go to Home Depot, Lowe's, Ace Hardware, O'Reilly, Autozone, NAPA, etc.... Walk around for a few hours and figure out a way to fix it another way.
Maybe a cab vent for a Chevy, Toyota, Nissan, Dodge, or a F150 would fit or inspire a solution.
I could be wrong, but I was under the impression they were rubber and could be squeezed into place from the inside of the cab. Never played with them...
they are two soft rubber flaps set into a hard plastic shell that clips into the back of the cab from the outside. there are 2 drop over tabs on bottom, with two locking tabs on top, with a sealing gasket to keep water out of the lip and the cab panel. i have already tried silicone all around to seal them with no luck. the gaskets are ripped, and the lock tabs are broke. apparently the previous owner liked to store crap behind the seat.
while they are a very good design when they work, when they don't work they stink. and accessing them for installation is a royal PITA.
i was looking this afternoon during a break in the rain, and i think i may just be able to sneak them in with some long thin pry bars and a lot of luck..
you shouldnt have to cut the bed bolts. i have a 04 and mine come right out with no problems. i just took the out again last week to re sand blast them and paint them again because of my rhino liner.
tjc, on my scale of 4-10, that sounds like a solid 6 on the beer scale. I tend to rate my chores by how much beer it will take to get it done. Notice that all chores start at 4. Frown on me or raise one up. It's all good.