Tonneau Cover Fitting Instructions

Ford PX Ranger XL

Dual Cab With HeadBoard June 2013 - Current

Part Number: 10129 Package includes

� 1 x Tonneau Cover � 2 x Side Extrusion (Notched, 1400mm)

� 1 x Warranty Card � 1 x Tailgate Extrusion (1330mm)

� 2 x Bar Bracket (300474) � 1 x Rope Track (1410mm Long)

� 23 x 4 mm Rivet (300482) � 1 x Fitting instructions

� 1 x Lock Bracket � 3 x Drill Templates – PVC (including seal)

� 1 x Support Bar (300516) � 1 x Seal Tape x 1 (1.6m)

� 1 x Support Bar Cover - PVC Sheath

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– IMPORTANT – THE HEADBOARD ON THIS VEHICLE WAS CHANGED IN

MAY 2013.

PLEASE REFER TO THE IMAGE BELOW TO CONFIRM THE

HEADBOARD ON THE VEHICLE MATHCES THE IMAGE

ON THE RIGHT HAND SIDE.

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Table of Contents

1. TONNEAU COVER FITTING .............................................................................................................. 4

1.1 BASIC TOOL REQUIRED ................................................................................................................. 5

1.2 TONNEAU COVER INSTALLATION PROCEDURE ............................................................................ 5

2. TONNO LOCK ................................................................................................................................. 12

2.1 BASIC TOOL REQUIRED ............................................................................................................... 12

2.2 TONNO LOCK CONTENTS ............................................................................................................ 12

2.3 FITTING TONNO LOCK ................................................................................................................. 12

3. MULTI-FIT SUPPORT BAR .............................................................................................................. 12

2.1 BASIC TOOL REQUIRED ............................................................................................................... 13

2.2 MULTI-FIT SUPPORT BAR CONTENTS ......................................................................................... 13

2.3 FITTING MULTI-FIT BAR .............................................................................................................. 13

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1.1.1.1. TONNEAU COVER FITTINGTONNEAU COVER FITTINGTONNEAU COVER FITTINGTONNEAU COVER FITTING

NOTE To install this accessory, follow the fitting instructions precisely. Failure to follow these

fitting instructions could result in vehicle or accessory damage and/or serious injury.

• Be sure to recycle all discarded components and packaging following the local council guide

lines.

Ensure that appropriate clothing is worn and use safety equipment.

• Inspect the vehicle and note any damage or concerns found prior to accessory fitment.

• Ensure special care is taken and the applicable fitting instructions are followed to prevent

any damage to the vehicle and/or vehicle components.

• Protect and safely store any vehicle components that are removed.

• Ensure all bare metal surfaces are protected using automotive bare metal primer and

touch-up paint or suitable soft seal compound with rust inhibitor.

• Ensure metal swarf and dust is removed from all vehicle surfaces.

• It is advisable to seek assistance when lifting heavy components.

• Do not repair or modify this accessory in any way as this will void the warranty.

• Do not remove any of the accessory labels.

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1.1 BASIC TOOL REQUIRED1.1 BASIC TOOL REQUIRED1.1 BASIC TOOL REQUIRED1.1 BASIC TOOL REQUIRED

1.2 TONNEAU COVER INSTALLATION PROCEDURE

Step 1.

Required tools: Tape Measure, Drill, 4mm Bit, Non permanent marking pen

Using a 4mm drill bit, drill a hole 50 mm in from the edge and 9 mm up from the bottom of the rope track as shown in Figure 1a.

Measure and drill remaining 5 holes at 262 mm centers and 9mm up from the bottom edge of the rope track as shown in Figure 1b.

Figure 1a

Figure 1b

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Step 2.

Required tools: Tape Measure, Drill, 4mm Bit, Non permanent marking pen

Sit the flat side of the assembled rope track on the tailgate side of the headboard with the 'C' channel facing upward and align the bottom edge of the rope track with the bottom edge of the headboard then centralise the rope track as shown in Figure 2

Drill through the holes in the rope track and into the top edge of the tub working from the centre out, placing a 4mm rivet in each hole as it is drilled, but do not rivet.

Once all holes have been drilled, remove the rivets and disassemble the rope track, discard the dowels and clean any swarf from the tub.

Step 3. Required tools: Clear silicone adhesive & Gun, Rivet Gun, Apply a bead of silicone to the flat face of the 3 sections of the rope track as shown in Figure 3 then rivet the rope track sections into place

Figure 2

Figure 3

Figure 4

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Step 4.

Required tools: Tape Measure, Non permanent marking pen, Drill, 4mm Bit, Rivet Gun

Attach the side aluminium extrusions – Driver’s Side (1400mm Long).

Clean the top surface of the drivers side of the tub with a damp rag. Allow to dry. Remove the red backing tape from the under side of one of the side profiles. See Figure 4.

Step 5.

Required tools: None

Align the NOTCHED inside edge of the extrusion with the inside drivers side edge of the tub pushing the notched area side extrusion up against the headboard mounting area (already fitted) and slide the profile down keeping the taped surface square with the top of the tub until the tape contacts the top face of the tub. See Figure 5

Press down firmly to ensure adhesion

Step 6.

Required tools: Drill, 4mm Bit, Non permanent marking pen

Position the side template (1355mm Long) along the bottom edge and the front edge of the side extrusion, mark the locations onto the side extrusion with the Non permanent marking pen. Drill each of the marked locations through the aluminium and into the inside edge of the tub.

See Figure 6.

NOTE: Notches in template are to align with bottom of side alloy and front edge (Notched)

Figure 5

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Step 7.

Required tools: R i v e t G u n

Attach the bar bracket, ensuring the chamfered edge of the hole is facing up, by placing a 4mm rivet through each hole of the bracket and into the centre holes in the extrusion.

Apply rust inhibitor and rivet into place.

See Figure 7

Apply rust inhibitor and rivet the front and rear holes to complete attachment of side extrusion.

Repeat steps 4 to 7 for the passenger side of vehicle.

Step 8.

Required tools: None

Attach the tailgate aluminium extrusion.

(1380mm Long)

Clean the top surface of the driver’s side of the tub with a damp rag and allow to dry. Remove the red backing tape from the underside of one of the side profiles. See Figure 8

Step 9.

Required tools: N o n e

Centre the extrusion and align the inside edge of the extrusion with the inside edge of the tailgate and slide the profile down keeping the taped surface square with the top of the tailgate until the tape contacts the top face of the tailgate.

Press down firmly to ensure adhesion.

See Figure 9

Figure 8

Figure 9

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Step 10.

Required tools: Drill, 4mm Bit, Non permanent marking pen

Position the tailgate template (1380mm Long) along the bottom edge of the tailgate extrusion, mark the locations onto the tailgate extrusion with the Non permanent marking pen. Drill each of the marked locations through the aluminium and into the tailgate. See Figure 10.

NOTE: Notches in template are to align with bottom of side alloy and front edge (Notched)

Step 11.

Required tools: Rivet Gun

Apply rust inhibitor and rivet the tailgate extrusion to the tailgate to complete the attachment.

See Figure 11.

Step 12.

Required tools: 3mm Allen Key

Fit the adjustable support bar.

Refer to section 3.

Step 13.

Required tools: None

Slide the front rope of the tonneau cover into the rope track and centre the cover then drape the cover over the head board.

See Figure 13

Figure 10

Figure 12

Figure 13

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Step 14.

Required tools: None

Clip the drivers side of the cover onto the drivers side extrusion then attach the passenger side of the cover using the pull loops in the corners to help stretch the cover.

See Figure 14

Step 15.

Required tools: None

Clip the plastic onto the tailgate extrusion using the pull loops in the corners to help stretch the cover.

Step 16.

Required tools: Tape Measure, Non permanent marking pen, Scissors.

Fit Seal Tape between Headboard and Tub.

Cut 2 pieces from the supplied seal tape 270mm long. use the supplied Seal Template to mark and cut 1 piece to suit the drivers side of the headboard and 1 piece to suit the passenger side of the headboard. Refer figure 16

Figure 14

Figure 16

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Step 17.

Required tools: None

Partially peel the backing paper from the drivers side seal. Align the notched section and the first hole to the vehicle and apply the seal tape to cover the gap between the headboard and the cabin end of the tub. Refer figure 17

Remove the rest of the backing paper and finish applying the seal.

Repeat for Passenger side.

Step 18.

Required tools: Drill, 4mm Bit, Rivet Gun

Use the remainder of the tape to cover the remaining gap between the center section of the headboard and the cabin end of the tub. Overlap the remaining tape evenly at both ends (approx 30 -40mm) Refer figure 19

You can adjust your tonneau, to make it tighter or looser,

by simply raising or lowering the height of your tonneau support bar.

Figure 18

Figure 17

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2.2.2.2. TONNO LOCKTONNO LOCKTONNO LOCKTONNO LOCK

The Tonno Lock is now a standard feature included with all Tuff

Tonneaus. The Tonno Lock is situated at the front of the tonneau

cover, so as not to impede the accessibility of the Tuff Tonneau.

Fitting the lock is simple and only requires a small attachment on the

inside edge of the tub behind the cab. Together with a padlock, it

provides you with an extremely effective theft deterrent. The Tonno

is designed to suit all utes and prevent thieves stealing your Tuff

Tonneau, so you can continue to rely on the Tuff Tonneaus’ name to

you what you want in a tonneau cover.

2.1 2.1 2.1 2.1 BASIC TOOL REQUIREDBASIC TOOL REQUIREDBASIC TOOL REQUIREDBASIC TOOL REQUIRED

Rivet gun, Drill, Torch, and Marking Pencil/Pen.

You will need to buy a small Padlock- make sure the padlock will go through the hole on the Tonno lock.

2.2 2.2 2.2 2.2 TONNO LOCK CONTENTSTONNO LOCK CONTENTSTONNO LOCK CONTENTSTONNO LOCK CONTENTS

- 2 X 4MM Aluminium rivets

- 1 x Tonno Lock bracket

2.3 2.3 2.3 2.3 FITTING TONNO LOCKFITTING TONNO LOCKFITTING TONNO LOCKFITTING TONNO LOCK

1. Attach the black lock bracket to the bracket on the tonneau with your padlock, and fit the tarp.

2. Getting under the tarp with a torch, place the lock bracket against the body and mark holes with a pen.

3. Remove tonneau and drill the marks with a 4 mm drill bit, place the lock bracket in position and rivet.

3.3.3.3. MULTIMULTIMULTIMULTI----FIT SUPPORT BARFIT SUPPORT BARFIT SUPPORT BARFIT SUPPORT BAR

The Tuff Tonneau Multi - Fit Support Bar is designed to fit almost all

Utes on the Market, from Subaru, Brumby’s, to Cab Chassis and

aluminium trays.

Part No: 300516

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2.1 2.1 2.1 2.1 BASIC TOOL REQUIREDBASIC TOOL REQUIREDBASIC TOOL REQUIREDBASIC TOOL REQUIRED

Drill, 4mm drill bit

2.2 2.2 2.2 2.2 MULTIMULTIMULTIMULTI----FIT SUPPORT BARFIT SUPPORT BARFIT SUPPORT BARFIT SUPPORT BAR CONTENTSCONTENTSCONTENTSCONTENTS

- 1 x hollow bar centrepiece - 2 x grub screws

- 2 x solid bar end piece - 1 x Tonneau bar sheath

2.3 2.3 2.3 2.3 FITTING FITTING FITTING FITTING MULTIMULTIMULTIMULTI----FIT BARFIT BARFIT BARFIT BAR

1. Insert solid bar pieces into either end of hollow tube. Adjust bar so it fits between bar bracket holders

the holes facing to the ground (so the grub screws don’t rub against the tonneau), as shown above and

with a white pencil make a mark through the small holes of the hollow bar onto the solid ends. This is

where you will drill a hole to the depth of about 1-2mm (do not go any further)

2. Join the pieces back together and screw grub screws through the hollow bar into the holes that you

drilled. Make sure you do not over tighten the grub screws. Then place the tonneau

sheath over the bar to stop the bar wearing against the tonneau. Refit the bar. You may kink the bar in

middle to give it some extra height to assist with water runoff.

3. Warning if you do not fit the tonneau sheath over the bar, the tonneau cover will quickly wear through

which is not covered by warranty.

Your Tuff Tonneau is now ready for work.