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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Tonneau Cover Fitting Instructions · Tonneau Cover Fitting Instructions Ford PX Ranger XL Dual Cab With HeadBoard June 2013 - Current Part Number: 10129 Package includes 1 x Tonneau
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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
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
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