Tuffy Security 240 User Manual

INSTALLATION INSTRUCTIONS

Please read and fill out the enclosed warranty registration card to activate your warranty.

SHIPMENT CONTENTS

DRAWERS #240

#1 Lid #2 Rear #3 Left side panel #4 Right side panel

#5 Left side bracket #6 Right side bracket #7 (2) Trays

10.10 (2) 1 7/16” Seal #10.6 (2) 4 1/8” Seal #10.5 (2) 5 7/16” Seal #10.8 Rubber seal

HARDWARE PACKAGE

#10.1 (4) 3/8 x 5/8” Bolts (2 are used in packaging) #10.18 (10) ¼-20 x ¾” Screws #10.15 (2) 10-32x1 ¼” Screw

#10.11 (4) ¼-20x1” Knob Screw #10.17 (10) ¼-20 Nylock nuts #10.19 (2) ¼-20 Hex washer Nuts #10.13 (2) 10-32 Rubber
Well Nut

#10.2 (4) 3/8” Fender Wash #10.3 (4) 3/8” Wash #10.16 (16) ¼” Wash #10.14 (2) #10 Wash #10.4 (4) Rubber spacers

TOOLS REQUIRED

• All applications: Ratchet, 7/16” socket or wrench, Phillips head screwdriver, T-50 Torx, T-40 Torx, 1/8” Allen wrench, 7/32”
Allen wrench and a utility knife.

• Additional tool requirements for TJ 1997-2002: ½” Socket

• Additional tool requirements for YJ: ½” Socket, T-30 Torx, (Optional: Drill & 3/8” bit)

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INSTALLATION

PLEASE READ ALL SAFETY WARNINGS AND INSTRUCTIONS THOROUGHLY BEFORE STARTING INSTALL

• NOTE: THIS DECK ENCLOSURE ASSEMBLY IS DESIGNED FOR USE IN VEHICLES WITH THE OEM FLOOR

CARPET IN PLACE. ADJUSTMENTS TO SOME MOUNTING POINTS AND/OR THE USE OF SPACERS (NOT
INCLUDED) MAY BE REQUIRED FOR PROPER ALIGNMENT IF NON-OEM CARPET OR NO CARPET IS USED.

•

For safety do not place any items on top of the enclosure that are not adequately secured to the
vehicle to prevent movement in the event of an accident or abrupt speed changes.

1. Remove the bolted-on protective metal brace from the front edge of the lid. Save these bolts #10.1 they will be
reused.

2. Install the lid hardware on all (4) welded studs by sliding #10.4 rubber spacers on first then #10.2 fender washer, 10.3
washer and #10.1 Bolt. (See Figure 1)

3. Cut and install the #10.8 rubber seal on #1 Lid in the center of the flange as illustrated. (See Figure 1)

Figure 1

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4. Install the pre-cut trim seal #10.5 and #10.6 on both side brackets #5 and #6 as illustrated with the bulb facing the
inside of the enclosure assembly. (See Figure 2)

5. Install the pre-cut trim seal #10.10 on both side brackets #5 and #6 with the bulb overlap protruding toward the inside
of the enclosure assembly. (See Figure 2)

Figure 2

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