How to Install Tuffy Universal Lock Box Mounting Kit on your 1987-2013 Wrangler

PLEASE READ ALL INSTRUCTIONS THOROUGHLY BEFORE STARTING INSTALLATION.

Warning! Check the roof rack ratings for maximum load capacity less the weight of the Tuffy storage box and Tuffy mounting kit (55#), and any other items on the rack to calculate the Tuffy storage box load weight capacity. Clearance: Check vehicle clearance issues, adds 10 3/4” height.

Important pre-installation planning issues:

• The #3 Clamps are designed to fit around a 1” square or 1” round crossbar. For other diameter crossbars the #3 Clamps can be flipped backwards, this may require different length mounting hardware not supplied by Tuffy.

• The #3 Clamp brackets have obround holes which allow for some variance in the distance between the cross braces.

• The Tuffy storage box is predrilled for mounting it to a rack with the cross braces oriented front to back. Since there are a wide variety of racks on the market with different crossbar spacing and orientations they may require drilling additional/alternate holes in the Tuffy Storage box. In this case it is recommended that the unused holes in the Tuffy storage box be plugged with the additional hardware included, (8) ¼-20x3/4”
Screws, (8) ¼-20 Lock-nuts, and (16) ¼” Washers.

1. Install rubber seal on lid. The rubber seal should be installed on the 45 degree angle where it meets with the box when closed. (SEE FIGURE 1)

Warning! The side of the box with the lid opening must be facing the rear. Any other orientation can cause damage to the box and lid and create a safety hazard when operating the vehicle (See Figure 2).

2. Position the Tuffy Storage box on the rack (See above pre-installation planning issues for alternative mounting options). Clamp the box to the rack crossbars using (4) Clamp brackets #3, (8) 5/16-18 x 2 ¼” Grade 8 bolts #2.4, (8) 5/16 Lock-Nuts #2.1, and (16) 5/16 USS Washers #2.2. (See Figure 2)

3. Check to make sure the Tuffy storage box is securely clamped to the rack crossbars and cannot shift or loosen.

4. Check the lid and latching mechanism to be sure that both latches are engaging and working properly.

Warning! Always make sure the lid is secured shut by both latches before operating the vehicle. The latching mechanism and all the mounting fasteners should be checked and tightened monthly.

ATTENTION:

FREQUENT LUBRICATION IS NECESSARY ON THE LOCKING SYSTEM

The pushbutton lock contains an “O” ring seal to protect the interior from dust and water. If this mechanism is not lubricated regularly it will become difficult to operate and it may not return to its home position preventing the key from operating the lock. If this happens simply pull up on the pushbutton to manually bring it back to its home position. Lubricate the pushbutton with a light lubricant such as silicone spray. The pushbutton may have to be periodically disassembled and cleaned.​