WEATHER GUARD 178-X-01 through 181-X-01 User Manual

Page 2

CAUTION

INSTALLATION INSTRUCTIONS

CAUTION

WARNING

To keep debris out of your eyes when checking the underside of the vehicle, or when drilling, always wear protective eye wear.

Note:

• If your pickup is fitted with a plastic drop-in bed liner, it may need to

be drilled, trimmed, or cut for proper installation of truck box.

• Truck box cover may not properly latch until box is fully bolted to

truck bed.

• Periodically check tightness of mounting bolts to insure proper

attachment.

• Use touch-up paint on any drill holes to prevent oxidation.

• Install boxes with vehicle parked on level ground.

Before marking the leg mounting holes, check inside the box for location of gas spring housing and components that may obstruct safe drilling.

Prior to drilling, so as not to cut or puncture fuel tanks, fuel lines, brake lines, electric wries, etc., check under vehicle for locations.

All floor mounting bolts near the gas tank area should be installed from the underside of the vehicle, to guard against the gas tank being punctured

in the event of a collision. This would mean not using Blind Fastener in this area. Holes drilled in this area should be 3/8”.

Step 1: LOCATE BOX IN TRUCK BED
• Mount Saddle/Cross Box first (if applicable).

• Place rubber mounting pads on bed rails.

• Place box into position on top of mounting pads.

Lock should be facing the rear of the vehicle.

• Support box with blocking until mounted.

• Square box to bed and level box so top is horizontal when viewed from rear.

• Leave a 5-6” gap between side box and saddle/cross box (if applicable).

• Make sure cover opens fully without interference.

Note:

Fasten leg mounting feet directly to bed floor not bed liners or mats.

Step 2: MARK AND DRILL MOUNTING HOLES

• Position rear leg as shown in Figure 1. Use square to ensure vertical orientation.

• Mark both holes at top of leg and both holes in truck bed floor.

Note:

To maintain full floor width between wheel wells, legs should be aligned with the inside edge

of wheel wells. The foot of the leg must be squarely mounted on or between the tops of floor ribs.

• Repeat leg placement and marking process for other leg. Remove box from truck.

• Drill all marks on box and truck with 3/16” drill bit. Redrill all holes with 1/2” drill bit.

• Install all Blind Fasteners (see Figure 1, 2 and 3).
Step 3: ATTACH BOX TO TRUCK BED

Note:

If you encounter interference with the mounting clamp and a stake pocket in the truck bed, it

may be necessary to drill a 1/2” hole in the truck box and use the “J” bolt instead of mounting clamp.
Note:

It is recommended that all fasteners be tightened hand tight first to ensure fit, then go back

and fasten securely with wrench.

• Place box back in original position.

• Install all bolts in leg mounting feet as shown in Figure 1.

• Insert the two mounting clamps as shown in Figure 2.

Note: Mounting clamp bolt may be difficult to turn due to the “lock nut” feature. Apply a small amount

of grease to bolt threads prior to installation to ease assembly.

MntngClampInstall.eps

Bed Lip

Mounting Pad

End Panel Slot

Mounting Clamp

Fender Washer

5/16"-18 x 2-1/4"

Hex Head Bolt

Figure 1

Figure 2

5/16"-18 x 2-1/4"

Hex Head Bolt
Fender Washer
Blind Fastener
5/16" Flat Washer

5/16" Lock Washer
5/16"-18 x 1-1/4"

Hex Head Bolt

Leg
Mounting Pad
Mounting Clamp

Blind Fastener

1/2" Holes

5/16"-18 x 1-1/4"

Hex Head Bolt
5/16" Lock Washer
5/16" Flat Washer

SideBoxInstall-1.eps