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View Full Version : SUT Tonneau Cover Install Instructions and Photos


H2ummer
02-01-2009, 09:42 PM
I decided to put the Tonneau Cover (PN 12499433) on my SUT even though many had said "Take it to the dealer".
I ran into one issue and diverted from the Instructions. I thought it would be a better job than the way they said to to do. This involves installing some weatherproofing behind the Sail panels (See Do First 1). They have you pull back the Sails at the bottom, and try to work blindly with just your fingertips. So I just removed the Sails and put the weatherproofing on while the parts were in my lap. Below are the instructions followed by some install photos. It took me 4-5 hours to put it on, but could do another one much quicker, after learning what I was doing. I have been pleased with the outcome.
I purchased the Tonneau Cover from an Online dealer for right at $1,000 delivered to my doorstep. Shipping costs a bit, as it is about the size of a twin size mattress while it is in the box. The Retainer Clips (PN 11588882), that are needed if you pull the Sail Panel completely off I also got online for about $50 delivered.

Here are the instructions:

Do First 1 (http://fredericksburg-va.net/Tonneau/Do%20First%201.pdf) Do First 2 (http://fredericksburg-va.net/Tonneau/Do%20First%202.pdf) Install 1 (http://fredericksburg-va.net/Tonneau/Install%201.pdf) Install 2 (http://fredericksburg-va.net/Tonneau/Install%202.pdf) Install 3 (http://fredericksburg-va.net/Tonneau/Install%203.pdf) Install 4 (http://fredericksburg-va.net/Tonneau/Install%204.pdf) Install 5 (http://fredericksburg-va.net/Tonneau/Install%205.pdf) Install 6 (http://fredericksburg-va.net/Tonneau/Install%206.pdf)

The Photos right after the break.

H2ummer
02-01-2009, 09:57 PM
Ok, Here are the Photos starting with a shot of the bed without it.

http://fredericksburg-va.net/Tonneau/Tonneau1.JPG


Remove the Torx Screw.
http://fredericksburg-va.net/Tonneau/Tonneau2.JPG


Remove the Torx Screw.
http://fredericksburg-va.net/Tonneau/Tonneau3.JPG


At this point the instructions have you pull the Sail back and install the weatherproofing. See Do First 1. If you do as I did, you will need to remove the top Torx and Marker Light.
http://fredericksburg-va.net/Tonneau/Tonneau4.JPG


Remove Light.
http://fredericksburg-va.net/Tonneau/Tonneau5.JPG


Remove light mount.
http://fredericksburg-va.net/Tonneau/Tonneau5.JPG


Move the Light and mount out of the way so you can take the Sail Panel off.
http://fredericksburg-va.net/Tonneau/Tonneau6.JPG


Pull Sail Panel Back. If you move it back very far it will break the retainer clips. I went ahead and removed it so I broke all 7 retainer clips and replaced them with new ones that I had ordered.
http://fredericksburg-va.net/Tonneau/Tonneau7.JPG

H2ummer
02-01-2009, 10:19 PM
Here is one of the broken retainer clips.
http://fredericksburg-va.net/Tonneau/Tonneau8.JPG


Sail Panel removed and retainer clip holes exposed.
http://fredericksburg-va.net/Tonneau/Tonneau9.JPG


Backside of the Sail Panel with new 3M Tape and new Retainer Clips installed. Also the weatherproofing has been installed. Very easy to install the weatherproofing with it off.
http://fredericksburg-va.net/Tonneau/Tonneau10.JPG


Sail Panel in position to POP in using the new clips.
http://fredericksburg-va.net/Tonneau/Tonneau11.JPG


The Driver side with the Sail Panel removed and the broke retainer clips exposed.
http://fredericksburg-va.net/Tonneau/Tonneau12.JPG


Rail - Panel Brackets being laid out.
http://fredericksburg-va.net/Tonneau/Tonneau13.JPG


Panel Brackets Mounted to Rail.
http://fredericksburg-va.net/Tonneau/Tonneau14.JPG


Hatch Pin mounted to Rail
http://fredericksburg-va.net/Tonneau/Tonneau15.JPG


Install Rail pieces to both sides and set Cover in place. Then tighten the 6 bolts and nuts holding it down.
http://fredericksburg-va.net/Tonneau/Tonneau16.JPG


Install the Hydraulic Shocks
http://fredericksburg-va.net/Tonneau/Tonneau17.JPG

More to come after the break.

H2ummer
02-01-2009, 10:25 PM
Here is the Tailgate Latch Stop.
http://fredericksburg-va.net/Tonneau/Tonneau18.JPG


Hatch Pin Installed.
http://fredericksburg-va.net/Tonneau/Tonneau19.JPG


Cover Catch/Release
http://fredericksburg-va.net/Tonneau/Tonneau20.JPG


Vertical Seal (Installed earlier)
http://fredericksburg-va.net/Tonneau/Tonneau21.JPG


Other Vertical Seal
http://fredericksburg-va.net/Tonneau/Tonneau22.JPG

More To Come After the Break.

H2ummer
02-01-2009, 10:29 PM
All Done shown with Cover up.
http://fredericksburg-va.net/Tonneau/Tonneau23.JPG


Another completed shot.
http://fredericksburg-va.net/Tonneau/Tonneau24.JPG


Last One.
http://fredericksburg-va.net/Tonneau/Tonneau25.JPG

Intercooled
02-02-2009, 01:00 AM
Great tutorial! I already had mine when I bought my H2 but I will book mark this for future trouble shooting. Nice job! Now go get a GOBI bed rack!
:perfect10s:

pjensen
03-20-2012, 07:20 PM
Anyone still have these pictures and or instructions?? If so, please email to me at pjensen@copter.com

glennf1
03-21-2012, 01:55 AM
Better yet it would be better to post them back on this thread for everyone to see. I would love to see those instructions.

STL Zombie Hunter
02-08-2014, 05:03 PM
Better yet it would be better to post them back on this thread for everyone to see. I would love to see those instructions.

+1

fyr145
02-09-2014, 12:08 AM
im not seeing any photos at all.:(

H2ummer
02-10-2014, 03:57 PM
Instructions can be downloaded here. https://www.dropbox.com/s/7z6x13te7zdoom0/Tonneau%20Install%20Scans.zip

I can put the photos up there too, if someone needs them.

H2ummer
Wendell

clsimmon
01-13-2017, 04:03 AM
Does anyone have a copy of the instructions for installing the SUT tonneau cover? All of these links in this thread appear to be dead.