Thunderbolt Van Lock Model 1 User manual

Installation Guide
Van Kit Lock Models
®
Protect your valuables, cargo, and livelihood.

We appreciate your trust in our company and look forward to signi-
cantly improving your van’s security.
This booklet is only a guide to installing Thunderbolt® locks and is not
a complete or comprehensive manual since every vehicle is different
from year to make and model. We recommend consulting a profession-
al installer or up-tter if you are not comfortable with the installation
process at any time.
You can follow this guide to walk you through the installation process;
however, we encourage you to watch the “General Installation” video
on our website. Keep in mind we continue to update our website with
installation tips, photos, and videos.
Additionally, we are here to help; our goal is for your installation to go
smoothly. If you need guidance, feel free to contact our team. If you
have any questions regarding your order, please email us directly at
[email protected] or call us, and one of our customer service
representatives will get back to you.
Please note: Thunderbolt® deadbolt locks are intended to protect
contents and should NOT be engaged while the vehicle is occupied by
persons as a safety precaution. The Thunderbolt® manual release knob
should be installed in a location that is easily seen and easily accessi-
ble. Be sure to read the entire installation guide prior to installing the
locks.
Best regards,
Team Thunderbolt®
2.
®

Lock Case
Lock Housings
(1) Straight or
(1) Angle
Manual Release Knob
Wire Extensions
(colors will depend
on lock ordered)
(1) Strike Plate
(1) Backer Plate (optional use)
These plates are identical.
Emblem Plate
(8) Self-Tapping Screws
Suggested Tools
Kit Contents
Van Lock Kit Models
(2) Mounting Brackets
Deadbolt
Tape Measure
3/32” Hex Key
(Included)
5/8” Wrench Wire Crimper Electrical TapePliers
Step Drill Bit Power Drill with Bits Rivet Gun
(Recommended)
3.
(2) Small Rivets
(6) Large Rivets
(2) Wire Connectors
Marker
3/32” Hex Key
Marking Gum
Van Lock Model 1 (M1)*
Factory Key-Fob Controlled
Van Lock Model 2 (M2)
Built-In Remote Control
*Available with Lock Inhibitor or without.

We suggest watching the general in-
stallation video on our website to get
a feel for the process before starting
your installation.
Every van application is a bit different,
but the installations are similar overall.
If you plan on installing multiple locks,
we suggest starting with the rear
swing doors.
WHICH DOOR SHOULD THE LOCK
GET INSTALLED INSIDE?
The lock should be installed inside the
driver’s side rear door. This is because
a metal edge usually protrudes out on
most vans that can obstruct the bolt.
Some vans that do not have the ex-
tended edge on the driver’s side rear
door are the Chevy Express and the
Nissan NV2500. These vans allow in-
stalling the lock in the passenger’s
side rear door. The advantage is that
the wiring for the factory lock motor
is already in that door. If you’ve pur-
chased the Strike Plate Bracket ac-
cesssory, it can allow for installations
in the passenger’s side rear door on
almost any van.
Watch the General Installation Video before
beginning your installation. You can scan the
QR code with your phone or visit our website.
Ford Transit
On the Ford Transit for example the lock
housing gets installed in the driver’s side
rear door because of the extending edge.
(See below)
Example of the Extended Edge
on the driver’s side rear door.
Example of NO Extended Edge
on the driver’s side rear door.
Scan Me
For Video
NO
Extended
Edge Extended
Edge
4.
Strike Plate Bracket (accessory)
this braclet can be installed on the
driver’s side rear door to allow for
passenger door lock installations.

REMOVE THE DOOR PANEL
Remove the panel cover from the
door where the lock housing will be
installed.
MOUNT THE CASE
Choose a spot that works best to
mount the case using the brackets.
The brackets can be cut or bent for a
custom installation. Once the location
is determined, attach the brackets to
the Thunderbolt® case using the four
rounded head bracket bolts provided
on the front of the case. (See below)
Always remember the cables’ loca-
tion when picking a spot to mount the
case. Additionally, ensure the location
does not impede the window from roll-
ing down the front doors.
Always keep your cables free
owing with “J” bends.
Example of the Extended Edge
on the driver’s side rear door.
Then mount the case with the brackets
attached inside the door cavity using
four supplied self-tapping screws. The
case can get mounted anywhere in the
door. We always suggest replacing the
self-tapping screws
with the rivets once the nal loca-
tion is determined. Keep your ca-
bles free-owing; you do NOT want
sharp-angled bends as they may bind
the cable.
The rounded head bolts are used to
secure the brackets to the case.
This photo shows where rivets have been
used to replace the self-tapping screws.
Brackets should be attached as shown on
left or can be cut to span a large opening
as shown on right.
5.
Bracket
Bolts
Cut bracket
to expand use.

MANUAL RELEASE LEVER
Select an ideal spot for the manual re-
lease lever and drill a 3/8” hole for its
installation.
Unscrew the knob and nut from the
manual release cable and guide it
through the drilled opening. Now se-
cure it with the nut and then screw on
the knob. (See below)
The manual release lever can be mounted in almost any position or location on
the door, as shown in the photos below, but be sure it is easily accessible.
Position the manual release lever where it is accessible and
visable by passengers. Place the provided manual release
sticker above the knob for identication.
6.

INSTALLING THE HOUSING
Determine if an angle or straight hous-
ing will better t your application. All
swing doors use a straight housing,
as do many sliding doors. However,
some sliding doors with a steep angle
use an angle housing. Visit our website
for info on your van make. Prepare to
drill a hole for the housing by making
sure there are no obstacles inside
the door, and that the mating door
has nothing to impede the strike plate
installation. This diagram shows the
locations of housings and strike plates
on a Ford Transit. Keep in mind that
every van is different and Thunder-
bolt® locks are universal, allowing for
various housing installation locations.
Straight lock
housing gets
installed in this
swing door.
Strike plate
gets installed
on this door.
Strike plate for the
sliding door gets
installed on the
side door C-pillar.
Lock housing gets
installed on this side of
the sliding door and can
be either a straight or
angle housing, depend-
ing which ts better.
Nothing
ever gets
installed on
this side of
the sliding
door.
Mark the spot for
the housing and
drill a 7/8” hole.
Then release
the deadbolt by
loosening the set
screws.
Unscrew the hous-
ing from the cable
and feed the
cable through the
hole and prepare
to reconnect the
housing.
The housing 7/8”
hole on the side
sliding door will
be drilled in the
edge of the door
on the left side.
The strike plate
7/8” hole will be
drilled on the side
door C-pillar.
7.
C-pillar
B-pillar
A-pillar

ATTACH THE HOUSING TO THE CABLE
With the cable extending through the hole in the door, re-
attach the housing by screwing it back on the cable’s end
tting, and then slide the deadbolt back on the cable. Next,
it’s time to adjust the bolt length inside the housing.
Note: A backer plate is provided in case your metal is thin.
It can be used or discarded as it is your choice. If you feel
your vehicle metal is thin, this plate will help reinforce the
housing installed. It should be installed over the housing on
the inside of the door. This is the time to keep it hanging on
the cable or remove it. You will install it in just a few steps.
DETERMINE THE BOLT LENGTH
Decide how far the deadbolt should extend out of the hous-
ing while at rest. Since the throw of the deadbolt is about
5/8”, extend the bolt out of the housing until it touches the
other door, then back it away from the mating door about
1/4“. Mark the length with the provided marker on the bolt.
SET THE BOLT LENGTH
Once you have decided the required length of where the
bolt should be sticking out of the housing, insert the dead-
bolt back onto the ex cable at the marked length and
lightly tighten down the set screws. Ensure the manual
release is entirely in the “unlock” or “up” position before
tightening the set screws. This will ensure that the bolt will
fully extend.
TIGHTEN THE SET SCREWS (DO NOT OVER-TIGHTEN!)
The set screws are designed with dog ear tips to hold the
cable without the need to over-tighten. If you over-tighten
the set screw, you could damage the cable and hinder the
ability to make a second adjustment if needed. If this hap-
pens, you may need to order a replacement cable.
Measure the gap between doors (minus a 1/4”) and mark the bolt
with the marker. This is where the deadbolt should extend outside
the housing while at rest.
DO NOT OVER-TIGHTEN THE SET SCREWS! The set screws have a
dog ear end tip that secures the cable without the need for over-tightening.
8.

INSERT THE HOUSING
Now that you have the deadbolt secured to the cable inside
the housing, it is time to t the housing into the 7/8” hole.
Be sure the deadbolt has been appropriately adjusted to
clear the door as it will stick out a bit from the housing while
at rest, and we do not want the mating door to hit it when
closing. Do not secure the backer plate at this time. You
must make sure the bolt is hitting its target rst.
SECURE THE HOUSING IN THE DOOR
Using two of the self-tapping screws, secure the housing
into the door. Be sure NOT to close the door on the dead-
bolt while it is in its extended position. Use the manual re-
lease to disengage the bolt and test closing the door slowly
to see if it clears the mating door. If it doesn’t, remove the
housing and make the corrected adjustment on the dead-
bolt.
LOCATE THE MARK
Once the spot for the strike plate is marked with the mark-
ing gum, use the provided marker to enhance the marking
and prepare for drilling.
DRILL A HOLE FOR THE STRIKE PLATE
Drill a small pilot hole rst, then use the step drill bit to
achieve your 7/8” hole.
Use a tiny amount of marking gum and “center” it on the end of the bolt
for an accurate mark. Apply “very light pressure” for a few seconds when
marking. Use the provided marker to enhance the gummed spot.
9.
MARKING FOR THE STRIKE PLATE
Place a tiny bit of marking gum on the CENTER of the bolt’s
tip to mark where to drill the strike plate hole. Ensure the
deadbolt is retracted by using the manual release to disen-
gage the bolt. Wholly and slowly close the door and GEN-
TLY engage the deadbolt using the manual release knob.
Hold for a few seconds, and then release the knob. Do
not press the knob with a lot of force to prevent the inter-
nal cable’s kink. If you feel you may have kinked the cable
open the case cover to inspect the cable. If needed, gently
straighten the cable with long nose pliers as needed.

SECURE THE STRIKE PLATE
Before attaching the strike plate, slowly close the door and
ensure the hole is in the correct spot so the deadbolt will ac-
curately engage into it. Once you are certain that the dead-
bolt and strike hole will align, secure the strike plate using two
self-tapping screws. Now is the time to secure the backer plate
if you feel it will reinforce your application.
BACKER PLATE LOCATION
If you plan on using the backer
plate, it gets installed in this loca-
tion and must be secured with riv-
ets. The rivets get inserted through
the housing holes, the van’s metal,
wall, and the backer plate.
Model 1 connects to the existing factory lock wires in each door, and your current key
fob will operate your deadbolts. Each Thunderbolt® M1 kit lock includes a built-in lock
inhibitor to prevent the deadbolts from engaging while the van’s ignition is on as a safety
precaution.
Each Model 1 lock has a green and blue wire that connects to your factory lock motor
wires to control the locking operation. The white wire gets connected to a 12-volt ignition
source wire, and the black gets connected to common ground, and these will prevent the
lock from engaging while the vehicle’s ignition is on for safety. Keep in mind, van models
tend to use different color wiring, so be sure to consult your vehicle’s repair manual or test
the wires to know which ones are the factory lock wires.
Model 1 is also available without the lock inhibitor, whereas there will only be a blue and
green wire. These models are for cargo doors where passengers are never riding, such as
the rear doors of work vans.
10.
Most vans with power windows
have a 12-volt ignition wire at the
power window switch.
WIRING YOUR THUNDERBOLT® LOCKS
Thunderbolt® locks get connected in one of two ways, depending on which model you
choose. Model 1 operates in conjunction with your current locks via your key fob. Model 2
operates independently from an included Thunderbolt® remote controller.
WIRE COLORS:
White = Ignition
Black = Ground
Blue = Lock
Green = Lock
Van Lock Kit Model 1 (M1)
Factory Key-Fob Controlled
NOTE: Power contact
switch will be needed
to connect ignition relay
wiring in side sliding
doors if passengers will
be present.