Auto Manual Resource: 06/25/09

UVS Operating & Applications Manual

The UVS is an Advanced Serial Diagnostic system which has been designed and developed to offer the most advanced diagnostic capabilities. The UVS can be used as a hand held portable diagnostic system, and is equipped with 64MB of RAM which is used for the application data, and 4MB of Flash for the protocol handling system. In addition to this it has a RS232 interface connection for transferring application data from a PC and printing.

The unit has a 128×64 Dot Matrix Back Lit LCD TFT display along with membrane keypad. The unit is capable of reading fault codes, clearing fault codes, displaying live data, performing special functions, and recording live data both statically and on the road. The unit is powered from the vehicle battery, and connects to the serial diagnostic connector through a 25way D-Type cable system.

POWER CONNECTION
The unit is powered by the vehicle 12 volts battery which is connected to the diagnostic socket. If no power is available through the vehicle diagnostic socket then the adapter cable will have the vehicle battery connections.

VEHICLE CONNECTION
The master cable UVS is used to connect the equipment to the various adapters available for the different vehicle connector types. This system enables the equipment to be kept up to date with the various diagnostic connectors at a reasonable cost.

LCD BACKLIGHT
The LCD BACKLIGHT is automatically switched on when the unit has power. This cannot be switched off or adjusted. If the unit is not used for a period of time the LCD backlight will automatically switch off, and as soon as any key is pressed it will switch back on again.

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RTS 2002 Towing Manual

Ford Motor Company salutes the towing industry and applauds you for your many fine years of service to the automotive industry. We will continue to work with you to provide our customers and yours with damage-free towing. This manual contains the latest towing procedures for 2002 Ford, Lincoln and Mercury passenger cars and light trucks. As you turn the pages of this book, you will find the instructions easy to follow with clear illustrations showing the correct hook-up for damage-free towing.

As an additional safety measure, be sure you use safety chains on every tow, including wheel lift and flat bed hook-ups. This will prevent you from losing the vehicle in the event of equipment failure or vehicle breakage at the tow chain attachment.
New materials and aerodynamic styling require new methods of towing to eliminate the possibility of vehicle towing damage. Wheel lifts and flatbed equipment are required to tow many vehicles. Refer to the instructions given for the specific vehicle you are towing.

Preparatory Steps
Release the parking brake, and place transmission/transaxle in NEUTRAL. As a general rule, vehicles should be towed with the drive wheels off the ground. If the vehicle is to be towed on its drive wheels, the transmission/transaxle and differential must be operable. If the transmission/transaxle is not operable, place the rear wheels on a dolly or disconnect the rear driveshaft on rear wheel drive vehicles. DO NOT disconnect the driveshaft on Lincoln LS, Thunderbird or Mustang; refer to the caution in Lincoln LS, Thunderbird or Mustang portion of this manual. If the differential is not operable, place the rear wheels on a dolly. When a vehicle is towed on its front wheels, the steering wheel must be clamped in the straight ahead position with a steering wheel clamping device designed for towing service use, such as those provided by towing system manufacturers. Do not use the vehicle’s steering column lock to lock the wheels in a straight ahead position when towed from the front or rear. If the ignition key is not available, place a dolly underneath the driving wheels of the vehicle and tow with the non-drive wheels raised.

Flat Beds
When using a flatbed to transport a vehicle, always use T-hooks inserted in the appropriate tie down slot. Never fasten J-hooks to any suspension or driveline component because J-hooks will damage driveline and suspension components. When using winches, take care to avoid damaging the bumper system, lower body panels, or air dams. On vehicles equipped with an air suspension system, be sure the air suspension service switch is turned off prior to vehicle tie down. Refer to Owner Guide for switch location.
CAUTION: Improperly tying down a disabled vehicle may damage the vehicle’s suspension, driveline or body parts.

Towing Slings
To avoid possible damage to bumper system, lower body panels, or air dams, a belt sling should be used to lift and tow all vehicles. When attaching towing slings, take care to avoid damage to license plate and frame, or fog lamps, if equipped.

Towing Speeds
See specific model instructions for vehicle towing speed and distance limitations.
UNLTD = Unlimited speed or mileage.
On rough pavement, the maximum towing speed is 35 mph (55 km/h). Maximum towing speed of 35 mph (55 km/h) should be used whenever the tow truck operator is not sure of road surface condition.

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Ford Territory 2004 onwards - Ford FG Falcon 2008 onwards Installation Manual

This manual is used for Integrated DVD Rear Seat Entertainment System in to Ford Territory 2004 onwards, Ford BA Falcon 2003 onwards, Ford FG Falcon 2008 onwards.

Step 1
Disconnect cable from the negative battery terminal.
Step 2
Remove existing front seat headrests from vehicle by disengaging the pole guide lock and lifting the headrest in upwards direction.
NOTE: Identify the type of seat back by inspecting the rear of the seat if it is plastic it is a hard back type, if it is a material type it is a soft back type.
Step 3
Hard-back Seat
Remove the 2 screws holding the back seat trim panel. Remove panel by sliding in a downwards direction. Repeat for opposite seat.
Step 4
Soft-back Seat
Starting at the bottom of the left-hand side of the seat, unclip the plastic retainer and work up towards the top separating the retainer. Repeat on the right side of the seat.
Step 5
Unclip the plastic retainer at the top of the seat-back. Work across the seat separating the retainer.
Step 6
Using the flat-blade screwdriver, release the 2 scrivet clips. Remove the scrivet clips and slide the seat-back in a downward direction to remove.

Get pdf Ford Territory 2004 onwards - Ford FG Falcon 2008 onwards Installation Manual

Front Wheel Drive vs. Rear Wheel Drive in the Light Vehicle Marketplace

A lot of ink has been spilled in recent years over the subject of a vehicle’s driven wheels - specifically, which set (front or rear) should receive the power? This issue has become particularly relevant in recent months because several important upcoming products are to be based on natively rear drive platforms (note: we use the term ‘natively’ since a number of vehicles, both FWD and RWD, are available with AWD systems). A significant number of investment dollars may be poured into the factory retoolings necessary to manufacture rear wheel drive passenger cars, so in this Observation we would like to examine the larger market trends behind these investment decisions.

Market Shifts
Driven primarily by the need for better fuel economy and more efficient utilization of interior space, Canadian consumers embraced the first generation of mainstream front drive products in the early 1980s. In 1982, 46.6 percent of Canadian passenger car sales represented natively FWD vehicles. That percentage had increased to 94.8 in 2001, and by the early years of our present decade, the rear drive layout (representing just 5.2 percent of the market in 2001) had become the exclusive domain of low volume Luxury and Sports cars. Manufacturers like Toyota have demarcated their mainstream and premium passenger car lineups along FWD/RWD lines. The volume Toyota brand remains exclusively front drive, while the majority of Lexus variants are rear drive.

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Model D-440A Refrigerant Gas Leak Detector User Manual

The D-440A features a long life heated sensor technology that is designed to detect the more current and difficult HFC refrigerants such as R-134a, R-410a, R-404a, R-407c, and R507 in addition to all HCFC (R22) and CFC (R12) refrigerants including SNAP approved hydrocarbon blends.

The D-440A’s unique digital leak size indicator takes the guesswork out of whether or not to repair a small leak. The digital display is independent from the audio alarm and sensitivity level, allowing the precise pinpointing of the leak source.

The D-440A does not require rechargeable batteries. An optional detachable UV light will soon be available that clips on to the probe to allow both electronic or UV detection with one tool.

Batteries:
Install Batteries: Remove screw located at rear end of unit and pull down hinged battery door to open as shown. Always insert all four batteries into the battery compartment in the same direction. Note polarity mark on the inside of the battery door for proper battery orientation.

Sensor:
Replace Filter: Unscrew sensor tip as shown to replace filter. Replace filter whenever it becomes visibly dirty or every 2 to 3 months depending on use. Replace Sensor: Remove sensor by pulling out of socket. Install the new sensor by aligning the notch in sensor cover with the raised keyway on sensor socket holder (see figure below).

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Steering drift and wheel movement during braking: static and dynamic measurements

This paper reports on an experimental investigation into braking-related steering drift in motor vehicles, and follows on from a previous paper by the authors in which it was concluded that braking can cause changes in wheel alignment that in turn affect the toe-steer characteristics of each wheel and therefore the straight-line stability of the vehicle during braking. Changes in suspension geometry during braking, their magnitude and the relationships between the braking forces and the suspension geometry and compliance are further investigated in an experimental study of wheel movement arising from compliance in the front suspension and the steering system of a passenger car during braking.

Using a kinematic and compliance (K&C) test rig, movement of the front wheels and the suspension subframe, together with corresponding changes in suspension and steering geometry under simulated braking conditions, have been measured and compared with dynamic measurements of the centre points of the front wheels. The results have enabled the causes and effects of steering drift during braking to be better understood in the design of front suspension systems for vehicle stability during braking.

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1999-2003 Ford F-Series 7.3L Power Stroke Edge Evolution Programmer Installation Instructions

Programming your vehicle may expose existing defects in your vehicle’s PCM that could disable your vehicle. It is advised that you do not program your vehicle in remote locations in case of vehicle failure.

All Edge modules and programmers are built to operate with OEM calibrations. When you take your vehicle to a service center they may, by your request or otherwise, update your vehicles calibrations. Therefore it is important that you return your vehicle to stock before taking it in for service. Edge updates its active products (i.e. those currently being manufactured) to work effectively with updated OEM calibrations. However, this process can take some time as Edge is not always made aware of calibration changes made by the OEM. In the case of discontinued products, Edge cannot ensure that your unit will work effectively if you take your vehicle to a dealership and you are given, by your request or otherwise, a new calibration. This is only for discontinued products.

Stock Program
The Evolution automatically makes a backup of your stock program from your PCM before writing a new program onto your PCM. This assures that you will have the stock program if/when you desire to reprogram your vehicle to its original stock program. It is strongly recommended prior to returning your vehicle to a service center or emissions check that you return your vehicle’s computer to the stock program. In the event that the service center re-flashes your vehicle’s computer (a common practice) and you have NOT returned it to stock, your Evolution programmer will be rendered useless. If this happens, call our technical support at (888) 360-EDGE and they can help you recover your Evolution for a small fee. Follow the steps included in this manual for returning your program to stock.

Tow Only Program
This setting is the lowest power setting. It is designed to provide a significant increase in horsepower and torque while still being safe enough to use for towing. While it isn’t necessary, a modified exhaust system will help improve overall performance and help reduce your EGT (exhaust gas temperature) levels.

Race Performance Program
If you plan to tow with this program, it is strongly recommended that you make appropriate modifications to your exhaust system and install an EGT (exhaust gas temperature) gauge to aid in the prevention of potential damage to your engine.

Extreme Performance Program
This is the highest performance setting for the Evolution. The fuel injection and fuel timing strategies are aggressively tuned to extract the maximum performance from your vehicle without sacrificing drivability or durability. The transmission strategy is modified to take advantage of the increased engine performance by providing quicker, firmer shifts.

Get pdf 1999-2003 Ford F-Series 7.3L Power Stroke Edge Evolution Programmer Installation Instructions

SMART/ryde Service Manual

The SMART/ryde ¡s an add-on axle suspension systBmthat utilizes MGR/ryde’s unique rubber springs. The primary features oí SMART/ryde are:
1. Use of triple rubber spring assemblies.
2. Position of rubber spring assemblies,
3. Maintains chasis suspension system, D dimension and driveline specifications.
4. Side to side adjustability to compensate for cross vehicle loading.
5. Specially valued shock absorbers.

The SMART/ryde suspension system provides:
1. A smooth rida. 2. Much improved handling. 3. Greater roll stability.
This service manual will provide information regarding routine maintenance and service instructions.

MAINTFNANCE
The SMART/ryde suspension utilizes MOR/ryde’s unique 100% natural rubber springs and rubber bushings. The rubber bushings and rutaber springs do not require lubrication, and maintenance is limited to periodic inspections to insure the rubber bushings and rubber springs are intact.
II-A SHOCK ABSORBER MAINTENANCE
The shock absorbers used on the SMART/ryde rubber suspension are specially valved and made specifically for MOR/ryde. The shock absorbers should be checked every 10,000 miles to make sure they are functioning properly, the bushings are not womr and the dust cover has not been damaged by road debris or stones. If a shock absorber is leaking or fails to operate, the complete unit should be replaced. The shock absorbers and iasteners can be ordered direct from MOR/ryde. See Section lll-B for replacement procedures.
II - B FASTENER MAINTENANCE
The bolts and nuts should be periodically checked for proper torque - please see torque chart for proper specifications (Section IV)

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Fords and stock watering point

Two new fords and a stock watering point were creat-
ed in the restored reach of the river downstream of Coleshill mill. Upstream of the mill two new fords were created (see Part 1, figs. 1.1.1 – 1.1.2). Each ford enables livestock to cross the river easily, as well as doubling as a drinking place. Those upstream of the mill are also used by farm vehicles and those downstream form part of an equestrian trail. Although all are similar in concept the configuration of each is significantly different to take advantage of local topography.

DESIGN
Downstream of mill
All three features were created at locations where the old, straight river course was crossed by the newly excavated meandering course. Each is formed within the old backfilled river course where the soils are loose and susceptible to erosion. Rather than protecting the banks with revetments, each was set back from the true line of the new river by incorporating stoned access ramps (1:6 or flatter) to form either a ford or a stock watering point. As the new river bed at each point is filled to c. 1m above the old bed this too needed to be protected with stone surfacing.

Stock watering point at ch. 100m (fig.8.1.1)
Located at ch. 100m just downstream of a sharp bend in the new river course where a fast flowing riffle of gravel was expected to form. This hydraulic condition, combined with the careful contouring of the adjacent river banks, helps to avoid the risk of siltation that all too often renders watering points useless. The post and rail fencing around the ramp is tied into bank top fencing on either side, as well as across the river, to form a secure field boundary point.

The river fencing comprises a single heavy wire cable strained tightly across on a diagonal line (see photograph). The extra length of the diagonal renders the cable less likely to form a complete blockage of the river if floating debris becomes snagged on it. The angle of the diagonal is aligned to direct turbulence caused by its presence towards the mouth of the watering point, further reducing the risk of siltation. The ramp, its upstream flank, and the river bed are all formed over compacted fill, and flat surfaces are covered with stone over a filter fabric.

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Powerline for Standard Ford and Chrysler Owners Manual

The POWERLINE solid State Multi-Battery Isolator is a product of extensive heat-chamber engineering and testing. POWERLINE isolators are designed to handle the total current rating through either leg. All POWERLINE isolators are negative ground (some positive ground models are available), multi-battery systems. . Please contact the factory if you need positive ground product or if your system requires a special model.

CAUTION:
Isolator rating must be equal or greater than alternator amperage rating. Prior to starting isolator installation, start engine and run at fast idle. Measure voltage at the battery terminal, it should be about 14 volts. After installation, re-check above to confirm the same voltage. VARIOUS POPULAR AND SOME SPECIAL ALTERNATORS REQUIRE SPECIFIC ISOLATOR MODELS FOR PROPER OPERATION, e.g.: Delco CS series alternators require an 33-14 or 33-25 isolator. Some Motorola, Bosch and other similar alternators require an isolator with a regulator sensing terminal. To insure proper battery charging, some internally regulated alternators and all one wire alternators may require a wiring change to provide external voltage sensing for the voltage regulator.

Prior to starting isolator installation, start engine and run at fast idle. Measure voltage at the battery terminal. It should be about 14 volts. After installation, recheck above to confirm the same voltage.
1. Disconnect ground/negative cable from battery.
2. Mount isolator in location away from maximum engine heat and in a location that will let the isolator receive maximum air flow.
3. Remove all wires connected to original alternator output post. Move these wires to the #1 battery post on the isolator, if original factory alternator is used. If you are upgrading to a higher output alternator, tape off original output wire from original alternator. Consult wire size chart and install a new larger output wire from the system battery to the #1 post of isolator.
4. Install new wire from alternator output post to the “Alt” post of isolator. Make up a new #8 gauge minimum or refer to wire size chart for proper wire size based on alternator rating.
5. Attach auxiliary battery to the #2 auxiliary battery post of isolator. Again, refer to wire size chart for proper wire size.
6. If circuit breaker is going to be used, it would be installed next to auxiliary battery.

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Ford FR500 Mustang Steering Wheel Installation Guide

This install guide is for the FR500 Steering wheel, which I purchased from AmericanMuscle. It is one of the very few racing-style steering wheels that allow for a stock-for-stock swap from the regular steering wheel. You put the horn, airbag, and cruise control switches back in the original location. The FR500 steering wheel features a noticeable fatter, softer feel over stock. The stock steering wheel measures 1.21″ thick. The FR500 steering wheel measures at 1.42″ When buying the FR500 steering wheel from AmericanMuscle.com, remember that only the steering wheel is what you are purchasing. It does not include the airbag and cruise control switches. You will be re-installing your original airbag and switches. I will go into more details further in the guide. This install was done on a 1998 Cobra.

Getting Started:
1. Make sure that the steering wheel is in the upright position and that the wheels are straight.
2. Next, disconnect the battery. ALWAYS disconnect the battery before trying to disconnect the airbag. You are at risk of injury if the battery is not disconnected. The airbag is set off by an electrical charge, which is why the battery must be disconnected. Please wait at least 10 minutes after disconnecting battery for the airbag power supply to drain.
Removing the Airbag
3. Remove steering wheel spoke caps on both sides of the steering wheel. There is one on each side.
4. Now the 5/16 retaining screws for the airbag can be seen. Remove the screws.
5. Gently lift the airbag straight off the wheel and disconnect the yellow wire from the module on the airbag.
6. Carefully place the airbag in a safe place for now (we will re-install it on the new wheel). Make sure to put it face down (white plastic facing up) Removing the Steering Wheel
7. Next is to remove the horn switches. There are four allen head bolts holding them in. Remove the bolts and place the switches aside for now (will re-install on the new wheel).

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Superior Wheel Installation Guide

This is the process used to install the Turbo Wheel without having to remove the Turbo from your
Engine. It should take a maximum of 5 hours.

Procedure:
• Start by removing the Intake hose
o Remove all of the Intake tubes, exposing the turbo inlet.
o Remove the 2 bolts from the CCV intake mount.
o Move the CCV mount, exposing the 2 Philips screws. Remove the CCV filter from the valve cover. (watch for the O rings)
• Loosen the “V” clamp that connects the turbo to the “Y” pipe.
• Remove the waste gate actuator off the turbo housing followed by the compressor housing. (Remove the 2 bolts that hold the Waste gate actuator to the turbo, move it up and back)
• Loosen the “V” clamp that connects the turbo to the down (exhaust) pipe. Drop the down pipe (the clamp for the down pipe is a pain to break loose just loosen the bolt on it shoot it with some PB blaster tap it with a long screw driver and a hammer and it will pop loose).
• Remove all the bolts (5/16ths) from the turbo housing. (you will need the 6″ wobbly to remove
the bottom back bolt, due to the valve cover) Split the turbo, exposing the stock turbo wheel.
• With a screwdriver, wrapped with tape, insert it in the exhaust side of the turbo, just enough to get a screwdriver in there to keep the turbine from turning when you remove the old wheel. Catch one of the vanes, with the 5/8ths wrench; remove the stock wheel (left to loosen). Make sure you use a clean rag, the vanes are razor sharp. Loosen the bolts with the ratchet, and then use a cordless screwdriver to back everything out.
• Install the Superior Wheel, Torque to 100 inch pounds (or, real snug. it’s tightening in it direction of rotation).
• Remove the old wheel.
• Reverse the assembly procedure and you are done.
• Install the new Compressor wheel, (Do Not Over-tighten) hand tight, and then using a wrench about a 1/4 turn. Same as in removal, then Tighten with the ratchet.
• Make sure when you put the down pipe back that you have it aligned right so the clamp seats good and that the exhaust is not rubbing anywhere. PS: After the install, and after 4 or 5 warm-up cool-downs, check and re-tighten all turbo bolts. Use Red Loc-titer.

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How to Install Ford IDS

1. Close any open programs make sure you have at least 700mb free.
2. Insert the VCM disk into your DVD Rom drive.
3. DVD should automatically run the disk, if not go to My Computer> and open the Purple Icon. Note: In this picture its labeled V2006.5-43, yours may be different depending on its manufacturing date.
4. Once you have opened the program or it has begun to run you will be presented with this screen.
5. Click on IDS.
6. Another window will open once the installation begins. It will ask you to select your language. After you select your language click “Next”
7. The next window tells you that IDS will be installed onto your computer.
8. After clicking “Next” the End User License will come up asking for your agreement. Click “I accept…” and “Next”
9. The next screen will inform you of IDS and Firewall Compatibility.
10. After Reading the Information Carefully, click “I have read and understand….” and click “Next.” Note: If you are unsure if IDS will work with your Firewall click IDS Troubleshooting Guide. It is best if you do not use any firewall or antivirus.
11. The next screen will ask you where you want to install IDS at. Click “Next.”
Note: Unless you have multiple Hardrives the C Drive will be the default drive.
12. The next window tells you that IDS is ready to be installed. If you are satisfied with your selections in the previous steps click “Install.” If you want to make any changes click “Back.”
13. Now the installation has begun, it is possible for multiple windows to open while the program is installing. Do NOT manually close any of these while the program is running, doing so could cause the installation to fail.

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2005–up Mustang “ENGINE START” Push-Button INSTRUCTION SHEET

The following information describes the installation procedure for the M-11572-GT “ENGINE START” push-button into a 2005-‘08 Mustang.
STEP 1: Start by removing the (2) screws found at the rear of the center console underneath the armrest. (Figure 1)
STEP 2: Remove the trim plate which surrounds the Shifter Handle (Auto) or Shifter Boot (Manual). (Figure 2)
Note: Manual transmission applications will require removing the shifter knob first. This can be removed by simply unscrewing it in a counter-clockwise direction.
STEP 3: Fully extend the E-Brake handle. Again, this will need to be FULLY extended to allow adequate clearance for removal of center console cover. (Figure 3)
STEP 4: Lift the center console cover beginning from the rear, and slide it past the emergency brake handle.
STEP 5: Remove the side cover from the center dash panel on the driver side. This is retained by clips, and can be removed by grasping from the bottom, then pulling straight back. (Figure 5)
STEP 6: Repeat the same for the side cover of the center dash panel on the passenger side.
STEP 7: Remove the (6) screws that retain the radio trim plate, using a ¼” nut driver.
STEP 8: Carefully remove the (3) plugs from behind, at the top of the radio trim plate. (Figure 7)
Note: These can be easily removed by depressing the tab located on the connector as seen in Figure 7. Each of the (3) individual connectors has a ‘release’ tab similar to that shown in Figure 7

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Ford Custom Graphs – 5.10E Install Instructions

The Ford Custom Graphs program is a powerful graphical tool that can be used to view Ford data in an easy-to-read graphical format. The Ford Custom Graphs program resides locally on the user’s PC. The following instructions explain how to install the program.

Prerequisites
The following items are required for the setup of your PC and your Windows OS:
• You must have one Gigabyte [1 GB] of free disk space for the Ford time series database, but, if necessary, you can put the database on a secondary drive.
• You must have local administrative rights to perform the installation on your PC; in order to create registry data in the Windows OS, and to satisfy other installation needs.

Installation
Installing the Software
1. Insert the Custom Graphs Install Kit CD-ROM into your CD-ROM drive.
2. Right-click the Windows “Start” button of your task bar, and choose “Explore”.
3. Click on FORD_GRAPHICS, which appears next to the drive letter of your CD- ROM.
4. You will see two command files in the directory listing of FORD_GRAPHICS.
5. Double-click on “1 Install Graphics Program”. Wait for the program to load and follow the on-screen instructions. When this program finishes, you are ready for the next step.
6. Double-click on “2 Install Graphics Database”. Wait for the program to load and follow the on-screen instructions.
7. If there is an upgrade kit [FGZ file] in the root directory of the CD-ROM, double-click it to install.
8. Check the task bar for active applications and close any Ford software applications that were associated to the installation process.

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EPIC for Windows v5.00 – Download and Install Instructions

EPIC for Windows is a powerful and easy to use application that helps analysts and portfolio managers maximize the usefulness of the Ford Data Base. EPIC – provides screening, sectoring, portfolio analysis, report generation, and custom variable creation. The following instructions provide a guide to downloading and installing the application on a single workstation.

Installing the Software
The latest version of EPIC is available for download from the Ford Update web site. Before installing the latest version of EPIC please verify with Ford Equity Research Technical Support that a security profile has been activated for you.
1. In Internet Explorer navigate to the link above.
2. Click on the EPIC for Windows Program (Version 5.00) link to download the software.
3. Enter your Ford user name and password.
4. If you get a File Download – Security Warning prompting to run or save the file, choose Run.
5. If you get a File Download – Security Warning stating that the publisher could not be verified, choose Run.
6. You will be presented with the EPIC for Windows Setup Program. Click Next to start the installation.
7. You will be prompted to select an installation folder. C:\EPICWIN is the default. Click Next

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Ford 6.0L Turbo Air Guide (TAG) install: 2003-2004

Remove the flexible rubber hose from the air filter to the hard plastic intake tube which connects to the turbo charger. Remove the bolts securing the hard plastic intake tube and associated tubing and clamp.

The picture to the left shows the orientation of the TAG to be inserted into the hard plastic intake tube.

NOTE: the supplied rubber O-Ring is installed on the TAG facing the plastic tube. The TAG will be inserted into the end of the tube which is connected to the turbo charger. Start the TAG into the tube as shown. Note that the tube has a ridged or recessed area that the TAG will fit into. The TAG is a snug fit into the tube so it may take a couple of tries to get it into the correct position.

When the TAG is properly inserted into the tube, it should look like the picture to the left. Install the intake tube, air filter hose and all associated connects to complete the job.

Get pdf Ford 6.0L Turbo Air Guide (TAG) install: 2003-2004

2005-2009 Ford Mustang V-6/GT Cold Air Induction System

Included in this kit: Inlet pipe, coupler hose, hose clamps, air filter, air filter shield, and rubber sealant strip. (2) M-4 screws.
Tools required: Small flat screwdriver or pick, 1/4″ ratchet, 8mm, and 10mm sockets, 2.5mm Allen wrench, T-20 Torx.
Step 1
Disconnect (–) negative battery terminal.
Step 2
Unplug the mass air meter by sliding the red colored locking clip back, and then squeezing the tab on the connector while pulling it from the mass air meter.
Step 3
Separate the PCV tube from the side of the inlet hose by twisting the green locking clip while pulling it away from the inlet hose.
Step 4
Loosen the hose clamp that attaches the inlet hose to the throttle body.
Step 5
Remove the bolt that holds the air filter box to the driver side fenderwell.
Step 6
Remove the stock intake hose/air box assembly from the vehicle by lifting the air box straight up and pulling the inlet hose away from the throttle body.
Step 7
Remove the plunger type fasteners that hold the radiator cover in place by gently prying/lifting the center (plunger) out, and then prying/lifting the outer portion out. Remove the radiator cover and set it aside.
Step 8
Unbolt the driver side radiator hold down plate, lift it off the radiator top post and set it aside.
Step 9
Place the supplied blue coupler hose over the throttle body opening and secure it with one of the supplied hose clamps.
Step 10
Remove the 2 Torx screws from the mass air meter and slide the meter out of the stock inlet hose, and then install it into the BBK inlet pipe using the supplied screws.
Step 11
Slip the inlet pipe/mass air meter assembly all the way through the shield. Place the BBK air filter over the end of the inlet pipe until it rests against the mass air meter bung. Secure the filter to the inlet pipe by tightening the supplied hose clamp. The end of the air filter will act as an isolator between the inlet pipe and the shield.
Step 12
Drop the inlet pipe/mass air meter/filter/shield assembly into position by placing the round hole on the front of the shield over the top post of the radiator and slipping the inlet pipe into the blue coupler hose on the throttle body.
Step 13
Tighten the remaining hose clamp over the blue coupler hose to secure the inlet pipe to the throttle body.
Step 14
Insert the original air box mounting bolt through the tab on the back of the shield and tighten it into the factory speed clip.

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1987-1993 Ford Mustang GT - 8Cyl 5.OL Installation Instructions

When working on under or around any vehicle exercise caution. Please allow the vehicle’s exhaust system to cool before removal, as exhaust system temperatures may cause severe burns. If working without a lift, always consult vehicle manual for correct lifting specifications. Always wear safety glasses and ensure saje work area. Serious injury or death could occur if safety measures are not followed.

Step 1 To begin removal of your OEM exhaust system, you will need to cut the tail-pipes just behind the mufflers. Remove the tail pipes from the OEM rubber insulators. Do not damage the OEM rubber insulators, as they will be re-used with your new system. Next unbolt the extension pipes from the H-pipe and remove the mufflers from their OEM rubber insulators. Do not discard the fasteners required to bolt the extension pipes to the mufflers, as they will be re-used.

Step 2: Remove the existing muffler mount brackets, and replace them with the new brackets supplied in the kit. Do not discard the OEM mount fasteners, as they will be re-used. Refer to diagram #2 for installation of the new muffler mounts.

Step 3 S Starting at the H-pipe, begin installing your new exhaust system by bolting up the front extension pipes with the flanges supplied in the kit and the OEM fasteners. Working rearward, install the mufflers, tail pipes and tips, using the supplied clamps, hangers and fasteners. Leave all components loose until a final position has been set.

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Ford 5.0L EFI Firewall Forward Russell Plumbing Kit Installation Instructions

Stock fuel rail disassembly
1. Make sure the vehicle is on level ground, and the gear selector is in park or 1st gear. Set the parking brake or chock the wheels.
2. Make sure that the vehicle has cooled down.
3. Disconnect the negative terminal on the battery.
4. Thoroughly clean the area surrounding the fuel injectors and the fuel rail. This will prevent debris from entering the fuel system or the intake manifold upon fuel rail/injector removal.
5. Relieve residual fuel pressure in the fuel system. Remove the dust cap cover over the Schrader valve located on the fuel tube leading to the rail. Hold a shop towel or rag around the valve while relieving the fuel pressure to prevent any fuel spray.
6. Using the EFI coupling release tool, disconnect the fuel feed and return lines. Use a shop towel or rag to catch any residual fuel remaining in the factory lines.
7. Remove the bolts holding the fuel rail to the intake manifold.
8. Remove the fuel regulator, vacuum hose, fuel rail, and the fuel injectors.
9. Inspect and replace the fuel injector o-rings if necessary.
10. You will also need to remove the remaining fuel hard tube (feed and return) running from the fuel rail to the lower firewall.

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Ford 2008 F250 / F350 Front Bumper Replacement Installation Instructions

Simple step to front bumber replacement:
1) Remove hood release latch from factory assembly on factory bumper. Set aside and retain factory hardware for future installation.
2) Remove 4 bolts beside tow hooks to remove factory bumper. Retain bolts and tow hooks for use in step 7.
3) Remove fog lights from factory bumper retain plastic pins and adjusting screw assembly for future installation.
4) Remove casing from factory fog lights and discard. Install fog lights to brackets located on backside of new bumper using hardware removed in step 2.
5) Lift bumper and align with truck frame and secure with (6) ½”x 2” bolts provided. ( see figure 3)
6) Install bumper support bracket provided to the backside of bumper using (4) ½”x2” bolts provided. ( see figure 4)
7) Adjust bumper and tighten all bolts with 75 lbs of torque.
8) Install tow hook removed in step 2 with original hardware. Plug in wiring harness to fog lights.
9) Install hood release latch removed in step 1 to bracket on new bumper.

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2005 Ford Front 6-8” Lift Kit Instructions

Step 1. Before you remove anything off the truck, measure the pinion on the front and rear axle differential. Make sure to record this measurement as we will want to put each axle back to this angle after the suspension lift kit is installed. This is especially important for the front axle. Putting the front axle back to the same measurement will keep the stock camber and caster.
Step 2. Jack up the truck and place a jack stand under the frame on each side of the truck. Jack the truck up enough so that the front tires are just barely off the ground. Take a motorcycle strap and wrap the strap around the differential and to the frame. This will help keep the axle in the generalproximitywhile the factory suspension is removed and the 4 link is installed.
Step 3. Remove shock absorbers, coil springs, swing arms, rear swing arm pivot, and sway bar.
Step 4. Use a ¼”drill and drill out the center of the rivets that hold the coil brackets to the frame. A couple of the rivets you may not be able to drill. Next, use a cutoff wheel, grinder, or rivet buster to remove the heads of the bolts. You can use a torch, but it will be more difficult to punch out the rivets. Chances are you will have to use a grinder and grind the slag off the rivets flush with the stamped part.
Step5. Locate upper bag mount and drill out the four 3/8” rivet holes in side of the frame to ½” Bolt the brackets to the side of frame using the four ½” grade 8 bolts. Make sure to check the back side of the frame for brake lines, fuel lines and on the Excursion, heater lines.
Step 6. Locate rear trailing arm bracket and fasten to the frame using the ½”bolts provided. You will first have to remove the factory transmission cross member. It will be required to drill the (4) holes in the bottom of the frame. Be careful not to drill into any fuel lines. After you fasten the two brackets to the frame, install the new cross member. Fasten into place using the 5/8” bolts. Fasten the transmission into place using the factory nuts.
Step 7. Locate the lower air bag mount; position this part on top of the axle. On the passenger side you will need to drill a ½” hole in the flat part of the axle. There is no drilling on the drivers’ side. Fasten into place using the 14mm metric bolt. If you use the factory bolt, it will need to be shortened about ½”. Locate the cross member that connects the two bag mounts in place. Fasten using the ½” x 1 ½” bolts.
Step 8. Locate the upper and lower trailing arms. Install the arms so that the upper arms are the same length and the lower arms are the same length. Try and install so the pinion angle is close to original.

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1935 to 1940 Ford Crossmember Kjt Installation Instructions

1. Start by supporting the car on 4 jack stands. The car should be sitting on approximately the same angle as it does on the ground, or slightly lower in front.
2. Remove all the old front suspension components. Note that on the underside of the frame are the two rubber axle snubbers (or the holes for them, if they are missing) directly above the axle. Mark them for later reference.
3. We would recommend that at this point, you tack weld or clamp a temporary brace across the frame rails in front of the old crossmember as shown in Figure 1. This helps to maintain the rail dimension after the old crossmember is removed.
4. Remove the old crossmember. The front gussets, which are also the radiator mounts, may be trimmed in the frame, or removed to be cut and then reinstalled. Also, remove the old steering box mount. j
5. Now it’s time to recondition your frame rails. Your frame is two layers thick in the froot area. During the past 40 some years, rust forms between the layers of the frame rail flanges and swells, causing them to separate. This causes tile rail flanges to actually open up, as in Figure 2A. Your rails will probably look similar to this. It is necessary to squeeze the two layers back together, using a vice-grips or hammer and block. Then, using a large C-clamp, bend both flanges back together so the rail is square again. (See Figure 2B.) It does not need to be perfect for the entire length, but it should be close in the areas, where the new crossmember and spring towers mount. The better you can make toe-rails in this step, the easier it will be to weld in the new components. Also/grind off and weld in the rivets on the top of the”frame rails.

The next step is to box the rails. The edges of two layers of metal probably don’t line up very well on the frame flanges. Grind them down so they are flush and straight, and the boxing plates fit tight against them. (If the boxing plates fall into the frame rails, the rails are still too wide. Repeat step 5.)
Caution: Do not grind too much material off the flanges. The finished boxed rails should end up being 2-5/8 inches wide in the new crossmember area. The rest of the rail is not as critical. See Figure 3.

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1998 Ford Explorer Mirror-Beam Model MBEX98 Installation Guide

To Remove the Side Mirror Assembly:
1. Remove the door panel from the vehicle.
2. Remove the nuts that secure the mirror housing to the vehicle. Unplug the mirror’s harness cable from the door’s power harness.
3. Carefully remove the mirror housing from the vehicle.

To Prepare the Mirror Assembly:
1. Position the mirror assembly on the workbench so the mirror surface is facing away from the installer.
2. Locate the area marked “Corner”. From this point, measure a distance of 0.5” along the ascending vertical line (Fig. 1).
3. From this point, measure a distance of 3.5” parallel with line “A”.
4. After measuring the distances indicated, mark this location.
5. Using a 3/8” drill bit, carefully drill into the marked area. Be sure to remove any shavings caused by the drilling process.
6. Now position the mirror assembly so that its mounting surface is facing the installer. Locate the rubber extrusion projecting from the rubber mounting gasket. Cut an opening through the outer-most surface so that the harness cable can pass through (See Fig. 2).

To Prepare the Strobe Harness:
NOTE: Because the strobe harness must be routed through a specific, narrow and twisting path within the mirror assembly, it is necessary to temporarily extend the length of the harness with a make-shift “snake”.
1. Locate the tie-wrap included with your mirror beam and cut the fastener-end off.
2. Locate the end of the strobe harness that has SOCKET-type terminals installed on the free wires. Cut off the non-insulated wire (it is not used in this application).
3. Strongly secure the tie-wrap to the strobe harness with electrical or similar tape. Although the purpose of this procedure is to extend the harness length as much as possible using the tie-wrap, it is important to have a sufficient length of the tie-wrap secured to the harness (2” minimum).

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Ford 6.0L Powerstroke Turbo Diesel Vehicles Digital Propane Injection

Disconnect the batteries during installation of the DPI® system. When disconnecting the batteries, remove both negative battery cables first and install them last.
Note: The propane tank must be purchased separately and must meet Federal DOT and NFPA 58 requirements as well as state and local requirements that may apply. Information is available from your local propane professional which can be located at www.usepropane.com.

Installation Instruction
1. Remove the flex section of the air intake tube between the air cleaner outlet and the turbo inlet. Use care not to allow any foreign material to fall into the turbine inlet or air cleaner outlet.
2. Drill a 3/4” hole in the tube in the area shown in between the MAF Sensor and the Turbo (Figure 4).
3. Insert the Discharge Fitting in the 3/4″ hole.
4. From the inside,install the concave washer to the threads of the fuel discharge Fitting so the domed side faces the discharge Fitting and it aligns with the curve of the intake tube.
5. Install flat washer, nut and cotter pin.
Note: Tighten so that washer is seated to tube and fitting is aligned with vapor hose from regulator. Do not over torque. Coating with Red Loctite 272 or Blue Loctite 242 is highly recommended.
6. Insert the supplied cotter pin through the Discharge Fitting and bend the ends outward to prevent the nut from coming loose.
7. Reinstall the air intake tube to the engine.
8. Route the Propane Vapor Hose to the Regulator Outlet to the Discharge Fitting. It needs to be cut to fit. This hose is wire re-inforced and should be cut with cut-off saw or band saw.
Note: Verify there are no kinks in the hose and it is routed a safe distance away from sharp edges and hot engine components

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Ford Focus PRO-FIT Linear Fuel Doors – Installation Instructions

Do not perform this install near a flame source due to the risk of fire or explosion from gas fumes. Use a jack to lift rear of vehicle. Remove the passenger side rear tire. Remove the wheel well cover to expose the fuel filler neck behind the quarterpanel.
Note: For manual locking or manual non-locking fuel doors, do steps 1-4 only. For electric locking fuel doors, do all steps.

Step 1 – Remove stock fuel door
Remove the stock fuel door and plastic surround. The stock fuel door and plastic surround are a single unit. To remove, reach up behind the quarterpanel and release the tab at the top of the plastic surround. You may need to use a screwdriver to release the tab. Pull the stock fuel door and plastic surround straight out from the front.
Step 2 – Bend tabs
Bend the four tabs around the quarterpanel hole slightly inward using the back of a screwdriver handle or other blunt object. This is to allow clearance for the back of the fuel door ring (Fig. 1, black arrows).
Step 3 – Shift fuel filler neck
In order for the fuel door linear mechanism to function correctly, it must clear the metal collar surrounding the fuel filler neck (Fig. 5, arrow shows contact between the linear mechanism and collar). The fuel filler neck must be shifted to the left (towards the rear of the car) to make room (Fig. 1, white arrow). Loosen the 2 bolts holding the fuel filler neck to the body (Fig. 2 and 3, arrows) and shift the entire fuel filler neck towards the rear of the vehicle. Retighten. Check clearance by test fitting fuel door (Fig. 4). If there is still a clearance problem (Fig. 5), repeat the loosen bolts/shift neck/tighten bolts procedure. If necessary, elongate the holes on the brackets holding the fuel filler neck with a small drill or round file (Fig. 2 and 3, arrows).
Step 4 – Attach fuel door
Remove stock gas cap. WARNING – Do not perform the install near a flame source. Ensure adequate ventilation of gas fumes. Stuff opening with a small rag to prevent small items from falling into the gas tank. Insert the 4 long hex bolts into the ring as shown (Fig. 6, black arrows). Attach the L-brackets to the bolts from behind the fuel door ring. Fig. 7 shows the proper L- bracket orientation for the top left hex bolt. Attach a washer and nylock nut. Tighten using the supplied wrenches as shown (Fig. 8). Insert the short hex bolts into the remaining ring holes. Insert the replacement gas cap. Note that this gas cap has a trap door in the middle to allow fueling up without removing the cap.
Step 5 – Mount and attach actuator
Position the pull cable so that it goes up and over the wheel well towards the front of the car (Fig. 9, arrow). Mount the end of the pull cable into the slot on the end of the actuator bracket (Fig. 10). Remove the screw on the end of the actuator. Thread the screw through the eyelet at the end of the pull cable, then screw back in. Note that the screw is not tightened completely. Find a flat spot on the car body to mount the actuator (Fig. 9, arrow) with the screw-end of the actuator facing up. Clean the area thoroughly with alcohol or other degreaser, then peel the backing and….

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Ford F250 Superduty 4”-6” Suspension Kit

This kit is packaged as a leveling kit—raising the front 4”and the back 2”or raising the front 6”and the back 4”. If you desire a different look or if your truck has a tool box or something else that is going to bring the rear end down, please consult with your sales repetitive about option higher block and u-bolt options or the use of an add-a-leaf.
The 4”suspension system was developed for 35×12.50×17 tire on an after market wheel with 4.5”of back spacing.
The 6”suspension system was developed for 37×13.50×17 tire on an after market wheel with 4.5”of back spacing.

FRONT INSTALLTION INSTRUCTIONS
1. The tools needed , and parts for this installation are on the front cover. Make sure you have all of the proper tools an understanding of these directions before you proceed.
2. Place the truck on a clean level surface and set the parking brake. Chock the rear wheels and using a floor jack raise the front of the truck and support the frame rails with approved jack stands. NEVER WORK UNDER AN UNSUPPORTED VEHICLE, Using a 7/8 deep well socket remove the front wheels.
3. Using a 18mm and 13mm socket, remove the front bumper. Using a clip tool or a large flat head screw-driver, disconnect the rubber valance panel from underneath the front bumper. Disconnect the block heater plug from the bumper. (if equipped).
4. Using a 21mm socket, remove front crash bar. ( if equipped).
5. Using a 30mm socket, unbolt the track rod from the frame mount and let the bar hang. Using a 15mm wrench, unbolt the track rod bracket from the frame
6. Using a 18mm socket and 15mm wrench, remove the sway bar links from the sway bar, and the frame mounts on the frame rail.
7. Using a 18mm socket and wrench, remove the factory shock absorbers.
8. Leaf spring removal is done one side at a time starting with the drivers side. Position the floor jack under the driver side knuckle. Slightly load the jack so that it supports, not raises the axle. Make sure the frame rails are still secure on the frame stands.
9. Using a 22mm socket, remove the leaf spring u-bolts that secure the spring to the axle. Now remove the spring plate/ shock plate and the bottom u-bolt cradle. See Figure 1
10. Using a 21mm and a 24mm wrench, remove the spring shackle bolt and swing the shackle back away from the spring.

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Ford 7.3L 99-03 Powerstroke Turbo Diesel Vehicles Digital Propane Injection

The Vaporizer/Regulator assembly must have some components installed prior to mounting the unit. Figure 1 shows the location of the supplied components.
1. Install the Outlet Orifice. Verify assembly
is inserted as shown in Figure 12 pg. 12.
2. Install Propane Pressure Sensor.
3. Install Fuel Pressure Switch and propane lock-off solenoid.
4. Install the 90° coolant hose elbow fittings to the regulator’s coolant inlet/outlet ports.
Note: Figure 1 shows straight fittings, but the kit includes 90° fittings.
5. Install Fuel Line Fitting.

Mounting the Vaporizer / Regulator
1. Locate the relay support bracket on the driver side fender between the windshield washer bottle and the firewall. (Figure 2).
2. Remove the 6mm thread bolt holding the relay support bracket and remove the bracket.
3. Remove the relays from the bracket and tie them out of the way.
4. Using the supplied self-tapping screw, tap the boss in the lower part of the fender.
5. Mount the regulator assembly to the bracket so the inlet is on top.
6. Mount the regulator and bracket assembly to the driver side fender using the two mounting screws (Figure 3).
Note: Some applications, such as early ‘98 models, may require alternative mounting. For these applications verify the regulator is mounted with the regulator inlet at the top.
7. Connect the liquid supply line to the lock off solenoid inlet.

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Ford Escaspe In-Dash Mount Installation Instructions

Lund Industries, Inc is pleased to announce its multi-platform in-dash mount for 2003-2006 Ford Escape. The FE-CSMTS easily mounts in place of the factory AM-FM radio and allows Datalux TX-200, Data911, Fujitsu “T” Series, Kontron, Motorola MW-800 & 520, Palomar, Panasonic PDRC, Xplore iX104 & GII, and other displays to be mounted on the dash, enabling easy access to touch screens and other functions. The unit tilts 25° and swivels 12° for ease of viewing under high ambient light conditions. The FE-RRL Radio Relocator Bracket repositions the factory radio under the dash.

Installation Instructions
1. Remove the factory radio.
2. Remove the glove box door.
3. Route radio cables down to the glove box.
4. Install radio relocate bracket in glove box. Secure bracket with (4) screws.
5. Plug in radio connectors & snap radio into bracket
6. Install (2) “U” clips into radio slot and secure by tightening bolts provided. “U” clips attach to the black plastic around radio opening. Make bolts secure but do not over-tighten as plastic could crack.
Note: Separating the face plate from the mounting bracket will make monitor installation easier.
7. Mount monitor to face panel securely.
8. The plastic handles on the side of the mount allow the display to tilt up and down
and swivel left and right for best viewing

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99-2003 Ford 7.3L fuel pressure gauge install

The fuel pressure gauge used on the 7.3L Ford is a 0- 100 psi mechanical gauge and needs to be installed using a fuel isolator to ensure diesel fuel cannot enter the trucks interior due to a gauge or tubing failure. Install the gauge into the gauge mount with the tubing connected to the back of the gauge and fittings tightened. Pull the tubing through the firewall and near the back of the drivers side head light to the mounting location of the isolator.

The isolator is mounted in this location with the gauge side of the isolator facing up as shown in the photo. Drill the holes to locate the isolator at this time, but do not mount it yet or install the gauge side fittings. Install the fuel side fittings in the bottom of the isolator and tighten them with the other end connected to the fuel filter housing as shown in the picture. To make the connection to the fuel filter housing remove the plug from the back of the housing and install the supplied fitting. Connect the tube from the bottom of the isolator to this fitting making sure all connections are tightened properly. You are now ready to charge the next page.

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The SHUBB Fifth String Capo

We wrapped those little wires around the ends of the bar to make sure that the sliding part wouldn’t in ad ver tent ly come off prior to installation. It’svery tricky to get back on properly. There’s a little spring in there: one end of the spring holds the lever-arm above the string, and the other presses against the 45° angle of the bar—this is what controls the sliding action of the capo. If the spring is not seated properly, the sliding part will just fall freely on the bar… you don’t want that.

If it has come off the bar, you’ll need some sort of very small tool to help you flip the prong end of that spring back onto the angled part of the bar. My favorite is a #11 Exact-o blade. If you can’t do it, don’t feel too bad; it’s kind of tricky. Just send it to us and we’ll put it back together for you.

First, I’ll hold the capo bar in position at the edge of the fingerboard with its finger lowered, to simulate the action of the mounted capo: (fig. 1)

Because the edges of banjo necks are rounded, and not all the same, it’s a good idea to get a clear idea of how high to mount the bar at the edge of the fin gerboard. Generally it works out to about 1/16″ lower than the surface, but it pays to check to make sure. The idea is to have the bottom surface of the lever parallel to the surface of the fingerboard as the string is held against the fret. Next, I’ll figure out the lateral position. (fig 2) I want to make sure that the bar is close enough to the fifth fret so that the lever will be able to work easily at the sixth fret, which is the lowest fret position in which it will be used.

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1999-2007 Ford F250 / F350 Front Bumper Replacement Installation Instructions

1) Remove 4 bolts beside tow hooks to remove factory bumper. Retain bolts and tow hooks for use in step 7. ( see figure 1)
2) Remove fog lights from factory bumper keeping plastic pins and adjusting screw assembly in tact for future installation.
3) Remove casing from factory fog lights and discard. Install fog lights to brackets located on backside of new bumper using hardware removed in step 2.
4) Lift bumper and align with truck frame and secure with (4) ½”x 2” bolts provided through the tow hook cutout . ( see figure 3)
5) Install bumper support bracket provided to the backside of bumper mounting plate with (4) ½” x 2” bolts provided.
6) Adjust bumper and tighten all bolts with 75 lbs of torque.
7) Attach J bracket provided to bumper support bracket installed in step 5 using (1) ½’ x 2” bolt provided. Attach the other end of the bracket to the truck chassis using (1) ½” x 2” bolt provided. Tighten bolts with 75 lbs of torque. ( see figure 5)
8)Install tow hook removed in step 2 with original hardware. Plug in wiring harness to fog lights. ( see figure 6)

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How To Install a Subframe & Suspension

Chris Alston’s exclusive component packages are making real racing suspensions more affordable than ever. Today, anyone can purchase a complete 4-Link Suspension System, roll cage, and “tin” interior for less money than it takes to build a decent engine. Moreover, Chassisworks components and instruction sheets are specially designed for home installation by anyone with basic welding skills.

To demonstrate the economic advantages of various Chassisworks packages, Chris Alston set out to convert a stock 1965 Mustang GT into a combination Pro Street/Super Street machine — without spending more than $2000 (excluding wheels and tires). The finished product is rolling proof that a 10-second doorslammer chassis can, indeed, be built on even the most limited budget.

One secret to success is the universal Chassisworks Suspension System, which comes complete with a rear subframe; two coil springs; OEM-style shock absorbers; a tubular upper cross-member; adjustable-height lower shock mounts; front and rear suspension brackets; an adjustable track-locater assembly; and your choice of either ladder bars or 4-link. (Spring rates vary with the application; each set of springs is custom-matched to the particular vehicle by Chassisworks.)

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Russell FORD 5.0L Complete EFI Plumbing Kit Installation Instructions

Someone who has a basic knowledge of automobile repair and modification and is familiar with and comfortable with working on their vehicle can accomplish the mechanical installation of this kit using common tools and procedures. However, this kit is designed to allow you to custom fit the fuel lines and components to your application, and will require that you cut hoses to fit and drill holes for fuel pressure regulator mounting, junction blocks, etc. If you do not feel comfortable with any of the steps listed below, please consult a qualified professional installer. Make sure to read the instructions provided with the supplied fuel rail and fuel pressure regulator. These will be referenced throughout this instruction sheet.

Stock fuel rail disassembly:
1. Make sure the vehicle is on level ground, and the gear selector is in park or 1st gear. Set the parking brake or chock the wheels.
2. Make sure that the vehicle has cooled down.
3. Disconnect the negative terminal on the battery.
4. Thoroughly clean the area surrounding the fuel injectors and the fuel rail. This will prevent debris from entering the fuel system or the intake manifold upon fuel rail/injector removal.
5. Relieve residual fuel pressure in the fuel system. Remove the dust cap cover over the Schrader valve located on the fuel tube leading to the rail. Hold a shop towel or rag around the valve while relieving the fuel pressure to prevent any fuel spray.
6. Using the EFI coupling release tool, disconnect the fuel feed and return lines. Use a shop towel or rag to catch any residual fuel remaining in the factory lines.
7. Remove the bolts holding the fuel rail to the intake manifold.

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1997-2003 Ford F-150 & Expedition JLT Ram Air Intake Kit Installation Instructions

Please review complete instructions prior to installing.
Step#
1 Verify you have all of the following parts included in the kit:
(1) JLT painted pipe with IAT and PCV fittings, (1) Rubber Reducer w/ clamps, (1) Rubber coupler w/clamps,
(1) S&B 4×12” Oval Air Filter, (1) MAF Adaptor with bolts, (1) Wire Harness Extension Kit,
(1) Wire Harness Extension Cover, (1) section of 3/4” hose, and (1) section of 5/8” hose
2 Gather all of the following tools needed for the installation: 5/16 Nut Driver, 10mm Open End Wrench, 11mm Open End Wrench, Wire Cutters/Strippers, Regular Screwdriver
3 Remove the stock intake from the throttle body to the air box
4 Disassemble the stock air box in order to remove the MAF sensor.
5 There are 4 bolts holding the MAF sensor in the air box. Unbolt the MAF and pull wire harness through the hole. Once the MAF is out, bolt the JLT supplied Billet MAF adaptor to the MAF with the supplied bolts.
6 Install the reducing hump hose onto the JLT pipe. This is to connect to the throttle body. Note, the larger fitting on JLT pipe will be closest to the throttle body.
7 The remaining rubber coupler will connect the JLT pipe to the MAF assembly. Connect this now along with the filter.
8 Pull the IAT sensor from the stock inlet pipe and install into the hole in the JLT filter. It will fit a little loose, but this is not a problem.

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1999-2003 Ford F-Series 7.3L Power Stroke Edge Juice Module Installation Instructions & Manual

Thank you for purchasing the Ford 7.3L Juice Module for the Ford Powerstroke Diesel®. The Juice module has been developed and produced from the highest quality materials available to ensure the best performance for years to come. If you have any concerns or questions, please contact us. The Ford 7.3L Juice Module is a high performance product, use at your own risk! It is strongly recommended that EGT, transmission temperature, boost gauges, or Edge Attitude monitor be installed with the use of this product.

The Ford 7.3L Juice Module
The picture below shows the Ford 7.3L Juice Module for the Ford 7.3L engine with all available options – Both the Attitude™ display monitor and the three position switch. It is essential that the cables that are supplied with this module get connected as shown on the following pages.

Harness Connector
Your Juice module may be equipped with a harness that can be disconnected at the Juice module itself (See figure 1A). It is important to make sure that your juice module is always connected to the harness when the wiring harness is connected to the truck, otherwise the truck may not run properly, or may trip engine “codes.”

Engine Codes
As with many aftermarket electronic performance modifications available for the Ford 7.3L Power Stroke® Diesel engine the Ford 7.3L Edge Products Juice module for the Ford 7.3 Power Stroke® Diesel engine will likely set engine “codes.”
The engine codes are generally set during heavy acceleration. Although the codes will remain “set” in the PCM, the dash board indicator light should turn off within 15 minutes. Most codes that are set under hard acceleration are called “soft codes”. These soft codes are retained in the PCM and can be erased by unhooking the battery for 30 minutes, or by using the Edge
Products Evolution to clear the codes.
Codes that may be set:
• P1211 – Injector control pressure is different than expected
• P1209 – Peak injection pressure fault
The Ford 7.3L Juice Module modifies sensor readings that are monitored by the ECM. These sensor inputs may or may not be what the ECM is expecting at any point in time. Because of the difference in expected readings the ECM may set the engine codes. This is not expected to harm the Ford 7.3L engine and should not cause damage to the engine.

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2004 Ford E-350 Series Van 400-series Lighthead Housing Installation Guide

Installation:
1. Following the vehicle manufacturers instructions, remove the radiator shroud, grill, headlights and turn signals. Then remove the plastic substructure that they are mounted to (Fig. 1).
2. While holding the housing (without lighthead) in the exact mounting location, mark the location of the two mounting holes onto the mounting surface. There is a small notch cut into the inside of the two screw bosses on the housing. Use the notch as a guide, make your mark, then (with the housing removed) measure and make the mounting holes 5-3/8” apart (Figs. 2 & 3). NOTE: Depending on what lighthead you are using with this housing, you will need to drill a wire hole. Refer to the lighthead manual for the size and location.

REAR VIEW / DRIVER SIDE SHOWN
1. After checking all your measurements, drill appropriately sized mounting holes based on your mounting hardware. Also drill your wire hole(s) at this time.
2. Install the supplied rubber gasket to the top part of the rear of the housing as shown above. Make sure the gasket is mounted evenly on both sides.
3. Install the supplied Fastex grommets (Fig. 3) and attach the lighthead to the housing.
4. Apply Locktite® #242 to the supplied 1/4-20 X 3/4” Hex Head Bolts, and secure the housing (with lighthead) to the vehicle, then extend the wires to your power source.

Get pdf 2004 Ford E-350 Series Van 400-series Lighthead Housing Installation Guide

2005/2006 Ford SuperDuty Suspension Lift Kit Installation Instructions

While this kit is an easy bolt-on system, Rize Industries, LLC. strongly recommends that a professional installation center be contracted to do the install. Rize Industries, LLC. also recommends using a hydraulic lift when performing this installation.

Before starting installation of kit on vehicle verify the kit inventory and thoroughly read and understand all instructions.
1) Position vehicle on lift, locate front lift post on the body mount behind the front wheel.
(Fig A). Locate the back lift post on the bottom of the frame rail, just before the rail curves up in front of the rear tire. TIP: Use the front of gas tank as a reference point (Fig B)
2) Raise vehicle up just enough to remove wheels and tires. (Fig C)
3) Raise vehicle up in relation to the height of the support jack stands you are using. Support the front axle with jack stands and then lower vehicle just enough to slightly weight the stock coil springs and shocks.
4) Remove sway bar from vehicle, and retain factory hardware.
5) Remove front shocks and discard.
6) Remove the bolts (two per side) holding the brake line support brackets to the vehicle, one at the top front of the coil bucket and one at the bottom of the coil mount.
7) Disconnect / or re-route hub vacuum lines, and axle breather tube so there is enough slack to lower the front end down. Also make sure the brake lines have slack for the same purpose.
TIP: On passenger side it is helpful to unclip brake line from bottom of frame (Fig D)
8) Unbolt the electric wire holders from both factory radius arms.
9) Disconnect drive shaft from the front axle and secure out of the way.
10) Remove and discard factory steering damper
11) Remove the drag link from pitman arm, and secure out of the way. TIP: An easy way to accomplish this is to use two hammers, and simultaneously strike the pitman arm on opposite sides with the hammers. Two to four blows will cause the pitman arm taper to release the drag link. (Diagram 1)
12) With the front axle supported by jack stands, raise vehicle up just enough to un-weight the factory coil springs. Make sure that the brake and vacuum lines do not get pulled tight.
13) Remove stock coil springs (Fig E), retain rubber spring isolators for reuse.

Get pdf 2005/2006 Ford SuperDuty Suspension Lift Kit Installation Instructions

1937 Ford Cool LEDs Installation Instructions

1. Disconnect Battery. Do not skip this step. Also, do not try to “test” the LED array by connecting the leads directly to your battery. Permanent damage will occur to the LED array if you fail to heed these steps.
2. Remove taillight lens and bezel.
3. Remove light bulb and light bulb holder.
4. Remove the LED array from the stainless steel bracket.
5. Route the supplied electrical harness through the taillight and to the area where connections will be made.
6. Install the stainless steel bracket in the taillight housing using the supplied screw. Also attach the green ground wire from the supplied harness to this screw.
7. Attach the plastic connector on the supplied harness to the LED array.
8. Deform the supplied plastic spacers to hold them on the screw during installation.
9. Align the LED array and stainless steel bracket while installing the supplied stainless steel screws and lockwashers.
10.Reassemble the rest of the taillight.
11.Wiring. Using the supplied connectors, connect the wire from the taillight circuit to the black wire on the supplied harness. To use the connector:
12.Repeat by connecting the wire from the brake light circuit on your car to the red wire on the supplied harness. If your car is fiberglass, the housing must be grounded.
13.Repeat for the other side.
14.Reconnect the battery.
15.Test both STOP and taillight functions.
16.Enjoy!

Get pdf 1937 Ford Installation Instructions Cool LEDs

1994 Ford Crown Victoria SA340TS Mounting Kit Installation Guide

This document provides all the necessary information to allow your Whelen product to be properly and safely installed. Before beginning the installation and/or operation of your new product, the installation technician and operator must read this manual completely. Important information is contained herein that could prevent serious injury or damage.
• Proper installation of this product requires the installer to have a good understanding of automotive electronics, systems and procedures.
• If mounting this product requires drilling holes, the installer MUST be sure that no vehicle components or other vital parts could be damaged by the drilling process. Check both sides of the mounting surface before drilling begins. Also de-burr any holes and remove any metal shards or remnants. Install grommets into all wire passage holes.

Installation:
1. Attach the siren driver to the mounting bracket before installing.
2. Install the mounting bracket and siren driver by pushing through the air flow cut-outs on the vehicle’s underside, and by hanging the bracket by the cross member near it’s centerline.
3. Locate the siren clamp bracket assembly behind the vehicles cross member
4. Thread the 5/16″ hex bolts from the front into the clamp bracket assembly.
5. Push the Twinsonic horn thru the air flow cut-outs on the vehicle underside. Position the horn over the mouth of the driver and thread on the siren tip.
6. Position the entire assembly vertically and tighten the two hex bolts.

Get pdf 94 Ford Crown Victoria SA340TS Mounting Kit Installation Guide

2003-07 Ford Power-Stroke V8 6.0L

The 4” straight hose is pressed over the turbo inlet until its butted up against the inlet. Use two power bands to fasten the hose to the turbo inlet, tighten the clamp on the turbo inlet side for now. The 19mm hose is pressed over the 90 degree hard pipe (A) The 19mm hose is now installed (B).

The cast intake is lowered and aligned with the 4” hose over the turbo inlet. Once you have aligned the cast intake to the 4” hose, continue to insert the intake into the hose. Adjust the cast intake for best position but do not tighten the power band at this point.
Loop the 19mm hose over the radiator overflow tank and align it to the intake port. Use the small clamp in the kit to fasten the hose over the intake port. The clamp is now fastened over the 19mm hose as shown above.
Press the 5 1/2” hose over the end of the intake. Use two power bands and tighten the clamp over the cast intake for now.
Press the Injen/AMSOIL grommet into the the 3/4” pre-drilled hole located on the plenum. Note: The grommet has been designed to be rotated for proper clearance of the air restrictor gauge.

Get pdf 2003-07 Ford Power-Stroke V8 6.0L

Ford 4.0 L Ranger & Explorer Power-Plus Series Throttle Body Installation Instructions

Step 1
Set parking brake on vehicle and disconnect the negative battery terminal.
Step 2
Remove flexible inlet hose from throttle body and air box by loosening two hose clamps. Disconnect the tube to the valve cover and the inlet air temperature sensor if applicable.
Step 3
Remove plastic cover on the left side of the throttle body. Unhook the throttle cable from the throttle body link-age, disconnect the throttle position sensor and vacuum hose from throttle body.
Step 4
Remove the four bolts securing the throttle body to the intake; and remove the factory throttle body.
Step 5
Remove the throttle position sensor from the factory throttle body. You must use an impact screwdriver to remove the T.P.S. screws (to avoid rounding off the Phillips head) due to the use of Locktite on the factory fasteners. In the event the factory screws are rounded off and can’t be removed, the head of the screws will have to be ground off to remove TPS.
Step 6
Install the throttle position sensor on the new throttle body using supplied screws. Be sure the black plastic T.P.S. bushing is in place before securing T.P.S.
Step 7
Using the supplied screws and gasket, install the new throttle body on intake manifold and secure.
Step 8
Reattach the throttle cable, T.P.S. sensor connector and vacuum hose to throttle body.

Get pdf Ford 4.0 L Ranger & Explorer Power-Plus Series Throttle Body Installation Instructions

1994-1998 Ford Mustang - 8Cyl 4.6L/5.0L Installation Instructions

To begin removal of your OEM exhaust system, you will need to cut the tail-pipes just behind the mufflers. Remove the tail pipes from the OEM rubber insulators. Do not damage the OEM rubber insulators, as they will be re-used with your new system. Next unbolt the extension pipes from the H-pipe and remove the mufflers from their OEM rubber insulators. Do not discard the fasteners required to bolt the extension pipes to the mufflers, as they will be re-used.

Step 2i Remove the existing muffler mount brackets, and replace them with the new brackets supplied in the kit. Do not discard the OEM mount fasteners, as they will be re-used. Refer to diagram #2 for installation of the new muffler mounts.

Warning : When working on under or around any vehicle exercise caution. Please allow the vehicle’s exhaust system to cool before removal, as exhaust system temperatures may cause severe burns. If working without a lift, always consult vehicle manual for correct lifting specifications. Always wear safety glasses and ensure safe work area. Serious injury or death could occur if safety measures are not followed.

Step 4: Adjust all components for clearance of the frame, bodywork, and overall aesthetics. (MAGNAFLOW recommends at least 1/2″ of clearance between the exhaust tips and the rear fascia to avoid heat related body damage or fire.) Once a final position is chosen, tighten all hardware from front to rear, including H-pipe hardware, all U-clamps, exhaust tip clamps and exhaust tip slide hangers. Inspect all hardware after 25-50 miles of operation, and re-tighten if necessary.

Get pdf 1994-1998 Ford Mustang - 8Cyl 4.6L/5.0L Installation Instructions

1979-2004 Ford Racing Mustang C-Springs Installation Guide

Here we are installing Ford Racing C-Springs on an 04 Mustang GT. I’ll be using a 2-post lift for easy explanations and visual clarity, but the same procedure goes for those using a jack and jack stands. Remember, after installation, it is important to get a front wheel alignment. Camber/Caster plates may not be necessary when installing FRPP C-Springs.

Tools needed:
• Jack and jack stands
• Good size hammer. A sledge is recommended.
• 3/8″ Ratchet
• Needle nose pliers
• Side cutting pliers
• Metric sockets sizes- 15mm deep, 18mm deep, 21mm and 24mm deep
• 12″ or longer pry bar
• Standard torque wrench with a foot/pounds setting.

Installation - FRONT SPRINGS:
1. In order to begin installing the front springs, you will first want to set the car up on the jack stands, by placing one under each pinch rail, just behind the fenders
2. Remove the tire and the wheel.
3. Next, remove the tie rod stud cotter pin, using needle nose or side cutting pliers.
4. Remove the nut, using 18mm deep socket or wrench, and strike the spindle at the “X” shown in picture, to remove stud from spindle. If stud turns with nut, try using a pry bar to apply pressure on the tie rod stud to remove the nut. An air impact wrench is another possible way of removing the nut.
5. Remove the sway bar link bolt, by removing the nut underneath the lower control arm.
6. Now place a jack under the lower control arm, just enough to where there is slight pressure holding the arm in place.

Get pdf 1979-2004 Ford Racing Mustang C-Springs Installation Guide

1994-97 Ford Powerstroke Racor Unit Installation

Locate fuel supply line coming from tank on the drivers’ side frame rail. There are 2 steel lines, the top line (smaller of the 2 lines) is for fuel return to the tank, the bottom line is the fuel supply line (see Figure 1) and is the larger of the 2 lines.
STEP 1:
Cut and remove a section of the fuel supply line; approximately 6 inches will be enough. Use a flaring tool on both ends; this will help keep the fuel hose on the line.
STEP 2:
Next you need to mount the Racor unit. The unit will be mounted by the hood hinge on the drivers’ side (see Figure 2) where there are 2 empty holes. Using the provided nuts, bolts, and washers, mount the Racor unit.
STEP 3:
Install the provided brass elbows into the Racor unit. Use Teflon thread sealant on the threads before installing. Thread one elbow into one of the inlet ports and thread the second elbow into one of the outlet ports. Tighten elbows so the barbs on them both point down.
STEP 4:
Connect one end of the provided rubber fuel line to the fuel supply line that is coming from the tank. Install the provided hose clamp and tighten. Route the fuel line up to the Racor unit inlet port, leaving a little bit of slack in the line and cut the line. Connect the end of the rubber line that you just cut to the brass elbow that is in the inlet port of Racor unit. Secure the hose to the Racor unit with one of the hose clamps. Using the rest of the supplied rubber fuel line, connect one end to the brass elbow that is located on the outlet port of the Racor unit and secure with one of the hose clamps. Route the rubber fuel line down towards the frame and connect it to the open end of the metal fuel supply line and secure with hose clamp (see Figure 3).
STEP 5:
To prime the fuel system, unscrew the Racor filter from the filter head. Fill the filter with clean diesel fuel and re-install on the filter head and tighten. Start the vehicle and run for a few minutes to purge the fuel system of any air and check for leaks.

Get pdf 1994-97 Ford Powerstroke Racor Unit Installation

Brake & Torque Converter Controller Installation and Operation Manual

Exhaust Brake and/or Torque Converter Controller Kit Contents
• Integrated Control Module.
• Harness with labeled connections for a hassle-free install. Every possible convenience was included in the harnessing to ensure an easy installation experience.
• Small Parts Bag. A baggie containing fuse taps, taps, connectors, and zip-ties and such has been included to aid your installation.
• Optional Plug in Kits for your model year and make vehicle (if purchased with unit) (may also be purchased after initial sale)

Tools Required:
• A good DMM or DVOM (Multimeter) for probing circuits. A test light will do in a pinch, but remember that test lights can be misleading if not understood or used properly.
• A good quality wire stripping/cutting/crimping tool. Your installation will only be as good as the tools used!
• A wire fish (coat hanger) for running wires in tough to reach locations or through the firewall if necessary.
• Any additional items you wish to use to tidy up your installation. It is up to the installers ‘creativity’ to ensure the unit is properly secured. We have supplied most if not all of what you need in this department but everyone’s install will likely vary and therefore it is your responsibility to heed the warnings and specifications.
Vehicle Compatibility:
In general this unit is designed to be compatible with Ford and Dodge Turbo-Diesels
• Ford Diesel (Exhaust Brake and/or Transmission)
• Dodge Diesel (Transmission Only)

Use of the Cruise Control as an interface:
The methods used to read the cruise control circuit are the same ones used by the factory. We do not send any signaling on the wire(s) for your cruise control. We simply read the cruise control buttons and your new controller takes action based on those inputs. When you activate your cruise control (turn on or arm), we suspend acting on those signals. Simply put, when you have cruise on, you cannot change settings in your controller and when your cruise is off, you can make changes to your controllers programming.

The EBV as an Exhaust Brake Common Misconceptions:
The use of an EBV brake will damage the engine or drivetrain…Not true. There is no excessive wear on your vehicle. This unit will not cause EBV sticking or valve float or anything like that. The factory EBV is an effective and safe method of assisted braking on your vehicle. The exhaust brake feature for Ford 7.3L PowerStroke Diesels will also not raise your EGTs, as it is never on when you are accelerating.

Get pdf Brake & Torque Converter Controller Installation and Operation Manual

2004 & Older Ford Front System Kelderman Air Ride

Kelderman Air Ride systems are developed for 2004 & older Fords. This system was developed to improve the ride of the 3/4 & one-ton Ford pickups. There are several advantages to equipping your truck with air ride suspension:
• Improves the ride of the truck
• Bolts into existing holes on truck frame
• Increases load carrying capacity
• East to install, maintenance free

Before installation of the Air Ride unit, prepare a smooth, flat, hard surface and have all tools and equipment needed for the job. Chock the rear wheels of the truck, to prevent it from rolling forward or rearward. Place a jack on each side of frame behind the front wheels, in the vicinity of the front seat.

Installing the Air Ride
Step 1. Measure the height of the front of the truck while setting on a level surface. Record this measurement here: ______”
Step 2. Lift up the truck by placing a jack under the frame on the side of the truck which will be installed first. Place jack stand next to the jack for safety. Remove the front tire.

Get pdf 2004 & Older Ford Front System Kelderman Air Ride

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