Auto Manual Resource: 08/09/09

Ford 5R110 Transmission Pan Installation Instructions

The TCI Automotive® deep aluminum pan is designed to fit the factory Ford 5R110 transmission as supplied as original equipment. However, in some applications, or because of the use of certain factory options and/or aftermarket equipment, there may be clearance problems between your TCI Automotive® pan and other vehicle components. It is the responsibility of the owner/installer to ensure that there is no contact between the pan and other moving, obstructing or fixed vehicle components. Contact with any vehicle component, or the modifying of the TCI Automotive® pan voids the warranty. TCI Automotive® assumes no liability, expressed or implied, for damage or injury to persons or property.

Installation:
1. Park your vehicle on level ground and apply the parking brake. Use jack stands if the vehicle must be raised.
2. Position a large drain pan under the transmission to catch the fluid. Also drain the torque converter.
3. Starting at the rear, remove the 20 existing pan bolts.
4. Using a gasket scraper, start at the rear of the pan and carefully (so as not to gouge the transmission case) insert between the existing pan and transmission housing and pry the old pan off.
5. Allow all of the old oil to drain.
6. Using a gasket scraper, carefully remove all of the old gasket material (dried silicone) from the transmission case.
7. Use clean lint free rags to clean the transmission case gasket surface. The surface must be clean and flat for the O-ring to seal.
8. Before installing the TCI Automotive® pan, check the gasket mating, surface on the transmission case for dents, irregularities, or gouges. Should any exist, carefully remove the high spots using a smooth flat file. BE CAREFUL NOT TO “ROUND OFF” THE FLAT GASKET SURFACE.

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2005-2008 Ford Mustang 4.0L V6 Installation Instructions

1. Start by disconnecting the wire harness from the MAF sensor as shown.
2. Next loosen the hose clamp on the stock air tube to the air box as shown.
3. Remove the stock air tube from the stock air box as shown.
4. Remove the bolt that holds the stock air box in place and set aside for reuse with the MAC system.
5. Remove the stock air box by pulling it straight up as shown.
6. Remove the two rubber grommets from the air box as shown and reinstall them into the stock location.
7.Using the T20 torques head supplied in the kit, remove the MAF sensor and set aside for reuse with the MAC air system.
8. Install the two support posts to the bottom of the MAC air chamber as shown. Note:The spacer will be mounted to the rear post.
9. Install the two brackets onto the MAC air chamber as shown.
Note:The “L” shaped bracket will be mounted to the out side of the air chamber.
10. Install the MAC air chamber into the stock location and bolt it in using the stock bolt and hardware provided as shown.
11. Install the MAF sensor to the MAC mass air meter using the hardware provided. Note Do Not use the stock hardware on the MAC mass air.
12. Place the rubber gasket onto the MAC mass air meter as shown
13. Install the MAC mass air meter through the air chamber to the velocity adaptor using the hardware provided

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Retrofit Hydraulic Roller Lifter Installation Instructions

These lifters are engineered and manufactured to provide optimum performance and reliability. In order to take full advantage of the product, proper installation is required. Please follow the instructions below to insure complete satisfaction.

Pre-installation Considerations
Since the valve train in a typical overhead valve engine contains numerous components which may or may not be matched, care must be taken to avoid potential issues which may affect the overall performance of the lifters and the engine. These considerations can be best described in two categories: Mechanical Interference and Valve Train Geometry.

Mechanical Interference - Mechanical interference can occur between the various components which may lead to engine damage and failure. These potential problem areas must be checked prior to final adjustment of the lifters and operation of the engine. The following is a list of areas to consider:
• Piston to valve clearance
• Rocker arm slot to stud clearance
• Rocker arm to valve spring retainer clearance
• Valve spring retainer to guide/seal clearance
• Valve spring coil bind height

Valve Train Geometry - Proper overall valve train geometry must be maintained in order to optimize valve motion. The following can affect the geometry of the valve train:
• Deck height of block
• Cylinder head heights
• Camshaft lobe base circle diameter
• Seat height in lifter
• Pushrod length
• Rocker arm configuration
• Valve length

The simplest way to achieve the correct geometry and compensate for un-matched parts in the valve train is by using proper pushrod length. Table 1 provides the lengths for the most common applications. If you are unsure of the required pushrod length, refer to the Pushrod Length Procedure, otherwise, proceed to Installation Procedure.

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2000-2003 Ford Super Crew Installation Instructions

The Bedlocker is designed to carry rainwater from the cover into the canister and then out through the drains. Most truck models have standard OE drain holes or plastic/rubber access ports in the front of the truck bed. Check to make sure your truck has the OE drain holes so that drilling into the sheet metal is not required. If drilling is necessary, be sure to check the underside of the truck bed for the best location. The holes should be located near the side and as far forward as possible. Use a drill bit suitable for sheet metal (such as a taper drill or step drill). Drill drain tube clearance holes at 3/4” (19mm). This will need to be done before installing the cover.

The BedLocker also offers an optional wire harness (part # BL1120) to manually operate the tonneau cover from inside the cab of your truck. This harness is designed to plug into the custom-built electronics control box. Simply run the wire to the cab and attach under the dash in a suitable location.

TEP 1: REMOVE CONTENTS & PLYWOOD PACKAGING
Remove the canister and top cover from the box. Remove components from inside the canister. Perform a quick inventory to insure all parts are there.

Using the wrench or socket remove the 2 bolts holding the plywood packaging supports on the ends of the canister. Discard plywood packaging supports and bolts. Locate the rail guide bolts in the hardware pack and install them in the two holes where the packaging bolts and plywood were just removed. Repeat on both ends of the canister.

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97-03 Ford F -150 Side Skirts

Installing the cab skirts: Remove any mud guards or stepping bars from the truck. Open the door on the truck and hold the cab side skirt in place. Secure the front part of the side skirt in the wheel well with the factory screw from the mud guard, then close the door and check to see that you have about a ¼” door gap between the bottom of the door and the side skirt. While holding the side skirt in place open the door and with a 1/8” drill bit, drill through the existing holes in the side skirt. Then secure the side skirt with the screws supplied in the hardware packet. While holding the rear portion of the cab side skirt in place drill a 1/8” hole through the side skirt and into the rocker panel and secure it with the screw supplied in the hardware packet as shown in fig.A. We have supplied you with two braces to secure the lower portion of the side skirt, install them evenly apart as shown in fig.B

Installing the bed skirts: Hold the bed skirt in place and secure it with a factory screw from inside the wheel well. While holding the bed skirt in place drill a 1/8” hole through the side skirt and into the bed and secure it with a screw supplied in the hardware packet as shown in fig.A

Installing the 2 sided tape: After the side skirt has been painted install the 2-sided tape along the guideline on the back side of the side skirt where it touches the truck as shown in fig.C. The surface temperature where the 2-sided tape is contacting must be a minimum of 70o F. Allow 2-sided tape to dry 24 hours before driving. 97-98 F-150 super cab trucks do not have a door on the drivers side, install the 2-sided tape along the upper portion of the guide line as shown in fig.D 99-03 F-150 super cab trucks, install the 2-sided tap along the lower portion of the guideline as shown in fig.E

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2003-2006 Ford 6.0L Excursion 4″ Alum Kit Installation Instructions

Removal of Original System
1) Start under the vehicle. Remove the band clamp that holds the stock system to the converter by loosening the bolt and gently prying the clamp loose. If the clamp will not release continue to next step. When you have the rest of the system off shake the pipe from underneath the vehicle this will break the seal and you will here the clamp release. Gently remove the clamp and save for the reinstallation.
2) Remove the band clamp that holds the stock system to the converter by loosening the bolt and prying the clamp loose. Do not cut when installing on longer models.
3) Cut the original system just behind the muffler.
4) Spray the stock hangers with aerosol lube and pry rubber mounts from the system. Leave the rubber mounts attached to the truck for re-use.
5) Remove the old system from the cat back.
6) Loosen the bolts that hold the converter to the stock down pipe. Remove the converter and keep for reinstall. You must reinstall the converter.
7) Remove the Stock down pipe. You may need to cut it or remove the transmission mount to get enough room. Stop and think before you do either of these a mistake at this time could be very costly.

Installation of New Performance System
(Do not fully tighten any clamps until the complete system is installed and aligned.)
1) From under the truck, install the down pipe with the stock clamp to the turbo. Tighten clamp so you still have some movement.
2) Install the down pipe extension with a clamp.
3) Reinstall the converter to the down pipe extension with a gasket (not pictured).
4) Hang the muffler in the stock location using the hanger clamp on the outlet. This determines the placement of the rest of the system.
5) Install the first tail pipe into the outlet of the muffler using the hanger clamp already installed. Rotate the pipe as needed to pass next to the shock absorber and over the rear axle.
6) Install the second tail pipe into the outlet of the first tail pipe with a clamp. Rotate as needed to level the outlet behind the rear tire. Attach the hanger clamp in the stock location.
7) Measure between the outlet of the converter and the inlet of the muffler. Add 5” to this measurement for the slip-joints and cut the intermediate pipe to fit. Install the cut pipe between the converter and the muffler with a clamp at front and a clamp on the muffler inlet. Install the hanger clamp in the stock location near the front of the intermediate pipe and install the hanger clamp in the stock location near the rear of the intermediate pipe.
8)Starting at the turbo, align and tighten all the pipes and clamps. Start the engine and check for leaks.

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1999-2004 Ford Lightning JLT BIG Air Intake Kit Installation Instructions

We hope you are satisfied with the look and performance. You may use any polish or wax on the pipe as it’s painted with the same high quality paint as your car. It is also recommended to use some tire shine on the rubber elbow. Take your time and it will be a smooth install. 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 IAC, PVC, and Vacuum line fittings, (1) 45 degree Rubber Elbow w/ clamps to connect throttle body to JLT Pipe, (1) Silicone Reducer w/ clamps to connect JLT pipe to MAF, (1) JLT heat shield, (1) Billet MAF Adaptor with bolts, (1) 4×12” S&B Air Filter, (1) 5/8” Hose, (1) 3/4” Hose, (1) Vacuum Line, (1) Silicone Spacer (for use on early Lightnings with 80mm MAF only)
2 Gather all of the following tools needed for the installation: 5/16 Nut Driver, 10mm Open End Wrench, 11mm Open End Wrench, Phillips Head Screwdriver
3 Remove the factory Air Box Assembly from the Throttle Body to Air Box.
4 Remove the Mass Air Flow Sensor from the airbox and install the Billet MAF adaptor in the JLT kit.
5 Install the JLT heat shield onto the adaptor, rotating it in the direction you want to block engine heat.
Note: Keep the MAF in its stock rotation. Meaning, remember where the plug position was stock and return it to the same position.
6 Install the S&B filter at this time. Use pressure on the filter to “sandwich” the heat shield in position.
7 Install the 45 degree elbow onto the throttle body.

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2005-2008 Ford F350 4×4 Level Lift Installation Instructions

Step 1:
Position truck on a flat surface and block the rear wheels to keep it stable. Starting on the driver side remove the stock shock absorber and retain hardware.
Note: New longer front shocks will be needed for this installation. Level Lift™ recommends a shock that measures 23″ fully extended. ProComp* 924553 flirti ss
Step 2:
Continuing on the drivers’ side, remove the stock sway bar frame mount, retain the hardware for re-installation.
Step 3:
Next remove the stock brake line bracket from the bottom of the stock coil spring, keep the hardware for re-installation. For 05-08 F250 4×4 see addendum.
Step 4:
Scribe a mark on the lower coil spring plate as well as the coil spring. This is done to re-install the coil in the exact location. (Repeat Steps 1 thru 4 on passenger side of vehicle)
Step 5:
Place a pair of hydraulic jacks under the frame on both sides of vehicle. With a second persons help, raise the vehicle until the top of the coil springs are separated from the upper coil location. Keep raising jacks until coils can be removed

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05-06 FORD F-250/350 Cat Back Split Rear Exhaust Installation Instructions

When installing this exhaust system make sure to use proper safety precautions. Use jack stands when working under the vehicle, set parking brake, block tires and use safety glasses and gloves. Allow exhaust to cool before attempting installation. Severe injury or burns could occur if safety measures are not taken. Disconnect the negative battery cable before removal of OEM exhaust. This will allow the computer to reset and recognize the new exhaust. Lay out the exhaust on the floor so it looks like the drawing and compare parts with manual.

1. To remove the stock exhaust remove it from the clamp located in front of the stock muffler. Disengage the welded hangers using WD-40 from the OEM rubber grommets. Do not damage or remove the rubber grommets as you will re-use them to mountyour new system. Now, cut off tailpipe and remove exhaust.

2. Install head pipe #A onto your existing stock front pipe and attach with clamp #G. Use a jack stand to support the converter. Insert welded hanger into rubber grommet.

3. Install muffler #B onto head pipe #A 1½”-2” with the louvers facing towards the converter. Use a jack stand to support the muffler. Use clamp #G to secure the muffler to the headpipe. Do not tighten. Muffler inlet is looking into the louvers.

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1999-2003 Ford Super Duty 7.3L Powerstroke Installation Instructions

Removal of Stock System:
1. Loosen the nut on the band clamp located behind the catalytic converter using a 15mm wrench or socket.
2. If a hoist is being used for the installation, the original exhaust system can be removed in one piece by removing the passenger side shock. If a hoist is not being used the tail pipe must be cut behind the muffler to be removed.
3. Remove the muffler and tail pipe from the OEM rubber hangers and separate the stock exhaust at the slip joint located behind the catalytic converter and remove the muffler and tail pipe from under the truck. Re-install the passenger side shock.
4. Remove the catalytic converter by removing the two nuts holding the inlet flange together using a 15mm wrench or socket.
5. Remove the down pipe from the turbo by removing the band clamp using an 11mm socket. Retain the band clamp for the installation of the new down pipe. Cut the down pipe in front of the transmission cross member to remove. (Note: The stock down pipe can be removed in one piece by removing the transmission cross member. It is recommended that this only be done by qualified, trained professionals using tools and equipment designed to safely carry out this procedure.)

Installing Your Front Section of MBRPinc.
1. Install the Down Pipe in the same position as the stock down pipe and attach the flared end to the turbo using the stock band clamp. Do not fully tighten until all components are in place.
2. Loosely attach the Extension Pipe to the Down Pipe and place the hanger into the factory rubber insulator located on the frame. The Extension Pipe may need to be trimmed to mate up to the rear section of the “Smokers™”

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2004-2006 FORD F-150 4WD 4”-6” Suspension System Installation Instructions

Installation by a professional mechanic is recommended. Use of the appropriate tools, a Ford service manual, and a shop hoist can greatly reduce installation time. Prior to installation, carefully inspect the vehicle’s steering and drive train systems, paying close attention to the tie-rod ends, rack & pinion unit, ball joints and wheel bearing preload. Also check steering-to-frame and suspension-to-frame attachment points for stress cracks. The overall vehicle must be in excellent working condition; repair or replace worn parts.

• Read instructions carefully and study illustrations before attempting installation. RCD Suspension is not responsible for damage, failure or injury resulting from improper installation or parts substitution of this kit.
• Check parts and hardware against the parts list to assure that your kit is complete. Report any shortages to RCD Suspension at (1-619-588-4723). The parts and hardware supplied are of high-grade material and must not be replaced by inferior parts or failure may result. Do not begin installation if parts are missing.
• Separate parts according to the areas they will be used. Placing the hardware with brackets before you begin will save installation time.
• This kit is supplied as a bolt-on assembly. Do not weld anything to the components and do not weld the components to the vehicle.
• All components in this kit come with a protective coating. Do not plate (i.e. chrome, cadmium, zinc etc.) or otherwise alter the finish in any way. This could decrease the structural strength of the components.
• Secure and properly block vehicle prior to beginning installation.
• Always wear safety glasses when using power tools.
• Foot-Pound torque readings are listed on the Torque Specifications chart at the end of the instructions unless specifically stated in an instruction.

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1997-1998 FORD XLT & Lariat Models Only & F-150 & Light Duty F-250 Installation

1. Before beginning installation be sure to wear proper eye protection.
2. Remove the grille shell from the vehicle. Open the hood and remove the black ABS cover from grille to the radiator shroud. Remove the 8 phillips head screws on the retaining clips, lift cover up and remove the retaining clips.
3. Remove the turn signal / parking lamp assemblies by removing the 7MM head bolt at the inside corners behind each lamp. Grasp lamp and pull straight forward to remove. Lift the locking tabs on bulb socket and turn 1/4 turn CCW to remove.
4. Remove the 10 phillips head screws securing the grille shell. Six are located across the top edge of grille and two are located at each side behind the parking / turnsignal lamps.
5. On the F-150 4WD, and the Expedition 2WD and 4WD it will be necessary to remove the black filler beneath the grille shell and above the bumper, under each headlamp. With a flat blade screwdriver, pry down the retaining clips across the bottom of the grille and remove. On the F-150 2WD remove the two clips attaching the filler to fender at each side. NOTE: filler will be removed with grille shell.
6. Reach up throught the bumper opening to the underside of the grille. Depress the metal retainers located 12 inches right and left of center to release the grille from the panel.
7. Gently pull grille shell forward and remove.

INSTALLING THE SPEED GRILLE F-150 & F-250
1. Set the grille shell on a soft, covered, clean work bench or table. Remove the Ford emblem. NOTE: the emblem if desired may be installed in the center of the Speed Grille before installing into the grille shell.
2. Install the Speed Grille insert into the center opening of the grille shell. From the back side mark the location of the attaching clips at the triangular holes of the grille shell, to line up with the holes of the return edges of the Speed Grille insert. Grind or file a notch 3/16″ to 1/4″ deep on the edge.
3. Install clips so that the barbs inside the holes of the grille return edge. Install 6 clips across the top and
5 clips on the bottom. Install clips at each side of the top center, clips at each end and clips between. Install clips at bottom center, clips at each end and clips between. NOTE: Grind notches only deep enough for the barbs to reach holes for a tight grille insert fit.
4. Re-install grille shell on the vehicle with the original fasteners

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1960-1977 Ford/Mercury VariShock Bolt-In Front Coil-Over Conversion Installation and Tuning Guide

Remove Factory Shock and Spring
1. Raise front end of car and secure with jack stands. Wheels must not be in contact with ground.
2. Remove wheels, making note of which side of vehicle they were removed from.
3. Unbolt lower shock mount from spring perch.
4. Unbolt upper shock mount from shock tower.
5. Remove shock and mount from vehicle.
6. Using a spring compressor, remove the coil spring. Follow the tool manufacturer’s instructions for proper use of the spring compressor.
7. Unbolt lower spring perch from control arm.

Install Shock Tower Adapter (TCP COLVF-1X)
The shock tower adapter must be installed before proceeding. Refer to the installation guide packaged with your adapter kit. Depending upon the year and model of your vehicle, you will have received one of the following kits: TCP COLVF-13, TCP COLVF-14 (shown), or TCP COLVF-15. Shock Assembly - Lower Crossbar
8. On each urethane bushing put a small amount of poly lube on the area that will contact the inside of the lower shock eye.
9. Press two bushings into each shock eye, one from each side. Once completely seated apply poly lube to the inside bore of the bushings.
10. Thread the 1/2” set screws into two of the crossbar halves and then place an aluminum crush washer over the remaining set-screw stud.

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1996-2003 FORD 7.3L Power Stroke Diesel Vehicles Power Programmer III Installation Instructions

You are the owner of the Power Programmer III, the latest in high-performance tuning technology. Now you can optimize your engine’s tuning, as well as adjust other vehicle parameters (see table of contents), all at the touch of a button. Your vehicle has an onboard computer that controls the engine and transmission. Inside your vehicle’s computer is a FLASH memory chip which contains the vehicle’s programming. The programmer actually reprograms this FLASH computer chip, according to your specifications, with Hypertech’s Power Tuning. This is the only way an individual can reprogram some 1994-1995 and all 1996 and newer vehicles sold in the United States.

To reprogram your vehicle’s computer, simply plug the programmer cable into the vehicle’s diagnostic connector located under the dash panel on the driver’s side. Set the parking brake. Next, turn the ignition key to RUN but do not start the engine. Press the L arrow on the programmer. It will then identify your vehicle and display a series of options on its screen. When completed, turn the key to OFF and disconnect the cable from the diagnostic connector. Now you’re ready to Feel the Power! Hypertech’s Power Tuning can be stored in only one (1) vehicle at a time. The Power Programmer can be reconnected to remove the Power Tuning and return the vehicle to the factory programming at any time. After you have performed this step, your vehicle will be in its stock configuration.

You may also reconnect your programmer at any time to change the programming. For example, if you have replaced your factory tires with different diameter tires, you will want to correct your speedometer, odometer, and automatic transmission shift points. Simply reconnect your programmer, answer the necessary option(s), and reprogram your vehicle. You do not have to return to stock first.

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42-48 Ford Car Installation Instructions

Remove all parts from you dash, except Speedo trim ring. Install ( 10 ) 8/32 x 5/8 studs in dash adapter as shown in Photo #1.
Install ( 2 ) Gauges in dash adapter as shown in Photo #2.
Install dash adapter as shown in Photo #3
From rear of dash.
Using ( 2 ) 10/32 x 3/8 Pan Head Screws & Washers.
Install the 2 outside gauges as shown in photo #4 & #5.
Do Not Over Tighten Gauges to Panel. Overtightening may break the glass. Leave Clear Protective Covering On Your Panel Until It Is Com- pletely Installed, To Protect The Highly Polished Surface.

This is what it will look like before gauge trim ring is installed. If your dash still has the studs on the rear of the gauge trim ring they will have to be removed. Use doubled sided tape, or silicone to re-install trim ring. Install ( 4 ) 8/32 x 5/8 studs in adapter. Use brackets supplied to install Speedo or Tach adapter in dash from the rear. The 2 holes closest to outside edge of adapter is for the brackets. In some cases these brackets will have to be bent slightly. Now install Speedo or Tach as shown.

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Ford Bath Immersion Tester Elcometer 1270 Operating Instructions

The Elcometer 1270 Ford Bath Immersion Tester is designed to perform, with high reproducibility, a large number of standardised or conventional tests in order to assess the resistance of coatings, notably to blistering, when immersed in water.

Coated metal sheets are laid at an angle of 15°-20°on a grooved bottom and fully immersed in de-ionised water, warmed to 40°C ±1°C (104ºF ±2ºF). Once a predetermined time is reached, the samples are removed and the coating is inspected. The instrument is very simple and consists of a plastic tank with grooved sample holder, a plastic cover and a heater with circulation pump.

Features
• Easy to use and clean
• Bright LED temperature display, resolution 0.1°C
• Keypad operation
• Accurate temperature control
• Adjustable high temperature cut-out/dry-running protection

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1937-1948 Ford Disc Conversion 4 3/4” GM Bolt Circle Installation Instructions

1937-1948 Ford Disc Conversion 4 3/4” GM Bolt Circle Installation Instructions

iNSTALLATION:
1. Remove early Ford drums, brakes and backing plates from spindles. Make sure you retain the bearing nut and keyed washer.
2. Thoroughly clean grease and dirt from spindle. Check for cracks and damage.
3. Using the hardware supplied in the kit install the caliper mounting bracket on the REAR surface of the spindle using the lockwashers between the spindle and mounting bracket. DO NOT omit lockwashers as they are essential to the proper alignment of the bracket. If round spindles are being used check for adequate clearance between the spindle and bracket. FILE BRACKET if necessary. The bracket may be installed so caliper is forward or rearward of spindle centerline. REARWARD INSTALLATION IS HIGHLY RECOMMENDED.
4. Examine the inner wheel bearing seating area on the spindle for nicks, ect. Emery cloth area as required for a smooth surface.
5. Slide bearing adapter on spindle and drive into place using a hammer and a piece of tubing or pipe of suitable dimensions (1 1/2” pipe works great). DO NOT DAMAGE THE ADAPTER WHILE INSTALLING (use a rag for padding between tool and adapter). Drive adapter on until it seats firmly against spindle inner bearing shoulder.

NOTE: Bearings and adapter are machined to a +.0005” tolerance. If bearing does not slide onto adapter easily it may be due to tolerance “stack up.” This can be rectified by a small amount of fine emery “paper-work” on the bearing seating surface of the adapter. Check inner bearing for fit.

6. Fit inner wheel bearing for trial fit.
7. Grease inner and outer bearing with high temperature wheel bearing grease, install rear bearing and grease seal.
8. Install rotor on spindle followed by the outer wheel bearing then stock Ford washer and retaining nut. Adjust bearings as required and install cotter key and bearing dust cap.
9. Install caliper on mounting bracket with bleeder FACING UP using stock GM mounting bolts. Make sure that bolts aren’t bent or damaged before installing.
10. Fill the brake system with DOT 4 brake fluid, bleed and inspect for leaks.
11. Check for any brake caliper / rotor / wheel interference.

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97-98 Ford Air Dam 4×2 and 4×4 Installation Instructions

Tools needed: 8mm open end wrench or socket 7/16 socket or open end wrench 1/4×1 bolts, 5/16 flat washers and nuts
1. Using the 8mm wrench, remove the factory Air Dam.
2. Position Air Dam aligning the center hole of Air Dam with the center hole of bumper.
3. Using a bolt with flat washer on the bolt, push bolt up through Air dam into bumper.
4. Install a flat washer, and a locking nut from above. DO NOT tighten at this time.
5. Install the balance of the bolts making sure that a flat washer is against the Air Dam.
6. Once all bolts are installed, tighten starting from the center of the Air Dam working right and then center of the Air Dam working left.

Ford 4×2 Air Dam Fog Light Installation Instructions
Tools needed: 7/16 open end wrench
Note: The lights are marked with the word “TOP” on the lens face.
1. Feed light wires through slotted hole in Air Dam light pocket and align driving light center bolt with square hole in light pocket.
2. Place dish-shaped washer over light bolt and install nut; do not tighten at this time.
3. Gently pull wire slack through slot. One of the Air Dam bolts can be used for attaching the black ground wire with the eyelet.
4. Complete the wiring of the lights. The lights are fully adjustable in the pockets. Turn lights on and aim where desired. Hold the lights and tighten driving light nut with 1/2” open end wrench.

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VariShock 1960-1977 Ford/Mercury Bolt-In Front Coil-Over Conversion, QuickSet 1 Installation and Tuning Guide

Remove Factory Shock and Spring
Raise front end of car and secure with jack stands. Wheels must not be in contact with ground.
1. Remove wheels, making note of which side of vehicle they were removed from.
2. Unbolt lower shock mount from spring perch (Figure 3-1).
3. Unbolt upper shock mount from shock tower (Figure 3-2).
4. Remove shock and mount from vehicle (Figure 3-3).
5. Using a spring compressor, remove the coil spring. Follow the tool manufacturer’s instructions for proper use of
6. the spring compressor. Unbolt lower spring perch from control arm.

Install Shock Tower Adapter (TCP COLVF-1X)
The shock tower adapter must be installed before proceeding. Refer to the installation guide packaged with your adapter kit. Depending upon the year and model of your vehicle, you will have received one of the following kits: TCP COLVF-13, TCP COLVF-14 (shown), or TCP COLVF-15. Shock Assembly - Lower Crossbar
On each urethane bushing put a small amount of poly lube on the area that will contact the inside of the lower
8. shock eye. Press two bushings into each shock eye, one from each side. Once completely seated apply poly lube to the
9. inside bore of the bushings. Thread the 1/2” set screws into two of the crossbar halves and then place an aluminum crush washer over the
10. remaining set-screw stud.

11. Insert the crossbar assembly into the shock-eye bushing from one side, and then one of the unused crossbar halves into the opposite side. Thread them together until tight.
12. Using a vise and an adjustable wrench or two adjustable wrenches, tighten the crossbar halves until they are clocked evenly with each other and are perpendicular to the length of the shock. DO NOT tighten more than 1/2 turn.
Coil springs will NOT be installed at this time in order to more easily manipulate the suspension system.

Shock Installation - Mock Up
13. The outer shock tower reinforcment to which the factory suspsension bump stop is attached can be removed for easier access when mounting the upper stem of the shock. IMPORTANT: The shock tower reinforcement must placed back into it’s installed position when checking clearances in the following steps.
14. Bolt the shock’s lower crossbar to the top-side of the upper control arm at the factory spring perch mounting location. Use the 3/8-16 x 1-3/4” hex bolts, flat washers and locknuts provided. A flat washer should be used below the bolt head and the locknut. Torque to 30-35 lb/ft.
15. Set shock valving to the softest setting, fully extend the shock, and then insert the shock’s top stem through the tower-adapter mount hole. Raise and support the suspension using a floor jack.
16. Place the thick stem washer over the shock pivot stud followed by the 5/8” OD aircraft washer and thread the 5/8-18 half locknut onto the stud. (Refer to tower adapter instructions for exploded illustration.) Do not tighten locknut to final torque specs at this time. You will be unbolting the shock stem shortly.

Get pdf VariShock 1960-1977 Ford/Mercury Bolt-In Front Coil-Over Conversion, QuickSet 1 Installation and Tuning Guide

97-03 Ford F-150 Flare Side Step Covers

Prefit Before Painting. Install new, unpainted parts according to these instructions.Then remove parts, paint them and re-install.
Painted or Altered Parts are Non-Refundable
Remove the factory step cover. In the center of the lower – front hole drill a 1/8” hole through the center of the second panel as shown in fig.A, this hole will give you access to attach the step cover with the longer screw supplied in the hardware packet. The remaining 3 screws must be used with a washer as shown in fig.B.

The following painting procedures MUST be followed EXACTLY for PROPER ADHESION and to prevent fish eyes
1. To remove any mold release contaminants, clean the back of the part first. Using 2 new clean rags, saturate the first rag with plastic prep cleaner* and begin cleaning. Then use the second rag to remove the prep cleaner. Continuously fold both rags to their clean sides during the process. Use 3 sets of new rags throughout the process. This prevents mold release contaminants from transferring to the painted surface.
2. Repeat step one on the front of the part.
3. Rinse the part with water. Apply a generous amount of Ajax® or sand fix* to a red scuff pad* (3M Scotch Brite Brand) and scrub the surface to be painted THOROUGHLY (especially where the 2-sided tape is installed, on the back side of the part, and all the hard to reach areas). Then rinse with water and dry. The scrubbed surface should be dull. If any shiny spots show, repeat the process on those areas.
4. Using another set of clean new rags, again clean the surface to be painted with plastic prep cleaner.
5. Spray the surface to be painted with adhesion promoter* including the areas where the 2-sided tape is installed (follow the instructions on the can for application and drying time).
6. Apply 3 to 4 coats of urethane primer* with flex additive* (follow the instructions on the can for application and drying time).
7. Wet sand primer with 600 grit sandpaper. Be careful not to sand through the primer. If you do, you MUST clean those areas with plastic prep cleaner, apply adhesion promoter and prime. Once the primer has dried, wet sand the areas that were touched up. Your surface is now ready for paint.
* These items can be purchased at any auto body supply store.

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Ford 5.0 Bellhousing Installation Instructions

This bellhousing is designed to fit all 1965 and up 289, 302, and 351 W/C engines. You may use a 164 or 157 tooth flexplate. These are available from ATI in heavy duty and SFI versions with any weight configuration. This bellhousing can not be used with a 12″ diameter torque converter, but it can be used with 7, 8, 9, 10 or 11″ units. The torque converter bolt pattern must match your flexplate pattern.

INSTALLATION PROCEDURE
This bellhousing is shipped with its own bellhousing bolts, C-4 spacer ring and special pump bolts. The spacer ring and pump volts are used only if you are using a 164 tooth flexplate and torque converter. If you are using a 157 tooth flexplate and torque converter, do not use the spacer ring or pump bolts. Reuse your original C-4 pump bolts.

164 TOOTH FLEXPLATE
1. Match up the holes in the spacer ring to the front of your C-4 transmission. Place the ring on the pump. This ring will give the exact depth needed for the torque converter.
2. Place the bellhousing on to the front of the C-4 and using the supplied bolts, insert and torque to 45 ft. lbs.

157 TOOTH FLEXPLATE
1. Place the bellhousing on to the front of the C-4 and using the stock bellhousing bolts, insert and torque to 45 ft. lbs. Do not use the supplied spacer ring! The transmission is now ready to be installed onto the engine. Use the suppled Allen bolts to secure the transmission to the engine.
For Ford engine to GM transmission applications, use transmission specific (PG part # 915114, T350/T-400 part #915115) adapter ring and bolts only.

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1997-03 Ford F150/F250 L.D.4WD Torsion Key Front Lift/Leveling Kit

Due to the wide on-vehicle adjustment range of this product,a “floating” feature has been designed into the adjustment system. This feature allows the Forged Adjuster & Bolt assembly to reposition in the crossmember as ride height adjustments are made.

Important! Ford/Lincoln vehicles with factory Air Suspension systems require an alternate installation procedure. Only install this product and adjust ride height

AFTER following the prescribed Ford Motor Company procedure.
Step 1:Measure current front ride height. Take a measurement from the bottom of the wheel/rim to the lip of the fender on each side of the vehicle. Write down measurements to help in determining ride height after new torsion keys are installed.(Figure A)
Step 2:Position vehicle on a flat surface or automotive lift. Suspend front wheels, lifting by the frame with a floor jack or lift jack. Secure using jack stands.
Step 3:Locate the Torsion Keys. They are found where the Torsion Bars are received into the Crossmember between the frame.
Step 4:Remove ONE Torsion Key Adjusting Bolt completely. Important! Only work on one side of the vehicle at a time!
Step 5:Using a Torsion Bar Unloading Tool specific to Ford vehicles (OTC 7822A or similar with special bracket),COMPRESS the key until it clears the Threaded Adjuster Bracket where the Adjusting Bolt was housed.
Step 6:Remove the Threaded Adjuster Bracket,and SLOWLY release tension on the unloading tool until it can be fully removed.
Step 7:Slide Torsion Bar FORWARD,allowing original Torsion Key to be removed. It may be necessary to use an air hammer to release corrosive bond between the Key & Torsion Bar.
Step 8:Install new Patented Forged Torsion Key and reposition back into proper position in the vehicle Crossmember and the anchor points at the front of the vehicle. Be sure Torsion Bar passes through Torsion Key by a minimum of 1/8″ to 1/4″!

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Ford Extended Cab Underseat Storage Unit Installation Instructions

This product is designed to enhance the appearance of the vehicle and to shield the occupants from ordinary weather conditions. Do not rely in any way on the components of this product to contain occupants within the vehicle, or to protect against injury or death in the event of an accident. Never operate vehicle in excess of manufacturer’s specifications.

WEAR SEAT BELTS AT ALL TIMES
Read and follow, precisely, all installation instructions provided when installing this product. Failure to do so could place occupants of the vehicle in a potentially dangerous situation. After installing or reinstalling, check to make sure it has been properly installed.

Step One
Install BSR Tape on Mounting Brackets
Locate the Mounting Brackets in the Parts Kit. The BSR Tape will be installed along the edge of each bracket. Cut the tape to the desired length for each bracket. Peel the protective tape off the back of the strip and press the self-adhesive side of the BSR Tape onto each bracket.

Step Two
Attach Mounting Brackets to Partition
Locate the Mounting Brackets in the Parts Kit. Place a bracket on each side of the Partition so that the two holes near the bend in the bracket line up with the holes in the Partition and with the flared part of the bracket along the inside. Use two 1/4-20 x 3/8″ Button Head Screws to install each bracket. Do not tighten the screws at this time.

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2000-2003 JackRabbit Series Ford Super Crew Installation Instructions

The JackRabbit is designed to carry rainwater from the cover into the canister and then out through the drains. Most truck models have standard OE drain holes or plastic/rubber access ports in the front of the truck bed. Check to make sure your truck has the OE drain holes so that drilling into the sheet metal is not required. If drilling is necessary, be sure to check the underside of the truck bed for the best location. The holes should be located near the side and as far forward as possible. Use a drill bit suitable for sheet metal (such as a taper drill or step drill). Drill drain tube clearance holes at 3/4” (19mm). This will need to be done before installing the cover.

STEP 1: REMOVE PLYWOOD PACKAGING
Remove the canister from the box. Using the wrench or socket remove the 2 bolts holding the plywood on the ends of the canister. Use Side Cut Pliers to cut handle retaining straps. Discard plywood packaging and bolts.
JACKRABBIT: Locate (2 each) 1/2” and 3/4” Rail Guide Bolts and (2 each) 1/4” nuts in the hardware pack and install the 3/4” bolt in the blanket guide hole. Install the 1/2” bolt and nut into the remaining hole where the packaging bolts and plywood were just removed. Repeat on both ends of the canister. FULL-METAL JR: Locate the (4 each) 1-1/4” Rail Guide bolts in the hardware pack and install them in the two holes where the packaging bolts and plywood were just removed. Repeat on both ends of the canister.

2003-2006 Ford Crown Victoria 41F-12-F Front Shocks

1. The electrical power to the air suspension system must be turned o prior to hoisting, jacking or towing an air suspension vehicle. Failure to do so can result in unexpected ination or deation of the air springs, which can result in shifting of the vehicle during these operations. Turn the air suspension service switch o.
2. WARNING: Do not remove the center nut. This nut holds the upper spring mount in place and if this nut is removed the spring tension will be released. Failure to follow these instructions may result in personal injury. Remove and discard the nuts.
3. Remove the wheel and tire assembly.

Removal and Installation
4. Remove the bolts and position the caliper, pads and anchor plate aside.
5. Remove the brake disc.
6. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Remove and discard the nut.
Removal and Installation
7. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Remove the nuts and the stabilizer bar link.
* Discard the nuts.
8. Detach the retainer.
9. NOTE: Use the hex holding feature to prevent the stud from turning while removing the nut. Remove and discard the nut.

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2003-2007 Ford Powerstroke 6.0L Airaid Intake System Installation

1. Disconnect both negative battery cables. Unlatch all four factory clips on the factory airbox.
2. Remove factory air filter by separating the inlet and outlet sections of the assembly.
3. The filter is held in place by two rubber grommets on the bottom.(Note: make sure factory grommets remain in lower air box support.)
4. Disconnect electronic filter restriction gauge connector and remove the restriction gauge, and rubber grommet.(Note: retain these parts for later use.) Remove air filter inlet tube and hose assembly. USE CAUTION when removing these elements, as it is a tight fit. Be careful not to tear the factory insulation around the radiator support.
5. STOP AND LOOK! If you have a temperature sensor like this, proceed to step # 8. The early production 2005 F-250 and F-350 6.0 diesel trucks either came with a temperature sensor, or they came with a Mass Air Flow sensor. These pictures will help you determine which sensor you have. Whichever sensor you have, this Airaid Intake System will fit.
6. IF YOU HAVE A MASS AIR FLOW SENSOR LIKE THIS, A.) Disconnect the electrical connector, and remove the two screws using the supplied T-20 security bit, and remove the sensor. (Retain the sensor for later use.) B.) Using a 5/16” socket loosen the hose clamp on the end of the intake tube.
7. Remove complete factory air filter tube assembly. (Note: do not remove flexible turbo inlet hose from turbo housing.)
8. A.) If you have the temperature sensor shown in step #5, install the supplied grommet as shown above. B.) Install the factory air temperature sensor as shown, and then the factory grommet and filter restriction gauge. Skip to step #10.
9. A.) If you have the sensor shown in step # 6, install the gasket and sensor using 2 (black) 8/32”x 5/8” screws. B.) Install the factory grommet and filter restriction gauge.
10. Slide the Airaid filter tube into factory flexible turbo inlet hose. (Note: Do not tighten hose clamp until assembly is complete.) Reconnect the sensor to the factory plug. (Either the temperature sensor or the mass air sensor, which ever you have.)

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06-07 Ford Mustang Ultrasonic Parking Assist System Installation Instructions

Before beginning installation, familiarize your-self with the installation instructions and the ultrasonic parking assist system components.
To ensure your safety:
A) Make sure your vehicle is in “PARK”.
B) Apply the emergency brake.
C) Read this manual before starting.

CAUTION: It is advisable to disconnect the negative battery cable for 3 minutes before beginning installation, to avoid unintended air bag deployment. Note and record any anti-theft radio codes prior to disconnecting.

STEP 1: VEHICLE PREPARATION
1. Lift the trunk. Remove the rear door scuff panel and pull back luggage matt. (Figure1). Release passenger-side trunk lining. Remove tire cover to access the rubber grommet.

STEP 2: SENSOR LOCATION
1. If using mylar template, align with the surface of the bumper. Make sure the template is centered horizontally on the bumper. Use the trunk or tailgate latch bar as a reference for the centerpoint, and use the printed arrows and lines on the template as a guide. Secure the template to the bumper with masking tape.
2. For (4) sensor applications, measure the width of the bumper and mark locations at 1/8 and 3/8 distance in from each end as shown in Figure 2. For (2) Sensor applications, place one sensor at 1/4 distance from each end. The ideal location will be 18”-22” off the ground. Mark the holes in the template on the bumper. Using a 22mm or 7/8” hole-saw, drill holes at the four marked spots. Hold the drill steady and level such that the holes will be drilled perpendicular to the surface of the bumper. Use a deburring tool to carefully remove any burrs of plastic in the holes (Figure 3).

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