Auto Manual Resource: 08/24/09

Ford F-150 Bed Extender Bracket Installation

F-150 QUICK LATCH MOUNTING BRACKET INSTRUCTIONS
Step 1. Remove contents from box and check for damage. Verify all parts against parts list. Read and understand instructions completely before installation.
Step 2. Assemble brackets as shown in Figure 1.
Step 3. With lever towards the tailgate side insert lower hold-down bracket through lower hole on d-pillar.
Step 4. Insert upper hold-down bracket in upper hole of d-pillar.
Step 5. Tighten bolts until approximately ½ of thread is left.
Step 6. Center tabs on upper hold-down bracket in hole on d-pillar and tighten bolt while pulling outward to hold tabs in place.
Step 7. Repeat for lower mounting bracket.
Step 8. Check for interference with tailgate closed (Lever should be within 1/8 to 3/8 of tailgate).
Step 9. Torque bolts to 90 in-lbs (7.5 ft-lbs).
Step 10. Repeat steps 3-9 for other side.
Step 11. Slide Bed Extender into brackets until it locks into place.
Step 12. To remove extender either pull lever and pull upward on extender or rotate the extender 90° and then pull up on extender.

Get pdf Ford F-150 Bed Extender Bracket Installation

1989-2006 Ford Crown Victoria 40F-15-R-KIT Full Air Suspension Replacement

Removal and Installation
-Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury.
- Disconnecting an air line that is connected to the air compressor can cause personal injury or damage to components as high pressure air is vented uncontrolled.
- Do not attempt to install or inate any rear air spring that has become unfolded to prevent vehicle damage or personal injury.
- Failure to observe the following procedures may result in a sudden failure of the air spring or suspension system.
- Any rear spring which is unfolded must be refolded prior to being installed in a vehicle.
- The air spring refolding procedure should only be used for an air spring which has never supported the vehicle’s weight while in the improperly folded position.
- Improperly folded air springs found on vehicles during pre-delivery inspection or after use must be replaced.
- Do not attempt to inate any air spring which has been collapsed while uninated from the rebound hanging position to the jounce stop.
- When installing a new air spring, care must be taken not to apply a load to the suspension until springs have been inated using the air spring ll procedure.
- After inating an air spring in the hanging position, it must be inspected for proper shape.

Get pdf 1989-2006 Ford Crown Victoria 40F-15-R-KIT Full Air Suspension Replacement

91-95 Ford F-250/350 7.5L PowerAid Throttle Body Spacer Installation Instructions

Installation Instructions. Read Me!
1. DISCONNECT NEGATIVE (-) BATTERY CABLE.
2. Remove throttle body intake assembly.
3. Remove (2) bolts & save from linkage bracket. (Ref. C)
4. Remove (4) bolts from the throttle body. (Ref. D)
5. Remove gasket and clean surfaces.
6. Install power plate using (2) gaskets. (Ref. A)
A. Place one gasket between the throttle body and power plate.
B. Place second gasket between the power plate and manifold.
7. Replace (4) bolts using Step 4 as an example.
8. Locate and install (2) linkage plates using (2) flat head screws. (Ref. C)
9. Reinstall linkage bracket using saved bolts. Refer to Step 3
10. Inspect & Test the throttle linkage for full open & closed travel before driving. Some cruise or kickdown cables may require adjustment. Please refer to your vehicles service manual for proper adjustment.
11. Reinstall throttle body intake assembly using Step 2 as an example.
12. Reconnect battery cable. Enjoy.

Get pdf 91-95 Ford F-250/350 7.5L PowerAid Throttle Body Spacer Installation Instructions

2” Lift System for 1999 and newer Ford F-250 / 350 Super Duty 4WD Pickup

Installation requires a professional mechanic. Prior to beginning, check all suspension-to-frame attaching points for stress cracks. The overall vehicle must be in excellent working condition; repair or replace all worn parts. Read instructions several times before starting. Be sure you have all needed parts and know where they install. Read each step completely as you go.

NOTES:
• Ford made a mid-year production change to the front U-bolts in 1999. Vehicles with a production date prior 2-28-99 utilize square front U-bolts, while vehicles manufactured on or after 3-1-99 may utilize square U-bolts or large-radius U-bolts. Kit box #9625 includes the square U-bolts, while kit box #9626 includes both U-bolt styles. Verify the correct front U-bolts are supplied prior to beginning installation.
• The rear lift is sold separately and includes separate installation instructions.
• Save all factory mounting hardware for reuse, unless otherwise noted.
• A factory service manual must be on hand. The manual will contain fastener torque specifications, assembly techniques, and / or special tool requirements that are unique to this particular year and model vehicle.
• Do not add or fabricate any components to gain additional suspension height.
• Prior to attaching components, be sure all surfaces are free of grit, grease, undercoating, etc.
• A torque specification in foot-pounds is shown in parenthesis “( )” after each fastener.
• Use the check off box found at each step to help you keep your place. Two denotes that one box is for the driver side and one is for the passenger side.

Get pdf 2” Lift System for 1999 and newer Ford F-250 / 350 Super Duty 4WD Pickup

Ford 302 HO Hydraulic Roller Lifter Kit

This kit is designed to allow the installation of hydraulic roller cams in standard Ford 302 HO V8 engines originally equipped with hydraulic roller cams. In order to use this kit, your engine must have two bosses cast into the block (fig. 1) in the lifter valley area. These bosses may or may not be drilled and tapped for 1⁄4″-20 bolts. If yours are not drilled and tapped, then you must be prepared to do so during this installation process. Once you have installed your COMP Cams® Magnum Hydraulic Roller Camshaft per the camshaft installation and degreeing instructions supplied with the cam, you are ready to install the hydraulic roller lifters.

Installation Instructions:
1. Installing the lifters - Slide the lifters into the lifter bores just like a regular lifter, and then rotate them until the flat surfaces on the sides of each lifter all face inward toward the lifter valley. Each lifter has two flats, one on each side. It does not matter which flat faces the valley and which faces the cylinders. You may encounter some difficulty in trying to install the end lifters in each bank due to interference from an ear on each end of the head gaskets. Gently bend this ear out of the way, install the lifters, and bend the ear back into place. The purpose of this ear is to help locate the intake gasket during manifold assembly, so do not bend or remove it permanently.
2. Installing the lifter guides - The purpose of the guides is to prevent the lifters from rotating, therefore keeping the lifter wheels rolling over the cam lobes as opposed to sliding. With all the flats on the lifter in line, install one of the eight lifter guides over each pair of lifters in the valley. They should be installed with the word “UP” that is stamped into each guide facing up. It does not matter whether the “UP” stamp is toward the front or the rear of the block. The forks on each end of the guides should nest over the top of the flats on either side of each lifter.

Get pdf Ford 302 HO Hydraulic Roller Lifter Kit

Stake Pocket Rails Installation Instructions

Before installing any bed rail on any vehicle, you must insure there is adequate clearance for the installation. Some vehicles do not have a protective “inner bed wall”, and rough treatment can result in a distortion created from within the truck bed. Daws Manufacturing Co. Inc. will not be liable for any installation damages created by the installation or installer. Prior planning and care are the installer’s responsibility.

1. Read and understand these instructions before beginning the installation.
2. Attach the adjustable feet to the rail making sure the beveled side of the foot matches the bevel of the flat head screws. You must use 2 screws per foot to keep the foot straight. Use the chart on the reverse side of these instructions to set the correct length or gently set the bed rails in position being careful not to scratch the truck. Use the plastic gaskets for protection. Adjust the flat feet so the mounting hole is centered over the stake pocket hole. Tighten the screws securely.
3. Look at the truck from both sides and the rear to be sure you are satisfied with the appearance. NOTE: Ford F150 ’97 to current and 2001 Tundra will need to have the stake pocket covers marked for hole location where the bolt will pass through. When you are satisfied with the rail position, mark the hole location on the stake pocket cover.
4. Place the button head bolt through the protective plastic washer, rail foot, and rail gasket (now is the time to install the ’97 Ford or 2001 Tundra stake pocket cover if necessary). Thread the proper locking bar onto the bolt, just a few threads deep. You will need to keep the locking bar loose at this time.
5. Carefully place the rail on the truck bed while inserting the locking bars into the stake pocket hole. The locking bars must fit under the lip of the stake pocket hole so when the bolt is tightened, they hold the rail to the top of the truck’s bedrail.
6. Refer to the warning note at the top of the page. The locking bars must not contact the outer fender wall of the vehicle, or they may create a distortion in the metal when tightened. To help prevent this from happening, tension can be applied to the locking bar by lifting up the bed rail while tightening the button head bolt. This tension must be held to prevent the locking bar from turning in the hole and contacting the outer skin of the fender.
7. Tighten the bolts enough to secure the rail to the truck without unnecessary torque. Excessive tightening on the button head bolts can distort the fender top.

Get pdf Stake Pocket Rails Installation Instructions

Street Avenger Carburetor Installation, Tuning and Adjustment Manual

If you are using this carburetor with a GM overdrive transmission TH700R4 or a TH200R4, you must use a transmission kickdown cable bracket (Holley P/N 20-95) and stud (Holley P/N 20-2, 20-38, or 20-40). Otherwise, SEVERE transmission damage WILL result. This carburetor is not designed to work with ANY other automatic overdrive transmissions.

These carburetors have been designed and calibrated as a universal replacement carburetor for passenger cars and light truck applications equipped with V-6 and V-8 engines. It is designed for use on “square” flange intake manifolds. Carburetor adapters are not recommended to adapt to “spread” bore intake manifolds, since adapters may have an adverse affect on cylinder-to-cylinder distribution and ultimately, total engine performance. However, some manifolds may be universal (such as Weiand 8004). Please check with Holley’s Avenger Technical Service Department if you have any questions.

REMOVAL:
1. Remove the air cleaner, exercising care to carefully detach any vacuum lines to the air cleaner and marking them so they can be reassembled to the air cleaner in the same manner.
2. Remove the existing carburetor by the following procedure:
A. Carefully disconnect the fuel line.
WARNING: Carefully protect the open end of the fuel lines, so that no foreign particles can enter. Wrap the end of the fuel line with a clean lint-free cloth.
B. Disconnect and mark all the vacuum lines to the carburetor.
C. Disconnect the PCV hose.
D. Disconnect the choke rod or heat tubes (if equipped).
E. Disconnect and remove the throttle linkage and automatic kickdown linkage. SAVE ALL RETAINING CLIPS.
F. Unbolt and remove the carburetor from the manifold.
3. If the intake manifold is being changed at this time, install the new manifold according to the manifold’s manufacturer’s directions. Since we are not familiar with all manifold instructions, Holley cannot accept responsibility for their validity. We recommend that you only use Holley Street Avenger manifolds, which you can find in the Street Avenger catalog included with your kit.

Get pdf Street Avenger Carburetor Installation, Tuning and Adjustment Manual

Auburn Gear Differential Disassembly / Assembly Instructions

These instructions are intended as an aid for the experienced automobile mechanic in properly servicing the Auburn Gear Limited-Slip differential. It is expected that the mechanic be equipped with the proper tools, equipment, and experience before attempting to service the differential. Differential removal will be required for most maintenance operations. Refer to the vehicle service manual for differential removal and installation procedures.

INTEGRAL CARRIER AXLES
A. Differential Cross-pin
1. Remove axle housing cover to expose differential.
2. Remove the differential cross-pin lock screw and remove pin. See Fig. 1. The differential cross-pin may need to be driven out. Use a hammer and a brass drift to drive the differential cross-pin out
3. Install new cross-pin and torque new lock screw to 25 lb-ft.
4. Install axle housing cover.
5. Fill axle with the recommended axle lubricant for use with limited-slip differentials level with the filler hole.
NOTE: Some gear ratios require a flatted cross-pin. Replacing the cross-pin in this application will require differential removal and ring gear removal as well as modifying the new cross-pin.
B. Differential Disassembly Procedure
CAUTION: Do not attempt to remove the end cap of the differential. All servicing will be done through the large window of the differential case.
1. Remove differential from axle housing (refer to vehicle service manual).
2. Remove and discard ring gear screws.
3. Using a non-metallic hammer or brass drift punch, drive the ring gear loose from the differential case pilot and remove.

Get pdf Auburn Gear Differential Disassembly / Assembly Instructions

99-03 Ford 7.3L Power Stroke Diesel S6200AL Installer SERIES

Hardware kit sold separately, contact your local dealer/distributor for further information.
Removal of stock system:
Remove nut, with 15mm wrench or socket, from band clamp in front of muffler.
Remove rear exhaust from rubber hangers, remove bottom shock bolt at rear of truck &
separate the stock exhaust at the slip joint at the muffler.
Remove the muffler and tail pipe from under the truck, re-install the bottom shock bolt.
Remove extension pipe at flange using 15mm deep socket.
Remove down pipe, under the hood remove band clamp with 11mm at turbo then cut pipe in front of transmission cross member to remove.

(Note: The stock down-pipe can be removed in one piece by removing the transmission cross member, MBRP Inc. recommends that this procedure be only be done by qualified trained professionals using tools and equipment designed to safely carry out this process.)

Installation of MBRP Inc. Performance Exhaust:
Install down-pipe, flare side to turbo using stock band clamp. Do not fully tighten until all components are in place. Install the Mid-pipe using the pre-welded hanger into the OEM rubber hanger located on the frame. Install extension pipe over the down-pipe, included is an 34″ extension to accommodate each wheelbase. (Installation tip: Temporarily hang the muffler and tail pipe in place using the two OEM rubber hangers and measure to the mid-pipe to determine the length needed, cut if necessary)
Install muffler over the extension(s), the muffler core can flow either direction. If you install the core with the spiral openings towards the flow it will be quieter out the tailpipe and approx ½ db louder inside the cab. If you install the muffler with the core opening facing the rear of the truck it will be approx. ½ db quieter inside the cab and allow the sound to exit out the tailpipe.

Get pdf 99-03 Ford 7.3L Power Stroke Diesel S6200AL Installer SERIES

GM Power Steering Conversion Mid Fifty F-100 Instructions

KIT FITS: 1950 - 1964 ½ and ¾ ton Ford pickups and panels F-1, F-100, F-150. These instructions covers Drop Axle Kit as well but steering link and both tie rods are different. KIT INCLUDES: Plates for each side of frame rail with tubes pre-welded and pre-drilled for steering box mounting, seamless heavy wall tubing tie rod and steering drag link, 2 right and 1 left tie rod end, and a machined steering link (double tie rod end) *

ADDITIONAL PARTS YOU MAY NEED:
A 1965 to 1980 GM passenger car Saginaw power steering box. Can be front or rear steer, but look for one with 4 turns lock to lock and avoid Camaro-Firebird type, too quick for truck. The more turns lock to lock the better the handling, remember this is a heavy truck and most weight is forward.
A power steering pump with brackets that mount to your engine.
All necessary lines and hoses.
A pitman arm,* NOTE: Get the shortest pitman arm possible 5″ to 5 ½ ” ,center to center of holes. Try the larger GM 70’s cars such as Buicks and Station Wagons, 1978 Monte Carlo.
”Front of frame at bumper. Use short Pitman Arm 5” to 5 1/2” center to center is best. (1978 Monte Carlo) or heaver cars like Buicks or Station Wagons. Drag link should be as close to horizontal as possible at ride height.

Get pdf GM Power Steering Conversion Mid Fifty F-100 Instructions

2005-2009 Ford F-250 Super Duty 4WD w/o Camper Package Installation Instructions

ReadyLift Suspension Inc. recommends this system be installed by a professional technician. In addition to these instructions, professional knowledge of disassembly/ reassembly procedures and post installation checks must be known.

PRODUCT SAFETY WARNING: Modifying your vehicle ride height may result in the vehicle handling differently than a factory equipped vehicle. Extreme care must be used to prevent loss of control or vehicle rollover. Failure to drive your modified vehicle safely may result in serious injury or death. ReadyLift Suspension Inc. does not recommend the combined use of suspension lifts, body lifts, or other lifting devices. You should never operate your modified vehicle under the influence of alcohol or drugs. Always drive your modified vehicle at reduced speeds to ensure your ability to control your vehicle under all driving conditions. Always wear your seat belt.

Pre-Installation Notes
1. Special literature required: OE Service Manual for model/year of vehicle. Refer to manual for proper disassembly/reassembly procedures of OE and related components.
2. Adhere to recommendations when replacement fasteners, retainers and keepers are called out in the OE manual.
3. Larger rim and tire combinations may increase leverage on suspension, steering, and related components. When selecting combinations larger than OE, consider the additional stress you could be inducing on the OE and related components.
4. Post suspension system vehicles may experience drive line vibrations. Angles may require tuning, slider on shaft may require replacement, shafts may need to be lengthened or trued, and U-joints may need to be replaced.
5. Secure and properly block vehicle prior to installation of ReadyLift Suspension Inc. components. Always wear safety glasses when using power tools.
6. If installation is to be performed without a hoist, ReadyLift aSuspension Inc. recommends rear alterations first.
7. Due to payload options and initial ride height variances, the amount of lift is a base figure. Final ride height dimensions may vary in accordance to original vehicle attitude. Always measure the attitude prior to beginning installation.

Get pdf 2005-2009 Ford F-250 Super Duty 4WD w/o Camper Package Installation Instructions

Ford EEC-V J3-8B Chip module Install Instructions

When working with static sensitive electronic parts, care must be taken to ensure the electronics are not damaged from static electricity discharge. You can wear a static strap grounded to the vehicles body as the safest way to guard against static discharge. Alternatively you can touch a raw metal (unpainted) part of the body to ground yourself and discharge any static buildup. Do this regularly to prevent static build up.

Try to handle the chip module on the edges. Avoid touching the pins.
When working on the ECU it is good practice to remove the negative lead from the battery before plugging in or removing the chip module.
If you have a security coded radio fitted, make sure you have the code before disconnecting the battery
#1) Start by removing the plastic kick panel on the passenger side foot well to expose the ECU.
#2) Remove the brace holding the ECU in place.
#3) Looking at the bottom of the ECU there is a black plastic cover, use a flat screwdriver and pry it off.
#4) Once removed, the contacts for the chip module are exposed. The contacts are coated with some type of silicon grease, this needs to be removed. Use the supplied swabs to remove grease.

After cleaning the contacts there will be some soft jel still left behind and it will need to be scraped off. Use a dull non metallic object to give the contacts a scraping, an icy pole stick is ideal. Use an up down motion as apposed to side to side for best results. Give the contacts one final wipe to remove any residue left behind. It may be easier to remove the ECU from the car for the purpose of cleaning the contacts. Use a 10mm socket or spanner to un do the bolt on top of the connector, the plug will come out with the bolt.
NOTE: It is very important that the contacts are well cleaned. If the module is not able to make proper contact it won’t function correctly or wont function at all. You don’t want the car to cut out while driving!

Get pdf Ford EEC-V J3-8B Chip module Install Instructions

1997-2000 F250 Light Duty Pickup Bracketron Phone Mount Installation Instructions

When installing in a vehicle with an Auto Climate Control you will not be drilling or using the included screws. See step (3). When re-installing the auto climate control unit in the cavity you will need to apply some downward pressure on the unit so the centering pins and four factory screw holes will line up. Install the four (4) screws that secure the auto climate control then tighten. The mount will be nice and tight.

Grasp the bezel that surrounds the radio and climate control in the upper right corner and carefully pull toward you to release the first of five (5) clips that secure the bezel in place. Continue working the bezel loose releasing the remaining four (4) clips, two (2) on the left and two (2) on the right. When the bezel is loose, disconnect the wiring to the left of the climate control only. Let the rest of the bezel hang, or prop it out of the way to gain access to the radio and climate control.

Locate four (4) holes in the face of the radio. Insert the (Ford Radio Removal DIN Tools) into the holes and pull outward while at the same time pulling the radio out of its cavity. Disconnect the wiring too the radio and place the radio in a safe place. Locate and remove the four (4) screws that hold the climate control in place. Slide the climate control out of its cavity and prop it up to the right to keep all the wiring and vacuum lines out of the way.

Place the Bezel Mount in the cavity of the climate control. Make sure the hole on the Bezel Mount is aligned with the lower left screw hole that secures the climate control in place. In the two (2) remaining holes on the Bezel Mount, use the marking pen to mark two spots for drilling pilot holes. Remove the Bevel Mount and set it aside. Carefully drill two pilot holes with the 5/64” drill bit and drill. Place the Bezel Mount back into place, insert the provided screws and tighten with the #2 Phillips screwdriver. Place the climate control back into its cavity. Insert the four (4) holes that secure it in place and tighten.

Get pdf 1997-2000 F250 Light Duty Pickup Bracketron Phone Mount Installation Instructions

OmniTrac Brake Control Installation Guide

Drilling or use of longer screws may damage unit.
1. Securely mount bracket to a solid surface.
2. Insert supplied #6 x 3/8″screws on each side into the mounting holes.
3. Adjust control to desired position and tighten screws until snug.
4. Once the brake control is securely mounted, point the Internal Sensor Adjustment Arm down to the ground.

The Brake Control must be mounted from 20 degrees nose down to 70 degrees nose up.

Setting Up the Brake Control
The brake control has independent soft and hard effort brake settings.
• Soft Effort – setting for gradual stops, which allows for effective braking without the wheel “hop”
• Hard Effort – setting for hard or panic stop, which is sensed by the Internal
Sensor and braking effort is automatically switched over to the Hard Effort Setting.

Setting the Internal Sensor Arm
Once the brake control is securely mounted, the internal sensor adjustment arm must be pointed directly toward the floor of the vehicle. To Fine Tune the sensor, the arm can be moved to change the switching level. This needs to be done after the soft and hard effort levels are set.

Setting the “Hard” Effort
Adjustment
1. Connect trailer to tow vehicle.
2. Set HARD adjustment slide to mid-position.
3. Tow trailer at low speed (20-30 mph) on a level, dry and paved surface and apply Manual Slide Knob.
- If trailer brakes DO NOT lock up:
- Increase HARD braking effort by sliding HARD adjustment to the right.
- If brakes DO lock up:
- Decrease HARD braking effort by sliding HARD adjustment to the left.
4. Repeat step (3) until HARD braking effort has been set to a point just below wheel lock up or at a sufficient force as to achieve maximum braking power.

Get pdf OmniTrac Brake Control Installation Guide

Ford Falcon Hard Tonneau Cover Fitting Instructions

This product should be fitted by experienced people.
Be sure you read fitting instructions carefully and completely before fitting ute lid to vehicle.
1. Remove all packaging from ute lid.
2. With assistance - carefully place ute lid onto ute tub body, ensuring lid is sitting correctly with even gaps all around.
3. At the front of the lid, mark a line onto the tub liner on each side of both lid hinges.
4. Remove ute lid from vehicle.
5. Place the slotted hinges (1) flush with the body- between the lines you marked (2) and attach both hinges to body using self drilling screws supplied.
6. On the top inside edge of tub, measure 880mm back, then 60mm down and mark position. This mark is the position for the ball on the strut bracket. Attach gas strut bracket with self drilling screws provided. Repeat for opposite side.
7. Attach thinner shaft end of struts onto strut brackets.
8. On the ute lid, attach strut brackets - using screws already fitted onto ute lid.
NOTE; strut brackets may be already attached
9. With assistance - carefully lift ute lid to almost vertical position and mate up hinge tongues on lid with hinge slots on body-sliding tongues into slots.
NOTE: ensure tongues are fully inserted into slots before lowering or damage will result.
Lower lid slightly and attach struts to strut brackets on lid.

Get pdf Ford Falcon Hard Tonneau Cover Fitting Instructions

Ford Rotunda Approved SF99 Servo Bore Repair System: 5RW

1. Install the drill jig into the case by setting the jig into the servo. Retain the jig in the case with the servo’s snap-ring.
2. Drop the 9/16” guide into the jig. It doesn’t matter which one of the lands on the guide you use, as long as one of the lands is under the 3/8” Allen screw.
3. Ream out the bore using the 9/16” reamer, applying ample lubrication.* DO NOT REAM ABOVE 500 RPM.
4. Replace the 9/16” reamer guide with the 5/8” guide, and the 9/16” reamer with the 5/8” reamer.
5. Ream the bore out using the 5/8” reamer with ample lubrication.* Take care not to either push too hard on the reamer or turn the reamer faster than 500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
6. Clean the case before proceeding to step number seven.
7. Apply Loctite® (preferably green #680) or equivalent to the bushing and drive the bushing in by hitting the driver until the bushing bottoms. The 5RW kit uses a smaller diameter installation tool identified by a groove cut in the handle.
8. After installing the bushing, using a 15/64” bit, drill a hole in the side of the bushing by following the holes in the case (use the appropriate picture to the left as a map).
9. Insert the provided sizing pin into the bore. It may be necessary to start the pin in the bushing with a rubber mallet. Once the pin is inside the bushing, use a punch to drive the pin all the way through the bushing. Repeat as necessary.

Get pdf Ford Rotunda Approved SF99 Servo Bore Repair System: 5RW

Xcalibrator 2 User Instructions

How to use the Xcalibrator 2:
Plug the OBD-II connector into the port under the dash of the vehicle you wish to program. Some vehicles may have a panel that needs to be removed to access it. With the key off, use the up and down arrows to navigate through the main menu.

Vehicle Diagnostics
The Xcalibrator 2 can read and erase DTCs (Diagnostic Trouble Codes) on the LCD display. This feature will work on any Ford based OBD2 vehicle. The Xcalibrator 2 can also read the Strategy of the vehicle, This is very useful on vehicles that have been reflashed to a updated calibration. This feature can ensure your SCT dealer programs your vehicle with the newest release calibration.

Program Vehicle Menu:
First disconnect the fuel pump and electric fan fuses. From the main menu, scroll down to the Program vehicle menu and press select. Here you select what file type you want to install into the vehicle, Custom Tune or Return to Stock. In the Custom Tune menu, use the up and down arrow keys to select the file you want to program onto your vehicle. With that file displayed, press the select button to start the flashing process.

Turn the key on when prompted on the LCD display.
If there are user adjustable options available for that file, the display will read Enter Opt Parms? (Enter Option Parameters) which will allow you to make minor changes to the file. Press the Cancel button to skip the custom options and go straight to the flashing process.

User Adjustable Options: Press the Select button to enable custom tune options. Using the up and down arrows navigate through the selectable options. Press the select button to make a change to that category. Press select when finished with that category to choose the next category. Repeat until finished. Once you have made all of your changes press the Cancel button to start the flashing process. Once the flashing process is complete, the display will display “Program Complete, Press Select” followed by “Turn key off, Press Select” Turn the key off and press select. Your vehicle is now programmed and you can unplug the Xcalibrator 2.

Get pdf Xcalibrator 2 User Instructions

Installation Voltage Regulators Instructions

You have bought a quality voltage regulator. This unit is engineered and built to give you maximum service when properly installed. The fact that you are replacing the voltage regulator indicates the possibility that some trouble may exist in the electrical system that caused the old regulator to fail. To avoid damaging the new regulator follow these instructions carefully.

IF CHARGING RATE IS LOW OR NO CHARGE AT ALL,
MAKE THESE TESTS:
1. Check battery water and general battery conditions to see if it will take and hold a charge. Check for specific gravity of 1.240 to 1.290 and make load test with a cell tester.
2. Check wiring for damage. Make sure all wiring connections at generator, regulator and battery are tight and free from corrosion.
3. Check fan belt for tension. Set to vehicle manufacturer’s specifications.
4. Run motor at medium speed, using a wire to touch one end to regulator base and other end to a good ground. If generator now charges, regulator is not properly grounded.
5. If, after the preceding test, the generator still does not charge, run the engine at medium speed and make the following tests illustrated.
FORD REGULATORS ONLY:
Connect a piece of number 10 or larger copper wire between the ARM terminal and the BAT terminal. Touch one end of another piece of wire to the FLD terminal and the other end to the ARM terminal. If the generator now charges, replace the regulator. If the generator does not charge, the trouble is in the generator.

Get pdf Installation Voltage Regulators Instructions

Ford Ranger Rear Stabilizer Bar Installation Instructions

Before beginning installation be sure to set the parking brake and chock the wheels.
NOTE:
To ease installation and properly adjust the bar, the weight of the vehicle must be on the suspension as if driving down the road. Do not raise the vehicle by the frame.
1. Lubricate the D-bushings and place them onto the straight areas of the bar on each side of the center hump as shown in the photos.
2. Hold bar up to the axle and locate the position on the axle tubes to mount the u-bolts. Be sure to put the U-Bolts Under Any Brake Lines, Wires or Hoses on the Axle to Avoid Any Possible Damage. The threads of the U-Bolts will point down.
3. Place saddle brackets onto the U-Bolts on the axle tubes. Place the U-Plates over the D shaped bushings on the bar and attach the bar to the U-Bolts and saddle brackets with the flat washers and nuts provided. LEAVE LOOSE AT THIS TIME to allow for adjustment later.
4. Adjust sway bar so that the end links are parallel with the ground and center the bar side to side. Chose the spacer tube and bolt that best fits the vehicle and assemble end links to frame bracket as shown in photos using 4 bushings and 4 washers per end link. Ensure that the end links are installed square to the mounting brackets and the ends of the sway bar.
5. Attach frame bracket to frame rail using the 1/2” X 1-1/2” bolt and 1/2” locknut. Install bolt with the large diameter flat washer mounted to the inside of the frame rail.
6. Tighten nut on end link until the bushings start to bulge slightly.
7. Adjust sway bar on axle so that there is at least 1/2” clearance between the bar and the axle. Ensure adequate clearance between the sway bar and all shock absorbers, brake lines, hoses, cables and electrical connections. When all clearances are confirmed, tighten U-bolts to 45-50 ft-lb. Double nut and tighten.
8. Bounce vehicle and check for clearance on all undercarriage components. Recheck installation, look for clearance on gas lines, exhaust pipes, brake lines, wiring, etc.
9. Drive vehicle for a few miles, then recheck for position and tightness, readjust and retorque as needed. Then recheck periodically thereafter.

Get pdf Ford Ranger Rear Stabilizer Bar Installation Instructions

2005-07 Ford Mustang GT 4.6LV-8 Airaid Installation Instructions

1. Disconnect negative battery cable. PLEASE READ #22 ON THE BACK PAGE!! Push the green plastic tabs, and remove breather hose from vehicle. (Save for later use).
2. Loosen the intake tube hose clamp on the throttle body. Slide the red tab on the electrical connector, and disconnect the mass air sensor.
3. With a 10mm socket, remove the bolt holding the factory airbox to the fender, and save it for re-installation in step #8.
4. Remove the complete factory intake. Use caution to retain the factory grommets in the inner fender.
5. Using the provided #20 torx bit, remove two screws and the mass air sensor from the factory airbox lid. Note the direction of the sensor for proper re-installation later. (Save the mass air sensor for re-installation in step #13, the factory screws will not be re-used).
6. With a 10mm socket, remove and save the bolt from the anti-lock brake bracket. It will be re-installed later in step #9.
7. Install the provided grommet (#16), with the groove at the top, into the Cool Air Dam (CAD) hole, as shown. Next slide the aluminum sleeve (#17), into the center of the grommet.
8. Install the air filter adapter (#6) into the Cool Air Dam (#7) as shown, using 3 button head bolts (#10) and ¼” flat washers (#11).
9. Install the CAD into the factory grommets in the inner fender, and re-install the bolts from steps #3 and #6
10. Install the hump hose (#5) on the filter adapter (#6), with two #64 hose clamps (#14). Tighten only the clamp next to the CAD.
11. Install the supplied grommet (#15) and aluminum fitting (#18) into the Airaid intake tube as shown.
12. Install the Modular Venturi Tube (MVT) (#3) into the Airaid Intake Tube (#2) as shown. Option: For additional air flow, delete the MVT. This requires custom computer programming. Engine damage will result without the use of custom tuning.

Get pdf 2005-07 Ford Mustang GT 4.6LV-8 Airaid Installation Instructions

Overdrive Manual Control Cable Assembly

The overdrive cable assembly must be cut to a specified length depending on the vehicle application. The chart at the top displays the correct cable casing lengths for specific Ford vehicles. Length of cable casing (From shoulder of threaded fitting to end of casing.) Allow 5″ of wire beyond trimmed casing The cable casing length is determined by the illustration above. It is recommended to allow an additional 5″ of wire to extend beyond the trimmed cable casing while the handle assembly is completely pushed in.

HOW TO CUT THE CABLE TO LENGTH ANS INSTALL THE OVERDRIVE CABLE RETAINING SLEEVE.
I. Mark the correct cable length then pull the wire back into the cable casing out of the way of the cutting procedure. Cut the cable casing by using a bench grinder and carefully grind through the coiled exterior. Push the wire back into position and cut it 5″ longer than casing.
Í. A crimping tool and an aluminum end sleeve are supplied In the kit. Place the crimping tool around the sleeve and slide the sleeve onto the cable. Note that the Inset shouldered end of the sleeve faces the handle assembly.
This Is what the overdrive cable end should look like once the aluminum sleeve has been crimped Into position. Notice that the end of the sleeve is flush with the trimmed cable casing. It is recommended that an additional 5″ of wire extend beyond the casing so that it may be trimmed to exact length once the assembly has been installed In the vehicle.
REMEMBER: Measure Twice, Cut Once.
■ Slide the sleeve onto the cable so that the end is flush with the end of the casing. Place the crimping tool and cable assembly into a vise as shown above. Compress the crimping tool until the sleeve is secured to the cable.

Get pdf Overdrive Manual Control Cable Assembly

1997-2002 Ford Expedition/Navigator Secure Idle Installation Instructions

“SECURE IDLE” is an ignition switch bypass device designed to provide all the electrical functions that the OEM ignition switch normally provides. For proper operation and long term performance, do not deviate from the wire connection instruction. For each wire connection, remove approximately one half inch of insulation from the OEM wire, but DO NOT cut the wire into. Cutting the wires causes high resistance and a possible failure point. Strip app. one half inch of insulation from the end of the “SECURE IDLE” wires to be attached to the OEM wires. Wrap the “SECURE IDLE” wire around the bare area of the OEM wire and solder the connection. Tape the connection thoroughly after it cools.

DO NOT use “Scotch Lock” type pinch thru connectors. These connectors cannot handle the higher amperages of the ignition circuits, and will void the “SECURE IDLE” warranty. Use the attached wiring diagram to locate the correct wire and pin location.

INSTALLATION
1. Remove the lower dash panel under the steering column to access the OEM ignition switch which is mounted on the steering column. Mount the “SECURE IDLE” unit near the ignition switch.
2. Locate a good metal ground and connect the BLACK “SECURE IDLE” wire using the ring connector provided.
3. Locate the OEM ignition switch and wiring. Remove the insulation from the Gray/Yellow wire, Pin A4, Circuit 687, and attach the RED 14 Ga. “SECURE IDLE” wire according to the above instructions. This OEM wire will be hot in RUN ONLY.
4. Locate the DK.BLUE/LT.GREEN wire, Pin I 1, Circuit 964. Attach the WHITE 14 Ga. “SECURE IDLE” wire according to the instructions.

Get pdf 1997-2002 Ford Expedition/Navigator Secure Idle Installation Instructions

S/R Cylinder Heads Iron 2.9L V6 Ford Specifications and Instructions

These heads are a direct 50 state legal replacement cylinder heads for 1986 to 1992 2.9 liter V6 Ford engines that use Ford cylinder head part number part number 6090CAJ.
CARB Exemption: This product is certified as 50 State Legal under E.O. # D-343. The included exemption sticker MUST by law be placed next to your vehicle’s emission sticker.

Before Final Assembly:
1. Please inspect castings for defects or damage prior to modification, assembly or installation. Cylinder heads that have been modified, installed or used ARE NOT RETURNABLE.
2. Refer to the factory service manual for proper torque specifications and assembly and disassembly procedures. Brackets and Accessories:
1. All accessory bolt holes on the World S/R 2.9 heads are 10 mm. Some factory brackets may have 8 mm bolt holes and will need to be enlarged to a 10 mm hole. The dimensions for the new bolts are as follows: Top Alternator bolt is 10 mm x 1.5 thread and 40 mm long. Bottom Alternator bolt is 10 mm x 1.5 thread and 65 mm long. A/c bolt is 10 mm x 1.5 thread and 30 mm long.
2. Consult the factory service manual for specific issues regarding thermostat replacement.

Get pdf S/R Cylinder Heads Iron 2.9L V6 Ford Specifications and Instructions

Flyin’ Miata Fuel Rail Installation Instructions

Congratulations on purchasing the FM Fuel Rail! We’re confident that this is a high quality piece that will help ensure the safety and performance of the engine in your Miata. Following are instructions that will help you safely install this piece.

1. The fuel system first needs to have its pressure re- lieved. There are two ways to do this, it’s safest to do them both. First, find the relay that’s pictured to the side. It will be underneath the dash, near the steering column. It should look similar to the relay in the picture, but different years had different relays, so it might not be exactly the same. Look for a blue wire with a red stripe, that’s the wire that goes to the fuel pump. Start the car and let it idle. While the car is idling, unplug the relay. This will kill the engine, as it’s no longer being fed the fuel it needs. Turn the car off once the engine has stopped. The gas cap also needs to be removed, to ensure that pressure doesn’t build up in the tank. Don’t reinstall it until the fuel rail is in.
2. Disconnect the negative terminal for the battery. You’ll be working near the starter, and you don’t want to accidentally touch one of the stainless steel lines to the lead on the starter.
3. Remove both of the rubber fuel lines from the metal hard lines. Fuel will spill out from these lines, so try to have something to catch the spillage. These can be a pain to remove, try twisting the rubber line to break the adhesion between the rubber and metal lines. It’s also a good idea to try to drain as much as possible from the lines, this will make the rest of the mess smaller.
4. ‘99 - ‘05 cars only: The upper intake manifold needs to be removed. There are six bolts that need to be removed to allow the two pieces to separate. Be sure to remove any of the hoses and such that will prevent the top half from being lifted off. Make a note of where all of the lines go, so you’re sure to put them back in the right places. Once these have been removed, tilt the top half forward and out of the way. Be careful of the various lines going to the throttle body. While they can remain attached, you need to make sure that they don’t get kinked. Also put rags in the open holes, to ensure that nothing accidentally falls down there.

Get pdf Flyin’ Miata Fuel Rail Installation Instructions

1999-05 Ford F-250/F-350 ¾ & 1 Ton, S/D, S/B, L/B Under Bed Hitch Installation

Installation Instruction:
1. Carefully examine the location of fuel lines, brake lines and electrical wires before installation. Be certain you will not damage fuel lines, brake lines or electrical wires when positioning hitch components, drilling holes, tightening fasteners, and lifting and lowering the truck bed.
2. Read installation manual and installation drawing completely. Understand all components and parts before installation.
3. Hitch ball location: Two wheel Drive Short & Long Bed 49” 46” Four wheel Drive Short & Long Bed 49” 46” Ball location in front of axle 6-1/2” 3-1/2”
The front crossmember is able to accommodate either installation location by turning the angle end-for-end. The notches are made at two different depths; the shallower notches would sit on the frame for the 49 inch location and the deeper notches are used against the frame for the 46 inch location. The rear crossmember will work for both locations.
4. Measure the correct hole location in the truck bed floor. Measure from the back end (tail gate end) of the truck bed floor by hooking a tape measure over the end of the truck bed (not including the tail gate) and marking the floor at the correct measurement. Center the measurement between the fender wheel wells. This location is critical to the correct installation of this hitch, so measure, mark and saw carefully. If the truck has a plastic bed liner, you may drill through both. Make a 4-inch hole at this location using a four-inch hole saw, or a cutting tool.
5. Remove the heat shield located above the rear axle under the truck bed. Some newer trucks have adhesive heat shields installed on the under side of the bed floor and may not need to be removed.

Get pdf 1999-05 Ford F-250/F-350 ¾ & 1 Ton, S/D, S/B, L/B Under Bed Hitch Installation

1965-1972 Full-Size Ford DB1512M Installation Instructions

Installation of any component or kit should only be performed by persons experienced in the installation and proper operation of disc brake systems. It is also the responsibility of the person installing any brake component or kit to determine the suitability of the component or kit for that particular application.
NOTE: Before operating the vehicle after installation test the function of the brakes under controlled conditions. Make several stops in a safe area from low speed and gradually work up to nor- mal speeds. DO NOT DRIVE WITH UNTESTED BRAKES! Always utilize safety restraints when operating the vehicle.

STEP 1:
1. Check to be sure that your kit has all the necessary parts needed to complete this project! (Use the supplied parts list as a check list.)

STEP 2:
Remove the following components from you car:
Tech tip: Prior to disassembly spray the nuts and bolts that will be removed with a penetrant.
1. If you are performing the installation with a jack, be sure that the parking brake is set and that the rear wheels are chocked. Support the front of the vehicle with jack stands. Never work on sloping ground.
2. If you are using a lift, raise the vehicle to a comfortable working height.
3. Remove the front tires.
4. At this point, be sure to place the proper support under the lower control arm. Failure to do so will allow the coil spring to blow out when spindle is removed, which could result in vehicle damage and possible serious injury or even death.
5. Next, disconnect the drum brake hoses from the hard line using the appropriate flare wrenches.
6. Detach the steering arm from the tie rod.
7. Now disconnect the ball joints from the spindle and remove the drum brake assembly as a unit.
8. Clean and inspect ball joints and tie rod ends for excessive wear or damage, replace at this time if necessary, in preparation for assembly.

Get pdf 1965-1972 Full-Size Ford DB1512M Installation Instructions

99-02 Ford Expedition/Navigator 4.6L- 5.4L 2/4WD Cat-Back Dual Sport Truck Exhaust Instruction Manual

Lay out the exhaust on the floor so it looks like the drawing and compare parts with manual. To remove the stock exhaust, un-clamp it just in front of the muffler. You may need to heat it up for easier removal. Leave all rubber grommets in place. Use WD-40 to aid in removal of exhaust and the hangers. Now cut off your stock tailpipe just behind the muffler

Install head pipe #A onto your existing stock front pipe and secure with clamp #H. Use a jack stand to support the converter. Do not tighten.
Install muffler #B onto head pipe 1 ½” to 2” with the louvers facing towards the converter. Use a jack stand to support the muffler. Use clamp #J to secure the muffler to the head pipe. Do not tighten. Outlets should be on the bottom.

Install rear mufflerT- hanger #K into rubber grommets located just above the muffler outlets. Shorter side of the hanger will be inserted on the passenger side grommet. Slide clamp onto passenger side muffler outlet. Do not Install the passenger side front tailpipe #E 1 ½” to 2” into muffler. Use clamp # H to secure front tailpipe to muffler, and attach hange # K. Do not tighten.
Install drivers side front tailpipe #C into muffler 1 ½” to 2”. Use clamp #H to secure front tailpipe to muffler. Do not tighten.

Install passenger side overaxle tailpipe #F onto front tailpipe using clamp #I to secure pipes together. Do not tighten. Slide welded hanger into rubber grommet Install drivers side overaxle tailpipe #D onto front tailpipe Use clamp #I to secure together. Do not tighten. Use bolt kit #L to secure pipes together. Tab on drivers’ side tailpipe will be on top.

Install the stainless steel tips. Clamp down. To clean your stainless tips, use a scotch brite pad and any stainless steel or aluminum cleaner. Now go back and tighten all clamps, nuts and bolts. Start from the front and work back.

Get pdf 99-02 Ford Expedition/Navigator 4.6L- 5.4L 2/4WD Cat-Back Dual Sport Truck Exhaust Instruction Manual

BMK-21 Single Mount By-Pass Filter System Installation and Servicing Instructions

This filter system is not designed to replace the engine’s normal full-flow filter. Do not attempt to install a by-pass filter element in place of the existing full-flow filter.
WARNING: Extreme care should be taken to avoid bodily harm during installation. Before starting, ensure the engine is cool to avoid burns and never work in the engine compartment area with the engine running.

Attaching the filter mount
1. Survey the engine compartment for possible mounting locations. Solid structures such as the firewall, fender well, radiator support or frame are normal locations. (Do not mount on engine.) Refer to diagram B for minimum area requirements and consider accessibility for servicing.
2. Refer to diagram A for preferred mounting positions.
3. When the location has been determined, use the mounting template provided to locate and mark mounting holes. This can be easily done with a center punch and hammer.
4. Install adapter fittings (BP-208) on filter mount (BK-303) using provided thread sealant as noted in diagram C. If desired, 90° angle fitting (BP-52) may also be used. Using a 7⁄16 wrench, tighten fittings 2-3 turns beyond finger tight. Keep in mind the direction you wish to have the hoses intersect the mount.
5. With a 5⁄16 drill bit, drill out the previously marked mounting holes and attach the mount using the 5⁄16 bolts, nuts, small washer and fender washers provided. Bolts should be tightened to 16-18 foot pounds. 1⁄2 wrenches or socket will be required for this operation.
6. Fill the By-Pass Filter element with the same motor oil being used in the vehicle. Lubricate the filter gasket with oil and spin filter onto mount. Tighten per instructions on the filter.

Get BMK-21 Single Mount By-Pass Filter System Installation and Servicing Instructions

Free Auto PDF Manuals