K9 KIT INSTALLATION INSTRUCTIONS CROWN VIC KK-K9-F7-K

Transcription

1 K9 KIT INSTALLATION INSTRUCTIONS CROWN VIC KK-K9-F7-K TOOLS REQUIRED: Power Drill (Cordless preferable) Drill Bit Set Standard Wrench and Socket Set Metric Socket Set Screwdriver Set Torx Bit Set Wire cutters / Crimping tool Caulking gun HARDWARE: QTY: DESCRIPTION: USED FOR: PART #: 12 #10 x ½ Flat head sheet metal screw Window guards GSM #10 x ½ Stainless sheet metal screw Hinge, door panel GSM ¼ x ½ Stainless carriage bolt Basic unit assembly GSM ¼ x ¾ Stainless carriage bolt Sliding door handle GSM ¼ Serrated nut Basic unit assembly GSM /16 x ¾ Hex head bolt Front cage bracket GSM /16 Nylock nut Front cage bracket GSM /16 Flat washer Front cage bracket GSM Edge molding (7 foot section) Ceiling PRM #10 x 1 Sheet metal screw Rear deck filler GSM #10 x ¾ Stainless sheet metal screw Trim & rear cage GSM Tube silver silicone Sealing PRM #10 x ¾ Sheet metal screw Dome light GSM33195 COMPONENTS SUPPLIED WITH KIT: 1 Front Cage 1 Rear Cage 1 Floor 1 Ceiling 2 Front Cage Upper Lexan Fillers 2 Front Cage Lower Aluminum Fillers 2 Step Sill Molded Plastic 2 Rear Cage Lower Molded Plastic 2 Rear Upper Molded Plastic 1 Rear Cage Aluminum Deck Filler 2 Front Cage Bracket 2 Door Panels Aluminum 2 Window Guards 1 Dome Light Kit 1 Rubber Mat

2 Rear Deck Filler (Part is not visible) Front Cage Brackets Step Sill Molded Plastic Filler Panels- Aluminum & Lexan TIPS FOR INSTALLATION: Read instructions prior to installation. Cordless drill with Phillips bits works very well when installing self-drilling sheet metal screws. PVC protective covering should be removed during installation. Peel it back while attaching hardware. Photo 1 SUB ASSEMBLIES: 1. Attach rear deck/filler panel to rear bulkhead using (3) ¼ x ½ Carriage bolts. (See Photo 1) NOTE: Rear deck filler must be attached prior to installing rear cage into vehicle. This piece is the width of the vehicle and goes from rear deck of vehicle to rear cage. 3. Attach dome light to ceiling using #10 x ¾ Sheet Metal Screws (use 5/32 pilot hole) and attach 14-gauge red wire found in dome light kit. 2

3 INSTALLATION: 1. Remove necessary interior trim parts: Remove rear seat (bottom and back) Remove OEM door panels. NOTE: if the door has an electric lock system and/or window controls, the switches must be reconnected. The switch assembly must be wire tied to inner door panel so as not to interfere with the window or lock mechanisms. Photo 2 Remove OEM door lock pin, handle assembly and arm rest bracket NOTE: The rivets holding the door handle and arm rest brackets must be drilled out in order to remove these parts. Remove OEM step sill trim panel Remove seat belts remove inboard belt latch and buckle (center of car) Remove upper B pillar trim (both sides) Photo 3 2. Place Floor: Place floor (See photo 2) Photo 4 3. Mount Rear Cage: (See Photo 3) Place rear cage on top of floor. Be sure rear deck filler is attached. Attach rear deck filler panel to OEM rear deck using #10 x 1 Sheet Metal Screws. Use 5/32 pilot hole. NOTE: Run screws through carpeted deck panel into the back seat frame. Use #10 x ¾ Stainless Sheet Metal Screws and attach bottom of rear cage to floor. Use 5/32 pilot hole. (See Photo 3) 4. Mounting Brackets: (See Photo 4) Remove seat belt b pillar assembly on both sides Attach upper cage bracket to lower bolt on seat belt assembly Do not completely tighten seat torx bolts yet. Photo 5 5. Mount Front Cage: (See photo 5) Place the cage on top of floor. Attach to upper cage mounting bracket using 5/16 x ¾ hex head bolts, 5/16 nylock nuts and 5/16 flat washers, but do not tighten yet. Attach bottom of cage to floor using ¼ x ½ Stainless carriage bolts and ¼ serrated nuts. 3

4 Photo 6 Notch Trim Photo 8 6. Mount Ceiling: (See photo 6) Make sure rear cage window is hinged down. Place ceiling on top of front and rear cages. Attach using ¼ x ½ Stainless carriage bolts. Align and tighten all ceiling carriage bolts. Tighten b pillar brackets on cage. NOTES: APPLY WAX TO STAINLESS SHEET METAL SCREWS TO PREVENT SCREW FROM BREAKING APPLY PRESSURE TO FILLER PANELS WHILE INSTALLING TO ACHIEVE A TIGHT FIT. 7. Mount Step sill trim panel: (See photo 7) Position trim as shown above. Press down on step sill to ensure OEM door will not hang up on step sill. Mark and drill K9 floor using OEM step sill holes as a template. Pre-drill using 5/32 drill bit. Reposition step sill and attach to K9 floor and vehicle using #10 x 3/4 stainless sheet metal screws. Notice that the K9 floor and the step sill are NOT PERPENDICULAR (arrow) to each other. This is crucial for proper door operation. The flanges on the ends of the panel will go on the front side of the front lower aluminum fillers and behind the rear lower fillers. This will allow the water to flow out of the vehicle when washing out. 8. B Pillar Trim: (See photo 8) Hold trim at original position and mark where new brackets are located. Notch plastic (see bottom right) Tighten torx bolts on seat belt assembly Reattach trim 8. Rear Lower Fillers (See Photo 9) Position and attach to rear cage using (3) #10 x ¾ Stainless sheet metal screws. Use 5/32 pilot hole. Attach to step trim using (1) #10 x ¾ Stainless sheet Attach w/ #10 x 3/4 screws Photo 7 Photo 9 4

5 metal screws. Use 5/32 pilot hole. 9. Rear Upper Fillers: (See photo 10) Applying pressure to rear upper filler panel, tight to rear cage ceiling and bottom trim, mark and pre-drill mounting holes Attach to cage using (3) #10 x ¾ Stainless sheet metal screws. Use 5/32 pilot hole. At location where upper and lower plastic trim pieces come together secure both using (1) #10 x ¾ Stainless sheet metal screw. Use 5/32 pilot hole. (See circled area on photo 8) 10. Edge molding: (See photo 11) Apply rubber edge molding to ceiling section as noted by arrow. Photo Mount door panels: (See photo 12) Center so edges do not hang over. Photo 11 NOTE: Make sure height of door panel works with window guard and window guard bracket prior to installing. Pre-drill door using 5/32 drill bit. Attach to door using #10 x ½ Stainless sheet metal screws. NOTE: APPLY WAX TO SHEET METAL SCREWS TO EASE INSTALLATION 12. Mount window guards: NOTES: Window guards have holes around perimeter for permanent mounting. These holes are not used with hinge kit. They also come flat in shipping and the guard must be pre-bent (outward) to fit the contour of the window frame. (See Photo 13) Do not use holes on side of window guard to mount with the hinge application! Photo 13 Photo 12 5

6 Hold window guard with pre-assembled hinge and upper bracket onto window frame. Make sure guard is centered on window. Attach hinge to door panel using #10 x ½ Stainless sheet metal screws. Use 5/32 pilot hole. Mark upper aluminum bracket location on window frame and remove from window guard. Attach aluminum bracket onto window frame using #10 x ½ Flat head sheet metal screws. Use 5/32 pilot hole. Hinge up window guard and reattach to bracket using #10 x ½ Stainless Machine Screws. 13. Front Lower Aluminum Fillers: (See photo 14) Attach as shown using (3) ¼ x ¾ carriage bolts and serrated nuts. Close door to position and then tighten nuts. Photo 14 Photo 16 Photo 15 NOTE: step trim flange should be in front of this panel. (Arrow on photo 16) 14. Front Upper Lexan Fillers: (See photo 15) Close door to position and then drill ¼ holes through lexan and cage. Attach using (3) ¼ x ¾ carriage bolts and tighten 15. Silicone: (See Photo 16) Silicone all seams and gaps. 16. Rubber matting: (See Photo 17) After silicone is dry, place rubber floor matting. 17. Dome Light Switch Box: The switch box location can be at the customer s discretion. Mounting on driver s side of the vehicle in upper left corner is recommended. Photo 17 6