STYLE BAR & TONNEAU COVER INSTALLATION INSTALLATION MANUAL: 2005 to '09 Mustang P/N: 10-8002-C12071B Saleen Performance, Inc. 1225 East Maple Rd., MI 48083 800-888-8945 www.saleen.com 1
IF YOU ARE NOT EXPERIENCED IN THE AREA OF AUTOMOTIVE MECHANICS, WE STRONGLY URGE THAT YOU REFER THIS INSTALLATION TO A CERTIFIED INSTALLER OR TECHNICIAN 2
Style Bar Kit / Tonneau Cover Installation Guide for 2005 to '09 Mustang Thank you for buying a Style Bar Kit and/or Tonneau Cover for the '05 to '09 Mustang. We appreciate your business, and we hope you enjoy your product. For your benefit, please read the following instructions completely and thoroughly before attempting to install a Style Bar Kit or Tonneau Cover. Many questions we have received from customers about the installation of our products could have been easily solved by information listed in this installation guide. We want you to enjoy the product in its fully functional state, and reading this tutorial is a great first step to getting you on your way to a more unique and attractive Mustang. Again, thank you for choosing Saleen! 3
PARTS INCLUDED IN SPORT BAR KIT: Item Description of Part Quantity Included in Kit Sport Bar 1 Driver Side Bracket with Set 1 Screw Sport Bar Kit Passenger Side Bracket with Set 1 Screw Button Head Screw 4 Flange Nut 4 PARTS INCLUDED IN TONNEAU COVER KIT: Item Description of Part Quantity Included in Kit Tonneau Cover 1 Strap Assembly 1 Capscrew Hex Head 5/16-24x7 1 Nyloc Nut 5/16-24 2 Tonneau Cover Kit Washer 2 Blackout Top Left 1 Blackout Top Right 1 Blackout Center 1 Leather Bolster 1 4
TOOLS REQUIRED FOR KIT INSTALLATION: Sport Bar Kit 3/8 drive ratchet 3/8 drive 3 extension 3/8 drive 10mm socket 3/8 drive 13mm socket 2 hole saw T-50 torx bit 1/4 allen wrench 1/2 wrench drill motor 1/8 drill bit 3/8 drill bit door trim tool (fork tool) center punch hammer Tonneau Cover 1/4 allen wrench (if vehicle has a Sport Bar or will have a Sport Bar installed) Scissors or knife Drill motor 3.16 in. bit Drill stop for 3/16 in. bit 9/16 in. wrench 3M Scotch Grip Rubber & Gasket Adhesive (#847) Paint-safe masking tape *NOTE: If you do not have any of the tools listed above, you may be able to obtain them from your local tool lending service. 5
SPORT BAR KIT INSTALLATION PROCEDURE: NOTE: The tonneau cover installation procedure starts on page 10. IMPORTANT: Use suitable covers to protect upholstery, carpet, trim, etc. when performing this procedure. 1. Remove Back Seat: a) Locate the retainers securing the seat bottom into the vehicle, approximately 10 inches from the end of the cushion, either side. Use your thumb to push in the retainer release tab (see Figure 1). Lift the seat up to remove. Figure 1 b) Remove the two 13mm screws securing the seat back, located on each lower corner. Lift seat upward to release seat back from brackets at the top. You can carefully prop the seat back under the retracted top (see Figure 2 below); however, use caution if choosing this method not to damage or scratch the seat vinyl. You can remove the seat from the vehicle completely by disengaging the flanges securing the top of the rear seat to the fabric of the convertible top well (see Figure 3 below). Figure 2 Figure 3 6
2. Remove Quarter Trim Panel Caps and Quarter Trim Panels: Quarter Trim Panel Cap a) First, grip the Quarter Trim Panel Cap at the shoulder strap opening and lift up to dislodge the retaining clips (see Figure 4). Figure 4 b) Second, pull the forward edge of the Upper Quarter Trim Panel over the pinch weld in the door jamb (see Figure 5). The inside Quarter Trim Panels are two-piece panels. Remove the upper portion of the Quarter Trim Panel from the vehicle. It is not necessary to remove the lower portion. Upper Quarter Trim Panel Pinch Weld Figure 5 7
c) Then, use a Door Trim Tool (Fork Tool) to dislodge the pushpin retainer at the rear edge of the Trim Panel approximately 4 down from the top (see Figure 6). Pry the Trim Panel toward the outside of the car to release the retainer (see Figure 6). Figure 6 Figure 7 3. Install Sport Bar Brackets: a) Remove the shoulder belt guide retaining bolt with a T-50 Torx Bit. Remove the 10mm head bolt directly behind the shoulder belt guide. Bolts (Remove) Figure 8 8
b) Install the Sport Bar Bracket to the vehicle using the factory bolts removed in the above step. Torque seat belt guide bolt (T-50 Torx) to 30lb-ft. c) With the Sport Bar Bracket in place and secured by the 10mm head bolt and the shoulder strap guide bolt reinstalled and tight, center punch through the two Bracket attachment holes. Drill ⅛ pilot holes through Bracket hole into sheet metal, making sure you catch all the drilling debris. Enlarge pilot holes to 5/16 (again, make sure you catch all the drilling debris). Install Bracket Under Factory Bolts Figure 9 Figure 10 NOTE: It is imperative that the shoulder strap guide bolt spacer fit inside of the clearance hole of the Sport Bar Bracket so that the seat belt functions properly and the Sport Bar Bracket fits properly. It is very important that you protect the seat belt and the shoulder strap retractor from the cutting debris that is created during the drilling process. We recommend using a magnet to catch the debris. d) Secure the Sport Bar Bracket with the Button Head Screws, making sure you securely tighten the screws. e) Reinstall the upper portion of the Quarter Trim Panels. Figure 11 Button Head Screws 9
4. Cut holes in Quarter Trim Panel Caps: a) Cut out the Template (supplied in kit) and place it on the Driver Side Trim Panel Cap and align as directed on the Template. Center punch the 2 hole center point, remove the template and drill an ⅛ pilot hole. Then, follow in the pilot hole with a 2 Hole Saw. Figure 12 align drill b) Flip the Template over and place it on the Passenger Side Trim Panel Cap and repeat the above steps for marking and drilling the 2 hole. 5. Reinstall Quarter Trim Panel Caps: a) Re-install the Quarter Trim Panel Caps onto their respective sides and verify that the 2 holes drilled in step #4 do not obstruct the Sport Bar Bracket receiver tube. If the receiver tube is blocked, trim the Cap as needed to achieve an unobstructed path for installing the Sport Bar. 6. Install the Sport Bar: Note: If you are installing a Tonneau Cover, tighten the Sport Bar Bracket Set Screw after the Tonneau Cover is installed. See the Tonneau Cover Installation Procedure (next page). a) Evenly lower the Sport Bar into the receiver holes, making sure the Bar is fully seated onto the tops of Trim Panel Caps. With the bottom of the Sport Bar flat against the trim panel Caps, tighten the Sport Bar Bracket Set Screw (see Figure 13). Figure 13 10
7. Reinstall the Back Seat: a) Reinstall the back seat in the reverse order of removal. Make sure the seat belt buckles are pulled up through the seat openings. NOTE: This Sport Bar is not a roll bar; it is not intended as a structural element to protect occupants in the event of a rollover. Questions? Call our front desk at 949-597-4900 and ask for the Tech line. 11
TONNEAU COVER SUBASSEMBLY PROCEDURE: Order of operations: 1. Install the U-shaped rubber trim around the perimeter of the tonneau cover as follows: a. Place the tonneau cover upside down on a clean, padded surface. b. Apply a 1/8 bead of 3M Scotch Grip Rubber & Gasket Adhesive (#847) on the cut edge around the perimeter of the tonneau cover (see Figure 14). Do not apply adhesive to the cut edge that goes around the sport bar (see Figure 15). This area will not be covered with the U-shaped rubber trim. Apply Adhesive to Cut Edge of Tonneau Cover Figure 14 c. Apply a 1/8 bead of 3M Scotch Grip Rubber & Gasket Adhesive (#847) to the bottom of the rubber trim channel as shown in Figure 16. No Adhesive in Sport Bar Depression Area Figure 15 Apply Adhesive to Bottom of Rubber Trim Channel Figure 16 12
d. Install the rubber trim around the perimeter of the tonneau cover making sure trim is fully seated (see Figure 17). Install Rubber Trim to Edge of Tonneau e. Apply masking tape to hold down the rubber trim while the adhesive dries (see Figure 18). f. Cut the rubber trim (both sides) as shown in Figure 19. Remember, the rubber trim does not get installed to the cut edge that goes around the sport bar. Figure 17 Apply Masking Tape to Hold Down Rubber Trim While Adhesive Dries Figure 18 Cut Rubber Trim Figure 19 13
2. Install the two decals to the tonneau cover as follows: a. Using a soft cloth and wax & grease remover, carefully clean the decal bonding surface area (see Figure 20). b. Trim off the excess paper around the decal (see Figure 21), making sure you do not cut the decal. Clean With Wax & Grease Remover Figure 20 Trim Off Excess Paper Around Decal Figure 21 14
c. Apply masking tape to the tonneau cover as shown in Figure 22. The masking tape will serve as a guide for correctly positioning and installing the decal. Make sure the decal angle and head rest depression angle match (see Figure 22). NOTE: Place masking tape strips starting at the center of the depression radius (see Figure 22). Make Sure Decal Angle and Head Rest Depression Angle Match Masking Tape Strip 3 1/8 Long Placed in Center of Head Rest Depression Area 6 4½ Masking Tape Strips 2 3/16 Long 7 1/2 Masking Tape Strips 2 3/8 Long NOTE: Place masking tape strips starting at the center of the depression radius. Figure 22 15
d. Apply masking tape at the top of the decal as shown in Figure 23. The masking tape will serve as a hinge point. Apply Masking Tape at Top to Act as a Hinge Point e. Peel off the self-adhesive backing from the decal (see Figure 24). f. Carefully press and smooth the decal from the center outward removing any bubbles (see Figure 25). Figure 23 Peel Off Self-Adhesive Backing Figure 24 Carefully Press and Smooth Decal From Center Outward Figure 25 16
g. Continue to press and smooth the decal around the outer perimeter until all bubbles are removed (see Figure 26). Press and Smooth Around Outer Perimeter of Decal h. Peel off the top protective cover from the decal (see Figure 27). i. Press and smooth the remaining portion of the decal (see Figure 28). Figure 26 Peel Off Top Protective Cover Figure 27 Press and Smooth Remaining Portion of Decal Figure 28 17
3. Install the center cushion as follows: CAUTION: WHEN PERFORMING THE NEXT STEP, DO NOT DRILL DEEPER THAN 3/8 OF AN INCH TO PREVENT DRILLING THROUGH THE INNER PANEL OF THE TONNEAU COVER. USE A DRILL STOP. a. Use a drill motor with a 3/16 drill bit to remove paint build-up in the four center cushion mounting holes (see Figure 29). b. Install the center cushion Christmas tree clips into the four holes in the tonneau cover (see Figure 30), making sure the cushion is fully seated. Figure 29 Remove Paint Build-Up With 3/16 Drill Bit CAUTION: DO NOT DRILL DEEPER THAN 3/8 OF AN INCH Install Center Cushion Christmas Tree Clips Into Holes Figure 30 18
4. Install the two securing straps as follows: a. Remove the two acorn nuts and washers from the threaded stud (see Figure 31). b. Install the straps, washers, and acorn nuts. Then tighten the nuts so the straps are in the vertical position as shown in Figure 32. Remove Nuts & Washers Figure 31 Install and Tighten Straps in Vertical Position Figure 32 19
TONNEAU COVER INSTALLATION PROCEDURE: IMPORTANT: Use suitable covers to protect upholstery, carpet, trim, paint, etc. when performing this procedure. 1. Make Sure Sport Bar Set Screw Is Loose (if applicable): a. If the vehicle is already equipped with a sport bar or if you are installing a new sport bar along with the tonneau cover, make sure the sport bar set screw is loose (see Figure 33). Insert allen wrench through shoulder strap opening and loosen set screw Figure 33 CAUTION: When performing step 2, be careful not to damage the vehicle paint, trim, etc. 2. Install Tonneau Cover: a) With the tonneau cover positioned as shown in Figure 34, carefully insert the L brackets at the rear edge of the cover under the body opening trim (see Figure 35). Tonneau Cover L Bracket Body Opening Trim Figure 34 Figure 35 20
b) If the vehicle has a sport bar, perform step c (below) and then skip to step e (next page). If the vehicle does not have a sport bar, go to step d (next page). c) Once all the L brackets are inserted under the body opening trim: Carefully raise the sport bar about two inches and hold it in this position Lower the front end of the tonneau cover until it barely touches the sport bar Lower the tonneau cover and sport bar together until they are fully seated Sport Bar Figure 36 Tonneau Cover 21
d) Once all the L brackets are inserted under the body opening trim, lower the tonneau cover until it is fully seated. e) Secure the tonneau cover by inserting the tie-down strap metal ends into the rear seat belt buckles (see Figure 37). Figure 37 3. Make Sure Sport Bar Set Screw Is Tight (if applicable): a) Tighten the sport bar set screw (see Figure 38). Figure 38 22