Ford Mustang Rear Fascia Valance Kit Installation Instructions

Ford Mustang Rear Fascia Valance Kit Installation Instructions
Ford Mustang Rear Fascia Valance Kit
Installation Instructions
Application: 2005-09 Ford Mustang GT Model
Requires ROUSH Exhaust System #R12000023 or #R12000024
Before installing your ROUSH Performance Product(s), read through the entire installation procedure
and check to make sure all items are present. Contact ROUSH Customer Service at 1-800-59-ROUSH,
9:00 AM to 5:00 PM weekdays, for any questions regarding fit or instructions that are unclear to you.
Packaging List for Complete Rear Fascia Valance Kit #R03030060
Item
Quantity
Rear Valance Center (#R03030061)
Hardware Kit, Valance Center (#R03030068)
Template Lower Holes
Bracket, Valance Center RH
Bracket, Valance Center LH
Bracket, Valance Center
Pin, 6.35x27mm Push
Scrivet, 10.4x25.4mm
Screw, M4.2x1.41x18mm Hex
U-Nut, M4.2x1.41mm
Tape, 12x100mm Adhesive
Tape, 12x275mm Adhesive
Rear Valance Side LH (#R03030066)
Rear Valance Side RH (#R03030067)
Hardware Kit, Valance Side (#R03030082)
Bracket, Valance Side ‘Z’
Bracket, Valance Side ‘U’
Pin, 6.35x27mm Push
Screw, M4.2x1.41x19mm
Screw, M4.2x1.41x18mm Hex
U-Nut, M4.2x1.41mm
Tape, 8x195mm ‘L’ Adhesive
Tape, 12x40mm Adhesive
Tape, 12x85mm Adhesive
Tape, 6x420mm Adhesive
Drill Template, Rear Valance Center (#R03030089)
Installation Instructions (#R03030076)
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Drill Template, Rear Valance
Center, Lower Holes
#R03030089
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Rear Valance Center
#R03030061
Rear Valance Side LH
#R03030066
Rear Valance Side RH
#R03030067
1-800-59-ROUSH
Push Pin,
6.35x27mm
Scrivet
10.4x25.4mm
Bracket, Valance
Center
U-Nut,
M4.2x1.41mm
Tape,
Tape,
Tape,
Tape,
Screw,
4.2x1.41x19mm
Tape, 12x100mm
Tape, 12x275mm
Bracket, Valance
Side ‘Z’
Screw,
M4.2x1.41x18mm Hex
Bracket, Valance
Center RH/LH
8x195mm
12x85mm
12x40mm
6x420mm
‘L’ Adhesive
Adhesive
Adhesive
Adhesive
Bracket, Valance
Side ‘U’
Equipment and Supplies Required
Ratchet
Sockets
Soft Cloth
#2 Phillips Head Screw Driver
Drill
Drill bits (1/4”, 1/8”, 5/16”)
Reciprocating Saw (Jig Saw)
Grease Pencil
Roll of Masking Tape
Suggested Materials
Dupont® 2319 Plastic Prep
Dupont® 2330S or equivalent Adhesion Promoter (for paint)
3M 4298 Adhesion Promoter (for double-sided tape)
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LIMIT OF LIABILITY STATEMENT
The information contained in this publication was accurate and in effect at the time the publication
was approved for printing and is subject to change without notice or liability. ROUSH Performance
Products (RPP) reserves the right to revise the information presented herein or to discontinue the
production of parts described at any time.
SAFETY REQUIREMENTS
STOP! READ IMPORTANT SAFETY CAUTIONS AND WARNINGS BEFORE PROCEEDING.
IMPORTANT SAFETY NOTICE
Appropriate disassembly, assembly methods and procedures are essential to ensure the personal
safety of the individual performing the kit installation. Improper installation due to the failure to
correctly follow these instructions could cause personal injury or death. Read each step of the
installation manual carefully before starting the actual installation.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Always wear safety glasses for eye protection.
Place ignition switch in the OFF position.
Always apply the parking brake when working on a vehicle.
Block the front and rear tire surface to prevent unexpected vehicle movement.
If working without a lift, always consult vehicle manual for correct lifting specifications.
Operate the engine only in well-ventilated areas to avoid exposure to carbon monoxide.
Do not smoke or use flammable items near or around the fuel system.
Use chemicals and cleaners in well-ventilated areas.
Batteries produce explosive gases, which can cause personal injury. Therefore, do not allow
flames, sparks or flammable substances to come near the battery.
10. Keeps hands and any other objects away from the radiator fan blades.
11. Keep yourself and your clothing away from moving parts when the engine is running.
12. Do not wear loose clothing or jewelry that can get caught in rotating parts or scratch
surface finishes.
13. Allow the engine, cooling system, brakes and exhaust to cool before working on a vehicle.
1.
Paint Preparation
a. Wipe each part with plastic prep (Dupont® 2319 or equivalent)
b. Wipe entire part with tack cloth
c. Apply adhesion promoter (Dupont® 2330S or equivalent) prior to color and clear coat
applications. This part is made of TPO (Thermoplastic Polyolefin) and requires a promoter
for paint adhesion.
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2.
Pre-Installation
a.
b.
c.
d.
e.
3.
Wear eye protection
Clean Rear fascia and quarter panel thoroughly before using drill template.
Lift vehicle up for removal of rear wheels
Secure vehicle on jack stands
Remove the rear wheels
Remove Fascia Attachments
a. Remove pushpins underneath the fascia, 3 total (Refer to Figure A).
Figure A
b. Remove the trim from the inside of the trunk, by removing 4 pushpins and 2 plastic
fasteners (Refer to Figures B & C).
Figure B
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Figure C
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c. With the trunk trim removed, loosen the nuts that secure the rear fascia to the vehicle until
they are near the ends of the studs, 4 total (Refer to Figure D).
Figure D
d. Remove screws in the rear wheel well that hold the fascia to the body, 2 each side (Refer to
Figure E). Keep the screws; they will need to be replaced when the valance is reinstalled.
Figure E
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4.
Drill Fastener Holes in Rear Fascia
1.
Rear
a.
b.
c.
Valance Center, Lower Holes
Tape Drill Template #R03030089 to rear fascia (Refer to Figure L).
Pre drill holes (3) with 1/8” drill bit, and then drill holes (3) using 5/16” drill bit.
Remove drill template from rear fascia.
Figure L
5.
Prepare Rear Valance
1. Rear Valance Center (Refer to Figure F for the following steps):
a. Install supplied u-nuts to center valance, 4 total.
b. Apply adhesion promoter to the areas where double-sided tape will be used.
c. Install supplied tape strips to center valance.
(12x100) End locations between u-nuts, 2 places
(12x275) Center location between u-nuts
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U-Nuts
(4 places)
Tape Areas
Figure F
2. Rear Valance Side LH/RH (Refer to Figure G, next page, for the following steps):
a. Install supplied u-nuts to side valance, 3 per side.
b. Apply adhesion promoter to the areas were double-sided tape will be used.
c. Install supplied tape strips to side valance.
Tape
Tape
Tape
Tape
(8x195mm) ‘L’ surface, 1 per side.
(12x40mm), 1 per side.
(12x85mm), 1 per side.
(6x420mm) along valance top edge, 1 per side.
d. Repeat procedure for other side valance.
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‘L’ surface
U-Nuts
Tape
(12x40mm)
Tape (6x420mm)
Tape
(12x85mm)
Figure G
3. Mark Faster Hole Center Line on Valance Components
a. Using a grease pencil mark the center of the fastener locations on the top outside edge
of the valance components: Rear Valance Side LH/RH and Center (Refer to Figure H)
Figure H
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6.
Modify Rear Fascia
1. Install Center Valance to rear fascia. The top of the valence should fit flush with the body
lines of the rear fascia/license plate indent. (Do not remove red tape covering at this time).
a.
Use masking tape to fixture center valance to the vehicle (Refer to Figure I)
Figure I
2. Install
a.
b.
c.
d.
e.
side valances (Do not remove red tape covering at this time).
Hold Side Valences onto vehicle
Check fit of parts: verify consistent gaps to body and center valence.
Align holes of Side Valances to the 2 screws in the wheel well (2 per side).
Use masking tape to hold the side valences in place. Trace the outline of the Center,
LH, and RH Side Valence onto the rear fascia with a grease pencil.
Transfer the fastener center line marks from the Center, LH, and RH Side Valence onto
the rear fascia with a grease pencil. (Refer to Figure J).
Fastener Center
Line Marks
Transfer Fastener
Center Line Marks
Trace Outline
Center of fastener hole is
22 mm from trace line
Figure J
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Figure K
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f.
Measure 22 mm down from trace outline where fastener center line marks are identified
(Refer to Figure K). This is the drill location for the valence fastener holes.
g. Pre drill mounting holes with 1/8” drill bit, and then drill holes using 5/16” drill bit.
3. Rear Valance Cutout
a. Trace cutout lines for exhaust tips from RH/LH Rear Valance components (Refer to
Figure M).
b. Remove center and side valences from rear fascia of vehicle.
c. Cut above marked lines at the exhaust openings.
Trace Cut-out
Lines
Material to Be
Removed
Figure M
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7.
Loosen Rear Fascia
a.
b.
With the fascia attachments removed/loosened the fascia can be loosened from the car.
Grabbing the fascia at the wheel well, carefully pull the fascia clear of the car. There
will be a pop as fasteners release (Refer to Figure N).
Figure N
c.
Holding the loosened fascia at the wheel well push the fascia rearward to further loosen
the fascia from the car. There will be a pop as fasteners release (Refer to Figure O).
Figure O
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d.
8.
The fascia should be loose from the car, attached only by the 4 nuts loosened to the ends
of the studs.
Center Valance Installation
a. Apply adhesion promoter to the rear fascia in a 1/2in strip just below the previously marked
grease pencil lines. This is the area where the Center Valance double-sided tape will
interface the rear fascia (Refer to Figures P a. and b.).
b. Install center valance to rear fascia by removing tape backing just enough to make a tab to
pull once part is correctly situated on vehicle (Refer Figure Q).
c. Once the part is aligned to previously marked grease pencil lines, pull the tape backing off
using the tabs and press firmly to ensure good adhesion (Refer Figure R).
d. Reach into the loosened fascia and install M4.2 x 18-mm screws into center valance (4
total). Do not over tighten screws or warping of the fascia will occur.
a.
Figure P
Figure Q
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b.
Figure R
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9.
Side Valance Installation
a. Install side valances to rear fascia by removing tape backing just enough to make pull-tabs.
Align part to previously marked lines.
b. Once the part is aligned to previously marked grease pencil lines, pull the tape backing off
using the tabs and press firmly to ensure good adhesion (Refer to Figure S).
Figure S
c. Reaching into the loosened fascia, install M4.2 x 18 mm screws into side valances (3 each
side). Do not over tighten screws or warping of the fascia will occur.
10.
Replace Fascia
a. Replace the rear fascia. Reverse the steps of the Loosen Rear Fascia section.
b. With fascia seated properly to rear of vehicle, reengage fascia sides into body retaining
clips.
c. When the fascia is in place, replace the screws in the wheel wells (2 each side) and tighten
the nuts from inside the trunk.
d. Replace pushpin into the center fascia support found underneath the fascia. (Note- this is
the only support remaining, the other two were removed for exhaust cutouts)
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11.
Valance Brackets installation
1. Install “L” brackets to the Center Valance.
a. Fasten using pushpins, 2 each bracket (Refer to Figure T).
Figure T
b.
Using the existing hole in the Center Valance as a guide, drill a hole into the fascia using a
¼” drill bit. Install the middle bracket using pushpins (2) through the “guide” hole and the
“drilled” hole (Refer to Figure U).
¼” hole drilled for
pushpin into fascia
Figure U
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2. Installing “U” Brackets to Side Valances
a. Using the existing holes in the side valance(s) as a guide, drill a hole into the fascia using a
¼” drill bit. Install the “U” bracket using pushpins (2 each side) through the “guide” hole
and the “drilled” hole (Refer to Figure V).
¼” hole drilled for pushpin into
fascia
“U” bracket installed in
valance
Figure V
b. Using the existing holes in the side valance(s) as a guide, drill a hole into the fascia using a
¼” drill bit. Install the “Z” bracket using pushpins (2 each side) through the “guide” hole
and the “drilled” hole (Refer to Figure W).
Figure W
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Congratulations!!! You have completed the installation of the ROUSH Performance Products, Ford
Mustang Rear Fascia Valance Kit. It is recommended that you save all parts removed from your
vehicle during the installation of this kit.
Note: If items are missing or for any questions regarding the installation of this kit, please contact
ROUSH Performance toll free at 1-800-59-ROUSH.
WARRANTY
All retail parts carry a 90-day warranty from the date of purchase. This warranty covers
defects in materials or workmanship, and does not include (i) normal wear and tear,
environmental conditions, improper installation; (ii) road hazards, misuse, abuse, neglect,
accidents, collision, fire, theft, freezing, vandalism, riot, explosion, or objects striking the
vehicle; (iii) misusing the vehicle, such as driving over curbs, overloading, racing, or using the
vehicle as a stationary power source; (iv) altering, disassembling or modifying the parts; (v)
defects caused or induced by failures, breakdowns, or damage by other parts, components or
the vehicle; (vi) subjecting the parts to excessive moisture or water or any motor vehicle
fluids (e.g.: oil, anti-freeze, battery acid, brake fluid, etc.); (vii) acts of God, natural disasters
and other similar causes beyond the reasonable control of ROUSH; or (viii) application of
chemicals that affect the parts. This Limited Warranty does not cover surface deterioration of
paint, trim, and appearance items that result from use and/or exposure to the elements, such
as stone chips, scratches, bird droppings, lightning, hail, windstorm, dings, dents, earthquake,
road salt, tree sap, water or flood.
ROUSH SHALL NOT BE LIABLE TO REIMBURSE CUSTOMER/DEALER FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES RESULTING FROM THE INSTALLATION OR USE OF ANY
PRODUCT SOLD THROUGH THIS CATALOG OR ARISING OUT OF ANY BREACH OF
WARRANTY. EXCEPT AS MAY BE STATED IN THIS CATALOG, ROUSH DISCLAIMS ALL
EXPRESS AND IMPLIED WARRANTIES, INCLUDING THE WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL
ROUSH’S LIABILITY EXCEED THE PRICE PAID BY CUSTOMER/DEALER FOR PRODUCTS
SOLD REGARDLESS IF ROUSH HAS BEEN ADVISED IN ADVANCE OF ANY POTENTIAL
PROBLEM OR IF A CLAIM IS BASED ON CONTRACT, TORT, STRICT LIABILITY, PRODUCT
LIABILITY OR OTHERWISE. SOME STATES DO NOT ALLOW THE EXCLUSION OR
LIMITATION OF IMPLIED WARRANTIES OR THEIR DURATION, OR LIABILITY FOR
INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE EXCLUSIONS OR
LIMITATIONS MAY NOT APPLY
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