Automotive Manual PDF

STEP I ASSEMBLY INSTRUCTIONS – Fuel Pump / Carburetor / Manifold
A) Install fuel pump on carburetor, using shortest fuel line hose (1 ū” long) and two small diameter clamps. Ensure that you connect the correct nipple from the fuel pump to the carburetor. (Refer to Fig. 3)
B) Install carburetor and fuel pump assembly on the intake manifold, along with gaskets, insulation block, lock washers and nuts supplied in kit. (Refer to Fig. 2) Tighten nuts to 8 – 12 foot lbs. torque.
C) Attach one end of 7″ fuel line to the pulse tube on the intake manifold. Slide two small diameter clamps over the fuel line and then attach the other end of the line to the crankcase fitting on fuel pump. (Refer to Fig 3.) Position clamps at each end of hose and tighten securely. Proceed to STEP II.
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Before you begin:
Remove all components from the shipping carton.
The rack should be assembled on a padded surface such as carpet to prevent scratching of aluminum surfaces. Remove bands securing components together.
Read the instructions thoroughly to familiarize yourself with the assembly sequence.
Note that you DO NOT tighten any nuts and bolts until the completed rack is installed on the vehicle unless specified. This allows for minor adjustments to the rack during the installation process.
Gather the following tools used to assemble and install the rack.
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The Flip tarp is designed and pre-assembled for a drivers side mount, however it can also be mounted on the passenger side by applying some simple modifications. FOR A DRIVERS SIDE MOUNT SKIP TO STEP II.
Modifications for a drivers side mount
a. Locate the power unit mounting plate in the motor assembly.
b. Unbolt the mounting plate and rotate 180 degrees. Re-place bolts.
c. Unbolt the actuator and rotate it until the valves are one bolt pattern off vertical, pointing down and towards the power pack. Re-place bolts. (task is best accomplished with 2 people, one holds the actuator which weighs approx. 50 lbs, and the other removes and places the bolts.)
d. Unbolt the Sun Hydraulic Counterbalance Valve and rotate it 180 degrees. Re-place bolts.
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Connect front and rear sections
Each side rail side contains a front and rear section preassembled for easier assembly. The front and rear sections are banded together. Remove the banding and separate the front and rear rail sections from packaging. On a flat surface, place boards under the front and rear rail sections as shown so that the rear ‘Y’ bracket does not touch the ground. This will make aligning the front and rear rail sections faster. On the front section (the end with the straight round tube), slide the 5” bracket backwards until the two back holes on the 5” bracket line up with the two holes on the end of the lower rectangle tube. Insert the rear rail section into the 5” bracket and line up with two remaining holes.
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Before any tear-down or disassembly begins, it is important to verify which bearing you have. There are two types of “Green Bearings” being supplied by axle manufacturers. Your setup should look like Figure 2 (below left), not the Figure 1 configuration, otherwise this kit will not fit. Furthermore, review the wheel clearance diagram (Figure 3, below right) to verify that there is adequate clearance with the wheels you will be using with this installation.
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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.
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Tensioner
1. Hold Tensioner Body in a vise to remove bolt & washer from tensioner pulley (note; bolt is a left-handed thread, turn clockwise to remove). Discard washer.
2. Place Tensioner Cover Plate (781-A) on Tensioner Body & replace pulley.
3. Mount Tensioner Nose Cover Retainer (780-A) on tensioner pulley & replace bolt.
4. Mount Tensioner Nose Cover (307) to Tensioner Nose Cover Retainer (780-A) using three 8-32 x 5/8” socket head cap screws.
5. Mount Tensioner to Tensioner Base (30019) using one 5/16-18 x 3” socket head cap screw.
6. Mount Tensioner Base (30019) to engine block thru water pump mounting holes using two 5/16-18 x 2 3/4” socket head cap screws & to engine block using one 3/8-16 x 3” socket head cap screw & one Spacer (TP3 1.775), placing Spacer (TP3 1.775) between Tensioner Base (30019) & engine block.
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Remove of the interior door panel
Steps:
#1 Use flat head screwdriver to remove the plastic panel along side the window. A 6-mm -socket head screw is now visible to remove.
#2 Use flat head screwdriver to remove speaker grille, (4) 6-mm socket head screw are now visible to remove speaker. You must remove the (4) white nut bosses by pushing from the backside to pop them out.
#3 Use a flat head screwdriver to remove the window control switch panel. Inside the door panel to the left is located 10-mm socket head bolts. Use 10-mm -socket w/ ratchet and 3” long extension to remove.
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Install
Windshield:
Please check all components in Figures 1 and 2 before assembly.
Align windshield tabs with three holes in Mustang hood and place windshield in position.
Secure windshield by placing three lock washers on windshield tabs on underside of hood
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