K9 KIT INSTALLATION INSTRUCTIONS
1998-2011 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:
12
#10 x ½” Flat head sheet metal screw
40
#10 x ½” Stainless sheet metal screw
40
¼” x ½” Stainless carriage bolt
5
¼” x ¾” Stainless carriage bolt
45
¼” Serrated nut
2
5/16” x ¾” Hex head bolt
2
5/16” Nylock nut
4
5/16” Flat washer
1
Edge molding (7’ foot section)
5
#10 x 1” Sheet metal screw
45
#10 x ¾” Stainless sheet metal screw
1
Tube silver silicone
3
#10 x ¾ Sheet metal screw
USED FOR:
Window guards
Hinge, door panel
Basic unit assembly
Sliding door handle
Basic unit assembly
Front cage bracket
Front cage bracket
Front cage bracket
Ceiling
Rear deck filler
Trim & rear cage
Sealing
Dome light
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
1
2
2
2
1
1
PART #:
GSM33150
GSM34169
GSM32022
GSM32024
GSM30023
GSM33011
GSM30017
GSM31006
PRM97622
GSM33196
GSM34170
PRM97343
GSM33195
Rear Upper Molded Plastic
Rear Cage Aluminum Deck Filler
Front Cage Bracket
Door Panels Aluminum
Window Guards
Dome Light Kit
Rubber Mat
Rear Deck Filler
(Part is not visible)
Front Cage
Brackets
Step Sill
Molded Plastic
Filler PanelsAluminum & 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
KK-K9-F7-K_INST_3-11.docx6-09
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 4
2. Place Floor:
• Place floor (See photo 2)
3.
Photo 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
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Photo 8
Photo 6
6.
•
•
•
•
Notch
Trim
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.
Attach w/ #10
x 3/4” screws
Photo 7
Photo 9
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
4
KK-K9-F7-K_INST_3-11.docx6-09
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 10
11. 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
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•
•
•
•
•
•
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.
6
Photo 17
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