Installation Instructions

Transcription

1 Installation Instructions AUXILIARY SHOCK MOUNT REPAIR KIT Better Solutions Supply

2 Table of Contents WARRANTY INFORMATION... 3 INTRODUCTION BEFORE YOU BEGIN... 4 SAFETY INSTRUCTIONS... 4 VEHICLE COMPATIBILITY... 5 PARTS SUPPLIED... 5 TOOLS REQUIRED (NOT INCLUDED)... 5 STEP 1 - REMOVING INNER TRIM PANNELS... 6 STEP 2 - LIFTING THE VEHICLE... 7 STEP 3 - REMOVING THE RUSTED MATERIAL... 8 STEP 4 - POSITIONING AND INSTALLING THE BRACKET STEP 5 - SEALING THE WHEEL WELL STEP 6 - APPLYING THE PROTECTIVE RUBBER COATING (STEP 7) - FINISHING UP (STEP 2 IN REVERSE) (STEP 8) - FINISHING UP (STEP 1 IN REVERSE)... 20

3 Limited Lifetime Warranty Our Warranty BSS warrants that each product meets the applicable product specifications at the time of shipment. BSS obligation under the Limited Lifetime Warranty is limited to a one-time replacement or one time refund equal to the original purchase price of the defective product. Warranties are non-transferable, contain no cash value, and are only etended to parts sold provided that the ownership has not changed since the installation of the unit. This warranty does not apply to units which have been altered, modified, damaged from neglect, abuse or an accident, misused, improperly installed, installed on lowered of lifted suspension vehicles, vehicles used for racing purposes, or used in applications other than recommended by the manufacturer. BSS provides reimbursement for labor involved in replacement under warranty, but does not provide reimbursements for delay, mileage, or any other costs involved in installation or reinstallation of the auto parts in question. Warranty does not cover parts installed for an incorrect application. This warranty gives you specific legal rights, as you may also have other rights which vary from state to state. Contact us to verify the status of any warranty on your auto parts. Please allow 5-7 business days for the processing of your warranty claim. LIMITATION OF LIABILITY Ecept where prohibited by law, BSS will not be liable for any loss or damage arising from the BSS product, whether direct, indirect, special, incidental or consequential, regardless of the legal theory asserted Better Solutions Supply - Auiliary Shock Mount Repair Instructions 3

4 Before you begin PLEASE READ ALL INSTRUCTIONS THOROUGHLY PRIOR TO BEGINNING It s important to familiarize yourself with each step of the process prior to beginning installation. This step will allow you to fully understand the process from beginning to end, allowing for a successful installation. IMPORTANT Observe all governing codes and ordinances. Skill level Installation of this device requires basic mechanical skills. Proper installation is the responsibility of the individual completing the installation. Product failure due to improper installation is not covered under our warranty. Completion Time 3 Hours for each side to repair. FOR YOUR SAFETY STOP Read and observe all CAUTIONS and WARNINGS shown throughout these instructions. While performing the installation described in this booklet it is important to follow safety procedures and at all times gloves, and safety glasses should be worn. WARNING To reduce the risk of injury or bodily harm, the individual responsible for installation must ensure that the car is securely stabilized on the lift at all times. Wear all necessary safety equipment in accordance with the safety instructions provided by the manufacturer of all tools and chemicals you will be using during this installation. READ CAREFULLY AND KEEP THESE INSTRUCTIONS HANDY If you have any problems during installation, please contact your dealer. The installer is responsible for performing an adequate installation according to the following instructions and must ensure that the installation complies with local law and/or legislation Better Solutions Supply - Auiliary Shock Mount Repair Instructions 4

5 Vehicle compatibility Prior to beginning installation please ensure that your vehicle is compatible with the auiliary shock mount replacement kit. Year Make Model Trim Engine 2001 to 2012 Ford Escape All All 2001 to 2011 Mazda Tribute All All 2005 to 2011 Mercury Mariner All All Slight variations can occur between the parts that are pictured in this manual and those that are supplied in your kit, based on the information provided at purchase for your vehicle. Supplies Checklist PARTS SUPPLIED (1**) Heavy duty 1/2 thick steel patented auiliary shock mount (bracket) (2**) 1/2 bolts with washers and locking nuts (2**) Shock mounting bushings (2**) Strut-mount washers (5* **) Natural bristle brushes for fiberglass application (1*) Large fiberglass reinforced resin container (1* **) Large weaved fiberglass cloth (1*) Black asphalt undercoating spray can *Complete repair kit only **Quantity doubles to repair both side TOOLS REQUIRED (NOT INCLUDED) Grinder with cutting disc and wire wheel attachments Drill with a ½ metal bit and a smaller one (Approimate size : ± ¼ ) Two 3/4 wrenches and/or ratchets Ajustable wrench (spanner) Car jack and wheel nut wrench Large plastic (or cloth) protective covering for seats Medium sized marker or pen 2018 Better Solutions Supply - Auiliary Shock Mount Repair Instructions 5

6 Step 1: Remove the inner trim panels Approimately 10 minutes for each side 1 Some of the pictures used below show the Ford Escape Hybrid Model, although the bracket is compatible with many other models. The hybrid model features a large, shiny metal coloured top and black sides battery in the floor of the trunk, instead of the emergency jack black plastic compartment on non-hybrid models. You will often see this battery in the pictures. The presence of the battery does not influence the eecution of the installation. You should not use pry tools to remove any plastic panel, as those tools will leave white marks or break the plastic pins that clip the panels to the inner body of the car. Start by removing the carpet over the trunk floor (over the emergency jack compartment on a non-hybrid model or over the hybrid battery on a hybrid model). Remove the long scuff plastic trim plate at the edge of the trunk, over the trunk door locking pin. This plate overlaps the large trim panels on each side. Pull the plate up using your hands only and allow it to un-pop entirely from each of the si retaining points. (Optional) On non-hybrid models, remove the four (4) 15 mm bolts retaining the trunk floor panel and remove this panel. Fold the back seats down completely. For each side where you want to install an auiliary shock mount, pull off the small round panel surrounding the back seat s retaining steel attachment. Then pull off the large trim panel. This one begins just behind the rear passenger door and goes all the way to the trunk door. Simply help it off by sliding your fingers behind the panel and shaking it off lightly, then remove it off completely Better Solutions Supply - Auiliary Shock Mount Repair Instructions 6

7 Step 1: Remove the inner trim panels (continued) On hybrid models, you will find behind the large trim panel a cooling system for the hybrid battery. You should not have to take it off. Behind the large trim panel is a black plastic sound module on certain models. If this is your case, remove it to clear out the working space (8mm bolts). Unplug the rear passenger air bag wire to allow the sound module to be set aside. Leave the sound module attached to the wire which goes to the front of the car. Simply put the sound system on the folded rear seats for the duration of the installation. Step 2: Lift the vehicle Approimately 5 minutes for each side 2 Place the car on an hydraulic lift and lift it to remove wheel. If you don t have access to a professional lifting device, you can use an hydraulic jack or screw jack, such as the one provided with certain vehicles. When lifting the car on its wheels, put the parking brake ON and place blocks in both directions on each wheel. Special attention should be made to prevent any movement of the car during the installation. Follow the safety instructions inside jack and car manuals). Nº 1 - We recommend using a professional lifting device, although you can use your emergency jack Better Solutions Supply - Auiliary Shock Mount Repair Instructions 7

8 Step 3: Remove the rusted material Approimately 25 minutes for each side 3 Nº 2 - Cutting disc and wire wheel attachments. Nº 3 - Hang a protective covering for the rear seats and ceiling. Place a large protective covering such as a painters plastic sheet or a large cloth to avoid hot metal grindings and debris from reaching the seats or ceiling (See picture Nº 3). You will need a grinder with a cutting disc and a wire wheel attachment to clean off the rusted material around the original shock mount location. (See picture Nº 2) Start by unbolting the lower and upper ends of the shock absorber to remove it completely. Using the grinder with the cutting disc attachment, cut the entire contour of the rusted area where the original upper shock mount is (or was) located on the wheel well panel. Then use the grinder wire wheel attachment to remove any paint or surface rust, both inside and outside of the vehicle, on at least 1 to 2 inches of width, on the contour of the hole. Leave only unattacked metal material that can hold the future fiberglass patch. You will end up with a medium to large size hole in the wheel well panel, depending of the intensity of the rust. This hole will have a unique shape proper to the particular case of each affected vehicle. Rusted areas to remove normally have a 0.5 to 2.5 ft² surface. Be careful not to damage the gasoline reservoir entry pipe: Cutting the gasoline pipe can cause a fire or an eplosion, leading to potential casualties or permanent injury. Be careful not to damage the brake line that passes near the frame in the damaged area Better Solutions Supply - Auiliary Shock Mount Repair Instructions 8

9 Step 3: Remove the rusted material (continued) Pay a particular attention to any residue of the edge of the panel, under the hole, spot welded just over the side of the vehicle s frame. If necessary, remove the spot welding using a chisel or a flat screwdriver and pull it off with pliers, or cut it off. Nº 5 - Use a chisel or a flat screwdriver to pull off any remaining residue of the edge of the original wheel well panel (Right side shown as an eemple) Nº 4 - Use a pair of pliers to pull off any remaining residue of the edge of the original wheel well panel (Right side shown as an eemple) The side of the vehicle s frame under the hole should form a FLAT surface all the way up to the lower frontier of the hole. Do not hesitate to hammer the edge of the hole to create an equal and flat surface with the side of the frame where the bracket is going to be sit and bolted (shown as a black line on picture 6). Nº 6 - Do not hesitate to hammer the side of the frame to make an equal and flat surface. (Here right side shown) 2018 Better Solutions Supply - Auiliary Shock Mount Repair Instructions 9

10 Step 4: Position and install the bracket 4 Approimately 45 minutes for each side Drawings Nº 7 and Nº 8 show how the bracket has to be bolted on the frame rail, under the hole. The frame rail is represented by a section (or portion) of itself. To position the bracket, the shock absorber has to be fied temporarily to the lower mount behind the wheel and it s upper end (strut) has to go temporarily through the mounting hole on the upper end of the bracket. IT IS NOT NECESSARY TO PUT THE RUBBERS IN PLACE NOR TO TIGHTEN THE END-NUT at this time (see pictures Nº 9 and Nº 10). Nº 7 - (Driver Side) - How the bracket has to be bolted to the frame Nº 8 - (Passenger Side) - How the bracket has to be bolted to the frame First, have a medium sized marker pen near you to mark the position of the holes to be drilled when it will be determined. Up-Down positioning Place the bracket vertical and perpendicular to the frame and move it up or down until the lower end of the bracket comes flush with the lower face of the frame (see pictures Nº 9 and Nº 10). Nº 9 - (Driver Side) - Move the bracket until the lower end isflf lush with the lower face of the frame. Nº 10 - (Passenger Side) - Move the bracket until the lower end isflf lush with the lower face of the frame Better Solutions Supply - Auiliary Shock Mount Repair Instructions 10

11 Step 4: Position and install the bracket (continued) Front-Rear positioning While you hold the bracket at the up-down level described before, slide it first in the direction of the FRONT of the car until the shock absorber hits the control arm of the wheel. Notice where the point of contact is. Then slide the bracket to the REAR of the car until you have a (1/32) to (3/8) clearance between the control arm of the wheel and the shock absorber (See pictures Nº 11 and Nº 12). Mark the position of the sides of the bracket and take the shock absorber apart to mark the holes to be drilled. Nº 11 - (Driver Side) - Allow a 1/32 to 3/8 clearance between the absorber and the control arm of the wheel. Nº 12 - (Passenger Side) - Allow a 1/32 to 3/8 clearance between the absorber and the control arm of the wheel. Remember that the clearance with the control arm is smaller when the vehicle is on a lift or jack, and becomes larger when the vehicle is sitting on its wheel, while the angle of the absorber is going to be different because of the weight of the vehicle on the wheel. When you position the bracket, the vehicle is standing on a jack or lift, the suspension is fully depressed, and the clearance with the control arm should not be greater than 3/8, as this could later cause a clearance issue with the interior plastic trim panel which would not clip back properly due to the presence of the bracket being installed too far towards the rear. Carefully set the clearance between 1/32 and 3/ Better Solutions Supply - Auiliary Shock Mount Repair Instructions 11

12 Step 4: Position and install the bracket (continued) Depending of the unique shape of the rusted area that you have removed, you may also have to cut out a bit of healthy (undamaged) sheet metal above the edge of the frame in order to slide the bracket towards the rear, enough to get the proper clearance with the control arm (see pictures Nº 13 and Nº 14, not to be used as an indication for the correct position of the bracket). Double check that the bracket can sit flat and vertical on the side of the frame. Nº 13 - (Driver Side) - If there is any, cut off the healthy (undamaged) sheet metal preventing you from sliding the bracket towards the rear, enough to clear the control arm of the wheel appropriately. *Do not use this picture as an indication of the correct position of the bracket, but instead use the previously described positioning method. Nº 14 - (Passenger Side) - If there is any, cut off the healthy sheet metal preventing you from sliding the bracket towards the rear, enough to clear the control arm of the wheel appropriately. *Do not use this picture as an indication of the correct position of the bracket, but instead use the previously described positioning method Better Solutions Supply - Auiliary Shock Mount Repair Instructions 12

13 Step 4: Position and install the bracket (continued) BEFORE DRILLING THE HOLES READ ALL STEPS BEFORE PROCEEDING! VERY IMPORTANT: MAKE SURE YOUR DRILL IS PLACED PERPENDICULAR AS MUCH AS POSSIBLE TO THE FRAME RAIL SO THAT: the bolts will be PARALLEL the bolts will be perpendicular to the frame as much as possible the washers will not enter in contact with each other on the opposite side of the frame rail After you finish to drill the center of ONE of the holes with the ±¼ bit, enlarge it using the ½ bit, then continue pushing the drill further to drill through the backside (opposite face of the frame rail) maintaining the orientation as described. Then temporarily mount the bracket with a first bolt and drill the other hole in the frame with the ½ bit using the remaining hole in the bracket to guide the bit through. Drill the second hole completely. On the left side be careful not to damage the brake line that passes behind the frame while you drill the holes. You do not have to remove the brake line to bolt everything in place if you use a wrench instead of a ratchet in this area, but you must pay particular attention not to damage the brake line when you drill the holes. In addition to this, remember that if you need etra space to drill or to bolt, brake lines are somewhat fleible and can be bent lightly. If necessary, bend the brake line slightly further away from the frame, the bolts and the nuts. THE BRAKE LINE SOULD NOT TOUCH THE END OF THE BOLTS IN ROAD CONDITIONS. This could cause the brake line to wear and leak over time. If needed, bend the brake line slightly further away to avoid any contact. On the right side, room is clear for drilling on both sides of the frame Better Solutions Supply - Auiliary Shock Mount Repair Instructions 13

14 Step 4: Position and install the bracket (continued) Bolt the bracket firmly in place (be careful: over-tightening could warp or damage the frame). Note that further unscrewing of the auto-locking nuts will weaken their auto-locking end and will necessitate the replacement of the nuts provided. Bolt firmly the lower end of the shock absorber. Assemble the washers and bushing kit. Place the hollow side of the washers facing the bushings and place the smaller-ridge side of the bushings against the bracket (see pictures Nº 18 and Nº 19). Tighten the end strut-nut. If you have a torque wrench (not necessary), tight it to 18 Nm (13 ft. Lbs.). Notice that your installation kit is composed of a spare strut-nut that may not be necessary. Nº 16 - (Driver Side) - Bolt everything permanently as described. Nº 17 - (Passenger Side) - Bolt everything permanently as described Better Solutions Supply - Auiliary Shock Mount Repair Instructions 14

15 Step 4: Position and install the bracket (continued) Nº 18 - (Driver Side) - Place the hollow side of the washers facing the bushing and place the smaller ridged side of the bushings against the bracket. Nº 19 - (Passenger Side) -Place the hollow side of the washers facing the bushing and place the smaller ridged side of the bushings against the bracket Better Solutions Supply - Auiliary Shock Mount Repair Instructions 15

16 Step 5: Seal the wheel well 5 Approimately 45 minutes for each side The necessary material for step 5 and further steps below are supplied only in the COMPLETE REPAIR KIT. These steps are very important in order to complete your repair and seal your wheel well against rust, water, and road debris. READ ALL STEPS BEFORE PROCEEDING! Notice that the fiberglass patch will insulate the bracket and the shock absorber completely OUTSIDE of the car. Thus, if ever the shock absorber needs to be replaced in the future, its upper strut-nut will need to be untightened FROM THE OUTSIDE, AND NOT FROM THE INSIDE, unlike in the original configuration. Enough clearance has to be left between the bracket and the fiberglass patch to complete this operation. This clearance over the bracket should be minimal so that the inner trim plastic panels can clip back in place properly. A clearance of more or less 1¾ to 2 over the bracket is optimal. Pre-cut the fiberglass cloth to the size and shape of the hole. Consider the necessary space over the bracket as mentioned above. Clean the contour of the hole of any loose debris. Only when you are ready to attach the fiberglass cloth to the contour of the hole, mi appropriate amounts of resin and hardener in a disposable container following the instructions of the manufacturer. About half the volume of the lid of the resin container (2.5 oz / 72 ml) should be enough for now. REMEMBER YOU HAVE LIMITED TIME TO APPLY IT ONCE YOU HAVE MIXED THE RESIN AND THE HARDENER. Apply the resin mi with a supplied brush on contour of the hole (1 to 2 wide) and on the back of the bracket (see pictures Nº 20 and Nº 21 on the net page) Better Solutions Supply - Auiliary Shock Mount Repair Instructions 16

17 Step 5: Seal the wheel well (continued) Nº 20 - (Driver Side) - Start by applying resin mi on the contour and on the back of the bracket. Nº 21 - (Passenger Side) - Start by applying resin mi on the contour and on the back of the bracket. Then place the pre-cut fiberglass cloth over the hole and use your brush to press the cloth against the resin all along the contour and behind the bracket so that it sticks to the metal. DO NOT TRY TO APPLY THE RESIN MIX ON THE CENTER OF THE CLOTH RIGHT AWAY. Wait until the fiberglass resin applied on the contour has hardened enough to hold the cloth in place when you will put a first layer of resin mi on the center of the cloth. One layer of a 1 ft² patch requires (5 oz / 145 ml or one lid) of resin mi. You normally have enough material to apply three layers if you measure quantities carefully at each coat. Start by applying the resin mi on the inner side and quickly cover also the outer side. Before this coat starts to harden, shape the patch using your brush to meet the following requirements: The clearance above the bracket is optimal (±1¾ to 2 above the bracket); The shape of the patch does not restrict too much the inner space, so the inner plastic panel can clip properly Better Solutions Supply - Auiliary Shock Mount Repair Instructions 17

18 Step 5: Seal the wheel well (continued) When this first layer is hardened enough to allow for the application of another layer without deforming, apply two additional layers of resin mi and cloth. We recommend the application of THREE LAYERS of resin mi and cloth. These three layers, in addition to the rubberized coating, will give the patch a great resistance to cracking, water and road debris. Nº 22 - (Driver Side) - What your fiberglass patch should look like (First coat shown on the picture). Nº 23 - (Passenger Side) - What your fiberglass patch should look like (Frist coat shown on the picture) Better Solutions Supply - Auiliary Shock Mount Repair Instructions 18

19 Step 6: Apply the asphalt undercoating 6 Approimately 5 minutes for each side, ecluding drying times Apply the black asphalt coating generously on each side of the the fiberglass patch, on the bracket and on the upper end of the shock absorber, including bushings, strut, washers and nut (See pictures Nº 24 to Nº 27). The rubberized coating will retain a certain elasticity over time and will not prevent the nut from becoming unscrewed. Nº 24 - Apply the asphalt coating on the inner side of the fiberglass patch. Nº 25 - Apply the asphalt coating on the inner side of the fiberglass patch. Nº 26 - Apply the rubberized coating generously on the outer side of the fiberglass patch, on the bracket and on the upper end of the shock absorber, including bushings, strut, washers and nut. The rubberized coating will retain a certain elasticity over time and will not prevent the nut from being unscrewed. Nº 27 - Apply the rubberized coating generously on the outer side of the fiberglass patch, on the bracket and on the upper end of the shock absorber, including bushings, strut, washers and nut. The rubberized coating will retain a certain elasticity over time and will not prevent the nut from being unscrewed Better Solutions Supply - Auiliary Shock Mount Repair Instructions 19

20 Steps 7 & 8: Finishing up Approimately 15 minutes total for each side. Step 7 Complete Step 2 in reverse, approimately 5 minutes for each side. Step 8 Complete Step 1 in reverse, approimately 10 minutes for each side. Note: Pay particular attention to the wiring present around the hole. Look for any wear, particularly on the wiring of the rear lights, casually worn or cut in cases where the original shock mount has detached from the body during driving. Repair the wear (if any) or replace the wiring if necessary. Firmly tape this wire on the inner metal panel if it s loose enough to shake and hit any surface over road bumps and cause rattle noises Better Solutions Supply - Auiliary Shock Mount Repair Instructions 20