INSTALLATION MANUAL FORD PI SEDAN PRISONER TRANSPORT SEAT WITH OS-BELT SEATBELTS (PI02) Required Tools: Drill Bits: 9/16 (.5625 ) Power Drill Socket Wrench Set Square #2 Driver Rubber Mallet Utility Knife Page 1 of 9 PTS FORD PI SEDAN INSTRCUTIONS: OS BELT VERSION: B.1
FORD PI SEDAN PRISONER TRANSPORT SEAT WITH OS-BELT SEATBELTS PARTS LIST PARTS LIST: Description Qty. Part No. FORD PI SEDAN, OS-BELT 1 PI02 Ford PI Sedan Seat, OS-Belt Trim 1 PI51 OUTSIDE BELT COVER KIT 1 P300 Toothed C- Retainer 2 P004 #6x0.625 Sheet Metal Screw, Black 8 P057 CENTER BELT COVER KIT 1 P301 Belt Slot Cover 2 P005 #6x0.625 Sheet Metal Screw, Black 14 P057 STORAGE TONGUE KIT 1 P302 Storage Tongue 2 P003 #10 x 0.75 Pan Head Square Drive Self Drilling Screw 4 P051 RETRACTOR KIT, FORD PI SEDAN 1 PI71 Retractor 2 P001 Seat Belt Sliding Buckle 2 P002 Hip-Side Tongue 2 PI81 ½-13 Serrated-Flange Hex Locknut 1 P155 ½-13 x 1.0 Serrated Flange Hex Cap Screw, Black 1 P204 Retractor Mount, Ford PI 1 PI86 REAR DECK KIT, FORD PI SEDAN 1 PI72 ½ Standard Washer 1 P102 ½-13 Jam Nut 1 P151 ½-13 Serrated-Flange Hex Nut 1 P155 ¾ Steel Spacer 1 P109 Rear Deck Reinforcement Plate 1 PI83 SEAT MOUNTING KIT, FORD PI SEDAN 1 PI77 #14 x 1.5 Hex Head Self Drilling SMS, Black 7 P055 P300 P301 P302 PI77 P057 P004 P057 P005 P051 P003 P055 PI71 PI72 P001 PI83 P102 P155 P109 P151 P002 PI81 PI86 P204 P155 Page 2 of 9 PTS FORD PI SEDAN INSTRCUTIONS: OS BELT VERSION: B.1
Ford PI Sedan with OS-Belt Installation Instructions NOTE: IF INSTALLING A FLOOR PAN DO SO BEFORE INSTALLING SEAT. CAUTION: LOCATE ALL WIRING, FUEL LINES, BRAKE LINES, AND/OR COOLING LINES BEFORE DRILLING HOLES OR INSTALLING FASTENERS. NOTE: WAIT TO INSTALL CENTER PARTITION UNTIL AFTER YOU HAVE INSTALLED THE SEAT. THE SEAT REQUIRES THAT THE FRONT SEATS BE MOVED FORWARD TO ALLOW INSTALLATION. 1. Remove Factory Seat a. Remove bottom seat: unclip front lever latches, lift up slightly, slide back, and lift out. b. Remove the nuts from the three seatbelts on the bottom the vehicle. c. Remove the seat back by removing the nuts from the bottom studs then releasing the two latches at the top (The pull cords for releasing latches may be tucked behind the seat and more easily accessible from the trunk). [Pic 1] Factory Seat Removed (We suggest leaving the latches on to act as locating points for the seat) d. Remove top deck for easy access and remove factory seatbelts. e. Replace all remaining nuts back onto the original studs for keeping. Pic 1 2. Gently bend the child seat anchors (that are welded to the frame) so they are no more than 1.5 inches above floor pan. Note: These will need to be bent back for vehicle resale. [Pic 2] Bend Child Seat Anchors Page 3 of 9 PTS FORD PI SEDAN INSTRCUTIONS: OS BELT VERSION: B.1 Pic 2
3. Install the Retractor Kit (PI71). a. Remove the three nuts on the upper level of the middle plate that is connected to the frame. [Pic 3] b. Put Retractor Mount Assembly over the three studs and re-secure the nuts. [Pic 3] Install Retractor Assembly Remove/Install Nuts c. Using bolts and bolt locations for the factory seatbelt retractors, install (2) Hip-Side Tongues (PI81). [Pic 4] Pic 3 Install Hip-Side Tongues Pic 4 4. Install Rear Deck Kit (PI72). a. Remove plastic cover for middle child seat anchor in top deck. [Pic 5] b. From inside the trunk, use a 9/16 drill bit to enlarge the hole in the sheet metal of the top deck just behind the middle child seat anchor. [Pic 6] c. Cut away enough of the top deck to allow the bolt to come up through the top deck without interference. Page 4 of 9 PTS FORD PI SEDAN INSTRCUTIONS: OS BELT VERSION: B.1
Remove Plastic Cover Pic 5 Drill Out Hole (Trunk View) Pic 6 d. Using (1) ½ Standard Washer (P102) and (1) ½-13 Jam Nut (P151), install (1) Rear Deck Reinforcement Plate (PI83) through recently enlarged hole by placing the washer over the screw and securing the jam nut. Place the (1) ¾ Steel Spacer (P109) and (1) ½-13 Serrated Flange Hex Locknut (P155) onto the screw but wait to tighten. [Pic 7] WARNING: A CRITICAL WIRE HARNESS RUNS BENEATH THE TOP DECK IN THE VICINITY OF WHERE THIS BOLT IS PLACED. EXERCISE CAUTION TO NOT PINCH THIS WIRE HARNESS BETWEEN THE NUT, WASHER, AND BOLT ASSEMBLY. Page 5 of 9 PTS FORD PI SEDAN INSTRCUTIONS: OS BELT VERSION: B.1
PINCHING THIS WIRE HARNESS WILL CAUSE A MALFUNCTION IN ONE OR MORE ELECTRICAL SYSTEMS DUE TO THE SYSTEMS BECOMING GROUNDED. (The two ends of the retractors will be connected later) Assemble Rear Deck Kit (Exploded View) 5. Cut a ¼ inch slot along the rubber door trim just above the hard plastic lower door trim. This is to allow the seat to sit underneath the rubber trim. Repeat for other side. Pic 7 Cut ¼ Slot 6. Install Ford PI Sedan Seat (PI51) in vehicle with Seat Mount Kit (PI77). a. Feed Retractor webbing through the slots in the middle hump of the Ford PI Sedan Seat. b. Top of seat will rest on the factory latches and against front edge of top deck. c. While lowering Ford PI Sedan Seat, feed (2) Hip-Side Tongue through outboard slots. d. Feed Ford PI Sedan seat under rubber door trim on both sides. [Pic 9] Pic 8 Page 6 of 9 PTS FORD PI SEDAN INSTRCUTIONS: OS BELT VERSION: B.1
Feed Seat Under Rubber Trim Pic 9 e. While firmly holding seat in place, use provided locations in the seat to drill pilot holes into the sheet metal of the vehicle. NOTE: WE STRONGLY RECCOMEND USING A CENTER PUNCH THRU THE HOLES IN THE PLASTIC SEAT TO SPOT THE LOCATION IN THE SHEET METAL PRIOR TO DRILLING FOR SCREW HOLES. f. Use the (5) #14x1.5 Hex Head Self-drilling Sheet Metal Screws (P055) in the provided holes to secure the seat to the vehicle; two on bottom, three on top. [Pic 10] NOTE: BE SURE THAT CABLES/WIRES ARE TUCKED FAR ENOUGH UNDER THE SEAT SO THAT THEY DON T INTERFERE WITH THE SEAT CONTACTING THE VEHICLE. Install 5 #10 Sheet Metal Screws Pic 10 Page 7 of 9 PTS FORD PI SEDAN INSTRCUTIONS: OS BELT VERSION: B.1
7. Install Outside Belt Cover Kit (P300) a. Place (1) Toothed C-Retainer (P004) on webbing of outboard seatbelt and outboard slot so that it pinches webbing and closes gap around webbing. Secure with (4) #6 x 0.625 Sheet Metal Screws (P057). [Pic 11] b. Repeat for other side. Install Toothed C-Retainer 8. Install Center Belt Cover Kit (P301) a. Install (2) Belt Slot Cover (P005) around Retractor webbing using the built-in cutout in the Belt Slot Cover. Cutout should face away from prisoners (towards center) to avoid pinching the webbing. b. Using (14) #6 x 0.625 Sheet Metal Screw, Black (P057), install Belt Slot Covers to the Ford PI Sedan Seat. c. Slide (2) Seat Belt Sliding Buckle (P002) onto Retractor webbing. Check buckle to ensure button is facing the desired direction. [Pic 12] Pic 11 Install Belt Slot Covers Pic 12 Page 8 of 9 PTS FORD PI SEDAN INSTRCUTIONS: OS BELT VERSION: B.1
9. Using (1) Serrated-Flange Hex Nut already located on the top deck, extend and secure connector plates of the Retractors to the top deck between the Rear Deck Spacer and Hex nut. [Pic 13] Secure Connector Plates 10. Install the Storage Tongue Kit (P302) a. Using (4) #10x0.75 Square Drive Self-Drilling Screw (P051) and (2) Storage Tongue (P003), secure the Storage Tongues to the vehicle Center Partition. Be sure to install the Storage Tongues low enough in the vehicle to avoid head injury during prisoner entry and exit. [Pic 14] Pic 13 Pic14 Page 9 of 9 PTS FORD PI SEDAN INSTRCUTIONS: OS BELT VERSION: B.1