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Installation of the billet trunk
release kit is fairly straightforward.
Patience is key to getting the job done
right! Prior to beginning the
installation you should layout a work
area with enough room for you to work
with the doors wide open. The work area
should be clean and free from grease. You
should also make sure that you have all
of the proper tools to do the job right.
We suggest the following:
TOOLS:
* Screwdrivers in various
sizes, Flat and Phillips style
* Pliers and wire cutters
* Torq head driver set
* Door handle removal tool (available at parts
stores)
* 3/8" Ratchet and socket set with 1" deep well
socket
* Allen wrench set
* Automotive test light
* Ruler or tape measure
* Box and open end wrenches in various
sizes
* Electric Drill with 1/8" drill bit
* 5/8" Hole saw
* Set of Allen Wrenches
1. It is now time to determine
the exact location where you will place
the trunk release kit.
Be
extremely careful here, once the
holes are drilled you're
committed!!! There are a number of things to
consider when determining the pacement of
the cable. The most important factor is
to determine the spot where the kit will
exit. Most people exit out at the
fenderwell or from underneath the floor.
Either spot works well, it really depends
on you andhow you feel about security. If
you are really concerned about security,
you could have the kit exit out of the
right fenderwell or the right floorboard.
Would-be thieves will not usually look on
the passenger side for a trunk
release.
2. Open the trunk and locate the
trunk latch. Now you need to determine
how you will attach the cable to the
latch. You will also have to consider how
you plan to run the cable, so it will not
be visible or get in the way of moving
things in and out of the trunk. Once you
have determined the proper location drill
a 1/8" pilot hole at the exit
spot.
3. Now it is time to drill the
mounting hole for the bulkhead fitting.
Please note that the bulk head fitting
has a 5/8" diameter and that the hole
needs to be drilled
prcisely.
YOU HAVE TO BE ACCURATE WHEN YOU
DRILL THIS HOLE.
4. After having drilled the bulk
head fitting mounting hole, insert the
fitting into the hole to checkfor any
interference with moving parts. With the
fitting sitting in the hole, attach a nut
and check the clearence. Make sure that
you can get a socket or a wrench onto the
nut. Run the nut all the way up on the
fitting.
5. In the event that the
bulkhead fitting needs to be shortened, mark
off the spot where the fiiting needs to be cut.
Remove the bulkhead fitting from the door, and
run the nut up all the way on the fitting. This
step is very important in order to clean up the
threads after cutting. Run the nut up and down
the fitting a number of times to insure that
the threads have been cleaned up and no
cross-threading occurs.
6. You should apply a good rust
inhibitor to the exposed metal round the
hole you drilled prior to installing the
fitting. A good rust proofing paint
should work well too. Make sure it dries
before continuing. Once you have applied
the rust inhibitor it is time to attach
the fitting to the cable. Pull out about
3" of the stranded metal cable beyond the
black housing and install the fitting
onto the cable.
7. Notice that the bottom of
the fitting has a nylon bushing installed.
Insert the the black cable housing into the
bushing using a slow turning method. You should
feel some resistance as it is a tight fit. You
should be able to insert the cable about a
1/2", at which point you should hit the
shoulder stop on the bushing.
8. Now take the billet knob and
insert the metal cable into the knob as far as
it will go. Take an Allen and tighten the set
screw down tightly. Make sure that the set
screw is tightened down securely onto the
cable. Push the knob all the way into the
bulkhead fitting.
9. Run the cable through the
exit hole, and run the nut up over the cable
and screw it onto the bulkhead fitting. Tighten
the fitting with a wrench and check the cable
to make sure that it moves smoothly.
10. Now it is time to route the
cable and secure it with the cable clamps. The
trick here is not to make sharp turns with the
cable, but rather to make smooth easy curves.
At each turn make sure you set the cable with a
clamp so that the cable won't bounce
around.
11. Now it is time to attach
the cable to the trunk lock. Determine how much
cable you will need and carefully cut the black
housing (a utility knife works well for this)
away from the metal cable. Leave about 3 - 4"
of metal cable showing beyond the plastic
tubing. Now slide the crimp sleeve over the
metal cable. Loop the metal cable through the
trunk release lever and back into the crimp
sleeve.
12. You ready now to make the
final connection. Pull the cable until it is
slightly taught. Crimp the sleeve with a pair
of linemens pliers. Make sure that the sleeve
is fully compressed and that the cable cannot
move around in the sleeve. Now check the
operation of the cable by pulling on the billet
knob. The trunk lock should open. If all works
well you're done!!!
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