Transcript
Van Step Installation Ford, all full size Kit #907520000 Kwikee #1420760 Rev.2 2/04
Van Step Installation Instructions Fits all full size Fords, Kit #907520000
Read all instructions before beginning. Disconnect the vehicle battery before beginning any installation or wiring procedure. Follow instructions in sequence. Safety glasses should be worn while performing installation.
MOUNTING BRACKET PARTS Qty Description 2 4 2 9 10 10 4 4 4 1 1
Mounting brackets 5/16-18 x 1" long hex head bolts 5/16-18 x 1 1/4" long hex head bolts 5/16" flat washers 5/16" split lock washers 5/16-18 nylock type nuts 1/4-20 x 1" long hex head bolts 1/4" split lock washers 1/4-20 hex nuts 5/16" x 1" long sheet metal screw Instructions
OTHER TOOLS NEEDED l drill motor l 1/4" dia. drill l 5/16" dia. drill l 9/32" dia. drill l socket wrench l 7/16" socket l 1/2" socket (deep) l Alignment jig (30 series step) Part 7550, available from Kwikee (see Note in Step 3) l 7/16" combination or open end wrench l 1/2" combination or open end wrench l pencil or marker l flashlight or drop light l safety glasses
Mounting Bracket Installation
Tighten all wing nuts. NOTE: the alignment jig is not necessary for the installation of the step, however, Kwikee cannot guarantee proper alignment of the mounting brackets without it.
1. Locate and drill four 5/16" diameter holes in the step well for the upper mouting bolts. See Figures 1 and 2. NOTE: Carefully measure the 1" and 1 1/2" dimensions down from the 4. On 1-ton vans, mark the positions of steel floor surface. Do not measure the holes in the back end of both from the floor covering or any kind mounting brackets with the tail piece of trim. in the down position as shown in Figure 2. 2. Bolt the top of both mounting brackets in place using the 5/16-18 hex head On 1/2- and 3/4-ton vans rotate the tail bolts and the wing nuts that are piece to the up position as shown in Figure 2 before marking the locations. included in alignment jig. Refer to Figure 2. NOTE: Do not use the NOTE: These positions must be 5/16-18 nylock type nuts until the very accurate. final mounting procedures. 5. NOTE: Leave the alignment jig attached to the mounting brackets 3. Bolt the alignment jig to the studs in and remove the mounting brackets the mouting brackets using the wing nuts supplied with the alignment jig. and the alignment jig as a unit. Suggested door switch location
Figure 1: Step Well
5 1/2" 31" 1 1/2" 1" Steel floor
Step
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Van Step Installation Instruction: Ford
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6. Drill 9/32" diameter holes in the frame at the marks transferred from the back end of the mouting brackets at tail piece. NOTE: These positions must be accurate.
Step Installation
7. Bolt the top of the mounting brackets in place using the 5/16-18 x 1" hex head bolts. NOTE: Leave the alignment jig attached. Use the 5/1618 hex head bolts, 5/16" flat washers, 5/16" split lock washers, and the 5/1618 nylock type nuts. Do not tighten. Refer to Figure 2.
2. The step should be in its extended 3. Mount the step to the studs in the position for ease of mounting. Use 10 mounting brackets attached to the gauge wire for jumpers to extend the vehicle. Use the 5/16" flat washers, step. CAUTION: Keep hands clear of 5/16" split lock washers, and 5/16-18 the step mechanism. nylock type nuts to attach the step to the mounting brackets. Tighten all Place the step upside-down on its nuts. Refer to Figure 2. WARNING: mounting surface. Ground the Do not re-use the nylock nuts. negative (-) post of a 12-volt battery to Replace with new nylock type nuts the ring terminal of the 31" long 10 if used. gauge green ground wire from the 4. Drill a 1/4" dia. hole in the vehicle's control unit. frame to attach the 10 gauge green Plug the four way plug* into the plug ground wire. Scrape the paint clear leading from the step control unit. around the hole to achieve a good *Plug included in wiring kit or may be ground connection. ordered separately - Kwikee Part No. 5. Attach the 10 gauge green ground 909306000. wire from the step control unit to the Connect the 10 gauge jumper wire vehicle's chassis. Use the 5/16" x 1" between the positive (+) post of the long sheet metal screw and a 5/16" flat battery and the red and white wire washer. NOTE: A good ground leads on plugs with four wire leads. On connection is a must to ensure plugs with two wire leads, just connect proper step operation. the red wire. 6. Tie the ground wire up out of the way NOTE: For steps without a control so it will not interfere with the step or unit, connect the motor's red wire the vehicle operation. to the positive (+) post of the battery and touch the motor's yellow wire to the negative (-) post of the battery to extend the step.
WARNING: Do not reuse the nylock type nuts. Replace with new nylock type nuts if used. NOTE: Do not use the wing nuts for permanent mounting of the brackets. 8. Attach the rear of the mounting bracket tail piece in place using two 1/4-20x1" long hex head bolts, two 1/4" split lock washers and two 1/4-20 nylock type hex nuts on each bracket tail piece. 9. Tighten all mounting nuts and bolts. Remove the alignment jig from the mounting brackets only after all the bolts have been tightened.
1. It is recommended that all wiring to the step be in place before mounting the step to the mounting brackets.
Disconnect the jump wire from the battery. The step will stay in the extended position and is ready for mounting.
Figure 2: Mounting Bracket
1-Ton Vans 5/16" flat washer 5/16-18 x 1: long hex head bolt
1/2- or 3/4-Ton Vans
5/16" split lock washer 5/16" nylock type nut (SEE NOTE) MOUNTING BRACKET 1/4-20 hex nut
5/16-18 x 1" long hex head bolt
MOUNTING BRACKET
1/4" split lock washer
5/16" flat washer 5/16" split lock washer 5/16" nylock type nut (SEE NOTE)
5/16-18 x 1" long hex head bolt 5/16" flat washer 5/16" split lock washer 5/16" nylock type nut (SEE NOTE)
1/4-20 hex nut 5/16-18 x 1 1/4" long hex head bolt 5/16" split lock washer
NOTE: Nylock type nuts used for final mounting procedure.
1/4" split lock washer TAIL PIECE 1/4-20 x 1" long hex head bolt 5/16" nylock type nut (SEE NOTE)
5/16-18 x 1" long hex head bolt
TAIL PIECE
5/16" split ock washer
1/4-20 x 1" long hex head bolt
5/16" nylock type nut (SEE NOTE)
