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ASSEMBLY

OPERATION

REPLACEMENT PARTS

READ complete manual CAREFULLY

BEFORE attempting operation.

BOLT TORQUE SPECIFICATIONS

Size Grade Torque

5/16” 5 20 ft/lbs.

3/8” 5 35 ft/lbs.

7/16” 5 56 ft/lbs.

1/2” 5 85 ft/lbs.

Size Torque

8mm 22 ft/lbs.

10mm 42 ft/lbs.

12mm 70 ft/lbs.

14mm 95 ft/lbs.

STANDARD BOLTS:

METRIC BOLTS:

09-05

TP20039,Rev.4

DEMCO • Dethmers Mfg. Co. • 4010 320th Street • P.O. Box 189 • Boyden, IA 51234

PH: (712) 725-2311 • Toll Free: 1-800-543-3626 • FAX: (712) 725-2380 or 1-800-845-6420

www.demco-products.com

REF. PART

NO. NO. QTY. DESCRIPTION

1. 07928 2 1/4” x 1-1/2” Pan Hd. Sheet Mtl. Screw

2. 00214 5 1/4” Flatwasher

3. 00523 14 3/8”-16UNC x 1-1/4” Hex Bolt Gr.5

4. 00060 14 3/8” Lockwasher

5. 00059 6 3/8” Flatwasher

6. 00061 10 3/8”-16UNC Hex Nut

7. 07594 2 3/8” x 1” Thread Cutting Bolt

8. 01896 2 1/2”-13UNC x 4” Hex Head Bolt Gr.5

9. 00084 2 1/2” Lockwasher

10. 00083 2 1/2”-13UNC Hex Nut

11. 07927 3 6mm x 1.000 x 30mm Hex Bolt Gr.8.8

12. 07479 8 8mm x 1.250 x 25mm Hex Bolt Gr.8.8

13. 07286 8 8mm Lockwasher

14. 07895-35 1 Left Pull Ear Pod

15. 07896-35 1 Right Pull Ear Pod

16. 07897-35 2 Nut Strip

17. 07898-35 2 Bumper Bracket

18. 07899-35 1 Sub-Frame Mount ‘97-’98 (Shown)

18. 10322-35 1 Sub-Frame Mount ‘99

19. 07900-35 1 Left Stabilizer Brace

20. 07901-35 1 Right Stabilizer Brace

21. 07902-95 8 Heavy Frame Washer (1-1/4”OD)

22. 12329 1 Loctite (not shown)

9517039 PARTS LIST

Please order replacement parts by

PART NO. and DESCRIPTION.

Ford Taurus

Mercury Sable

ITEM #1 IS NOT SHOWN

Pin Height - 14” Pin Centers - 23-1/2”

Doing Our Best to Provide You the Best

Summary of content (11 pages)

PAGE 1
09-05 TP20039,Rev.4 Ford Taurus Mercury Sable ASSEMBLY OPERATION REPLACEMENT PARTS Doing Our Best to Provide You the Best BOLT TORQUE SPECIFICATIONS STANDARD BOLTS: METRIC BOLTS: Size 5/16” 3/8” 7/16” 1/2” Size 8mm 10mm 12mm 14mm Grade 5 5 5 5 Torque 20 ft/lbs. 35 ft/lbs. 56 ft/lbs. 85 ft/lbs. READ complete manual CAREFULLY BEFORE attempting operation. Torque 22 ft/lbs. 42 ft/lbs. 70 ft/lbs. 95 ft/lbs.
PAGE 2
WARNING: FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN LOSS OF TOWING VEHICLE CONTROL, SEPARATION OF THE TOW BAR FROM THE TOWING VEHICLE, SEPARATION OF THE TOWED VEHICLE FROM THE TOW BAR, CAUSING SEVERE PERSONAL INJURY, DEATH, OR PROPERTY DAMAGE. CAUTION Safety is of utmost importance at all times. There are several items that must be checked each time before using and while using a tow bar.
PAGE 3
INSTALLATION INSTRUCTIONS 1996-1999 Ford Taurus 1996-1999 Mercury Sable 2000-2003 Ford Taurus 1. Remove lower splash panel. 2. Remove inner fender to facia screw. each side. 1. Remove lower splash panel. Do this on 3. Remove lower headlight pod bolt (from each side), located approximately 6 inches above horn bracket. Remove three top headlight bolts and loosen long headlite bolt. Unplug and remove headlite. 2. Remove inner fender to facia screw.
PAGE 4
1996-1999 Ford Taurus 1996-1999 Mercury Sable 2000-2003 Ford Taurus 4. Remove two more bolts, fender to facia, by headlight openings. 4. Remove front nosecone assembly (five bolts across the front, two by each headlite outer edge, and one on each side by wheelwell. 5. Remove grill, four plastic push fasteners, lift up and out. Remove two plastic push fasteners from top of facia and remove facia. 5. Pull front facia out on each side by wheelwell, and lift up on metal edge across the front.
PAGE 5
1996-1999 Ford Taurus 1996-1999 Mercury Sable 6. Remove front bumper styrofoam by drilling out pop-rivets, and set aside. One at a time replace all eight bumper bolts with eight heavy washers, and 8mm bolts and lockwashers. 2000-2003 Ford Taurus 7. Slide each pull ear pod starting from center of bumber out and measure approximately 1-9/16” from edge of center bumper channel to edge of pull ear pod. Pull ears have to measure 23-1/2” center to center. Clamp in place with “C” clamp. 8.
PAGE 6
1996-1999 Ford Taurus 1996-1999 Mercury Sable 2000-2003 Ford Taurus 9. Slide nut plate thru bumper hole and fasten with 3/8” x 1-1/4” bolts, and lockwashers. 10. Fasten angle bracket, with 3/8” x 1-1/4” bolts, flatwashers, and lockwashers to pod and loosely tighten. Drill 5/16” hole in center of bumper using angle bracket as template. Attach here with 3/8” self threading bolt. Tighten all previously installed bolts for pods at this time. 10.
PAGE 7
1996-1999 Ford Taurus 1996-1999 Mercury Sable 11. Attach subframe mount (‘99 model uses narrow mount) with 1/2” x 4” bolts, lockwashers, and nuts on bottom side. 12. Attach 1/4” x 2” brace with two 3/8” x 1-1/4” bolts, lockwashers, and nuts on each side and one 3/8” x 1-1/4” bolt, lockwasher, flatwashers and hex nut on each side in back to subframe mount. Braces are left and right, second slot is for pass thru bolt clearance into fiberglass housing for lower splash panel. 13.
PAGE 8
DEMCO PRODUCTS ORIGINAL PURCHASERS LIMITED WARRANTY 1. Extent and Duration of this Warranty: Your Demco product has a Lifetime Limited warranty to be free from defects in materials and workmanship under normal use and service from date of purchase by the original (first) retail owner, or until it is resold or transferred by the original owner.
PAGE 9
Warranty Registration Dethmers Manufacturing Company 4010 320th Street • Box 189 • Boyden, Iowa 51234 Toll Free 800-54DEMCO (800-543-3626) • FAX 800-845-6420 www.demco-products.
PAGE 10
Postage Dethmers Manufacturing Company 4010 320th Street, Box 189 Boyden, Iowa 51234
PAGE 11
DETHMERS MFG. COMPANY 4010 320th St., P.O. BOX 189, BOYDEN, IA. 51234 PH: (712) 725-2311 FAX: (712) 725-2380 or 1-800-845-6420 TOLL FREE: 1-800-54DEMCO (1-800-543-3626) www.demco-products.