Demco TP20039 User Manual

ASSEMBLY
OPERATION
REPLACEMENT PARTS

09-05

TP20039,Rev.4

Ford Taurus
Mercury Sable

Doing Our Best to Provide You the Best

BOLT TORQUE SPECIFICATIONS

STANDARD BOLTS:

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.

20

16

4

3

3

5

4

6

3

3

21

13

12

15

8

18

9

10

Please order replacement parts by

PART NO. and DESCRIPTION.

READ complete manual CAREFULLY

METRIC BOLTS:

Size Torque
8mm 22 ft/lbs.
10mm 42 ft/lbs.
12mm 70 ft/lbs.
14mm 95 ft/lbs.

14

6
4

17

5

7

2

11

3

16

17

19

BEFORE attempting operation.

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

ITEM #1 IS NOT SHOWN

9517039 PARTS LIST

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)

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

PH: [phone] • Toll Free: 1-800-543-3626 • FAX: [phone] or 1-800-845-6420

www.demco-products.com

R

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.

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.
Before allowing anyone to hook up or operate a tow bar, be sure they
have read and understand the proper operating procedure.

DO NOT use worn or damaged cables and/or pins.
Be sure the SAFETY CABLES are hooked, chassis to chassis, to both

the towing and towed vehicles using the crisscross method.
Check clearance between vehicles in a turning situation.
Check base plate mounting bolts for tightness and frame for metal

fatigue.
Do not load the towed vehicle with anything as you may exceed the

towing capacity of the tow bar.
Keep fi ngers away from pivot points to prevent personal injury.
Be sure the steering components of the towed vehicle are properly

aligned.
NOTE: This unit can be backed up in moderate increments. Any

severe backwards cornering could result in damage to the Tow Bar
and/or towed vehicle chassis.

For automatic transmissions: Consult your vehicle owners manual
for towing suitability with the drive shaft connected. Otherwise, the
towed vehicle will have to be equipped with a transmission pump or
drive shaft disconnect.

Check to make sure that all lights are in proper working order.

The information on towability of vehicles is reprinted with per­mission of MotorHome

However, Demco does not warrant the information to be correct.
Always consult your towed vehicle owner’s manual and follow towing
instructions. Each year, MotorHome© Magazine, compiles a list of
vehicles that can be towed four-down behind a motorhome with no
modifi cations required. This guide contains only those vehicles that
have been approved by their manufacturers for towing. This list is

enclosed with this manual.

Caution: MotorHome
have towing speed limits slower than 55 m.p.h., or distance limits of
less than 200 miles. At a minimum, these vehicles require signifi cant
modifi cation, such as the use of an aftermarket product, to make
them towable. The availability of a Demco Tow Bar Base Plate does
not imply that these vehicles can be modifi ed or that there is an af­termarket product available. Refer to your vehicle owner’s manual or
consult your dealer to determine whether your vehicle can be modifi ed
to make it towable. Failure to observe this precaution could result in
property damage or personal injury.

CAUTION

©

Magazine, and is believed to be reliable.

©

Magazine left out any vehicles that

NOTE: The dimensional variations between otherwise

IMPORTANT INSTALLATION ITEMS

DEMCO products and accessories are intended to be
installed by professional installers with experience,
proper equipment and the ability to do modifi cation
work. Installers with these qualifi cations can be
found in RV and Automotive Service Centers.

If the car to be towed has been in an accident, the
chassis may be damaged in an area where the Base
Plate attaches. It may no longer be suitable for tow­ing. Extreme caution and careful examination are
required in such a situation. It is also likely, even
from a minor accident, that the hole alignment will
be more diffi cult due to hole alignment problems.

Many DEMCO Base Plates are designed to use
existing holes and hardware to mount the Base Plate
to the towed vehicle. Even though the bolt is there,
however, do not assume it is adequate for mounting
the Base Plate. Manufacturers make many changes
in hardware both within and between model years.
Be sure the bolt is long enough to protrude past the
nut a distance no less than 1/2 the diameter of the
bolt, after the Base Plate is mounted. The threads
should be in good condition. We require that

“

bolt is required, be sure it is SAE Grade 5 or Metric

8.8.

identical vehicles can be considerable. Some mi­nor modifi cations may have to be made to ensure
a proper fi t.

Blue” be used on all bolts. If a new

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. Do this on
each side.

1. Remove lower splash panel.

2. Remove inner fender to facia screw. Pull inner
fender back or remove completely to gain access to
one bolt, fender to facia. Do this on each side.

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.

3. Remove headlights, one bolt in front and two
L-shaped fasteners in back, pull these staight
up. Pull headlight out and unplug wiring.

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 (fi ve 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. Pull
forward and unplug turn signal lites, and side
marker lites.

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.