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.

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.

6 4

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

www.demco-products.com

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.

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