Whelen M4FC User Manual

®

ENGINEERING COMPANY INC.

51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: [phone]
Fax: [phone]

M4, M7, 400, 500 and 700 Series

2008 Ford E- & F-Series

Installation Guide:

Lighthead Housings

Internet: www.whelen.com
Sales e-mail: [e-mail]
Canadian Sales e-mail: [e-mail]
Customer Service e-mail: [e-mail]

Safety First

This document provides all the necessary information to allow your Whelen product to be properly and safely installed.
Before beginning the installation and/or operation of your new product, the installation technician and operator must
read this manual completely. Important information is contained herein that could prevent serious injury or damage.

• Proper installation of this product requires the installer to have a good understanding of automotive electronics,
systems and procedures.

• If mounting this product requires drilling holes, the installer MUST be sure that no vehicle components or other
vital parts could be damaged by the drilling process. Check both sides of the mounting surface before drilling
begins. Also de-burr any holes and remove any metal shards or remnants. Install grommets into all wire
passage holes.

• If this manual states that this product may be mounted with suction cups, magnets, tape or Velcro®, clean the
mounting surface with a 50/50 mix of isopropyl alcohol and water and dry thoroughly.

• Do not install this product or route any wires in the deployment area of your air bag. Equipment mounted or
located in the air bag deployment area will damage or reduce the effectiveness of the air bag, or become a
projectile that could cause serious personal injury or death. Refer to your vehicle owner’s manual for the air bag
deployment area. The User/Installer assumes full responsibility to determine proper mounting location, based
on providing ultimate safety to all passengers inside the vehicle.

• For this product to operate at optimum efficiency, a good electrical connection to chassis ground must be
made. The recommended procedure requires the product ground wire to be connected directly to the NEGATIVE
(-) battery post.

• If this product uses a remote device to activate or control this product, make sure that this control is located in
an area that allows both the vehicle and the control to be operated safely in any driving condition.

• Do not attempt to activate or control this device in a hazardous driving situation.

• This product contains either strobe light(s), halogen light(s), high-intensity LEDs or a combination of these
lights. Do not stare directly into these lights. Momentary blindness and/or eye damage could result.

• Use only soap and water to clean the outer lens. Use of other chemicals could result in premature lens cracking
(crazing) and discoloration. Lenses in this condition have significantly reduced effectiveness and should be
replaced immediately. Inspect and operate this product regularly to confirm its proper operation and mounting
condition. Do not use a pressure washer to clean this product.

• It is recommended that these instructions be stored in a safe place and referred to when performing
maintenance and/or reinstallation of this product.

• FAILURE TO FOLLOW THESE SAFETY PRECAUTIONS AND INSTRUCTIONS COULD RESULT IN DAMAGE TO
THE PRODUCT OR VEHICLE AND/OR SERIOUS INJURY TO YOU AND YOUR PASSENGERS!

Automotive: Lightheads

For warranty information regarding this product, visit www.whelen.com/warranty

©2008 Whelen Engineering Company Inc.
Form No.14166A (040209)

Page 1

Installation:

WARNING: Lights on the front of the vehicle must be mounted a minimum of 18” apart, measured
from the center of the lighthead. Lights must also be a minimum of 30” from the road and be
mounted below the windshield. Read all warnings before starting installation.

WARNING: Permanent mounting of this product will require drilling. It is absolutely necessary to
make sure no other vehicle components could be damaged by this process. Check both sides of
the mounting surface before starting. If damage is likely, select a different mounting location.

Before Mounting: Be sure the vehicle is parked on a level surface.

For the Front Fender: For maximum effectiveness mount the housings as far forward as possible.

For the Front of the Vehicle: housings will mount to the front of the hood. No less than 18” apart.

For the Vehicle Grille: Housing is contour-cut to self locate to the upper corner of the grille it is designed

for. No gasket is required for grille mounting. Lighthead must project parallel with the road.

1. On the next page, find the photo for your vehicle showing mounting location and specifications.

NOTE: In the part number of the housing, there will be an “R” or an “L” to indicate wether it
goes onto the Right or Left of the vehicle.

2. Hold the housing up against the mounting surface in its suggested mounting location. Measure the
distances shown in the photo and position the housing accordingly.

3. With the housing in place put a level on top and make sure it sits level with the road (for grille
housings also put a level on the front to be sure the lighthead isn’t pointing up or down). With the
housing in position, mark off the 4 mounting holes using the housing as a template.

4. Install the supplied rubber gasket onto the housing. Start the gasket at the bottom of the housing.
The gasket will be longer than needed so you will have to cut off the excess to fit. Pinch the back of
the gasket together as you install it to make the job easier (see illustration). No gasket is used for
grille mounting.

5. Drill the mounting holes with an appropriately sized drill bit depending which mounting hardware is
supplied with your housing. You will also need to drill a wire hole. Refer to the
lighthead manual for wire hole size and location.

CAUTION: When mounting onto fiberglass, after you drill the mounting
holes, chamfer the top of the hole or the fiberglass will crack with use.

6. Secure lighthead with housing to vehicle using supplied mounting hardware.

IMPORTANT: Certain housings may have up to four different sized mounting screws to match the
vehicle contour. To be sure you use the correct screws, insert them into the housing before
mounting. All four screws should extend out of the housing the same amount.

IMPORTANT! Before returning this vehicle to active service, visually confirm the proper operation
of this product, as well as all vehicle components/equipment.

Chamfered

drill hole

"R" or "L" in part number
indicates left or right side
of vehicle

Start gasket on
bottom of housing

Gasket

Installation

Tip:

When installing the gasket,
pinch the top together to
open the gasket, which will

HOUSING

make installation easier.

Make sure the housing is
level with the road.

Also be sure that the
lighthead projects
straight forward
and not up or
down.

HOUSING

NOTE: Lightheads are shown
here for reference. They are
not included with the kits.

400 Series

NOTE: These drawings indicate
the order of mounting hardware,
lenses and gaskets. Grille light
housings do not use gaskets.

Mounting Gasket

700 Series / 23"

P/N 38-0542989-05

Mounting Gasket
400 & 500 Series / 18-1/2"
P/N 38-0542989-04

700

Series

500 Series

IMPORTANT NOTE: The instructions in this manual are for vehicle specific custom
lighthead housings. If you have a standard flat housing the mounting location will
not be as critical as described here. Housings mounted to the front of the vehicle
must still be at least 18” apart.

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