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 94400 Billet Trunk Release Kit: Installation Instructions

Installation of the billet trunk release kit is fairly straightforward. Patience is key to getting the job done right! Prior to beginning the installation you should layout a work area with enough room for you to work with the doors wide open. The work area should be clean and free from grease. You should also make sure that you have all of the proper tools to do the job right. We suggest the following:

 TOOLS:

* Screwdrivers in various sizes, Flat and Phillips style
* Pliers and wire cutters
* Torq head driver set
* Door handle removal tool (available at parts stores)
* 3/8" Ratchet and socket set with 1" deep well socket
* Allen wrench set
* Automotive test light
* Ruler or tape measure
* Box and open end wrenches in various sizes
* Electric Drill with 1/8" drill bit
* 5/8" Hole saw
* Set of Allen Wrenches

1. It is now time to determine the exact location where you will place the trunk release kit. Be extremely careful here, once the holes are drilled you're committed!!! There are a number of things to consider when determining the pacement of the cable. The most important factor is to determine the spot where the kit will exit. Most people exit out at the fenderwell or from underneath the floor. Either spot works well, it really depends on you andhow you feel about security. If you are really concerned about security, you could have the kit exit out of the right fenderwell or the right floorboard. Would-be thieves will not usually look on the passenger side for a trunk release.

2. Open the trunk and locate the trunk latch. Now you need to determine how you will attach the cable to the latch. You will also have to consider how you plan to run the cable, so it will not be visible or get in the way of moving things in and out of the trunk. Once you have determined the proper location drill a 1/8" pilot hole at the exit spot.

3. Now it is time to drill the mounting hole for the bulkhead fitting. Please note that the bulk head fitting has a 5/8" diameter and that the hole needs to be drilled prcisely. YOU HAVE TO BE ACCURATE WHEN YOU DRILL THIS HOLE.

4. After having drilled the bulk head fitting mounting hole, insert the fitting into the hole to checkfor any interference with moving parts. With the fitting sitting in the hole, attach a nut and check the clearence. Make sure that you can get a socket or a wrench onto the nut. Run the nut all the way up on the fitting.

5. In the event that the bulkhead fitting needs to be shortened, mark off the spot where the fiiting needs to be cut. Remove the bulkhead fitting from the door, and run the nut up all the way on the fitting. This step is very important in order to clean up the threads after cutting. Run the nut up and down the fitting a number of times to insure that the threads have been cleaned up and no cross-threading occurs.

6. You should apply a good rust inhibitor to the exposed metal round the hole you drilled prior to installing the fitting. A good rust proofing paint should work well too. Make sure it dries before continuing. Once you have applied the rust inhibitor it is time to attach the fitting to the cable. Pull out about 3" of the stranded metal cable beyond the black housing and install the fitting onto the cable.

7. Notice that the bottom of the fitting has a nylon bushing installed. Insert the the black cable housing into the bushing using a slow turning method. You should feel some resistance as it is a tight fit. You should be able to insert the cable about a 1/2", at which point you should hit the shoulder stop on the bushing.

8. Now take the billet knob and insert the metal cable into the knob as far as it will go. Take an Allen and tighten the set screw down tightly. Make sure that the set screw is tightened down securely onto the cable. Push the knob all the way into the bulkhead fitting.

9. Run the cable through the exit hole, and run the nut up over the cable and screw it onto the bulkhead fitting. Tighten the fitting with a wrench and check the cable to make sure that it moves smoothly.

10. Now it is time to route the cable and secure it with the cable clamps. The trick here is not to make sharp turns with the cable, but rather to make smooth easy curves. At each turn make sure you set the cable with a clamp so that the cable won't bounce around.

11. Now it is time to attach the cable to the trunk lock. Determine how much cable you will need and carefully cut the black housing (a utility knife works well for this) away from the metal cable. Leave about 3 - 4" of metal cable showing beyond the plastic tubing. Now slide the crimp sleeve over the metal cable. Loop the metal cable through the trunk release lever and back into the crimp sleeve.

12. You ready now to make the final connection. Pull the cable until it is slightly taught. Crimp the sleeve with a pair of linemens pliers. Make sure that the sleeve is fully compressed and that the cable cannot move around in the sleeve. Now check the operation of the cable by pulling on the billet knob. The trunk lock should open. If all works well you're done!!!



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