FORD MUSTANG 1999 - 2004

LSD INSTALLATION

INSTALLATION INTRODUCTION

1. REMOVING THE FENDER AND DOORS FROM THE A-PILLAR AND DISCONNECTINGTHE WIRE HARNESS @ THE DOOR JAM

2. REMOVING THE EXISTING DOOR HINGES FROM THE DOORS; TOP AND BOTTOM.

3. MODIFYING THE INTERNAL FENDER AREAS FOR THE HINGE CLEARANCE.

4. MODIFYING THE ELECTRICAL HARNESS.

5. HANGING AND ALIGNING THE VEHICLE DOORS.

6. INSTALLING THE FENDER AND CHECKING FOR CLEARANCE.

7. REMOVE FENDER AND ROUTING THE WIRING.

8. RE-INSTALL FENDER AND CHECK FOR CLEARANCE.

9. JOB COMPLETE!

Installation Instructions LamboStyleDoors

(The instructions are to be used as a reference only. Please repeat steps for both doors.)

Pre-installation check list:

•Battery disconnected •Front bumper removal •Front fender removal•Vehicle must be accident free •Vehicle must have inner fender cover

Preparations: (Disassemble parts according to the vehicle manufacturers’ specifications)

• Disassemble the door stopper

• Disconnect the wire harness between the chassis and the door (remove the harness from the door interiorwhen necessary)

• Disassemble the door. For this procedure, un-bolt the from the A-Pillar.

• Un-bolt the hinges located on the door.

• Extend the factory door wire harness with the enclosed wire harness extension kit.(See enclosed “wire harness extension, page )

• Modify the fender(See enclosed “modifying the fender”, page 14)

• Relocate the door lock vacuum case (when necessary).(e.g. from the passenger’s side inner fender to the engine compartment)

• Modify the windshield washer reservoir (when necessary).

! Safety Information: Attention!

LSD door kits must be installed according to the vehicle-specificinstructions provided by LSD-Doors. The installation should beperformed by an authorized dealer.

When extending factory wire harness, follow the vehicle manufacturer's guidelines for cable repairs. When extending CAN-bus, pay attention to the processes of rerouting, screening, and twisting (check vehicle manufacturer's specifications). Be careful not to damage any systems.

After installation of the kit, side airbags (if any) should be tested for proper operation by an authorized dealer.

Performing final adjustments of the doors, make sure they close and lock according to the OEM specifications (check originalclosing angles, locking positions, gaps, etc.).

Be careful while working in the operating area of the doors and hinge system (be especially careful when working with a partner or when there are other people in the working area).

All doors must be securely closed before setting vehicle into motion. Driving with open doors is prohibited.

Do not mount heavy loudspeakers without increasing pressure of the gas spring.

Adjust horizontal opening angle of the doors to the possible maximum.

The gas spring should hold your door at the maximum height under all operating conditions. To guarantee that, choose gas spring with the appropriate pressure level.

Empty door storage compartments, otherwise all the objects placed in there will fall as the door opens and the weight of thedoor will change, which may influence the gas spring operation.

WARNING: gas spring is under extreme pressure! Make sure all mounting brackets are securely fastened in the right places.

General instructions:

A properly instructed partner will make the installation process easier.

Regular servicing of the doors and gas springs at a specialized body shop will expand their service life.

An additional inside handle must be installed to simplify opening and closing of the doors from seated position.

White door lights must be disabled via removal of light bulbs or bulb sockets in accordance with Fig. 5.22 of ECE Reg. No. 48.

After installation of the LSD hinge system, reinstall original innerfender cover to keep LSD hinges free from debris.

Functionality of the vehicle comfort systems, e.g., central locking system (if any), must be checked at an authorized body shop.

Check functionality of all other systems and components (loudspeakers, anti-theft systems, CAN-bus, window rollers, crash-sensors, driver seat memory, mirror heating/adjustment, etc.) at an authorized body shop.

When adjusting the doors, be careful to place them in the proper door openings not to cause any damage to other components. The processes of adjustment and testing must be performed with great attention.

If A-pillar or doors have been modified, use supplied chassis glue (if specified in the list and included in the set) for tight joint. Make sure that sealed surfaces are free from dust and grease before applying chassis glue. Proper door sealing will guarantee safety.

Note: gas springs have been tested on standard doors. If your doors come with additional equipment, it may slightly modify their weight and you may need to order stronger or lighter gas spring (additional costs may arise).

Please note that the gas spring pressure may vary due to temperature, which will influence opening and closing force. Warranty claims will not be honored unless there is defect in material or workmanship.

When body work is performed, apply anti-corrosion covering to all the modified surfaces according to the manufacturer’s guidelines.

After the LSD kit installation, the doors opening angle is limited. The doors must be first carefully opened outwards and then upwards. When too much force is applied to the limiters/stop points body parts may damage.

The warranty does not cover damages caused by improper use, improper installation, or application of excessive force to the limiters/stop points.

General Lubrication Information

In order for the LSD Door System to function properly, adequate lubrication is essential at all pivot points on the system. Periodic lubricating of all pivot points is highly recommended on a consistent basis. This helps in the life of all bearings involved and provides for a smooth operating LSD Door System.

Listed below are helpful hints of when to lubricate:

- After washing the vehicle, open the doors and check to see that all pivot points are properly greased

- Every three months, open doors and check to see that all pivot points are properly greased

- If the vehicle is subject to a harsh environment, such as salt or sand, it is critical that all pivot points stay lubricated, especially if the doors are being used frequently. Open the doors and check to see that all pivot points are greased properly

1x A 6X B 2x C 1x D

Snap ring 683 50 023 Serrated bolt 683 20 049 Nut 683 10 044 Hexagon bolt 683 23 083

3x E 1x F 2x G 3x H

Distance Spacer 651 51 016 Grommet 685 10 045 Screw M8X30 683 20 044 Shim 653 21 350

7x I 1x J 1x K 1x L

Tie wraps 685 10 040 LSD Door System LSD Swing Arm LSD Ground Plate

1x M 1x N 2x O 2x P

Gas damper 649 01 290

HARDWARE LIST ( per vehicle side)

5x Q 1X R 1x S 1x T

Washer 683 30 027 Glue 685 10 041 Cover Plate 653 21 590 Sticker 685 80 007

HARDWARE LIST ( per vehicle side)

1x U

Screw 683 20 045

K

B

O

L

B

B

A

B

C

Q

E

C

U

E

MAGIC STIK

G

G

B

B

Q

M.A.R.A SYSTEM

STEP 1 REMOVING THE O.E.M. DOOR AND O.E.M. HINGES

1a. Remove the front fender and locate the mounting hardware that mounts the door hinges (Photo 1).

1b. Un-bolt the four bolts that mount the O.E.M. hinges (with the doors attached) and re- move them completely off the A-Pillar.

1c. Remove the four bolts mounting the hinges to the door frame, removing the hinges completely.

PHOTO 1

TOP HINGE AREA

A-PILLAR

BOT HINGE AREA

2. MODIFYING THE A-PILLAR

Once the fender has been removed, the A-Pillar top fender mount tab needs modification done to it.This is needed so the new LSD Door Kit fits to the A-Pillar.

2a. Mark the area that needs modification (Photo 2).

2b. Using a cutting tool, cut along the marked lines, removing the top fender mount tab, grindingthe cut edge smooth to the A-Pillar (Photo 3).

PHOTO 2 PHOTO 3

STEP 3 DIS-ASSEMBLING THE SWING ARM FROM THE GROUND PLATE

3a. Your new LSD Door Hinges have come assembled.

3b. As identified in (Photo 4), disassemble the swing arm from the ground plate. Un-bolt all four mounting bolts or allen-heads and remove completely, detaching the swing arm from the ground plate.

3c. Place the four mounting bolts in an area where they will not be lost.

PHOTO FOR REFERENCE ONLY PHOTO 4

MOUNTING BOLTS

SWING ARM GROUND PLATE

STEP 4 MODIFYING THE CHASSIS WIRING HARNESS

IMPORTANT NOTE: Prior to beginning extending the wiring harness from the A-pillar, each individual wire needs to be cut one at a time. Each wire that is cut, has to be staggered (See 4g) from the previous cut wire. By doing this, you will eliminate, when wrapping all the wires, one large taped ball.

4a. If the wiring harness comes equipped with an insulation cover, this will need to be removed.

STEPS 3b thru 3f are for REFERENCE ONLY (using the white wire as reference) 4b. Isolate a single wire (Photo 5). Start the first cut on the white wire approximately 3”

from the door frame.

4c. Cut the wire sheath (coming from door frame) back approximately 1/4” (Photo 6). Twist the end tight.

4d. Cut the wire sheath (from kit supplied white wire) back approximately 1/4”. Twist the end tight.

4e. Using the kit supplied heat shrink connector ends, insert the wire ends into the connec- tor, one from each end (Photo 7).

4f. Using the heat gun, shrink wrap the connector ends to securely mate with the wire ends (Photo 8).

PHOTO 5

PHOTO 6 PHOTO 7 PHOTO 8

STEP 4 MODIFYING THE CHASSIS WIRING HARNESS –cont’d-

4g. VERY IMPORTANT:

4h. Remember to stagger the cuts for each individual wire. This will eliminate having a large wrap and will allow for minimal size and maximum flexibility.

4i. In the photo below an (INCORRECT) version is shown. By cutting it this way, wrapping the wire at the end, will create a large ball in the middle of the newly extended wire har-

ness.

4j. By staggering the cuts, (CORRECT), you eliminate creating a large taped ball, thus making it easier to install back in the chassis.

4k. Prior to soldering on the A-Pillar wire connector end, its important to remember to in- stall the kit supplied rubber grommet and cover plate that mounts to the A-Pillar (Photo

9).

4m. Once the rubber grommet has been fed onto the new extension wire harness, you are able to attach the wire connector end of the A-Pillar (Photo 10).

INCORRECT CUTS CORRECT CUTS

PHOTO 9 PHOTO 10

RUBBER GROMMET & COVER PLATE

STEP 5 MODIFYING THE FENDER

5a. Mark the areas on the fender that are going to be modified (Photo 11). For detailed dimensions, see Page 15.

5b. Using a pneumatic air saw, cut the areas that you have designated to remove.

5c. (Photo 12) shows what the final cut should look like.

PHOTO 11

PHOTO 12

BEFORE

AFTER

STEP 5 MODIFYING THE FENDER –cont’d-

5d. In (Photo 13), the area has been marked for removal. Using a cutting tool cut along the marked area, using the dimensions, as shown below.

5e. Its important to maintain the 2mm lip along the edge for rigidity.

PHOTO 13

240mm(9.44in)

160mm(6.30in)

45mm(1.18in)

30mm(9.44in)

10mm (.39in)

2mm(.07in)

STEP 6 MOUNTING THE LSD GROUND PLATE

6a. Using the existing O.E.M. tapped mounting holes, mount the LSD ground plate matching up each respective mount hole. Two mount holes at the top and two at the bottom (Photo 16).

Locate the mounting bolts at the center of their respective slotted mount holes on the ground plate.

6b. Using the O.E.M. mount bolts, insert and finger tight only.

PHOTO 16

TOP MOUNT

BOT MOUNT

TOP MOUNT (OUTER)

BOT MOUNT (OUTER)

STEP 6 MOUNTING THE LSD GROUND PLATE

6d. Access to both top and bottom outer holes are a little different from the other four mounting holes. To gain access to these holes, you will need to actually remove the inside bottom panels (Photo 16a) to install the mounting washers and nuts.

6e. Once the inside bottom panels have been removed, you will need to remove the small pump/motor (Photo 16b) There is only one screw holding this in place.

PHOTO 16a

PHOTO 16b

STEP 6 MOUNTING THE LSD GROUND PLATE

6f. Using the four O.E.M. mounting bolts, install the inner mount bolts. Using the kit sup- plied bolt, washers, and nuts, install the outer mounting bolts (Photo 16c).

6g. Tighten remaining mounting bolts to 20ft.lbs.

PHOTO 16c

STEP 7 MOUNTING THE LSD SWING ARM

7a. Using the existing O.E.M. tapped mounting holes, mount the LSD swing arm, matching up each respective mount hole. Two mount holes at the top and two at the bottom (Photo 17).

7b. Using the O.E.M. mounting bolts, insert the bolts and finger tight only.

7c. Using a wrench, torque the bolts to 20ft-lb., making sure the mounting bolts are at the center of their respective mounting slots.

PHOTO 17

TOP MOUNTS

BOT MOUNTS

STEP 8 MOUNTING THE DOOR TO THE A-FRAME IMPORTANT NOTE: THIS STEP SHOULD BE DONE WITHOUT THE GAS SPRING INSTALLED

8a. Place the door back on the vehicle and close the door completely.

8b. Install the MAGICSTIK into position (Photo 18) Initially, this is done for mounting pur- poses only, using the MAGICSTIK as a guide.

8c. Lifting the door into position, guide the MAGICSTIK into its mating block (Photo 19), manually holding the door there, as close to the closed position as possible.

8d. Attach the swing arm to the ground plate with the four (4) kit supplied bolts and adjust the door via moving the swing arm adjustable plate connection mount with the horizon-

tal door gap adjuster in the right or left direction until the gap measurement is like the original (Photo 20).

ADJUSTING THE DOOR HEIGHT

8e. Adjustment height of the door is by moving the chassis plate (Q) vertically. Make sure the mounting hardware is loosened to perform this function.

8f. Adjustment depth of the door is by moving the door horizontal. Make sure the mount- ing hardware is loosened to perform this function.

PHOTO 18

PHOTO 19

PHOTO 20

IMPORTANT NOTE: Torque mounting bolt to 10ft-lb.

ADJUSTING THE DOOR HEIGHT –cont’d

8g. Use the adjustment screw (Photo 21) as a point to guide the front door into the correct position.

8h. Attach the Swing Arm to the chassis plate with the (Photo 22) four(4) kit supplied bolts or allen-head bolts, and adjust the door by moving the Swing Arm to the chassis plate adjustable connection mount with the horizontal door gap adjuster (2) in the left or right direction until the gap dimension is the same O.E.M dimen-

sion (prior to disassembling the door).

PHOTO 21

PHOTO 22

8i. Adjust the height of the door by moving the chassis plate vertically (up or down) (Photo 23).

Loosen the six mount bolts prior to adjusting, but not removing them completely. Three at the top, three at the bottom. The use of a rubber mallet would be useful in moving the chassis plate (Ground Plate)

PHOTO 23

B

B

IF REQUIRED

8j. If the Magic Stick (Photo 24) (lower adjustment screw)(1) is not in the correct position when the door is closed, a spacer (Photo 25) (D) has to be installed under the M.A.R.A (2) as shown in the pictures below.

PHOTO 24

PHOTO 25

D

D D

D

2

2

2

2

STEP 1A - TOP

STEP 1B - TOP

STEP 2A - BOTTOM

STEP 2B - BOTTOM

STEP 8 ADJUSTING THE DOOR OPENING –cont’d

The door openings of vehicles will vary from one model to another. This adjustment controls the gap between the Swing Arm and the front edge of the door and the rear edge of the front fender (See Photo AA)

8k. This can be done with or without the fender removed. Slowly open the door. Using a measuring tape, measure from the outside top corner of the door to the frame of the chassis (Photo BB). This dimension has been pre-determined to be 700mm(27.5”).

IMPORTANT NOTE: IT IS VERY IMPORTANT TO INSTALL ONTO THE ADJUSTMENT SCREW, LOC-TITE™. THIS WILL PREVENT THE ADJUSTMENT SCREW FROM BECOMING LOOSE THROUGH VEHICLE VIBRATION OR OVER A PERIOD OT TIME.

PHOTO AA PHOTO BB

700mm (27.5in)

PHOTO - CC

ADJUSTMENT SCREW M.A.R.A. SYSTEM

STEP 8 ADJUSTING THE DOOR OPENING –cont’d

8m. Once this width of opening has been established, tighten the ADJUSTMENT SCREW on the M.A.R.A. system (Photo CC).

8n. Once you have tighten the ADJUSTMENT SCREW (with the use of Loctite™), you can now slowly lift the door to the upward position, checking for any interference.

8o. Locate the door back to the closed position.

8p. Re-install the fender (if removed) back on the vehicle. Open the door slowly and place it in the upward position, checking for any interference with the fender as it is being lifted upward.

STEP 9 MOUNTING THE GAS DAMPER (after correct gap distance has been established)

IMPORTANT NOTE:• PRIOR TO MOUNTING THE GAS DAMPER AT ITS RESPECTIVE MOUNTING POINTS, WE HIGHLY

RECOMMEND USING AN ANTI-RUST LUBRICANT, WIPING DOWN THE MOUNT POINTS TO PRE-VENT RUSTING.

• KEEPING THE MOUTNING POINTS LUBRICATED, ENHANCES THE LONGEVITY OF THE LSDDOOR SYSTEM TO WORKING PROPERLY

GAS DAMPER TOP PIVOT POINT ON LSD SWING ARM

GAS DAMPER BOTTOM PIVOT POINT ON LSD GROUND PLATE

STEP 9 MOUNTING THE GAS DAMPER

9a. Hang (mount) the gas damper(M) on the mount point of the swing arm (Photo 29). Se- cure it with the kit supplied security ring, by using needle-nose pliers.

9b. NOTE: Use care when installing the security ring.

9c. Carefully pivot the door up and hang in the gas damper at the fitting point of the chassis plate. Secure it with the kit supplied security ring (Photo 30)

PHOTO 29

DANGER: The gas damper is under extreme pressure! Please make sure the security rings are installed correctly and are snapped their respective guides.

PHOTO 30

PHOTO 31

4 4

VERTICAL ADJUSTMENT

HORIZONTAL ADJUSTMENT

T O P V I E W

SWING ARM PLATE

STEP 10 ROLLER ADJUSTMENT

IMPORTANT NOTE: The door needs to be in the closed position for this adjustment to be properly done.

NOTE: This adjustment also needs to be done with the gas damper installed.

10a. Install the kit supplied slide roller (as shown in the picture).

10b. Adjust the slide roller (4) so the LSD swing arm has the initial contact and pre- load while opening and closing of the door. (Photo 31).

10c. Periodically lubricate the slide roller to insure a constant smooth open/close sequence.

11. SUPPORTING THE CHASSIS PLATE (IF REQUIRED)

NOTE: PAGE 28 IS FOR REFERENCE ONLY.

11a. Re-assemble the modified fender back on the vehicle, using only two (2) bolts to mount it.Double check for any obstructions. Remove the fender again.

11b. Locate the slotted hole that the distance bushing will be mounted to (Photo 32).

11c. (Photo 32) shows what the final mount of the distance bushing will look like once mounted to the Ground Plate to the frame chassis.

PHOTO 31

PHOTO 32

D

Q

E

P

T O P V I E W

11. SUPPORTING THE CHASSIS PLATE (IF REQUIRED) -cont’d-

THIS PAGE FOR REFERENCE ONLYTRANSFERRING THE MOUNTING HOLES

11e. Placing the long mount bolt through the mount slot and keeping it level (Photo 33a), mark thearea where the end of the bolt comes into contact with the frame. Make sure to locate the bolt at the center of the mount slot.

OPTIONAL: Remove the hinge assembly to drill the mount holes

11f. Using a long drill bit, drill a pilot hole initially, then using the 8mm drill bit, drill the mount holes. Do this for both mount holes (Photo 33b)

11g. Using a measuring scale (Photo 33c), get the length of spacer(s) needed for the top distance spacer.

11h. Once the hole has been drilled insert the kit supplied hardware bolt, flat washer, distance bushing (E) at their respective locations (Photo 33d).

11i. Torque to specs.

PHOTO 33a

L

PHOTO 33b

PHOTO 33c

C O

PHOTO 33d

LENGTH OF SPACER

E

STEP 12 ROUTING THE WIRE HARNESS

12a. Pivot the door carefully up and make sure there is sufficient clearance on the fender, A- pillar and hood. If necessary, adjust the LSD chassis plate or the LSD swing arm

again.

12b. Lay the wire harness on and attach it to the marked points shown (Photo 34). Securethe wire harness with the kit supplied cable ties. The wire harness is located on the backside of the LSD chassis plate.

PHOTO 34

COMMON TROUBLESHOOTING QUESTIONS and ANSWERS

Q1: WHY DOES THE BOTTOM OF THE DOOR NOT SIT FLUSH, AT THE FRONT OR REAR?:

A1: LSD door hinges are engineered and designed to compensate for this issue. They are designed to be installed in the center location of all mounting slots. Some vehicles are different however; adjusting the location of the swing arm mounts on the door will fix this problem. Mounting the swing arm towards the interior of the door, top or bottom will move the door out; mounting the swing arm towards the exterior of the door will move the door in. In some cases, the mounting will be slightly different be-

tween top and bottom mounts.

Q2: WHY DO THE DOORS “SPRING” A-JAR WHEN OPENING THE DOOR?:

A2: LSD door hinges are engineered and designed to compensate for this issue. It is common on vehicles that the left and the right sides are not quite the same. When a door “springs” open there is a misalignment between the swing arm and the ground plate. This can be remedied by increasing the distance of the “third” point on the ground plate. The “third” point is usually located towards the front of the ve-

hicle. Increasing the distance and angle of the ground plate to the vehicle will release any pressure and/or contact between the swing arm and the ground plate.

Q3: WHY DOES THE DOOR HITS/RUBS AGAINST THE FENDER WHEN OPENING?:

A3: LSD door hinges are engineered and designed to compensate for this issue. Attaching the LSD hinge in the center location of the slots and adjusting the magic stick such that the tuff lock is centered is the optimum desired installation. Making minor adjustments to the “MARA”/“C” profile, the “third” point, and/or the “Magic stick” should alleviate this problem.

Q4: WHY IS THE WIRING HARNESS TOO LARGE FOR THE ROUTE SHOWN IN THE INSTRUC- TIONS?:

A4: LSD door hinges are engineered and designed to compensate for this issue. LSD wiring kits are designed for the MAXIMUM wires installed on vehicles. If additional wires are added or modified that are larger than original, wiring routing might have to be modified. Vehicle owners are responsible for this modified routing.

Q5: WHY DOESN’T THE GAS SPRING HOLD THE DOOR UP?:

A5: LSD door hinges are engineered and designed to compensate for original door weight, i.e. speakers and electronics. NOTE: As temperature fluctuates, the gas pressure in each shock increases or decreases. Example; in the heat, the gas pressure will expand, in the cold; it has a tendency to contract. Any modifications to the speakers or electronics may require a larger gas spring. Vehicle owners are required to purchase these larger gas springs from their local dealer. If you have not modified your door, your gas spring may be faulty. Vehicle owners are required to contact their local dealer for re

placement(s).