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385 viewsThe clutch stack. See how the left edge of the friction plate teeth are worn and hammered.
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385 viewsRemoving the spacer.
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385 viewsThe red wire for the HID bulb is pushed into the top of the headlight bucket. The blue wire that I'm holding will be next.
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385 viewsI ground the planetary pin level and then drilled a 3/16" hole in it to a half-inch depth. I got a piece of 3/16" rod from the local hardware store, beveled the edge, then pushed it into the hole.
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385 viewsSame thing for forward gear.
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384 viewsFog harness using a hook on the right side radiator fan surround.
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384 viewsShowing the path of the LED array as it goes down on the front part of the head light. That blue thing is simply a nylon auto trim tool I had laying nearby that I used to hold the fascia away from the head light so I could work with both hands. Now just apply power from the turn signal tap!
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383 viewsNext, I used a 15/64" (almost 6mm which would work fine) and hand drilled the hole for the grommet (yes, I twisted it with my bare fingers). I wanted to make sure I drilled straight and using a hand-held drill would've caused the hole to be at a slight angle due to the head light housing interfering with the drill chuck.
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383 viewsUnscrew the bolts and remove the spring caps and springs. The pressure plate then pulls straight out and the push rod comes with it.
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...after.382 views
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382 viewsInside of rearward gear and planetary gear mating teeth.
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Left side shown. Right is just like the left side.381 viewsAfter removing the bumper skin fasteners remove the 10mm bolt and pin retainer. Do this for both sides (remove all fasteners). This will allow the front fascia and bumper skin to be pulled back enough to get to the head lights. The bumper is still attached to the vehicle by lower fasteners but for this situation it doesn't need to be fully removed.
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381 viewsThe ground lug I used on the left side. Use a ring connector for the grounds. This insures the nut will still make a connection even if the nut gets loosened.
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381 viewsThis shows just how much the head lamps are angled on top. The left side has the LED array far back (towards the engine) whereas on the right side I wasn't as accurate and the LED array is about 3mm-5mm more forward (away from the engine). This clearly shows how the lip on the head lamp disburses the light. The left side is what I was originally looking for so I should've been more patient when installing the right side. Experience gained.
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381 viewsHow the product comes packaged after you pull it out of the box. Very nice!
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Cable shifter380 views
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380 viewsFlap fully open, allowing some of the heated air to divert into the center of the Bus for the rear passengers.
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380 viewsNow the bar-end mount is up two inches at 34" high.
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380 viewsBearing grease (red) applied on the planetary teeth for mating to the rearward gear. I followed the instructions for the "new" teeth so I hope this is okay for the "old" teeth. I think it should be.
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LED dual-element array (alternating white and amber LEDs).379 viewsCut the other end to the desired length or to simply remove the other wires. Use some heat-shrink at the end to seal it from the elements. I left a little over-hang and then bent the heat-shrink back on itself, then gently clamped with some needle-nose pliers.
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