KK-K9-F16-K INSTALLATION INSTRUCTIONS K9 Kit for

KK-K9-F16-K INSTALLATION INSTRUCTIONS
K9 Kit for 2011-2016 FORD EXPLORER
(Retail Model Vehicle with OEM Center Shifter Console)
TOOLS Needed:
Phillips Screw Driver
Standard Socket set
Metric Socket set
Power Drill with Drill Bits
Wire Cutters /Crimpers
Awl and 90° Scribe
Trim panel removal tool
Caulk Gun
PARTS & HARDWARE:
QTY
DESCRIPTION
1
Floor
1
Rear wall
1
Passenger side lower filler
1
Driver side lower filler
1
Front wall / bulkhead with sliding door
1
Ceiling
2
Lower “B” pillar bracket
2
Upper “B” pillar bracket
1
Rear floor bracket A
1
Rear floor bracket B
1
Front floor bracket
1
Passenger side upper filler
1
Driver side upper filler
1
Rubber Mat
2
Ceiling vent / duct
1
Driver side door panel
1
Passenger side door panel
1
Driver side hinged window guard
1
Passenger side hinged window guard
1
Dome Light Kit
1
Silicone caulk (sealant)
33
1/4 x 3/4” Carriage bolt – Stainless Steel
33
1/4” serrated nut
8
1/4 x 3/4” Phillips pan head screw - Stainless Steel
8
1/4 Flat washer - Stainless Steel
3
1/4 x 3/4” Hex head bolt
3
1/4 Flat washer
10
#10 x 1/2 Phillips flat head sheet metal screws - SS
14
#10 x 1/2 Phillips pan head sheet metal screws - SS
20
#10 x 3/4 Phillips pan head sheet metal screws- SS
2
Rubber Bumper
2
6MM nut
PART #
KNM004351
KNM004352
KNM004353
KNM004354
KNM004440
KNM004356
KNM004369
KNM004370
KNM004375
KNM004376
KNM004393
KNM004404
KNM004405
KNM004408
KNM004392
DP-F18-1A
DP-F18-6A
WGI-F18-1-K9
WGI-F18-6-K9
KK-K9-DOME-LED
PRM97343
GSM32024
GSM30170
GSM34102
GSM31048
GSM33001
GSM31005
GSM34150
GSM34169
GSM34170
GSM21105
GSM30201
KK-K9-F16-K_INST_6-11 rev 5-14
NOTES!
 Read all instructions before installing any Havis, Inc. products.
 Use hardware provided with install kit.
 Vehicle battery should be disconnected during installation. It will need to be temporarily
reconnected to move electric seats or check electric door locks.
KK-K9-F16-K Assembly
(Door panels and window guards not shown)
KNM004370
Upper “B”
Pillar Bracket
KNM004369
Lower “B”
Pillar Bracket
KNM004392
Ceiling vent / duct
KNM004356
Ceiling
KNM004404
Passenger side
upper filler
KNM004405
Driver side
upper filler
KNM004355
Front Wall
KNM004353
Passenger
side lower
filler
KNM004352
Rear Wall
KNM004375
Rear floor
bracket A
KNM004351
Floor
KNM004354
Driver side
lower filler
KNM004376
Rear floor
bracket B
KK-K9-F16-K_INST_6-11 rev 5-14
Remove rear passenger door panels
first. Behind the door open paddle
handle, remove plastic cover and bolt.
(10mm socket)
Underneath door handle, remove
plastic cover and bolt.
(10mm socket)
Note: A small 90° scribe helps to
pick plastic covers off.
Remove / unsnap entire door
panel from door.
(Trim removal tool)
Disconnect latch cable from door
handle.
Remove window switch from
door panel and reattach it to
original plug. Neatly wire tie the
speaker wire, switch wire with
switch inside the speaker cavity
so it does not interfere with the
window operation.
Carefully remove the door lock
rod from O.E.M. lock assembly
or loosely wire tie it out of the
way.
NOTE: It is very important
that lock rod does not prevent
the electric lock from working.
Removing the rod is
recommended
Remove screws at bottom of door
panel. (7mm socket)
Remove door speaker.
(7mm socket)
NOTE: It is very important to
check the lock operation several
times before installing the new
K9 door panel. To simulate the
door closing, Use a tool to close
the latch mechanism. Use
exterior handle to open latch.
KK-K9-F16-K_INST_6-11 rev 5-14
Make sure O.E.M. door parts are
secure and locks and windows are
operational by using front door
controls.
Fold seats up in order to access the
seat floor mounting hardware.
Middle seats have a total of four (4)
bolts and four (4) nuts to remove.
Remove and save hardware for K9
front floor bracket.
(15mm socket)
Remove third seat forward
brackets. Save nuts for K9 rear
floor bracket.
(13mm socket)
Temporarily remove plastic panels to
access the third seat rear brackets.
Remove seat and seat belt bolts.
(13mm socket)
Temporarily remove (unsnap) rear
cargo hatch door sill trim panel.
Temporarily remove (unsnap) rear
cargo side wall trim panels.
NOTE: This is necessary in order
to get rear seat out.
Remove seat and replace seat bolts.
(13mm socket)
NOTE: Be very careful not to
damage the rear air conditioning
refrigerant lines.
Replace all cargo trim panels.
Interior is now ready for K9
equipment installation.
KK-K9-F16-K_INST_6-11 rev 5-14
Place K9 kit door panel onto door. The top will
hook onto rubber molding. Position so it lines
up with the two existing (protruding) bolts.
Drill mounting holes with 5/32” drill bit. Attach
door panels with #10 x 3/4 Phillips pan head
sheet metal screws.
Attach rubber bumper to OEM door stud with
6mm nut. This will go on top of existing nut.
Bumper is used as a stud guard.
This step can be done before or after the door
panel installation, but make sure the stud is
center on the hole.
NOTE: Window guards are
shipped flat. On the edge of a work
bench, bend a contour in the
middle of the guard so it will fit
tight against the window frame.
Position window guard inside
window frame. Use 5/32” drill bit
and drill hinge mounting holes in
door panel. Attach hinge with # 10 x
1/2 Phillips pan head sheet metal
screws.
With upper mount bracket attached
to window guard, mark mounting
hole locations in upper door /
window frame.
Drill 5/32 holes.
Attach upper mount bracket with
#10 x 1/2 Phillips flat head sheet
metal screws.
Attach front bracket and rear floor
bracket “A” with previously
removed O.E.M. seat mount
hardware.
Tighten hardware.
(13mm and 15mm sockets)
Attach rear floor bracket “B” to K9
floor with 1/4 x 3/4 carriage bolts
and serrated nuts.
Tighten hardware.
(7/16 socket)
Door Panel and Window Guard
complete.
NOTE: It is very important to
check the lock and window
operation several times before
closing door.
KK-K9-F16-K_INST_6-11 rev 5-14
Place floor into vehicle.
Loosely attach rear floor bracket “B”
to rear floor bracket “A” with 1/4 x
3/4” hex head bolts and flat washers.
Note: Bracket “A” already has
nutserts installed.
Attach front floor bracket to K9
floor with 1/4 x 3/4 carriage bolts
and serrated nuts.
Tighten all floor hardware.
(7/16 socket)
Loosely attach rear wall to floor
with 1/4 x 3/4 round head Phillips
bolts and washers.
Note: Floor already has nutserts
installed.
Remove O.E.M. grab handles on
“B” pillar. Reuse original hardware
and loosely attach front wall
mounting brackets.
(7mm socket)
Attach front wall to “B” pillar
brackets with 1/4 x 3/4 carriage
bolts and serrated nuts.
(7/16 socket)
Loosely attach bottom of front wall
to floor with 1/4 x 3/4 Carriage
bolts and serrated nuts.
Loosely attach ceiling to front wall
with 1/4 x 3/4 carriage bolts and
serrated nuts.
Loosely attach ceiling to rear wall
with 1/4 x 3/4 carriage bolts and
serrated nuts.
.
KK-K9-F16-K_INST_6-11 rev 5-14
Determine correct driver and
passenger side upper and lower
filler panels.
Loosely attach top filler panel to
ceiling and rear wall with 1/4 x 3/4
carriage bolts and serrated nuts.
Note: Filler panel flange goes behind
wall and underneath ceiling as shown.
Loosely attach lower filler to rear
wall with 1/4 x 3/4 carriage bolts
and serrated nuts. Attach filler to
floor with 1/4 x 3/4 round head
Phillips bolts and washers.
Note: Filler panel flanges go in
front of wall and floor as shown.
Use an Awl or other pointed tool to
help align mounting holes.
After all parts are attached, double
check and tighten all hardware.
Adjust as necessary to minimize gaps.
(7/16 socket or wrench and Phillips
screwdriver)
Insert ceiling vent / ducts and attach
with #10 x 1/2 Phillips pan sheet
metal screws.
Vent / ducts will line up directly
below the O.E.M. ceiling vents.
Insert and attach dome light to ceiling with
#10 x 1/2 Phillips pan sheet metal screws.
(connect wire before installing)
Wire dome light to on/off switch. Switch
location to be determined by the installer.
K9 kits include an LED dome as of
1/3/2014
See instructions included with LED light.
Neatly silicone / caulk the lower
seams to shed water out of vehicle.
Note: The floor pan is designed to
minimize the need for sealant.
Caulk (sealant) is mostly needed
where the floor meets the door sill
and lower filler panels.
Note: Make sure the O.E.M.
vents are fully open.
KK-K9-F16-K_INST_6-11 rev 5-14
Example mounting location for the
optional Hot-N-Pop door gas spring.
Example mounting location for the
optional Hot-N-Pop exhaust fan.
Note: Fan can be mounted to either
side of the real wall. Fan does not
mount to window guard.
After silicone is dry (preferably
overnight), place rubber mat into
K9 insert.
View of completed KK-K9-F16-K installation
KK-K9-F16-K_INST_6-11 rev 5-14