Substrate Integrity Drilling Instructions

Service Part Number



AFFECTED VEHICLES:
1986 Model Mustang/Capri (Built after 12/31/85) - 49 States, 3.8L engine, 1986-88 Model Thunderbird/Cougar (Built after 12/31/85y- 49 States, 3.8L engine

Instructions

Special Drilling Instructions


Drill only the UNDERBODY catalyst on 1986 Mustang/Capri and 1986/87 Thunderbird/Cougar cars (Kit Code "A" and "B" cars).

Drill all three (TOEBOARD AND UNDERBODY) catalysts on 1988 Thunderbird/Cougar cars (Kit Code "C" cars).

1. Remove heat shields from toeboard and underbody catalysts (as required).

2. Position vacuum hose over drill bit, leaving approximately 3/8-inch of drill bit tip exposed.
CAUTION:
The vacuum hose is used as a drill stop to prevent the drill from going too far into the substrate.





3. Drill a hole (.128 dia.) approximately 3/8-inch deep in each catalyst. Refer to illustration. Inspect drill after drilling each hole; a white chalky powder indicates catalyst substrate was drilled.

4. Carefully probe each hole using a .128 diameter drill to determine if the substrate material is intact (the drill should stop 3/8-inch into the drilled hole and there should be no side-to-side movement of drill).





5. For 1988 Thunderbird and Cougar only (Kit Code "C" cars). Replace both the underbody and toeboard catalyst assemblies if either toeboard catalyst substrates are not intact, (use parts from Kit "C"). If both toeboard catalysts are intact, install a screw in each drilled hole using Thread Sealer Loctite(R) RC/620 or equivalent.

6. Replace underbody catalyst assembly if catalyst substrate is not intact. If underbody catalyst is intact, install a screw in the drilled hole using thread sealer.

^ If the Substrate Integrity Drilling for Thunderbird/Cougar reveals that only the underbody catalyst requires replacement, use parts from Kit "B" for repair.





AUTHORIZED MODIFICATIONS DECAL

^ Prepare an Authorized Modifications Decal (Form-8262-PP) as follows:
Insert your dealer P & A code and the date of service. Affix the decal to a clean, flat surface on the fan shroud. Install the clear overlay over the decal.