REMOVAL & INSTALLATION
1983 Thunderbird and XR-7
- On the XR-7, remove the park and turn signal lamp sockets.
- Remove the bumper cover assembly from the bumper (8 pushpins and 4 bolts).
- Remove the 8 bumper retaining bolts, then remove the bumper from the car.
- If a new bumper is being installed, remove all of the transferable parts.
- Fit the bumper on the car, then tighten the bolts snugly.
- Adjust the bumper height so that the bottom edge of the bumper is 14 47 / 64 in. plus or minus 1 1 / 2 in. (374.25mm plus or minus 38mm) from the ground. Tighten the bolts to 35 ft. lbs. (47 Nm).
- Remove the 3 bolts attaching the bumper reinforcement to each isolator, then remove the bumper. Note the number and position of any shims.
- You can now remove the isolator brackets and rubber extensions.
- Squeeze the bumper pad retaining tabs with pliers and push them through their holes until the pads are removed.
- If a new bumper is being installed, remove any transferable items.
- Installation is the reverse of removal. Tighten the mounting bolts snugly.
Adjust the distance between the top edge of the bumper and the ground is 21 1 / 4 in. + 1 1 / 3 in. -1 1 / 2 in. (540mm +34mm -38mm).
Adjust the bumper so that the distance between the front face of the bumper and the front face of the headlight door is 4 3 / 64 in. + 3 / 8 in. - 1 / 4 in. (103mm +10mm -6mm).
Adjust the bumper so that the clearance between the rubber extensions and the fender panels is 5 / 8 in. plus or minus 1 / 4 in. (16mm plus or minus 6mm). Tighten the bolts to 35 ft. lbs. (47 Nm).1984-88 Models
See Figures 1, 2, 3, 4, 5 and 6
- Remove the park and turn signal lamp sockets.
- Remove the bumper cover assembly from the bumper.
- Remove the bumper retaining bolts and remove the bumper from the car.
- If a new bumper is being installed, remove all transferable parts.
- Fit the bumper to the car and tighten the bolts snugly.
Adjust the bumper height so that the top edge of the bumper is 20 3 / 4 in. plus or minus 1 1 / 8 in. (527.05mm plus or minus 29mm) on 1983-86 models and to 15 7 / 16 in. plus or minus 9 / 32 in. (392.1mm plus or minus 7.1mm) and 1987-88 models from the ground. Tighten the bolts to 66 ft. lbs. (89 Nm).
See Figures 7 and 8
The front bumper is an integral part of the welded structure of the front end. Therefore when replacement is necessary it must be installed with the proper tools and welding equipment. The bumper cover and isolator can however be replaced as follows:
- Remove the park/turn signal and side marker lamps.
- Unscrew the cover at the front edge of fender.
- Remove the five plastic retainers, retaining the bottom of cover and air deflector to the bottom of the radiator support.
- Remove the plastic retainer securing the bracket at center of cover to the bumper beam.
- Remove four (two on each side) nuts retaining the cover ends to side of front fender.
- Remove the two (one on each side) screws retaining the ends of the cover to front fenders and splash shield.
- Remove the cover by sliding the top edge out from slot in grille opening support panel.
- Drill out the three rivets retaining the isolator to the bumper beam, and remove the isolator. On Cougar, remove isolator insert.
- Position the front cover on the vehicle by sliding the top edge into the slot in the grille opening panel reinforcement.
- Position the four studs on the front cover into the slots located in the side of the fenders.
- Install the two retaining screws at the front edge of the fender and tighten to 1-2 inch lbs. (5-7 Nm).
- Install the four nuts to retain the bumper cover ends to the fenders. Tighten to 46-62 inch lbs. (5-7 Nm).
- Install the three rivets retaining the center of the bumper cover in the grille opening panel reinforcement.
- Attach the five plastic retainers for the bottom of the cover and air deflector-to-grille opening reinforcement. (Super Coupe only)
- Install one plastic retainer attaching the cover center bracket to the front bumper.
- Install the park, turn signal and side marker lamps.