Whelen Engineering Company MirrorBeam MBCV96 User manual

ENGINEERING COMPANY INC.
ROUTE 145, WINTHROP ROAD
CHESTER, CONNECTICUT 06412-0684
TELEPHONE: [phone]
To remove the glamour cap from the mirror assembly...
1. To remove the glamour cap from the mirror assembly, the glamour caps three
retaining tabs must be carefully lifted off the rear housing retaining pins. This is
accomplished with a small flatblade screwdriver or other suitable device.
2. To gain access to the glamour caps upper retaining tabs, the mirror must be gently
positioned so that it’s lower edge is pressed inwards as far as it will travel. This will
allow the two, upper retaining tabs to be accessed with the screwdriver.
3. Position the screwdriver blade under either of the upper retaining tabs and pry tab
upwards and off its retaining pin. Repeat for remaining upper retaining tab.
4. To gain access to the glamour cap’s lower retaining tab, the mirror must be gently
positioned so that it’s upper edge is pressed inwards as far as it will travel. This will
allow the lower retaining tab to be accessed with the screwdriver.
5. Position the screwdriver blade over the retaining tab and pry tab downwards and off
its retaining pin. With all three retaining tabs free, pull glamour cap and its guide pin
away from the mirror assembly.
The mirror assembly will now be prepared for the new strobe harness cable.
To prepare the mirror assembly...
1. With the glamour cover removed, look at the rear of the mirror assembly. Locate the
upper retaining tab slot indicated.
2. Draw a perpendicular line that extends 1 inch from the middle of the bottom of the
slot.
3. At the end of this perpendicular line, carefully drill a 3/8” hole into the mirror
assembly.
4. Now remove the triangular rubber mounting gasket from the mirror assembly by
pulling this gasket over the three, mirror assembly mounting studs.
5. Slide the mounting gasket a few inches along the mirror assembly harness.
Remove the mirror assembly harness from under the retaining arm that secures the
harness to the mirror assembly. Do not break this retaining arm!
The strobe harness will now be prepared for routing through the mirror assembly.
To prepare the strobe harness...
NOTE: Because the strobe harness must be routed through a specific, narrow
and twisting path within the mirror assembly, it is necessary to
temporarily extend the length of the harness with a make-shift “snake”.
1. Locate the tie-wrap included with your mirror beam and cut the fastener-end off.
2. Locate the end of the strobe harness that has SOCKET-type terminals installed on
the free wires. Cut off the non-insulated wire (it is not used in this application).
3. Strongly secure the tie-wrap to the strobe harness with electrical or similar tape.
Although the purpose of this procedure is to extend the harness length as much as
possible using the tie-wrap, it is important to have a sufficient length of the tie-wrap
secured to the harness (2” minimum).
The strobe harness will now be routed through the mirror assembly.
©1997 Whelen Engineering Company.
Form No.13128C (092199)
1“ Inch
Right (Passenger) Side Mirror
(Rear view with Glamour Cap removed)
Side View
To remove the side mirror assembly....
1. Remove the driver side door panel from the vehicle.
2. Remove the three hex nuts that secure the mirror assembly to the vehicle. Unplug
the mirror assembly harness cable from the door’s power harness.
3. Carefully remove the mirror assembly from the vehicle.
The glamour cap will now be removed from the mirror assembly.
MirrorBeam Model MBCV96 for the
1996-97 Ford Crown Victoria

Routing the strobe harness ...
1. Insert the end of the tie-wrap through the hole in the rubber mounting gasket where the
mirror assembly power harness is routed (See Fig. 1). It should only be necessary to pull
about 2 and a half feet of the strobe harness through the gasket.
2. Insert the end of the tie-wrap into the mirror assembly via the same pathway as the mirror
power cable. Push the tie-wrap through this opening until the end of the tie-wrap sticks out
from behind the top, inboard corner of the mirror. Pull the tie-wrap until the slack in the
harness is gone.
3. Now look down into the area behind the mirror (the mirror cavity). Towards the middle, there
is a plastic boss that runs from the back of the mirror case towards the front. It is necessary
for the strobe harness to be routed under this boss. Re-insert the tie-wrap back into the
mirror cavity so it is between the harness and the boss.
4. Route the tie-wrap so it travels under the boss and out of the mirror cavity at the top
outboard corner of the mirror (See Fig. 2). Pull the tie-wrap until the slack in the harness is
gone.
5. Now push the tie-wrap back into the mirror cavity and out the hole drilled in the “To prepare
the mirror assembly...” section. There should not be more than 4 or 5 inches of harness
sticking out of the hole. If the length is different from this, adjust harness length accordingly.
The tie-wrap is now removed from the harness and the wire terminals inserted into their 3
position connector (supplied) as follows (For detailed information, refer to the instruction tag
attached to the harness):
Position 1 = Red
Position 2 = Black
Position 3 = White (Clear)
Fig. 1
Fig. 2
Re-assembling the Mirror-Beam assembly...
1. Locate the provided screw grommet.
2. Insert this grommet into the slotted hole located on the rear of the mirror assembly (Fig. 3).
Be sure to insert this grommet as shown in this illustration. Push the grommet in as far as it
will go.
3. Plug the harness cable into the Mirror-Beam strobe light socket.
4. Place the Mirror-Beam assembly in the same location as the glamour cap and insert the
Mirror-Beam mounting tabs into their appropriate mounting slots.
IMPORTANT NOTE: Factory mirror assembly tolerances may vary from one
assembly to another. If a Mirror-Beam tab does not fully engage it’s respective
retaining pin due to insufficient slot length, remove the two screws that mount the
tab to the Mirror-Beam assembly. Using masking tape or similar product, put several
layers on the back side of the mounting end of the tab (fig 4.). Remove the tape
blocking the mounting holes and re-mount the tab to confirm that additional
clearance has been achieved. Add additional layers until proper mounting is
attained. A small screwdriver will help the tab engage its mounting pin.
5. When all mounting tabs have fully engaged their mounting pins, insert the supplied #6
sheet metal screw through the Mirror-Beam and into the grommet installed in steps 1, 2
and 3 of this section. Tighten firmly.
6. Return the mirror assembly power harness and the strobe harness to the service loop
retainer located on the triangular mounting area of the mirror assembly. Return the rubber
mounting gasket to it’s original location and secure its position around the 3 mirror
assembly mounting studs.
7. Re-connect the mirror assembly to it’s main power harness. Route the Mirror-Beam
harness through the door, along the exact same path as the vehicle’s main power harness
and finally to the strobe power supply mounted in the vehicle.
9. Cut the non-insulated wire off the strobe harness. Insert the PIN-type
terminals into the provided connector as detailed in the “Routing the strobe harness...”
section of this manual. Insert plug into power supply and confirm proper strobe operation.
IMPORTANT NOTE: After re-mounting the mirror assembly onto the vehicle, field
adjustments are mandatory! Confirm that the Mirror-Beam’s warning light is
properly projected (Fig. 5 indicates beam parallel with road).
To adjust beam projection angle, the three mirror assembly mounting holes
(located on the vehicle door) must be enlarged by approx. 1/16”. With these holes
enlarged the mirror assembly can now be positioned for optimum beam projection.
Side View
Beam
Projection
Fig. 3
Fig. 4
Fig. 5
IMPORTANT: The outer surfaces of this
product may be cleaned with mild soap
and water. Use of any other chemicals
may void product warranty.
Do not use a pressure washer.