Group 20 - Ford Mustang Power Wheels - Gate 2 - Disassembly
From GICLWiki
Disassembly Procedure
| Step | Description | Tools Used | *Time Required | Difficulty Level | Notes |
|---|---|---|---|---|---|
| 1 | Removal of hood | Hands | 0:00:54 | 1 | Allowed access to battery |
| 2 | Removal of battery | Hands | 0:01:00 | 1 | First priority was to remove power for safety reasons |
| 3 | Removal of screws connecting front bumper to car frame | Phillips head #2 screwdriver | 0:04:36 | 1 | |
| 4 | Removal of screws connecting seats to car frame | Phillips head #2 screwdriver | 0:03:07 | 1 | |
| 5 | Removal of seats from car frame | Hands | 0:01:13 | 1 | |
| 6 | Removal of screws connecting steering wheel cap to steering wheel | Phillips head #2 screwdriver | 0:02:54 | 1 | |
| 7 | Removal of steering wheel cap from steering column | Hands | 0:01:01 | 1 | |
| 8 | Removal of steering wheel pin from steering column | Hands | 0:02:05 | 2 | |
| 9 | Removal of steering wheel from steering column | Hands | 0:07:56 | 3 | Clips held steering wheel in, brute force was used to pull wheel out |
| 10 | Removal of screws connecting two halves of the steering wheel together | Phillips head #2 screwdriver | 0:00:37 | 1 | |
| 11 | Separation of steering wheel into two halves | Hands | 0:01:43 | 2 | |
| 12 | Removal of screws connecting exhaust pipes to rear bumper | Phillips head #2 screwdriver | 0:01:40 | 1 | |
| 13 | Removal of exhaust pipes from rear bumper | Hands | 0:00:34 | 1 | |
| 14 | Removal of screws connecting lower grille from front bumper | Phillips head #2 screwdriver | 0:01:01 | 1 | |
| 15 | Removal of lower grille from front bumper | Hands | 0:00:46 | 1 | |
| 16 | Removal of screws connecting upper grille from front bumper | Phillips head #2 screwdriver | 0:02:17 | 1 | |
| 17 | Removal of upper grille from front bumper | Hands | 0:00:40 | 1 | |
| 18 | Removal of secondary screws connecting front bumper to car frame | Phillips head #2 screwdriver | 0:10:23 | 2 | Screws were difficult to reach |
| 19 | Removal of front bumper from car frame | Hands | 0:01:08 | 1 | |
| 20 | Removal of screw connecting Right headlight to front bumper | Phillips head #2 screwdriver | 0:00:33 | 1 | |
| 21 | Separation of right headlight into lens, frame, and lamp | Hands | 0:01:34 | 1 | |
| 22 | Removal of screw connecting left headlight to front bumper | Phillips head #2 screwdriver | 0:00:17 | 1 | |
| 23 | Separation of left headlight into lens, frame, and lamp | Hands | 0:01:18 | 1 | |
| 24 | Removal of screws connecting dashboard to side panels | Phillips head #2 screwdriver | 0:00:59 | 1 | |
| 25 | Removal of screws connecting windshield to car frame | Phillips head #2 screwdriver | 0:02:15 | 1 | Allows the removal of the windshield and the dashboard as one subsystem |
| 26 | Removal of screws connecting radio to dashboard | Phillips head #2 screwdriver | 0:01:33 | 1 | |
| 27 | Removal of radio from dashboard | Hands | 0:01:00 | 1 | |
| 28 | Removal of screw connecting key to dashboard | Phillips head #2 screwdriver | 0:01:04 | 1 | |
| 29 | Removal of key from dashboard | Hands | 0:00:40 | 1 | |
| 30 | Removal of screws connecting dashboard to windshield | Phillips head #2 screwdriver | 0:02:08 | 1 | |
| 31 | Removal of dashboard from windshield | Hands | 0:00:57 | 1 | |
| 32 | Removal of screws connecting right mirror to dashboard | Phillips head #2 screwdriver | 0:01:10 | 1 | |
| 33 | Removal of right mirror from dashboard | Hands | 0:00:44 | 1 | |
| 34 | Removal of screws connecting left mirror to dashboard | Phillips head #2 screwdriver | 0:00:58 | 1 | |
| 35 | Removal of left mirror from dashboard | Hands | 0:01:03 | 1 | |
| 36 | Removal of screws connecting windshield to windshield frame | Phillips head #2 screwdriver | 0:03:46 | 1 | |
| 37 | Removal of windshield from windshield frame | Hands | 0:01:06 | 1 | |
| 38 | Removal of screws connecting left interior door trim to left upper body panel | Phillips head #2 screwdriver | 0:01:00 | 1 | |
| 39 | Removal of screws connecting lower left body panel to car frame | Phillips head #2 screwdriver | 0:00:36 | 1 | |
| 40 | Removal of lower left body panel from car frame | Hands | 0:04:26 | 2 | Due to clips, was difficult to pull off |
| 41 | Removal of left interior door trim from upper left body panel | Hands | 0:01:21 | 2 | |
| 42 | Removal of screws connecting right interior door trim to upper right body panel | Phillips head #2 screwdriver | 0:00:51 | 1 | |
| 43 | Removal of screws connecting lower right body panel to car frame | Phillips head #2 screwdriver | 0:00:44 | 1 | |
| 44 | Removal of lower right body panel from car frame | Hands | 0:03:47 | 2 | Due to clips, was difficult to pull off |
| 45 | Removal of right interior door trim from upper right body panel | Hands | 0:02:18 | 2 | |
| 46 | Removal of screws connecting center console to car frame | Phillips head #2 screwdriver | 0:02:48 | 1 | |
| 47 | Removal of center console from car frame | Hands | 0:01:09 | 1 | |
| 48 | Removal of screws connecting trunk lid to car frame | Phillips head #2 screwdriver | 0:01:18 | 1 | |
| 49 | Removal of trunk lid from car frame | Hands | 0:00:48 | 1 | |
| 50 | Removal of screws connecting spoiler to trunk lid | Phillips head #2 screwdriver | 0:02:18 | 1 | |
| 51 | Removal of spoiler from trunk lid | Hands | 0:00:34 | 1 | |
| 52 | Removal of screw connecting rear light panel to car frame | Phillips head #2 screwdriver | 0:01:03 | 1 | |
| 53 | Removal of rear light panel from car frame | Hands | 0:00:42 | 1 | |
| 54 | Removal of center caps from the hubcaps | 3/16 inch flathead screwdriver, hands | 0:07:12 | 2 | Had to use flathead screwdriver for leverage to pry off hubcaps |
| 55 | Removal of front right tire locknut from front axle | Included wrench | 0:02:44 | 3 | Large force was initially needed to loosen locknut |
| 56 | Removal of front left tire locknut from front axle | Included wrench | 0:02:56 | 3 | Large force was initially needed to loosen locknut |
| 57 | Removal of hubcaps from front tires | Hands | 0:00:38 | 1 | |
| 58 | Removal of right tire from front axle | Hands | 0:01:05 | 1 | |
| 59 | Removal of left tire from front axle | Hands | 0:00:49 | 1 | Left and right tire are different molds |
| 60 | Removal of right bushing from front axle | Hands | 0:00:33 | 1 | |
| 61 | Removal of left bushings from front axle | Hands | 0:00:42 | 1 | |
| 62 | Removal of right 7/16 inch washers from front axle | Hands | 0:00:29 | 1 | |
| 63 | Removal of left 7/16 inch washers from front axle | Hands | 0:00:20 | 1 | |
| 64 | Removal of screws connecting front support to car frame | Phillips head #2 screwdriver | 0:03:01 | 1 | |
| 65 | Removal of front support from car frame | Hands | 0:00:37 | 1 | Allows the removal of the front support as one subsystem |
| 66 | Removal of screws connecting front bumper support to front support | Phillips head #2 screwdriver | 0:01:53 | 1 | |
| 67 | Removal of front bumper support from front support | Hands | 0:00:31 | 1 | |
| 68 | Removal of screws connecting steering column retainer to steering column | Phillips head #2 screwdriver | 0:00:42 | 1 | |
| 69 | Removal of steering column retainer from steering column | Hands | 0:00:27 | 1 | |
| 70 | Pull and rotate steering column to remove from linkage | Hands | 0:01:18 | 2 | |
| 71 | Removal of retainer caps from back axle | 3/16 inch flathead screwdriver, hands | 0:08:26 | 4 | In removing the caps, hubcaps received damage from screwdriver; due to force required, safety glasses were worn |
| 72 | Removal of slip rings from back axle | Needlenose pliers | 0:09:37 | 5 | Very difficult to remove, had to break rings to remove them; due to force required, safety glasses were worn |
| 73 | Removal of hubcaps from back tires | Hands | 0:00:51 | 1 | |
| 74 | Removal of right tire from back axle | Hands | 0:01:13 | 1 | |
| 75 | Removal of left tire from back axle | Hands | 0:01:02 | 1 | |
| 76 | Removal of left and right sprockets from gearbox and back axle | Hands | 0:00:54 | 1 | |
| 77 | Removal of back axle from car frame | Hands | 0:01:42 | 1 | |
| 78 | Slide gearboxes from car frame | Hands | 0:01:15 | 1 | Isolates the gearboxes so that the electrical system can be removed from the car frame |
| 79 | Removal of screw connecting wire cover to car frame | Phillips head #2 screwdriver | 0:00:47 | 1 | |
| 80 | Removal of wire cover from car frame | Hands | 0:00:41 | 1 | Exposed wires so that entire electrical system could be removed |
| 81 | Unclip pedal enclosure from car frame | Needlenose pliers | 0:02:46 | 4 | Due to difficulty and force needed to unclip, safety glasses were worn |
| 82 | Removal of pedal enclosure from car frame | Hands | 0:00:26 | 1 | |
| 83 | Removal of electrical system (gearboxes, wires, etc.) from car frame | Hands | 0:00:40 | 1 | |
| 84 | Removal of screws connecting battery holder to car frame | Phillips head #2 screwdriver | 0:01:22 | 1 | |
| 85 | Removal of battery holder from car frame | Hands | 0:00:49 | 1 | |
| 86 | Separated battery holder side clips from battery holder frame | Needlenose pliers, hands | 0:01:07 | 2 | |
| 87 | Removal of retainer caps from front axles* (left and right) | 3/16 inch flathead screwdriver, hands | 0:05:19 | 3 | Due to forces used, safety glasses were worn |
| 88 | Removal of slip rings from front axles | Needlenose pliers, hands | 0:06:44 | 5 | Due to forces used, safety glasses were worn |
| 89 | Removal of front support from front axles | Hands | 0:00:48 | 1 | |
| 90 | Removal of steering support bar from front support | Hands | 0:01:00 | 1 | |
| 91 | Removal of 7/16 inch washer from front axles | Hands | 0:00:24 | 1 | Axles originally thought to be one bar, actually two separate bars |
| 92 | Removal of front axles from linkage | Hands | 0:00:30 | 1 | Linkage system is press-fitted and therefore could not be dissected without destroying it's components |
| 93 | Separated molex connectors from speed selector housing | Hands | 0:00:55 | 1 | |
| 94 | Removal of screws connecting speed selector cover to speed selector housing | Phillips head #2 screwdriver | 0:01:38 | 1 | |
| 95 | Separated speed selector cover from speed selector housing | Hands | 0:00:41 | 1 | |
| 96 | Separated speed selector knob from speed selector housing | Hands | 0:00:23 | 1 | |
| 97 | Removal of speed selector switches from speed selector housing | Needlenose pliers, hands | 0:04:39 | 4 | Switches force fitted into housing |
| 98 | Separated pedal molex connector from pedal support | Hands | 0:00:53 | 1 | |
| 99 | Removal of screw restricting pedal to pedal support | Phillips head #2 screwdriver | 0:00:59 | 1 | |
| 100 | Removal of pedal from pedal support | Hands | 0:00:27 | 1 | |
| 101 | Removal of pedal switch from pedal support | Hands | 0:02:21 | 2 | |
| 102 | Removal of screws connecting motor to gear box housing | Phillips head #2 screwdriver | 0:00:58 | 1 | |
| 103 | Separated motor from gear box housing | Hands | 0:00:32 | 1 | |
| 104 | Removal of screws connecting gear box cover to gear box housing | Phillips head #2 screwdriver | 0:02:04 | 1 | |
| 105 | Separated gear box cover from gear box housing | Hands | 0:00:35 | 1 | Put on gloves as lubricant was assumed to be in housing |
| 106 | Separated fourth stage reduction gear from gear box housing | Hands | 0:00:29 | 1 | |
| 107 | Separated third stage reduction gear from gear box housing | Hands | 0:00:24 | 1 | |
| 108 | Separated second stage reduction gear from gear box housing | Hands | 0:00:22 | 1 | |
| 109 | Separated first stage reduction gear from gear box housing | Hands | 0:00:23 | 1 | |
| 110 | For second gear box, repeat steps 102-109 | Assorted | 0:03:46 | 1 | |
| 111 | Removal of Screws Holding Radio Cover Together | Phillips head #2 screwdriver | 0:01:11 | 1 | Didn't remove circuit boards as wouldn't add to analysis and damage to chips wasn't desired |
*It should be noted that the preceded times include the time it took to physically dissect the vehicle, and the documentation of the individual steps for the dissection. This time in total was 3 hours, 12 minutes, and 22 seconds. However, when discussion regarding challenges faced and how to approach the next dissection step are taken into account, the total time is approximately 5 hours.
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