Group 20 - Ford Mustang Power Wheels - Gate 4 - Reassembly
From GICLWiki
Reassembly Procedure
| Step Number | Description | Tools Used | Time Required* | Difficulty Level | Notes | Illustration | |||
| Number of Connections | Connection Complexity | Force Required | Tools Required | ||||||
| 1 | Insert Screws into Radio Cover | 603-3 inch Phillips Head Screwdriver | 0:00:38 | 4 | 2 | 1 | 1 |  | |
| 2 | Insert Speed Selector Switch #1 into Speed Selector housing | Hands | 0:00:11 | 1 | 1 | 1 | 1 |  | |
| 3 | Insert Speed Selector Switch #2 into Speed Selector housing | Hands | 0:00:10 | 1 | 1 | 1 | 1 |  | |
| 4 | Insert speed selector knob into speed selector housing | Hands | 0:00:05 | 1 | 1 | 1 | 1 |  | |
| 5 | Attach speed selector cover to speed selector housing | Hands | 0:00:08 | 1 | 1 | 1 | 1 |  | |
| 6 | Insert Screws into speed selector cover | 603-3 inch Phillips Head Screwdriver | 0:00:43 | 5 | 2 | 1 | 1 | At this point the speed selector assembly is set aside. |  |
| 7 | Insert pedal switch into pedal support | Hands | 0:00:15 | 1 | 1 | 1 | 1 |  | |
| 8 | Insert gas pedal into pedal support via the slot in the pedal support | Hands | 0:00:07 | 1 | 1 | 1 | 1 |  | |
| 9 | Insert restraining screw through pedal support into gas pedal | 603-3 inch Phillips Head Screwdriver | 0:00:23 | 2 | 1 | 1 | 1 |  | |
| 10 | Insert pedal molex into pedal switch | Hands | 0:00:12 | 1 | 1 | 1 | 1 |  | |
| 11 | Insert 6 Chamber Molex #1 into Speed Selector Switch #1 | Hands | 0:00:10 | 1 | 1 | 1 | 1 |  | |
| 12 | Insert 6 Chamber Molex #2 into Speed Selector Switch #2 | Hands | 0:00:10 | 1 | 1 | 1 | 1 |  | |
| 13 | Insert first stage reduction gear into gear box housing | Hands | 0:00:07 | 1 | 1 | 1 | 1 |  | |
| 14 | Insert second stage reduction gear into gear box housing | Hands | 0:00:05 | 2 | 1 | 1 | 1 |  | |
| 15 | Insert third stage reduction gear into gear box housing | Hands | 0:00:05 | 2 | 1 | 1 | 1 |  | |
| 16 | Insert fourth stage reduction gear into gear box housing | Hands | 0:00:04 | 2 | 1 | 1 | 1 |  | |
| 17 | Attach gear box cover to gear box housing | Hands | 0:00:32 | 4 | 2 | 1 | 1 |  | |
| 18 | Insert screws into gear box cover | 603-3 inch Phillips Head Screwdriver | 0:01:33 | 4 | 2 | 1 | 1 |  | |
| 19 | Insert Johnson motor into the gear box housing | Hands | 0:00:18 | 2 | 1 | 1 | 1 |  | |
| 20 | Insert screws through the gear box into the Johnson motor | 3/16th Flathead Screwdriver | 0:00:38 | 2 | 1 | 1 | 1 | | |
| 21 | Repeat Steps 13-20 for the second gear box | Assorted | 0:03:48 | 1-4 | 1-2 | 1 | 1 | At this point both gearboxes are set aside. |
|
| 22 | Attach two halves of Steering Wheel together | Hands | 0:00:09 | 1 | 1 | 1 | 1 |  | |
| 23 | Insert screws into Steering Wheel (Bottom Half) | 603-3 inch Phillips Head Screwdriver | 0:01:15 | 5 | 2 | 1 | 1 | At this point the steering wheel is set aside. |  |
| 24 | Attach (Bottom and Top of) L Mirror to Dashboard | Hands | 0:00:20 | 1 | 1 | 1 | 1 |  | |
| 25 | Insert screws into bottom of L Mirror and through Dashboard | 603-3 inch Phillips Head Screwdriver | 0:00:41 | 2 | 1 | 1 | 1 |  | |
| 26 | Attach (Bottom and Top of) R Mirror to Dashboard | Hands | 0:00:19 | 1 | 1 | 1 | 1 | | |
| 27 | Insert screws into bottom of R Mirror and through Dashboard | 603-3 inch Phillips Head Screwdriver | 0:00:38 | 2 | 1 | 1 | 1 | | |
| 28 | Insert Key and washer into Dashboard | Hands | 0:00:32 | 1 | 1 | 1 | 1 |  | |
| 29 | Fasten Key and washer onto Dashboard | 603-3 inch Phillips Head Screwdriver | 0:00:24 | 1 | 1 | 1 | 1 | | |
| 30 | Attach Windshield to Windshield Frame | Hands | 0:00:21 | 1 | 1 | 1 | 1 |  | |
| 31 | Insert screws through Windshield into Windshield Frame | 603-3 inch Phillips Head Screwdriver | 0:02:02 | 7 | 3 | 1 | 1 |  | |
| 32 | Attach Dashboard to Windshield | Hands | 0:00:14 | 2 | 1 | 1 | 1 |  | |
| 33 | Insert screws through Dashboard and Windshield into Windshield Frame | 603-3 inch Phillips Head Screwdriver | 0:00:56 | 4 | 2 | 1 | 1 | At this point the dashboard assembly is set aside. |  |
| 34 | Attach L Interior Door Trim to Car Frame | Hands | 0:00:58 | 6 | 2 | 2 | 1 |  | |
| 35 | Insert screws through L Interior Door Trim into Car Frame | 603-3 inch Phillips Head Screwdriver | 0:00:42 | 2 | 1 | 1 | 1 |  | |
| 36 | Attach R Interior Door Trim to Car Frame | Hands | 0:00:34 | 6 | 2 | 2 | 1 | | |
| 37 | Insert screws through R Interior Door Trim into Car Frame | 603-3 inch Phillips Head Screwdriver | 0:00:31 | 2 | 1 | 1 | 1 | | |
| 38 | Insert Pedal Support into Car Frame | Hands | 0:01:50 | 4 | 2 | 1 | 1 |  | |
| 39 | Insert Speed Selector Assembly into Car Frame | Hands | 0:00:03 | 1 | 1 | 1 | 1 |  | |
| 40 | Attach Wire Cover to Car Frame | Hands | 0:01:29 | 8 | 3 | 1 | 1 |  | |
| 41 | Insert screw through Wire Cover into Car Frame | 603-3 inch Phillips Head Screwdriver | 0:00:12 | 1 | 1 | 1 | 1 |  | |
| 42 | Attach Center Console to Car Frame, covering the Speed Selector Assembly | Hands | 0:00:33 | 4 | 2 | 1 | 1 |  | |
| 43 | Insert screws through Center Console into Car Frame | 603-3 inch Phillips Head Screwdriver | 0:01:12 | 6 | 2 | 1 | 1 |  | |
| 44 | Position the gear boxes at Rear Wheel location openings | Hands | 0:00:40 | 1 | 1 | 1 | 1 |  | |
| 45 | Insert Back Axle through left gear box, Car Frame, and right gear box | Hands | 0:01:58 | 4 | 2 | 1 | 1 | Took Extra Time because all parts needed to be lined up |  |
| 46 | Attach Lower Left Body Panel to Car Frame | Hands | 0:01:24 | 6 | 2 | 1 | 1 |  | |
| 47 | Insert screws through Lower Left Body Panel into Car Frame | 603-3 inch Phillips Head Screwdriver | 0:00:27 | 2 | 1 | 1 | 1 |  | |
| 48 | Attach Lower Right Body Panel to Car Frame | Hands | 0:01:11 | 6 | 2 | 1 | 1 | | |
| 49 | Insert screws through Lower Right Body Panel into Car Frame | 603-3 inch Phillips Head Screwdriver | 0:00:19 | 2 | 1 | 1 | 1 | | |
| 50 | Insert Left Sprocket onto Back Axle | Hands | 0:00:04 | 2 | 1 | 1 | 1 |  | |
| 51 | Insert Left Tire onto Back Axle | Hands | 0:00:09 | 2 | 1 | 1 | 1 |  | |
| 52 | Attach Hub Cap to Left Tire (and onto Back Axle) | Hands | 0:00:08 | 2 | 1 | 1 | 1 |  | |
| 53 | Insert Slip Ring onto Back Axle | Needlenose Pliers, 3/16th Flathead Screwdriver | 0:05:47 | 1 | 1 | 3 | 2 | Slip rings were loose upon reattachment due to damage incurred upon removal. Because of this, they were manipulated back into shape by using pliers to angle the "teeth" outward. Then the slip rings were pushed onto the back axle with a large force. This step requires multiple people and is very difficult. |  |
| 54 | Attach Retainer Cap to Back Axle | Hands | 0:00:32 | 1 | 1 | 2 | 1 |  | |
| 55 | Attach Center Cap to Hub Cap | Hands | 0:00:28 | 3 | 1 | 2 | 1 |  | |
| 56 | Insert Right Sprocket onto Back Axle | Hands | 0:00:03 | 2 | 1 | 1 | 1 | | |
| 57 | Insert Right Tire onto Back Axle | Hands | 0:00:07 | 2 | 1 | 1 | 1 | | |
| 58 | Attach Hub Cap to Right Tire (and onto Back Axle) | Hands | 0:00:10 | 2 | 1 | 1 | 1 | | |
| 59 | Insert Slip Ring onto Back Axle | Needlenose Pliers, 3/16th Flathead Screwdriver | 0:05:28 | 1 | 1 | 3 | 2 | Slip rings were loose upon reattachment due to damage incurred upon removal. Because of this, they were manipulated back into shape by using pliers to angle the "teeth" outward. Then the slip rings were pushed onto the back axle with a large force. This step requires multiple people and is very difficult. | |
| 60 | Attach Retainer Cap to Back Axle | Hands | 0:00:23 | 1 | 1 | 2 | 1 |  | |
| 61 | Attach Center Cap to Hub Cap | Hands | 0:00:34 | 3 | 1 | 2 | 1 | | |
| 62 | Slide Steering Support Bar through slit on bottom of Front Support | Hands | 0:00:46 | 1 | 1 | 1 | 1 |  | |
| 63 | Place Steering Linkage onto Steering Support Bar lining up the holes | Hands | 0:00:13 | 2 | 1 | 1 | 1 | | |
| 64 | Insert Front Axle (Left and Right) through Steering Linkage, Steering Support Bar, and Front Support | Hands | 0:00:39 | 3 | 1 | 1 | 1 | Make Sure all holes are lined | |
| 65 | Press Slip Rings onto non-threaded ends of the Front Axle | Needlenose Pliers, 3/16th Flathead Screwdriver | 0:04:03 | 1 | 1 | 3 | 2 |  | |
| 66 | Press Retainer Caps onto non-threaded ends of the Front Axle | Hands | 0:00:23 | 1 | 1 | 2 | 1 |  | |
| 67 | Slide Front Bumper Support into Front Support | Hands | 0:00:17 | 1 | 1 | 1 | 1 |  | |
| 68 | Insert screws through Front Bumper Support into Front Support | 603-3 inch Phillips Head Screwdriver | 0:00:28 | 2 | 1 | 1 | 1 |  | |
| 69 | Insert Steering Column through Front Support and then rotate and insert the column into the Steering Linkage | Hands | 0:00:47 | 1 | 1 | 1 | 1 |  | |
| 70 | Attach Steering Column Retainer to short end of Steering Column | Hands | 0:00:09 | 1 | 1 | 1 | 1 |  | |
| 71 | Insert screw through Steering Column into Steering Column Retainer | 603-3 inch Phillips Head Screwdriver | 0:00:15 | 2 | 1 | 1 | 1 | This Completes the Front Support Assembly |  |
| 72 | Attach Front Support assembly to Car Frame | Hands | 0:00:54 | 3 | 1 | 1 | 1 | Someone needs to hold it in place before it can be fastened |  |
| 73 | Insert screws through Car Frame into Front Support assembly | 603-3 inch Phillips Head Screwdriver | 0:01:03 | 4 | 2 | 1 | 1 |  | |
| 74 | Place Front Bumper onto Car Frame | Hands | 0:00:18 | 1 | 1 | 1 | 1 |  | |
| 75 | Insert screws through Front Bumper into Car Frame | 603-3 inch Phillips Head Screwdriver | 0:02:46 | 12 | 3 | 1 | 1 |  | |
| 76 | Place Lower Grille onto Front Bumper | Hands | 0:00:19 | 1 | 1 | 1 | 1 |  | |
| 77 | Insert screws through Lower Grille into Front Bumper | 603-3 inch Phillips Head Screwdriver | 0:00:34 | 2 | 1 | 1 | 1 |  | |
| 78 | Place Upper Grille onto Front Bumper | Hands | 0:00:12 | 1 | 1 | 1 | 1 |  | |
| 79 | Insert screws through Upper Grille into Front Bumper | 603-3 inch Phillips Head Screwdriver | 0:00:57 | 4 | 2 | 1 | 1 |  | |
| 80 | Insert L Headlight Lamp into L Headlight Frame | Hands | 0:00:02 | 1 | 1 | 1 | 1 |  | |
| 81 | Place L Headlight Lens onto L Headlight Frame | Hands | 0:00:06 | 2 | 1 | 1 | 1 |  | |
| 82 | Place L Headlight onto Front Bumper | Hands | 0:00:10 | 1 | 1 | 1 | 1 |  | |
| 83 | Attach L Headlight to Front Bumper with L Bracket and screw | Hands, 603-3 inch Phillips Head Screwdriver | 0:00:27 | 1 | 1 | 1 | 2 | L Bracket serves as a washer. Screw goes through lens into Front Bumper |  |
| 84 | Insert R Headlight Lamp into R Headlight Frame | Hands | 0:00:03 | 1 | 1 | 1 | 1 | | |
| 85 | Place R Headlight Lens onto R Headlight Frame | Hands | 0:00:09 | 2 | 1 | 1 | 1 | | |
| 86 | Place R Headlight onto Front Bumper | Hands | 0:00:18 | 1 | 1 | 1 | 1 | | |
| 87 | Attach R Headlight to Front Bumper with R Bracket and screw | 603-3 inch Phillips Head Screwdriver, Hands | 0:00:23 | 1 | 1 | 1 | 2 | R Bracket serves as a washer. Screw goes through lens into Front Bumper | |
| 88 | Place Exhaust Pipes onto Car Frame | Hands | 0:00:09 | 1 | 1 | 1 | 1 |  | |
| 89 | Insert screws through Exhaust Pipes into Car Frame | 603-3 inch Phillips Head Screwdriver | 0:00:28 | 2 | 1 | 1 | 1 |  | |
| 90 | Attach Rear Light Panel to Car Frame | Hands | 0:00:36 | 4 | 2 | 1 | 1 |  | |
| 91 | Insert screw through Rear Light Panel into Car Frame | 603-3 inch Phillips Head Screwdriver | 0:00:16 | 1 | 1 | 1 | 1 |  | |
| 92 | Attach Spoiler to Trunk Lid | Hands | 0:00:04 | 1 | 1 | 1 | 1 |  | |
| 93 | Insert screws through Trunk Lid into Spoiler | 603-3 inch Phillips Head Screwdriver | 0:00:59 | 4 | 2 | 1 | 1 |  | |
| 94 | Attach Trunk Lid to Car Frame | Hands | 0:00:39 | 4 | 2 | 1 | 1 |  | |
| 95 | Insert screws through Car Frame into Trunk Lid | 603-3 inch Phillips Head Screwdriver | 0:00:31 | 2 | 1 | 1 | 1 |  | |
| 96 | Insert Battery Holder into Car Frame | Hands | 0:00:28 | 2 | 1 | 1 | 1 |  | |
| 97 | Insert screws through Battery Holder into Car Frame | 603-3 inch Phillips Head Screwdriver | 0:00:27 | 2 | 1 | 1 | 1 |  | |
| 98 | Attach Windshield-Dashboard Assembly to Car Frame | Hands | 0:00:04 | 4 | 2 | 1 | 1 |  | |
| 99 | Insert screws through Windshield-Dashboard Assembly into the Car Frame | 603-3 inch Phillips Head Screwdriver | 0:01:45 | 6 | 2 | 1 | 1 | | |
| 100 | Slide the Steering Wheel onto the Steering Column | Hands | 0:00:08 | 1 | 1 | 1 | 1 |  | |
| 101 | Press Steering Wheel into Dashboard (Apply force) | Hands | 0:00:15 | 1 | 1 | 2 | 1 |  | |
| 102 | Insert Steering Wheel Pin into Steering Wheel through the hole in the long end of the Steering Column | Hands | 0:00:18 | 2 | 1 | 1 | 1 |  | |
| 103 | Place Steering Wheel Cap onto Steering Wheel | Hands | 0:00:02 | 1 | 1 | 1 | 1 |  | |
| 104 | Insert screws through Steering Wheel Cap into Steering Wheel | 603-3 inch Phillips Head Screwdriver | 0:00:33 | 2 | 1 | 1 | 1 |  | |
| 105 | Place one 7/16 inch Washer onto each end of Front Axle | Hands | 0:00:10 | 1 | 1 | 1 | 1 |  | |
| 106 | Place one bushing onto each end of Front Axle | Hands | 0:00:12 | 1 | 1 | 1 | 1 |  | |
| 107 | Insert Left Tire onto Front Axle | Hands | 0:00:07 | 2 | 1 | 1 | 1 |  | |
| 108 | Attach Hub Cap to Left Tire (and onto Front Axle) | Hands | 0:00:10 | 2 | 1 | 1 | 1 |  | |
| 109 | Fasten Locknut onto Front Axle securing Left Tire | Hands | 0:00:43 | 1 | 1 | 1 | 1 |  | |
| 110 | Attach Center Cap to Hub Cap | Hands | 0:00:13 | 3 | 1 | 2 | 1 | | |
| 111 | Insert Right Tire onto Front Axle | Hands | 0:00:11 | 2 | 1 | 1 | 1 | | |
| 112 | Attach Hub Cap to Right Tire (and onto Front Axle) | Hands | 0:00:12 | 2 | 1 | 1 | 1 | | |
| 113 | Fasten Locknut onto Front Axle securing Left Tire | Included Wrench | 0:00:41 | 1 | 1 | 1 | 1 | | |
| 114 | Attach Center Cap to Hub Cap | Hands | 0:00:12 | 3 | 1 | 2 | 1 | | |
| 115 | Place Seats onto Car Frame | Hands | 0:00:10 | 2 | 1 | 1 | 1 |  | |
| 116 | Insert screws through Seats into Car Frame | 603-3 inch Phillips Head Screwdriver | 0:00:48 | 3 | 1 | 1 | 1 | | |
| 117 | Insert Pretend Radio into Dashboard | Hands | 0:00:05 | 1 | 1 | 1 | 1 |  | |
| 118 | Insert screws through Dashboard into Pretend Radio | 603-3 inch Phillips Head Screwdriver | 0:01:04 | 2 | 1 | 1 | 1 | Awkward Angle to fasten screws |  |
| 119 | Insert Battery into Battery Holder | Hands | 0:00:04 | 1 | 1 | 1 | 1 |  | |
| 120 | Attach Hood to Windshield Frame | Hands | 0:00:13 | 2 | 1 | 1 | 1 |  | |
*It should be noted that the preceded times include the time it took to physically reassemble the vehicle, and the documentation of the individual steps for the assembly. This time in total was 1 hour, 15 minutes, and 47 seconds. However, when discussion regarding challenges faced and how to approach the next assembly step are taken into account, the total time is approximately 2 hours.
