Durango upfitter guide 2.3.pdf

OREGON STATE POLICE

DODGE DURANGO

Upfitter Guide Produced by Alvarez, Jorge

Jorge.Alvarez@osp.oregon.gov

Table Of Contents Getting Started _______________________________________________________________________ pg.3 - 14

Decals _______________________________________________________________________ pg.3

Interior removal ______________________________________________________________ pg. 4 - 14

Rear Hatch ___________________________________________________________________________ pg.15 - 21

Parts List, Panel Removal ______________________________________________________ pg. 15

Panel Removal, Light Programming, Light Installation _____________________________ pg. 16 - 17

Slick Top Rear Lights ___________________________________________________________ pg. 18

Rear Radar Cone, Rear Inner Edge, Stop Sticks ___________________________________ pg. 19 - 21

Roofline _____________________________________________________________________________ pg 22 - 29

Parts List, Headliner Removal __________________________________________________ pg. 22

Anttena Placement & Cable Routing ____________________________________________ pg. 23

Light Bar______________________________________________________________________ pg. 24

Rear Radar Cable, Rear Cargo Light _____________________________________________ pg. 25

Rear Partition Anchor Installation _______________________________________________ pg. 26 - 28

Dual Radio Installation (Lt. Build Only) __________________________________________ pg. 29

Cargo Copmartment __________________________________________________________________ pg 30 - 45

Parts List, Wire Harness Prep ___________________________________________________ pg. 30

Rear Tail Light Flasher Installation & Routing _____________________________________ pg.31 - 32

Equipment Tray & Wiring _______________________________________________________ pg.33 - 39

Rear Quarter Panel & Side Lights _______________________________________________ pg.41

Setina Cargo Box Mount, Rear Compartment ____________________________________ pg.42

Equipment Compartment, Rear Partition ________________________________________ pg. 43 - 45

Cargo Box ____________________________________________________________________ pg. 45 - 46

Prisoner Compartment _______________________________________________________________ pg. 47 - 68

Parts List, Wire Routing ________________________________________________________ pg. 47 - 48

Axon Wifi/GPS Antenna, Front Camera Cable Routing ____________________________ pg. 49 - 50

Front Partition Mounting Bracket _______________________________________________ pg. 51 - 54

Rear Prisoner Seat ____________________________________________________________ pg. 55 - 59

Rear Partition Plexiglass Divider ________________________________________________ pg. 59 - 60

Prisoner Compartment ________________________________________________________________ pg. 47 - 68

Weapon Mount, Printer Bracket, Harris Speaker Bracket __________________________ pg. 61 - 62

Front Partition ________________________________________________________________ pg. 62 - 66

Rear Camera, Weapon Lock ____________________________________________________ pg. 67

Rear Door Panels ______________________________________________________________ pg. 68

Driver Compartment ___________________________________________________________________ pg. 69 - 72

Parts List, Axon ________________________________________________________________ pg. 69

Printer, Harris Radio Speaker ____________________________________________________ pg. 70

Radar, Weapon Lock Foot Switch ________________________________________________ pg. 70 - 71

Whelen Durango CAN Cable, Axon Front Camera _________________________________ pg. 72

Center Console ________________________________________________________________________ pg. 73 - 78

Parts List, Ground Harness ______________________________________________________ pg. 73

Center Console, Wiring _________________________________________________________ pg. 74 - 77

MDT Mount, MDT, Center Console Finishing ______________________________________ pg. 78

Front Bumper __________________________________________________________________________ pg. 79 - 95

Parts List ______________________________________________________________________ pg. 79

Bumper Removal _______________________________________________________________ pg. 79 - 81

Push Bumper Installation ________________________________________________________ pg. 82 - 86

Push Bumper Wiring Vehicle Side _________________________________________________ pg. 86

Push Bumper Light Programming, Wiring __________________________________________ pg. 87 - 88

Push Bumper Installation ________________________________________________________ pg. 89 - 90

Slick Top Front Lights, and Siren __________________________________________________ pg. 91 - 95

Getting Started

Wash Durango before bringing it in to shop, this insures the body is clean for decal placment.

Decals Align OSP Star 22” from rear door edge to center of star, and the center of the star (black circle) aligns with the door body line (red line). (see photos 1 & 2)

Align State Trooper fender decal 4” from fender edge to edge of decal paper, and 2” from body line to edge of decal paper. (see photo 3)

Align Oregon State Police hatch lid decal centered on hatch lid above door handle. (see photo 4)

Align call OSP decal in center of rear bumper between center parking sensors.(see photo 4)

4”

2”

Photo 3 Photo 4

22”

Photo 1 Photo 2

Interior Removal

Remove equipment compartment lids by prying up, a pry tool can be used to assist with removal.

Once the lid is loose you will have remove the saftey strap by pinching the clasp on the strap and pulling up.

(see photos 5 & 6 ) * Driver side shown, repeat for passenger side.

With the equipment compartment lids removed install the equipment tray into the compartment, place the equipment tray so it lays flat, and pushed towards the rear of vehicle on the center hump. (see photo 7)

Installing equipment tray before removing the equipment compartment insures the tray is sitting in the compartment properly, and reinforces the compartment for triming in a later stage of the build.

Fold the rear passenger seats forward, by pulling on the levers on the side of the seat.

Remove the equipment compartment front trim by prying up, a pry tool can be used to assist with removal.

(see photo 8)

Equipment Compartment

Rear Storage Compartment

Photo 5 Photo 6

Photo 7 Photo 8

Remove the VSIM from front of equipment compartment by pressing the release tab located on the passenger side, and the wire harness push pin from the equipment compartment. (see photo 9)

Remove the rear storage compartment lid by prying up, a pry tool canbe used to assist with removal.

(see photo 10)

Remove equipment compartment by removing the two 7mm fasteners, and pulling equipment tray up.

(see photo 11) * Driver side shown repeat for passenger side.

Note: The equipment compartment has two locating tabs that go into the rear cargo compartment, removing the equipment tray first will faciltate in the removal of the rear cargo compartment.

Remove the rear hatch door lower trim by prying up, a pry tool can be used to assist with removal.

(see photo 12)

Photo 9 Photo 10

Photo 11 Photo 12

Remove the rear storage compartment by removing the four 10mm fasteners, disconecting the harness from under the storage compartment, and prying up on the rear storage compartment, a pry tool can be used to assit with removal. The vehicle floor jack cover will have to be removed to access two of the 10mm fasteners.

(see photos 13 & 14 )

Remove rear passenger seat by lifting the plastic covers at the front of the seat and removing the rear door running boards to access the 18mm fasteners securing the seat, a pry tool can be used to assist with removal of plastic covers, and running boards. (see photos15-17 ) * Driver side shown, repeat for passenger side

Photo 13 Photo 14

Photo 15 Photo 16

Photo 17

Once the fasteners are removed there are 2 cabels under the seat witch need to be pulled simultaneously in order to release the seat from the vehicle.

With the seat folded reach under the seat from the front and back of the seat to locate the cables. Pull on the cables simultaneously while lifting the seat from the rear to unlock seat from vehcile. (see photo 18 )

* Driver side shown, repeat for passenger side.

* Seat shown in the released , and straight up position ready for removal to show cables.

Remove rear headliner trim panel by prying down, use a pry tool to assist with removal. (see photos 19 & 20 )

The rear headliner trim panel will be used for rear red/white cargo light, later in the build.

Photo 18

Photo 19 Photo 20

Remove the rear d-pillar trim by prying panel away from vehicle, a pry tool can be used to assist with removal.

Once panel is loose release the saftey strap from vehicle by pressing in the locking tab located on the safety strap. (see photos 21-23 ) * Driver side shown, repeat for passenger side.

Remove the rear seat belts from vehcile by removing the 18mm anchor bolts. Save anchor bolts they will be needed later in the build. (see photo 24) * Driver side shown, repeat for passenger side.

Photo 21 Photo 22

Photo 23

Photo 24

Remove rear quarter panels by removing three 7mm fasetners, two located along bottom edge, and one under a cover. Use a pry tool to lift the cover at the front of the panel to locate one 7mm fastener.

Remove the rear door seal by prying away from vehicle, once fasteners and door seals are removed pry the panel away from vehicle to remove. (see photos 25 & 26)

Note: Label each door seal when removed to insure door seals get returned to there original location.

* Driver side shown, repeat for passenger side.

Remove rear window trim by gently prying the air bag and retaining clip from panel, remove two 7mm fasteners, and pry panel down from roof.

Once panel is loose locate the saftey strap and release from vehcle by pressing in on locking tab and pulling strap away from panel.

(see photos 27 & 28)

Photo 25 Photo 26

Photo 27 Photo 28

Remove c-pillar trim by removing one 7mm fastener and prying away from vehicle.

With panel loose remove seatbelt opening trim, and pull seat belt through trim piece and panel. Return trim piece to panel once seatbelt is pulled through. ( see photos 29 & 30 ) *Driver side showen, repeat for passenger side.

Remove front passenger seat by removing seat belt anchor panel, and seat belt anchor T50 torx fasetner from seat. Remove the plastic covers to access the four 15mm fasteners securing the seat. Disconect the seat harness and the harness retaing clip before removing seat from vehicle. (see photos 31-34)

Photo 29 Photo 30

Photo 31 Photo 32

Photo 33 Photo 34

Remove front door running board by prying up, use of pry tool can assist with removal.

With door sill removed remove front door seal by prying seal away from vehicle. (see photo 35 & 36)

Remove b-pillar trim use a pry tool to pry the lower panel from vehicle.

Remove 7mm fastener from upper panel and pry away from vehicle. (see photos 37 & 38) *Passenger side shown, repeat for driver side.

*Because driver seat is not removed, driver side b-pillar upper panel does not have to be removed from vehicle, but can be placed aside on the driver seat to keep out of the way. (see photo 39)

Photo 35 Photo 36

Photo 37 Photo 38

Photo 39

Remove passenger side a-pillar trim by prying away from vehicle, using a pry tool can assist with removal.

Once a-pillar is loose locate the safety strap and push in locking tab while pulling strap to release panel from vehicle (see photos 40 & 41)

Remove dashboard side panel by prying away from dashboard, a pry tool can be used to assist with removal.

(see photo 42) * Driver side shown, repeat for passenger side.

Remove kick panel by prying away from vehicle, using a pry tool can assist with removal. (see photo 43)

Remove lower dash cover by prying the three retaing pins down from dashboard, and disconnecting harness.

(see photo 44 ) * Passenger side shown, repeat for driver side.

Photo 40 Photo 41

Photo 42 Photo 43

Photo 44

Remove center console floor plate, and lower dash panel by removing four 10mm fasteners. With fasteners removed pull lower dash panel away from dash board. (see photo 45 - 47) *Driver side shown, repeat for passenger side.

Remove passenger floor liner, by removing the push pin retainers and pulling liner up. With floor liner removed remove the four 10mm fasteners securing the floor plate and remove. (see photos 48 & 49)

Photo 45 Photo 46

Photo 47

Photo 48 Photo 49

Lift the center floor liner and rear floor liner to access the rear passenger floor plate. Remove rear passenger floor plate by removing the four 10mm fasteners. (see photos 50 & 51)

Durango with seats, and interior removed ready for installation of police equipment. (see photo 52)

Photo 50 Photo 51

Photo 52

REAR HATCH

Parts List Part Number Qty Whelen Rear Inner Edge Dodge Durango BS44Z 1 Feniex Cannon Quad (Rear Hatch Lights) FEN-Q-2222 2 Stalker Rear Radar Cone from Stalker Radar Kit 1 Stalker 20ft Antenna Cable from Stalker Radar Kit 155-2591-20 1 Stalker Short Radar Cone Mounting Bracket 1 Sound-Off Taillight Flasher Kit Dodge Durango ETTFK02 1 Whelen Vertex Red Light (Slick Top Only) VTX609R 1 Whelen Vertex Blue Light (Slick Top Only) VTX609B 1 Stop Stick Kit 53012K 1 18 AWG Yellow Wire 15 ft 18 AWG Black Wire 15 ft 18 AWG Red Wire (Slick Top Only) 15 ft 18 AWG Brown Wire (Slick Top Only) 15 ft

Caution: Rear hatch panel is fragile and will break if care is not taken while removing.

Before removing rear hatch panel, drill the holes for the rear hatch lights, drill through the panel and hatch lid to insure proper alignmet. Use the rear hatch lights template for location of holes. (see photo 53)

Remove rear hatch grab handle, use a pry tool on the top part of the grab handle to release from vehicle.

(see photo 54) * Driver side shown, repeat for passenger side.

Photo 53 Photo 54

Remove the rear hatch lower panel by prying away from the hatch door, start by the rear glass and work around to the bottom of the panel. Use a long pry tool to assist with removal. (see photo 55)

Remove rear hatch upper panel by prying away from vehicle, use a pry tool to assit with removal.

(see photo 56)

With the upper panel remove, pry the factory harness clips away from vehicle and move harness aside. Drill a 1” hole between the slot for the harness clip and the slot for the upper panel retaing clip to pass the hatch wires into the cab. (see photo 57) * Driver side shown, repeat for passenger side.

Hatch Lights (Fenix Quads) Program to alternating flash patern, dual color red and blue, triple flash.

When programing the lights set the leader and follower first, this step resets the lights to default. If light color or pattern are done before, they will need to be set again to the desired settings.

Connect the light red wire (mode 1) to 12V+, and the black wire to ground. The yellow wire (mode 2), and white wire (mode 3) are not used.

Programing alternating flash paterns, with the light powered on hold the blue wire to ground for 3 seconds.

The light will turn a steady blue for leader and red for follower. Set the lights to one leader and one follower.

Programing colors with light powered on, momentarly tap the green wire to 12V+ to switch colors. Tap green wire until light flashes blue and red. 4 taps to 12v+ should set light to blue/red.

Photo 55 Photo 56

Photo 57

Programing patterns with light powered on, momentarily tap the blue wire to ground to switch patterns. Tap the blue wire until light flashes triple flash pattern. 7 taps to ground should set light to triple flash pattern.

Light wiring

• Red Yellow wire to the Core connector J17-3 Yellow

• Black Black wire to ground

• Blue Blue sync wire between both lights.

• Yellow Not used

• White Not used

• Green Not used

Install hatch quads in holes made earlier at bottom of hatch door. Route wires from driver side light to passenger light then along factory harness to the 1” hole drilled earlier, then through the passenger side door boot. (see photos 58 & 59)

Rear Tail Light Flasher Remove the passenger side connector and install the rear flasher center ring bypass harness. Route the wires through the passenger side door boot into the cab, insert the bypass harness into the door and reinstall the passenger side conector to the door. (see photos 60 & 61)

Note: Black plastic housing around door connectors will need to be trimmed at the top corners to fit the light bar mounting brackets. (see photo 60) * passenger side circled repeat for driver side.

Photo 58 Photo 59

Photo 60 Photo 61

Passenger side connector

Driver door boot Passenger door boot

Rear Lights (Slick Top Only) Remove inner revers light from hatch light, enlarge hole to 1” for installation of Vertex lights. Program Lights to steady before installation. (see photos 62-65)

Light Programming connect the red wire to 12v + and the black wire to ground. With the light powered on apply 12v + to the white wire for more then one second and release, this will cycle the pattern to the previous pattern. If lights are at default going back one pattern will set to steady. Applying 12v + to the white wire for less then one second will advance to the next pattern.

Light Wiring

Red Light:

• Red Red wire to Core J10-2 Red

• Black Black Wire to rear ground stud.

• Green Not used

• White Not used

Blue Light:

• Red Brown wire to Core J10-1 Brown

• Black Black wire to rear ground stud.

• Green Not used

• White Not used

Photo 62 Photo 63

Photo 64 Photo 65

Rear Radar Cone mount radar cone to rear inner edge light. Drill a hole 3” from light edge x 2 3/8” from rear edge. Use 1/4X20 Button head bolt, and nyloc nut to secure bracket to rear inner edge. (see photos 66 & 67)

* photo show bracket and light installed on vehicle.

Rear Inner Edge Mount the brackets to the lightbar as shown using the four supplied 8-32x3/8” pan head torx screws. (see photo 68)

The tabs on the mounting brackets go into two of the slots the wire harness clips snap into. Put the lightbar onto the vehicle inserting the two tabs on the mounting brackets into the two slots in the vehicle.

(see photo 69) * Driver side shown, repeat for passenger side.

3”

2 3/8”

Photo 66 Photo 67

Photo 68 Photo 69

Mark the mounting hole locations for each bracket onto the mounting surface, then remove the lightbar and drill the mounting holes using a drill sized for the supplied mounting hardware. Install light mounting brackets to the vehicle with the supplied hardware. (see photo 70) * Driver side shown, repeat for passenger side.

Hatch upper panel triming, place template on panel and mark location for cutting, drill a 1” hole for rear lightbar, and radar cables to pass through. (see photo 71 & 72)

Route rear lightbar, and radar cable through hatch upper panel, then through the 1” hole in the vehicle, and through the driver side door boot into cab. Return the hatch upper panel to vehicle. (see photo 73)

Photo 70

Photo 71 Photo 72

Photo 73

Mount the rubber seal to the front edge of the lightbar. Return the lightbar to the mounting brackets and secure with supplied hardware.

Install the rear radar cone. (see photos 74 & 75)

Stop Sticks Install stop sticks before rear hatch panel is returned to vehicle. Use Spacers to fill space beteween stop stick and door panel. (see photo 76)

Return rear hatch panel to vehicle. (see photo 77)

Spacer

Photo 74 Photo 75

Photo 76 Photo 77

Roof Line

Whelen Legacy WCX 48" Lightbar EB8EEEE 1 7-in-1 SHKFIN Kit – GPSD4 GP-IN2680 1 GPSD4 Ribbed Panel Adapter Kit (Foam Adapter) SAB-312 1 Black Antenna/Harris Radio NMO150/450/758 1 Harris GPS/NMO Antenna Base GPSNMO 1 3" Round Red/White Compartment Light 3SRCCDCR 1 18 AWG Red Wire 3 ft 18 AWG Black Wire 3 ft

Remove the two pushpins from the rear of the headliner.

Remove the two roof hooks by using a small pry tool on the cover to expose the T30 torx fastener, remove the fastener and pry the hook away from the venhicle.

Remove the passenger side grab handle by using a small pry tool to remove the caps from the handle to expose two T30 torx fasteners. Remove the fasteners and pry the handle away from vehicle.

Lower the headliner by pulling down from vehicle, a long pry tool can assist release the light retaning clip (see photos 78 - 81)

Photo 78 Photo 79

Photo 80 Photo 81

Antenna Placment Mark locations in center of roof ridges, Harris radio antenna 25” from rear edge of roof, drill hole to ¾”, Cradle Point Panorama antenna at 42” from rear edge of roof, drill hole to 1”.

Route antenna cables towards driver side, then back to D-pillar and down to equiment compartment.

(see photos 82-84)

Harris 25” Cradle Point 42”

Lightbar 64”

Photo 82 Photo 83

Photo 84

LightBar Set legs 2” from bracket edge to Whelen logo tab. Legs should messure 46 ¾” +/- 1/8” between legs Mark location for Wires 64” from rear edge of roof. Drill hole to 1” Install rubber gromet, route wires down passenger side to A-pillar, then to center consloe. Place support legs at front edge of rear door.

(see photos 85 - 88)

Photo 85 Photo 86

Photo 87

Photo 88

Rear Radar Cable Route cable down driver side headliner to A-pillar. Cable will be routed to Radar Counting Unit with front radar cone cable and Counting unit power cable at later time. (see photo 89)

Cargo Red/White Lite Install the light on the forward edge of panel and the switch just behind the light in the rear center headliner trim panel. (see photo 91) * Arrow pointing towards rear of vehicle.

note: keep panel off, it will be installed at later time.

Splice power and ground from Cargo dome light and extend wires to rear of headliner and terminate with a 2 pin molex conector. (see photo 90)

Light Wiring:

• Red Red wire spliced to cargo dome power yellow/blue wire

• Black Switch - pin 1

• Black/White Switch - pin 3

• Switch - pin 2 Black wire spliced to cargo dome ground black wire.

Note: Enlarge circled holes with 25/64” drill bit while headliner is down. Holes will be used for Setina rear partition installation at a later time. (see photo 92)

Photo 89

Photo 91 Photo 92

Photo 90

Rear Partition Install rear partion Lower anchor point see Setina rear partition installation instructions steps 18-25.

Note: Do not discard the template for C pillar cut out, save for future use.

Return the remainder of the window trim to the vehicle, secure the the panel with factory fasteners, and return the air bag to its original location. (see photo 93)

Note: Do not return D-pillar trim to vehicle at this time. Rear qurter panels must be returned to vehicle prior to installing D-pillar trim.

Photo 93

Dual Radio Installation (LT. build only)

Rear Radio mounting bracket will need to be fabricated before proceeding with install.

Locate the pocket on the passenger side shown. Use the mounting bracket to locate position of mounting holes and mark locations, use a 9/32 drill bit to make the holes. Install the rear radio mounting bracket in the roof pocket as shown. (see photos 94 & 95)

Passenger side D-pillar will need to be trimed as shown, to fit the second radio mounting bracket .

Trim along the rear edge of d-pillar molding as shown.

(see photos 96 & 97)

Note: Do not return D-pillar trim to vehicle at this time. Rear qurter panels must be returned to vehicle prior to installing D-pillar trim.

Photo 94 Photo 95

Photo 96 Photo 97

Cargo Compartment

Setina Cargo Box TK0250DUR11 1 Setina TPO Prisoner Seat w/ Outside Buckle QK0566DUR11 1 12VS Prisoner Partition w/ Poly Window 1 Equipment Tray 1 Harris XL200 Radio kit 1 Cradle point R980 1 911 26 Circuit Fuse Panel and Wire Harness CH26 1 911 Circuit Durango Bypass Harness Durango.Upfitter 1 Whelen CenCom Core Main Control Box C399 1 Whelen WeCanX Control Head w/ Knob CCTL6 1 Whelen CANport (RAM, Durango, and Charger) C399K3 1 Whelen TLI Light RED/Blue TLI2J 2 NOCO Jump Starter 797WK6 1 Fire Extinguisher UN1044 1 Amerex FE Bracket Vehicle Heavy-Duty 5# Red #5BRKT 1 18 AWG Light Green Wire 20 ft 18 AWG White/Orange Wire 20 ft 18 AWG Orange/White Wire 20 ft 18AWG Yellow/White Wire 20 ft 18 AWG Black Speaker Wire 20 ft 18 AWG Green Wire 6 ft (x2) 18 AWG Brown/White Wire 6 ft (x2) 18 AWG Black Wire 6 ft (x2) 10 AWG Black Wire 6 ft (x3) 12 AWG Black Wire 6 ft 16 AWG Black Wire 6 ft (x7)

Wire Harnes Prep Rear to Front Bypass Harness Use the following wires 18 AWG White/Orange, 18 AWG Light Green, 18 AWG Orange/White, 18 AWG Yellow/White, and 18 AWG Black speaker wires and tape together to build the Rear to Front bypass harness.

Side Light Harness Use the following wires 18 AWG Dark green, 18 AWG Brown/White, and 18 AWG Black Wires and tape togeher to build the side light harness. Two side light harnesses are needed, One per side.

Core Controller Data Cable Harness Take the PA extension cable from the WeCan X Control Head box (CCTL6), the Whelen control head ethernet cable from the CenCom Core Main Control box (C399), Whelen CANport (C399K3) Dodge CAN interface cable and tape together to create the Core Data Cable Harness.

Rear Ground Harness Use (3) 10 AWG Black, (1) 12 AWG Black, and (7) 16 AWG Black wires for the ground harness, Use a closed end ring terminal to terminate one end of the ground harness.

Rear Tail Lights Remove rear tail lights for rear flasher bypass harness install. Remove the two retaing clips and pry the light away from the vehicle. Use a non scratching pry tool to assist with removal. (see photos 98 &

99) *Driver side shown, repeat for passenger side.

Drill ½” hole at corner of light cavaty for wire routing into cab seal wire passthrough, and return lights to vehicle.

Remove alluminum seal and insulation from d-pillar and route harness to equipment tray area, return insulation and alluminum seal to vehicle.

(see photos 100 -102) *Driver side shown, repeat for passenger side.

Photo 98 Photo 99

Photo 100 Photo 101

Photo 102

Wire Routing Route Rear Hatch harness, passenger tail light harness, and passenger side light harness, along factory harness to equipment compartment.

Note: Route Side light Harnes from rear quarter window to equipment compartment following the rear flasher, and rear hatch circuites. (see photos 103 & 104)

Route Harris antenna cabels, Cradlepoint cables, driver tail light harness, and rear lightbar cable along factory harness to equipment compartment. (see photo 105)

Rear Ground Harness Use Factory Ground Studs and route harness with passenger side harness to equipment compartment.

Use the ground studs indicated by arrows. (see photos 103, 105-106)

Note: The ground studs need to be cleaned with a wire brush to remove factory coating on stud base to insure proper ground to OSP equipment.

Photo 103 Photo 104

Photo 105 Photo 106

Equipment Tray Follow Setina 2nd partition instalation instructions steps 37, 41- 44 for directions on triming front cargo compartment to fit 2nd partition.

Note: Additional triming will be needed to storage compartment for equipment wiring. Make a 3rd mark following the yellow line shown. (see figures 41 & 42)

Trim corners of equipment tray as shown to fit cargo box mounting legs.

(see photo 107) * Driver side shown, repeat for passenger side.

Install equipment compartmint into vehicle. Install Harris Radio Base, Cradlepoint, Whelen Cencom Core controller, 911 26 circuit fuse panel, and rear tail light flasher. (see photos 108 & 109)

Route antenna cables to harris radio, and cradlepoint. Route rear hatch lighting, tail light flasher, and side lights to Whelen Cencom Core. (see photos 110 & 111)

Photo 108 Photo 109

Photo 110 Photo 111

Photo 107

Equipment Tray Wiring

911 Fuse Panel

Note: Circuit 5 Harris Base fuse on HOT side. Circuit 20 Core fuse on SWITCHED side.

Note: The CH26 fuse panel has timer switches for the orange, blue, and white circuits. The blue and white circuits set to TMR 1, and the orange circuits set to IGN.

Circuits Hilighted in red indicate rear circuits, cir 13 & cir 17 only used when equiping dual radio face.

Prep wire harness for install separate front and rear cicuits. Cut the rear circuits to equal length as the short grey siren speaker 1 circuits, short tan siren speaker 2 circuits, and panel ground wire.

Route power cable, long gray siren speaker 1, long tan siren speaker 2, and remainder of 911 circuits forward.

Install 911 circuits Durango upfitter bypass harness to vehicle. Separate the white Brake Sense wire, and the white VSS Vehicle Speed Sense wire and route forward to passenger floor area, routing completed later in the buld.

911 CH26 Circuit Layout Red Circuits Orange Circuits Yellow Circuits White Circuits Blue Circuits

Cir 1 CradlePoint 5A Cir 5 Harris Base 20A Cir 11 Harris Face 5A Cir 15 Harris Face 5A Cir 21 Printer 10A Cir 2 Gun Lock 15A Cir 6 Open Circuit Cir 12 Flash Light 5A Cir16RearFlasher20A Cir 22 Harris Base 3A Cir 3 Axon 15A Cir 7 CradlePoint 5A Cir13 RHarrisFace5A Cir17RHarrisFace 5A Cir 23 Lind 5A Cir 4 Light Bar 40A Cir 8 Power Port 20A Cir 14 Open Circuit Cir 18 Radar 10A Cir 24 Core J14-3 3A Cir 9 Jump Pack 15A Ignition Input Cir 19 Front Visor15A Cir 25 Rear TA 15A Cir 10 Axon Ign 1A Cir 20 Core 30A Cir 26 Core 30A

Route the Rear to Front Bypass harness and the Core Data Cable harness forward from equipment compartment to the passenger floor area, routing completed later in the build. (see photos 112 & 113)

Remainder of circuits from upfitter harness remain in equipment compartment.

Harris Radio Base Route Harris Radio Ethernet and Harris Speaker wire forward. (see photos 112 & 113)

Note: Speaker cable harness is connected at harris radio base. Speaker 1 output will need to be split, one set for Whelen Cencom Core controller, and one set to for Harris speaker. Speaker 2 output is not active per ODOT, do not use.

Wiring :

• Red Orange Cir 5

• White Blue Cir 22

• Black Black Ground

Photo 112 Photo 113

Cradle Point Identify Axon supplied Ethernet cables with colored tape, blue for LAN cable, yellow for WAN cable, and route cables forward. (see photos 112 & 113)

• Cell A Antenna Port 1

• Cell B Antenna Port 2

• Cell C Antenna Port 3

• Cell D Antenna Port 4

• GPS Antenna Port 5

• Ground Ground Stud 6

• Wi-Fi 1 Wi-fi Port 1

• Wi-Fi 2 Wi-Fi Port 2

• Yellow Taped Ethernet Cable Ethernet Port WAN

• Blue Taped Ethernet Cable Ethernet Port 1

4 Pin Power Cable 4 Pin Power Port

Wiring:

• Red Red Cir 1

• Orange Orange Cir 7

• Black Black Ground

• Blue Not used

1 2 5 3 4

Wi-Fi 1 Wi-Fi 2

Rear Flasher Route wires from tail lights, and center light to flasher connectors. Brown wire will need to be extended to reach Core controller use extra 911 circuits orange Rear Wig Wag wire to Core controller.

• White White Cir 16

• Brown Spliced together with Rear Wig Wag at Core J17 – 1 Orange

• Green Black Ground

Horn Sense Relay

• Pin 30 Horn Sense Wire

• Pin 85 Oarange/Black spliced with Horn Mute at Core J17-4 Brown

• Pin 86 Black ground

• Pin 87 White/Black to Core J6-1 White/Brown

Cencom Core Controller

Follow Whelen Cencom Core installation worksheet on next page to finish wiring of controller.

Note: After connecting the siren wires to the controller, keep extra grey siren 1 wires, and tan siren 2 wires that were cut for use to extend the wires from the siren speakers when building the push bumper later in the build.

Note: Move equipment compartment aside and return rear interior panels to vehicle. Panels will need to be cutout as shown, for wire routing from equipment tray. (see photo 114 & 115)

Side Lights Finish installing side lights to rear quarter panel locate light bracket 5 ¼” from panel edge to light.(see photo 116)

Note: Slick top vehicles will need the lights tinted before installation.

Light Programming each color will need to be programmed individually. connect the red wire (red light) or the blue wire (blue light) to 12v + and the black wire to ground.

With the light powered on apply 12v + to the white wire for more then one second and release, this will cycle the pattern to the previous pattern. If lights are at default setting going back one pattern will set the light to steady.

Applying 12v + to the white wire for less then one second will advance to the next pattern.

Light wiring:

• Red Green wire to Core J10 – 5 GRN

• Blue Brown/ White wire to Core J10 – 9 WHT/BRN

• Black Ground

• Gray Not used

5 ¼”

Photo 114 Photo 115

Photo 116

Note: Install Cargo Box legs before returning cargo compartments back to vehicle. Follow Setina Cargo box install instructions step 5.

Install lower mount brackets before returning cargo compartments back to vehicle. Follow 2nd Partition installation instruction step 26

Rear Cargo Compartment Install USB plug for charging NOCO Jump Pak in rear cargo compartment.

Reinstall cargo bin. (see photo 117)

Photo 117

Equipment Compartment Return compartment to vehicle and install lids. Lids will need front corners trimed to fit cargo box legs. (see photos 118 & 119)

Rear Partion Follow Setina #12 2nd Partion install instructions steps 33-36.

Photo 118 Photo 119

Follow Steps 38-40 for the Durango Vehicle System Interface Module (VSIM) installation. Do not install VSIM as shown in step 39 install on oppisite side of partition inside front equipment compartment. (see photo 120)

Cargo Box White Board LT. slicktop only. Install white board before installing cargo box in vehicle.

Note: Drill holes for fire extingisher before installing cargo box in vehicle.

Cargo Box follow Setina cargo box install guide steps 1, 8-10

Photo 120

VSIM

Rear storage compartment lid will need the corners from the top cover trimmed as shown to fit the cargo box legs. (see photo 121)

Completed rear cargo compartment. (see photo 122)

Photo 121 Photo 122

Prisoner Compartment

Interior Remove passenger floor liner, by removing the push pin retainers and pulling liner up. With floor liner removed remove the four 10mm fasteners securing the floor plate and remove. (see photo 123)

Wire Routing Route the Black Speaker cable, white VSS Vehicle Speed Sense, and Brake Sense wires through wire passthrough at center of vehcile to center consloe. (see photo 124) Remove white harness passthrough cover and route circuits from equipment tray through and return cover.

(see photo 125)

Setina 6VS Single Prisoner Transport (Front) 1K0574DUR11FSR 1 Setina Single Prisoner Partition GT0536DUR11 1 Setina TPO Prisoner Seat w/ Outside Buckle QK0566DUR11 1 Setina Rear TPO Door Panels DK0100DUR11 1 Black-Rac 1 5/8" Tube Mount 1 Axon Rear Camera 1 Axon Wi-Fi / GPS Antenna 1 Axon 6' Ethernet Cable 1 Axon 10' Ethernet Cable 1

Photo 123

Photo 124 Photo 125

Wire Routing Continued

Route remainder of rear circuits, wires along the factory harness, and across to the center console.

(see photo 126 & 127)

Route 911 circuit 6 AWG red power cable, grey siren speaker 1, and tan siren speaker 2 forward to engine compartment along factory harness and through the passthrough hole in fire wall. (see photos 126, 128, 129)

911 Circuit Breaker Install 911 circuit breaker as shown, route red 6AWG wire from cabin to AUX terminal on circuit breaker, reut battery side of circuit breaker to the factory jump post. (see photo 130)

Photo 126

Photo 128

Photo 127

Photo 129

Photo 130

Axon Install Wi-Fi/GPS antenna on passenger corner of dash. Route cables down the dashboard then to battery compartment (see photos 131- 133)

Photo 131 Photo 132

Photo 133

Axon camera cable route from headlier as shown, route across to the passenger side a-pillar and down to the battery compartment. (see photos 134 – 137)

Photo 134 Photo 135

Photo 136 Photo 137

Front Partition Mounting Bracket Follow Setina Front Partition Installation guide Steps 6-20. Reinstall b-pillar trim, door seals and door sill trim.

Note: Return the rear door seals and the rear door runing boards to vehicle before installing rear prisoner seat.

Rear Prisoner Seat follow Setina 2nd partition installation instructions steps 45-62.

Note: Step 58 should be done before installing seat in vehicle.

Rear Partition Plexiglass Note: Slide rear partition plexi from rear of vehicle forward, push up on headliner to clear the rear dome light.

If vehicle is equipt with white board plexi will have to be monuvered into place from prisoner seat it will not go into place if you try to go from rear forward.

Front Partition Prep partition for install, install the wall adapter plate to the front partition following the Setina front partition instllation instructions step 31. (see Figure 31)

Cut the foam were the wall adapter plate contacts the foam. (see photo 138)

Slide foam to side and install Black-Rac Tube Mount to partition loosly. (see photo 139)

Note: Tube mount may need grip tape on inside surface too keep clamp from rotating. (see photo 140)

Photo 138

Photo 139 Photo 140

Printer mount and Harris speaker mount can be installed at this time.

The printer mount will need to be trimed to fit flat on the wall adapter plate. Align the printer mount and the Harris speaker mount along the cut on the wall adapter plate. (see photos 141 & 142)

Follow Setina front partition installation instructions steps 21-39 to complte installation.

Photo 141 Photo 142

Note: Step 68 replaces step 30, for installation of the end release buckle to the front partiotion.

Note: Setina Instructions are miss labled Steps 37-39 are labeled as Steps 33-35

Rear Camera Install rear camera to front partition and route camera cable to front side and down to center console. (see photos 143 & 144)

Weapon Lock Finish instalation of Black-Rac tube mount by rotating mount so base plate is touching headliner plastic trim.

Install Black-Rac mount to tube mount on lower set of mounting holes.

Slide Black-Rac lock onto mount and secure loosly.

Place weapon in lock and adjust placment to desired location then tighten fasteners.

Extend gun lock wires and route to center consloe. (see photos 145 - 148)

Photo 143 Photo 144

Photo 145 Photo 146

Photo 147 Photo 148

Rear Door Panels Before installing rear door panel cover make sure door compartments are empty. Follow Setina Door panel installation instructions Steps 1-4.

Driver Compartment

Axon Hub and Mount 1 Axon Wire Harness 1 Axon Front Camera 1 Black-Rac Gun Lock 1 Havis 23" Durango Console C-VS-2300-DUR 1 Stalker Radar 2XDSR 1 Stalker Dodge Durango CU/Antenna Mount 200-1377-10 1 Stalker 4ft Antenna Cable 155-2591-04 1 Stalker Front Antenna Bracket (Zephyr) 4081-015 1 Stalker, VSS Cable Kit w/ Serial Port Cable 200-0623-00 1 Harris Radio External Speaker 1 Zebra C Printer Bracket ZQ521 (3808144) 1 Zebra Battery Eliminator Dock ZQ521 (4302294) 1 Zebra Printer ZQ521 (69305509) 1 Zebra Printer Charger/Power Supply ZQ521 (4863883) 1 Zebra 6' USB Cable 1 USB Extension Cable 1 Gun Lock Foot Switch 1 18 AWG White/Orange Wire 10 ft 18 AWG Black Wire 10 ft 18 AWG Light Green Wire 6 ft 18 AWG Red Wire 6 ft 18 AWG Black Wire 6 ft Speaker Wire 6 ft

Axon Install WAN, front camera, rear camera, and Wi-Fi/GPS cabels to Axon hub. Install Axon circuit harness to hub and mount Hub and Signal Box to Front Partition behind passenger seat route harness to center console. (see photo 149)

Printer install printer to printer mount and route power, and usb cables to center consloe.

Photo 149

Harris Radio Speaker Install Speaker to mount and route wires to center console. (see photo 150)

Radar Install the Stalker Dodge Durango CU mount, insert the mount hooks into the full 7th and 9th open windshield defrost slots. Make sure that the hooks secure to the dash and not the thin plastic pieces that tie the fins together. (see photo 151)

Position the other end of the mount just over the air conditioning ventt as shown. Insure the metal end plate does not interfere with the operation of the vent or restrect air flow. Secure with the provide hardware, make sure that the endplat is secured and tight against the dash. (see photo 152)

Route rear radar cable between front edge of a-pillar and windshield down to dash then across to radar counting unit, along with front radar cone cable and Stalker VSS/Power cable.

Photo 150

Photo 151 Photo 152

Route Stalker VSS cable down dashboard on driver side to center console. (see photo 153 & 154)

Gun Lock Foot Switch connect white/orange wire, and black wire to foot switch terminals. Install foot switch at hiest point on driver floor liner as hown. Route wires along with Stalker powercable to center console.

(see photo 156)

Photo 153

Photo 155

Photo 154

Photo 156

Whelen Durango CAN cable route cable to Durango CAN port follow supplied installation instructions for location where to plug in cable. (see photo 157)

Axon Front Camera Install Front camera to Axon glass mount bracket using the supplied hardware. Clean the windshield with the supplied glass treatment disposable wipe.

Open packet and remove pad, wipe on glass covering vertically, then repeat in a horizontal direction to insure complete coverage. Be sure pad is wetting the glass surface.

While the glass surface is wet, wipe dry with a clean, dry cloth or paper towel. Apply the camera mount as shown within 30 minutes. (see photo 158)

Note: Vehicles with a tint banner will need the tint to be cut around the Axon windshield mount prior to placing mount to windshield. (see photo 159)

Photo 157

Photo 158 Photo 159

Center Console

Havis Mounting pole C-HDM-214 1 Havis ACT, HDM Slide C-MD-119 1 Havis MDT Mounting Plate C-HDM-426 1 Havis Panasonic Dock HA-33LVDLT2 1 Havis Panasonic Screen Support Arm DS-DA-420 1 Havis Harris XL200 Mounting Component C-EB30-HXL-1P 1 Havis 4" Whelen Cencom Core Mounting C-EB40-CCS-1P 1 Havis Lock Box C-AP-0645-L 1 Havis Cup Holder CUP2-1001 1 Havis 2" Blank Plate C-FP-2 1 Havis Internal Pole Mount Durango Console C-HDM-426 1 Lind Power Supply 2090640 1 Lind Power Supply Bracket 4081-043 1 Magnetic Mic MMSU-4 2 Magnetic Mic Zee Bracket 5045-020 1 Harris Radio Face 1 Whelen WeCanX Control Head w/Knob CCTL6 1 Stalker Remote Control 200-0919-00 1 Stalker Remote Control Cable #48102 1 Pelican Patrol Flashlight 7060-051-110-04 1 10 AWG Black Wire 3 ft (x2) 12 AWG Black Wire 3 ft (x2) 16 AWG Black Wire 3 ft (x8)

Ground Harness Use (2) 10 AWG Black wires, (2) 12 AWG Black wires, and (8) 16 AWG Black wires, ground harness to factory ground stud. (see photo 160 & 161) * Use ground stud shown, the second ground stud is covered by center console and will not have acceses for future service.

Photo 160 Photo 161

Center Console Drill a hole for PA mic using a 25/64” drill bit on the top of console next to the power port plate.

Drill a 1” hole for the MDT cables on the passenger side of the console. (see photos 162 & 163)

Install flash light to rear of console before installing center console in vehicle.(see photo 164)

Return the lower dashboard trim to vehicle. Plug in the vehicle harness to corresponding connections, and clip the panel back into place. (see photo 165)

Photo 162 Photo 163

Photo 164 Photo 165

Center Console position front mounting bracket and carfully route the factory harness and park release cable underneath, route the OSP installed wires, and cables over the mounting bracket.

Note: Ground wire may need to be removed and reattached to position bracket correctly.

Position the rear mounting bracket to the OEM bracket as shown. Secure the front and rear monting brackets to the vehicle using the OEM hardware removed during disassembly. Fully tighten hardware.

(see photos 166 & 167)

Slide main console housing onto floor brackets. Position the Havis telescopign mounting pole as shown, and Loosely attach housing to brackets with 1/4” X 3/4” carriage bolts and serrated nuts. (see photos 168 & 169)

With console and pole mount in position tighten all hardware, and run all wiring as needed.

Photo 166 Photo 167

Photo 168 Photo 169

Note: After console is installed return passenger seat to vehicle, see Front Partition installation instructions step 36 to complete front partition installation

Wiring:

Whelen Core Controll Head plug in data cable from Cencom Core controller, and connect harness from Light bar or front inner edge slicktop wecan cable.

• Green Green

• Gray Gray

• Black/White Bare wire.

Harris Radio Face install data cable from radio base, wire in power cable.

• Red Cir 11

• White Cir 15

• Black Black Ground

Axon cutout inline fuses, tape extra wires to side.

• Red Cir 3

• Orange Cir 10

• Black Black ground

• Yellow/White Yellow/White

• Orange/White Orange/White

• Blue/White Brake Sense

Radar

• Red Cir 18

• Black Black ground

• White VSS Vehicle Speed Sense

• Brown Not used

Power Port Circuit will need to be spliced for both power ports.

• Center pin Cir 8

• Outer pin Black ground

Flash Light

• Black/White Cir 12

• Black Black ground

Printer Power Supply

• Red Cir 21

• Black Black ground

Lind route circuits, LAN data cable, printer USB cable to MDT dock

• Red Cir 23

• Black Black ground

Gun Lock & Gun Lock Relay

• Red Cir 2

• Black Black ground

• Green Pin 87

• Black ground Pin 30

• Black ground Pin 85

• Light Green from Core controller Pin 86

Gun Lock Foot Switch

• White/Orange White/Orange from Core controller J6-3 White/Orange

• Black Black ground

MDT Dock Install Havis slide mount to the pole mount and secure with provided hardware. Install the MDT mount bracket to the havis slide mount, route LAN, printer USB, and Lind power cables to MDT Dock, and install dock to mounting bracket.

Install Whelen Core controll head, Harris radio controll head, 2” filler plate, storage box, cup holders, and pole mount block off plate. (see photo 170)

Mag Mic install one mag mic to MDT using zee bracket, and one to dashboard bellow screen. (see photo170)

Secure PA mic, and Harris radio mic with p clips on console.

Photo 170

Front Bumper

Setina Push Bumper w/ lights K2020DUR21 1 Setina PB10 Aluminum Headlight Guard HK2273DUR21 1 Whelen Siren Speaker 2 Whelen Siren Speaker Mounting Bracket 2 18 AWG Black/White Wire 6 ft

Remove front bumper following Setina Push Bumper Instalation Instructions steps 1-8.

With bumper removed route both siren and light harness down passenger fender liner and out to pushbumper. (see photos 171 & 172)

Slick Top keep siren and light harness in engine compartment, connections for lights and siren will be made in the engine compartment. Slick Top skip to page 88 for build instructions.

Use factory ground stud for ground circuit to front lights. Use black/white wires for ground circuits to front lights. (See photo 172)

Photo 171 Photo 172

Push Bumper Follow Setina Push bumper installation instructions steps 9-32

Caution: When performing Step 15 of push bumper installation instructions, hold the frame spacer in place with a wrench. Spacers will spin loose when removing bolts and will not return to original location.

(see photo 173)

Photo 173

With fascia returned to vehicle complete push bumper wiring to molex connector.

Front Red 1 & Front Blue 1

• Brown/White pin 1

• Brown/Orange pin 2

• Black/White Ground pin3

• Siren 1w/Mute Grey pin4

• Siren 1 pin 5

• Orange pin 6

Front Red 2 & Front Blue 2

• Orange/Brown pin 7

• Black pin 8

• Black/White Ground pin9

• Siren 2w/Mute Grey pin10

• Siren 2 pin 11

• Not Used pin 12

Note: Program push bumper lights to steady burn before installing push bumper.

Light Programming apply 12v + to the desired wire to be programmed red wire = red light, orange wire = blue light, yellow wire = white light, and the black wire to ground.

With the light powered on apply 12v + to the white wire for more then one second and release, this will cycle the pattern to the previous pattern.

If lights are at default going back one pattern will set to light to steady.

Applying 12v + to the white wire for less then one second will advance to the next pattern.

Push Bumper install the siren bracket, and the siren speakers to the push bumper using template for mounting position. (see photos 174 – 176)

Use the left over grey speaker wires from the cargo compartment to extend the driver side siren wires along with the driver side light wires to the passenger side.

Photo 174 Photo 175

Photo 176

Push Bumper Wiring The Driver side forward facing light, and the passenger side intersection light will be connected together and will be Front Red 1 and Front Blue 1.

The passenger side forward facing light, and the driver side intersection light will be connected together and will be Front Red 2 and Front Blue 2.

Connect the forward facing lights, yellow wires together, and extend to pin 6

Note: The side intersection lights, yellow wires are not used.

Note: Two wires will not fit into the molex connector used for the pushbumper. The wires that need to be paired will need to be connected together and a single wire will need to be extended to the molex connector.

Front Red 1 & Front Blue 1

• Red pin 1

• Orange pin 2

• Black pin3

• Siren 1w/Mute Grey pin4

• Siren 1 pin 5

• Yellow pin 6

• White not used

• Black/White not used

Front Red 2 & Front Blue 2

• Red pin 7

• Orange pin 8

• Black pin9

• Siren 2w/Mute Grey pin10

• Siren 2 pin 11

• Yellow pin 6

• White not used

• Black/White not used

Follow Setina Push Bumper Installation Instructions Steps 26-32

Slick Top Front Bumper

Whelen Siren Speaker 2 Whelen Siren Speaker Mounting Bracket 2 Whelen TLI Light Red/Blue (Slick Top Only) TLI2J 4 Feniex Cannon Quad (Slick Top Only) FEN-Q-2222 2 Siren Grille Mount Bracket (Slick Top Only) 1 18 AWG Brown/White Wire 10 ft 18 AWG Brown Wire 10 ft 18 AWG Orange/Black Wire 10 ft 18 AWG Orange Wire 10 ft 18 AWG Blue Wire 10 ft 18 AWG Green Wire 10 ft 18 AWG Black Wire 10 ft (x6) 18 AWG Black/White Wire 6 ft

Install the Siren Speaker to the Siren Grille Mount Bracket using the supplied hardware. Extend the Siren speaker wires and install assembly on vehicle.

Remove the two 15mm fasteners shown and set aside, slide the siren grille mount bracket behind support bars and secure with the factory 15mm fasteners removed. Install supplied mounting bracket and fastened to support bars. (see photo 178 & 179)

Note: Front Lights will need to be tinted and programmed to steady before installation.

Light Programming each color will need to be programmed individually. connect the red wire (red light) or the blue wire (blue light) to 12v + and the black wire to ground.

With the light powered on apply 12v + to the white wire for more then one second and release, this will cycle the pattern to the previous pattern. If lights are at default setting going back one pattern will set the light to steady.

Applying 12v + to the white wire for less then one second will advance to the next pattern.

Photo 178 Photo 179

Install the Lights to the siren mount bracket and extend the wires to engine compartment. Following the factory harness.