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Factory Five Racing Gen 3 Type 65 Coupe, Owner'S Manual

The Factory Five Racing Gen 3 Type 65 Coupe is a high-performance sports car built for adrenaline junkies. To better understand and unleash its full potential, make sure to get your hands on the comprehensive Owner's manual. Download it for free from manualshive.com and embark on an unparalleled driving experience.

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www.factoryfive.com

  508-291-3443

 

Required Supplies  

Stick with name brand products like Eastwood

, 3M

, and Duplicolor

.  The Eastwood brand coatings are 

great for bringing weathered and oxidized parts up to show quality.  PPG brand and DuPont brand paints are 
excellent. 
 

  

Engine degreaser 

  

Silicone Door and window sealant, GE Silicone II or equivalent - 4 tubes 

  

Coolant – 2 gallons of concentrate 

  

Engine oil, Type and quantity depends on engine and oil pan ~5-8 Qts. 

  

Gear oil, 80W-90 (for rear end) – 2 Qts. 

  

Transmission fluid, Mercon automatic Trans fluid – 3 Qts. 

 

Brake fluid, DOT 3 – 1 Qt. 

  

Oil filter 

  

Fuel filter 

  

Battery 

  

Spark plugs 

  

5 minute epoxy glue 

  

Black permanent marker with pointed tip – 2 ea. 

 

2” Masking Tape – 1 roll 

  

Duct tape 

 

Electrical tape 

  

Bodywork supplies 

  

Rags 

  

Gojo

®

 pumice hand cleaner 

 

Spray paint (for donor parts, pick a color) 

  

Acetone, carburetor cleaner, or other solvent 

  

Aluminum polish/cleaner 

 

3M Super 77 spray adhesive – 1 large can 

 

Helpful Tools 

  

#8 hex driver attachment for cordless drill 

  

Adapter for cordless to use ¼” socket driver 

  

Wire brush or wire wheel attachment for drill 

  

Flare nut wrenches (⅜” x 

7

/

16

”) 

  

Flat file and round file 

  

Scissors 

  

Aluminum snips 

  

Friends 

  

Pizza and beer for previous line item 

Summary of Contents for Gen 3 Type 65 Coupe

Page 1: ...R E V I S I O N 4 B O C T O B E R 2 0 1 7 ...

Page 2: ... 2017 Factory Five Racing Inc 9 Tow Rd Wareham MA 02571 Phone 508 291 3443 Fax 508 291 3883 ...

Page 3: ...g a donor 22 Donor Parts Selection Tips 23 87 93 Mustang 23 Other Donor years 23 Where to look 23 Price 24 Running Gear 24 Disassembly of a Mustang Donor for Parts 25 Radiator Cooling System 26 87 93 Steering Rack 26 Engine Bay Sensors and Electrical Connections 27 Interior 28 Computer 28 Turn Signal and Ignition Switches 28 Dash Wiring Harness 29 Front Wiring Harness 30 Speedometer sending unit 3...

Page 4: ...cking Your Kit 46 Kit Parts Prep 46 Headliner and Optional Carpet 46 Body Removal 46 Area set up 49 Aluminum Prep and removal 49 Aluminum panel diagram 51 Chassis Assembly 53 Steering Rack 54 Stock Mustang power steering rack prep 54 manual or optional power steering rack prep 56 Steering rack install 58 Front Suspension 60 Front lower control arm 60 Front Coil Over Shocks 63 Front upper control a...

Page 5: ...rt 115 Optional Independent Rear Suspension 116 Parts needed 116 Mustang IRS Specifications 117 Parts preparation 117 Installation 126 Fluids 145 Capacities 145 Alignment specs 145 Torque Specifications 145 Optional IRS Brakes 146 Fuel System 146 Frame prep 146 Fuel filler neck 149 Fuel Pick up 152 Fuel Gauge Sender 156 Fuel Tank install 162 Fuel filler neck 164 Fuel filter 165 Hard lines 168 Vent...

Page 6: ...eering Shaft 210 Upper Steering Shaft 214 Clutch Cable 216 Accelerator Cable 219 87 93 5 0L Fuel Injected Applications 219 Carbureted applications 220 Cable adjustment 221 Brake System 221 Left front 223 Front right 226 Rear brake line 228 Stock rear brakes 229 IRS brakes 230 Banjo bolt torque specs 232 Brake reservoir and hose 232 Emergency Brake 238 E brake Handle 238 Cables 249 Handle and Cable...

Page 7: ...298 Overflow Tank 303 Aluminum panels 306 Trans tunnel sides aluminum 306 Transmission Tunnel Cover 307 Cockpit rear inside aluminum 307 Left outside footbox aluminum 309 Left door hinge inside covers 310 Hatch floor 310 Under door aluminum 313 Exhaust 314 Headers and J pipes 314 Side Exhaust 317 Seats Harness 317 Seats 321 Nameplate 322 Gauges and Dash 323 Steering Wheel 327 Rolling Chassis Check...

Page 8: ...r 375 Body Cut outs 376 Fuel filler 376 Tail light 378 License plate bracket 380 License plate light 381 Turn Signal 384 Headlights 385 Side Mesh Nose latch 390 Nose Latch 392 Radiator Exit opening 395 Side exhaust 395 Door hinge 398 Door hinge 404 Door frame prep 407 Latch 408 Doors 413 Trimming 414 Door frame install 416 Inside door handle 424 Door Striker 427 Nose Scoops Optional 429 Final Prep...

Page 9: ... Neck 481 Aluminum 485 firewall extension 486 Cockpit outside corners 488 Outside nose mount cover 489 Inside shock tower cover 490 Fuel tank access covers 491 Hatch area rear wall 492 Rear hatch final 494 Interior Rearview Mirror 496 Side Mirror 496 Light wiring 501 Check straps 502 Steering wheel center section 504 Rear Quarter side windows 507 Side Exhaust 510 Aluminum Splash guards 511 Front w...

Page 10: ...chargers 531 Seats 532 Helpful Reference Material 532 Must Reads 532 Helpful 532 Catalogs Parts 533 Factory Five Aftermarket 533 Tools 533 Insurance 533 A Final Note about Completed Cars and Car Builders 533 Appendix A Templates 534 Appendix B Donor Parts List 539 Appendix C Race Yearly check sheet 541 Appendix D Torque Specifications 544 General Bolt torque specifications 545 Appendix E Mustang S...

Page 11: ...x www factoryfive com 508 291 3443 ...

Page 12: ...all the idea of building your own car is NOT for everyone It is a serious endeavor that should be undertaken with care and consideration The desire to build your own custom car goes way back It is part of our uniquely American car centric culture and those who build their own cars are at the very center of this Since the earliest days of Hot Rodding literally tens of thousands of people have built...

Page 13: ...d perhaps order a kit from us With the whole pregnancy thing well for most folks that s even easier to get started When my wife was pregnant with our first daughter I was sure we would never have any more children From the swollen ankles to the morning sickness to the delivery room scene from the movie Alien the whole process was difficult and while she didn t complain too much thru the nine month...

Page 14: ...er Factory Five cars are found I smile to hear the inevitable first words every guy says to me Let me show you what I ve done The cars that we build are more than cars They are a reflection of us The badge of honor that comes with having built your own car is a special one indeed You will join a community of others who have earned their own and THAT is the story of Factory Five Racing and that is ...

Page 15: ...or a particular purpose are expressly disclaimed by Factory Five While Factory Five products are thoroughly tested under actual race conditions Factory Five cannot control the quality of the installation or application of these products The products offered for sale are true race car components the installment of which often requires considerable time and fabrication skill Before attempting any in...

Page 16: ... or electrical systems and always keep a fire extinguisher handy Don t allow children in the work area Partially assembled cars attract a crowd Keep garage doors closed or mark off work areas Make sure that all electrical equipment is grounded If working alone have someone check on you periodically When using an engine hoist make sure that the working load rating is correct for the weight Work in ...

Page 17: ...hen the resulting car should be a great handling sports car We have included an Icon key as the beginning of each section that contains useful information for each assembly that details the tools needed for that assembly what assembly in the kit parts are packaged in that are needed for that step and any useful information or warnings There are differences between the base kit which uses Mustang s...

Page 18: ... Most customers will send out the body and paint work to a professional body shop Fuel pump You are responsible for purchasing an external carbureted or fuel injected inline fuel pump Battery We recommend a battery sized for a Ford Mustang Wheels and Tires See the appendix for complete recommended sizes ...

Page 19: ...engraved on the 1 50 x 1 50 tube going across the car at the front of the cockpit Above is an example of how the nameplate looks The VIN number space is provided so that your state issued VIN number can be engraved if you so desire This can be engraved at any Trophy or mall engraver Optional part Instructions Part instructions for all Factory Five parts and options can be found online at www facto...

Page 20: ...rench set 3 8 15 16 Metric combination wrench set 10mm 18mm Standard and Phillips head screwdrivers Standard Hex key set Long nose pliers 4 5 Internal snap ring pliers Pop rivet tool with 1 8 and 3 16 heads Cordless Drill Drill bits 3 32 9 64 3 16 7 32 5 16 7 16 Caulk gun 24 oz Plastic Dead Blow hammer Razor knife Wire stripper crimping tool 1 and 2 hole saws Body cut outs Bench top vise Tape meas...

Page 21: ...nsmission fluid Mercon automatic Trans fluid 3 Qts Brake fluid DOT 3 1 Qt Oil filter Fuel filter Battery Spark plugs 5 minute epoxy glue Black permanent marker with pointed tip 2 ea 2 Masking Tape 1 roll Duct tape Electrical tape Bodywork supplies Rags Gojo pumice hand cleaner Spray paint for donor parts pick a color Acetone carburetor cleaner or other solvent Aluminum polish cleaner 3M Super 77 s...

Page 22: ...21 www factoryfive com 508 291 3443 Donor Parts and Prep Chapter 2 ...

Page 23: ...ned or driven 5 0L Mustang s feel that the car is the rightful heir to the legacy of the original high performance 289 Mustangs of the 60 s We saw the Mustang as more than just the functionally perfect donor car It is truly the spiritual successor to the factory muscle Fords of the 60 s The 289 block that beat Ferrari in 1965 still beats strong in each donor built Factory Five Coupe The lightweigh...

Page 24: ...to use older or newer donor parts call the FFR tech department and ask about what specific parts you can use If you go to a salvage yard for parts the donor parts list in the Appendix will help you check to see that you have procured all the required parts in order to avoid a return trip Try to get everything you need before you pay and leave We ve found that the average parts yard doesn t exactly...

Page 25: ...ts were stolen you need to have documentation on the origin and sale price Check the numbers twice The VIN numbers are located on the back of the engine block on a flat spot between the heads where the bell housing meets the block Some solvent or WD 40 can usually clean this area off enough to see the numbers The VIN numbers on the transmission are typically stamped on the side of the main transmi...

Page 26: ...recommend using only yokes from manual transmission cars the automatic cars have a weight that limits the universal joint movement The front spindles should be clean dry and have decent rotors and calipers without much dirt or crud accumulation There should be no deep grooves or huge flakes of rust inside the rotor contact area If you do have rotors with lots of rust inside the cooling fins you ar...

Page 27: ... pump area so that it will not spill fluid as the engine is removed later Remove the fan clutch from the water pump shaft so that it is sitting in the fan shroud Loosen the bolts on the brackets at the top of radiator Lift the radiator shroud and the fan up and out of the engine bay Discard the 1987 1993 fan Keep the shroud You will not need the 1987 1993 Mustang fan since a 16 electric fan is inc...

Page 28: ...m the firewall behind the engine Disconnect and remove the mass air sensor Store it with the computer Disconnect the throttle cable from the throttle body on the engine Cut the heater core hoses from the firewall on the passenger s side making sure to leave the bends intact on the larger hose so it can be used to complete the coolant circuit loop Napa sells a replacement heater hose loop part numb...

Page 29: ...wiring harness part in this section We recommend the use of a fuel inertia cut off switch in your car if using an electric fuel pump EEC IV computer and cradle Remove the kick panel in the passenger footbox Disconnect the ground strap in the footbox next to the computer Remove the computer and its plastic holder from the passenger footbox area Turn Signal and Ignition Switches Socket set extension...

Page 30: ...tify both ends of every connector that you disassemble The easy way to do this is to tape and number each side of the connector the same or use colored zip ties The connectors will only work if they re mated to the other similar shaped connector Almost every connector is different in the car so cross wiring is rare Labeling will help speed up the job later Remove the dash from the car Remove the w...

Page 31: ...screwdrivers needle nose pliers hammer and marker tape Front wiring harnesses Pull the rubber grommet out of the firewall into the engine bay Remove the front light harness from the engine bay wall working from the starter solenoid area to the alternator Unscrew any ground wires and mark the connectors Especially the headlight and turn signal lights as you go ...

Page 32: ...d dirt from entering Shifter and Shifter handle Socket set Phillips head screwdriver Shifter The kit comes with new bolts for the shifter handle so you don t need the OEM bolts Save them anyway according to rule 85 of the car guys handbook which states save any and all fasteners in rusty coffee cans This of course makes finding and using such fasteners in the future all but impossible but it makes...

Page 33: ... avoid cutting any leads Ford uses multiple grounds in circuits and cutting any line may interrupt a circuit Keep any all seemingly useless leads intact and handle harness with care If you decide to cut your harness down remove all non essential wires follow a wiring schematic Remove bulb bases from the rear light housings if they are still on your donor Use tape and a marker to label the wires Re...

Page 34: ...job Use extreme caution when moving engine assembly Work on a clear and level surface Remove the two large nuts that hold the engine mounts to the frame of the car The driver s side bolt hole is notched for ease of removal The passenger s side engine mount has a single bolt hole Disconnect the drive shaft from the rear end pinion Using a 12 point 12mm wrench or socket Remove the drive shaft carefu...

Page 35: ... transmission that must be removed All you need is the transmission mount with the two bolts sticking down Front Suspension Spring compression tool socket set wrenches breaker bar tubing cutter floor jack tire iron jack stands chain needle nose pliers rags ball joint removal tool or plastic dead blow hammer Brake calipers rotors spindles front lower control arms The front springs are compressed in...

Page 36: ...tool or dead blow hammer the ball joint through the spindle Remove the spindle from the car Remove the large bolts and nuts from the lower control arm mounts These bolts and nuts should not be heated get a big wrench and breaker bar to remove them Remove the lower control arm from the car Fuel Tank Socket set wrenches small flat head screwdrivers floor jack jack stands fuel line disconnect tool go...

Page 37: ... to the front of the car if you plan to use it Rear End Drill drill bit socket set wrenches duct tape tire iron floor jack and jack stands 8 8 rear end assembly complete with quad shocks and springs Rear brake assembly w lines OEM fasteners Quad shock fame brackets The rear end assembly weighs 225 lbs Use caution when removing this assembly Use extreme caution when removing any compressed coil spr...

Page 38: ...nes and fuel filter mount Remove the fuel filter and fuel filter mount from the frame Disconnect the rear fuel line going from the tank to the filter and store Cut the plastic return line hose going to the tank 4 from the tank and store Donor Part Preparation Solid Axle sockets wrench drill bit drill floor jack jack stands Torque Wrench 8 8 Rear axle assembly Solid axle adapters hardware Box Musta...

Page 39: ...already done fill the axle with gear oil See Appendix for specifications and capacities If using a used rear axle remove the lower shock mounts and the anti vibration weight under the pinion Drill the lower control arm holes out with a drill bit ...

Page 40: ...rms to mount the front shocks Front Lower Control Arms Hack saw file grinder Remove the area near the center of the spring mount to prevent damage to the coil over unit thru any contact whatsoever Attach the rear shock mount to the control arm through the hole in the spring seat with the small leg sticking up ...

Page 41: ... must move freely without contacting the control arm surface Fuel Filter Fittings Razor knife Donor plastic fuel line fittings from fuel filter to body hard line and from return line from body hard line to fuel tank Carefully without damaging the plastic barb cut the hard plastic off the plastic barbs ...

Page 42: ...ch side Remove the inner rubber hose Driveshaft Shortening a driveshaft is not for the Do it yourselfer Take the driveshaft to a professional shop to have it shortened to the drawing If you don t know of one ask a local auto parts store or search the yellow pages See appendix A for the driveshaft diagram to provide the shop with written instructions Make sure your machine shop puts new U joints on...

Page 43: ...ft side of the engine Thread all of the bolts on the headers before tightening any of them to make installation easier Alternate Drive Pulley Preparation Cordless drill drill bit needle nose pliers Alternate drive pulley template On 87 93 EFI cars the pulley and fan belt supplied replace the A C compressor and power steering pump If you are planning on using under drive pulleys do not use the temp...

Page 44: ...dispose of properly Steam clean or use a strong detergent such as Gunk engine cleaner If the parts are really dirty you can take the parts and assemblies to a do it yourself car wash They usually have an engine degreaser as an option and most places run very high water temperature that helps loosen debris and grease If doing this tape over the engine intake holes engine wiring connectors and coola...

Page 45: ...44 www factoryfive com 508 291 3443 spark plug reveals about the engine s performance When replacing the spark plugs make sure you gap them before installing them ...

Page 46: ...45 www factoryfive com 508 291 3443 Disassembly of the kit Chapter 3 ...

Page 47: ...R FRAMES EA 2 00 60347 48 DOOR HINGE ARM EA 2 00 13565 HINGE ADJUSTER BRACKET EA 2 00 15176 E BRAKE LOWER HANDLE ASSEMBLY EA 1 00 14788 WILWOOD BRAKE LIGHT SWITCH MOUNT EA 1 00 13551 EXHAUST FRAME MOUNT ASSEMBLY EA 2 00 60391 NOSE HINGE BRACKET ASSEMBLY EA 2 00 60525 LEFT SIDE HATCH HINGE MOUNT EA 1 00 60526 RIGHT SIDE HATCH HINGE MOUNT EA 1 00 15224 REAR HATCH HINGE ARM FRAME SIDE EA 2 00 15252 R...

Page 48: ...47 www factoryfive com 508 291 3443 Remove the duct tape from the kit Remove the nose and rear hatch Unscrew the body in the door openings using a 5 16 socket and ratchet or 5 16 nut driver ...

Page 49: ...st recess and the rear wheel well Carefully pull the front sides of the body out and up around the door hinge mounts while at the same time lifting the rear of the body Rotate the back of the body down and the front up once the back is clear of the frame ...

Page 50: ...tored on the ground outside Area set up Jack stands garage Use jack stands to position your frame in your workspace with plenty of room to move and walk around the whole frame Aluminum Prep and removal nut driver black or blue marker Do one panel at a time Be careful of the sharp aluminum edges they can cut you ...

Page 51: ...f space or interference then make a small note not to drill in that area This is done to locate where to drill rivet holes when the panels are permanently mounted later on Mark each panel and take pictures of how the panels fit together i e which is on top Remove each panel after it has been marked until the chassis is bare Keep the 8 screws to help with the aluminum positioning later during build...

Page 52: ...51 www factoryfive com 508 291 3443 Aluminum panel diagram ...

Page 53: ... REAR INSIDE SPLASH RT 1 23 60143 FOOTBOX TOP 2 24 60125 60150 FOOTBOX OUTSIDE WALL RIGHT 1 25 60128 60168 COCKPIT FLOOR RIGHT 1 26 60502 RIGHT FOOTBOX FRONT 1 27 60148 FOOTBOX INSIDE UPPER WALL RIGHT 1 28 60146 FOOTBOX INSIDE LOWER WALL RIGHT 1 29 12959 BLOCK OFF PLATE 2 30 60314 DASH 1 31 60315 PLATINUM GAUGE PANEL 1 32 60316 GAUGE VISOR 1 33 60273 FOOTBOX OUTSIDE NOSE MOUNT COVER 2 34 60274 605...

Page 54: ...53 www factoryfive com 508 291 3443 Chassis Assembly Chapter 4 ...

Page 55: ...hings Steering rack extensions Pull back the rubber boot on the inner tie rod and remove the inner tie rod from the steering rack The inner Tie Rod Extensions are for stock Power Steering Racks only The inner Tie Rod Extensions are not for the FFR manual steering rack The inner Tie Rod Extensions are not for the optional FFR power steering rack If using the power rack and you have not already done...

Page 56: ...f the steering rack Attach the steering rack extension to the steering rack using a 1 50 wrench and tighten Put a dot of thread lock on the threads of the steering rack extension and attach the Mustang inner tie rods to the steering rack Push the boot back onto the steering rack body and attach with zip ties ...

Page 57: ...e com 508 291 3443 manual or optional power steering rack prep Factory Five Manual and power racks are installed in a similar way Unpack the steering rack assembly Push the bushings into the mounting bosses on the rack ...

Page 58: ...making them as flush as possible with the surface of the bushing Screw the grease nipple into the outer tie rod end Thread the outer tie rod and jam nut 1 2 down onto the steering rack inner tie rod The outer tie rods may come with either a castle nut and cotter pin or a nylon locknut ...

Page 59: ...ve com 508 291 3443 Steering rack install wrench socket ratchet Lower the rack into the chassis right side first Allow the rack to drop far enough into the opening to swing the other side down into its mounting bracket ...

Page 60: ...ve com 508 291 3443 Locate the rack between the mounting brackets Locate the x 4 steering rack bolts washers and locknuts There are two sets of mounting holes lower for standard street car ride height Top for race car ...

Page 61: ...street car ride height use the lower set of holes to mount the steering rack Use a wrench and ratchet to fully tighten the steering rack Front Suspension Front lower control arm socket 5 16 15 16 wrenches Torque wrench Front lower control arm assembly ...

Page 62: ...com 508 291 3443 Unpack the front lower control arms and hardware Screw the grease fittings into the arms using a 5 16 wrench There are two sets of mounting holes lower for standard street car ride height Top for race car ...

Page 63: ...er set of holes line up with the control arm bushing sleeves and insert the front mounting bolt The rear bushing mount on the chassis is wider use one of the large washers as a shim to take up the extra space on the backside of the rear bushing attach the nuts and tighten the lower arms ...

Page 64: ... ride characteristics WARNING Incorrect assembly and maintenance of this part can cause serious injury or death The front shocks extended measurement is 15 15 center to center They are 2 50 shorter than solid axle rear shocks Unpack the front shocks coil over kit and hardware Double check the jam nut under the rod end and bump stop to make sure that it is tight Screw the spring seat down on the sl...

Page 65: ...olds it in place Remove this snap ring to assemble the coil over shock Slide the rubber bumper about two inches down on the shaft Put the spring and hat on the shock and rotate the spring seat back up the sleeve so that the spring pushes the hat tight against the end of the shock ...

Page 66: ...re not aligned Front shock installation If using the silver double adjustable shocks these must be mounted with the body of the shock down in the top hole location for both street and race cars For the stock red Koni shocks there are two sets of mounting holes lower for standard street car ride height Top for race car wrench socket Ratchet Torque wrench Front shock set IFS Components ...

Page 67: ...3443 Locate the coil over mounting hardware in the kit At the upper shock location using the longer 3 25 bolt and a washer thread it through the lower mounting hole in the frame and install one of the four longer 0 675 spacers on it ...

Page 68: ... location for both street and race cars For the stock red Koni shocks there are two sets of mounting holes lower for standard street car ride height Top for race car Install the coil over shock and a second longer 0 675 spacer on the bolt and thread the bolt through the back mounting bracket and loosely thread a nut onto the bolt to hold it in place ...

Page 69: ...508 291 3443 Using the shorter 2 75 bolt and shorter 0 40 spacers repeat the process for the lower control arm mount and hand tighten the locknut to hold in place The coil over should now be holding the arm in place as shown ...

Page 70: ...43 Run zip ties through the holes in the spring hat and around the spring to prevent the spring from becoming unseated Torque the upper and lower mounting bolts for the coil overs to 40 ft lbs and repeat for the other side of the frame ...

Page 71: ...ead locker wrench socket Torque wrench IFS components Unpack the upper control arm assembly Start threading the upper ball joints into the control arms so that the balljoint angles out on the bottom The arms are the same side to side so they will not appear symmetrical ...

Page 72: ...71 www factoryfive com 508 291 3443 Use a little red Loctite on the balljoint threads If you do not have a balljoint socket clamp the balljoint in a vice and use the arm itself for leverage to tighten ...

Page 73: ...72 www factoryfive com 508 291 3443 Screw the grease fittings in to the ball joints and tighten with a wrench Unpack the upper control arm mounting hardware ...

Page 74: ... one of the inner bolts from the upper control arms and wrap the cross shaft of the arm around behind the coil over Slide the cross shaft in between the two mounting flanges and thread the mounting bolts into place with the nuts on finger tight ...

Page 75: ...e to 135 149Nm 100 110 lbft Pivot endplay Adjust the locknuts on the ends of the pivot shaft so that there is minimal endplay but so the pivots can still rotate easily on the shaft The control arm should just drop slowly under its own weight when you hold it out straight and let it go The pivots may be a little stiff at first but once on the car they will loosen slightly Adjusting the upper contro...

Page 76: ... take grease the endplay may be too tight There should never be more than 1 of thread showing past the tightened down jam nuts on either end of both adjusting tubes The Pivot Bolts must be loosened while the car is being aligned and retightened afterwards Spindles Donor Spindles 13 16 socket Torque wrench Needle Nose Pliers Rubber Mallet IFS components Mustang Spindles Make sure the grease boot is...

Page 77: ...er Side Spindle These refer to the way they are mounted on the FFR Hot Rod which is rear steer The FFR Coupe uses these as Front steer so they are mounted opposite The DSS spindle is mounted on the right side and the PSS spindle is mounted on the left side Make sure the grease boot is in place on the balljoint then mount the spindle to the lower control arm ...

Page 78: ...correct height Torque to 106 149Nm 80 110 lbft and install the cotter pin Attach the upper ball joint to the spindle and torque to 75 ft lbs and install the cotter pin The upper ball joint boot will look crushed and out of shape when the car is in the air this is OK The boot will seat when the car is on the ground ...

Page 79: ...nt from the bottom the taper on the hole will open out toward the bottom and the kink in the arm angles the arm outward toward the rotor Torque to 60 ft lbs The hub is a snug fit on the spindle and may require a light tap with a soft mallet to get in place Torque the hub nut to 305 338Nm 225 250 ft lbs ...

Page 80: ...oryfive com 508 291 3443 Using a large socket or a flat head screwdriver and rubber mallet hit the dust cap onto the hub IFS Bracket IFS components Mustang strut bolts These are not used in the complete Coupe kit ...

Page 81: ...y strut bolts and torque to 135 149Nm 100 110 lbft Attach the upper ball joint to the spindle and torque to 75 ft lbs and install the cotter pin The upper ball joint boot will look crushed and out of shape when the car is in the air this is OK The boot will seat when the car is on the ground Front Suspension Torque Specs Chart Item Nm Lbft Front lower control arm to frame 135 162 100 110 Front low...

Page 82: ... Tie Rod Ends Some tie rods have the nylon locknuts and others have the castle nuts with cotter pins both are correct Attach the tie rod to the spindle torque the nut to 25 ft lbs If a castle nut is used torque the nut then install the cotter pin ...

Page 83: ...e spindle Push the outer bearing on then the flat washer and adjusting nut Adjust the bearing play Attach the nut lock and insert a cotter pin Using a large socket or a flat head screwdriver and rubber mallet hit the dust cap onto the rotor Clean the rotor with brake cleaner Install the caliper on the spindle make sure that the fluid bleeder is at the top of the caliper Torque the caliper mounting...

Page 84: ...83 www factoryfive com 508 291 3443 Install the caliper slider pins on the caliper using the supplied bolts and a 16mm wrench and 12mm socket Torque to 23 26 ft lbs ...

Page 85: ...84 www factoryfive com 508 291 3443 Install the slider grease boots on the slider pins ...

Page 86: ...85 www factoryfive com 508 291 3443 ...

Page 87: ...x steel clips that are designed to separate the pads from the caliper These clips allow the pads to slide on a smooth surface and not wear on the caliper The four clips that go on the ends of the hanger are different end to end and must be installed with the long tab facing out ...

Page 88: ...center hole Insert the clip from the inside of the caliper through the large center hole with the larger tab on the side facing the pistons then press down on the outer part of the clip so the small clip goes through the large hole and clips on Grease the slide pins using the supplied grease Slide the caliper hanger onto the caliper ...

Page 89: ...he slider bolts correctly Look at the back side of each brake pad to find the inside pads and the outside pads The difference is the location of the studs that are on the back of each pad The studs on the inside pads are out near the ends of the pad while the studs on the outside pads are near the middle ...

Page 90: ...89 www factoryfive com 508 291 3443 ...

Page 91: ...90 www factoryfive com 508 291 3443 Install the brake pads in the Caliper Clean the rotor with brake cleaner and push it onto the hub ...

Page 92: ...91 www factoryfive com 508 291 3443 Install the caliper on the spindle make sure that the fluid bleeder is at the top of the caliper Torque the caliper mounting bolts to 130Nm 95 ft lb ...

Page 93: ...11 Solid axle Traction Lok brackets Rear control arms Use caution when working with the rear end assembly it weighs 225 lbs Two bolts for the lower control arms are included in the kit with the Traction Lok Brackets The other two bolts are included with the optional control arms If not on the axle attach the desired rear brakes to the axle Check out the Appendix for the optional FFR brake install ...

Page 94: ...lready done fill the axle with gear oil See Appendix for specifications and capacities If using a used rear axle remove the lower shock mounts and the anti vibration weight under the pinion Drill the lower control arm mount holes with a drill bit ...

Page 95: ...94 www factoryfive com 508 291 3443 Position the Traction Lok brackets on the rear end with the bolts provided the two short bolts go on the sides Axle Bracket left side ...

Page 96: ...95 www factoryfive com 508 291 3443 Axle Bracket right side Temporarily put the lower shock bolt through the traction lock bracket and stock shock hole on the axle ...

Page 97: ...3 Tighten the two short bolts Torque to 75 95 Nm 55 70 lbft Attach the lower control arms to the brackets on the axle using the bolt provided Torque to 101 111Nm 75 82 lbft The lower bolt holes provide more traction than the upper holes ...

Page 98: ...g the Mustang hardware Skip the 3 Link section and continue on with the rear axle installation section Optional 3 Link Rear Suspension 3 16 drill bits 15 16 1 wrenches 15 16 sockets 5 16 Hex key Ratchet Torque Wrench Drill Ruler Tape measure Pliers Flat head Screwdriver Tin Snips scissors razor Marker 3 Link rear suspension with kit The Panhard bar frame mount is mounted to the chassis during ship...

Page 99: ...he upper link bracket is welded to the axle Test fit the two halves of the upper arm mount together If it is hard to put all of the bolts in the mount holes put in as many as you can then use a drill bit through the remaining bolt holes Attach the upper link bracket onto the axle using the fine hardware FFR 12217 12218 ...

Page 100: ...the upper link axle mount attaches to the hole on the flange section of the pumpkin This hole has some variance and may need to be drilled out from the bottom side using the mount as a guide Attach the front of the upper link axle mount to the front axle flange ...

Page 101: ...wo of them are left hand thread Insert the rod ends into the swedged tubes one is right hand thread and one is left hand thread The longer tube is the Panhard bar and the shorter one is the upper link Attach the short upper link tube to the axle upper link mount using the spacers on either side of the rod end ...

Page 102: ...art can cause serious injury or death If using the silver double adjustable shocks these must be mounted with the body of the shock down Unpack the rear shocks coil over s and hardware Double check the jam nut under the rod end and bump stop to make sure that it is tight Screw the spring seat down on the sleeve so it is closer to the unthreaded end The center high part of the set should be pointed...

Page 103: ...ssemble the coil over shock Slide the rubber bumper about two inches down on the shaft Put the spring on the shock then install the spring hat on the shaft end of the shock and push the rubber bumper up against it Rotate the spring seat back up the sleeve so that the spring pushes the hat tight against the end of the shock ...

Page 104: ...ing and the slot in the spring hat are not aligned Use zip ties to hold the spring to the spring hat Assembled solid axle Koni coil over shock Rear Axle installation Solid axle shock mounting components wrench socket ratchet torque wrench floor jack Have someone help with this step the rear axle is very heavy and mistakes can result in serious injury ...

Page 105: ... 3 link shown Make sure that the rear jack stands are positioned under the frame as far back as possible to prevent the frame from tipping up once the axle is mounted Do not hold the end of the axle from the bottom of the disc if the axle falls the axle can crush your fingers and result in serious injury ...

Page 106: ...3 With one person holding one side of the axle raise the axle so that the lower control arms can be bolted onto the frame Attach the lower control arms to the frame mounts using the OEM bolts or bolts supplied with the lower control arms ...

Page 107: ... the frame If using the silver double adjustable shocks these must be mounted with the body of the shock down in the top hole location for both street and race cars For the stock red Koni shocks there are two sets of mounting holes lower for standard street car ride height Top for race car ...

Page 108: ...he body end of the shock to the frame using the lower shock mount hole two 1 09 spacers along with the x 4 00 bolts and locknuts Jack the rear axle up so the rod end of the shocks can be mounted on the axle through the shock mount hole Right side ...

Page 109: ...each lower shock mount From the rear the bolt goes through the bracket shim shock then the long spacer 1 09 followed by the bracket and axle Use a socket and Torque wrench to tighten both upper and lower mounts to 40 ft lbs Check to make sure that the spring is seated correctly on the shock ...

Page 110: ...he spring from becoming unseated 4 link Rear Suspension Torque Specs Chart Item Nm Lbft Upper control arm to axle 101 111 75 82 Upper control arm to frame 101 111 75 82 Lower control arm to axle 101 111 75 82 Lower control arm to frame 101 111 75 82 Upper shock to frame 54 67 40 50 Lower shock to axle bracket 54 67 40 50 ...

Page 111: ...110 www factoryfive com 508 291 3443 For a 4 link car loosely mount all 4 arms and then lift axle until lower arms are flat to torque the mounting hardware ...

Page 112: ...bber fuel line to the vent tube on the rear axle or center section Tie the top of the tube up high under the trunk allowing room for the axle to move If running a 4 link skip to the next section 3 link Panhard Bar Frame mount The Panhard bar frame mount is mounted to the chassis during shipping ...

Page 113: ...508 291 3443 With the axle jacked up attach the Panhard Bar frame mount to the inside of the quad shock brackets the forward leg will attach to the back of the angled 2 x 3 tube Do not tighten the quad shock bracket bolts yet ...

Page 114: ...ill through the sleeve on the mount Make sure before drilling that the hole is away from the side of the 2 x 3 tube so that a nut can be attached on the back of the bolt from the bottom of the tube Install the 13 x 2 5 bolt and tighten Tighten the bolts on the quad shock brackets ...

Page 115: ...ts to the car using the x 3 bolts and spacers Install the Panhard bar to the right side traction lock bracket Three spacers are used in the front 2 0 375 FFR 14064 and 1 0 25 FFR 14065 The rear uses the thin 0 0625 shim FFR 13337 It will be necessary to adjust the length some to fit make sure that you adjust the same amount on both sides There should never be less than of threads screwed into eith...

Page 116: ...adjust this to fit your particular set up The Panhard bar can center the axle left to right in the frame At ride height level the Panhard bar as much as possible Double check all your nuts and bolts and make sure that all four jam nuts are tight 3 link Rear Suspension Torque Specs Chart Item Nm Lbft Upper link to axle 101 111 75 82 Upper link to frame 101 111 75 82 Lower control arm to axle 101 11...

Page 117: ...il over shocks Springs Fasteners Driveshaft adapter Philips head screwdriver 5 8 Drill bit 13 16 15 16 wrenches 13 16 15 16 18mm Sockets Large adjustable wrench up to 15 8 1 8 Hex Key Marker Ruler Hacksaw Drill Plastic mallet Hammer Torque wrench Parts needed 2015 or newer Ford Mustang IRS parts Super 8 8 center section L R spindles L R brake parts ...

Page 118: ...20mm Solid rotor 45mm single piston aluminum caliper 12 6 320mm Solid rotor 45mm single piston aluminum caliper 13 0 330mm Vented rotor 45mm single piston iron caliper Parts preparation Spindles 5 8 drill bit drill saw marker Remove the brake calipers from the spindle if they are mounted They will be reinstalled after the spindle is put on the car Use a 5 8 drill bit to drill out the tapered hole ...

Page 119: ...t the top just to the inside of the top inside hole down to the corner of the small boss at the bottom of the ear Use a saw to cut the ear off the spindle If using a Sawzall or similar use a wood blade a 14tpi blade or finer will just get gummed up with the aluminum ...

Page 120: ...het 20 lugnut torque wrench Rear wheel studs Removal of the hub from the spindle is not necessary but can make things easier Use a vise to lightly hold the side of the wheel stud head then use a hammer to bang out the Mustang studs Repeat for all of the studs ...

Page 121: ...e com 508 291 3443 Insert one of the included wheel studs into the hub from the back and use a washer and lug nut on the front side Use a ratchet to draw the wheel stud into the hub and torque the stud to 135Nm 100lb ft ...

Page 122: ...121 www factoryfive com 508 291 3443 Repeat for the other wheel studs If the Hub was removed use Loctite on the threads and reattach to the spindle Torque the bolts to 133Nm 98ft lb ...

Page 123: ...2 www factoryfive com 508 291 3443 Center section 5 8 drill bit drill Use a 5 8 drill bit to chase the front mount holes on the center section Frame Rubber plastic mallet Differential mounting components ...

Page 124: ...123 www factoryfive com 508 291 3443 Bushing locations Use a plastic mallet to install the polyurethane bushings marked 2048 and the longer 31 16 sleeves where the front of the center section will mount ...

Page 125: ...com 508 291 3443 Use a plastic mallet to install the polyurethane bushings marked 2123 and the shorter 2 40 sleeves where the rear of the center section will mount Upper control arms Upper control arm components Grease gun ...

Page 126: ... Grease the control arms using chassis grease until the grease comes out of the flutes in the bushings next to the pivot sleeves Lower control arms Grease gun Grease the control arms using chassis grease until the grease comes out of the flutes in the bushings next to the pivot sleeves ...

Page 127: ... arms Assemble each of the toe adjustment arms as shown Installation Center section Rubber plastic mallet torque wrench 18mm 13 16 sockets 15 16 wrench Differential mounting components Use a friend to help with the heavy center section in the next steps ...

Page 128: ...127 www factoryfive com 508 291 3443 Use rags to protect between the front center section mount on the frame ...

Page 129: ...128 www factoryfive com 508 291 3443 With the help of a friend lift the center section nose up into the frame and over the front mount ...

Page 130: ...rizontal then back it up so it is above the mount locations and lower it down so the bolts can be installed The smaller shorter bolts are used for the rear mounts The larger longer bolts and nuts are used for the front mounts Torque both the front and rear bolts to 135Nm 100 ft lb ...

Page 131: ... the frame mount bracket when installing the toe arms Attach the toe arms to the frame below the front lower arm mount using the 1 8 thick spacer in the back and the spacer on the front side of the rod end Use the 5 8 x 2 25 bolts to attach them to the frame Torque bolts to 135Nm 100 ft lb Lower control arms IRS lower control arm components 13 16 socket 15 16 wrench torque wrench ...

Page 132: ...the frame with the shock mount towards the rear and spindle brackets up Use the longer M16 x 110mm 45 16 bolts Hold the arm horizontal and torque the bolts to 135Nm 100 ft lb Upper control arms IRS upper control arm components 13 16 socket 15 16 wrench torque wrench ...

Page 133: ...triangular area as shown in between the frame mounts Use the longer M16 x 110mm 45 16 bolts Hold the arm horizontal and torque the bolts to 135Nm 100 ft lb CV Axle CV Axles spindles The inside CV joint is different for each side of the car make sure to use the correct one when installing ...

Page 134: ...ter section When fully installed there should be an 1 8 3mm gap between the inside of the CV joint and the center section If necessary compress the CV axle and with the CV axle nut on the end hit the CV axle in with a plastic mallet Pull on the inner CV joint to make sure that it does not come out ...

Page 135: ...134 www factoryfive com 508 291 3443 Slide the spindle onto the outer CV joint and start the nut on the end ...

Page 136: ... com 508 291 3443 Spindle to Lower arm Connect the bottom of the spindle to the lower control arm using the M16 x 90mm bolts and locknuts Right side shown Wait to torque the bolts until after the other arms are installed ...

Page 137: ...ve com 508 291 3443 Spindle to Upper arm Insert the angled mount adapter into the upper arm rod end Reuse the 5 8 washer that was on the old bolt and place it on the new 5 8 x 4 25 bolt along with a misalignment spacer ...

Page 138: ...291 3443 Attach the upper control arm to the spindle using the bolt with the misalignment spacer Use a 15 16 wrench 15 16 socket and ratchet to tighten the locknut Wait to torque the bolts until after the other arms are installed ...

Page 139: ...138 www factoryfive com 508 291 3443 Check the angle of the upper control arm rod end make sure that the rod end is not touching the spindle and that it is aligned with the upper control arm ...

Page 140: ...cket Ratchet floor jack Shock set Insulated clip hardware The shocks are pre valved at the factory in compression and rebound for good street use The shocks can be adjusted in rebound as per Koni s instructions if so desired The Roadster Coupe IRS springs are 400lb Other springs are available for different ride characteristics WARNING Incorrect assembly and maintenance of this part can cause serio...

Page 141: ... and bump stop to make sure that it is tight Screw the spring seat down on the sleeve so it is closer to the unthreaded end Slide the coil sleeve over the body of the damper beginning at the end which has the rubber bump stop The unthreaded end of the sleeve goes first so that it will sit on the snap ring on the shock body ...

Page 142: ...holds it in place Remove this snap ring to assemble the coil over shock Slide the rubber bumper about two inches down on the shaft Put the spring and hat on the shock and rotate the spring seat back up the sleeve so that the spring pushes the hat tight against the end of the shock ...

Page 143: ... hat so that it holds onto the shock end Make sure that the slot in the snap ring and the slot in the spring hat are not aligned Attach the rod end of the shock to the upper shock mount using the two equal length 1 09 kit spacers Torque the upper shock bolt to 54Nm 40 ft lb ...

Page 144: ... in front of the shock Torque the lower shock bolt to 54Nm 40 ft lb Remove the floor jack Driveshaft adapter There are two different Driveshaft adapters one for center sections from automatic cars which is coated clear zinc The Driveshaft adapter for center sections from manual cars is coated yellow zinc Driveshaft adapter fasteners 8mm hex socket torque wrench Loctite Apply the emergency brake ...

Page 145: ...ww factoryfive com 508 291 3443 Apply Loctite to the 6 M10 x 25mm socket head screws Attach the driveshaft adapter to the center section pinion flange and torque the bolts in a star pattern to 55Nm 41 ft lb ...

Page 146: ...5 to 0 75 Total Toe 1 8 in or 0 28 in Torque Specifications LB FT Nm CENTER SECTION TO FRAME FRONT 129 175 CENTER SECTION TO FRAME REAR 129 175 BRAKE CALIPER TO CALIPER BRACKET 24 32 BRAKE CALIPER BRACKET TO SPINDLE 129 175 BRAKE HOSE BANJO BOLT TO CALIPER 29 39 LOWER CONTROL ARM TO FRAME 100 135 LOWER CONTROL ARM TO SPINDLE 100 135 TOE LINK TO FRAME 100 135 TOE LINK TO SPINDLE 100 135 UPPER CONTR...

Page 147: ...to the brake caliper Torque the banjo bolt to 39 Nm 29 ft lb Run the brake hose over to the frame while the suspension is in droop and keep the brake line slack to locate the frame mount Run the hard brake lines in the kit to the brake line mount The e brake cables are mounted later with the e brake handle Fuel System Insulated clip hardware Fuel line components 5 16 fuel lines OEM fuel tank compo...

Page 148: ...147 www factoryfive com 508 291 3443 Unpack the fuel strap fasteners Unpack the square plastic end caps from the secondary body fasteners ...

Page 149: ...148 www factoryfive com 508 291 3443 Push the two plastic end caps into the tubes hanging down in front of the gas tank area Put the Fuel tank bolts in the gas tank front frame mounts ...

Page 150: ... 508 291 3443 Hang the fuel tank straps from the rear mount of the chassis using two of the strap fasteners The longer strap goes on the right side Do not tighten the nuts Fuel filler neck Marker tape measure saw razor knife ...

Page 151: ...150 www factoryfive com 508 291 3443 Unpack the OEM fuel tank components including the tank and straps Insert the large rubber filler neck gasket in the side of the tank ...

Page 152: ...1 www factoryfive com 508 291 3443 Use a ruler or wall and a tape measure to measure 6 50 and 8 50 up from the bottom edge of the filler tube and mark the tube Cut the filler tube on the two places marked ...

Page 153: ...arts com instructions for in tank fuel pump set up Prep If the car will have a high horsepower fuel injected engine there are a few tweaks we recommend get done to the fuel pick up Drill pliers 1 8 5 32 9 32 or 19 64 drill bits Remove and discard the rubber piece on the end of the return line this can affect the fuel pressure at the engine ...

Page 154: ...it drill out the end of the send line then change to a 9 32 or 19 64 drill bit the pressed end is a little restrictive Starting with a drill bit drill out the end of the return line then change to a 9 32 or 19 64 drill bit the pressed end is a little restrictive ...

Page 155: ...iled O ring sent with the pick up Set the rubber O ring in place for the fuel pump pickup Slide the pickup down into the tank you will have to rotate as you go to get the tubes into the sump and line up the tabs on the pick up and slots on the tank You can see this looking through the filler neck hole ...

Page 156: ...155 www factoryfive com 508 291 3443 ...

Page 157: ... the mounting collar and tap tightly into place with a punch and hammer Make sure that the lock ring is held by all three locking tabs on the tank or the sender will leak Fuel Gauge Sender Use the O ring included with the kit not the square profiled O ring sent with the sender ...

Page 158: ...157 www factoryfive com 508 291 3443 Set the rubber O ring in place for the fuel level sending unit Insert the fuel level sender into the tank ...

Page 159: ...158 www factoryfive com 508 291 3443 Tap the locking ring tightly into place with a punch and hammer Make sure that the lock ring is held by all three locking tabs on the tank or the sender will leak ...

Page 160: ...yfive com 508 291 3443 Fuel Tank Vent 5 16 sockets ratchet 7 8 wrench razor knife vise Screw the vent into the plastic bushing and tighten Insert the small rubber vent gasket in the small hole on the top of the tank ...

Page 161: ... vent into the grommet A little oil or WD40 on the rubber gasket helps Slide the lower filler tube section into the tank A little oil or WD40 on the rubber gasket helps Put masking tape over the end of the tube so that nothing drops into the tank ...

Page 162: ...m 508 291 3443 Slide the retaining bracket down the filler tube and mark its mounting location on the tank Move the retainer out of the way and make sure your mark is outside the weld that holds the two tank halves together ...

Page 163: ...ole through the tank flange on the mark made Remove the filler neck tube Fuel Tank install 9 16 wrench 9 16 deep socket ratchet At the locations on the tank where the tank straps come near the tank use a pair of pliers and bend the bent parts flat ...

Page 164: ...163 www factoryfive com 508 291 3443 Put the metal tank in the plastic tank cover With the help of a friend or using a jack in the center of the tank raise the tank up into place on the chassis ...

Page 165: ...164 www factoryfive com 508 291 3443 Bolt the straps in with the strap fasteners and drop the jack if used Fuel filler neck Insert the fuel filler neck into the fuel tank ...

Page 166: ...165 www factoryfive com 508 291 3443 Use the bolt and locknut to attach the retainer to the tank Fuel filter Unpack the fuel filter and mounting hardware ...

Page 167: ...08 291 3443 Open the hose clamp and slide it through the slots in the mount and start to tighten it back up into a hoop just bigger than the filter Clamp the filter in place on the mount with the filter flange oriented as shown ...

Page 168: ...end can attach to either end as shown here we have attached it to the tank Line the filter up to the chassis tube the back of the bracket should be no more than 9 inches behind the rear shock mount tab to leave room for the splash panel Hold up the bracket and mark the holes then drill and rivet the bracket on using 3 16 rivets Aftermarket filter shown ...

Page 169: ...es and the fuel line assembly which is in the secondary chassis components box The larger 5 16 line is the send fuel line to the engine If you are running a return system then there is line provided for that as well There are barbed fittings are provided for both sizes ...

Page 170: ...gh slack in the rubber hoses for the engine to move Which side you run down may depend on where you are hooking up to your fuel rail carburetor or pressure regulator These pictures show a crate engine Coyote which has a the fuel rail hook up on the left side of the engine Use the flexible line 5 16 flexible line and fuel injection hose clamps to connect the nylon fuel line connectors to the hard l...

Page 171: ...d line up to the front of the transmission tunnel Finish running your fuel system by hooking up either to your carburetor fuel rail or fuel pressure regulator Here we mounted a pressure regulator on the firewall and ran a single line over to the rail ...

Page 172: ... 291 3443 Connect the return line to the fuel tank Vent hose Attach a 25 section of 5 16 fuel line and fuel line clamp onto the vent then run the vent hose down to the tube near the vent and attach it to the tube using a zip tie ...

Page 173: ... for a cable clutch installation are included below Unpack the pedal box assembly Now is a good time to paint all of the bare steel brackets The pedal box comes with two pedal switches one for the brake lights and the other can be used as a clutch safety switch used to prevent starting the car while in gear if desired Brake and clutch safety switch mounts Using the brake light switch mount tabs ma...

Page 174: ...173 www factoryfive com 508 291 3443 Repeat the marking for the switch in front of the clutch pedal Drill the two holes you have marked out with a 3 16 drill bit ...

Page 175: ...4 www factoryfive com 508 291 3443 Attach the switch mounts to the pedal box using the black 10 screw and locknut Connect the switches to the switch mount using a hex nut on each side of the mount bracket ...

Page 176: ...www factoryfive com 508 291 3443 Clutch Cable Quadrant 3 16 5 16 hex keys 9 16 wrenches socket ratchet file external snap ring pliers Assemble the clutch quadrant to the Wilwood clutch pedal as shown above ...

Page 177: ...actoryfive com 508 291 3443 Use snap ring pliers to remove the clevis at the top of the clutch pedal If necessary use a file to remove the forging centerline so the 3 8 bolt can go through the clutch pedal hole ...

Page 178: ...6 wrench drill bit drill 5 32 hex key Pedalbox left side mount Place the pedal box assembly in the driver s footbox Make sure that the left side of the pedalbox sits on top of the frame mount and the right side goes on top of the front mount and under the rear mount as shown above ...

Page 179: ...ch the Wilwood pedals to the mounting brackets using four 5 16 Button head screws locknuts 3 16 hex key and wrench Attach the 60193 pedalbox top mount to the top of the pedalbox using the stainless x 0 50 flange head screws and a 5 32 hex key ...

Page 180: ...ive com 508 291 3443 Drill through the 1 frame tube through the bracket mounting holes using a drill bit Attach the pedalbox mount to the tube using the x 1 25 bolts and nuts along with a 7 16 socket ratchet and wrench ...

Page 181: ...6mm socket deep socket ratchet wrench saw Master cylinders With the jam nut on the threaded shaft cut 5 8 off each of the master cylinders Screw the 90 brake line adapter into the end of the master cylinder making sure that the opening points up when tight ...

Page 182: ...nto the threaded mount on the brake pedal As a starting point thread the shaft in until you can see it is flush on the other side of the mount Repeat this for the 5 8 master cylinder in the right master cylinder mount location The brake pedal master cylinder pushrod mounts are different from each other Only one has a screw and nut This is normal ...

Page 183: ...e locknuts using a wrench and deep socket holding the master cylinder to the pedal box then repeat for the other master cylinder Put the plastic angled inlet adapter with hose clamp on the master cylinders Use a 6mm socket and ratchet to tighten the hose clamp ...

Page 184: ...he other To set up the balance bar thread the master cylinder pushrods through their respective clevises to obtain the desired position Threading one pushrod into its respective clevis means threading the other one out the same amount Sometimes this will lead to a cocked balance bar when the pedal is in the relaxed position no pedal effort This is acceptable as long as each master cylinder pushrod...

Page 185: ...slight movement not loose movement Master cylinder pistons should be against the retaining snap ring under boot Accelerator Pedal OEM Mustang 3 16 hex key 7 16 wrench pliers marker OEM accelerator pedal accelerator cable components Hold the accelerator pedal up to the mount on the front of the foot box The higher you can mount the pedal the better the pedal will be positioned on your foot Make sur...

Page 186: ... cable components accelerator pedal components pedal box hardware The Accelerator cable is designed to be used with all types of engines carbureted or fuel injected The stock cable has the barrel end on it for the 4 6L throttle body and the ball for a Mustang accelerator pedal If installing a Coyote or other throttle by wire engine skip this section Unpack the throttle pedal and separate the arms ...

Page 187: ... from the pedal box hardware position the accelerator pedal so that the pedal pad is at a comfortable height on your foot and there is still room at the top of the accelerator pedal on the front of the footbox for the accelerator cable to come through Mark the accelerator pedal mount holes then drill the plate ...

Page 188: ...nuts Rotate the pedal so the top of the pedal where the accelerator cable will attach is 1 50 away from the front of the footbox and mark the front of the footbox directly in front of the ball stud Drill a 5 16 hole at the point marked on the footbox If running a 4 6L engine do not do the next step ...

Page 189: ...cylinder end off Make sure your cutters are very sharp so as not to fray the cable Pull the inner cable completely out of the sheath and thread it through hole in the top of the throttle pedal and then the cable retaining lock nut from the accelerator cable components assembly ...

Page 190: ...sheath back over the cable Tighten the cable sheath to the firewall with the retaining nut A piece of tape on the end of the cable will help prevent it from backing out of the sheath Check the full range of the accelerator pedal travel to ensure that there are no interferences with the pedal or travel ...

Page 191: ...is hole spacing marked The distance from the edge of the tool to the holes is correct to center the rivets on the tubes Use the rivets for all of the aluminum panels unless otherwise directed Align the edge of the tool with the marker line made around the tubes and mark the rivet holes with a marker Drill the rivet locations using a 1 8 drill bit Right footbox aluminum nut driver drill 1 8 drill b...

Page 192: ...one to the backside of the panels or chassis whichever is easier in the areas where they will make contact Locate and hold the right footbox aluminum panels inside front and outside using the kit 8 screws originally holding the aluminum to the frame ...

Page 193: ...actoryfive com 508 291 3443 Drill through the rivet holes in the footbox front aluminum into the frame tubes using a 1 8 drill bit Rivet the panel to the frame Drill and rivet the inside footbox aluminum panels ...

Page 194: ...193 www factoryfive com 508 291 3443 Run a bead of silicone along the inside bottom of the footbox Silicone drill and rivet the outside footbox aluminum panel ...

Page 195: ...e Left footbox aluminum nut driver drill 1 8 drill bit rivet tool Secondary body fasteners kit aluminum Do not rivet the panels together until everything fits together in the correct location Apply silicone to the backside of the panels or chassis whichever is easier in the areas where they will make contact ...

Page 196: ... com 508 291 3443 Locate and hold the left footbox front aluminum panel using the kit 8 screws originally holding the aluminum to the frame Locate and hold the left footbox inside top aluminum panel using the kit 8 screws ...

Page 197: ...e tubes using a 1 8 drill bit Rivet the panels to the frame Do not attach the outside panel yet Cockpit rear wall Drill drill bit rivet tool Silicone caulking gun 8 self tapping screws nut driver ruler marker Acetone or carburetor cleaner rags Packaged aluminum mounted aluminum Secondary body fasteners Do one panel at a time Be careful of the sharp aluminum edges they can cut you ...

Page 198: ...197 www factoryfive com 508 291 3443 Silicone the rear cockpit wall frame tubes Use the 8 screws to hole the panel in place then drill and rivet the cockpit rear wall to the frame ...

Page 199: ...8 www factoryfive com 508 291 3443 Cockpit floors Silicone the tubes under the main floor areas Set the floors in place Use the 8 screws to hole the panel in place then drill and rivet the floors in place ...

Page 200: ...199 www factoryfive com 508 291 3443 Riveted floors Drivetrain Install If installing a Coyote engine check our parts catalog www factoryfiveparts com instructions for install instructions ...

Page 201: ...0 www factoryfive com 508 291 3443 Frame prep On the right engine mount sand or grand any coating away around one of the hole shown above for the engine ground strap Transmission prep 13mm sockets ratchet ...

Page 202: ...3443 Remove the shifter handle for easier install using a 13mm socket and ratchet Put masking tape over the hole If not already attached attach the transmission mount to the transmission using a socket and ratchet 6speed Magnum shown ...

Page 203: ...engine and transmission already bolted together and lowered in as a unit Also remove anything that will make your job easier shifter assembly headers power steering pump etc If using a 4 6L or Coyote engine a shallow oil pan is required If using a 4 6L or Coyote engine remove the stock oil pan and install a shallow oil pan Unpack the engine and transmission mounts and loosely attach to the engine ...

Page 204: ... the engine mount bolts Tighten all of the engine mount bolts 87 95 Oil Filter Relocator wrench razor knife Teflon tape chassis grease hex key Oil filter relocating kit oil oil filter This is needed only if running shorty headers and J pipes on a 302 or 351 engine Max torque for the fittings on the relocate kit is 28 lbft ...

Page 205: ...is grease to hold it in place while spinning on the adapter Tighten turn after solid resistance is felt The outlets for the hoses should be facing towards the front of the engine Install the oil filter relocate base plate on the engine Install the block off plugs with a hex key in the adapter holes not being used Use the Teflon tape on the threads of the plugs as you tighten them ...

Page 206: ... 3443 Use Teflon tape on the threaded barbs and thread them into the oil filter relocator Thread the short end of the threaded nipple into the relocator Mount the oil filter relocator on the frame after the engine has been installed ...

Page 207: ...206 www factoryfive com 508 291 3443 Engine Transmission Installation Engine hoist chain 2 3 friends 13 16 socket ratchet and extension Attach engine hoist chain to the engine ...

Page 208: ... transmission into place The more hands you have to help the better Go very slowly Install the engine mount to chassis nuts and tighten using a 13 16 socket extension and ratchet Make sure the alignment pins on the mounts are in the holes on the chassis pads ...

Page 209: ...factoryfive com 508 291 3443 Transmission Mount 5 8 sockets ratchet floor jack Transmission mount hardware Use this transmission mount orientation for 302 351 with TKO applications and all 6 speed applications ...

Page 210: ...ame mount in the correct orientation From the top pass the carriage bolts through the transmission mount plate and frame mount and hand tighten the locknuts on Attach the transmission mount plate to the transmission mount using a 5 8 socket and ratchet Tighten the carriage bolts using a socket and ratchet Engine ground 3 16 hex key socket ratchet Electrical completion parts complete kit ...

Page 211: ...ey socket and ratchet complete kit only Steering Shaft 5 32 3 16 hex keys 9 16 wrenches marker drill 3 16 drill bit Philips head screwdriver Steering bearings Hardware Steering shaft Do not tighten the locknuts on the steering shaft bearings all the way until the whole steering shaft has been installed Unpack the steering shaft assembly ...

Page 212: ...line than a manual steering rack and the 94 04 Power rack uses a Pyramid shaped end All of these lower adapters are available from FFR If running power steering do not change the splined adapter skip the next step two steps Remove the splined adapter from the end of the steering shaft ...

Page 213: ...et screw align the set screw with the flat side on the input shaft then slide the new adapter down onto the rack as far as possible Slide the 1 flange bearing onto the upper shaft so that the locking collar is on the upper steering shaft side as shown ...

Page 214: ... footbox front with the set screw toward the inside of the footbox Both sides of the flange mount to the front side of the footbox plate Attach the flange to the footbox using the 5 16 x 1 stainless button head screws locknuts 3 16 hex key and wrench Do not tighten the locknut all the way until all of the steering parts have been installed ...

Page 215: ...less button head screws locknuts 3 16 hex key and wrench Do not tighten the locknut all the way until all of the steering parts have been installed Upper Steering Shaft 5 32 3 16 5 16 hex keys wrench rubber mallet Steering system hardware Use thread locker on all the steering shaft screws that do not have jam nuts and the adapter screws Unpack the upper steering shaft from the primary chassis comp...

Page 216: ...the spring washers are facing up and set the washers in place Then tap the upper shaft down until the upper clip just disappears into the lower shaft Line up the steering shaft and adapter and push the rack adapter onto the steering shaft Tighten the upper and lower bearing mounting bolts ...

Page 217: ...216 www factoryfive com 508 291 3443 Tighten the set screws on both the upper and lower bearings Clutch Cable Slide the clutch cable boss through the front of the driver footbox ...

Page 218: ...217 www factoryfive com 508 291 3443 Hook the clutch cable over the quadrant Attach the clutch cable to the front of the footbox using the small 8 screw provided and wrench ...

Page 219: ...e steering shaft or the cable may fail prematurely Connect the clutch cable to the bellhousing and the clutch fork Thread the cable end adjuster nut on so that the cable has no play in it Using zip ties or insulated clips tie the cable safely away from the headers and the moving steering components Check the full range of travel for the clutch pedal ...

Page 220: ...th an OEM pedal but using the supplied ball studs and retainers it can be adapted for all applications Cut the barrel fitting off the end of the cable Push and twist the ball stud retainer onto the end of the cable and attach the ball stud retainer using a 5 64 hex key 87 93 5 0L Fuel Injected Applications Run the accelerator cable to its proper position on the engine ...

Page 221: ...of moving or hot parts as well Check the idle screw underneath the throttle body to see if the throttle arm is hitting it If it is not either loosen the ball stud retainer set screw and readjust the cable or bend the small tab behind the accelerator pedal until the idle screw hits the throttle arm You will notice a fairly high idle later when the car starts if the throttle is held open Carbureted ...

Page 222: ...vel to ensure that there are no interferences with the pedal or travel Also remove the air cleaner and ensure you are getting full travel in both the open and closed directions After driving the car for the first time you may want to adjust the pedal location for optimum heal toe and shoe size differences Brake System Tube bender 3 16 drill bits drill 7 16 11 16 wrenches 7mm socket ratchet rivet g...

Page 223: ...ke line adapter parts in the picture above are for the stock Mustang flexible brake lines The small black screws are for the e brake boot If building the complete kit unpack the remaining hardware from the front brake assembly The stainless laser cut mounts with the circles on are for the Complete kit or Wilwood brake braided lines ...

Page 224: ...can be run and the following is just one example Most importantly when choosing a routing path is to keep away from heat or moving parts and ensure there is room for the flex lines to not be pulled tight under the full range of wheel travel including lock to lock steering travel The master cylinder is used for front and the 5 8 master cylinder is used for the rear brakes Left front Run one of the ...

Page 225: ...Run the brake line down the 1 50 tube to the bottom frame tube then up the front side of the angled rear suspension tube When you are happy with the routing use the small insulated line clips and 3 16 rivets to hold the brake line in place ...

Page 226: ...line will bend very easy but be careful not to kink it Left flexible brake line The laser cut flexible brake line brackets attach to the rear angled chassis tube on the left front suspension Drill and rivet these in place using two 3 16 rivets then attach the flexible line to the open end on the fitting ...

Page 227: ...3443 Front right From the T fitting run a 60 brake line down the 1 50 tube forward to the front of the frame and over to the right side of the frame Run along the 1 50 tube behind the lower control arm and up the rear angled 1 50 tube ...

Page 228: ... to hold the brake line in place Like the left side push the flexible brake line through the bracket from the outside in rivet the bracket in place and screw the flexible line onto the brake line fitting and tighten Attach the front flex lines to the caliper making sure there is a crush washer on either side of the fitting ...

Page 229: ... flex lines will not interfere with anything in the suspension wheels during travel or turning full lock to lock Rear brake line From the right 5 8 master cylinder run a 60 brake line towards the center of the car then to the rear of the inside footbox panel ...

Page 230: ...t to the calipers Newer axles and the FFR rear brakes run the flexible brake lines direct from the chassis to the caliper If using the 87 95 Mustang mount connect a 20 brake line using a brake line union and run the brake line straight up and towards the middle of the frame If necessary use another brake union and one of the 8 brake lines to get the brake line to the top middle near the axle where...

Page 231: ...se the small insulated line clips and 3 16 rivets to hold the brake line in place IRS brakes At the back of the tunnel connect the 3 way female T adapter and an 8 brake line up the left rear tube Off the other leg of the T run the 20 brake line across the 1 50 tube that goes across the frame at the back of the tunnel ...

Page 232: ... through the bracket from the outside in screw the flexible line onto the brake line fitting tighten by hand Use channel lock pliers to install the clip that holds the flexible brake line in place Locate drill and rivet the bracket of the frame using two 3 16 rivets ...

Page 233: ... use the small insulated line clips and 3 16 rivets to hold the brake line in place Make sure that your flex lines will not interfere with anything in the suspension wheels during travel Tighten the banjo bolts on the calipers Banjo bolt torque specs Front Brake hose to caliper Banjo bolt 39Nm 29lbft Rear brake caliper hose to caliper Banjo bolt 43Nm 32lbft When your system is finished being plumb...

Page 234: ...ach master cylinder Additional reservoirs can be purchased at www factoryfiveparts com Unpack the master cylinder reservoir fittings and the reservoir kit from the pedal box assembly Screw in the hose barb Loosely screw the mounting bracket onto the reservoir ...

Page 235: ...e engine being used or mount to the front of the footbox Keep the reservoir high enough so that the lid is higher than master cylinder This picture shows a coyote engine with placement on the firewall behind the engine The best way to pass the hose through the wall of the footbox is using the included bulkhead hose fitting ...

Page 236: ...ster cylinder hose and drill a hole through the aluminum for the bulkhead fitting The fitting is slightly larger than so wiggle the bit around to oversize it Insert the bulkhead fitting and spin the nut on the backside of the panel Tighten the fitting using 7 16 and 11 16 wrenches ...

Page 237: ...ut the hose clamps on the hose before pushing onto the barb it is hard to get the hose off the barb after Route the hose from the reservoir to the bulkhead fitting push a hose clamp onto the hose then onto the barb Tighten using a 7mm socket and ratchet ...

Page 238: ...237 www factoryfive com 508 291 3443 From the bulkhead route to the master cylinders splitting it using the Y provided Make sure that the line cannot get in the way of moving parts ...

Page 239: ... 291 3443 Fill the system with DOT 3 fluid and bleed being very thorough in checking for leaks Emergency Brake E brake Handle 5 32 3 16 hex keys 7 16 wrenches channellock pliers WD 40 E brake handle assembly brake line components ...

Page 240: ...239 www factoryfive com 508 291 3443 ...

Page 241: ...240 www factoryfive com 508 291 3443 Unpack the emergency brake handle components Some parts are not used for the Coupe application Push a nylon bushing into one side of the fixed gear ...

Page 242: ...five com 508 291 3443 Push the other bushing into the other side of the fixed gear From the right side of one of the Handle to ratchet mounts insert the shoulder bolt through the ratchet mount and then the fixed gear ...

Page 243: ...ide of the fixed gear Using a 3 16 hex key and wrench tighten the shoulder bolt lock nut so that the ratchet to handle mount plates are against the bushings but they can still move up and down Make sure the ratchet to handle mount plate next to the locknut does not get caught on the edge of the shoulder bolt ...

Page 244: ... 291 3443 Slide the lower handle between the ratchet to handle mount plates and bolt the three pieces together using the two 5 16 x 1 button head screws Put the ratchet tooth on the long anchor bolt as shown in the picture below ...

Page 245: ...actoryfive com 508 291 3443 Rotate the fixed gear out of the way and pass the anchor bolt up through the lower handle Rotate the ratchet tooth between the handle to ratchet mount plates and align the mount holes ...

Page 246: ...de the 1 nylon spacer onto the end of the anchor bolt There are two nylon spacers included They provide preload on the spring so there is more force holding the ratchet tooth to the fixed gear and making the release button harder to push Try using the 1 long spacer first After the handle is assembled try the handle and if desired the other spacer can be added ...

Page 247: ...246 www factoryfive com 508 291 3443 Spray a little WD 40 on the lower handle threads and screw the upper handle onto the lower handle Insert the spring into the upper handle over the anchor bolt ...

Page 248: ...247 www factoryfive com 508 291 3443 Screw the button onto the end of the anchor bolt Screw the male and female rod ends together ...

Page 249: ...443 Use a wrench to spread the ears of the ratchet to handle mounts so that the rod end can just slide between them Slide the male rod end between the ratchet to handle mount plates and attach it using the flange head bolt and locknut ...

Page 250: ...factoryfive com 508 291 3443 Attach the handle to the frame using the 5 16 x 1 button head bolts Cables If there is a rubber washer on the end with the clip frame end of the cable shown remove the rubber washer ...

Page 251: ...250 www factoryfive com 508 291 3443 Check the fit of the emergency brake cable end in the brake cable clevis ...

Page 252: ...ryfive com 508 291 3443 If necessary use a drill bit and drill or a Dremel tool to open up the slot slightly Push one of the cables through the bracket in the transmission tunnel until the sheath end clicks in place ...

Page 253: ... 508 291 3443 Push the second cable into the frame bracket Solid Axle Route the cables back to the calipers and attach Make sure your routing is out of the way of any moving parts and the cable has slack to move with the axle ...

Page 254: ...ive com 508 291 3443 On the end of the Emergency brake cable sheath with no clip on pull push the cable so that 3 of cable sticks out of the sheath From the bottom insert the cable through the hole in the brake caliper ...

Page 255: ...he sheath into the hole The end of the sheath may or may not bottom on the flange It is normal for the sheath to look like the picture the end is being held in place and cannot move Move the end of the cable around the spring bracket so it will be captured ...

Page 256: ...255 www factoryfive com 508 291 3443 Push the cable so that the end of the cable sits on the spring bracket IRS Route the cable back behind the shock and towards the middle of the car ...

Page 257: ...256 www factoryfive com 508 291 3443 Route the cable up over the center section and to the bracket in the transmission tunnel Wilwood IRS E brake adapter ...

Page 258: ...257 www factoryfive com 508 291 3443 Insert the cable end into the bent bracket then bolt the bracket to the e brake lever Handle and Cable Adjustment Put the clevis brackets onto the end of the cables ...

Page 259: ...iers Facing the cable slots towards each other attach one of the cable clevises to each side of the female rod end using the x 1 50 socket head bolt and locknut Leave the locknut loose for now Slowly pull up on the handle to set the brake pads and remove any slack from the brake cables ...

Page 260: ...ase the brake and if necessary remove the clevis bolt and readjust the rod end so that the cable is tight Reinstall the clevises and bolt then tighten the bolt so that the clevis ends are closed this will prevent the cable ends from coming out ...

Page 261: ...rench 3 16 hex key Secondary Body fasteners Battery Tray components Insulated clip hardware misc electrical components battery electrical system completion components complete kit only Battery tray Unpack the Battery Tray components Position the battery on the battery tray front of the engine as shown above It is centered side to side ...

Page 262: ...factoryfive com 508 291 3443 Mark the corners of the battery on the tray Drill 4 holes through the tray and 1 tubes in the front and the 1 50 cross tube so that the holes are outside where the battery will sit ...

Page 263: ...tray and on the 1 tube that is on the side of the negative post remove any coating for the ground cable to connect Use one or two of the washers between the battery tray and the frame on the side of the positive post and the ground cable on the negative side ...

Page 264: ...263 www factoryfive com 508 291 3443 Use the x 2 25 bolts through the 1 50 tube and the x 1 75 bolts through the 1 tubes Bolt from the bottom up using a 7 16 wrench socket and ratchet ...

Page 265: ...264 www factoryfive com 508 291 3443 Place the battery on the tray with the crossbar hold down Insert the J bolts through the battery tray and up through the hold down ...

Page 266: ...265 www factoryfive com 508 291 3443 Bolt the hold down to the tray using the washers locknuts 7 16 deep socket and a ratchet Battery cable Attach the positive battery cable to the battery ...

Page 267: ...battery cable down the right 1 50 tube to the starter attaching it to the frame using the 5 8 clamps and 3 16 rivets Attach the battery cable to the battery post on the starter Leave the ground cable off until after the wiring harness is installed ...

Page 268: ...s up to the Oil filter Relocator and the adapter on the engine Make sure that the lines go to the correct ports or the engine will be starved for oil The out on the engine goes to the in on the Relocator and the out on the Relocator goes to the in on the engine Locate and attach the relocator to the chassis where the hoses will reach and will not get burned by the exhaust or hit by the steering sh...

Page 269: ...with the windshield support flange facing toward the front of the car Run a bead of silicone down the top of the frame tube the firewall sits on top of and lower it into place The bottom flange faces toward the rear of the car and the top windshield flange faces forward ...

Page 270: ...the firewall to the frame so that the firewall is flush with the front of the tube upper flange not shown Trans tunnel top front Position the Trans tunnel top front aluminum panel it can be used to pass wires through Once the wiring is done rivet in place ...

Page 271: ...m 508 291 3443 Wiring harness Complete Kit Chassis wiring harness The chassis wiring harness controls everything for the car except the engine Route the front and rear harness through the transmission tunnel top front panel ...

Page 272: ...e to the battery LED Flashers Misc Electrical Components Locate the electronic flashers in the kit pack These must be used instead of the standard flashers because of the LED rear lights The flashers are located on the fuse block for the flasher and turn signal ...

Page 273: ...ly plug that may not be the same color is the fuel tank harness All other plugs that go together should be matching in color and shape or they will not connect Different color plugs means you may have a different year harness than the rest of the harness that you have and could cause complications later when trying to start the car If you decide not to use the Mustang chassis harness because there...

Page 274: ...273 www factoryfive com 508 291 3443 This is the harness layout using the stock Mustang wiring harness only not the optional chassis harness ...

Page 275: ...s tripped Use the switch as a template and drill two holes in the trunk aluminum on the far corner of the left side then mount with the provided screws Run 2 wires using the blue wire extensions in the misc electrical components from the left rear side marker light to the center to be used for the license plate light Leave the wires in the center for now Run the harness forward to the beginning of...

Page 276: ...he drilled holes and the zip tie trick to keep the harness in the corner along the floor Headlight Harness The headlight harness is started at the alternator and runs forward to the right headlight area then goes under the radiator to the left side headlight area and then rearward to the coil and starter relay area The Mustang is wider than the FFR Coupe in front and there is extra wiring between ...

Page 277: ...begins at the front of the left footbox and goes rearward Starter Solenoid There are two different starters that were used and the wires are run differently for each On older large starters the cable runs from the starter to the empty post on the solenoid On the newer starters the heavy starter wire connects to the same terminal as the body and the smaller 8 10 gauge wire runs to the empty termina...

Page 278: ...ter When the wire harness is installed mount the fuse panel to the 1 50 square tube going across the car in the left footbox Leave the headlight and hazard switches hanging for now Attach the harness across the 1 50 square tube using the insulated line clips ...

Page 279: ...d any time you are working with the computer The engine harness begins in the right foot box In the footbox top use a hole saw to cut two holes then connect the holes using tin snips to create the oval shaped computer plug grommet hole Push the computer plug through the hole from the engine bay side through the oval shaped hole on the passenger footbox top The computer can be mounted in a couple o...

Page 280: ...ash harness by the master cylinder and the coil plug If you are running EFI without emissions equipment the vacuum electrical solenoids located on top of the foot box along with the vacuum reservoir on the firewall are not necessary Plug the vacuum outlets on the intake remove the unused parts Use screws provided with kit to mount the vacuum controls and BAP Barometric Air Pressure sensor to the f...

Page 281: ...alk pointed towards the seat as high as possible on the 1 50 square tube going across the car so that your knee or leg does not hit it Use two 10 x 1 screws and a 5 16 socket and 9 64 drill bit The ignition switch mounts near the turn signal stalk on the 1 50 tube Mount the switch to the outside of the turn signal so that they do not hit each other when the turn signal is operated Use two 14 x 1 5...

Page 282: ... switch Speedometer Sending Unit 11mm deep socket ratchet wire crimping tool Speedometer sending unit components misc electrical components The sending unit electrical connection is only needed if the Speedometer is not GPS controlled The sending unit does still need to get installed though to prevent a transmission fluid leak Unpack the speedometer sending unit components complete kit ...

Page 283: ...om 508 291 3443 Install the gear on the end of the sender and hold it in place with the clip Put a little oil on the o ring and install the sender in your transmission Use the original bolt to hold the sending unit in place ...

Page 284: ...g fuel injection you may also need to send this signal to the computer as well depending on your system Horns 14mm wrench wire cutters wire crimpers 5 32 hex key drill 3 16 drill bit 3 8 socket ratchet Electrical system components Assembly shows complete kit parts mount donor horn in similar location ...

Page 285: ... the included bracket using one of the 14mm lock washers and nuts included Note the orientation of the wire connectors when tightening the bracket so that it will be correct when installed The flat horn outlet is pointed right Mounting brackets on the horns ...

Page 286: ...ns the connectors should be spaced so that the wires will not hit each other Locate the chassis harness horn wires on the front chassis harness Cut 2 off the end of the chassis harness horn ground wire and strip the end of the chassis harness ground wire ...

Page 287: ...43 Twist the chassis harness ground wire and small wire ground together and insert them into one of the female connectors included then crimp the connector on Cut the same 2 off the green horn power wire and strip the ends of both wires ...

Page 288: ...ire and small wire ground together and insert them into one of the female connectors included with the horns then crimp the connector on Attach the chassis harness horn wires to one horn and push the jumper wires on to the other horn Either connector on the horn will work ...

Page 289: ... the frame so that the wires are not too tight This picture show the 1 50 tube coming down from the footbox and drill a 3 16 mounting hole Attach the two horns to the frame using a supplied 14 screw Then drill a second 3 16 hole so the horns will not rotate ...

Page 290: ...sire the fan to run with the key out which could drain your battery power the fan directly from the battery or from an always hot fuse in the fuse panel Ground the black electric fan wire to the frame Connect the other electric fan wire to the 87 tab on the fan relay Ground the 85 tab to one of the 2 position dash toggle switches The toggle will serve as your on off switch Ground the other side of...

Page 291: ... cylinder head to install the thermostat switch and thread it in Ground the black electric fan wire to the frame Connect the other electric fan wire to the 87 tab on the fan relay Attach the 85 ground tab to the thermostat switch Connect the 86 and 30 tabs to a 12V 30A fuse in the fuse panel ...

Page 292: ...he driveshaft should be shortened to the length specified in the appendix for the engine transmission combination being used Unpack the driveshaft and slip it up into the rear of the transmission The most room to do this is usually to hold the shaft just above the center section and come in from the driver s side ...

Page 293: ... and should have thread locker on them already If thread lock is not there put a small bead on each bolt Fit the driveshaft snug against the yoke and install the bolts and tighten You can put the transmission in gear to stop the driveshaft from turning while you tighten Torque the bolts to 109Nm 80 ft lb ...

Page 294: ...80 ft lb Cooling System Marker Hack saw Insulated Clip hardware Drill drill bit 3 16 Hex key 7 16 wrenches ruler flathead screwdriver razor knife Fan mounting components Radiator mount components Stainless Radiator Hose kit cooling system insulated clip hardware packaged aluminum Unpack the roadster cooling system assembly ...

Page 295: ...www factoryfive com 508 291 3443 Aluminum Duct Silicone drill and rivet the radiator duct back to the frame Silicone drill and rivet the radiator duct sides to the duct back and the nose hinge support tubes ...

Page 296: ...95 www factoryfive com 508 291 3443 Fan Mounting Unpack the fan and push the four mounting brackets into the angled tab mounts Center the fan on the radiator and mark the brackets to trim off the excess ...

Page 297: ...he hardware provided Make sure and tighten the hardware that came pre installed on the mounts Radiator Mounting Use a razor knife and slit the 8 5 long sections of fuel line lengthwise Push the slit sections of fuel line onto the lower radiator frame mounts at the front of the frame and trim off any extra ...

Page 298: ...r the radiator mount and install the radiator from above the frame Attach some half moon stick on weather stripping to the underside of the radiator top mount bracket Position the top mount bracket so that the small tab sticking up is on the rearward side of the bracket ...

Page 299: ...e two 1 nose tubes on the chassis Attach the radiator top mount bracket to the frame using the 5 16 x 1 5 button head screws locknuts washers 7 16 socket and ratchet Radiator Hoses Cut the tube using a hack saw or if available a cut off wheel If necessary clean the end up with tin snips or a grinder Shake and blow the tube out so that no metal pieces are in the tube ...

Page 300: ...299 www factoryfive com 508 291 3443 Unpack the stainless radiator hose kit and remove the hose connectors from the boxes ...

Page 301: ...300 www factoryfive com 508 291 3443 Use the smaller sections of tube inside the adapters to fit them to smaller fittings on the radiator and intake Then fit the larger adapters over them ...

Page 302: ...iator duct hole to the upper radiator hose location Mark the tube where it needs to be cut so that the tube will just touch the attaching location Remove the tube from the vehicle Cut the tube using a hack saw or if available a cut off wheel If necessary clean the end up with tin snips or a grinder Shake and blow the tube out so that no metal pieces are in the tube Reattach the tube assembly to th...

Page 303: ...ryfive com 508 291 3443 Lower radiator hose Connect the lower radiator hose to the radiator Run the tube under the lower control arm mount and attach the stainless hose to the end using an adapter then to the engine ...

Page 304: ... car for the first time once coolant is added and while the system is still warm retighten the hose clamps used on the cooling system Overflow Tank Unpack the overflow assembly Bolt the mounting tabs loosely onto the tank so they can be slid around to fit ...

Page 305: ...g location for the tank and mark the holes Make sure the tank is accessible and visible inside to check the level on the finished car then bolt it in place Mount the overflow tank to the frame aluminum Attach the larger radiator hose to the inline filler ...

Page 306: ...8 291 3443 Use the adapter and attach the smaller hose and route the overflow hose to the overflow tank Make sure you attach the hose to the tube that runs off the bottom of the tank and not the one that extends up into the tank ...

Page 307: ...inum panels Drill 1 8 drill bit Silicone Caulking gun Rivet gun Roadster Secondary Body Fasteners Components Packaged Aluminum mounted aluminum Trans tunnel sides aluminum Drill and rivet the cockpit transmission side aluminum panels in place ...

Page 308: ...actoryfive com 508 291 3443 Transmission Tunnel Cover Silicone and install the transmission tunnel top Cockpit rear inside aluminum nut driver drill 1 8 drill bit rivet tool Secondary body fasteners kit aluminum ...

Page 309: ...308 www factoryfive com 508 291 3443 Silicone drill and rivet the inside cockpit corner aluminum panels to the frame Silicone drill and rivet the driveshaft cover aluminum panel to the frame ...

Page 310: ...minum nut driver drill 1 8 drill bit rivet tool Secondary body fasteners kit aluminum Make sure all of the clutch brake switches and any other pedal adjustments are done before install Silicone drill and rivet the left footbox outside aluminum panel to the frame ...

Page 311: ...08 291 3443 Left door hinge inside covers Silicone drill and rivet the left door hinge inside cover to the frame Hatch floor 1 8 drill bit silicone rivet gun caulk gun Mounted Aluminum Packaged Aluminum secondary body fasteners ...

Page 312: ...actoryfive com 508 291 3443 Start with the hatch floor front panel Silicone and rivet in place To install put the right side in as far as possible S the panel so that the middle right side can clear the rollbar ...

Page 313: ...312 www factoryfive com 508 291 3443 Bow the left side to get the left side to clear the rollbar Final panel installed ...

Page 314: ...313 www factoryfive com 508 291 3443 Insert silicone and rivet the rear panel in place Under door aluminum 1 8 drill bit silicone rivet gun caulk gun Packaged Aluminum secondary body fasteners ...

Page 315: ...314 www factoryfive com 508 291 3443 Silicone drill and rivet in the under door aluminum panels Exhaust Headers and J pipes 7 16 9 16 wrenches 7 16 socket ratchet extension 5 16 hex key ...

Page 316: ...e com 508 291 3443 Headers or straight tubes and shorty headers Mount the headers to the engine If you are using full length headers they bolt in place with the gaskets and hardware provided Thread locker is recommended ...

Page 317: ...y headers or stock manifolds bolt them back on On a small block 302 or 351 the headers are switched side to side and on the Coyote the headers also face forward If you are using the J pipes bolt them to the headers The shorter pipe will go on the passenger side ...

Page 318: ...sket to the header or J pipe with using the shorter bolts and mechanical locknuts Drill a 3 16 hole in the 1 50 x 1 50 outrigger tube directly above the middle hole in the mounting bracket Get this hole as high as you can get it while still being able to mount the rubber exhaust hanger about down from the aluminum floor Seats Harness wrench socket drill bit drill ratchet Seat Harness Fasteners Unp...

Page 319: ... www factoryfive com 508 291 3443 Position the lap harnesses make sure to have the red release handle on the right side of the seat Bolt the lap harnesses to the frame Inside mount left outside mount right ...

Page 320: ...319 www factoryfive com 508 291 3443 Remove the mounting tab from the harness Loop the harness over the roll bar crossbar ...

Page 321: ... harnesses are side specific so make sure you have the sides correct Follow the manufacturer s directions inside the seat harness boxes on how to loop the harness straps through the slider bracket Adjust the harnesses to where they fit you comfortably ...

Page 322: ...e seats Unpack the seats and set them in the cockpit Sit in the seats and locate them in the position you are most comfortable This is a critical fitment so take your time and make sure you are happy with the location Remove the seat cover if attached Drill the first hole for the seat mounting and install the bolt ...

Page 323: ...Certificate of Origin matches the number engraved on the 2 x 2 tube going across the car at the front of the cockpit on the driver side Below is an example of how the nameplate looks The VIN number space is provided so that your state issued VIN number can be engraved if you so desire This can be engraved at any Trophy or mall engraver A few places that people have riveted these plates are front o...

Page 324: ...d aluminum dash electrical components electrical system completion components If using the factory Five Coupe GPS gauges have built in indicator lights so the large dash mounted ones included are not necessary Unpack the dash and the gauges Depending on which gauges you are using you may need a different aluminum part for the correct gauge size The standard gauges are the Platinum gauges Install t...

Page 325: ...ess Install your switches in the dash The horn button can be located where desired The factory Five Coupe GPS gauges have built in indicator lights so the large dash mounted ones included are not necessary If being used drill holes and mount the turn signal and high beam indicators in the gauge panel The red light can be used as a warning light for the engine controls if desired ...

Page 326: ...eatherstrip on the front edge of the dash Attach the dash onto the chassis by drill four 4 7 64 holes two of them through the top gauge panel holes and using the black 6 screws and a Philips screwdriver Attach the gauge visor to the dash using rivets ...

Page 327: ...326 www factoryfive com 508 291 3443 Locate the dash side panels Right side shown Attach the side panels to the ends of the dash and the frame using 1 8 rivets ...

Page 328: ...327 www factoryfive com 508 291 3443 Steering Wheel Philips head screw driver 10mm wrench 5 16 hex key Steering wheel Hardware Unpack the steering wheel hardware ...

Page 329: ...yfive com 508 291 3443 Bolt the steering wheel to the boss The pattern is not symmetrical so it will only line up in one direction Bolt the steering wheel assembly to the steering shaft Use thread locker on this bolt ...

Page 330: ... all your hardware make sure your wiring and hoses are away from extreme heat and moving parts make sure the steering turns freely lock to lock and make sure your brake flex lines have enough slack for the full range of wheel movement IRS Axle Nuts Torque Wrench 36mm socket IRS components ...

Page 331: ...d step on the brakes Torque the rear axle nuts to 175 ft lbs Wheels Install and torque your wheels Make sure they rotate freely and do not interfere with the brake calipers lines or any suspension components Fluid Levels and Grease Grease gun chassis grease ratchet rags ...

Page 332: ... differential with gear oil Any 8 8 in ford has a fill plug that is removed and filled until the oil just reaches that level The IRS has it in the rear cover and the solid axle has it in the front Transmission Fill the transmission with fluid and install the shifter assembly Leave the shift handle and knob off for now ...

Page 333: ... 291 3443 Engine Fill the engine with Oil and coolant Both these fluids should be rechecked after you have started the engine for the first time Make sure there is some coolant in the overflow to start out about 1 3 full is good ...

Page 334: ...olt your side pipes in place to keep things quieter If you have the space in your driveway or have access to a small parking lot it is very helpful to drive the chassis around a little to make sure everything is working before you seal it all up If you do this bolt the seat harnesses in and use them You will be very surprised at how quickly the car responds to small inputs and it is amplified by b...

Page 335: ... pushrods in or out of the master cylinders because of the pedal pivot location a small adjustment will make a large difference Set the pedal height of the clutch with the stop and cable adjuster usually about above the brake pedal Make sure that your feet are comfortable on the pedals and you can press them all without hitting the others You can also move the steering wheel in and out to get your...

Page 336: ...335 www factoryfive com 508 291 3443 Body Section Chapter 4 ...

Page 337: ...al removed for a perfect fit The easiest method for getting the best fit is to sand or trim the panel edges just enough so they will sit down in the openings then fully mount them with hinges and latches Once the surfaces are all matched between panels and the body then trim away the edges until the gaps are all even and slightly larger than you want them on the finished car The paint will fill in...

Page 338: ...337 www factoryfive com 508 291 3443 Push weather strip goes across the top of the firewall on either side of the windshield support flange Push weatherstrip around the radiator aluminum ...

Page 339: ... also be trial fit adjusted Since the rear clip is one piece get two people to help when you re ready to position the body onto the frame The body is delicate but can be pulled around the frame without any problems If body cut outs were ordered the side exhaust side louver headlight taillight turn signal wiper gas cap and side mount holes are done at the factory The body comes standard with the la...

Page 340: ...e holding the door and side exhaust recess and one in the rear move towards the frame from the rear with the back slightly lower than the front Pull the sides of the body out to clear the frame Watching the rear of the frame move the body forward slowly lowering the front ...

Page 341: ... body down in place Locating Ruler long level marker floor jack tape measure Once the body is sitting down on the frame inside the door area adjust it forward or backwards so that there is a 0 25 gap between the body and frame at the front of the door area At the back of the body measure up 7 from the bottom corners of the hatch opening and mark the body ...

Page 342: ...341 www factoryfive com 508 291 3443 Put a long level in the back of the hatch opening Use masking tape to hold the level at the 7 marks ...

Page 343: ...he side of the hatch area measure over 18 and mark the level This should be the center of the opening At the center point marked on the level use a floor jack to raise or lower the body so that the bottom of the level is 10 25 up from the frame ...

Page 344: ...443 In the rear wheel well area measure horizontally from the frame shock mount over to the edge of the wheel well This should be the same on both sides of the car Rear body mount Drill 5 16 drill bit socket ratchet 5 32 hex key friend ...

Page 345: ...6 holes through the middle of the rear body mounting bracket slot and into the recessed rear part of the body Bolt the body to the bracket with the 5 16 x 1 button head stainless screws washers and locknuts using a socket 5 32 hex key and a friend ...

Page 346: ...345 www factoryfive com 508 291 3443 Use a couple of the aluminum attachment screws through the bottom of the door opening into the tube ...

Page 347: ...346 www factoryfive com 508 291 3443 Side body cuts Drill 5 16 holes at the top side locations where the lower 1 50 frame tubes will hit the side of the body and cut the body for clearance ...

Page 348: ...347 www factoryfive com 508 291 3443 Nose Hinge 15 16 socket 15 16 wrench Nose fasteners Screw the jam nut half way onto the rod end ...

Page 349: ...e end of the rod end up through the nose mount at the front of the frame loosely putting another jam nut ono the end of the rod end Pass one of the 5 8 bolts through one side of the nose hinge bracket and place one of the 5 8 washers on the bolt ...

Page 350: ...443 Place one of the 3 8 spacers on the bolt Hold the hinge bracket up to the rod end on the frame and pass the bolt through the rod end another 3 8 spacer 5 8 washer the other side of the bracket and loosely put a locknut on the bolt ...

Page 351: ...e front of the body Move the nose around so there is a small gap i e 3 16 along the backside of the nose against the rear body clip and along the bottom edge of the nose Use paint sticks or washers in the gap to keep it consistent Use a tape measure to measure in the wheel well from the edge of the body to the upper shock mount on one side Measure the other side and adjust the nose left right unti...

Page 352: ... and attach the hinge brackets to the nose using 5 16 button head screws locknuts 3 16 hex key and socket Put the small bumpers around the edge of the nose opening and try closing the nose so that the nose height is even with the body If it is too low try the large bumpers ...

Page 353: ...bs the body lip all of the way around This will leave a line on the panel that may be thicker or thinner in areas Sand grind or cut the panel back so the marker line cannot be seen Remount the panel and the resulting gap should be the same around the whole panel about 3 16 Repeat this gap procedure later after mounting the doors Nose gas Struts Marker masking tape 3 16 drill bit drill rivet tool 1...

Page 354: ...ock mount 8 50 and mark the top of the tube Hold the 90 degree strut mounting bracket on the top tube so the center hole is aligned with the mark made the ball stud is pointed towards the outside of the car and the inside of the bracket is aligned with the edge of the tube Mark the center hole ...

Page 355: ...508 291 3443 Remove the bracket and drill the mounting hole with a 3 16 drill bit Remove the tape and insert a rivet through the center bracket hole and frame hole then drill the rear mounting hole using the bracket as a guide ...

Page 356: ...355 www factoryfive com 508 291 3443 Insert another rivet in the second hole then use a rivet tool to pull the rivets Drill and rivet the last mounting hole ...

Page 357: ...nge 16 50 and mark the nose liner flange Hold the flat strut mounting bracket up to the outside of the flange on the nose The point marked is center mounting hole again Mark and the center mounting hole so that all three mounting holes are on the flange Drill the center hole using a 3 16 drill bit ...

Page 358: ...ad mounting screws through the bracket and flange Drill one of the other mounting holes then insert and tighten two of the button head screws using an 1 8 hex key 3 8 socket and ratchet Drill and attach the remaining screw Attach the body end of the gas strut to the nose ...

Page 359: ...358 www factoryfive com 508 291 3443 Attach the rod end of the gas strut to the frame ...

Page 360: ...le saw Drill the rivet location marks with a drill bit Enlarge the hole drilled in the body section using the drill bit Silicone and rivet the Locator bracket to the backside of the nose Place a washer on the 3 8 locator bolt and pass it up from the underside of the body Place another washer on the topside of the body followed by the acorn nut Close the nose to test the locating pin height Add or ...

Page 361: ...360 www factoryfive com 508 291 3443 Put the hatch hinge arms onto the button studs so that they point forward and the arms are on the inside ...

Page 362: ...361 www factoryfive com 508 291 3443 ...

Page 363: ...362 www factoryfive com 508 291 3443 Press a bushing into the hinge arms so that the bushings are on opposite sides ...

Page 364: ...363 www factoryfive com 508 291 3443 Push a bushing into the rollbar clamp from the outside of the clamp left side shown Hand tighten the jam nuts on the bottom of the studs Repeat for the other side ...

Page 365: ...ll 0 813 rubber washers on the small button studs Push the small button studs through the holes on the sides of the glass Push the medium 0 922 rubber washers onto the small button studs on the inside of the glass Put a washer on the small button stud ...

Page 366: ...ttach the hinge arm to the rollbar mount using the short shoulder bolts wave washer regular washer locknut 3 16 hex key and wrench Do not fully tighten the locknut the arm needs to be able to rotate Right shown Measure and mark the centerline of the front end of the hatch opening on the body From the centerline measure 11 in each direction and make a mark for cutting the hinge arm clearance on the...

Page 367: ...sure 1 in each direction and draw a box leaving about in of the flange at the top Cut along the line to give your opening The trim looks best with a small radius at both the upper and lower corners as has been done on the right hand side of the cut out pictured ...

Page 368: ...nge arms onto the body and center in the opening Loosely attach the hatch rollbar mount plate welded to the outside to the rollbar rotate the mount so that the pivot point is as close to the roof as possible and slide the mount out so you can use bolt to the hatch glass mount ...

Page 369: ...om 508 291 3443 Tighten the rollbar mount Remove the hatch Use a drill bit to drill a hole at the point marked Hatch Struts The hatch will not sit correctly until the weatherstrip has been installed after painting the body ...

Page 370: ...ew the ball stud into the tube collar using some locktite to prevent loosening Attach the tube collar to the rollcage rear leg on the frame so the ball stud is 7 from the back of the rollbar as shown and push on the shaft end of the gas strut ...

Page 371: ...w factoryfive com 508 291 3443 Attach the body side of the strut to the hatch ball stud Hatch Latch socket ratchet flat head screwdriver Philips head screwdriver 3 32 drill bit drill Rear glass hatch assembly ...

Page 372: ... factoryfive com 508 291 3443 The hatch will not sit correctly until the weatherstrip has been installed after painting the body Find the hatch latch and its striker plate Insert the hatch latch into the hole ...

Page 373: ... the latch and orient the latch so that the striker points towards the back of the car then use a set of slip joint pliers to tighten the nut With the hatch raised put tape on the back body flange inside the hatch area in the center where the hatch latch is located ...

Page 374: ... 16 and mark the location on the tape where the hatch latch is located Hold the latch catch bracket against the flange so that the top of the bracket is aligned with the mark made then mark the mounting hole locations Drill 3 32 holes in the center of the ovals marked ...

Page 375: ...luminum 1 8 spacer and the black 6 x Philips head screws to hold the bracket inn place An alternative would be to use the 10 x 5 8 black button head screws provided and rivnuts Test the latch on the catch Adjust the height of the catch if necessary ...

Page 376: ...r spoiler On the original car this was a riveted on part but some customers have had their body shops fiberglass the spoiler into the body Hold the rear spoiler up to the body Sand or cut the flange to fit or as desired Mark the location of the rivets Drill the spoiler and body for the rivets ...

Page 377: ...376 www factoryfive com 508 291 3443 Body Cut outs Fuel filler Drill 7 32 drill bit 3 hole saw or air saw or jig saw masking tape scissors Fuel filler template Aston Lemans Cap components ...

Page 378: ...gas cap recess of the body Use a drill bit for all except one of the outer screw holes Use a 7 32 bit drill for the last small hole Use a 3 hole saw for the center opening drill out the holes for the filler If you do not have a hole saw this size you can cut the center circle out of the template and use the remaining template to mark for a jig saw instead ...

Page 379: ...cissors masking tape ruler Tail light template Red rear light Cut the rear mesh area out and tape the tail light template on the back of the body aligning the rear mesh area on the template and body Mark the horizontal centerline between the two lights for the license plate bracket later ...

Page 380: ...toryfive com 508 291 3443 Use a 7 32 bit to drill the outer holes for the taillight studs then cut out the center using a 1 hole saw Test fit the tail light mounting plate and drill out the holes to fit if needed ...

Page 381: ...et legal Factory Five Racing does not build completed or partially completed street vehicles If you choose to title register and operate your kit on public roads you are responsible for ensuring that the vehicle you build complies with all Federal State and local laws regarding its use If not marked when doing the taillight holes mark the center vertically between the top and bottom lights From th...

Page 382: ... 16 rivet through the bracket and into the hole drilled then level the bracket and drill through the other mounting hole in the bracket into the body License plate light Drill 17 8 hole saw 11 64 drill bit masking tape marker License plate light ...

Page 383: ...the license plate bracket and mark 2 above and centered on the bracket If possible use a 17 8 hole saw or if not available a 1 holes saw to drill the light location Test fit the light so that it will sit flat on the body If it will not open the hole up slightly ...

Page 384: ...383 www factoryfive com 508 291 3443 Drill the screw holes in the light out using an 11 64 drill bit Hold the light up to the body and use the light as a template to drill the 3 16 mounting holes ...

Page 385: ... 508 291 3443 Turn Signal Drill hole saw marker Front turn signal light From the headlight mounting surface measure out and mark the bucket at 4 and 7 so that the turn signals will be lined up with the center of the headlight ...

Page 386: ...85 www factoryfive com 508 291 3443 Drill the mounting holes with a hole saw Headlights Drill 1 8 7 16 drill bit razor knife masking tape air saw or jig saw level Headlight template headlight components ...

Page 387: ...Cut out the headlight templates from the back of the manual on the outermost diameter and tape them in the center of the fender with the line level with the ground Cut the center of the template out and trace the inner circle with a marker ...

Page 388: ...08 291 3443 Drill the two smaller corner holes with a drill bit to mark their location Follow this with a 7 16 drill bit Using a jig saw cut the inner hole out of the body use a larger drill bit to make a hole to start your cut ...

Page 389: ...388 www factoryfive com 508 291 3443 Put the rubber gasket on the light bucket Push the rubber grommet into the bucket ...

Page 390: ...389 www factoryfive com 508 291 3443 Test fit the light bucket making sure that they sit flat Drill the four mounting screw holes with the bucket as a template using a 1 8 drill bit ...

Page 391: ...de Mesh Nose latch Drill drill bit jig saw or air saw marker Packaged aluminum Hold the template up to the nose so that the bottom of the template is even with the bottom of the nose and the hood latch area is aligned with the finger recess ...

Page 392: ...391 www factoryfive com 508 291 3443 Mark the template on the body Use a jigsaw or hacksaw to cut the holes leaving the finger recess for the latch as shown ...

Page 393: ...rench 9 16 deep socket chassis grease rivet gun masking tape vise Nose trunk fastener assembly Open the latches and apply a little bit of chassis grease to the sides of the latch Work the latches a few times to help loosen them up Use a vise to flatten the mounting ears on each nose latch ...

Page 394: ...late to the front side of the latch as shown Position the latch from the backside of the body make sure the latch looks straight in the cutout from the outside then mark the back side of the body through the mounting holes Drill 7 32 holes for the mounting screws ...

Page 395: ...394 www factoryfive com 508 291 3443 Mount the latches to the nose Use the washers on the backside of the body Attach the U bolts to the nose latch striker mounts on the frame Do not tighten them yet ...

Page 396: ...395 www factoryfive com 508 291 3443 Radiator Exit opening Air saw or jig saw Use a jigsaw to make sure the opening is straight and even Side exhaust Air saw or jig saw ...

Page 397: ... pattern for the side exhaust cut out is pre traced on the body Use an air saw or jig saw to cut the area out Hold up the side exhaust to make sure there is clearance especially the lower front corner Locate the side exhaust rear mount parts ...

Page 398: ...ack under the cockpit area The body should be slotted for the hanger Attach the long leg of the exhaust hanger to the back side of the side exhaust mount using a 5 16 x 1 button head screw Attach the rubber mounts to short end of the hanger using the 5 16 x button head screws ...

Page 399: ... hangers to the frame mount using the 5 16 locknuts The body will have to be cut for the mounts to attach to the frame Door hinge 9 16 socket ratchet 3 16 long drill bit drill air saw or jig saw masking tape ruler measuring tape Door latch hinge components ...

Page 400: ...8 291 3443 Attach the door hinge mounts to the front of the frame mounts and center them up and down in the slots using the 3 8 carriage bolts locknuts and 9 16 socket On the door side put masking tape over the whole hinge area ...

Page 401: ...400 www factoryfive com 508 291 3443 Use a ruler to draw a line 0 25 in from the inner door recess Use a long 3 16 drill bit directly above the door hinge and drill through the body ...

Page 402: ... com 508 291 3443 Use a long 3 16 drill bit directly below the door hinge and drill through the body Repeat this for the bottom hinge arm On the inside of the door hinge area draw a line 1 75 in from the edge of the body ...

Page 403: ...02 www factoryfive com 508 291 3443 Use a tape measure to measure up from the lower door opening to the drill holes made and note the dimensions On the inside of the door opening mark these same heights ...

Page 404: ...403 www factoryfive com 508 291 3443 Draw lines across connecting the drilled holes and inner marks made Mark the area between the lines that will need to get cut for the hinge arms ...

Page 405: ...404 www factoryfive com 508 291 3443 Cut the areas out using an air saw or jig saw Door hinge Door latch hinge components ...

Page 406: ...405 www factoryfive com 508 291 3443 Push the door hinge bushings into the door hinge arms Left side door hinge ...

Page 407: ...nge openings in the body and to the frame mounts Attach the hinge arm assembly to the adjuster plate using the 2 shoulder bolts washers and 5 16 nuts It makes installing the shoulder bolts a bit easier if you grind an angle on the end of the shoulder instead of having it square ...

Page 408: ...ou tighten the nut down and you can still rotate the hinge easily then the washer is caught on the shoulder Loosen slightly adjust the washer and retighten Door frame prep 3 8 socket deep socket 7 16 2 9 16 wrenches 3 16 hex key Phillips head screwdriver rivet tool Door components body assembly secondary body fasteners ...

Page 409: ...408 www factoryfive com 508 291 3443 Latch Locate the left door frame Attach the door latch to the door frame using the flange bolts washers latch and 3 8 socket ...

Page 410: ...e clevis to the release lever using the x screws locknuts Philips head screwdriver and 7 16 wrench Locate the cable mount tabs jam nuts and release cable Attach the cable mount to the cable in the center of the adjustment range by hand only for now ...

Page 411: ...410 www factoryfive com 508 291 3443 Attach the other end of the release cable to the handle as shown Insert the ball end into the clevis on the latch ...

Page 412: ...ide of the top tube so that the cable is tight but not pulling on the release lever and the mount tab does not stick out past the side of the frame that will touch the door liner flat side Mark the mounting holes Drill 3 16 mounting holes where the mounting tab should be mounted ...

Page 413: ...508 291 3443 Attach the mounting tab using long 3 16 rivets and a rivet tool Adjust the play in the cable then use some blue Loctite and tighten the jam nuts using 2 9 16 wrenches Repeat this assembly for the right door latch ...

Page 414: ... 9 16 socket Leave the locknuts loose enough so that the door frame can still slide Doors Drill 5 16 drill bits 1 hole saw Loctite marker air saw or jig saw vise grip clamps masking tape Door components body assembly Take your time to align the doors properly There is plenty of built in adjustability ...

Page 415: ...ark an even inch flange around the door recess you can use a washer or small block of wood to help keep an even spacing around the inside of the door area Drill a 5 16 hole on the inside of the line marked to allow the saw blade to go into the door ...

Page 416: ...415 www factoryfive com 508 291 3443 Cut the inside of the door out along the line leaving the flange ...

Page 417: ...move to insert the door frame Cut the marked area of the door front using an air saw or jig saw Door frame install 5 16 drill bit drill 5 32 hex key flashlight socket ratchet marker ruler measuring tape The install pictures are shown off the car These steps are done with door frame attached to the frame still ...

Page 418: ... the door frame still on the car start inserting the door onto the frame at the top rear corner then swing it down Push the door onto the door The door frame will self locate around the door cut out clamp the door frame to the inner door liner ...

Page 419: ...ttom and front of the door We usually use a paint stick as a guide let the door sit on them and make sure it can fit around the front The door frame should touch the back of the fiberglass door If necessary loosen and move the door frame Clamp the door to the door frame then using a ruler draw lines at the same location as the flanges in the door opening on all four sides ...

Page 420: ...3443 Use a tape measure to measure on the inside of the door from the flange to the door frame Add 0 50 to the measurement so that the mark will be in the center of the tube and mark the inside of the door so that there are four marks ...

Page 421: ...420 www factoryfive com 508 291 3443 Rough locations of holes around door opening Drill through the door and frame with a 3 16 bit then open it up to 5 16 ...

Page 422: ...421 www factoryfive com 508 291 3443 Bolt the door to the door frame using the 5 16 x 1 50 button head screws locknuts 5 32 hex key and socket ...

Page 423: ...toryfive com 508 291 3443 Press the door latch so that it is in the locked position then use a flashlight to shine through the door opening at the back of the door so that you can see the circle of the door latch ...

Page 424: ...cut for the door striker to go into the door Allow room around the striker so that it will not hit the door fiberglass Remove the door from the door frame and use an air saw or jig saw to cut out the area marked on the door Reattach the door to the door frame ...

Page 425: ...between the door latch striker and body Inside door handle Marker air saw 3 32 drill bit drill Philips head screwdriver Make sure the hole will be above the upper door tube The flat end of the cut out area towards the back of the door Use the template above to mark the inside area to cut Use a ruler to check the scale before using ...

Page 426: ...ea towards the back of the door Use the cable and handle still hooked to the latch as a guide for the max reach of the cable Having a bend in the cable is ok Make sure the hole will be above the upper door tube Mark the inside of the template Use an air saw or jig saw to cut out the area marked on the door ...

Page 427: ...emove the cable from the handle and insert the door handle into door hole just made and reattach the cable Use the handle as a template to drill the 3 32 mounting screw holes Attach the handle to the door using the 8 chrome oval head screws ...

Page 428: ...the door reach through the center of the door latch with a marker and mark the body for the door striker It is easier to get a good center if the latch has been closed so you have a hole instead of an open slot to trace Use the 1 hole saw to drill for the striker ...

Page 429: ...Bolt the striker plate to the frame and the striker to the plate using the center of the slot through the body as a starting point for adjustment Adjust the latch striker on the mount plate until you have a nice fit on the door and tighten ...

Page 430: ...ose Scoops Optional From FFR the nose scoops are cosmetic we do not include parts to make them fresh air ducts for the footboxes like the originals If installing the optional nose scoops drill the mounting holes for them now Left side shown ...

Page 431: ...430 www factoryfive com 508 291 3443 Right side duct Final Prep Sand paper ...

Page 432: ... on the car before it is painted One of the most important details in the bodywork is the finish on all the edges and openings All of the following edges are visible on the finished car and need to be evened out and have a small radius sanded in for a good looking finish We suggest painting the wheel well backside of body near exhaust underside of nose and rear mesh insert area flat black Doors Re...

Page 433: ...432 www factoryfive com 508 291 3443 Backside of body near exhaust area Main radiator opening Door hinge openings Underside of Nose and fender flange ...

Page 434: ...uch nicer finish as well The headlight taillight fuel cap turn signal quick jack and trunk openings all are covered and do not need the finish work of the other areas Mark the trunk and door hinges before removing the last time so that you can bolt them back together in the same position that they came off They may still need minor adjusting during final body installation but this will get you muc...

Page 435: ...lease compound and a thorough cleaning with a wax remover is the best way to begin this job A lot of time and energy was spent on the mold so that the body work can be kept to a minimum Our body shop has stated that any more than 40 hours of body work is unnecessary Allow the bodywork or repairs performed to sit for several days outside in the sun or at elevated temperatures to allow the repair ma...

Page 436: ...435 www factoryfive com 508 291 3443 Final Assembly Chapter 5 ...

Page 437: ...the e brake boot Fit the boot over the handle and check the handle actuation When you are in a position where the boot clears the handle movement drill through the material into the tunnel and screw it into place Shifter Handle and Boot wrench 1 8 drill bit drill Philips head screwdriver marker thread lock Shifter handle components ...

Page 438: ...m 508 291 3443 Unpack the shift handle and bolt it to the transmission These bolts have a tendency to rattle loose so use a little thread locker Push the boot and trim rind down over the handle so it sits flush on the tunnel ...

Page 439: ...438 www factoryfive com 508 291 3443 Using a silver marker or white paint marker mark your screw holes on the tunnel Remove the boot and drill 1 8 holes in the spots you marked ...

Page 440: ...3 Re install the boot and screw down to the tunnel with the countersunk screws A small screwdriver can help to locate the holes Screw the two piece knob onto the shift handle and tighten so the shift pattern is in the correct orientation ...

Page 441: ...440 www factoryfive com 508 291 3443 Headlights Philips head screwdriver Headlight components Unpack the headlight mounting assembly Headlight fasteners 13419 13415 13418 13420 13416 ...

Page 442: ...441 www factoryfive com 508 291 3443 Screw the adjuster screws about halfway into the buckets Push the grommet into the side of the bucket ...

Page 443: ...442 www factoryfive com 508 291 3443 Screw the bucket onto the body Run the light plug harness through from the inside ...

Page 444: ...proper orientation The bottom of the bucket is the only screw boss that comes in from the side and the writing on the headlight should be right side up Screw the mounting flange onto the light with the 3 small tabs and small screws The tabs are bent to fit around the bosses on the light ...

Page 445: ... the connector Mount the bulb to the bucket The slotted parts of the mounting flange go onto the adjusting screws between the screw head and flange at the top and left side of the light The bottom right screw attaches the bucket to the light mounting flange ...

Page 446: ...he bucket The trim ring hooks over the bucket on the top and gets a screw it in the bottom using the oval head screw Drill a hole through the bottom of the nose headlight area so that a Philips head screwdriver will line up with the mounting hole location Turn Signals Front turn signal lights ...

Page 447: ...446 www factoryfive com 508 291 3443 Push the rubber bushing into the body hole Slide the trim ring onto the light ...

Page 448: ...447 www factoryfive com 508 291 3443 Pass the wires through the grommet Push the light into the rubber bushing ...

Page 449: ...ght Covers Drill drill bit Philips head screwdriver masking tape marker ruler and sandpaper Headlamp covers fasteners Put masking tape around the edge and on the inside around the edge of the headlight bucket so the paint will not get scratched ...

Page 450: ...at four points on the cover Move your fingers as necessary so that the cover is flush with the body everywhere If necessary use sandpaper on the edge of the plastic to shape the plastic Mark on the masking tape where your fingers were located Remove the cover At the points marked measure down from the edge of the bucket and mark the tape ...

Page 451: ...450 www factoryfive com 508 291 3443 Tape four of the mounting tabs in the bucket opening at the points marked Mark the locations of the mounting tap holes ...

Page 452: ...451 www factoryfive com 508 291 3443 Drill 3 16 holes into the bucket Use 3 16 rivets to attach the tabs to the headlight bucket ...

Page 453: ... www factoryfive com 508 291 3443 Reposition the cover carefully If necessary use a pair of pliers to bend the tabs to match the surface of the lens A drill bit for plastic is suggested to prevent cracking ...

Page 454: ...r Before final mounting the edges should be sanded to a smooth finish Start with 400 grit paper and work down to 1200 grit before finishing with 3M plastic polish for a nice finished edge Be extra careful not to scratch the surface of the lens using a small paint stick to wrap the paper around helps ...

Page 455: ...com 508 291 3443 Attach the cover to the mounting tabs using the 6 truss head screws and a Philips head screwdriver Tail lights Pliers masking tape 3 8 socket ratchet Tail light components Unpack the tail light components ...

Page 456: ...455 www factoryfive com 508 291 3443 ...

Page 457: ...456 www factoryfive com 508 291 3443 Put the light in the trim ring Put the inner rubber gasket in on top of the light ...

Page 458: ... ring in on top of the gasket and orient the studs so that there is one stud at the top of the light and two at the bottom when looking at the text on the lens Starting with the squared off end push the snap ring into the retaining groove in the trim ring ...

Page 459: ... duct tape or use a paint stick around one of the jaws on a set of pliers and squeeze the snap ring into the groove so that it is seated all the way Put the rubber mounting gasket onto the light assembly Cut the plug off the wires right next to the plug ...

Page 460: ...459 www factoryfive com 508 291 3443 Push the wires through the body mounting hole then attach the light to the body using the 10 32 locknuts 3 8 socket and ratchet Mounted taillights ...

Page 461: ...driver 11 32 or 9mm wrench Secondary body fasteners license plate light bracket components If not already in push the plastic license plate nuts into the bracket Attach the license plate bracket to the body using 3 16 rivets License plate light Insert the screws through the light and body ...

Page 462: ...91 3443 On the backside of the body place the ground wire for the light on one of the screws and then place a washer and locknut and tighten using a Philips head screwdriver and 11 32 or 9mm wrench Gas Cap Philips head screwdriver ...

Page 463: ...462 www factoryfive com 508 291 3443 Aston Lemans Cap Unpack the fuel cap and mounting hardware Put the gasket on the bottom surface of the cap ...

Page 464: ...ody and screw in using 5 of the countersunk screws Leave the inside most forward hole open The one remaining cap fastener is a longer screw and nut used for the ground strap screw it in from the top then put the ground strap washer and nut on from underneath ...

Page 465: ...se side mesh Silicone caulking gun duct tape Coupe pressed mesh Position the mesh screen behind the louver cut out area on the nose to see where the mesh will touch Apply silicone around the cut out area on the nose that the mesh will touch ...

Page 466: ...465 www factoryfive com 508 291 3443 Push the mesh into the silicone and use masking tape on the back to hold it in place or paint sticks and zip ties from the outside ...

Page 467: ...1 3443 Rear mesh Tin snips marker Coupe pressed mesh The rear mesh is a nice touch for looks but not necessary There are different ways to mount the mesh using spacers and fasteners or bend the sides and use silicone it is up to you ...

Page 468: ...ground to prevent scratching the roof of the body With the help of a friend turn the body upside down and place the roof on the rags The adhesive used to hold the headliner down is 3M Super77 or Super90 work best We have had the best results following the directions and spraying both material and body and waiting 1 minute to get tacky before final fit ...

Page 469: ...ill be no gaps Rough trim if there is excessive material left over but the final trim is best after the liner is glued in place The liner should follow the windshield pillars down to where they reach the dash and door opening Trim material around this area to get the liner to sit nicely into this channel ...

Page 470: ...nding wheel carefully bring these areas down flush to the roof Starting with the liner in position lift the front half of the roof not the window pillars while keeping either some books or helping hands holding the liners position on the body Spray both the liner and roof and then after 1 minute lay the liner back down slowly working from the middle out to prevent wrinkles or air pockets ...

Page 471: ...king the material in tightly to the inside corners make sure the adhesive is nice and uniform and covers these areas completely as they are where separation is the most likely to happen Spray and fit the windshield pillars still leaving them a little oversize to be trimmed later ...

Page 472: ... front glued in place and the rear half still loose check the fitment around the rear quarter window scoops and trim where needed to get the material to sit nice and flat Making pie cuts around the tighter curves helps get the material to lay flat ...

Page 473: ...mold seam location this is also a likely spot for bumps or high spots sand these away being careful not to go deeper than flush Spray and stick the rear half of the liner also working from front to back and saving the quarter window edges until last ...

Page 474: ... all corners and edges you can now trim it very carefully with a razor knife It is ok to leave a little extra around the window and pillar area as this will be covered up by weatherstripping The windshield weather strip without the bulb is for the windshield surround ...

Page 475: ...474 www factoryfive com 508 291 3443 The weather stripping with the build is for the side windows the bulb faces toward the outside of the car ...

Page 476: ...the liner In order to get the liner to not get pushed off the body start at an angle with the trim covering the liner side and then push it on so the body side edge is what is what is sliding in place If needed you can open up the trim with a punch or screwdriver to help if it is too tight and pulling back the liner ...

Page 477: ...he chassis Be very careful with the sides and slowly work it down into position Pull the sides out around the chassis and make sure the body covers the rear cockpit wall and top of the dash without pulling the material off either Nose mounting Reattach the nose hinges to the nose ...

Page 478: ...ional windshield installation shop do this installation Most glass shops prefer to use their own weather strip and materials to install the glass since they warranty the installation Our local installer used 409 T 102 weather stripping on our race car There are two ways to install the windshield with weatherstrip around the edge of the windshield or without weatherstrip We prefer without Have the ...

Page 479: ...91 3443 Apply urethane around the windshield flange Push the windshield into place Tape it if necessary so that it will not slip down Do not move touch the windshield for 24 hours Windshield mounted on the body without weatherstrip ...

Page 480: ...479 www factoryfive com 508 291 3443 Windshield mounted on the body with 409 T 102 weatherstrip Hatch side aluminum Push weatherstrip onto the top edge of the hatch side aluminum Right side shown ...

Page 481: ...yfive com 508 291 3443 From the wheel well push the hatch side aluminum into place so that the lower flange goes under the floor aluminum Push the front bottom in so that the side panel touches the side of the floor ...

Page 482: ...factoryfive com 508 291 3443 At the back push the panel in again so that the side panel touches the side of the floor Fuel Filler Neck Razor knife socket ratchet 3 16 drill bit drill Aston Lemans Cap components ...

Page 483: ...ller strap to the chassis using the screw that came in the cap hardware This wire prevents any static charge build up and must be used Use a measuring tape and marker to mark the filler tube 3 50 up from the lower bent section and 3 up from the line marked ...

Page 484: ...www factoryfive com 508 291 3443 Cut the hose at the two places marked Push the lower 90 hose section onto the gas cap along with a hose clamp Rotate the hose so it points down towards the fuel tank filler ...

Page 485: ...484 www factoryfive com 508 291 3443 Connect the other section of filler tube and hose to the fuel tube in the tank as shown Assemble the pieces together before tightening the hose clamps ...

Page 486: ...485 www factoryfive com 508 291 3443 Screw the plastic gas cap into the Aston Lemans style cap Aluminum 1 8 drill bit drill rivet gun silicone caulking gun Secondary body fasteners packaged aluminum ...

Page 487: ...ive com 508 291 3443 firewall extension Push weatherstrip around the curve of the panel and the horizontal area shown Right side shown Insert the panel into the area in front of the door hinge from the engine bay side ...

Page 488: ...8 291 3443 Attach weatherstrip to the top and bottom of the inner firewall extension Right side shown Insert the inner extension panel and move the panels until they fit together Trim the outer panel around the body if necessary ...

Page 489: ...ive com 508 291 3443 Use the kit aluminum screws to attach the panels together to the firewall and to the outside of the footbox Cockpit outside corners Push weatherstrip on to the curve of the aluminum panels as shown ...

Page 490: ... factoryfive com 508 291 3443 Attach the panel to the chassis by putting the panel behind the body flange and so it rests against the rollbar tubes Outside nose mount cover Locate the Outside nose mount covers ...

Page 491: ...oryfive com 508 291 3443 Drill silicone and rivet the panel behind the nose latch mounts Inside shock tower cover Check the fit of the hatch area inside shock tower cover and note the locations available for rivets ...

Page 492: ...ww factoryfive com 508 291 3443 Silicone drill and rivet the covers in place Fuel tank access covers Silicone and install the patch panels in the hatch area that cover the fuel sender and pickup access holes ...

Page 493: ...8 291 3443 Hatch area rear wall Put weatherstrip on the top edge of the aluminum leaving 3 8 at each end so the weatherstrip on the side panels does not hit the weatherstrip on this panel Insert the panel through the hatch area ...

Page 494: ...ive com 508 291 3443 From the wheel well push the hatch side aluminum flange behind the rear wall and use masking tape to hold it in place Drill and rivet the panel to the floor panel and the side hatch flange aluminum ...

Page 495: ...gainst the body hatch area flange then drill and rivet the panel to the flange Rear hatch final Razor knife socket ratchet Secondary body fasteners The rear hatch uses the weather stripping that has two legs on it one longer than the other the longer leg goes on the inside towards the hatch area ...

Page 496: ...he weather stripping onto the body with the longer leg towards the inside of the hatch to help prevent water getting to the hatch area Remount the hatch by placing the glass back in the opening set the gap around the body opening and bolting the two halves of the hinge arms together ...

Page 497: ...dshield area mount on the windshield Hold the mirror in place to find the best location up down and mark this on the windshield Follow the directions on the glue for attaching the mount to the windshield Side Mirror Phillips head screwdriver drill 3 32 3 16 drill bits marker wrench Rearview mirrors fasteners Only a driver side mirror is included with the kit A passenger side one is available if de...

Page 498: ...497 www factoryfive com 508 291 3443 Unpack the side mirror assembly Disassemble the mirror removing the large base from the stand ...

Page 499: ...291 3443 The large base is replaced by the smaller insert and gasket Temporarily bolt the mirror back together with the small insert Sit in the seat to find a good location you can see it from and see clearly over the rear fender ...

Page 500: ...www factoryfive com 508 291 3443 Mark the location and use the gasket to locate and drill the mounting holes Disassemble the mirror and bolt the mounting insert with mounting bolt and the gasket to the body ...

Page 501: ...500 www factoryfive com 508 291 3443 Slide the stand off and upper gasket down the bolt and onto the mounting bracket Bolt the main body of the mirror to the mounting stand off ...

Page 502: ... mirror into the body and adjust it before tightening Light wiring Wire strippers wire crimpers chassis harness instructions Headlight components amber front turn signal lights rear lights license plate light electrical system completion components ...

Page 503: ...ow beam Wire the turn signals up to the chassis harness On the light the white wire is the ground and the black wire is the positive Wire the taillights We normally run the upper lights in the rear for brakes and the lower for turn signals Wire the license plate light Check straps 3 16 drill bit drill rivet tool marker masking tape Secondary body fasteners door components ...

Page 504: ...factoryfive com 508 291 3443 Unpack the door check straps Drill and rivet the check strap to the 1 50 vertical frame tube near the top of the tube using a 3 16 rivet Put masking tape on the door near the front ...

Page 505: ... of the cut out The straps will stretch slightly over time so allow enough room for this by closing the door slightly from the maximum Use the check strap and mark the hole locations on the door Drill and rivet the check strap to the door Steering wheel center section WD40 5 32 hex key Steering wheel hardware Factory Five Badge ...

Page 506: ...ing wheel in the position that is most comfortable for you tighten the set screws on the upper steering bearing collar Unwrap the steering wheel center section and push it into the steering wheel and boss a little WD40 on the o ring helps if it is tight ...

Page 507: ...l the backing off the badge and stick it in the center section making sure you are aligned with the top of the steering wheel If necessary file any flashing off the bottom edge of the emblem so that it will fit Optional leather steering wheel ...

Page 508: ...plastic with a 60 point instead of the standard 118 or 135 point will reduce the chance of cracking during drilling They can be found at Mcmaster com in their plastic drill bit section Leave the protective film on the quarter window to prevent scratching Open the door Hold the quarter window up to the body for fitment and mark the areas that need to be sanded away or trimmed for a perfect fit ...

Page 509: ...ally has the most overhang make a mark on the window that lines up with the leading edge of the door From your edge mark draw a straight line up to the top flange of the quarter window for trimming Remove the window and evenly mark the window screw locations ...

Page 510: ...nd rough edging drill holes and mount the window using the screws provided Once you are happy with the mounted fit you can polish the finish edge We usually start with 400 grit sand paper and step up to a 1200 grit before finishing with 3M plastic polish ...

Page 511: ...510 www factoryfive com 508 291 3443 Side Exhaust 3 16 5 16 Hex key 9 16 socket ratchet 9 16 wrench drill Side Exhaust Attach the side exhaust using the kit fasteners 5 16 hex key and 9 16 socket ...

Page 512: ...mounts to the underside of the 1 50 tubing using the 10 x 1 self tapping screws Aluminum Splash guards 1 8 3 16 drill bit drill rivet gun silicone caulking gun socket ratchet extension marker Secondary body fasteners packaged aluminum front wheel and tire ...

Page 513: ... that the exhaust goes through the hole it makes Front wheel rear lower With the nose up put a wheel and tire on the front and turn the steering so that the rear of the tire is as close as possible to the frame Put some of the press on bulb seal around the outside edge of the aluminum where they will contact the body ...

Page 514: ...art of the body in front of the side exhaust Use a level to make sure the surface that will be close to the nose is flat Put a wheel and tire on the car and check for aluminum clearance If necessary push the aluminum back and mark the location on the inner aluminum panel Remove the wheel Drill and rivet the lower splash panel on ...

Page 515: ...anel to the bend only not the thin part that goes forward Right side shown Close the nose and align the splash panel with the lower splash panel and clamp the front part to the flange on the nose Open the nose and rivet the panel to the nose flange and silicone the backside of the weatherstrip to the side of the nose ...

Page 516: ...515 www factoryfive com 508 291 3443 Rear Wheel Push a piece of the bulb seal weather stripping around both rear splash guards where they will contact the body ...

Page 517: ... is not visible from the outside Silicone and rivet the panels in place Use a long 1 8 rivet as low as possible to attach the tab to the lower fender Carpet Optional Razor knife silicone caulking gun spray glue brake cleaner or acetone Interior trim carpet The carpet kit is optional on the Coupe although not originally equipped with it it helps with sound and noise insulation and makes the cockpit...

Page 518: ...517 www factoryfive com 508 291 3443 ...

Page 519: ...SION TUNNEL TOP CARPET EA 1 00 13 60558 TRANSMISSION TUNNEL REAR CARPET EA 1 00 14 60559 COCKPIT REAR WALL AND HATCH CARPET EA 1 00 15 60577 HATCH REAR WALL EA 1 00 16 60578 RIGHT FOOTBOX INSIDE WALL EA 1 00 17 60579 RIGHT FOOTBOX FRONT TOP EA 1 00 18 60580 RIGHT FOOTBOX FRONT BOTTOM EA 1 00 19 60581 RIGHT FOOTBOX FRONT RIGHT EA 1 00 20 60582 RIGHT FOOTBOX OUTSIDE CARPET EA 1 00 21 60583 RIGHT FOO...

Page 520: ...oryfive com 508 291 3443 The adhesive used to hold the carpet down is the same as we used on the dash pad 3M Super77 or Super90 work best Wipe down the bare aluminum with acetone or brake cleaner for good adhesion ...

Page 521: ...3 Double check the aluminum edges and corners for any areas that look like they are not sealed Run a small bead of silicone in these corners seams and around the slots where the seat harness mounts poke through Install the carpet pieces ...

Page 522: ...ot only perform poorly but may also offend oncoming traffic When replacing bulbs it is a good idea to verify that your lights are properly aimed Slight variances in filament position can translate to large variances in beam pattern The following procedure does not require special aiming equipment and ensures proper aim Find a flat level surface next to a vertical white wall where the car can be pa...

Page 523: ... vehicle centerline mark at the distance of Measurement B from the vehicle centerline vertical line Turn the headlights on and adjust the vertical aim of the headlights so that the top horizontal cutoff of each of the beams is located along the horizontal line drawn on the wall Adjust the horizontal aim of the low beam headlights so that the point at which the top cutoff of the beam begins to slop...

Page 524: ...1 8 Toe in 0 28 in Adjusting the upper control Arm Use the diagram below for reference Slightly loosen the three pivot bolts using a wrench and socket Loosen the jam nuts on both ends of each adjusting tubes using a 1 wrench Turn the adjusting tubes to lengthen or shorten the arm After you have adjusted the arm to the desired length tighten down the jam nuts against the adjusting tubes and then ti...

Page 525: ...ar is being aligned and retightened afterwards 2015 IRS Once the car has been aligned use a 15 8 wrench to loosen the upper control arm large jam nut and put some Loctite on the threads where the jam nut will sit Retighten the jam nut Optional Parts Check out www factoryfiveparts com for the latest options available Instructions are available in the parts catalog at www factoryfiveparts com instru...

Page 526: ...525 www factoryfive com 508 291 3443 Performance Reference Material and Technical Support Chapter 6 ...

Page 527: ... Halibrand style wheel we recommend using B F Goodrich Radial T A s but in different sizes The dimensions are the same 235 60 R15 s up front but bigger 275 50 R15 s in the rear Tire Rim Acceptable range 235 60 15 6 5 8 5 245 45 17 8 7 5 9 275 50 15 7 5 10 275 40 17 9 9 11 315 35 17 10 10 12 335 35 17 11 11 13 Information from Pirelli com yokohamatire com and bfgoodrich com The max rim width for a ...

Page 528: ...ar it is possible to use aftermarket 10 5 wide 27mm offset wheels If using a rear end that has been converted to 5 lug using the Cobra brake kit use two 4 5 95 backspace wheels 17 x 9 and 17 x 10 5 FR style wheels For a more vintage look take a look at our Halibrand style wheels Our online parts catalog www factoryfiveparts com has more views of these wheels on cars ...

Page 529: ...he parts less than a 3 100 lb Mustang does so all of the components will last longer and can take more abuse than they did on the Mustang Check out www factoryfive com to see what we offer Gears The Mustang 5 0 manual transmission car comes with either 2 73 or 3 08 rear end gear ratios from the factory If you can get a rear from an automatic car it will have 3 27 gears There is an ID tag on the re...

Page 530: ...ake more power Below is information for a pushrod 302 1987 1995 Mustang engine Throttle Body Stock 87 93 Mustang size 58mm A 65mm throttle body work well up to 350hp Ford Racing BBK Jegs Summit Racing etc sell many other sizes Mass Air Meter Stock 87 93 Mustang size 55mm In order to increase the flow of air above 5000 rpm upgrade from the stock mass air sensor Aftermarket 70 mm or 75 mm mass air u...

Page 531: ...ds bent tubing The stock ones are not and are restrictive on non stock engines If using a 351W engine there are two options use 351W engine swap headers from Ford Racing M 9430 A58 or MAC E358692 or if smog catalytic converters are not necessary use our full length 4 into 4 headers Timing Most computer chips simply change the timing of the engine and slightly enrich the mixture Using a timing ligh...

Page 532: ...ch component below has been selected to optimize the capabilities of the system If an attempt is made to utilize some of the specified components but not all of them in correct combination then braking abilities may not be satisfactory Some of the setups may not clear some wheel sizes and designs If doing a donor build we highly recommend using Carbotech XP 8 Porterfield R 4 or Hawk Blue brake pad...

Page 533: ...ve Racing kits Also has many vendor links Helpful 5 0L Ford Dyno Tests By Richard Holdener www cartechbooks com Building 4 6 5 4L Ford Horsepower By Richard Holdener www cartechbooks com Engineer to Win By Carroll Smith www motorbooks com Prepare to Win By Carroll Smith www motorbooks com Ford Fuel Injection Electronic Engine Control 1988 1993 By Charles O Probst www bentleypublishers com ford mus...

Page 534: ...surance com Country Companies 800 950 5877 www countryfinancial com Spinap Fred Benedict Eastern US 914 946 9300 A Final Note about Completed Cars and Car Builders If you are reading this manual then you are at least contemplating the idea of building your own race car Many component car companies offer services to those folks who find part or all of this too much to tackle We don t If you are con...

Page 535: ...534 www factoryfive com 508 291 3443 Appendix A Templates ...

Page 536: ...535 www factoryfive com 508 291 3443 ...

Page 537: ...536 www factoryfive com 508 291 3443 ...

Page 538: ...537 www factoryfive com 508 291 3443 ...

Page 539: ...538 www factoryfive com 508 291 3443 ...

Page 540: ...539 www factoryfive com 508 291 3443 Appendix B Donor Parts List ...

Page 541: ...ket and hoses High pressure fuel line tank to filter Low pressure return line to fuel tank High and low pressure solid fuel lines attached to engine fuel rails Fuel evaporative canister solenoid and tubing Brakes Wheels Front and rear brake rotor drum calipers pads flexible lines etc Mount front and rear brake line riveted to donor Front and rear wheels with lug nuts Spindles front Rear upper cont...

Page 542: ...541 www factoryfive com 508 291 3443 Appendix C Race Yearly check sheet ...

Page 543: ...collars taped tight ___ Tire pressure set recommend 22 25 psi ___ Lug nuts tight 90 lbft ___ Brakes Front Caliper bolts tight ___ Rear caliper bolts tight ___ Rotors clean no cracks or groves ___ Brakes bled bleeders tight ___ No leaks under pressure ___ Master cylinder bolts tight ___ Reservoir full ___ Flexible lines tied up and undamaged ___ Cockpit Seat securely bolted ___ Harnesses securely b...

Page 544: ...joints no bind or wear ___ Output shaft snug no bind ___ Drive shaft bolts tight ___ Transmission mount bolts tight ___ Bellhousing bolts tight ___ Starter tight ___ Engine Oil level checked changed cap tight ___ Water level checked including reservoir ___ Plug wires tight including coil ___ Belts tight ___ Engine mount nuts tight ___ Fuel lines no leaks under pressure ___ No coolant or oil leaks ...

Page 545: ...544 www factoryfive com 508 291 3443 Appendix D Torque Specifications ...

Page 546: ... 24 19 16 30 24 34 7 16 14 48 7 16 24 54 13 75 20 83 9 16 12 100 9 16 18 100 11 100 14 100 Thread SAE Metric Zinc Plated Ft Lb M8 18 M10 33 M12 61 M14 98 M16 120 ATTENTION Use the following specs in order to torque Stainless Bolts 3 16 11 ft lb 132 in lb 16 ft lb 192 in lb Use above specs unless otherwise noted in the assembly process ...

Page 547: ...546 www factoryfive com 508 291 3443 Appendix E Mustang Specifications ...

Page 548: ... 6L 265 5000 305 4000 Solid Axle T 45 17 x8 03 04 Cobra DOHC 4 6L Supercharged 390 6000 390 3500 Independent T 56 17 x8 03 04 Mach 1 DOHC 4 6L 305 5800 320 4200 Solid Axle Tremec 3650 17 x8 Engine Year Engine Horsepower Torque Rating Induction Comp Ratio 1982 5 0L V8 157 4200 240 2400 2V carb 8 3 1 1983 5 0L V8 175 4200 245 2400 4V carb 8 3 1 1984 5 0L V8 175 4200 245 2400 4V carb 8 3 1 1984 5 0L ...

Page 549: ... a built in program to run the engine rich at wide open throttle Oxygen sensors will usually be most effective when placed near the collection point of headers because the exhaust will remain very hot and an average measurement of all of the cylinders can be taken All oxygen sensors are recommended to be used when placing a fuel injected engine into a Factory Five kit Exhaust headers 1986 to 1993 ...

Page 550: ...ering racks from 1987 2004 are 15 1 In 1994 the racks switched from having a splined shaft for attachment to the steering column to a triangle shaped end as well as changing the inner and outer tie rod ends The 1994 to 2004 inner and outer tie rods are too long and do not work with an FFR kit The Factory Five 4 6L steering kit includes the correct inner and outer tie rod ends along with the correc...

Page 551: ...550 www factoryfive com 508 291 3443 Appendix F Fluid Specifications ...

Page 552: ... 0L Coyote 5W 20 8 0 qts w FFR pan Transmission Oil Type T 5 T 45 3650 TKO T 56 Mercon Dexron III Trans Fluid 2 8 qts 3 25 qts 4 0 qts 2 64 qts 4 0 qts 8 8 Solid Rear Axle Oil Type Capacity Friction Modifier 80W 90 Gear oil 1 875 qts 4 oz 8 8 IRS Oil Type Capacity Friction Modifier 80W 90 Gear oil 1 50 qts 5 oz ...

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