Factory Five Racing Mk3 Roadster Assembly Manual Download

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237

www.factoryfive.com

508-291-3443

3 Link Rear Suspension

Installation Instructions – Initial Build with Frame Prepared at Factory

Parts Included in Kit:

1326

3 LINK HARDWARE

1.00

1083

1/2"-13 x 1.25" BOLT

4.00

1397

6 1/2"

WASHER

10.00

1238

7 5/8"

WASHER

EA 4.00

1238

5/8"-11 NYLON LOCKNUT

2.00

1406

SHOCK SPACER BUSHING, 0.32"

1.00

1378

1/2"-13 x 3.50" BOLT

2.00

1083

1/2"-13 NYLON LOCK NUT

6.00

1321

SHOCK SPACER SHIM

2.00

1321

5/8"-11 x 3.50" BOLT

2.00

1378

UPPER LINK FRAME MOUNT

1.00

1320

PANHARD BAR FRAME MOUNT

1.00

1320

PANHARD BAR AXLE MOUNT (PASSENGER SIDE)

1.00

1402

TRACTION-LOK BRACKET (DRIVER)

1.00

1414

PANHARD BAR KIT

1.00

1316

7 PANHARD

BAR

EA 1.00

1316

JAM NUT, LEFT HAND THREAD

1.00

1316

ROD END, LEFT HAND THREAD

1.00

1238

JAM NUT, RIGHT HAND THREAD

1.00

1234

ROD END, RIGHT HAND THREAD

1.00

1406

ROD END SPACER, 0.375"

4.00

1406

ROD END SPACER, 0.25"

1.00

1238

5/8"-11 x 3" BOLT

2.00

1238

7 5/8"

WASHER

EA 2.00

1238

5/8"-11 NYLON LOCKNUT

2.00

1238

2.5" LOWER FRAME MOUNT BOLT

1.00

Summary of Contents for Mk3 Roadster

Page 1: ...i www factoryfive com 508 291 3443...

Page 2: ...PUSH ROD 63 COCKPIT ALUMINUM 65 FUEL BRAKE AND BATTERY LINES 70 FUEL LINE 73 BATTERY RELOCATION KIT 75 ENGINE PREPARATION 77 ALTERNATE DRIVE PULLEY 78 ENGINE TRANSMISSION DRIVE SHAFT 79 ACCELERATOR C...

Page 3: ...ION 177 EMERGENCY BRAKE BOOT INSTALLATION 178 SHIFTER INSTALLATION 179 NAMEPLATE 180 FINISHING TOUCHES 181 CHAPTER 3 PERFORMANCE REFERENCE MATERIAL AND TECHNICAL SUPPORT 184 TECHNICAL SUPPORT 185 REGI...

Page 4: ...o existing cars As fun as this project is a person should be candid about their abilities turning a wrench This is not a place for novices That is even more true in racing where danger and risk are pa...

Page 5: ...in an unreasonable and perhaps even undeserved way All the way thru the process as you build your car the seasoned guys at Factory Five in tech support will help you The larger community of Factory Fi...

Page 6: ...only a collection of parts designed for use primarily as a race car Factory Five Racing does not build completed or partially completed vehicles You are responsible for ensuring that the vehicle you...

Page 7: ...d safety practices such as the use of eye protection protective clothing and gloves Keep the battery disconnected whenever you work on fuel or electrical systems and always keep a fire extinguisher ha...

Page 8: ...ch set 3 8 15 16 Metric combination wrench set 10mm 18mm Full set of standard and Phillips head screwdrivers Standard Hex key set Long nose pliers 4 5 Snap ring pliers Pop rivet tool with 1 8 and 3 16...

Page 9: ...d 4 Qts Brake fluid DOT 3 Oil filter Fuel filter Battery Spark plugs 5 minute epoxy glue Black permanent marker Duct tape Electrical tape Bodywork supplies Rags Gojo pumice hand cleaner Spray paint fo...

Page 10: ...10 www factoryfive com 508 291 3443 Chapter 1 Donor Parts and Parts Needed...

Page 11: ...e 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...

Page 12: ...A H Motors Los Angeles CA 310 678 1617 Richard Gillespie Mustang Village Fontana CA 909 823 7915 Scott or Tom Cypress Auto Berkley CA 510 451 3034 Mike Percy Mustang Depot Las Vegas NV 702 281 4517 C...

Page 13: ...the rear end is to grab the rear wheel at the top and rock the car back and forth by pushing and pulling in and out This will give you an idea of free play in the axles Some play about 1mm is OK What...

Page 14: ...o disassemble a Mustang please refer to the Appendix B donor parts list The Chilton s repair manual has quite good step by step disassembly instructions for each assembly We have tried to be helpful h...

Page 15: ...RTS Mustang power booster push rod 1 Remove the brake rod retainer clip from the top of the brake pedal 2 Remember the order in which these washers and spring clips are removed so that you can reinsta...

Page 16: ...e marker and bucket PARTS Mustang coil EGR assembly vacuum lines starter solenoid mass air meter and throttle cable 1 Disconnect and remove the battery 2 At the starter solenoid and coil disconnect th...

Page 17: ...emove the center consul cover the handle 3 Remove the carpet from the car Pedal Box Accelerator Pedal and Clutch Cable ATTENTION The pedal box comes unpainted from Ford Even on newer cars there is a l...

Page 18: ...r and Speedometer Cable TOOLS Socket set Phillips head screwdrivers Needle nose pliers PARTS Mustang Speedometer cable 1 Remove all visible screws from the dash gauge pod You can reach the two screws...

Page 19: ...set extension Phillips head screwdrivers needle nose pliers PARTS Turn signal and ignition switches Steering column with ignition turn signal stalk and under dash mounts 1 Remove the steering column m...

Page 20: ...ess and all of the black boxes hooked into it from the dash Mark all of the connectors to prevent any confusion later 3 Disconnect the connectors from the headlights and engine harnesses marking each...

Page 21: ...e exhaust in the engine bay 3 Remove the wiring harness plug from the sending unit 4 Remove the speedometer sending unit bolt using an 11mm socket 5 Pull the sending unit straight out 6 Replace the sc...

Page 22: ...ming from the handle it should move a couple of inches 4 Carefully remove one brake cable from the T at a time 5 Unbolt and remove the emergency brake handle Fuel Inertia cut off switch ATTENTION Sock...

Page 23: ...all oval rubber pieces to hang the rear post on the side exhaust to the frame 3 The H Pipe is mounted to the headers using four nuts and is mounted to the transmission cross member with sliding pins i...

Page 24: ...n exhaust H pipe tube holder plate sandwiched between the transmission mount and the transmission that must be removed All you need is the transmission mount with the two bolts sticking down Front Sus...

Page 25: ...aker bar to remove them 21 Remove the lower control arm from the car Fuel Tank ATTENTION Extreme caution should be used when handling and storing used fuel tanks Make sure to close off openings Use th...

Page 26: ...Make sure not to damage dent or crimp the brake lines mounted to the rear end If using an independent rear suspension you will still need to remove the quad shocks but you do not need the frame brack...

Page 27: ...The sway bar does not improve the handling of the car 16 Use a drill with a bit to drill out the rivets on the brake bracket which retain it to the body above the differential Keep this bracket for us...

Page 28: ...used on the front control arms for the coil over shocks 3 Drill the lower control arm mount holes with a drill bit Front Lower Control Arms 1 Remove the area near the center of the spring mount to pr...

Page 29: ...lower than the bolt there is another set of holes This hole is the four cylinder pivot bolt hole By keeping the master cylinder push rod in the same place and lowering the brake pedal bolt to the fou...

Page 30: ...443 Accelerator pedal modified 3 Remove the bracket for the cruise control brake switch from the pedal box 87 93 Pedal Box 1 Mark the mounting face of the 1 up from the bottom of the mounting plate 87...

Page 31: ...dal box Top outside of pedal box 2 Remove the cruise control switch located under the plastic clutch quadrant on the right side of the pedal box 3 Drill out the four spot welds on the front face of th...

Page 32: ...cers on pedal box front 6 Relocate brake pedal spring to pedal box triangular opening Brake pedal spring in triangular opening Wiring Harness Many people choose to cut down the wiring harness to use o...

Page 33: ...rod is on the cockpit side of the booster canister and must be removed for use 4 To get the power booster push rod out of the housing put cockpit side of the booster in a vise and break the plastic e...

Page 34: ...side on the right side of the engine and the right header on the left side of the engine Thread all of the bolts on the headers before tightening any of them to make installation easier Alternate Driv...

Page 35: ...le plug Keep in mind this must not be airtight Air must be allowed to move in and out of the holes If you use a hole plug drill a small air release hole in the center Cleaning and Detailing Before you...

Page 36: ...ubber lines hoses 5 When repainting parts a consistent color scheme works best and looks the nicest 6 After cleaning the engine replace the spark plugs When removing the plugs look for oil on them or...

Page 37: ...cover The Internet has changed this part of the business forever Parts are now much easier to find on line Check out a number of customer and enthusiast based forums for help and advice If you are goi...

Page 38: ...38 www factoryfive com 508 291 3443 Chapter 2 Step By Step Chassis Build up...

Page 39: ...e 8 hex driver 1 Four strong people can lift and move the body frame assembly into the work area Lift by the quick jacks in the back and the radiator nose hole and wheel wells in the front 2 Remove th...

Page 40: ...y buck to support it A body buck diagram is in the appendix The dimensions do not have to be exact A rough shape is all that is needed to hold the body Body buck Aluminum Removal and Preparation ATTEN...

Page 41: ...ashion Engine Bay Aluminum TOOLS Eye protection drill w 8 hex nut driver drill bits drill rivet tool silicone caulk gun 8 self tapping screws PARTS Engine bay aluminum FFR 10892 1 Before you install t...

Page 42: ...ion 9 Run a silicone bead along the front of the horizontal 2 x 2 between the upright on the passenger side and the angled tubes in the driver foot box area 10 Attach the firewall with sheet metal scr...

Page 43: ...he clamped ball joint The same arm is used for both sides of the car 2 Attach the control arms to the frame Torque the two bolts that hold the arm to the frame to 135 149Nm 100 110 lbft Adjusting the...

Page 44: ...nt use the spacer that comes with the ball joint Ball joint in IFS Bracket 6 Attach the Spindle adapter bracket upper A arm assembly to the spindle using the factory strut bolts and torque to 135 149N...

Page 45: ...is in the air this is OK The boot will seat when the car is on the ground It is only a dust boot and the grease will not leak Koni Front Coil Over Shock Assembly TOOLS Snap ring pliers wrench socket r...

Page 46: ...nd bump stop to make sure that it is tight 3 Screw the spring seat down on the sleeve so it is closer to the unthreaded end 4 Slide the coil sleeve over the body of the damper beginning at the end whi...

Page 47: ...at on the shaft end of the shock and push the rubber bumper up against it 8 Rotate the spring seat back up the sleeve so that the spring pushes the hat tight against the end of the shock 9 Install the...

Page 48: ...k bracket on the stock lower control arm using the 0 43 spacers that are supplied in the kit 11 Check for shock clearance on brake lines emergency brake cables Brake Calipers frame and control arms 12...

Page 49: ...49 www factoryfive com 508 291 3443 14 Fasten the shock to the top mount with the fasteners and 0 675 spacers provided 15 Adjust the ride height of the car...

Page 50: ...ep socket PARTS Steering system hardware FFR 11073 Box 9A Steering shaft assembly 14453 pillow block hardware FFR 11072 1 Install the driver s side foot box front aluminum vertical wall FFR 10904 usin...

Page 51: ...t the shaft into the 1 DD tube 10 Tighten the set screws and the jam nuts on both U joints and the 1 locking collar 11 Tighten the bolts holding the Pillow block and 1 flange bearing to the frame 12 R...

Page 52: ...ower Steering shaft FFR 13701 Donor steering rack Above Ford steering rack and fasteners hydraulic lines removed 1 If not already in insert the stock rubber bushings and kit spacer sleeves into the ra...

Page 53: ...ts to the bolt torque spec Steering rack mounted to frame Note The inner Tie Rod Extensions are for stock Power Steering Racks only not for manual steering racks 5 Pull back the rubber boot on the inn...

Page 54: ...the boot back onto the steering rack body and attach with zip ties 9 The track of the FFR Roadster front end is a little narrower than the Mustang Screw in the tie rod ends until the inner tie rod is...

Page 55: ...axle with gear oil See Appendix I for specifications and capacities 2 Position the brackets on the rear end with the bolts provided the two short bolts go on the sides Attach the lower shock bracket t...

Page 56: ...e has between 300 and 400 hp use the middle set of holes If the engine has more than 400 hp use the lowest set of holes Use the highest set of holes possible that prevents the car from having axle hop...

Page 57: ...ising the rear taking care to position the two lower control arm rubber spring mounts and the springs in their correct seats on the lower control arms Rear driver s side quad shock mount Leading bolt...

Page 58: ...izontal quad shock to the frame w axle straps 24 Put the wheels and tires on the suspension and lower the chassis to the correct ride height Ride height should be 4 at the front and 4 at the back meas...

Page 59: ...ks that contain fuel Make sure to close off the tank with the factory cap and seal the fuel line ends Keep the tank level TOOLS 9 16 and 5 16 deep sockets combination wrenches rubber mallet hammer 5 1...

Page 60: ...o the front posts Use kit fasteners provided Tank strap attached to frame Side view The Mustang fuel tank installed into the rear frame Fuel Filter ATTENTION Make sure to install the fuel filter in th...

Page 61: ...o make sure there is sufficient clearance Fuel filter mounted to the passenger side 2 x 3 tube Pedals TOOLS 9 16 sockets 3 16 5 16 hex key drill 9 16 combination wrench 7 16 drill bits silicone rivet...

Page 62: ...box Positioning the pedal box 2 There are four holes on the Mustang pedal assembly on top of the tubing Mark these holes on the tubes 3 The right hole for the master cylinder must also be marked on th...

Page 63: ...es in the front of the foot box The four socket head bolts hold the foot box to the tubes Use the large fender washers FFR 12337 on the underside of the tubing 11 Attach the trimmed accelerator pedal...

Page 64: ...or taller then use more 2 One of these bolts doubles as a foot box lower mounting bolt 3 Tighten all of the mounting bolts for the pedal box and master cylinder 4 Install the push rod from the power b...

Page 65: ...dash harness hole in the front of the driver footbox The engine harness hole in the passenger side firewall extension The Passenger side F panel hole The transmission top cover shifter hole The speedo...

Page 66: ...of the transmission tunnel 7 Drill the panel for the rivet holes 9 Remove the Front Vertical Wall panel 8 Wipe and clean the aluminum panel and frame 9 Apply silicone to the back side of the top tab...

Page 67: ...anel with self tapping screws 18 Leave the top edge of the panel that rests along the tubing unattached so that the foot box top can fit under it later 19 Rivet the panels in place Driver s footbox 20...

Page 68: ...g the factory mounting hole and self tapping screws Note where the panel touches the frame 5 Remove the panel 6 Apply silicone to the underside of the 2 x 2 frame tube where the panel will contact 7 I...

Page 69: ...7 Rivet the panel in place 18 Position the outside wall with self tapping screws 19 Mark where the rivets will go remove the panel and apply silicone to the panels 20 Install the outer wall and drill...

Page 70: ...o below 2 Mark where the rivets will go 3 Remove the panel and apply silicone to the frame 4 Attach the panels with self tapping screws 5 Rivet the panel in place U joint and Transmission rear corner...

Page 71: ...TOOLS Phillips and regular head screwdrivers tube bender double flaring set tube cutter 3 16 drill bit drill rivet tool marker tape measure electrical tape PARTS Insulated clip hardware FFR 11029 batt...

Page 72: ...ang mount Front Brake Line 1 Hold the front flexible line to the frame just behind the upper A arm on the tubing in the opening Rotate the front wheels to check for wheel clearance Move the brake line...

Page 73: ...al steering rack Fuel Line 1 The return FFR 10784 and 5 16 send FFR 10783 fuel lines are provided in the kit The vapor line is used from the Mustang donor 2 Measure two feet of both lines and mark wit...

Page 74: ...ee to four inches from the fuel filter 6 Continue the line to the end of the 2 x 3 frame member then go down and make another bend so that the line will clear under the tubing that forms the lower tru...

Page 75: ...h the hard line to the fuel canister which will be mounted later to about where the fuel lines end up in the engine bay Battery Relocation Kit 1 Attach the battery ground cable securely to an area fre...

Page 76: ...tube in for the bolt to go into Note In SCCA as long as the battery does not move it is ok NHRA rules specify two bolts as required Mark the locations of the bolts on the aluminum so that holes can b...

Page 77: ...he cable to the side of the foot box and the floor using kit zip ties 26 Drill two 3 16 holes and pass the zip ties through one hole inside the car then through the other hole and fasten it 27 Leave t...

Page 78: ...going to mount the relocate bracket on the X member make sure to drill this before you install your engine Otherwise your drill won t fit in between the engine and the frame Alternate Drive Pulley AT...

Page 79: ...lly align the front side of the pulley with the front side of the other pulleys If the new pulley is not lined up properly and is too far in use the arbor shims included with the kit to go between the...

Page 80: ...arm and must be trimmed off level as shown in the picture Tremec housing with torque arm mount Torque arm mount removed for crossmember clearance NOTE If you are using a TKO transmission two spacers n...

Page 81: ...hen removing the headers and reversing the headers Engine transmission on hoist 4 The engine transmission assembly should be drained of oil to ease installation and so that the transmission oil does n...

Page 82: ...d driver s side mount Engine mount on the frame Note the ground cable hole in the side of the engine mount 8 Tighten the large engine mount bolt on each side and secure the two smaller transmission bo...

Page 83: ...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 15 Fill the Transmission...

Page 84: ...g the cable straight so it will not rub on the side of the cable sheath If a higher location is desired some material can be removed from the bottom of the clutch quadrant stop If mounting higher mark...

Page 85: ...ck 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...

Page 86: ...oles for the bolts in the pedal 4 Attach the accelerator pedal to the mount using the x bolts washers and lock nuts 5 Cut the accelerator pedal capture in the corner using a pair of wire cutters 6 Sli...

Page 87: ...he cover and a circlip anchors the cable shielding to the bell housing Be careful anchoring the cover as the aluminum threads can strip easily Installing the clutch cable Note The Inner footbox wall w...

Page 88: ...t w two 14 screws 2 Attach the vent hose from the gas tank to the canister and the hose leading to the engine Emissions fuel vapor canister mounted Radiator Hoses Fan Shroud ATTENTION Avoid damage to...

Page 89: ...of the fan housing once the fan is attached to the shroud If they do make contact with the housing loosen the screws attaching the mount bars and bend the tabs of the mount bars so that the fan housi...

Page 90: ...reduce the adapter hose from 1 75 to 1 50 and from 1 75 to 1 25 15 If an adapter is needed use one of the adapter hose kits Measure which reducer will be needed and remove the one that is not needed...

Page 91: ...ame 28 Double check the hose clamps on the tube Note If using the stock Mustang radiator the radiator hose should be routed through the F panel If the FFR radiator is being used the upper radiator hos...

Page 92: ...a time starting the car after each cut to make sure it runs Use the Chilton s or Ford wiring diagrams If you did not take the harness out of the car yourself when connecting the plugs together check t...

Page 93: ...t the inertia fuel cut off switch on the inside Mustang inertia cut off switch 3 Run 2 wires using blue wire extensions provided in kit from the left rear side marker light up through the roll bar rea...

Page 94: ...vement to the beginning of the driver foot box passing over the transmission harness section on the way 8 Place insulation grommeting around the hole in the upper corner of the inside driver foot box...

Page 95: ...arness is started at the alternator and runs forward to the passenger headlight area then goes under the fan shroud to the driver s side headlight area and then rearward to the coil and starter relay...

Page 96: ...f the driver s side foot box 2 The key to routing the dash harness is to start on the inside of the foot box and push the smaller items through the large hole from the inside 3 The connections for the...

Page 97: ...lenoid 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 terminal The newer starters can be recognized by their s...

Page 98: ...adlight and hazard switches using the aluminum pieces FFR s 10566 10638 in the center of the car just to the left of the transmission front cover 11 Attach the harness across the 2 x 2 tube using the...

Page 99: ...side of the firewall provided the optional heater defroster is not being used 3 Use the drilled holes and cable tie trick to hold the extra harness to the top of the passenger foot box 4 The harness s...

Page 100: ...100 www factoryfive com 508 291 3443 Engine harness plug mounted in firewall...

Page 101: ...P sensor used on speed density cars except it does not get hooked up to a vacuum source it is left open to the air 6 Attach the computer connectors to the starter solenoid and the ground to the backsi...

Page 102: ...e with the kit to seat in the holes 4 Attach the male pin connectors in the kit to one end of the wire extensions using a crimping tool 5 Attach the blue wire connectors to the other end of the wire e...

Page 103: ...ate steel that also holds the windshield and the vertical tubing next to it The switch spans the gap Use two 1 screws and a 5 16 socket and 9 64 drill bit 2 The ignition switch mounts under the turn s...

Page 104: ...104 www factoryfive com 508 291 3443 Front trunk side wall 2 The Rear trunk sidewall is mounted to the outside of the frame Rear trunk side wall...

Page 105: ...to the upper trunk This can be tricky but take your time and it will fit without damage This is one of those steps where you need to take your time and proceed slowly Fitting the mid trunk panel Bend...

Page 106: ...unts in the trunk Emergency Brake Handle and Cables ATTENTION The 99 04 Parking brake handle has different mounting locations and T cable length than the older 87 98 handles TOOLS deep socket 3 16 hex...

Page 107: ...ount bracket 3 Push the cable through the holes and snap in the cable retainers 4 If using 87 92 cables after the sheath is snapped into the bracket and run the cable down and under the 4 cross member...

Page 108: ...108 www factoryfive com 508 291 3443 Brake cables running under the 4 crossmember Brake cables attached to the T cable...

Page 109: ...the underside 6 On 99 04 handles remove the small bracket and screw that prevents the ratcheting adjustment gear from turning Ratchet gear stop bracket and screw 7 Bolt the handle to the mount bracket...

Page 110: ...using the button and make sure it is all the way in the down position 10 Pull on the cables one at a time and slide them into the slots on the T connector from the Mustang Emergency brake T 11 Pull u...

Page 111: ...eels Tires and Ride Height ATTENTION The wheel tire size charts are in the performance modification section of the manual 1 Mount the wheels onto the car 2 The ride height in the front is 4 5 This is...

Page 112: ...ound to be missing cut the connector off and attach a circular ground connector 5 Various clicking and whirring sounds are a great indication that things are working well 6 Check the oil level and oil...

Page 113: ...eck the distance to the white gauge pod on the firewall The length of the wires from the ignition and turn signal switches to the white control box is very tight Make sure that these items are install...

Page 114: ...on then slide the front hoop on all the way down to the small knobs on the holders Push the rear leg up onto the front tube 2 Use vise grips or a friend to hold the rear roll bar leg in place 3 Drill...

Page 115: ...st louver headlight tail light turn signal windshield slots wipers if ordered gas cap hood scoop and side mount holes are done at the factory The body comes standard with the large nose hole oil coole...

Page 116: ...of the cutout Windshield Cut Outs TOOLS Hand jigsaw marker pen and ruler 1 At the factory in the chassis assembly station we drill two holes at each side of the body forward of the cockpit area and ne...

Page 117: ...oyed TOOLS Hand jigsaw 2 5 hole saw drill marker clear tape 1 Cut out the side exhaust template from Appendix A 2 The template goes down to the bottom edge of the body There is nothing but air under t...

Page 118: ...ke it fit perfectly 5 Use a 1 25 hole saw at the Tail light mount location to make the center hole 6 Cut out the template in Appendix A using the center holes to position the template on the body 7 Dr...

Page 119: ...t template that follows cut out the two small holes and the inner solid line circle Leave the template attached to the paper so that it has extra support 3 Tape the template to one of the headlight lo...

Page 120: ...corners of the hood scoop leaving room on the edge slightly more than the thickness of the material 2 Cut out the scoop making sure that the saw has clearance on the backside and is not at an angle 3...

Page 121: ...is kit complies in any way with these laws TOOLS Drill 3 16 drill bits masking or clear tape PARTS License light bracket components FFR 11041 1 Position the template found in Appendix A on the flat ar...

Page 122: ...he top plate with the front tube Top hood pin plate mounted to side plate 3 Drill a 3 16 hole in the front tube 4 Rivet the plate to the front tube L Shaped Hood Handles TOOLS Drill drill bit 7 8 hole...

Page 123: ...od on the car The driver s side handle square rod is too long and hits the top of the foot box Mark and shorten this rod with a hacksaw until it clears the foot box 6 The handle is locked pointing tow...

Page 124: ...ood handles Mounted L shaped hood handle with cam wedge Body Mounting ATTENTION It is smart to have some help when doing this step Much of this positioning is push and pull until all holes line up The...

Page 125: ...ts The quick jack and body mount plate does not go through the brake vent holes nor does it go through the front nose openings 6 Gently lower the rear tail section of the body At the same time have so...

Page 126: ...n wrenches socket 5 16 hex key floor jack PARTS Quick jack bumper components FFR 10533 1 Lower the gas tank using a jack in the middle of the tank to hold it You ll need a 9 16 wrench and 5 16 hex key...

Page 127: ...g plate of the front coil over bracket Check the line up with the front X member so that the tape measure is parallel Make this measurement on each side of the body so that the front of the body is ce...

Page 128: ...the panel with a 3 16 line 4 Remove the door and trim the panel so that the line can not be seen This will give an even gap around the door Repeat as necessary to set the size gap that is both necess...

Page 129: ...body surface with 80 grit sandpaper For flat sections you can use a harder rubber sanding block For curved sections use a firm sponge at an angle to the curve that you are sanding 7 Make sure the body...

Page 130: ...s on the bulb type gasket material with care Do not press too hard use caution the bare edge of trimmed aluminum can be sharp TOOLS Tin snips razor knife slip joint pliers PARTS Secondary body fastene...

Page 131: ...5 Use the large adhesive weather stripping on the passenger side footbox as well Note The large weather stripping is self expanding Over a two day period the foam will expand to a height of 2 It will...

Page 132: ...132 www factoryfive com 508 291 3443 Upper splash panel 5 Position the lower splash panels in place on top of the upper panel and in front of the floor lip...

Page 133: ...ere the panels touch each other and where they touch the frame Remove the panels 9 Apply silicone to the upper splash panels 10 Install the upper splash panels with 8 screws 11 Apply silicone to where...

Page 134: ...e arched tube 4 The hinge studs and Z shaped metal brackets are held to the body with lock nuts as installed at the factory Rivet or screw the Z shaped metal bracket to the arched tube where they cros...

Page 135: ...e it stops the trunk from opening Note Trim the sleeve if necessary to pull the body into alignment with the trunk lid Side louvers TOOLS Silicone caulk gun and duct tape PARTS Side Louvers FFR 10985...

Page 136: ...Stainless steel neck has been provided for this application TOOLS deep well socket hex key set Phillips head screw driver hack saw drill 1 8 3 16 drill bit safety goggles PARTS Aston Lemans Cap Compo...

Page 137: ...ive com 508 291 3443 87 98 Mustang fuel tank neck with kit extension tube Optional Stainless Steel filler neck 3 Use a hose clamp to attach the fuel neck extension tubing to the lower half of the Must...

Page 138: ...d point the tube towards the ground to prevent anything from falling into the tank 5 Place the Aston Lemans Gas cap and rubber gasket on the body Align the holes in the cap and gasket and then open th...

Page 139: ...d onto the bolt followed by the large washer and locknut 12 Tighten the bolt with the ground strap pointed towards the trunk wall 13 Locate the vertical tube on the trunk wall and hold the loose end o...

Page 140: ...he ones from the wind wings and sun visors are longer and can break the windshield if used in the wrong place TOOLS combination wrench deep socket small regular screw driver small hex key set drill dr...

Page 141: ...Make sure that you are pressing down when this is done and the rubber is seated on the body 6 Remove the windshield and lay it flat on a clean non scratching surface 7 At the points that were just ma...

Page 142: ...16 drill bits Phillips head screwdriver 2 11 16 combination wrenches PARTS Three lock set and fasteners FFR 11019 hood trunk fasteners FFR 10646 1 Attach the hood pin vertical posts to the top mountin...

Page 143: ...of the posts and the angle of the hole through the posts so that the hood is held firmly in place The pins can be removed and installed pointed in the direction desired Hood pin side mounting plate wi...

Page 144: ...144 www factoryfive com 508 291 3443 Latch without cover mounted to door 5 Bolt the door to the car and do a rough alignment bolt in the center of the slot at the hinge end Top backside of door hinge...

Page 145: ...508 291 3443 Door hinge 6 Remove the striker bolt from the striker plate 7 Loosely bolt the striker bolt to the frame Door striker mounted Note seat and carpet are mounted in photo which would not hav...

Page 146: ...check straps simply stop the door from opening all the way up and scratching your paint Test the placement of the strap for door travel before final assembly 1 Attach a check strap to each door hinge...

Page 147: ...Mark the rivet locations on the aluminum panel 3 Remove the panel and silicone the frame 4 Rivet the panel in place Finished lower under door aluminum 5 Test fit the upper under door aluminum piece on...

Page 148: ...m Passenger side upper under door aluminum positioned 6 Remove the panel and silicone the frame 7 Use the self tapping screws to hold the aluminum in place 8 Rivet the panel in place Side View Mirror...

Page 149: ...rror 3 Sit in the driver s seat and determine a comfortable position for the mirror 4 Once you have determined a comfortable position with ample clearance mark around the base of the mirror with a pen...

Page 150: ...jack bumper hole 2 Use a floor jack under the radiator to hold it in place 3 Cut and remove the zip ties 4 Mark the radiator floor piece for either screws or rivets for a cleaner look attach every 2...

Page 151: ...p of the quick jack mount 10 From the wheel well side of the radiator mark the aluminum along the tubing that goes down to the quick jack mounts This way you can get straight evenly spaced rivets Pass...

Page 152: ...rom the radiator 20 Apply silicone where the aluminum and body meet and where the radiator and aluminum meet Side Exhaust ATTENTION Try not to drop the side exhaust assembly as it will probably land o...

Page 153: ...Attach the side exhaust mount to the side pipe using the 5 16 button head bolts and locknuts as shown below Side exhaust hanger installed 5 The side exhaust are positioned with the rear mount on the b...

Page 154: ...t mount post and its relative position to the front side body mount bolts Side exhaust mounted on car 8 Tighten the straight pipe bolts to the header 9 Tighten the straight pipe to side exhaust bolts...

Page 155: ...weight of the side pipe and drill a 3 16 hole through the hanger into the one side of the tube 17 Use a washer and the 1 5 screw to attach the hanger to the tube Side Exhaust mount attached to frame...

Page 156: ...mirror is located The mirror is off center to match the Tonneau cover 3 Measure the distance from the middle of the tube to the edge of the body 4 Measure this same distance and mark on top of the bo...

Page 157: ...mping tool electrical tape wire cutters Phillips head screw driver 3 8 socket head and socket wrench razor knife spray adhesive silicone caulk gun scraper masking tape marker 5 32 phillips head drill...

Page 158: ...rom the back side and scribe a mark from the front at each mounting hole The mounting holes are already laser cut into the dash At the same time trace the perimeter of the plastic on the back of the d...

Page 159: ...in the kit and use a drill to screw the screws into all of the gauge mounting holes from the front side of the dash Next take the included 2 long steel tube and place it on a hard surface then one by...

Page 160: ...n signal light uses a three prong flasher unless two lights are used one for each direction Using the one light in the kit remove the two prong flasher from above the passenger compartment Break cut t...

Page 161: ...so that it does not overlap on the back 21 Press the material onto the adhesive covered edge on the backside of the dash 22 While looking at the front of the dash find each gauge hole Using a razor cu...

Page 162: ...revent the shaft from sliding in and out while driving around 32 You should not see a gap between the dash and body at the top edge while sitting in the car Installation of the dash with Mustang gauge...

Page 163: ...clearance If necessary push the aluminum in and mark the inside of the body at the outer edge of the splashguards 9 Drill and rivet the Splash Guards to the F pieces using rivets 10 Attach the Splash...

Page 164: ...e com 508 291 3443 Rear splash guard mounted Headlight Assemblies TOOLS Phillips head screwdriver drill drill bit wire strippers wire cutters electrical tape marker Chilton s manual PARTS Headlamp com...

Page 165: ...five com 508 291 3443 Headlight Fasteners 1 Insert the grommet in the hole in the side of the bucket Grommet installed 2 Push the headlight chrome clip FFR 13415 onto the bucket bracket 13419 13415 13...

Page 166: ...clip mounted 3 Screw the two headlight adjustment screws FFR 13420 half way into the bucket using a Philips head screwdriver Adjustment screws installed 4 Turn retaining ring over and positioned so th...

Page 167: ...are as shown below 6 Screw FFR 13418 the retaining ring clips FFR 13416 to the retaining ring See the picture below for the correct locations Headlight positioned and retaining tabs attached 7 Attach...

Page 168: ...1 3443 Pigtail wires and covering pulled through grommet 9 Slide the retaining ring slots around the adjustment screws Adjustment screw in slot 10 Attach the retaining ring to the bucket using the las...

Page 169: ...es 14 Screw on each headlight with four screws Attaching the headlight to the body 15 The trim ring slides down over the top of the light and is fastened at the bottom This is a tight fit and takes so...

Page 170: ...wn On the light the red wire is the dim light and the green wire is the bright light and the brass ring is the ground 3 If the turn signals do not work when the lights are hooked up the answer is comm...

Page 171: ...rake and running lights Use the bottom light for the turn signal and running lights Inserting the rear taillights into the body License Plate Light and Bracket TOOLS Regular head screwdriver drill 3 1...

Page 172: ...ing screws provided with the kit ATTENTION This kit is only a collection of parts designed for use primarily as a race car Applying the license plate bracket does not mean that this vehicle is street...

Page 173: ...tube and tubing so finding these is easy 3 Look on the underside of the frame to find the steel plate between the X Mark this on the aluminum 4 Test fit the seats on the floor to find where it is mos...

Page 174: ...08 291 3443 7 If the seat can not get mounted in four places reposition the seat Note The further apart the mounting locations are the more solid the seat will feel 8 Drill 13 64 holes through the sea...

Page 175: ...the carpet can be installed Carpet Installation TOOLS Razor knife 3M Super 77 Spray Adhesive marker pen ruler silicone and caulk gun PARTS Mk III Black carpet FFR 13936 1 Install any remainder of the...

Page 176: ...cockpit wall Transmission top cover U joint cover Passenger side footbox outside front walls Driver side footbox outside front walls Driver inside middle passenger inside walls Driver side dropped flo...

Page 177: ...lision you can be seriously injured when your head hits steel TOOLS socket and combination wrench PARTS Seat harness fasteners FFR 13024 1 Feed the rear section each harness through the aluminum rear...

Page 178: ...time to finish off the lower door openings door sills 3 Cut the door press on trim in half and press over the body lip and carpet edge 4 The weather strip should start at the bottom of the door hinge...

Page 179: ...le onto the transmission neck using the shifter bolts provided 2 Slide the boot over the shifter to determine where the holes need to be for the screws to hold it in place 3 Drill the four holes with...

Page 180: ...n be engraved with the serial number from the Certificate of Origin which also matches the number welded in the end of the 2 x 3 tube behind the driver seat The VIN number space is provided so that yo...

Page 181: ...riances in filament position can translate to large variances in beam pattern The following procedure does not require special aiming equipment and ensures proper aim 1 Find a flat level surface next...

Page 182: ...nterline mark at the distance of Measurement B from the vehicle centerline vertical line 8 Turn the headlights on and adjust the vertical aim of the headlights so that the top horizontal cutoff of eac...

Page 183: ...gnment can cause very twitchy handling Avoid temptation and never drive a car without proper alignment For a manual steering car use the following specifications Caster 3 Camber 0 5 Total Toe 1 16 For...

Page 184: ...184 www factoryfive com 508 291 3443 Chapter 3 Performance Reference Material and Technical Support...

Page 185: ...imple We are easily reached in a number of ways The Web www factoryfive com Phone 508 291 3443 Fax 508 291 3883 E mail Tech factoryfive com Mail 9 Tow Rd Wareham MA 02571 Left FFR s Dave Smith discuss...

Page 186: ...iving your car Take the time to make sure you have made it race worthy and safe and legal before you get behind the wheel Wheels For the FRONT wheel use the following equations 1987 1998 Spindles widt...

Page 187: ...obra Brakes 17 x 9 and 17 x 10 5 FR style wheels 1994 1998 rear end Use two 4 9 wide 5 95 backspace wheels in the front and the rear If you would like a wider tire than this in the rear it is possible...

Page 188: ...t the rear end was modified To find out what ratio is on the differential mark the pinion and axle at a start point Turn the axle exactly one rotation and count the number of rotations that the pinion...

Page 189: ...ir Meter Stock 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 units are an excellent choice and have proven ef...

Page 190: ...l for the stock engine If you want to go to an aftermarket set the 1 MAC shorty unequal length headers or Ford Motorsport 1 unequal length headers fit as bolt on parts They will reward you with an app...

Page 191: ...l yield about the same effort feel The 20 1 ratio rack means the steering wheel will have to be turned more in corners For those that like the easy power steering type feel switching to a manual 20 1...

Page 192: ...sive good replacement that roughly 20 stiffer than stock For the pro road racer rear coil over shocks gives you the ease to change spring rates ride height i e drag racing vs road racing and shock val...

Page 193: ...l custom brackets to make these calipers work OR Complete 87 88 Thunderbird Turbo Coupe rear axle This axle measures 61 125 hub to hub where the 87 93 Mustang measures 59 25 hub to hub so wheel offset...

Page 194: ...rent e brake cable attachment 4 or 5 lug 12 Front Baer Racing Baer Claw System E7FM 10119 4 or 5 DN Kit includes spindles 15 16 master cylinder 12 diameter 0 81 thick rotors aluminum hubs that are sep...

Page 195: ...essary We have used a unit from CNC brakes part 241 This unit uses the Mustang bolt pattern so it will simply bolt to the FFR foot box Use the following table to determine each master cylinder require...

Page 196: ...ide blowers may get in the way of the steering shaft if the blower is too big Alternate brackets may be available from the manufacturer to remedy this situation Kenne Bell Supercharger Installed super...

Page 197: ...nd Service and Modify Ford Fuel Injection Electronic Engine Control 1988 1993 By Charles O Probst Published and distributed by Robert Bentley Inc Publishers 1000 Massachusetts Avenue Cambridge MA 0213...

Page 198: ...ort Magazine A Final Note about Completed Cars and Car Builders If you are reading this manual then you must be at least contemplating the task of building your own race car Many component car compani...

Page 199: ...199 www factoryfive com 508 291 3443 Appendix A Templates...

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Page 201: ...201 www factoryfive com 508 291 3443...

Page 202: ...202 www factoryfive com 508 291 3443...

Page 203: ...203 www factoryfive com 508 291 3443...

Page 204: ...204 www factoryfive com 508 291 3443...

Page 205: ...205 www factoryfive com 508 291 3443...

Page 206: ...206 www factoryfive com 508 291 3443...

Page 207: ...DWG NO A SIZE TITLE NAME DATE COMMENTS Q A MFG APPR ENG APPR CHECKED DRAWN 3 4 PLYWOOD FINISH MATERIAL DIMENSIONS ARE IN INCHES TOLERANCES TWO PLACE DECIMAL 0 01 THREE PLACE DECIMAL 0 005 FOUR PLACE D...

Page 208: ...ER SPEC CAR COUPE SPYDER REVISIONS DESCRIPTION REV DATE APPROVED DRIVESHAFT DIAGRAM C 13023 SHEET 1 OF 1 UNLESS OTHERWISE SPECIFIED SCALE 1 2 WEIGHT REV DWG NO A SIZE TITLE NAME DATE COMMENTS Q A MFG...

Page 209: ...209 www factoryfive com 508 291 3443...

Page 210: ...R CHECKED DRAWN 0 040 6061 T6 ALUM FINISH MATERIAL DIMENSIONS ARE IN INCHES TOLERANCES TWO PLACE DECIMAL 0 01 THREE PLACE DECIMAL 0 005 FOUR PLACE DECIMAL 0 001 APPLICATION USED ON PROPRIETARY AND CON...

Page 211: ...211 www factoryfive com 508 291 3443 Appendix B Donor Parts List...

Page 212: ...RONT CUT 4 INTO STEEL LINES 2 MOUNT REAR BRAKE LINE RIVETED TO DONOR 1 MASTER CYLINDER BOOSTER DISTRIBUTION BLOCK STEEL CONNECTION LINES 1 FRONT WHEELS 15 ALUMINUM FAN TURBINE STYLE W 8 LUG NUTS 2 MOU...

Page 213: ...e body injected 1982 1993 4 Cylinder Donors Front brakes are 10 in diameter compared to the 87 93 11 diameter Rear drum brakes are 9 in diameter compared to the 87 93 10 diameter Gauges will not work...

Page 214: ...214 www factoryfive com 508 291 3443 Appendix C Roadster Standard Pack list...

Page 215: ...13976 WASHER SAE EA 8 00 14058 SPACER 0 675 FRONT COIL OVER SHOCK TOP EA 4 00 14059 SPACER 0 43 FRONT COIL OVER SHOCK BOTTOM EA 4 00 10937 COTTER PIN SPINDLE TO LOWER CONTROL ARM EA 2 00 11073 ROADSTE...

Page 216: ...A 1 00 14821 CENTER MOUNT BATTERY CROSSBAR HOLDOWN EA 1 00 10801 J BOLT 20 x 9 EA 4 00 10802 LOCK NUT NYLON 20 EA 4 00 11088 WASHER USS EA 4 00 10973 FLEXIBLE SERRATED POLYETHYLENE GROMMETING FT 1 00...

Page 217: ...RN BUTTON EA 1 00 14744 ASTON LEMANS CAP COMPONENTS 14651 ASTON LEMANS CAP EA 1 00 INCLUDED WITH ABOVE PART LEMANS ALUMINUM CAP LEMANS CAP TO BODY GASKET 2 HOSE CLAMP 1 9 16 2 5 8 x 3 4 SCREW GROUND S...

Page 218: ...S EA 1 00 INCLUDED WITH ABOVE PART 2 3 16 ALUMINUM RIVETS 2 LICENSE PLATE SCREWS 2 MOUNTING NUTS 11019 THREE LOCK SET AND FASTENERS EA 1 00 INCLUDED WITH ABOVE PART 2 HOOD HANDLE HOLD DOWN BRACKET 1 T...

Page 219: ...E EA 2 00 11065 DOOR COMPONENTS 10627 DOOR LATCH SET EA 1 00 INCLUDED WITH ABOVE PART LH DOOR LATCH RH DOOR LATCH 2 DOOR STRIKERS 13531 SPACER 3 16 STEEL DOOR LATCH EA 2 00 10983 SCREW 8 X 3 4 EA 12 0...

Page 220: ...A 1 00 12121 BRASS FITTING BARBED 1 2 x1 2 MPT EA 4 00 12134 THREADED HOLE PLUG EA 2 00 12118 OIL HOSE 1 2 ID x 5FT EA 1 00 11206 HOSE CLAMP CONNECTION FROM HOSE TO BARBS EA 4 00 13883 STAINLESS RADIA...

Page 221: ...ASH COVER EA 1 00 1227 5 ALUMINUM PANEL SPEEDOMETER CABLE BLOCK OFF PLATE EA 1 00 1227 4 ALUMINUM PANEL TRANSMISSION HARNESS BLOCK OFF PLATE EA 1 00 1458 2 ALUMINUM PANEL LH COCKPIT WALL UNDER DOOR SI...

Page 222: ...NEL LH RH TRUNK WALL FRONT SIDE COVER PANEL EA 2 00 1087 0 ALUMINUM PANEL LH RH TRUNK WALL REAR SIDE COVER PANEL EA 2 00 1458 5 ALUMINUM PANEL LH REAR SPLASH GUARD EA 1 00 1458 6 ALUMINUM PANEL RH REA...

Page 223: ...UDED WITH ABOVE PART 4 BOLTS 13 x 1 25 8 WASHERS SAE 4 LOCK NUTS NYLON 13 END OF BOX 8A BOX 9 A BLACK VINYL SEATS FFR Part Name Unit Qty Check off Status 13939 VINYL ROADSTER SEATS WITH HARDWARE BLACK...

Page 224: ...13965 LOCK NUT NYLON 7 16 14 EA 4 00 13976 WASHER SAE EA 8 00 13842 REAR SPRING PERCH KIT 13843 LH REAR SPRING PERCH EA 1 00 13652 RH REAR SPRING PERCH EA 1 00 10833 BOLT 1 2 13 x 1 25 UPPER REAR TRA...

Page 225: ...11213 LOCK NUT NYLON 1 4 28 VINTAGE HINGES SMALL EA 4 00 10873 TRUNK HINGE SUPPORT 1 16 STEEL BODY MOUNT REAR EA 2 00 10876 DOOR HINGE KIT 13326 NUT SQUARE CROWNED 5 16 18 DOOR HINGE TO FRAME EA 4 00...

Page 226: ...TICAL WALL INSIDE WALL EA 1 00 13138 ALUMINUM PANEL RH FOOTBOX VERTICAL WALL FRONT WALL EA 1 00 10551 ALUMINUM PANEL RH FOOTBOX VERTICAL WALL OUTSIDE WALL EA 1 00 10823 ALUMINUM PANEL REAR COCKPIT VER...

Page 227: ...227 www factoryfive com 508 291 3443 Appendix D Big Block Instructions...

Page 228: ...7 428 429 460 Installation Instructions These instructions are designed to supplement the assembly manual where the assembly process is different from the build up using a small block Sections of the...

Page 229: ...stang The old Pickup is held into the tank with a metal ring that needs to be spun about turn to be removed This is best accomplished with a punch or screwdriver and a hammer tapping a little at a tim...

Page 230: ...however some pumps must be mounted below the pickup so a bracket may have to be made III Engine Preparation 1 The intake manifold used must have sufficient clearance for the air cleaner underneath the...

Page 231: ...e header clears the filter in its stock location this segment of the manual can be ignored 427 Engine Mount with rubber isolator IV Transmission Preperation 16 The transmission we recommend is a Treme...

Page 232: ...ft to slide into the transmission with suspension travel is sufficient 18 On the Lakewood scattershield there is a mount for the pivot on the driver s side for a mechanical or hydraulic linkage This t...

Page 233: ...rs Two spacers need to be fit between the mount and the transmission which raises the entire assembly Even with this raise the rear of the transmission needs to be trimmed to fit over the 4 crossmembe...

Page 234: ...e ignition switch provided is for mounting in the dash on the right hand side underneath the smaller gauges The headlight switch can be place here as well or on the left side closer to the door 3 Bloc...

Page 235: ...Transmission 5 Speed Tremec TKO Bellhousing 15220 Lakewood Spacer 8607 Mcleod Flywheel 463226 Mcleod Clutch Disk 260873 Mcleod Pressure Plate 360821 Mcleod Throw out Bearing 87 93 Mustang 5 0 Pilot B...

Page 236: ...236 www factoryfive com 508 291 3443 Appendix E 3 Link Instructions...

Page 237: ...M EA 2 00 1321 2 5 8 11 x 3 50 BOLT EA 2 00 1378 0 UPPER LINK FRAME MOUNT EA 1 00 1320 6 PANHARD BAR FRAME MOUNT EA 1 00 1320 0 PANHARD BAR AXLE MOUNT PASSENGER SIDE EA 1 00 1402 1 TRACTION LOK BRACKE...

Page 238: ...Ratchet Drill Ruler Tape measure Pliers Flat head Screwdriver Tin Snips scissors razor Marker Note For participants in the Factory Five Challenge several of these components should be welded in place...

Page 239: ...lower control arm on each side using donor bolts Hand tighten The lower bolt holes provide more traction than the upper holes 4 Install rear coil over shocks using grade 8 bolts nuts washers and space...

Page 240: ...s showing between the jam nut and end of the rod end Panhard bar and upper arm 8 Mount the panhard bar to the car using the x 3 bolts and spacers Install the panhard bar into the passenger side tracti...

Page 241: ...eight was attached using the Allen head bolt If you still have this weight on your axle you will have to remove it If the mounting hole does not line up well with the existing hole drill the axle flan...

Page 242: ...242 www factoryfive com 508 291 3443...

Page 243: ...factory on the passenger side of the 2 x 3 frame rail Use the spacers and bolts provided The lower bolt hole provides more traction than the upper hole 14 Drill the Panhard bar frame mount hole for t...

Page 244: ...axle but you can adjust this to fit your particular set up 17 The Panhard bar can also be set left to right as well as leveled 18 Double check all your nuts and bolts and make sure that all four jam...

Page 245: ...245 www factoryfive com 508 291 3443 Appendix F Independent Rear Suspension...

Page 246: ...arly in the build up These instructions use donor Thunderbird parts The assembly process is similar if using the FFR 14791 IRS Completion Package Using the Factory Five Racing Independent Rear Suspens...

Page 247: ...bird parts needed If axle hop is felt add Mustang Quad shocks Do not use aftermarket KYB shocks Lug nuts if they don t come with your wheels 15 16 Master cylinder FFR 14739 if using a Mustang Pedal Bo...

Page 248: ...bender Snap ring pliers Ruler Tape measure Pliers Flat head Screwdriver Tin Snips scissors razor Marker V Supplies needed 3 25 pints Gear oil 4 oz Friction Modifier Brake Fluid Rear brake pads VI Torq...

Page 249: ...es We recommend one with the discs free upgrade from a drum brake solid axle When you find a rear you like ask for the whole rear clip from the car The whole thing unbolts with four bolts and they usu...

Page 250: ...he Installation section Do not throw away any parts from the IRS until the IRS is installed Spindles Note The Thunderbird uses a 5 lug x 4 25 Lug pattern This is not very helpful since the Mustang use...

Page 251: ...an not be used as they have a different wheel mount surface to rotor surface distance Wheel Stud holes elongated Brake Calipers Unpack the included parking brake cables and find the smooth end of the...

Page 252: ...e brake line mount 2 Drill two 3 16 holes one for the mount screw and one for the locating pin 3 Mount the T junction to the tubing 4 If using the Completion Package the brake line mount will attach t...

Page 253: ...kside of the 4 frame rail Differential Installation 1 Drain the Differential and make sure the rear cover seal does not leak Replace if necessary Do not fill with oil yet 2 If not installed install th...

Page 254: ...including the Jam nut sticking out of the arms of threads sticking out of arm 3 Attach the lower arms to the cage using the supplied fasteners Attach the front lower mount first using an equal number...

Page 255: ...in compression and rebound for good street use The shocks can be adjusted in rebound as per Koni s instructions if so desired The IRS springs are 750lb Other springs are available for different ride c...

Page 256: ...nd bump stop to make sure that it is tight 3 Screw the spring seat down on the sleeve so it is closer to the unthreaded end 4 Slide the coil sleeve over the body of the damper beginning at the end whi...

Page 257: ...at on the shaft end of the shock and push the rubber bumper up against it 8 Rotate the spring seat back up the sleeve so that the spring pushes the hat tight against the end of the shock 9 Install the...

Page 258: ...oil over shock 10 Position the shock so that the shock body is on top and the rod end is in the triangle of the lower control arm that the shock mount is in 11 Fasten the shock to the top mount with t...

Page 259: ...91 3443 Left Lower shock mounting fasteners spacers Right Upper shock mounting fasteners spacers 12 Fasten the shock to the bottom mount with the fasteners and spacers provided The longer spacer goes...

Page 260: ...Check for clearance on brake lines emergency brake cables Brake Calipers frame and control arm parts 14 Run zip ties through the holes in the spring hat and around the spring to prevent the spring fr...

Page 261: ...astic so that the threads are not destroyed Not a lot of pressure is needed to prevent the seat from turning Check to make sure that the spring is seated correctly on the shock Upper Control Arm Insta...

Page 262: ...l it clicks 2 Push the outer CV Joint through the spindle 3 Using the OEM T bird nuts and bolts fasten the spindle to the control arms Pin Drive Independent Rear Suspension assembled on the frame 4 At...

Page 263: ...y Brake Cable Installation 1 Release the emergency brake handle using the button and make sure it is all the way in the down position 2 Push the cable sleeves into the caliper brackets and attach the...

Page 264: ...tensioning cog can adjust the free play in the lines Fuel line Installation 1 Use the included 5 16 flexible line and fuel injection hose clamps FFR 10855 to connect the fuel filter to the hard line u...

Page 265: ...s are not destroyed Not a lot of pressure is needed to prevent the seat from turning 6 Check to make sure that the spring is seated correctly on the shock 7 Align the car to the specifications at the...

Page 266: ...266 www factoryfive com 508 291 3443 Initial testing at New Hampshire International Speedway Mark Drag racing the twin turbo IRS prototype car at Run Gun 1999 10 91 seconds at 127mph...

Page 267: ...267 www factoryfive com 508 291 3443 Appendix G Torque specifications...

Page 268: ...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 or...

Page 269: ...269 www factoryfive com 508 291 3443 Appendix H Mustang Specifications...

Page 270: ...penden t T 45 17 x8 00 Mustang Cobra R 331 5 4L 385 625 0 385 425 0 Independen t T 56 18 x9 5 01 Mustang Bullitt SOHC 4 6L 265 500 0 305 400 0 Solid Axle T 45 17 x8 03 04 Mustang Cobra DOHC 4 6LSuperc...

Page 271: ...PBR 2 piston calipers The 2000 Cobra R used Brembo 4 piston calipers and rotors In all cases the flexible brake lines with mounting brackets and banjo bolts are required from the donor More brake comp...

Page 272: ...Clutch Cable Quadrant Clutch cables and quadrants remain the same from 1982 to 1995 From 1996 to 2002 cables and quadrants changed Speedometer cable From 1983 5 to 1993 Mustangs used a mechanical spe...

Page 273: ...ram 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...

Page 274: ...an electric fan built in which is a required donor part Fuel tank pump pick ups vents 1986 2004 Mustang fuel tanks were stamped steel with a plastic under tray and had two straps that held them to the...

Page 275: ...etric size Front lower control arms Front lower control arms from 1979 to 1993 all have the same dimensions and will work with any FFR kit by following the simple modification shown below In 1994 the...

Page 276: ...t dash and transmission For a carbureted car a wiring harness for the entire vehicle can be purchased through Factory Five FFR 12411 Accelerator Pedal The accelerator pedals remained unchanged from 19...

Page 277: ...ies Engine Oil Type Capacity 302 10W 30 5 0 qts 4 6L 5W 30 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 So...

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