Factory Five Racing Type 65 Coupe Assembly Manual Download Page 260

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259

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508-291-3443

Body Section

Chapter

Summary of Contents for Type 65 Coupe

Page 1: ...R E VI SI O N 3 J A PR I L 2 0 1 3...

Page 2: ...2013 Factory Five Racing Inc 9 Tow Rd Wareham MA 02571 Phone 508 291 3443 Fax 508 291 3883...

Page 3: ...election Tips 24 87 93 Mustang 24 Other Donor years 24 Where to look 24 Price 25 Running Gear 25 Disassembly of a Mustang Donor for Parts 26 87 95 Brake Power Booster 27 87 93 Steering Rack 27 Engine...

Page 4: ...ng Harness 46 Brake Power Booster Push rod 47 Driveshaft 47 Engine Preparation 47 Emergency Brake Handle 48 Alternate Drive Pulley Preparation 49 Steering Rack 49 Cleaning and Detailing 50 Disassembly...

Page 5: ...ear Suspension Standard width 106 IRS Center Section 107 Lower Control Arms 109 IRS Rear Coil Over Shock Assembly 111 CV Axles 115 Spindles 115 Upper Control arms 116 Quad shock Installation 117 Rear...

Page 6: ...Harness 189 Rear Harness 190 Transmission Harness 191 Headlight Harness 192 Dash Harness 192 Starter Solenoid 193 Engine Harness 196 Ignition and Turn signal stalk 199 Battery 199 Mount 199 Battery Ca...

Page 7: ...ency Brake Boot 237 Interior Aluminum 238 Transmission Tunnel Cover 238 Driver Footbox 240 Seats Harness 240 Shifter Handle and Boot 243 Seats 247 Nameplate 249 Steering Wheel 250 Rolling Chassis Chec...

Page 8: ...ting 303 Firewall Extension Aluminum 305 Side Windows 307 Rear Quarter windows 309 Rear Hatch 310 Hatch Latch striker 310 Hatch Hinge 312 Hatch Struts 317 Hatch 318 Final Prep 321 Body Removal 321 Hea...

Page 9: ...356 Dash 356 Lower Switch Panel 360 Gauges 361 Interior Rearview Mirror 368 Side Mirror 369 Check straps 374 Steering wheel center section 375 Side Exhaust 377 Aluminum Splash guards 378 Front Wheel...

Page 10: ...399 IRS 400 Miscellaneous Brake Information 400 Helpful Reference Material 401 Must Reads 401 Helpful 401 Catalogs Parts 401 Factory Five Aftermarket 402 Tools 402 Insurance 402 Others 402 A Final Not...

Page 11: ...ble 434 Mass Air Sensor 434 Oxygen Sensors 434 Steering components 435 Fuel tank pump pick ups vents 435 Fuel lines fuel filter and bracket 435 Emergency brake handle 435 Rear quad shocks 435 Spindles...

Page 12: ...ll 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...

Page 13: ...r project you order a manual talk to car guys get all excited over glossy photos and perhaps order a kit from us With the whole pregnancy thing well for most folks that s even easier to get started Wh...

Page 14: ...to test out how long an 8 8 rear diff can run on a track without gear oil answer about three laps before deciding to stop moving There will be highs and there will be lows but in the end there are fe...

Page 15: ...a project of this magnitude This kit is 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 respons...

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...

Page 17: ...ect fasteners brackets and badges We make it easy for you to use the engine of your choice with a list of available exhaust and motor trans mount choices no charge For a complete packing list see the...

Page 18: ...rgency brake boot High quality fabric headliner Interior rear view mirror w fasteners Stainless steel shifter handle shift knob boot polished ring and fasteners Exterior Accessories and Lighting DOT a...

Page 19: ...87 2004 Ford Mustang Fuel tank pump and filter 1987 2004 Ford Mustang Electrical 1987 1993 Ford Mustang chassis and EFI harnesses with sensors computer ignition switch and turn signal stalk Brake part...

Page 20: ...r kit The serial number from the Certificate of Origin matches the number engraved on the 2 x 2 tube going across the car at the front of the cockpit Below is an example of how the nameplate looks The...

Page 21: ...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 22: ...automatic Trans fluid 4 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 Electrica...

Page 23: ...22 www factoryfive com 508 291 3443 Donor Parts and Prep Chapter 2...

Page 24: ...ed 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...

Page 25: ...rent Donor Vehicles Appendix for information on the different parts or 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...

Page 26: ...cumentation 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 Som...

Page 27: ...tic 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 dee...

Page 28: ...es and mark their positions on the master cylinder and distribution block Leave the lines that go from the distribution block to the master cylinder in place Cut 4 into the hard brake lines from the d...

Page 29: ...Disconnect and remove the coil from the engine compartment wall Disconnect and remove the starter solenoid from the same area Disconnect and remove the Barometric Air Pressure sensor from the firewal...

Page 30: ...ket set wrenches Phillips head screwdriver flat head Screwdriver Mustang pedal box accelerator pedal and clutch cable The pedal box comes unpainted from Ford Even on newer cars there is a light coatin...

Page 31: ...ut 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 Remov...

Page 32: ...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...

Page 33: ...and horn Speedometer and Clutch Cables Socket set duct tape Speedometer cable and sending unit clutch cable Pull the speedometer cable out from the dash area keeping the rubber grommet that is on it...

Page 34: ...t it makes us feel good Remove the shifter knob from the handle Unscrew the plastic console that retains the boot Remove the shifter boot and unbolt the rubber boot below it Unbolt and remove the shif...

Page 35: ...iring harness Whenever you handle a wiring harness make sure to avoid cutting any leads Ford uses multiple grounds in circuits and cutting any line may interrupt a circuit Keep any all seemingly usele...

Page 36: ...ct tape friends Mustang engine transmission assembly engine mounts transmission mount OEM fasteners Make sure to use an engine hoist that has sufficient load capacity for the job Use extreme caution w...

Page 37: ...ging the oil pan There is an 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 bo...

Page 38: ...m Use a ball joint separation 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...

Page 39: ...and you will see that this is not very difficult Remove the fuel vapor line going 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...

Page 40: ...under the car Remove the brackets that secure the quad shocks to the frame 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...

Page 41: ...cut across the part Do not replace these bushings with aftermarket silicone pieces as these will allow the springs to slide since they contain a slippery release agent in them Solid Axle sockets wren...

Page 42: ...41 www factoryfive com 508 291 3443 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 43: ...e area near the center of the spring mount to prevent damage to the coil over unit thru any contact whatsoever Drilled and modified front lower control arm Attach the rear shock mount to the control a...

Page 44: ...lter 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 with out damaging the plastic barb cut the...

Page 45: ...o put more pressure on the master cylinder By keeping the master cylinder push rod in the same place and lowering the brake pedal bolt to a different location more pressure is put on the master cylind...

Page 46: ...e original plastic pedal piece onto the shortened pedal if desired This can be accomplished by squeezing the bottom of the trimmed pedal and drilling a hole for the stock pin Accelerator pedal modifie...

Page 47: ...eads that are needed You can save about 20 lbs by doing this Be sure to follow the schematics and avoid cutting circuits you need Some suggested parts to remove are Speaker wires Radio wiring Heater w...

Page 48: ...to get it to release heat the aluminum fitting with a torch and the rod will pop right out Power booster with the rod removed Driveshaft Shortening a driveshaft is not for the Do it yourselfer Take t...

Page 49: ...equipment the hoses mounts and solenoids can be removed Install the headers using the header originally for the left side on the right side of the engine and the right header on the left side of the...

Page 50: ...ower steering mounting brackets for a non A C car Remove the A C and power steering pump Use the alternate drive pulley template to prepare the bracket for the pulley Use the template in appendix A to...

Page 51: ...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 wiri...

Page 52: ...51 www factoryfive com 508 291 3443 Disassembly of the kit Chapter 3...

Page 53: ...he contents before going on to the next box Body Removal Gloves 2 friends Be careful of the raw fiberglass edges they can splinter into your skin The body is shipped sitting on the frame Using two peo...

Page 54: ...com 508 291 3443 Lift in the exhaust recess and the rear wheel well Body with sides supported Aluminum Removal nut driver jack stands marker Do one panel at a time Be careful of the sharp aluminum edg...

Page 55: ...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 aft...

Page 56: ...55 www factoryfive com 508 291 3443 Use jack stands to position your frame in your workspace with plenty of room to move things around...

Page 57: ...56 www factoryfive com 508 291 3443 Chassis Assembly Chapter 3...

Page 58: ...ll of the aluminum panels unless otherwise directed Front Suspension Front lower control arm socket 15 16 wrenches Torque wrench Mustang lower control arms and fasteners Mount the front lower control...

Page 59: ...58 www factoryfive com 508 291 3443 Put thread locker on the upper balljoint threads Screw the upper ball joints into the control arms so that the balljoint angles out on the bottom...

Page 60: ...ch If assembling a complete Coupe kit with the FFR spindles skip to the next section Front upper control arm mounting with donor spindles Mount the upper control arms to the chassis with the grease fi...

Page 61: ...3443 Front upper control arm mounting with FFR Spindles Mount the upper control arms to the chassis with the grease fittings pointed up Use the mount holes that are vertical on the side of the 2 x 3 t...

Page 62: ...61 www factoryfive com 508 291 3443 Use a washer with the front locknut Do not use a washer on the rear locknut Torque the two bolts that hold the arm to the frame to 135 149Nm 100 110 lbft...

Page 63: ...Torque the pivot bolts to 60 lbft Grease both ends using chassis grease frequently to insure smooth trouble free operation If the pivots will not take grease the endplay may be too tight There should...

Page 64: ...pring 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 slee...

Page 65: ...508 291 3443 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 agains...

Page 66: ...he body of the shock up through the upper control arm and attach them to the lower control arm using the 0 43 spacers that are supplied in the kit Check for shock clearance on brake lines emergency br...

Page 67: ...1 3443 Fasten the shock to the top mount with the fasteners and 0 675 spacers provided and torque both upper and lower mounts to 40 ft lbs Spindles If assembling a complete Coupe kit with the FFR spin...

Page 68: ...Spindles 13 16 socket Torque wrench Needle Nose Pliers Rubber Mallet Spindle Assembly IFS components Unpack and lay out the hardware for the spindles assembly The spindles are marked DSS Driver Side...

Page 69: ...the spacer under the castle nut to ensure that the cotter pin is at the correct height Torque to 106 149Nm 80 110 lbft and install the cotter pin Attach the upper ball joint to the spindle and torque...

Page 70: ...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 Bolt the steering arms to the spindles with the tap...

Page 71: ...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 Using a large socket or a flat head screwdriver and rubb...

Page 72: ...ut 305 338 225 250 IFS Bracket IFS components Mustang strut bolts These are not used in the complete Coupe kit Attach the Spindle adapter bracket to the upper control arm to the spindle using the fact...

Page 73: ...ach 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 w...

Page 74: ...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...

Page 75: ...actoryfive 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 Install the slider grease boots on the slid...

Page 76: ...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 hange...

Page 77: ...76 www factoryfive com 508 291 3443...

Page 78: ...aliper with the tab sticking up through the 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...

Page 79: ...ctoryfive com 508 291 3443 Grease the slide pins using the supplied grease Slide the caliper hanger onto the caliper Push the rubber boots over the lip on the caliper bracket to seal the slider bolts...

Page 80: ...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 pa...

Page 81: ...80 www factoryfive com 508 291 3443 Install the brake pads in the Caliper...

Page 82: ...508 291 3443 Clean the rotor with brake cleaner and push it onto the hub Install the caliper on the spindle make sure that the fluid bleeder is at the top of the caliper Torque the caliper mounting b...

Page 83: ...82 www factoryfive com 508 291 3443 Solid Axle Rear Suspension sockets wrench drill bit drill floor jack jack stands Torque Wrench...

Page 84: ...g with the rear end assembly it weights 225 lbs Skip to the Independent Rear suspension if not installing a Solid axle See the donor parts prep section if the control arm holes have not been drilled o...

Page 85: ...84 www factoryfive com 508 291 3443 Axle Bracket Passenger Side Temporarily put the lower shock bolt through the traction lock bracket and stock shock hole on the axle...

Page 86: ...en the two short bolts Torque to Ford Specs 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 lb ft The lower bolt holes p...

Page 87: ...Mustang springs and rubber isolator mounts Hold the spring perches up to the frame so the vertical perch mount is in between the 2 x 3 tube and the vertical frame mount Mark the location of the holes...

Page 88: ...g is located halfway to the arm mount so any height changes at the spring will be multiplied by roughly two at the axle 4 Link Rear Suspension 18mm sockets ratchet 15mm wrench Mustang upper control ar...

Page 89: ...e 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 b...

Page 90: ...8 291 3443 The front attachment of 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 u...

Page 91: ...m nut on each of the rod ends remembering that two 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 P...

Page 92: ...tube to the axle upper link mount using the spacers on either side of the rod end Rear Axle installation Have someone help with this step the rear axle is very heavy and mistakes can result in serious...

Page 93: ...ossible 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 seriou...

Page 94: ...93 www factoryfive com 508 291 3443 Attach the lower control arms to the frame mounts Jack the rear axle up If using a 4 link attach the upper control arms to the frame...

Page 95: ...t ratchet ruler marker hack saw Roadster Coupe rear shock kit The rear shocks are pre valved at the factory in compression and rebound for good street use The shocks can be adjusted in rebound as per...

Page 96: ...loser to the unthreaded end The center high part of the set should be pointed away from the unthreaded end Slide the coil sleeve over the body of the damper beginning at the end which has the rubber b...

Page 97: ...at 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 Install the sna...

Page 98: ...yfive com 508 291 3443 Assembled solid axle Koni coil over shock Use zip ties to hold the spring to the spring hat Attach the body end of the shock to the upper shock mount using the two equal length...

Page 99: ...98 www factoryfive com 508 291 3443 Jack the rear axle up so the rod end of the shocks can be mounted on the axle through the shock mount hole...

Page 100: ...h the rear vertical shocks at the top through the holes in the plates located in the trunk area using the Mustang rubber bushings and fasteners Torque to 37 47Nm 27 lbft Install the kit x 4 bolts are...

Page 101: ...ive com 508 291 3443 Passenger side Driver Side Check for shock clearance on brake lines emergency brake cables brake calipers frame and axle parts Check to make sure that the spring is seated correct...

Page 102: ...back side of the vertical shock down low Tighten the bolts on the quad shock brackets 4 link Rear Suspension Torque Specs Chart Item Nm Lbft Upper control arm to axle 101 111 75 82 Upper control arm...

Page 103: ...08 291 3443 Panhard Bar Frame mount 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...

Page 104: ...ll 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 Ins...

Page 105: ...assenger side traction lock bracket Three spacers are used in the front 2 0 375 and 1 0 25 The rear uses the thin 0 125 shim It will be necessary to adjust the length some to fit make sure that you ad...

Page 106: ...05 www factoryfive com 508 291 3443 Attach the Panhard bar to the frame mount using the spacers provided There should never be less than of threads screwed into either the Panhard bar or the upper arm...

Page 107: ...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 Panhard bar 101 111 75 82 If a...

Page 108: ...e driveshaft flange pointing straight up and the axle holes lined up front to back with the chassis Use one rear bolt through the rear cover to hold it in place Raise the front of the center section a...

Page 109: ...108 www factoryfive com 508 291 3443 Slide the bushing sleeves into the bushings from the top Through bolt the two front bushings and the remaining rear mount with the mounting hardware and tighten...

Page 110: ...109 www factoryfive com 508 291 3443 Lower Control Arms Screw the rod ends with jam nuts into the lower control arm Screw the forward joint in all the way then back out 4 turns...

Page 111: ...he arm The rear bolt can be slip in place with no shims for now Shim the front bolts using 3 shims on the front side of the rod end on both the left and right arms Tighten the front bolts for both low...

Page 112: ...n and rebound for good street use The shocks can be adjusted in rebound as per Koni s instructions if so desired The rear springs are 350lb Other springs are available for different ride characteristi...

Page 113: ...readed 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...

Page 114: ...ock 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 Install the snap ring on the spring hat so t...

Page 115: ...d the spring to the spring hat Mount the coil over to the chassis mount using the two of the smaller length spacers on either side The body of the shock goes toward the top Mount the lower control arm...

Page 116: ...oryfive com 508 291 3443 CV Axles Push the CV joints into the rear axle and let them rest on the lower arm Spindles Slide the splined end of the outer CV joint into the hub and mount the spindle to th...

Page 117: ...Control arms Screw in the rod end and jam nut into the upper arm and attach it to the chassis using a short equal length spacer on either side of the rod end Attach the upper arm to the spindle and ti...

Page 118: ...end of the Quad shock to the upper arm of the IRS with the supplied metric bolt Attach the shaft end of the Quad shock to the rear quad shock bracket hole on the frame using the washer on the outside...

Page 119: ...he car on the ground check the ride height of the car to the bottom of the 4 frame rail Front 4 25 4 50 Rear Usually 4 75 with one person normally in the car or 5 00 with two people in the car Jack th...

Page 120: ...andard width or 54 00 for the Pin drive narrow width IRS If your measurement is different than above find the difference between your axle and the correct measurement then divide it by two This is the...

Page 121: ...e side of the suspension an alignment is not needed after the installation Jack the rear of the car up again and place on jack stands located on the lower control arms near the shock Double check the...

Page 122: ...121 www factoryfive com 508 291 3443 Insert a hex head bolt through the Caliper Mount Bracket hole so that the threads will point out...

Page 123: ...91 3443 From the outside in insert two hex head bolts through the Spindle caliper mount holes then through the caliper mount bracket Torque the bolts to 87 101Nm 64 75 lbft Place the caliper mount spa...

Page 124: ...liper with the brake pads Put a dot of Locktite on the threads of the two bolts with the spacers on Attach the caliper to the caliper mount bracket Hand tighten both bolts starting with the top on fir...

Page 125: ...ou are installing a heater defroster it is much easier to cut the firewall before installing Refer to those instructions for the template If you are installing the complete kit Wilwood pedalbox use th...

Page 126: ...125 www factoryfive com 508 291 3443 Pedal Box 9 16 sockets 3 16 5 16 hex key drill 9 16 wrench 7 16 drill bits silicone rivet tool marker Mustang pedal box pedal box hardware cockpit aluminum...

Page 127: ...126 www factoryfive com 508 291 3443 Mustang Pedal Box...

Page 128: ...g pedal box on the two angled tubes over the driver s feet and attach using two short bolts and two washers to the front wall at the front of the foot box There are four holes on the Mustang pedal ass...

Page 129: ...box aluminum panel in place using long rivets Install the pedal box with the two bolts and washers at the top as before They go through existing holes in the front of the foot box The four socket hea...

Page 130: ...e pedal box fastener assembly with a fender washer next to the head Leave all the hardware hand tight Complete kit pedal box 9 16 sockets 11 32 9 16 wrenches Drill 3 16 Drill bit 1 8 9 32 3 16 5 16 He...

Page 131: ...The parts and instructions required for a cable clutch installation are included in this kit Unpack the pedal box assembly Now is a good time to paint all of the bare steel brackets Use snap ring plie...

Page 132: ...tch mount between the brake pedal mount tabs on the side closest to the brake pedal pivot holes and drill a 3 16 hole through the brake switch mount hole and the pedal box Attach the brake switch moun...

Page 133: ...3443 Clutch Cable Quadrant Using snap ring pliers remove one of the retaining clips from the clutch pedal pivot sleeve Push the pivot sleeve out and remove the pedal and remove the second snap ring fr...

Page 134: ...g pliers attach one of the snap rings to the new longer pivot sleeve provided Push the pivot sleeve through the clutch quadrant from the left side If necessary chase the quadrant hole with a drill bit...

Page 135: ...8 291 3443 Put one of the Wilwood pedal washers on the pivot sleeve next to the quadrant Remove the snap ring holding the master cylinder mount to the clutch pedal push the pivot sleeve out and remove...

Page 136: ...to the underside of the mounting bracket using three button head screws and locknuts and the stud The stud should get mounted on the left side next to the clutch pedal pivot sleeve boss A tap in with...

Page 137: ...3443 Attach the Clutch pedal stop mount to the bottom of the pedal box using two socket head screws spacers and locknuts Put the actuator in a vise and snug up the bolts with a 5 16 hex key Do not ov...

Page 138: ...e com 508 291 3443 Slide the Quadrant and new pivot sleeve assembly through the hole in the side of the Wilwood pedal bracket and remount the clutch pedal Put the remaining thin washer and snap ring o...

Page 139: ...the actuator Snug up the bolt using a 3 16 hex key This 5 16 bolt is only used to hold the pedal in position when the pedal is not being pushed depending on the pedal height It does not put any press...

Page 140: ...e com 508 291 3443 Place the pedal box assembly in the drivers footbox Make sure that the brake pedal goes in front of the cross tube on the frame Unpack the pedal box hardware from the secondary chas...

Page 141: ...ware assembly and the one included in this pedal assembly through the front of the footbox and through the pedal box mount Push the rear pedal box mount onto the master cylinder mount studs and use a...

Page 142: ...ront screws then use a marker to mark the locations of the rear mount holes on the tubes Loosen the bolts and remove the pedal box assembly from the footbox then use a drill bit and drill to drill thr...

Page 143: ...mbly in the driver s footbox use the x 1 50 screws from the pedal box fastener assembly with a fender washer next to the head Leave all the hardware hand tight Master Cylinders Place a jam nut from th...

Page 144: ...nder mounts and turn the threaded shaft into 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 Attach and tight...

Page 145: ...144 www factoryfive com 508 291 3443 Tighten all the remaining hardware mounting the pedal box to the chassis Thread the jam nut onto the x 1 25 screw provided in the quadrant box...

Page 146: ...y 7 16 wrenches wire cutters Pedal box hardware Accelerator cable components The cable design is set up for a 96 04 4 6L Mustang engine with an OEM pedal but using the supplied ball studs and retainer...

Page 147: ...card the included ball stud It is for carbureted applications Push and twist the included ball stud retainer onto the end of the cable Do not tighten the set screw yet Insert the pedal end of the cabl...

Page 148: ...s desired some material can be removed from the bottom of the clutch quadrant stop If mounting higher mark and drill new holes for the bolts in the pedal Attach the accelerator pedal to the mount usin...

Page 149: ...k the throttle pedal and separate the arms You can leave the screw loose for now as this will be adjusted for fit later Use one x screw and locknut from the pedal box hardware position the accelerator...

Page 150: ...oryfive com 508 291 3443 Bolt the pedal to the mount plate using the x screws and locknuts Unpack the throttle cable and cut the cylinder end off Make sure your cutters are very sharp so as not to fra...

Page 151: ...ve com 508 291 3443 Thread the inner cable through the cable retaining lock nut from the accelerator cable components assembly Route the cable through the hole in the firewall and slide the sheath bac...

Page 152: ...cking 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 Steering System Steering Shaft 3 16 5 16 hex keys 9 16 1...

Page 153: ...flange bearing to the 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 Loosely mount the top pillow block to the...

Page 154: ...ng shaft into the footbox from the engine bay through the lower bearing 87 93 Power steering racks have a different spline than a manual steering rack and the 94 04 Power rack uses a Pyramid shaped en...

Page 155: ...hydraulic lines removed If not already in insert the stock rubber bushings and kit spacer sleeves into the rack Pull back the rubber boot on the inner tie rod and remove the inner tie rod from the ste...

Page 156: ...155 www factoryfive com 508 291 3443 Use thread locker on all of the steering shaft screws that do not have jam nuts and the adapter screws...

Page 157: ...only not for manual steering racks If using the power rack and you have not already done this in the donor prep stage cut 1 75 off the end of the inner tie rod Put a dot of thread lock on the threads...

Page 158: ...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 The track of the FFR Coupe front end is n...

Page 159: ...8 291 3443 The outer tie rods may come with either a castle nut and cotter pin or a nylon locknut Attach the tie rod to the spindle torque the nut to 25 ft lbs If a castle nut is used torque the nut t...

Page 160: ...stalled Upper Steering Shaft 5 32 3 16 5 16 hex keys wrench rubber mallet Steering system hardware Unpack the upper steering shaft from the primary chassis components box Slide the steering shaft thro...

Page 161: ...so the recessed bosses for 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 Tighten the upper and...

Page 162: ...crews 8 hex 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 ca...

Page 163: ...meets the chassis and rivet along the bottom of the 2 square frame crossbar only Use one of the original screws to temporarily hold it to the other small chassis tube Drill the tunnel front A shaped p...

Page 164: ...otbox inside wall Silicone and rivet the panel to the front tunnel A and the footbox top Mark the holes in the passenger footbox front panel upper and outer edges but do not drill yet Silicone the pan...

Page 165: ...en install and rivet it in place The floor sits on top of the flanges from the footbox walls Silicone the remaining flanges then install the outer wall top on the footbox with rivets Make sure the rea...

Page 166: ...165 www factoryfive com 508 291 3443 Passenger Floor Drill the passenger side floor where it was marked to attach to the chassis Mark the two front flanges but do not drill yet...

Page 167: ...in chassis rails are not riveted to but still need a bead of silicone run along the tops The top edge of the tunnel is not riveted yet but gets silicone as well Drill and rivet the floor in place to t...

Page 168: ...install the driver s footbox floor The outer flange does not get drilled yet Silicone drill and install the driver side floor Drill silicone and install the inner footbox wall The front flange tucks i...

Page 169: ...168 www factoryfive com 508 291 3443 U Joint Cover Mark the rear tunnel cover where it meets the chassis then silicone and rivet it in place...

Page 170: ...es tuck behind the tunnel sides and sit on top of the floor Mark the rivet spacing on the top edge and silicone and rivet the three flanges that make contact Cockpit rear wall Mark and drill the rear...

Page 171: ...ge and where they meet the chassis Drill silicone and rivet these in place Fuel System Fuel Tank 9 16 deep socket ratchet hammer 5 16 hex key floor jack friend Mustang Fuel tank fuel tank straps Secon...

Page 172: ...171 www factoryfive com 508 291 3443 Unpack the square plastic end caps from the secondary body fasteners Push the four plastic end caps into the tubes hanging down in front and behind the gas tank...

Page 173: ...fuel tank straps from the rear mount of the chassis using two of the strap fasteners The longer strap goes on the passenger side Using a jack raise the tank up into place on the chassis Make sure the...

Page 174: ...73 www factoryfive com 508 291 3443 Bolt the straps in with the strap fasteners and drop the jack Tighten only the driver s side strap as the passenger one will be removed for aluminum fitment later o...

Page 175: ...tank to filter nylon hose Mustang fuel vapor hose Make sure to install the fuel filter in the correct flow direction Determine whether or not a new filter is needed It s a good general rule to replace...

Page 176: ...nes 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...

Page 177: ...engine The most important things are To route the lines so that they are protected by the chassis not close to any heat source or moving parts and provide enough slack in the rubber hoses for the eng...

Page 178: ...rear cockpit wall and alongside the outside of the main 4 frame tube Which side of the frame you run down may depend on where you are hooking up to your fuel rail carburetor or pressure regulator We...

Page 179: ...five com 508 291 3443 Fasten the lines to the 2 x 2 square cockpit outriggers with the insulated line clips and 3 16 rivets If you are going to use the mustang Fuel vapor line run it along with the ot...

Page 180: ...ter push rod Avoid dripping brake fluid on any painted surfaces Clean up spills immediately The Master cylinder that you use depends on the size and number of pistons in the brake calipers Manual Brak...

Page 181: ...180 www factoryfive com 508 291 3443 Tighten all of the mounting bolts for the pedal box and master cylinder...

Page 182: ...od between the two ears of the brake light switch and slide it over the brake pedal post Put the clip through the hole in the pedal so that the push rod will not come off View up at the mounted brake...

Page 183: ...uel lines there are many ways to run these lines but you must be very careful to keep them protected from moving parts heat or being to close to the bottom of the car Which side you run down may depen...

Page 184: ...and tight is fine on all these for now Hard brake lines From the bottom of the master cylinder run the 20 brake line forward to the left front brakes Using the distribution block diagram below attach...

Page 185: ...will bend very easy but be careful not to kink it When you are happy with the routing use the small insulated line clips and 3 16 rivets to hold it in place Use a long 60 brake line and route from th...

Page 186: ...un the flexible brake lines direct from the chassis to the caliper the IRS is done like this there is an extra length of line and a T to allow similar routing to the front If using the 87 95 Mustang m...

Page 187: ...186 www factoryfive com 508 291 3443 Attach the T adapter to the flexible brake line and route the hard brake line coming from the front to the T...

Page 188: ...fuel tank mount tubes and over to the passenger side tube An alternative to running it this way would be to run it across the backside of the 2 x 3 tube Attach the passenger side flexible brake line...

Page 189: ...with anything in the suspension wheels during travel or turning full lock to lock Tighten the banjo bolts on the calipers Banjo bolt torque specs 87 95 Front Brake hose to caliper Banjo bolt 34Nm 25l...

Page 190: ...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 diffe...

Page 191: ...ht up through the roll bar rear leg hole to be used for the license plate light Leave the wires in the trunk for now The remaining section of the rear harness runs to the battery where it joins the ba...

Page 192: ...de floor aluminum Harness plug in floor aluminum Run the harness forward into the corner to the tube at the foot box front Then go up and along the angled tube to its connector Make sure that it does...

Page 193: ...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 the headlights By removing the tape from the harness under the...

Page 194: ...so that the coil can still mount on the outside of the tubing next to the master cylinder By doing this the amount of visible wiring in the engine bay is reduced Run the harness over the pedal box and...

Page 195: ...194 www factoryfive com 508 291 3443 Battery cable Yellow wire Green wire Orange Dark Blue wire Red blue wire Black cable to Starter Starter Solenoid Wiring Old Starter...

Page 196: ...ix A to determine the correct shape to the 2 x 2 dash hoop support and between the two x frame tubes in the driver s side footbox using the aluminum bracket provided and a few of the self tapping scre...

Page 197: ...running a carbureted engine you do not need this section Make sure that the battery is not connected any time you are working with the computer The engine harness begins in the passenger foot box The...

Page 198: ...ler harness goes forward and connects to the mass air sensor and to the harness on the engine for the O2 sensors and oil level sender The other larger bundle goes along the firewall and contains the v...

Page 199: ...ount the vacuum controls and BAP Barometric Air Pressure sensor to the firewall The BAP sensor is similar to a MAP sensor used on speed density cars except it does not get hooked up to vacuum it is le...

Page 200: ...4 drill bit The turn signal stalk can be cut shorter so that when it s mounted it will not protrude past the dash lip If you want to cut the stalk length do it after the dash is installed and you have...

Page 201: ...each side of the cross brace located on the driver side of the trunk Mark where the holes line up on the rear facing side of the tubing Drill the holes for the hooks on the rear face of the tube With...

Page 202: ...on on the battery and make sure the battery is straight Tighten the battery down until it is snug against the frame and does not move Do not over tighten and bow the sides of the battery causing damag...

Page 203: ...ened for now with zip ties everywhere so that the rear harness can be run with the cable later Use the insulated line clips and screws for final assembly Drill a 5 16 hole in the side of the passenger...

Page 204: ...Packaged Aluminum secondary body fasteners Position the panel on the frame overlapping the side wall tabs Mark where the rivets will go by tracing around the tubes the same way previously done Remove...

Page 205: ...arket TKO 500 and TKO 600 prep Hack saw or Reciprocating saw socket ratchet Transmission Polyurethane engine transmission mount kit The Coupe works well with the midshift option that is available with...

Page 206: ...205 www factoryfive com 508 291 3443 Trim off the unused mounting boss on the bottom of the case...

Page 207: ...ket wrench Alternate drive pulley components If you are using under drive pulleys or eliminating the smog pump do not drill the A C bracket according to the diagram Instead use the belt as a guide to...

Page 208: ...back with a pry bar carefully and install the fan belt If the belt does not fit using this routing check to see if after market under drive pulleys have been fitted on any of the accessories or the c...

Page 209: ...e engine block just above the oil pan near the bellhousing it is very small The Transmission VIN number is on the drivers side in front of the Speedo sensor near the middle of the transmission it is v...

Page 210: ...fasteners If not already done the driveshaft should be shortened to the length specified in the appendix for the engine transmission combination being used Slip the shortened driveshaft up into the re...

Page 211: ...hould have thread locker on them already If thread locker 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 transmis...

Page 212: ...el Lines to engine flat head screwdriver Fuel line components Finish running your fuel system by hooking up either to your carburetor or fuel rail Here we mounted a pressure regulator on the firewall...

Page 213: ...le safely away from the headers and the moving steering components It can be fastened to the engine using the bracket on the cable to the front lower bolt that holds the starter cable just before it l...

Page 214: ...213 www factoryfive com 508 291 3443 Connect the clutch cable to the bellhousing and the clutch fork...

Page 215: ...lutch Cable and Firewall Adjuster Push the firewall adjuster into the front of the footbox and attach to the front of the pedal box using the screws provided and a 9 64 hex key and an 11 32 wrench Pul...

Page 216: ...zor knife file or grinder to remove the plastic barbs from the plastic shaft Slide the clutch cable boss through the adjuster and loop the cable over the quadrant Speedometer Sending Unit 11mm deep so...

Page 217: ...factoryfive com 508 291 3443 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 Plug the wire harness connector into the...

Page 218: ...ll stud retainer onto the ball on the bottom of the throttle body Push pull the cable into the retainer so that the cable is tight Tighten the set screw in the retainer using a 5 64 hex key Check the...

Page 219: ...plied ball stud to the carburetor in the appropriate location Refer to the carburetor instructions for placement Attach the ball stud retainer to the ball stud Pull the cable tight holding the cable a...

Page 220: ...nd shoe size differences Mass air meter Air filter and Intake hose Drill 3 16 drill bit socket Wire harness mounting hardware Mustang mass air sensor mustang intake hose and clamps air filter Mass Air...

Page 221: ...3 Bolt the ground strap to the hole and then run the other end to a boss on the block In this case we used an engine mount bolt Fuel Vapor Canister Drill 3 16 drill bit socket Wire harness mounting ha...

Page 222: ...high flow fan radiator hose kit radiator mount components secondary body fasteners assembly and aluminum engine bay assembly Make sure the electric fan shroud does not bend oval or it will cause the f...

Page 223: ...m so that the mounting bolts will again go through the flange and the nut will go on the bolt Mark the upper and lower mount tab holes on the radiator flanges Mark where the lower mount tabs can be tr...

Page 224: ...ng 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 housing is not pulled...

Page 225: ...Install the radiator from above the frame Attach some 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...

Page 226: ...through the 1 x 1 tubes at the marked locations using a 5 16 drill bit Attach the top radiator mount bracket using the 5 16 x 1 5 screws washers and locknuts Top radiator mount bolt Radiator Aluminum...

Page 227: ...3443 Large radiator duct mounted Insert the radiator duct aluminum from behind the radiator Attach the driver and passenger side duct brackets to the top of the 1 x 1 tubes and the sides of the main...

Page 228: ...227 www factoryfive com 508 291 3443 Passenger side bracket Driver side bracket...

Page 229: ...91 3443 Stainless Radiator Hoses Unpack the stainless radiator hose kit and remove the hose connectors from the boxes Use the smaller sections of tube inside the adapters to fit them to smaller fittin...

Page 230: ...229 www factoryfive com 508 291 3443 Then fit the larger adapters over them Upper radiator hose Start at the engine and route the tube along the top of the passenger side duct bracket...

Page 231: ...230 www factoryfive com 508 291 3443 The kit includes a remote fill adapter that should be installed at the highest point in the cooling system which is the return hose back to the radiator...

Page 232: ...se over the top of the steering rack tie rod and under the steering shaft to the water pump Mark the tube where it needs to be cut so that the tube will just touch the attaching location Remove the tu...

Page 233: ...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...

Page 234: ...3443 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...

Page 235: ...hacksaw Mustang E brake handle brake line components Push the U nuts from the brake line components onto the E brake handle Bolt the handle to the mount bracket using the kit fasteners The holes are s...

Page 236: ...ke cables should be from the same car as your rear brakes 87 92 Mustang cables or the FFR cables mount to the bracket up near the 2 x 3 tube Route the cables through the upper bracket in the transmiss...

Page 237: ...236 www factoryfive com 508 291 3443 Route the inner cable down under the chassis and hook them to the T cable...

Page 238: ...andle a few times to make sure the self tensioner works and there are no problems with the cable Emergency Brake Boot drill bit drill Phillips head screwdriver Interior Trim Unpack the e brake boot an...

Page 239: ...Aluminum Transmission Tunnel Cover Drill drill bit Silicone Caulking gun Rivet gun Secondary Body Fasteners Components Packaged Aluminum mounted aluminum Remove the seats roll bar and harnesses and si...

Page 240: ...m 508 291 3443 Silicone and install the shifter hole cover Make sure it does not interfere with the movement of the shift lever Silicone and install the tunnel plug patch panel if not using the Mustan...

Page 241: ...www factoryfive com 508 291 3443 Driver Footbox Silicone and install the front patch panel Seats Harness wrench socket drill bit drill ratchet Seat Harness Fasteners Unpack the seat harnesses and hard...

Page 242: ...241 www factoryfive com 508 291 3443 Bolt the lap harness in position Remove the mounting tab from the harness Loop the harness over the roll bar crossbar...

Page 243: ...508 291 3443 The shoulder 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 thro...

Page 244: ...y fit you comfortably Shifter Handle and Boot wrench drill bit drill Phillips head screwdriver marker thread lock Shifter handle components Unpack the shift handle and bolt it to the transmission Thes...

Page 245: ...244 www factoryfive com 508 291 3443 Push the boot and trim rind down over the handle so it sits flush on the tunnel Using a silver marker or white paint marker mark your screw holes on the tunnel...

Page 246: ...actoryfive com 508 291 3443 Remove the boot and drill holes in the spots you marked Re install the boot and screw down to the tunnel with the countersunk screws A small screwdriver can help to locate...

Page 247: ...246 www factoryfive com 508 291 3443 Screw the two piece knob onto the shift handle and tighten so the shift pattern is in the correct orientation...

Page 248: ...t Racing seats with less padding give more room the more upright the angle of the seat the more room to straighten out your legs Unpack the seats and set them in the cockpit Sit in the seats and locat...

Page 249: ...www factoryfive com 508 291 3443 Using the rivet heads as a guide mark where the rails of the seat frame are above the seat mounting plates Drill the first hole for the seat mounting and install the b...

Page 250: ...249 www factoryfive com 508 291 3443 Drill the remaining holes for mounting the seats and install the bolts Nameplate 1 8 drill bit rivet gun drill...

Page 251: ...he 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 h...

Page 252: ...251 www factoryfive 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...

Page 253: ...252 www factoryfive com 508 291 3443 Bolt the steering wheel assembly to the steering shaft Use thread locker on this bolt...

Page 254: ...ock to lock and make sure your brake flex lines have enough slack for the full range of wheel movement Fluid Levels and Grease Grease gun chassis grease ratchet rags Transmission fluid rear axle gear...

Page 255: ...254 www factoryfive com 508 291 3443 Transmission Fill the transmission with fluid and install the shifter assembly Leave the shift handle and knob off for now...

Page 256: ...is some coolant in the overflow to start out about 1 3 full is good Get the engine up to temperature and check for leaks and make sure the fan is working If you need to you can temporarily bolt your s...

Page 257: ...3443 Suspension All of the suspension and steering components that have grease fitting need to be greased With a grease gun squeeze grease into each fitting on all the control arms including rear low...

Page 258: ...close to heat sources or moving parts loose grounds Suspension all hardware tight no binding or clearance issues Chassis all hardware double checked nothing loose or sharp Steering all set screws tig...

Page 259: ...al height Shim under the upper steering bearing to raise the steering wheel Use a smaller steering wheel Different shoes can make a large difference in foot room Left footbox aluminum Silicone and ins...

Page 260: ...259 www factoryfive com 508 291 3443 Body Section Chapter 4...

Page 261: ...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 trim away the edges until...

Page 262: ...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 do...

Page 263: ...around the hinges Move forward until the rear hatch tubing is lined up with the lip on the body and put the body down in place Watch the door hinge mounts and striker post mounts on the frame Once the...

Page 264: ...can break if dropped from a fairly low height The rear taillights double as the rear body mount There is a plate mounted on the frame to receive the light mount screws Use the template in Appendix A...

Page 265: ...uler Secondary body fasteners The body sides are mounted using four stainless 5 16 x 1 bolts with a washer next to the head The rear most side body mount needs 7 16 worth of washers between the body a...

Page 266: ...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 Locate the template in the appendix and only cut out around the outs...

Page 267: ...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 circ...

Page 268: ...emplate Cut out the side exhaust template The template goes down to the top edge of the body Tape or hold the template and mark around it with a pen Use a jigsaw to cut out the marked area The templat...

Page 269: ...268 www factoryfive com 508 291 3443 Radiator Exit opening Air saw or jig saw Use a jigsaw to cut out the area...

Page 270: ...es with a 1 hole saw Test fit a light and adjust if needed You may have to bend the ground tab slightly or file away a bit at the hole to make it fit perfectly Headlights Drill 1 8 7 16 drill bit razo...

Page 271: ...toryfive com 508 291 3443 Cut the center of the template out and trace the inner circle with a marker Drill the two smaller corner holes with a drill bit to mark their location Follow this with a 7 16...

Page 272: ...ut of the body use a larger drill bit to make a hole to start your cut Test fit the light bucket and rubber gasket making sure that they sit flat and the bucket is centered on the fender Mark and dril...

Page 273: ...272 www factoryfive com 508 291 3443 Side louver Drill drill bit jig saw or air saw At the corners of the louver indentation use a Drill bit Use a jigsaw or hacksaw for the straight edges...

Page 274: ...p socket jig saw marker chassis grease rivet gun masking tape 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 ti...

Page 275: ...274 www factoryfive com 508 291 3443 Cut the area for the latch on the nose leaving the lower finger recess for the bottom of the latch Tape the outside of the body around the latch area...

Page 276: ...actoryfive com 508 291 3443 Position the latch from the backside of the body Make sure the latch looks straight in the cutout and compared to the rear edge of the nose Drill 7 32 holes for the mountin...

Page 277: ...276 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 278: ...or opening for reference find the centerline of the nose and mark it on bottom on the inside Measure from this centerline 15 5 16 to determine the center mounting location for the hinge brackets The h...

Page 279: ...ure marker duct tape sander air saw or jig saw Nose trunk fastener assembly secondary body fasteners It is smart to have some help when doing this step The fiberglass edges can be very sharp Wear glov...

Page 280: ...f the nose with the front of the body Move the nose around so there is a small gap i e along the backside of the nose against the rear body clip and along the bottom edge of the nose Use wood or washe...

Page 281: ...uct tape and jack stands looking for movement in the nose Some readjustment may be necessary With someone on the other side of the nose unlatch the nose and slowly raise it You may have to pull out sl...

Page 282: ...be on the outside of the rib with the strut ball pointing in The stud should be 7 16 from the side of the rib to allow clearance for the strut Mark the locations of the mounting holes Use a 7 32 dril...

Page 283: ...es and the large center hole Remove the locator bracket Drill a 1 8 hole through the center hole mark through both the nose and the lower body section Open the hose and drill the remaining rivet hole...

Page 284: ...e com 508 291 3443 Underside view nose locator mounted Scoops Sandpaper drill bit drill marker Coupe scoops The original Coupe had three scoops two small ones mounted on the body and one larger one mo...

Page 285: ...284 www factoryfive com 508 291 3443...

Page 286: ...the rivet locations on the scoop flanges Drill through both the scoops and the body nose Rear Spoiler Sandpaper drill bit drill marker Coupe rear spoiler On the original car this was a riveted on par...

Page 287: ...ool floor jack marker ruler silicone caulk gun Secondary body fasteners engine bay aluminum Use care when handling aluminum the edges are sharp and can cut you Rivet and silicone the radiator side alu...

Page 288: ...condary body fastener assembly use some press on weather stripping on the three top sides the sides that will contact the radiator and along the lower front edge of the large radiator duct Insert the...

Page 289: ...actoryfive com 508 291 3443 Attach the driver and passenger side duct brackets to the top of the 1 x 1 tubes and the sides of the main duct using rivets and Silicone Passenger side bracket Driver side...

Page 290: ...surface and dent if it sounds like this has happened to us it has The side pipes are positioned with the rear mount on the bottom of the pipe facing the body Headers Mount the headers to the engine an...

Page 291: ...ton head screw washer and locknut Place a washer next to the locknut so that it will not pull through the rubber Slide the side pipes into position over the header tubes Align the pipes with the body...

Page 292: ...and store in a safe place This is a test fit only Once the windshield is installed the screws around the windshield are not accessible making the removal of the rear part of the body impossible withou...

Page 293: ...heights are correct remove the windshield Use the 3 16 bit and drill through the windshield body flange and frame mount flanges Attach the spacers using the 10 screws and locknuts from the secondary...

Page 294: ...or other reciprocating saw cut out the area traced Draw a line from the edge of the recessed area on the inside of each door Drill a hole in one corner and use this as a starting point to begin cuttin...

Page 295: ...handle Drill 3 32 3 16 drill bits drill rivet tool air saw or jig saw Philips screwdriver marker scissors Interior door handle components secondary body fasteners Attach the cylinder end of the door h...

Page 296: ...get in the way of the door skin Mark the location of the mount on the door frame Drill and mount the tabs using the 3 16 rivets included Install the driver side door frame into the driver door throug...

Page 297: ...line parallel to this line above the top line and below the bottom line Mark the door for drilling using the diagram for locations Drill through the door and frame with a 3 16 bit then open it up to 5...

Page 298: ...e will be able to reach Do not go forward of the cut out in the door as this will hit the window frame Mark the location on the door Remove the handle from the cable by pulling the sleeve out of the r...

Page 299: ...le insert the cable barrel fitting into its hole and slide cable sheath end in into the angled slot Mount the handle using the 8 sheet metal screws Door hinge Using the door hinge diagram in the appen...

Page 300: ...oryfive com 508 291 3443 Drill a hole in each of the cut out locations and cut out with a jig saw Install the adjuster plates to the frame using the square head bolts with nuts and washers but do not...

Page 301: ...into the holes in the hinge arms 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 a...

Page 302: ...Tighten the nuts down until the arm is hard to move and then loosen slightly If you tighten the nut tight and you can still rotate the hinge easily then the washer is caught on the shoulder Loosen sli...

Page 303: ...291 3443 Hinge arm mounted to adjuster plate NOTE this photo was taken before the door was mounted to the frame to clearly illustrate the frame mounting procedure Attach the doors to the hinge arms u...

Page 304: ...to drill through the body Use the 1 hole saw to drill from the front side of the body through the hole just drilled Hold the door in the door opening Remove material from the doors if necessary to all...

Page 305: ...om 508 291 3443 Use a jig saw to cut out the area marked on the door Attach the latch striker to the mount plate on the frame using two washers next to the striker flange to space it out and one washe...

Page 306: ...eet metal screws Engine bay packaged aluminum Insert the aluminum pieces outside first into the area between the body and the footboxes in the engine bay and hold in place Trim the outside if necessar...

Page 307: ...306 www factoryfive com 508 291 3443 Right side Left side...

Page 308: ...cessary trim the flange down to this height This will allow a tighter seal for the weather strip With the help of another person hold the window frame along with the bottom channel section up to the o...

Page 309: ...unting holes with a 7 32 drill bit Cut a slot in the recess at the top rear of the door for the rear weather strip mount looks like a number 1 using a hack saw blade Trial fit the weather strip mount...

Page 310: ...tripping may have to have a V cut with a pair of wire cutters out of the inside of the weather stripping in order to sit properly in the corners Insert the window into the window steel and assemble on...

Page 311: ...ance Remove the quarter window and mark the remainder of the quarter window It should be wedge shaped Carefully cut the window Hold the window up and recheck the clearance Remove the window and evenly...

Page 312: ...ctoryfive com 508 291 3443 Attach the Latch striker square bolt to the frame using the locknuts and washers provided Leave it adjusted as high as possible Do not tighten it down yet it will need some...

Page 313: ...312 www factoryfive com 508 291 3443 Hatch Hinge...

Page 314: ...n studs From the outside of the glass push the Large button studs through the hinge holes in the glass hatch Push another large 1 32 rubber washers onto the large button studs on the inside of the gla...

Page 315: ...Put a washer on the small button stud Carefully thread on and tighten a jam nut on the bottom of the small button stud Thread on and tighten a ball stud on the small button stud Repeat for the other s...

Page 316: ...vise to push them in evenly if necessary Insert the bronze bushings into the frame mounts on the roll bar From the inside of the rollbar attach the frame side hatch hinge arm using the shoulder bolt...

Page 317: ...3443 Rotate the hinge arm up so that it touches the body and mark the body where it hits Use a 7 16 drill bit to drill a hole just below the rear hatch flange Cut the sides of the hole with a hack saw...

Page 318: ...hatch area with the strut ball pointing in Make sure all of the mount holes land on the tube Mark the locations of the mounting holes Use a 7 32 drill bit for the mounting screws Attach the strut brac...

Page 319: ...hatch opening Use coins or washers etc along the bottom and sides so that the hatch is held in position The hatch should be flush with the body Rotate the frame side hinge arms up and if necessary loo...

Page 320: ...319 www factoryfive com 508 291 3443 Carefully try opening the hatch Attach the rod side of the gas strut to the ball stud mounted on the hatch...

Page 321: ...320 www factoryfive com 508 291 3443 Remove the hatch by unbolting the two halves of the hinge arms...

Page 322: ...radiator opening Door openings Hatch opening Cockpit edges The side body edges are not as visible but just taking a little time here to get the lines straight and a small radius makes for a much nice...

Page 323: ...down on a surface that you can cut on Change the blade in your razor knife to make sure the cuts are clean Place your paper template on top of the headliner making sure that it is the same way up as i...

Page 324: ...323 www factoryfive com 508 291 3443 Final Assembly Chapter 5...

Page 325: ...324 www factoryfive com 508 291 3443 Headlights Phillips head screwdriver drill 5 16 drill bit Headlight components Unpack the headlight mounting assembly...

Page 326: ...325 www factoryfive com 508 291 3443 Screw the adjuster screws about halfway into the buckets Push the grommet into the side of the bucket 13419 13415 13418 13420 13416...

Page 327: ...light plug harness through from the inside Line up the headlight with the bucket to get the proper orientation The bottom of the bucket is the only screw boss that comes in from the side and the writ...

Page 328: ...1 3443 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 Put the gasket on the bucket with the adjuster bosses pok...

Page 329: ...Remove the bucket and drill a 5 16 hole through the bottom of the bucket Screw the bucket to the body using the screw that came in the mounting assembly Plug the light into the connector and mount the...

Page 330: ...form 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 varia...

Page 331: ...the vehicle centerline Also measure from high beam center to vehicle centerline for 4 headlight systems Note these measurements On a piece of masking tape draw one horizontal line on the wall at a hei...

Page 332: ...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 slope upwards is loca...

Page 333: ...332 www factoryfive com 508 291 3443 Turn Signals 5 16 deep socket ratchet Amber front turn signal lights Screw the turn signal lights into their holes...

Page 334: ...in the opening with your hands as shown in the picture Only press down at four points on the cover Move your fingers as necessary so that the cover is flush with the body everywhere If necessary use s...

Page 335: ...ch the surface of the plastic Drill and rivet the tabs to the headlight bucket Drill and Mark the location of the tab holes on the cover Drill the holes marked for the mounting screws Remove the maski...

Page 336: ...335 www factoryfive com 508 291 3443 Unpack the fuel cap and mounting hardware Put the gasket on the bottom surface of the cap...

Page 337: ...dy 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 th...

Page 338: ...337 www factoryfive com 508 291 3443 Side Louver mesh Silicone caulking gun duct tape Side Louver mesh Position the mesh screen behind the louver cut out area on the nose...

Page 339: ...338 www factoryfive com 508 291 3443 Apply silicone around the cut out area on the nose that the mesh will touch Duct tape around the outside of the mesh...

Page 340: ...additional weatherstrip on the frame where gap areas were noted before paint The expanding foam weatherstrip is unique in that it has an adhesive side and it expands from tall to 2 tall over 24 hours...

Page 341: ...against the taillight plates in the rear the lower rear corners of the door opening should be at the corner of the tubes for the door latch and the windshield mounts should be close Final Tail light...

Page 342: ...16 worth of washers between the body and the frame so that the body is spaced correctly and there is enough thread left so the locking part of the nut is used When you are fitting the doors the numbe...

Page 343: ...mount Fuel Filler Neck Razor knife socket ratchet 3 16 drill bit drill Aston Lemans Cap components Ground the fuel filler strap to the chassis using the screw that came in the cap hardware This wire p...

Page 344: ...343 www factoryfive com 508 291 3443 Attach the 2 fuel filler hose to the bottom section of the Mustang filler neck Stock fuel tank filler neck with extension...

Page 345: ...508 291 3443 Optional Stainless Steel filler neck with extension Install the hose between the filler neck and gas cap with the clamps that came in the cap hardware Screw the plastic gas cap into the...

Page 346: ...345 www factoryfive com 508 291 3443 Nose mounting Re install the hinge brackets on the nose Replace the bumpers you used before on the body to line up the nose...

Page 347: ...e latch striker to the frame through the body Slowly close and engage the door latch Open the latch and swing the door frame open Door Weather Stripping Razor knife tin snips Secondary body fasteners...

Page 348: ...347 www factoryfive com 508 291 3443 Door Use masking tape around the body opening to prevent scratching or chipping...

Page 349: ...fasteners If necessary remove the seats for easier drilling Position the Door Sill aluminum on top of the body and even with the edge of the 2 x 2 vertical tube The side going down to the floor will...

Page 350: ...e com 508 291 3443 Rear front splash guards Position the rear front splash panels so that they are flat against the rear cockpit wall and the corner is against the aluminum panels Hold the panels in p...

Page 351: ...splash panels with 6 screws Use 1 8 drill bit and drill the rivet marks Rivet the panels in place with 1 8 short or long rivets Headlight Turn signal wiring Wire strippers wire crimpers chassis harnes...

Page 352: ...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 Sate...

Page 353: ...flat head screws and nuts Attach the license plate with the self tapping screws Take the front cover off the license light to use as a template Center the light cover over the license plate up from t...

Page 354: ...arranty the installation Our local installer used x 3 8 tall foam dam tape and 409 T 102 weather stripping on our race car There are two ways to install the windshield with weatherstrip around the win...

Page 355: ...354 www factoryfive com 508 291 3443 Prime the windshield flange for the urethane Apply urethane around the windshield flange Attach the weather stripping to the windshield...

Page 356: ...355 www factoryfive com 508 291 3443 Push the windshield into place Do not move touch the windshield for 24 hours Windshield mounted on the body...

Page 357: ...unt 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 Dash and Gauges Dash Wire stripper wire crimping tool e...

Page 358: ...t plate for the large gauges Be sure to leave 11 16 from the top of the dash for the dash support tubing Decide on the location for your turn signal and alternator charge indicator and high beam light...

Page 359: ...358 www factoryfive com 508 291 3443 Attach the dash sides to the dash Push some of the push on weather stripping onto the top edge of the dash sides and around the front edge of the dash...

Page 360: ...ace of the dash along the top for the mounting screws and two in each of the dash side pieces into the 2 x 2 tube Use the self tapping 6 screws to screw the dash to the x dash support The final mount...

Page 361: ...rbureted harness option and wiper option Top row left to right Ignition key headlight dimmer high low beams Bottom row left to right Turn signal fog lights open open Space the switches and knobs evenl...

Page 362: ...ok at the colors The notation for the wires as written in Chilton s are included in bold in the instructions to aid installation Using a 87 93 Mustang harness does not require the use of the Mustang w...

Page 363: ...it then wipe clean Do not get finger oils on it Wiring Harness Included with the gauge kit are wires and connectors to create a simple gauge wiring harness Cut the 5 long blue wire into sections 1 2...

Page 364: ...res at the 10 mark use the 1 wire and an undrilled tap connector This wire will run over the top of the speedometer to the tach For the red wire at the 10 mark use the 16 wire and a drilled connector...

Page 365: ...tach the short section of red wire on the 16 section to the horn button Use the remaining short section of red wire to jumper over from the horn button to the fan switch The connectors for the switch...

Page 366: ...Install the new water temp adapter short end goes in the manifold with a wrench Use the existing wire from the old sending unit and attach a ring connector to the wire and then attach the connector t...

Page 367: ...the 2 x 2 crossmember on the inside drivers wall Run the wire to the signal input on the gauge Attach ignition power and ground wires to the blocks and the backside of the gauge Remove one of the plu...

Page 368: ...dicator Connect one lead from the blue light to the black wire and the other lead to the second 4 conductor 2 section Attach the other end of the same wire to the gray plug pin 2 Dimmer to High Beams...

Page 369: ...ls to the chassis and then use the trim screws to attach them to the bottom of the dash Install the Mustang headlight and hazard switches in the aluminum brackets Interior Rearview Mirror Tape measure...

Page 370: ...n 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...

Page 371: ...370 www factoryfive com 508 291 3443 Disassemble the mirror removing the large base from the stand The large base is replaced by the smaller insert and gasket...

Page 372: ...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 Mark the location and use the gasket to...

Page 373: ...factoryfive com 508 291 3443 Disassemble the mirror and bolt the mounting insert with mounting bolt and the gasket to the body Slide the stand off and upper gasket down the bolt and onto the mounting...

Page 374: ...373 www factoryfive com 508 291 3443 Bolt the main body of the mirror to the mounting stand off Screw the mirror into the body and adjust it before tightening...

Page 375: ...374 www factoryfive com 508 291 3443 Check straps 3 16 drill bit drill rivet tool marker Secondary body fasteners door latch hinge components Unpack the door check straps...

Page 376: ...not enough so that the door hits the body The straps will stretch slightly over time so allow enough room for this by closing the door slightly from the maximum While holding the door open pull the c...

Page 377: ...376 www factoryfive com 508 291 3443 With the steering wheel in the position that is most comfortable for you tighten the set screws on the collar of the upper steering bearing...

Page 378: ...377 www factoryfive com 508 291 3443 Optional leather steering wheel Side Exhaust 3 16 Hex key socket ratchet Side Exhaust Remount the side exhaust...

Page 379: ...ckaged aluminum front wheel and tire Front Wheel 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 Clamp the fr...

Page 380: ...l not contact the tire Put some of the press on bulb seal around the outside edge of the upper aluminum splash guards Clamp the splashguard up against the nose The upper splashguard attaches to the si...

Page 381: ...eel and tire on the car and check for aluminum clearance and use some tape to mark the start location of the upper splash guard on the radiator opening and the lower splash guard on the 1 x 1 tube Pus...

Page 382: ...r splash guard where it will touch the 1 x 1 tube for rivets Drill and rivet the lower splash guard to the tube using rivets The lower splash guard on the outside can either mount on the inside of the...

Page 383: ...e body Note the Push some bulb weather stripping onto the splashguards where they can contact each other Silicone the weather stripping around the splashguard to the nose from the backside of the whee...

Page 384: ...one where it will contact the trunk side and along the inside of the flange on the body Drill and rivet the panel in place along the trunk side and through the bottom corner of the body into the alumi...

Page 385: ...fasteners 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 Lowes and...

Page 386: ...depth Finishing Touches Alignment Specifications Take your new car to an alignment shop and have the car aligned properly before hitting the track A minor flaw in alignment can cause very twitchy han...

Page 387: ...red length tighten down the jam nuts against the adjusting tubes and then tighten each of the three pivot bolts Torque the pivot bolts to 60 lbft Grease both ends using chassis grease frequently to in...

Page 388: ...387 www factoryfive com 508 291 3443 Performance Reference Material and Technical Support Chapter 6...

Page 389: ...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 3...

Page 390: ...e 17 Cobra R or FR style wheels If using the standard width 1987 93 rear 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 C...

Page 391: ...ant more side support Factory five offers a variety of different options Check out www factoryfiveparts com The following modifications and set ups fall under the category of getting more horsepower f...

Page 392: ...tial up and look on the ring gear While the rear is open change the fluid This never gets done enough on the car Changing the gear ratio is one of the least expensive ways to improve your car s perfor...

Page 393: ...number of intakes available from different companies e g Edelbrock Trick Flow Ford also makes a good intake the cast 1993 Cobra intake from Ford Racing Heads The 5 0L Mustang aftermarket is full of a...

Page 394: ...4 will do the same Higher octane fuel will be needed Under drive Pulleys Yes They work well on all cars Oil Cooler Not really necessary on small blocks or cars that aren t raced heavily They look nice...

Page 395: ...er a 15 1 or 18 1 rack will yield about the same effort feel This is good for most driving situations We have found that many of the Challenge Car racers prefer to use power steering This can be done...

Page 396: ...driving you do a majority of the time Each one is best for one application and is good in other applications 4 link suspension Good all around suspension for everyday driving Best for drag racing app...

Page 397: ...The IRS is best for rough surfaces Control Arms Stock Stamped steel with rubber bushings Front The stock front arms work well all round The Factory Five tubular lower control arms with polyurethane b...

Page 398: ...397 www factoryfive com 508 291 3443 Rear Using tubular control arms with polyurethane bushings helps to locate the solid axle and hook up better on the drag launches...

Page 399: ...aking capabilities These are systems that have been used successfully by our customers and us Each component below has been selected to optimize the capabilities of the system If an attempt is made to...

Page 400: ...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 offsets need to...

Page 401: ...per from the 1984 Lincoln Town Car or 1992 Lincoln Mk 7 will bolt on to the Mustang spindle although the piston is 73mm in diameter so it would not be well suited for the recommended brake setups abov...

Page 402: ...by Motorbooks International Publishers and Wholesalers Inc PO Box 2 729 Prospect Avenue Osceola WI 54020 Prepare to Win By Carroll Smith Published by Motorbooks International Publishers and Wholesaler...

Page 403: ...w northerntool com Paint over Rust 15 Stops rust permanently guaranteed 800 4576715 www por15 com Insurance Northeast Classic Auto Insurance Mike Smith 800 866 6440 www classiccarinsurance com Country...

Page 404: ...rized FFR dealerships and we cannot recommend any of the particular businesses that are on our lists nor do we warrantee their work They are provided simply to help you identify businesses in your are...

Page 405: ...404 www factoryfive com 508 291 3443 Appendix A Templates...

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Page 408: ...THE SOLE PR OPERTY OF FACTORY FIVE RACING INC ANY R EPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF FACTORY FIVE RACING INC IS PROHIBITED COMMENTS S HEET 1 OF 1 Q A MFG APPR ENG A...

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Page 417: ...416 www factoryfive com 508 291 3443 Appendix B Donor Parts List...

Page 418: ...S WHEELS BRAKE CALIPERS FRONT CUT 4 INTO STEEL LINES 2 BRAKE BOOSTER DISTRIBUTION BLOCK CONNECTION FITTINGS 1 MOUNT FRONT FLEXIBLE HOSE TO STEEL LINE MOUNTED TO BODY 2 EMERGENCY BRAKE HANDLE W T CABLE...

Page 419: ...418 www factoryfive com 508 291 3443 Appendix C Optional Rear Disc Brakes...

Page 420: ...formed by anyone with an average amount of mechanical experience but it is very important to follow the instructions and refer to a Mustang Shop Manual or equivalent If you do not feel comfortable aft...

Page 421: ...420 www factoryfive com 508 291 3443 Instructions Place the caliper C shaped caliper axle mount bracket over the Axle so that the open part of the bracket is facing down...

Page 422: ...421 www factoryfive com 508 291 3443 Insert the caliper axle mount bracket bolts from the outside in Torque the caliper bracket to 45 50 ft lbs...

Page 423: ...422 www factoryfive com 508 291 3443 Insert the caliper mount bracket bolts from the outside in through the four remaining bracket holes Slide the caliper mount bracket onto the four bolts...

Page 424: ...291 3443 Torque the mounting bolts to the same 45 50 ft lbs Next install the brake rotor using one lug nut to hold it in place Make sure to clean the surface of the rotor with brake parts cleaner bef...

Page 425: ...own on the pad to compress the wire springs on the top of the pad and then slide them into the slots in the caliper bracket When installing the caliper make sure that the brake fluid bleed screw is on...

Page 426: ...sure the caliper bracket is centered over the rotor then check to see if a spacer is needed between the caliper bracket and the caliper mount bracket or between the two brackets If needed remove the...

Page 427: ...426 www factoryfive com 508 291 3443 Recheck the clearance between the caliper bracket and rotor Tighten and torque the two 12mm mounting bolts to 55ft lbs using a 16mm socket...

Page 428: ...and seal the cover with RTV silicone Torque Specifications FASTENER TORQUE FT LBS DIFFERENTIAL PINION SHAFT LOCKING BOLT 15 30 BANJO BOLTS 30 40 WHEEL NUTS 85 105 AXLE ADAPTER REARBACKING PLATE BOLTS...

Page 429: ...428 www factoryfive com 508 291 3443 Appendix D Different Donor Vehicles...

Page 430: ...omatic transmissions were throttle 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...

Page 431: ...e 59 25 A different wheel offset could be used to make up the difference Front spindles are shorter if you specify we have brackets to make them work Wiring harness will not work Pedal box needs space...

Page 432: ...431 www factoryfive com 508 291 3443 Appendix E Mustang Specifications...

Page 433: ...1 1987 93 5 0L V8 225 4000 300 3000 SFI 9 0 1 1994 95 5 0L V8 225 4000 300 3000 SFI 9 0 1 Transmission Year Type 1st 2nd 3rd 4th 5th 6th R Torque Capacity lbs ft Part Number Weight 1983 5 T 5 2 95 1...

Page 434: ...s manufactured with a slightly wider opening for the rotor All flexible brakes lines and there mounting brackets are required donor parts for FFR kits Emergency brake cables will clip right into a Fac...

Page 435: ...t changing the transmission drive gear 1983 98 19 Tooth Pink C0DZ 00017271 B 1983 98 20 Tooth Black C1DZ 00017271 A 1983 98 21 Tooth Red C40Z 00017271 A 1983 98 23 Tooth White E6MS 0017271C M Mass Air...

Page 436: ...ation that pulses power using to the fuel pump to control pressure instead of using a mechanical regulator The top of the tank was changed so putting an older pump or gauge sender in the tank is not p...

Page 437: ...gned to mount in the outer chassis mount hole Springs MODIFICATION Rear springs from 1979 to 2004 will all fit an FFR kit with a slight modification as shown below Below is a chart of every spring rat...

Page 438: ...harness FFR has a harness for Mass Air engines 89 93 Ron Francis has a harness for 96 04 engines For a carbureted car we recommend using an aftermarket chassis harness Accelerator Pedal The accelerato...

Page 439: ...438 www factoryfive com 508 291 3443 Appendix F Fluid Specifications...

Page 440: ...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...

Page 441: ...440 www factoryfive com 508 291 3443 Appendix G Torque Specifications...

Page 442: ...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...

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