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Factory Five Racing Mk4 Roadster, Инструкция по сборке, Страница: 1 / 546

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R E V I S I O N   3 P ,   J U L Y   2 0 1 3  

Содержание Mk4 Roadster

Страница 1: ...R E VI SI O N 3 P J U L Y 20 1 3...

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

Страница 3: ...build 24 Donor Part Selection Tips 25 Fords Passive Anti Theft System PATS 25 Where to look 26 Price 27 Running Gear 27 Disassembly of a Mustang Donor for Parts 28 Radiator Cooling System 29 87 95 Br...

Страница 4: ...ont Lower Control Arms 52 Fuel Filter Fittings 55 Fuel Tank 56 Fuel Filler Neck 56 Brake Pedal 58 Accelerator Pedal 59 87 93 Pedal Box 60 1994 2004 Pedal Box 61 Wiring Harness 63 87 95 Brake Power Boo...

Страница 5: ...uspension 104 Solid Axle Preparation 104 Spring Perch mounts 109 4 Link Rear Suspension 109 Optional 3 Link Rear Suspension 110 Rear Axle Installation 114 Optional 3 link Panhard Bar Frame mount 116 P...

Страница 6: ...7 Passenger Footbox 168 Passenger Floor 173 Driver Floor 175 U Joint Cover 178 Transmission Tunnel rear corners 179 Cockpit rear corners 180 Cockpit rear wall 181 Fuel System 181 Fuel Tank 181 Fuel Fi...

Страница 7: ...48 87 95 Oil Filter Relocator 250 Headers and J pipes 251 Fuel Lines to engine 253 96 04 Connections 253 96 04 Hydro booster and Power Steering lines 254 Power Steering Oil Cooler If applicable 258 19...

Страница 8: ...0 Dash preparation 302 Gauge Installation 305 Steering Wheel 316 Rollbar 319 Rolling Chassis Check 323 Front Suspension 323 Fluid Levels and Grease 324 IRS Axle Nuts 328 Wheels 329 Power Steering Syst...

Страница 9: ...396 Carpet 404 Seats Harness lap belt 411 Emergency Brake Boot 413 Seat Final Install 415 Seat Harness Shoulder Belts 415 Shifter Handle and Boot 418 Headlights 422 Turn Signals 427 Tail lights 428 G...

Страница 10: ...erformance Reference Material and Technical Support 479 Maintenance 480 Wheels 480 1994 1998 rear end 482 1999 2003 rear end 482 Performance Modifications 482 Gears 483 EFI Engines 483 Oil Cooler 485...

Страница 11: ...ers Used 517 Appendix D Optional Rear Disc Brakes 519 Installation instructions 520 Torque Specifications 529 Appendix E Race car check sheet 530 Appendix F Torque Specifications 533 Appendix G Mustan...

Страница 12: ...lines fuel filter and bracket 541 Emergency brake handle 541 Rear quad shocks 541 Spindles 541 Rear 4 link control arms 541 Front lower control arms 541 Springs 542 Wiring harness 542 Accelerator Ped...

Страница 13: ...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...

Страница 14: ...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...

Страница 15: ...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...

Страница 16: ...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...

Страница 17: ...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...

Страница 18: ...charge For a complete packing list see the Appendix Frame Complete jig welded tube frame Includes all mounts ready to accept all Ford Engines Small block 4 6L 427 428 FE 429 460 engines Body Hand laid...

Страница 19: ...accelerator cable adjustable door hinges with bronze bushings and shifter boot Exterior Accessories and Lighting DOT approved windscreen License plate light and bracket Ceramic Factory Five nose and...

Страница 20: ...body shop Radiator and Fan shroud 1987 2004 Ford Mustang Steering Rack 1987 2004 Ford Mustang Fuel tank pump and filter 1987 2004 Ford Mustang Electrical 1987 2004 Ford Mustang chassis and EFI harness...

Страница 21: ...in along with a Nameplate for your 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 examp...

Страница 22: ...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...

Страница 23: ...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...

Страница 24: ...23 www factoryfive com 508 291 3443 Donor Parts and Prep Chapter 2...

Страница 25: ...ity and affordability Many who have owned 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...

Страница 26: ...ing system spindles brakes etc The Factory Five Roadster kit is designed to use parts from the 1987 2004 Mustang You can use many of the same parts from earlier and later model Mustangs but there are...

Страница 27: ...portant to keep all of the boxes that are connected to the wiring harness and along with the gauge cluster If you are not using the stock gauges you will still need them to be connected behind the das...

Страница 28: ...ew numbers on their bill of sale In the unfortunate event that these components were stolen you need to have documentation on the origin and sale price Check the numbers twice The VIN numbers are loca...

Страница 29: ...ill have a surface dusting of corrosion 4 6L DOHC blocks are aluminum up to 2002 Since our kit can use the original drive shaft that gets shortened the quality and condition of the slip yolk transmiss...

Страница 30: ...umber for the shroud is E6ZZ 8146 A and the reservoir part number is F2ZZ 8A080 B Place a bucket under the radiator drain petcock on the lower passenger side of the radiator Loosen the radiator drain...

Страница 31: ...de the foot box area Attach tape to the brake lines 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...

Страница 32: ...on block Remove the four bolts that connect the hydro boost mount and pedal box to the firewall On the Hydro booster remove the snap ring in front of the retaining nut inside the car Remove the nut th...

Страница 33: ...el the location of the brake lines and remove all the brake lines in the front half of the car This will minimize the number of flares needed Remove the ABS controller and mounting bracket from the en...

Страница 34: ...ering rack shaft begins Remove the inner clamps from the steering rack boots and pull them back Remove the steering rack inner tie rods from the rack If equipped disconnect the power steering cooler l...

Страница 35: ...and remove the Barometric Air Pressure sensor from the firewall behind the engine Disconnect and remove the mass air sensor Store it with the computer Disconnect the throttle cable from the throttle...

Страница 36: ...t from the car Pedal Box Accelerator Pedal and Clutch Cable Socket set wrenches Phillips head screwdriver flat head Screwdriver Mustang pedal box accelerator pedal and clutch cable The pedal box comes...

Страница 37: ...eel at this point Unbolt and remove the pedal box 94 04 Pedal box assembly Computer Socket set Mustang Computer and OEM plastic cradle If you are going to run the car with a Carburetor you can disrega...

Страница 38: ...ked up even if you are going to use aftermarket gauges Remove all visible screws from the dash gauge pod You can reach the two screws above the instrument pod with a short Phillips head screwdriver Th...

Страница 39: ...clips Remove the clear plastic gauge cover with a Torx screwdriver and discard Place the switches and gauge pod in your parts area awaiting kit assembly Turn Signal and Ignition Switches Socket set e...

Страница 40: ...g column mounts located under the dash above the driver floor Allow the column to fall down Remove the wiring connectors have from the turn signal and ignition switches Remove the turn signal stalk 96...

Страница 41: ...sh from the car Remove the wiring harness and all of the black boxes hooked into it from the dash Mark all of the connectors to prevent any confusion later Disconnect the connectors from the headlight...

Страница 42: ...crewdrivers needle nose pliers hammer and marker tape Front wiring harnesses Pull the rubber grommet out of the firewall into the engine bay Remove the front light harness from the engine bay wall wor...

Страница 43: ...to the body near the exhaust in the engine bay Remove the wiring harness plug from the sending unit Remove the speedometer sending unit bolt using an 11mm socket Pull the sending unit straight out Rep...

Страница 44: ...nscrew the plastic console that retains the boot Remove the shifter boot and unbolt the rubber boot below it Unbolt and remove the shifter and handle from the cockpit Duct tape over the handle hole an...

Страница 45: ...er pen and tape Donor car rear wiring 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 circ...

Страница 46: ...Remove the O2 sensors from the H pipe with an adjustable wrench Do not touch the ends Engine Removal Engine hoist socket set wrenches floor jack used tire or engine stand rags chain duct tape friends...

Страница 47: ...ft point 1997 4 6L DOHC Engine and T 45 transmission on hoist Take up the slack on the chain slowly Check to make sure that no hoses or wires remain connected to the engine Remove the bolts from the t...

Страница 48: ...positions even when the suspension pieces are lowered in their mounts These springs will cause serious injury or death if you are not extremely careful Loosen the lug nuts on the front wheels Raise t...

Страница 49: ...er pin and castle nut from the lower control arm 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...

Страница 50: ...l box mount Use a small screwdriver or pushing tool to push on the pin from the side as you push upwards to align it to the exit hole The pin is a very loose fit and you will see that this is not very...

Страница 51: ...d remain attached to the rear end assembly Once off place the bolts back into the arms and attach nuts so they do not get lost Remove the rear end from under the car Remove the brackets that secure th...

Страница 52: ...51 www factoryfive com 508 291 3443 96 98 Donor fuel system parts Donor Part Preparation Rear Coil Springs Hack saw or chop saw Rear coil spring Remove the rubber tubular spacer from inside the coil...

Страница 53: ...ne pieces as these will allow the springs to slide since they contain a slippery release agent in them Rear End drill bit drill vise Remove and save the control arms from the axle Remove the lower sho...

Страница 54: ...eat area shown in the picture below using the rear end shock mount as a guide for height If the hole is drilled too low you will have to clearance the middle of the spring area so the shock will not h...

Страница 55: ...nt lower control arm Attach the rear shock mount to the control arm through the hole in the spring seat with the small leg sticking up Check clearance with the new shock and the new mount These parts...

Страница 56: ...stic 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 hard plastic off the plastic barbs...

Страница 57: ...e the tank straps come near the tank use a pair of pliers and bend the bent parts flat Fuel Filler Neck Hack saw Fuel Filler neck 87 98 Cut the Mustang steel fuel neck in the mid section after the 90...

Страница 58: ...57 www factoryfive com 508 291 3443 Uncut Filler Neck Cut Filler Neck 99 04 Cut the donor filler neck just above the crimp line below the mounting flange...

Страница 59: ...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 cylinder when the pedal is press...

Страница 60: ...d attachment stud Remove 1 5 from the middle and MIG weld the pedal back together Make sure the top piece where the bolt is located is oriented correctly as the spacer on each side of the pedal is dif...

Страница 61: ...t the 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 87 93 Pedal Box Marke...

Страница 62: ...43 Mark the mounting face of the 1 up from the bottom of the mounting plate Cut off the marked area bottom of the front mount flange with a hack saw This is necessary for steering shaft clearance 1994...

Страница 63: ...factoryfive com 508 291 3443 Drill out the four spot welds on the front face of the pedal box Cut off the lower corner of clutch quadrant stop shown in the picture for accelerator pedal clearance Cut...

Страница 64: ...ocate brake pedal spring to pedal box triangular opening Wiring Harness Razor knife electrical tape Many people choose to cut down the wiring harness to use only the wires and leads that are needed Yo...

Страница 65: ...plugs and compare them to a Chilton s manual to make sure you are cutting the correct plug before actually cutting 96 04 Harness The following 2 steps can be done two ways cut and move the firewall gr...

Страница 66: ...kwards on the harness behind the short wiring branch with the large rectangular plug on it All of the remaining plugs should be pulled back behind the firewall plug Rewrap the harness with electrical...

Страница 67: ...d break the plastic end After separating the booster housing pull the rod out This rod will have an aluminum fitting attached to it In order to get it to release heat the aluminum fitting with a torch...

Страница 68: ...pection cover If you are not running emissions equipment the only engine controls that need vacuum are the PCV valve in the valve cover and the fuel pressure regulator The EGR can be left unhooked Mak...

Страница 69: ...68 www factoryfive com 508 291 3443 96 04 Driver side manifold 96 04 Passenger side manifold Note the casting touches the block...

Страница 70: ...ate If you are planning on running power steering the alternate pulley is not needed You will however need the power steering mounting brackets for a non A C car Remove the A C and power steering pump...

Страница 71: ...five com 508 291 3443 Insert the spring pins back into the two front holes on the block It may be helpful to put a dab of silicone to hold the pins in place until the bolts are installed 87 95 Transmi...

Страница 72: ...rly The rack is greased on the gears at the ends The Mustang power rack is converted to a manual rack by removing the hydraulic lines from it and draining the fluid You can leave the holes open withou...

Страница 73: ...ut half of the passenger side power steering mount off Drill a mounting hole in the bracket using a 3 16 drill bit Intake Tube The year and type of engine may give a different style intake tube Simila...

Страница 74: ...DOHC Cobra intake hose Cut the intake hose in the crease on the intake side of the bellow section marked in the picture Make sure not to cut the large bellow section 96 04 Air Filter Housing Unclamp...

Страница 75: ...74 www factoryfive com 508 291 3443 Mark the housing around the base of the dome Cut the flange off the housing Keep in mind the flange is the part you want to keep...

Страница 76: ...you can take the parts and assemblies to a do it yourself car wash They usually have an engine degreaser as an option and most places run very high water temperature that helps loosen debris and greas...

Страница 77: ...mechanic or a good auto parts store what the condition of the spark plug reveals about the engine s performance When replacing the spark plugs make sure you gap them before installing them Not using a...

Страница 78: ...77 www factoryfive com 508 291 3443 Disassembly of the kit Chapter 3...

Страница 79: ...T EA 1 00 15176 E BRAKE LOWER HANDLE ASSEMBLY EA 1 00 14734 WILWOOD PEDALBOX MOUNT EA 1 00 14735 WILWOOD PEDALBOX REAR MOUNT EA 1 00 14783 WILWOOD CLUTCH QUADRANT STOP EA 1 00 14788 WILWOOD BRAKE LIGH...

Страница 80: ...wrench gloves 2 friends Be careful of the raw fiberglass edges they can splinter into your skin Unbolt the door from the hinge leaving the hinge attached to the chassis Cut the zip ties in the door l...

Страница 81: ...8 291 3443 Unbolt the body sides from the chassis on the underside of the car Unbolt the Quick Jacks and remove the body Two people can do this but it is much easier with a third person to pull the si...

Страница 82: ...der the windshield holes running vertically to support the hood cowl area just forward of the doors under the windshield holes Use these 2 x 4 s whenever the body is on the ground otherwise make a bod...

Страница 83: ...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...

Страница 84: ...83 www factoryfive com 508 291 3443...

Страница 85: ...84 www factoryfive com 508 291 3443...

Страница 86: ...85 www factoryfive com 508 291 3443 Use jack stands to position your frame in your workspace with plenty of room to move things around...

Страница 87: ...86 www factoryfive com 508 291 3443 Chassis Assembly Chapter 3...

Страница 88: ...oles is correct to center the rivets on the tubes Align the edge of the tool with the marker line made around the tubes and mark the rivet holes with a marker Use the rivets for all of the aluminum pa...

Страница 89: ...ed aluminum panels that mount behind the suspension are mounted first Locate them and mark your rivet pattern in the location you traced Drill the panels using a 1 8 bit then clean the marker lines an...

Страница 90: ...91 3443 Apply silicone to the panel or chassis whichever is easier in the areas where they will make contact Use the original 6 screws to remount the panel then drill the 1 8 rivet holes through the p...

Страница 91: ...t the panel in place using 1 8 short rivets then remove the screws and replace them with rivets Repeat for the other side Front Suspension Front lower control arm socket 15 16 wrenches Torque wrench M...

Страница 92: ...94 04 stock lower control arms use the inner set of bolt holes FFR tubular lower control arms use the outer mounting holes While holding the control arm parallel to the ground torque the bolts to 135...

Страница 93: ...92 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...

Страница 94: ...93 www factoryfive com 508 291 3443 Tighten the balljoint using the arm for leverage with a Vice holding the ball joint Screw the grease fittings in to the ball joints and tighten with a wrench...

Страница 95: ...e to 135 149Nm 100 110 lbft The side mount holes are for the Factory Five optional spindles and provide a slightly different front geometry and handling Pivot endplay Adjust the locknuts on the ends o...

Страница 96: ...more than 1 of thread showing past the tightened down jam nuts on either end of both adjusting tubes The Pivot Bolts must be loosened while the car is being aligned and retightened afterwards Front C...

Страница 97: ...d and bump stop to make sure that it is tight Screw the spring seat down on the sleeve so it is closer to the unthreaded end Slide the coil sleeve over the body of the damper beginning at the end whic...

Страница 98: ...lds it in place Remove this snap ring to assemble the coil over shock Slide the rubber bumper about two inches down on the shaft Put the spring and hat on the shock and rotate the spring seat back up...

Страница 99: ...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...

Страница 100: ...s Mustang Spindles Make sure the grease boot is in place on the lower balljoint then mount the spindle to the lower control arm Attach the castle nut and torque the balljoint to 106 149Nm 80 110 lbft...

Страница 101: ...losest to the ball joint and the third hole down Using a 94 04 Spindles attach the bracket using the bottom and third hole up so that the ball joint is further away from the spindle Attach the upper b...

Страница 102: ...chassis grease rags brake cleaner Mustang front brake calipers and rotors Make sure that your brake pads and rotors are in good condition Make sure that the hub bearings are greased correctly and ade...

Страница 103: ...102 www factoryfive com 508 291 3443 94 04 Front Brakes Clean the rotor with brake cleaner and push it onto the hub...

Страница 104: ...103 www factoryfive com 508 291 3443 Install the caliper on the spindle make sure that the fluid bleeder is at the top of the caliper Torque the caliper mounting bolts to 130Nm 95 ft lb...

Страница 105: ...l bit drill floor jack jack stands Torque Wrench 8 8 Rear axle assembly Solid axle adapters hardware Box Mustang lower control arms Use caution when working with the rear end assembly it weights 225 l...

Страница 106: ...y done fill the axle with gear oil See Appendix for specifications and capacities If using a used rear axle remove the lower shock mounts and the anti vibration weight under the pinion 87 98 Axle Dril...

Страница 107: ...508 291 3443 99 04 Axle Drill the lower control arm holes out with a 9 16 drill bit Position the Traction Lok brackets on the rear end with the bolts provided the two short bolts go on the sides Axle...

Страница 108: ...107 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...

Страница 109: ...que 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 provide more traction than...

Страница 110: ...hread the cut rear springs onto the conical frame mounts all the way Insert the cut rubber spring mount between the spring and the steel seat Make sure the end of it is flush with the end of the sprin...

Страница 111: ...es 15 16 sockets 5 16 Hex key Ratchet Torque Wrench Drill Ruler Tape measure Pliers Flat head Screwdriver Tin Snips scissors razor Marker 3 Link rear suspension with kit The Panhard bar frame mount is...

Страница 112: ...ves of the upper arm mount together If it is hard to put all of the bolts in the mount holes put in as many as you can then use a drill bit through the remaining bolt holes Attach the upper link brack...

Страница 113: ...the upper link axle mount attaches to the hole on the flange section of the pumpkin This hole has some variance and may need to be drilled out from the bottom side using the mount as a guide Attach th...

Страница 114: ...o of them are left hand thread Insert the rod ends into the swedged tubes one is right hand thread and one is left hand thread The longer tube is the Panhard bar and the shorter one is the upper link...

Страница 115: ...e a floor jack to position the rear axle assembly under the frame Make sure that the rear jack stands are positioned under the 4 round tube as far back as possible to prevent the frame from tipping up...

Страница 116: ...ryfive com 508 291 3443 With one person holding a side of the axle raise the axle so that the lower control arms can be bolted onto the frame Attach the lower control arms to the frame mounts Jack the...

Страница 117: ...1 3443 If using a 4 link attach the upper control arms to the frame If using a 3 Link attach the upper link to the frame Optional 3 link Panhard Bar Frame mount The Panhard bar frame mount is mounted...

Страница 118: ...08 291 3443 With the axle jacked up attach the Panhard Bar frame mount to the inside of the quad shock brackets the forward leg will attach to the back of the angled 2 x 3 tube Do not tighten the quad...

Страница 119: ...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...

Страница 120: ...r side traction lock bracket Three spacers are used in the front 2 0 375 FFR 14064 and 1 0 25 FFR 14065 The rear uses the thin 0 0625 shim FFR 13337 It will be necessary to adjust the length some to f...

Страница 121: ...xle left to right in the frame At ride height level the Panhard bar as much as possible Double check all your nuts and bolts and make sure that all four jam nuts are tight 3 link Rear Suspension Torqu...

Страница 122: ...t ride characteristics WARNING Incorrect assembly and maintenance of this part can cause serious injury or death Unpack the rear shocks coil over s and hardware Double check the jam nut under the rod...

Страница 123: ...semble the coil over shock Slide the rubber bumper about two inches down on the shaft Put the spring on the shock then install the spring hat on the shaft end of the shock and push the rubber bumper u...

Страница 124: ...he snap ring on the spring hat so that it holds onto the shock end Make sure that the slot in the snap ring and the slot in the spring hat are not aligned Use zip ties to hold the spring to the spring...

Страница 125: ...291 3443 Attach the body end of the shock to the upper shock mount using the two equal length 1 09 spacers Jack the rear axle up so the rod end of the shocks can be mounted on the axle through the sho...

Страница 126: ...through the bracket shim shock then the long spacer 1 09 followed by the bracket and axle Use a socket and Torque wrench to tighten both upper and lower mounts to 40 ft lbs Check for shock clearance...

Страница 127: ...126 www factoryfive com 508 291 3443 Run zip ties through the holes in the spring hat and around the spring to prevent the spring from becoming unseated...

Страница 128: ...ks quad shocks quad shock brackets Quad shock fasteners assembly rear spring perches rear traction Lok brackets fasteners Attach the rear vertical shocks at the top through the holes in the plates loc...

Страница 129: ...ock clearance on brake lines emergency brake cables brake calipers frame and axle parts Check to make sure that the spring is seated correctly on the shock Mount the quad shocks and their brackets to...

Страница 130: ...67 40 50 Lower optional shock to axle bracket 54 67 40 50 If running a 4 link skip to the Firewall and Driver front footbox aluminum section Optional Independent Rear Suspension Standard width 3 16 d...

Страница 131: ...S completion parts IRS Center Section Mount the rear center section to the chassis It installs from the bottom with the driveshaft flange pointing straight up and the axle holes lined up front to back...

Страница 132: ...43 Raise the front of the center section and insert a bushing under each of the front mounting bosses Slip one of the large washers under the bushing before setting it back down Slide the bushing slee...

Страница 133: ...ough bolt the two front bushings and the remaining rear mount with the mounting hardware and tighten Lower Control Arms Screw the rod ends with jam nuts into the lower control arm Screw the forward jo...

Страница 134: ...ol arms The rod ends will be adjusted later IRS Rear Coil Over Shock Assembly Snap ring pliers wrench socket ratchet ruler marker hack saw Roadster Coupe rear shock kit The rear shocks are pre valved...

Страница 135: ...ht Screw the spring seat down on the sleeve so it is closer to the unthreaded end The center high part of the set should be pointed away from the unthreaded end Slide the coil sleeve over the body of...

Страница 136: ...semble the coil over shock Slide the rubber bumper about two inches down on the shaft Put the spring on the shock then install the spring hat on the shaft end of the shock and push the rubber bumper u...

Страница 137: ...he snap ring on the spring hat so that it holds onto the shock end Make sure that the slot in the snap ring and the slot in the spring hat are not aligned Assembled solid axle Koni coil over shock Use...

Страница 138: ...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 to the coil over with the remaining large and...

Страница 139: ...ve com 508 291 3443 CV Axles Push the inner CV joints into the center section 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...

Страница 140: ...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...

Страница 141: ...Rear Calipers and Rotors Push the slotted rotor onto the spindle Attach the caliper to the spindle using the OEM T Bird bolts Width Adjustment Mount your wheels and tires Lower the frame off the jack...

Страница 142: ...141 www factoryfive com 508 291 3443 Remove the rear wheels Use a couple of lug nuts on the wheel studs to ensure that the rotor is seated correctly...

Страница 143: ...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...

Страница 144: ...e car up again and place on jack stands located on the lower control arms near the shock Double check the axle width measurement Torque specs Item Nm Lbft Lower control arm to frame 135 149 100 110 Up...

Страница 145: ...291 3443 Bolts used on the caliper that do not use a locknut should have Loctite or other thread locker applied before installing Insert a hex head bolt through the Caliper Mount Bracket hole so that...

Страница 146: ...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...

Страница 147: ...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...

Страница 148: ...luminum Drill 1 8 drill bit rivet tool caulk gun silicone Firewall and Driver Footbox Front aluminum Secondary body fasteners If you are installing a heater defroster it is much easier to cut the fire...

Страница 149: ...Rivet the firewall in position on the chassis Mark drill and rivet in place the driver s side footbox front panel leave the lower section that attaches to the tube un siliconed and un riveted for the...

Страница 150: ...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 87 93 Pedal...

Страница 151: ...ww factoryfive com 508 291 3443 Position the Mustang 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 foo...

Страница 152: ...e Mustang pedal assembly on top of the tubing Mark these holes on the tubes The right hole for the master cylinder must also be marked on the pedal box Use the laser cut hole in the foot box steel as...

Страница 153: ...ts and washers at the top as before They go through existing holes 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...

Страница 154: ...Attach the pedal box using two short bolts and two washers to the front wall at the front of the foot box The right hole for the master cylinder must also be marked on the pedal box Use the laser cut...

Страница 155: ...yfive com 508 291 3443 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 Accelerator Cable 5 64 hex key 7 16 wrenche...

Страница 156: ...s 87 93 Fuel Injected and Carbureted Applications Using a ruler and marker measure and mark 2 from the cylinder slug on the engine end of the cable Using a pair of wire cutters cut the cable at the lo...

Страница 157: ...lled later 94 04 Fuel Injected Applications Loosen the nut on the engine end of the accelerator cable with the cylinder slug on the end Put the accelerator cable in the stock accelerator bracket slot...

Страница 158: ...r cable mounted on 96 2 valve intake Run the cable from the mount plate tightly against the intake and over to the driver s foot box front panel Insert the pedal end of the cable into the foot box Scr...

Страница 159: ...unt on the tube at the front of the foot box The higher you can mount the pedal the better the pedal will be positioned on your foot The key things to watch for is clearance between the accelerator pe...

Страница 160: ...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...

Страница 161: ...g 87 93 Power steering racks have a different spline than a manual steering rack and the 94 04 Power rack uses a Pyramid shaped end All of these lower adapters are available from FFR Steering Rack Nee...

Страница 162: ...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 steering rack...

Страница 163: ...to do the driver side first then swing the passenger side down into the mount Use thread locker on all of the steering shaft screws that do not have jam nuts and the adapter screws The inner Tie Rod E...

Страница 164: ...cut 1 75 off the end of the inner tie rod Put a dot of thread lock on the threads of the steering rack and attach the steering rack extension to the steering rack using a 1 50 wrench 87 93 Put a dot...

Страница 165: ...onto the steering rack body and attach with zip ties 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 flush with the e...

Страница 166: ...oryfive com 508 291 3443 Steering rack installed 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 com...

Страница 167: ...t through the upper bearing and start it in the lower shaft Turn the steering shaft so the recessed bosses for the spring washers are facing up and set the washers in place Then tap the upper shaft do...

Страница 168: ...e upper shaft Cockpit Aluminum Drill drill bit rivet tool Silicone caulking gun 8 self tapping screws 8 hex nut driver ruler marker Acetone or carburetor cleaner rags Packaged aluminum mounted aluminu...

Страница 169: ...nger footbox top and drill and mark the holes in the top flat surface only Silicone this panel where it meets the chassis and rivet along the bottom of the 2 square frame crossbar only Use one of the...

Страница 170: ...w factoryfive com 508 291 3443 Drill the tunnel front A shaped piece where it meets the chassis and silicone and rivet it in place Mark and drill the two vertical edges of the passenger footbox inside...

Страница 171: ...70 www factoryfive com 508 291 3443 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 ye...

Страница 172: ...171 www factoryfive com 508 291 3443 Silicone the panel and install with the temporary screws then drill through both panels and rivet it in place...

Страница 173: ...yfive com 508 291 3443 Mark and drill all three flanges on the passenger outer footbox top Silicone the flange between the outer top and the outer wall and attach the two pieces together using the tem...

Страница 174: ...er wall top on the footbox with rivets Make sure the rear edge is flush to the chassis and not caught up on the door hinge before you start riveting Passenger Floor Drill the passenger side floor wher...

Страница 175: ...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...

Страница 176: ...3443 Drill silicone and rivet the passenger outside wall in place Leave the rivets out of the rear vertical flange for now Driver Floor Drill silicone and install the driver s footbox floor The outer...

Страница 177: ...176 www factoryfive com 508 291 3443 Silicone drill and install the driver side floor Install the drivers side outer wall same as the passenger...

Страница 178: ...L engine than for any of the others The 4 6 panel is pictured on the left It has an extra bend about 10 in from the front Drill silicone and install the inner footbox wall The front flange tucks in be...

Страница 179: ...178 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...

Страница 180: ...291 3443 Transmission Tunnel rear corners The inner rear corner pieces 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...

Страница 181: ...180 www factoryfive com 508 291 3443 Cockpit rear corners The outer cockpit corners get marked on the bottom flange and where they meet the chassis Drill silicone and rivet these in place...

Страница 182: ...assis and aluminum flanges where it attaches and rivet it into place Fuel System Fuel Tank 9 16 deep socket ratchet hammer 5 16 hex key floor jack friend Mustang Fuel tank fuel tank straps Secondary B...

Страница 183: ...182 www factoryfive com 508 291 3443 Unpack the fuel strap fasteners Unpack the square plastic end caps from the secondary body fasteners...

Страница 184: ...Push the four plastic end caps into the tubes hanging down in front and behind the gas tank 87 93 Hang the fuel tank straps from the rear mount of the chassis using two of the strap fasteners The lon...

Страница 185: ...tank straps from the rear mount of the chassis using two of the strap fasteners The Strap with both flat ends goes on the passenger side shown Using a jack raise the tank up into place on the chassis...

Страница 186: ...85 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...

Страница 187: ...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...

Страница 188: ...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...

Страница 189: ...are protected by the chassis not close to any heat source or moving parts and provide enough slack in the rubber hoses for the engine to move Use the flexible line 5 16 flexible line and fuel injectio...

Страница 190: ...u are hooking up to your fuel rail carburetor or pressure regulator We usually run the fuel lines on the passenger side of the car and the brake lines on the driver side of the car Fasten the lines to...

Страница 191: ...measure razor knife round file or sand paper brake fluid 5 16 hex key 9 16 wrenches Pedal box hardware Insulated clip hardware Brake line components 3 16 brake lines Mustang master cylinder Mustang po...

Страница 192: ...the x 2 bolts provided to mount the master cylinder and spacers to the footbox front wall The number of spacers used dictates the height of the brake pedal Start with one spacer unless you are 6 or t...

Страница 193: ...bolts for the pedal box and master cylinder Install the push rod from the power booster into the master cylinder and insert the white plastic bushing in the ring end Hold the rod between the two ears...

Страница 194: ...4 Brake Hydro booster and Master Cylinder 5 16 hex key 9 16 socket ratchet ratchet Hydro boost nut tool Master cylinder Hydro booster OEM brake line fittings pedal box hardware Using the Hydro boost n...

Страница 195: ...194 www factoryfive com 508 291 3443 Put the clip through the hole in the pedal so that the push rod will not come off Front flexible brake lines Unpack the hardware from the brake line components...

Страница 196: ...close to the bottom of the car Which side you run down may depend on where you are hooking up to your fuel rail carburetor or pressure regulator We usually run the fuel lines on the passenger side of...

Страница 197: ...nd 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 t...

Страница 198: ...ger side brake hose mount The line 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 lo...

Страница 199: ...the middle of the axle then out to the calipers Newer axles and the FFR rear brakes run the flexible brake lines direct from the chassis to the caliper the IRS is done like this there is an extra len...

Страница 200: ...Using the FFR rear brakes we attached the flexible brake line mount to the driver side diagonal tube with the brake line clip Attach the T adapter to the flexible brake line and route the hard brake...

Страница 201: ...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...

Страница 202: ...rake caliper hose to caliper Banjo bolt 43Nm 32lbft When your system is finished being plumbed go back and check all the fittings for tightness Fill the system with fluid and bleed being very thorough...

Страница 203: ...that go together should be matching in color and shape or they will not connect Different color plugs means you may have a different year harness than the rest of the harness that you have and could c...

Страница 204: ...mponents to cover and protect the rear harness and the battery cable Replace the cable ties that were used earlier during the battery cable install with the large insulated line clips where possible R...

Страница 205: ...s side 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 not get in the way of the...

Страница 206: ...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 area 96 04 Starts at the...

Страница 207: ...d Hinge mount and the Power steering reservoir The Mustang is wider than the FFR Roadster in front and there is extra wiring between the headlights By removing the tape from the harness under the radi...

Страница 208: ...the inside The connections for the coil starter relay and the connectors for the rest of the harness easily fit through this hole and the big rubber grommet on the harness press fits into the laser c...

Страница 209: ...e are two different starters that were used and the wires are run differently for each On older large starters the cable runs from the starter to the empty post on the solenoid On the newer starters t...

Страница 210: ...209 www factoryfive com 508 291 3443 Old Starter New Starter...

Страница 211: ...e 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 screws Leave the hea...

Страница 212: ...the dash harness as described in the donor parts modification section at the beginning of the manual or cut a hole in the top outer footbox panel for the rectangular plug so the conical rubber bushin...

Страница 213: ...this hole and the big rubber grommet on the harness press fits into the laser cut hole Attach the rectangular plug to the other harness The remainder of the dash harness can be run on top of the 2 x 2...

Страница 214: ...pping screws The headlight switch can either be mounted in the dash to the left or right of the steering wheel next to the ignition or using the stock bracket mount it to the 87 93 headlight switch mo...

Страница 215: ...214 www factoryfive com 508 291 3443 Attach the PATS module pigtail to the dash harness and zip tie the ignition cylinder assembly to the dash harness 87 95 Engine Harness...

Страница 216: ...508 291 3443 Silicone and rivet the dash extension in position The engine harness begins in the passenger foot box The computer plug is pushed through the oval shaped hole on the Firewall extension f...

Страница 217: ...he short smaller 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 c...

Страница 218: ...he ground looks like a female stereo jack sort of The other half of the connector is on the battery negative cable so just cut the connector off and use the ring connector 96 04 Harness The harness sp...

Страница 219: ...otbox are not needed Using the fuel pump resistor as a template hold it against the firewall and mark the firewall where the mount hole and tab hole Drill 3 16 mounting holes for the resistor Use 3 16...

Страница 220: ...ll still need to be mounted behind the dash 96 04 If you are planning on flashing your computer to eliminate the PATS you will not need the gauge pod but you will need to have a 490 resistor in parall...

Страница 221: ...ainst the firewall when mounted Use an 11 64 drill bit and a steady hand to enlarge the holes in the gauge connectors on the back of the gauge pod This will help the male bullet connectors that come w...

Страница 222: ...l to make sure the harness plugs reach the connections on the pod You can trim the corner nearest the steering shaft pillow block so that the housing is sitting over the bearing bolt and closer to the...

Страница 223: ...t mounted in the dash Refer to the Mustang wiring diagrams to find the correct wires to attach to the key switch The turn signal stalk can be cut shorter so that when it s mounted it will not protrude...

Страница 224: ...oryfive com 508 291 3443 With the rear taillight harness tied up and secure silicone and install the lower trunk floor Re install the gas tank strap and tighten Silicone and install the trunk inner co...

Страница 225: ...ww factoryfive com 508 291 3443 Silicone and rivet the fuel tank strap patch panel from the packaged aluminum assembly Drill and silicone the upper trunk floor Bend it in the middle to get it into pos...

Страница 226: ...rivet it into place The rivets along the front 2 x 3 tube should be close to the back as possible for drill and rivet gun access Battery Mounting and Cable Drill 1 hole saw 3 16 5 16 drill bits rivet...

Страница 227: ...08 291 3443 Unpack the Battery mounting kit Position the battery with mounting bracket in the trunk for mounting It is centered side to side with just enough room for the mounting bracket between it a...

Страница 228: ...227 www factoryfive com 508 291 3443 Drop the J bolts in the mounting holes and mark where they hit the trunk floor Drill the mounting holes in the floor...

Страница 229: ...through the floor and bolt the battery down Hold the j bolts with a vice grip and be careful not to over tighten and crack or distort the battery Remove the powder coating from the small circle in th...

Страница 230: ...om 508 291 3443 Drill through the center of the circle and put a washer down in the cut out Bolt the Mustang ground cable to the chassis leave the battery terminal off for now while the rest of the sy...

Страница 231: ...230 www factoryfive com 508 291 3443 Drill out the hole you didn t use for the ground with a 1 hole saw Install one of the grommets in the hole...

Страница 232: ...508 291 3443 Route the small end of the batter cable from through the floor from the top and hook to the battery terminal Attach the battery positive terminal and leave enough slack to be able to rem...

Страница 233: ...th the car with the provided conduit to protect it from the elements Drivetrain Preparation Aftermarket TKO 500 and TKO 600 prep Hack saw or Reciprocating saw socket ratchet Transmission Polyurethane...

Страница 234: ...er FFR 13969 If using a 99 04 engine the Transmission mount adapter bracket provided in the kit must be used when using the stock transmission mount Drill the rivets out of the stock mount Locate the...

Страница 235: ...mission mount Adapter Bracket 87 93 Alternate Drive Pulley socket wrench Alternate drive pulley components FFR 11080 If you are using under drive pulleys or eliminating the smog pump do not drill the...

Страница 236: ...ll the bolt assembly on the A C bracket previously drilled in the disassembly section using the lock nut provided Pull the tension pulley back with a pry bar carefully and install the fan belt If the...

Страница 237: ...ey Oil filter relocating kit oil oil filter Place the O ring in the adapter groove If the O ring will not seat properly put it in the freezer for 15 minutes and use a small amount of chassis grease to...

Страница 238: ...237 www factoryfive com 508 291 3443 Use Teflon tape on the threaded barbs and thread them into the oil filter relocator Thread the short end of the threaded nipple into the relocator...

Страница 239: ...unt the relocate bracket on the X member Drill the mounting holes for the relocator Make sure to drill this before you install your engine Otherwise your drill won t fit in between the engine and the...

Страница 240: ...w factoryfive com 508 291 3443 Place the aluminum sleeve on the bolt with the flange towards the pulley wheel so that it slides inside the pulley Attach the pulley to the bracket to using the included...

Страница 241: ...ouble washers for the two front bolts that have the sleeves in the holes Pull the tension pulley back using a Ratchet in the square hole and install the serpentine belt using the picture for reference...

Страница 242: ...factoryfive com 508 291 3443 If not using power steering use the following picture for routing 96 98 DOHC Belt routing without power steering 99 03 DOHC Serpentine belt routed on engine using power s...

Страница 243: ...of the car See your gauge instructions for more information This oil pan holds approximately 8 quarts Use the stock oil dipstick for the oil level Use the heater bypass hose provided to loop between t...

Страница 244: ...w factoryfive com 508 291 3443 Install the new pick up provided Tighten the inlet tube bolts to 71 106 lb in 8 12Nm Tighten the inlet screen bolt to 15 22lb ft 20 30 Nm New oil pick up mounted to the...

Страница 245: ...rds tightening sequence and 15 ft lbs 20 Nm plus an additional 60 degrees Engine Transmission Installation Engine hoist chain 15 16 sockets ratchet extension Engine Polyurethane engine transmission mo...

Страница 246: ...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 very small The easiest method to install the drivetrain is...

Страница 247: ...hands you have to help the better Go very slowly and make sure the transmission tail shaft is above the rear cross member Install the engine mount to chassis nuts and tighten down all the engine moun...

Страница 248: ...unt If using a 99 04 T 45 or 3650 bolt the transmission mount to the underside of the frame mounts Do not use any spacers if using the stock mount and adapter If using the polyurethane mounts use the...

Страница 249: ...to the mount and tighten all the hardware on the mount and a frame Driveshaft 14mm wrench thread locker Mustang driveshaft and fasteners If not already done the driveshaft should be shortened to the l...

Страница 250: ...e rear of the transmission The most room to do this is usually to hold the shaft just above the center section and come in from the driver s side The mustang driveshaft bolts should have thread locker...

Страница 251: ...you tighten 87 95 Oil Filter Relocator Razor knife flathead screwdriver Oil filter relocating kit oil oil filter Hook the oil lines up to the Oil filter Relocator and the adapter on the engine Make su...

Страница 252: ...aders straight tubes Catalytic convertors and full length headers are available if required or preferred Mount the headers to the engine Thread locker is recommended particularly if you have aluminum...

Страница 253: ...Mount the straight pipes to the Mustang headers The shorter pipe will go on the passenger side Leave the bolts hand tight in order to locate the side pipes properly Aftermarket headers may require ova...

Страница 254: ...sh running your fuel system by hooking up either to your carburetor or fuel rail Here we mounted a pressure regulator on the firewall and ran a single line over to the rail 96 04 Connections socket ra...

Страница 255: ...et end onto the 5 16 hard line coming from the rear of the car 96 04 Hydro booster and Power Steering lines Tubing bender 5 16 hex key 9 16 wrench Mustang power steering and Hydro boost hoses Run the...

Страница 256: ...255 www factoryfive com 508 291 3443 Hydro boost lines shown in stock location Lines must be bent and re routed to fit behind aluminum Tubes bent around inside of Master cylinder...

Страница 257: ...256 www factoryfive com 508 291 3443 Lines in bent and routed in final locations Lines running from booster along steering shaft to steering rack...

Страница 258: ...257 www factoryfive com 508 291 3443 Hose routing for 96 2000 power steering cooler Power steering line for steering rack Note stock line bent...

Страница 259: ...on the front of the 4 main rails Use the original mount on the passenger side and the hole drilled in the preparation section earlier on the other side If using the tubular lower control arms drill tw...

Страница 260: ...diator so it is visible through the oil cooler opening or in the location above and in front of the radiator Both locations will require the fabrication of a mounting bracket for the passenger mount T...

Страница 261: ...com 508 291 3443 Drill and temporarily mount the driver side mount Measure the distance from the radiator and make a bracket to mount the passenger side mount such as the one shown Note the 90 degree...

Страница 262: ...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...

Страница 263: ...262 www factoryfive com 508 291 3443 Connect the clutch cable to the bellhousing and the clutch fork Speedometer Sending Unit 11mm deep socket ratchet Mustang speedometer sending unit...

Страница 264: ...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 sender Accelerator Cable 5 64 hex...

Страница 265: ...application Attach the engine end of the cable sheath to the cable mount on the intake using and 7 16 wrenches Put a dab of silicone on the rear edge of the rubber wipe then push the rubber wipe back...

Страница 266: ...4 valve intake Accelerator cable mounted on 96 2 valve intake 87 93 Push the ball stud retainer onto the ball on the bottom of the throttle body Push pull the cable into the retainer so that the cable...

Страница 267: ...he idle screw hits the throttle arm You will notice a fairly high idle later when the car starts if the throttle is held open Check the full range of the accelerator pedal travel to ensure that there...

Страница 268: ...ll the cable tight holding the cable against the ball stud retainer Align the ball stud retainer with the cable as if the cable was going into the retainer Mark on the cable where the retainer ends Me...

Страница 269: ...ten the set screw in the retainer using a 5 64 hex key Check the full range of the accelerator pedal travel to ensure that there are no interferences with the pedal or travel After driving the car for...

Страница 270: ...eters are used on 1989 and newer Mustangs 89 93 Mounting Flatten the outer edge of the mounting bracket using a hammer or vise Use the top OEM hole and mount to the front side of the vertical frame tu...

Страница 271: ...and the mass air meter Bend the Mass Air mount so that the hose will fit on the meter Rotate the two sections of the hose as needed Tighten the hose clamp connecting the hoses and the clamps at the e...

Страница 272: ...ryfive com 508 291 3443 87 95 Mounting Drill two 3 16 holes through the canister bracket OEM holes Mount with two 14 screws Attach the vent hose from the gas tank to the canister and the hose leading...

Страница 273: ...ystem 5 16 and sockets 9 64 3 16 drill bits drill Phillips head screwdriver rivet gun Hack Saw Tape Measure Marker Tin snips Fan mounting components Stainless Radiator Hose kit Mustang fan shroud with...

Страница 274: ...mbly in the mouth of the fan shroud so that the fan and shroud are flush if necessary bend the tabs on the mount strips outwards slightly to hold it in place Mark the position of the mounting strip ho...

Страница 275: ...fan housing is not pulled out of round when the fasteners are tightened Remount the radiator reservoir with a 5 16 socket and attach the overflow hose to the barb under the cap Mount the shroud and fa...

Страница 276: ...op flange to the two small mounting tubes on the chassis Mount the radiator top to the flange with the hardware provided The bottom stays zip tied for now 96 04 additional steps Hold the upper radiato...

Страница 277: ...and rivet the mount plate to the tube using rivets Mark the location of the radiator edge on the plate and mark rivet hole locations every 3 4 on the plate that will go through the top flange and moun...

Страница 278: ...ank so that it is centered across the front radiator mount plate DOHC overflow front overflow mounts positioned on the radiator mount Mount the rear of the overflow tank to the front side of the 2 x 2...

Страница 279: ...low tank to the radiator mount using 14x screws provided 96 04 If you prefer to use rubber radiator hoses use NAPA 7575 for the top hose Use the stock lower hose to the thermostat housing then use Gat...

Страница 280: ...279 www factoryfive com 508 291 3443...

Страница 281: ...280 www factoryfive com 508 291 3443 Stainless Radiator Hoses Unpack the stainless radiator hose kit and remove the hose connectors from the boxes...

Страница 282: ...281 www factoryfive com 508 291 3443 Use the smaller sections of tube inside the adapters to fit them to smaller fittings on the radiator and intake Then fit the larger adapters over them...

Страница 283: ...the radiator hose should be routed through the F panel to the radiator If the FFR radiator is being used the upper radiator hose should be routed above the X to the radiator If using an inline filler...

Страница 284: ...ube where it needs to be cut so that the tube will just touch the attaching location Remove the tube from the vehicle Cut the tube using a hack saw or if available a cut off wheel If necessary clean t...

Страница 285: ...the tube out so that no metal pieces are in the tube Remount the tube assembly and tighten the hose clamps on the mount locations After running the car for the first time once coolant is added and whi...

Страница 286: ...12V 85 Ground 86 12V 87 Fan Connect the other electric fan wire to the 87 tab on the fan relay Ground the 85 tab to one of the 2 position dash toggle switches The toggle will serve as your on off swi...

Страница 287: ...cylinder head to install the thermostat switch and thread it in Ground the black electric fan wire to the frame Connect the other electric fan wire to the 87 tab on the fan relay Attach the 85 ground...

Страница 288: ...8 drill bit Silicone Caulking gun Rivet gun Roadster Secondary Body Fasteners Components Packaged Aluminum mounted aluminum Silicone and install the transmission tunnel top Silicone and install the s...

Страница 289: ...er Footbox Side Aluminum drill bit drill rivet gun caulking gun silicone Mounted aluminum packaged aluminum secondary body fasteners Silicone and install the drivers side footbox outer wall The front...

Страница 290: ...brake Handle 3 16 hex key Mustang E brake handle brake line components The 99 04 Parking brake handle has different mounting locations and T cable length than the older 87 98 handles Push the U nuts...

Страница 291: ...acket and screw that prevents the ratcheting adjustment gear from turning Bolt the handle to the mount bracket using the kit fasteners The holes are slotted so the handle can get positioned properly t...

Страница 292: ...me car as your rear brakes 87 92 Mustang cables or the FFR cables mount to the bracket up near the 2 x 3 tube 93 04 Mustang cables mount to the bracket near the handle For 87 92 and FFR cables route t...

Страница 293: ...292 www factoryfive com 508 291 3443 For 87 92 and FFR cables route the inner cable down under the chassis and hook them to the T cable...

Страница 294: ...ning cable back to the calipers and attach Make sure your routing is out of the way of any moving parts and the cable has slack to move with the axle Pull up on the handle a few times to make sure the...

Страница 295: ...r section so that they curves to the rear of the lower control arm and attach the cable to the arm using zip ties from the kit Emergency brake cable in caliper bracket Pull up on the handle a few time...

Страница 296: ...caliper by pulling on the back of the caliper slightly and pushing the cable into the mount The cable will be very close to or touch the adapter bracket If necessary file a small angled recess in the...

Страница 297: ...section so that they curves to the rear of the lower control arm and attach the cable to the arm using zip ties from the kit Engine Ground Sand paper or grinder bit socket ratchet 3 16 hex key Mustang...

Страница 298: ...case we used an engine mount bolt Seats 5 16 drill bit drill 3 16 hex key deep socket marker Seat mount hardware seats Unpack the seats and set them in the cockpit Sit in the seats and locate them in...

Страница 299: ...98 www factoryfive com 508 291 3443 Lift up the bottom of the cushion to reveal the seat frame Using the rivet heads as a guide mark where the rails of the seat frame are above the seat mounting plate...

Страница 300: ...w factoryfive com 508 291 3443 Drill the first hole for the seat mounting and install the bolt Drill the remaining holes for mounting the seats and install the bolts Nameplate 1 8 drill bit rivet gun...

Страница 301: ...ips pliers spray glue brake cleaner razor knife drill 1 8 3 16 drill bit silicone caulking gun rivet gun wire crimper wire stripper Phillips screwdriver hack saw hammer marker ruler Mustang gauge conv...

Страница 302: ...301 www factoryfive com 508 291 3443 1987 1993 1994 1998...

Страница 303: ...er of the plastic on the back of the dash to see where any of the back side of the gauges overlap or interfere with any other components Trim off any of the pieces that interfere When cutting the top...

Страница 304: ...which gauges you are using you may need to open up the dash holes for the tachometer and speedometer If you need the larger holes the take a tin snip and cut through from the smaller hole to the traci...

Страница 305: ...f the 1 5 long Phillips head screws included 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 tub...

Страница 306: ...the different years so there will be some unused holes in the dash which will be covered by the padded dash 87 93 gauges installed note the screw holes used 94 98 Gauges installed note the screw holes...

Страница 307: ...holes for a good fit and so they lay flat against the dash If you would like to install the three lights that are included in the kit one possible layout is similar to the original Roadsters position...

Страница 308: ...light will light when the high beams are on 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 87 93...

Страница 309: ...ck With this set up the green light will flash when either the left or right turn signal is triggered Silicone over the dimpled area where the screws are so that the dash cover does not show any wrink...

Страница 310: ...ck the dash to the pad leaving about an inch border all around the top the bottom will be bigger for the flange Taping the ends of the pad helps to keep it flat After giving the front adhesive time to...

Страница 311: ...3 Cut the dash pad in angle shaped cuts every 2 even closer in the corners up to about from the dash Wrap the dash pad around to the back and glue it Use some heavy books to hold the pad in place unti...

Страница 312: ...ick on the bottom of the dash you can screw the corners down using some of the trim screws provided with the dash hardware Using a razor knife cut the gauge holes and switch holes out of the dash pad...

Страница 313: ...on only For 1987 1993 gauges pull out the trip counter button Install the switches in the dash One switch can be used to turn the fan on and off The other is up to your discretion The black push butto...

Страница 314: ...iring extension pins to connect the gauges to the white master panel the dash pod This was previously mounted on the firewall behind the dash Connect the electric fan wires to the fan switch if being...

Страница 315: ...wer as it goes to the middle Make sure the gauges do not hit the tubing Drill for the dash mounting screws 5 evenly spread through the dash and chassis with a 1 8 drill bit then drill back through the...

Страница 316: ...sh behind the top of the door hinge and screw through the hinge into the dash end Unpack the dash support headlight hazard brackets from the packaged aluminum Rivet the panels to the chassis and then...

Страница 317: ...com 508 291 3443 Install the Mustang headlight and hazard switches in the aluminum brackets Installation of the dash with Mustang gauge conversion set Steering Wheel Phillips head screw driver 10mm w...

Страница 318: ...317 www factoryfive com 508 291 3443 Steering wheel Hardware Unpack the steering wheel hardware...

Страница 319: ...five com 508 291 3443 Bolt the steering wheel to the boss The pattern is not symmetrical so it will only line up in one direction Bolt the steering wheel assembly to the steering shaft Use thread lock...

Страница 320: ...319 www factoryfive com 508 291 3443 Rollbar wrench 3 16 hex key 5 16 drill bit Drill Driver side Rollbar Assembly Unpack the rollbar and mounting hardware...

Страница 321: ...w factoryfive com 508 291 3443 Slide the rear leg of the bar down into the chassis mount Slide the main hoop into the chassis mounts and wiggle or tap with a soft mallet until it lines up with the rea...

Страница 322: ...all the way up flush Clamp the rear leg up with a pair of vise grips The front hoop will angle back about 6 or so Drill a hole all the way through each of the lower mounts and rollbar main hoop With t...

Страница 323: ...rilling each hole to ensure that the rollbar does not move Make sure the rear leg is tight up against the main hoop and drill the upper hole This bolt will be visible so keep this in mind when decidin...

Страница 324: ...lling Chassis Check Front Suspension Now is a good time to double check all your hardware make sure your wiring and hoses are away from extreme heat and moving parts make sure the steering turns freel...

Страница 325: ...324 www factoryfive com 508 291 3443 Fluid Levels and Grease Grease gun chassis grease ratchet rags Transmission fluid rear axle gear oil engine oil coolant water...

Страница 326: ...08 291 3443 IRS Fill the rear differential with gear oil Any 8 8 in ford has a fill plug that is removed and filled until the oil just reaches that level The IRS has it in the rear cover and the solid...

Страница 327: ...326 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...

Страница 328: ...291 3443 Engine Fill the engine with Oil and coolant Both these fluids should be rechecked after you have started the engine for the first time Make sure there is some coolant in the overflow to start...

Страница 329: ...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 lowers on a slid axle and tie r...

Страница 330: ...akes Torque the rear axle nuts to 175 ft lbs Wheels Install and torque your wheels Make sure they rotate freely and do not interfere with the brake calipers lines or any suspension components Power St...

Страница 331: ...to temperature and check for leaks and make sure the fan is working After running the car for the first time once coolant is added and while the system is still warm retighten the hose clamps used on...

Страница 332: ...ght for you While you still have easy access to the footboxes is the best time to do this Set the brake pedal height by screwing the pushrods in or out of the master cylinders because of the pedal piv...

Страница 333: ...08 291 3443 Racing seats with less padding give more room the more upright the angle of the seat the more room to straighten out your legs Driver Footbox aluminum Rivet the remaining inner cockpit wal...

Страница 334: ...91 3443 Silicone and install the footbox inside top panel Leave the top flange un riveted for now use some clamps or tape to hold it in place Silicone and install the outer footbox top section Your ro...

Страница 335: ...334 www factoryfive com 508 291 3443 Body Section Chapter 4...

Страница 336: ...hod for getting the best fit is to sand or trim the panel edges just enough so they will sit down in the openings then fully mount them with hinges and latches Once the surfaces are all matched betwee...

Страница 337: ...336 www factoryfive com 508 291 3443 The rectangular adhesive backed weatherstrip runs along the top of the chassis tubes on either side of the hood opening and the top of the curved trunk hoop...

Страница 338: ...points for the body are the rear quick jack mounts these will set the body in the correct position front to back as well as locating the rear half up and down and side to side When bolting the body d...

Страница 339: ...338 www factoryfive com 508 291 3443 The long sleeves go between the body and chassis with washers on both ends of all sleeves...

Страница 340: ...t and bolt use a wrench and socket to attach the rear quick jack bolts to the frame and body Even with the quick jacks removed it is still a good idea to wrap the bolts with some rags and duct tape to...

Страница 341: ...et ratchet Quick jack bumper components The front quick jacks mount the same as the rears except for the angled spacers and rubber backed washers that line up with the nose You can also mount the body...

Страница 342: ...rsized to allow the panel gaps to be sanded down to fit Set the hood in place and make sure it will fit the opening in the body if needed sand or file the edges to allow the panel to just fit with a v...

Страница 343: ...ttach the bumpers through the body and into the frame Once you are happy with the alignment you can set the panel gap and radius the edges An easy way to set the gap is by using a marker With the pane...

Страница 344: ...mount the panel and the resulting gap should be the same around the whole panel about 3 16 Repeat this gap procedure later after mounting the doors and the trunk Hood Pins Drill 3 16 3 32 7 16 drill b...

Страница 345: ...the hood pin mount plates to the chassis using the carriage bolts The bolts push in from the outside Position the Hood pin plates on the frame Attach the hood pin vertical posts hand tight to the mou...

Страница 346: ...the opening and press down This should leave a couple of small silicone marks on the underside of the hood Drill two 7 16 holes through the hood where the marks are located Place the circular chrome p...

Страница 347: ...346 www factoryfive com 508 291 3443...

Страница 348: ...e hood liner but you may need to clean them out with a 3 16 drill bit This is the initial install so you only need a few rivets if you are going to remove the hinge brackets prior to body painting rec...

Страница 349: ...com 508 291 3443 Drivers side long arm with bushings pressed in Passenger side long arm with bushings pressed in Press the bronze bushings into the holes in the hinge arms as shown The short hinge arm...

Страница 350: ...g the shoulder bolts spacers nylon lock nuts and washers The spacer fits over the bronze bushing after it is pressed into the arm holes The flange of the bronze bushings should contact the arm plate T...

Страница 351: ...com 508 291 3443 Attach the hinges to the chassis using the carriage bolts these push in from the outside for easier adjustment Leave the bolts loose enough so that the hinge assembly can be positione...

Страница 352: ...e and attach the two arms to the brackets from the underside of the body Install the threaded ball studs in the hole on the long hinge arms with the ball pointed toward the outside of the car using a...

Страница 353: ...five com 508 291 3443 Attach the piston body end to the ball on the hood Hood Handles 7 64 3 16 drill bits drill measuring tape Phillips head screwdriver pliers marker 2 5mm hex key file Three lock se...

Страница 354: ...508 291 3443 Measure the center of the hood liner rib along the trailing edge of the hood and mark it Measure out from the hood center 12 on each side and mark the middle of the hood liner rib for th...

Страница 355: ...e liner starting with smaller bits working up to a hole The larger bits sometimes work better by running the drill in reverse so they do not tear the fiberglass Remove the hood handles from the three...

Страница 356: ...3443 Set the handles in the holes drilled in the hood so that they are lined up squarely with the edge and mark the screw holes on the hood Drill the holes with a 7 64 bit then screw the handles down...

Страница 357: ...the hood and mark the body where the hood handles line up Open the hood and drill two 3 16 holes in the hood opening recess on either side of the centerline and back from the edge of the opening These...

Страница 358: ...he handle assembly center them on the line with the corner edge up against the inner radius of the hood opening and mark the two holes Drill the two holes just marked with a 7 64 bit and file the edge...

Страница 359: ...rews are used to hold these brackets in place They can either be countersunk into the body or used to hold down the hood bumpers to hide them completely Attach the cam wedge to the underside of the ho...

Страница 360: ...een box The strips along the sides of the windshield that the screws go into are brass The brass threads strip easily so take your time and make sure that they thread correctly Windshield cut outs may...

Страница 361: ...e arms If the arms are too long and prevent the windshield from sitting down then pull them back out and trim off the excess Remove the windshield from the car and then remove the sidebars from the wi...

Страница 362: ...ition and bolt in place using the windshield mounting hardware The windshield should remain bolted down while you fit the doors Doors 3 16 hex key marker socket ratchet air saw orbital sander 3 16 dri...

Страница 363: ...362 www factoryfive com 508 291 3443 If you have removed them remount the door hinges on the chassis The square nuts sit along side the tube so only one hex wrench is needed for adjustment...

Страница 364: ...291 3443 Position the door in the body to see where it may need to be trimmed to fit the opening Mark the door and only remove enough material to get it to fit Hold or tape the door in position and at...

Страница 365: ...door and match the curved surfaces Once the top of the door is good you can adjust the bottom of the body in and out to help fit the bottom edge of the door When you are happy with the fit of the doo...

Страница 366: ...wrench 1 8 drill bit drill Philips head screwdriver marker Lithium or silicone grease Door components Remove the door latch striker from the original mounting bracket and keep only the striker and th...

Страница 367: ...the striker to bring the base of the striker head flush with the door latch pad when the door is closed Latch the door latch onto the striker and close the door Adjust the striker if needed to fit the...

Страница 368: ...the 1 8 holes for the door latch Lubricate the moving parts of the latch using Lithium or silicone grease This will make the latches easier to use and prevent any binding Bolt everything together to d...

Страница 369: ...1 3443 Trunk air saw orbital sander marker trunk Trim the trunk lid edges enough so that it just fits into the opening Trunk Hinge wrench 3 16 hex key Trunk hinge components Press the bushings into th...

Страница 370: ...riage bolts and 5 16 locknuts to bolt the mounting pads to the arms leaving them just snug so they can be moved without loosening the bolts Hang the hinge arms on the chassis using the shoulder bolts...

Страница 371: ...e enough that they will just move Close the trunk and wiggle it into position then open and tighten the bolts This may take a little adjustment to get the trunk to sit down right You can also use some...

Страница 372: ...371 www factoryfive com 508 291 3443 Trunk Latch socket ratchet flat head screwdriver Philips head screwdriver 3 lock set and fasteners Find the trunk latch and components in the 3 lock set...

Страница 373: ...com 508 291 3443 Screw the trunk latch to the holder with the short 14 screws lining the small square hole with the hole for the handle Bolt the handle to the trunk running the bolts through the trunk...

Страница 374: ...olt that holds the latch pin in place goes through the plastic cap then the body then the sleeve and into the chassis plate Test fit to make sure the trunk is held snug If it is loose you can bend the...

Страница 375: ...sking tape scissors Fuel filler template Aston Lemans Cap components Locate the template in the appendix and only cut out around the outside diameter of the circle Tape the circle in the gas cap reces...

Страница 376: ...drill out the holes for the filler If you do not have a hole saw this size you can cut the center circle out of the template and use the remaining template to mark for a jig saw instead Tail light Dri...

Страница 377: ...wo outer holes for the taillight studs then cut out the center using a 1 hole saw There are marks on the body that locate these holes If the marks do not show there is also a template in the back of t...

Страница 378: ...Turn Signal Drill 7 32 drill bit 1 hole saw marker Turn signal template Amber front turn signal lights Remove the gasket from the turn signal box and use it to center and trace the mounting holes and...

Страница 379: ...factoryfive com 508 291 3443 Drill the outer holes with a 7 32 drill bit and the inner with a 1 hole saw Test fit a light and adjust if needed License plate light Drill drill bits scissors masking tap...

Страница 380: ...e responsible for ensuring that the vehicle you build complies with all Federal Sate and local laws regarding its use The inclusion of the license plate bracket does not indicate that this kit complie...

Страница 381: ...380 www factoryfive com 508 291 3443 Test fit the light with a license plate and adjust the holes with the drill bit if needed Side exhaust Drill 2 hole saw air saw or jig saw Side exhaust template...

Страница 382: ...1 3443 The pattern for the standard exhaust cut out is pre traced on the body Using a 2 hole saw cut the upper two corners of the pattern out Using a jig saw cut the remaining straight sections and ra...

Страница 383: ...drill bit razor knife masking tape air saw or jig saw level Headlight template headlight components Cut out the headlight templates from the back of the manual on the outermost diameter and tape them...

Страница 384: ...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...

Страница 385: ...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...

Страница 386: ...Drill 1 hole saw jig saw or air saw measuring tape marker Side louver template Use the template and measurements in the picture below to locate the template on the body Use a 1 hole saw to cut the co...

Страница 387: ...he holes with a jig saw Hood and Scoop Drill 3 16 drill bits marker ruler tape measure jig saw or air saw rivet gun Hood scoop hood secondary body fasteners Mark and drill around the edge of the scoop...

Страница 388: ...the hood on the liner trace the opening for the cut out in the hood 1 in from the side and rear edges and 4 back from the front edge of the scoop recess Use a larger drill bit to start the blade for...

Страница 389: ...the scoop measure from the leading edged of the hood back 19 on either side of the opening and draw a straight line across the width of the hood On the line just marked measure in 8 from each of the...

Страница 390: ...op using the straight edge and two marks Double check by measuring in from the rear edges of the hood to make sure that it is centered Drill two of the rivet holes on opposite sides for the scoop and...

Страница 391: ...390 www factoryfive com 508 291 3443 Drill out the remaining rivet holes and then separate the two pieces for painting Roll bar Drill 1 hole saw air saw or jig saw file 1 50 driver side Rollbar...

Страница 392: ...he marked circle and drilling vertically to match the angle the bar comes through the body To cut the rear roll bar leg make 2 holes overlapping so that they form the right length Use the same 1 hole...

Страница 393: ...w factoryfive com 508 291 3443 The rear of the hole is then finished using the whole saw vertically Trim the remaining flash on the opening with a file or jig saw and test fit the bar Final Prep Sand...

Страница 394: ...d need to be evened out and have a small radius sanded in for a good looking finish Doors Hood Trunk Hood Scoop Wheels Wells Side Vents Exhaust Brake Duct openings Main radiator opening Oil cooler ope...

Страница 395: ...und and a thorough cleaning with a wax remover is the best way to begin this job A lot of time and energy was spent on the mold so that the body work can be kept to a minimum Our body shop has stated...

Страница 396: ...395 www factoryfive com 508 291 3443 Final Assembly Chapter 5...

Страница 397: ...aluminum the edges are sharp and can cut you The radiator and its plumbing were installed before the body was mounted The radiator is being held up at the bottom by a couple of zip ties through a quic...

Страница 398: ...e com 508 291 3443 Pass the radiator floor piece through the nose Position the radiator floor aluminum so that it goes under the body lip and goes across to the bottom of the radiator Clamp the floor...

Страница 399: ...398 www factoryfive com 508 291 3443 Attach the radiator floor piece to the bottom of the radiator with a couple of self tapping screws on the marks or use a couple of clamps...

Страница 400: ...399 www factoryfive com 508 291 3443 Drill silicone and rivet the radiator floor aluminum to the bottom radiator lip Silicone and rivet the aluminum to the nose lip using three 3 16 rivets...

Страница 401: ...factoryfive com 508 291 3443 Pass the radiator sidepieces through the nose and put them on their respective sides Trimming aluminum may be necessary if you use the press on rubber bulb seal weather st...

Страница 402: ...five com 508 291 3443 Line up the edge of the radiator fins with the edge of the side aluminum and attach the piece to the tube using a self tapping screw From the backside of the panel mark the locat...

Страница 403: ...43 If using the press on bulb weatherstrip make sure there is of gap between the edge of the panel and the body Remove the side panel then measure mark drill rivet locations where the tube is located...

Страница 404: ...403 www factoryfive com 508 291 3443 Reinsert the side panel then silicone and rivet the panel to the tube and the radiator floor aluminum...

Страница 405: ...arpet Razor knife silicone caulking gun spray glue brake cleaner or acetone Interior trim carpet The adhesive used to hold the carpet down is the same as we used on the dash pad 3M Super77 or Super90...

Страница 406: ...508 291 3443 Double check the aluminum edges and corners for any areas that look like they are not sealed Run a small bead of silicone in these corners seams and around the slots where the seat harne...

Страница 407: ...ll of carpet Position it before gluing so you understand where it will go then apply the adhesive and glue it into position The cockpit rear corners go on next Be very careful spraying the adhesive on...

Страница 408: ...407 www factoryfive com 508 291 3443 Test fit the rear and main tunnel covers While you are fitting cut the handle opening for the e brake and shifter...

Страница 409: ...e com 508 291 3443 Glues down the tunnel top The tunnel rear section is slightly oversized to make sure it can cover small variances in the way the other pieces lay down Trim it for a perfect fit then...

Страница 410: ...r outside footbox wall carpet section The carpet tucks in behind the footbox protection tube Taping off the tube helps prevent getting the adhesive on it Fit and glue the driver s side footbox outer c...

Страница 411: ...410 www factoryfive com 508 291 3443 Fit and glue the tunnel firewall section of carpet Fit and glue the lower floor sections...

Страница 412: ...der door sections The floors are the last pieces to go in They may also need a slight trim for the best fit Glue them down and vacuum the carpet prior to the seats going in Seats Harness lap belt wren...

Страница 413: ...412 www factoryfive com 508 291 3443 Unpack the seat harnesses and hardware Drill through the inner lap belt mount into the tunnel with a in bit...

Страница 414: ...w factoryfive com 508 291 3443 Bolt the lap harness in position with the inner most nut inside the transmission tunnel Emergency Brake Boot 1 8 drill bit drill Phillips head screwdriver Interior Trim...

Страница 415: ...ck the e brake boot and a few of trim screws Fit the boot over the handle and check the handle actuation When you are in a position where the boot clears the handle movement drill through the material...

Страница 416: ...inal Install Drill back up through your seat mounting holes to put holes through the carpet and re mount the seats Seat Harness Shoulder Belts Razor knife wrench socket drill bit drill ratchet Seat Ha...

Страница 417: ...oryfive com 508 291 3443 Use some of the serrated grommeting from the electrical assembly to cover the edge where the harness passes through Cut the carpet with a single slit to allow the harness to p...

Страница 418: ...oryfive com 508 291 3443 Remove the mounting tab and slider from the harness Slide the harness through the rear wall from the front The shoulder harnesses are side specific so make sure you have the s...

Страница 419: ...291 3443 Replace the slider and mounting tab and bolt the tab to the chassis Adjust the harnesses to where they fit you comfortably Shifter Handle and Boot wrench 1 8 drill bit drill Philips head scr...

Страница 420: ...Shifter handle components Unpack the shift handle and bolt it to the transmission These bolts have a tendency to rattle loose so use a little thread locker Push the boot and trim rind down over the h...

Страница 421: ...420 www factoryfive com 508 291 3443 Using a silver marker or white paint marker mark your screw holes on the tunnel Remove the boot and drill 1 8 holes in the spots you marked...

Страница 422: ...Re install the boot and screw down to the tunnel with the countersunk screws A small screwdriver can help to locate the holes Screw the two piece knob onto the shift handle and tighten so the shift p...

Страница 423: ...422 www factoryfive com 508 291 3443 Headlights Philips head screwdriver Headlight components Unpack the headlight mounting assembly Headlight fasteners 13419 13415 13418 13420 13416...

Страница 424: ...423 www factoryfive com 508 291 3443 Screw the adjuster screws about halfway into the buckets Push the grommet into the side of the bucket...

Страница 425: ...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...

Страница 426: ...e 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 poking through the 2 larger holes Screw the...

Страница 427: ...www factoryfive com 508 291 3443 Plug the light into the connector and mount the bulb to the bucket The slotted parts of the mounting flange go onto the adjusting screws between the screw head and fla...

Страница 428: ...e spring clip onto the boss near the bottom of the bucket Mount the trim ring hooking it over the bucket on the top and screwing it into the bottom using the countersunk screw Turn Signals 5 16 deep s...

Страница 429: ...428 www factoryfive com 508 291 3443 Mount the turn signals to the body being careful not to over tighten the locknuts Tail lights 5 16 deep socket ratchet Red rear lights...

Страница 430: ...429 www factoryfive com 508 291 3443 Mount the taillights also being careful with the mounting hardware Gas Cap Phillips head screwdriver Aston Lemans Cap...

Страница 431: ...430 www factoryfive com 508 291 3443 Unpack the fuel cap and mounting hardware Put the gasket on the bottom surface of the cap...

Страница 432: ...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...

Страница 433: ...2 www factoryfive com 508 291 3443 Side Louvers Silicone caulking gun duct tape Side Louvers Unpack the side louvers Holding the top and bottom flanges bend the fins in so they are roughly at a 45 ang...

Страница 434: ...8 291 3443 Hold them up to the body to see how they fit They are designed to allow air to exit the engine bay so the flanges point from the rear edge in Apply silicone down the top and bottom flange o...

Страница 435: ...434 www factoryfive com 508 291 3443 Line up the louvers and tape them in place to hold them until the silicone dries Weatherstripping Razor knife tin snips Secondary body fasteners...

Страница 436: ...43 If you haven t already run the bulb seal up the sides and rear of the trunk and bolt the trunk hinges back in place and tighten Cut out a section of the C channel where the hoop comes across to all...

Страница 437: ...u removed any of the other weatherstrip on the firewall or hood support tubes replace it now When you are ready to mount the body unpack the expanding foam and run a small section up the outside of ea...

Страница 438: ...Be very careful with the sides and slowly work it down into position Pull the sides out around the chassis and make sure the body covers the rear cockpit wall and top of he dash without pulling the m...

Страница 439: ...438 www factoryfive com 508 291 3443 Re mount the nose with the front quick jacks Hood mounting Rivet the scoop back in position on the hood...

Страница 440: ...3443 Re install the hood latch plates and replace the bumpers you used before on the body to line up the hood Re Install the hood and latches Rollbar mounting A popular option are the Roll bar gromme...

Страница 441: ...actoryfive com 508 291 3443 Re mount the roll bar through the body Make sure that the rear leg is in the correct orientation so that your holes will line up Door and Latch mount Reattach the doors and...

Страница 442: ...om 508 291 3443 Once you are happy with the door fit install the covers on the door latches Windshield Mounting Position the windshield trim plates with gaskets on the body so that the notch faces the...

Страница 443: ...442 www factoryfive com 508 291 3443 Re mount the windshield Fuel Filler Neck Razor knife socket ratchet 3 16 drill bit drill Aston Lemans Cap components...

Страница 444: ...o the chassis using the screw that came in the cap hardware This wire prevents any static charge build up and must be used 87 98 Fuel Filler Neck Attach the 2 fuel filler hose to the bottom section of...

Страница 445: ...444 www factoryfive com 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...

Страница 446: ...04 fuel filler tube assembly Push on and attach the 1 fuel filler hose to the lower part of the filler neck using the included hose clamps Insert the upper part of the fuel filler neck into the other...

Страница 447: ...ww factoryfive com 508 291 3443 Unpack the 2 fuel filler hose and cut a 5 long section out of one end Use the short section of hose to connect the upper part of the stock filler neck to the Aston fuel...

Страница 448: ...ww factoryfive com 508 291 3443 Screw the plastic gas cap into the Aston Lemans style cap Fuel tank access covers drill bit drill rivet gun silicone caulking gun Secondary body fasteners packaged alum...

Страница 449: ...e fuel sender and pickup access holes Final Trunk Mounting Tin snips 3 16 hex key Secondary body fasteners Push the side mount weatherstrip on the trunk opening starting at the bottom next to the latc...

Страница 450: ...le Re mount the trunk to the hinges and re install the latch pin Interior Rearview Mirror Phillips head screwdriver drill 3 32 3 16 drill bits marker measuring tape Rearview mirrors fasteners Use a ta...

Страница 451: ...508 291 3443 Line up the rearview mirror with the center mark and mark the holes in the body Sit in the seat and make sure you are comfortable with the position Drill the body with a 3 32 bit and scre...

Страница 452: ...3 Side Mirror Philips head screwdriver drill 3 32 3 16 drill bits marker wrench Rearview mirrors fasteners Only a driver side mirror is included with the kit A passenger side one is available if desir...

Страница 453: ...452 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...

Страница 454: ...453 www factoryfive com 508 291 3443 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...

Страница 455: ...ww factoryfive com 508 291 3443 Mark the location and use the gasket to locate and drill the mounting holes Disassemble the mirror and bolt the mounting insert with mounting bolt and the gasket to the...

Страница 456: ...455 www factoryfive com 508 291 3443 Slide the stand off and upper gasket down the bolt and onto the mounting bracket Bolt the main body of the mirror to the mounting stand off...

Страница 457: ...mirror into the body and adjust it before tightening Light wiring Wire strippers wire crimpers chassis harness instructions Headlight components amber front turn signal lights rear lights license plat...

Страница 458: ...the chassis harness 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 Wire the taillights according to the wiring harness instructions...

Страница 459: ...check straps Rivet the check strap to the door hinge using a 3 16 rivet Open a door wide but not enough so that the door hits the body The straps will stretch slightly over time so allow enough room f...

Страница 460: ...508 291 3443 While holding the door open pull the check strap tight and mark the location of the mount holes on the inside face of the 2 x 2 tube Drill 3 16 holes at the marked locations and rivet th...

Страница 461: ...r trim carpet secondary body fasteners Unpack the under door aluminum panels They are shaped to fit around the bottom of the door with flanges to mount to the chassis Silicone and rivet the panels in...

Страница 462: ...r the doors Cut a section of the large C channel weatherstrip to fit from the bottom of the door hinge to the door latch and push it in place over the body aluminum and carpet to finish the edges off...

Страница 463: ...ection and push it into the steering wheel and boss a little WD40 on the o ring helps if it is tight Peel the backing off the badge and stick it in the center section making sure you are aligned with...

Страница 464: ...e steering wheel in the position that is most comfortable for you tighten the set screws on the collar of the upper steering bearing Side Exhaust 3 16 5 16 Hex key 9 16 socket ratchet 9 16 wrench dril...

Страница 465: ...464 www factoryfive com 508 291 3443 Unpack the hardware for mounting the side exhaust Bolt the mounting bracket to the pipe on the forward side of the bracket...

Страница 466: ...with using the shorter bolts and mechanical locknuts Drill a 3 16 hole in the 2 x 2 outrigger tube directly above the middle hole in the mounting bracket You want this hole as high as you can get it...

Страница 467: ...ssis with the sheet metal mounting screw using one of the washers between the rubber and the head of the screw Bolt the bottom section of the hanger to the side exhaust mounting bracket using the midd...

Страница 468: ...the 2 x 2 outrigger all the way through both of the tube walls and into the footbox area with a 5 16 bit Insert the rubber standoff between the bracket and outrigger and put the nut on finger tight th...

Страница 469: ...m 508 291 3443 Tighten the whole assembly together Aluminum Splash guards 3 16 drill bit drill rivet gun silicone caulking gun socket ratchet extension marker Secondary body fasteners packaged aluminu...

Страница 470: ...e of the press on bulb seal around the outside edge of the aluminum front splash guards they look like large elephant ears where they will contact the body Hold the splashguards up against the rear be...

Страница 471: ...needed trim them to fit around the outside edge the weatherstrip will cover the trimming Put a wheel and tire on the car and check for aluminum clearance If necessary push the aluminum in and mark the...

Страница 472: ...www factoryfive com 508 291 3443 Silicone and rivet the panels in place down the length of the flange Use one of the 3 16 rivets to attach to the bottom of the fender just forward of the exhaust cut...

Страница 473: ...outside perimeter if needed The small tab on the bottom faces towards the rear of the car and is on the bottom The bent edge should be vertical and aligned with the trunk side pieces where they drop d...

Страница 474: ...473 www factoryfive com 508 291 3443 Silicone and rivet the panels in place Bend the lower tab by hand to fit up flush with the body...

Страница 475: ...474 www factoryfive com 508 291 3443 Use a long 1 8 rivet as low as possible to attach the tab to the lower fender Finishing Touches Review the Race car checklist in the appendix...

Страница 476: ...y also offend oncoming traffic When replacing bulbs it is a good idea to verify that your lights are properly aimed Slight variances in filament position can translate to large variances in beam patte...

Страница 477: ...vehicle centerline mark at the distance of Measurement B from the vehicle centerline vertical line Turn the headlights on and adjust the vertical aim of the headlights so that the top horizontal cutof...

Страница 478: ...g the upper control Arm Use the diagram below for reference Slightly loosen the three pivot bolts using a wrench and socket Loosen the jam nuts on both ends of each adjusting tubes using a 1 wrench Tu...

Страница 479: ...ghtened down jam nuts on either end of both adjusting tubes The Pivot Bolts must be loosened while the car is being aligned and retightened afterwards Optional Parts Check out factoryfive com for the...

Страница 480: ...479 www factoryfive com 508 291 3443 Performance Reference Material and Technical Support Chapter 6...

Страница 481: ...mm Width 2 1 Width 2 2 Width 2 2 75 315mm Width 2 1 625 Width 2 2 5625 Width 2 3 25 Can be used up to 10 50 wide wheel 99 04 94 98 87 93 OEM 17 x 8 FRONT REAR 5 72 5 72 5 72 MAX TIRE WIDTH 245 45 R17...

Страница 482: ...del 17 Cobra R rims Right Ford Racing Cobra R 17 wheels and 12 Cobra Brakes 17 x 9 and 17 x 10 5 FR style wheels For a more vintage look take a look at our Halibrand style wheels Our online parts cata...

Страница 483: ...are wanted Use two 2 9 wide 5 95 backspace wheels in the front See the table above for different width wheel backspacing Performance Modifications The following modifications and set ups fall under th...

Страница 484: ...ge 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 performance and it is easiest to do before assembly since the rear...

Страница 485: ...f aluminum and cast iron heads for the small block Ford Our favorites are the Edelbrock Victor Jr and the Trick Flow aluminum heads These both flow very well have stock exhaust port heights which allo...

Страница 486: ...ffers an oil cooler with 10 Stainless Steel braided lines and mounting bracket Bellhousing If you are changing your transmission or want some safety piece of mind using a SFI approved safety bellhousi...

Страница 487: ...situations We have found that many of the Challenge Car racers prefer to use power steering This can be done by using the stock 1987 1993 15 1 Mustang power rack and power steering pump If changing t...

Страница 488: ...04 spindles Rear Suspension The standard solid axle 4 link rear suspension works well is low maintenance and is reliable Which rear suspension you choose depends on the type of driving you do a major...

Страница 489: ...driver that goes to more road course track events and wants to start exploring the limit without giving up the off the line bite of a solid axle IRS suspension Good everyday driving suspension The IR...

Страница 490: ...nd The Factory Five tubular lower control arms with polyurethane bushings are lighter eliminate the rubber and look better than the stock Mustang arms Rear Using tubular control arms with polyurethane...

Страница 491: ...s recommended below are designed for those searching for higher performance braking capabilities These are systems that have been used successfully by our customers and us Each component below has bee...

Страница 492: ...num 1 5625 PBR calipers OR Spindle OEM 94 newer Mustang front spindle Rotor OEM 99 01 Mustang GT 11 rotor CaliperOEM 99 01 Mustang GT 2 piston 1 5625 PBR caliper 13 Front Spindle FFR Roadster two piec...

Страница 493: ...Brake Information The caliper 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 rec...

Страница 494: ...ch piston and then add the areas together If the caliper has pistons on both sides of the rotor disregard one side Superchargers Factory Five Racing customers have successfully installed Kenne Bell Vo...

Страница 495: ...gparts com Tire Rack Tire and wheel source 888 541 1777 www tirerack com Repair Manuals Repair manual specialists 800 426 4214 www repairmanual com Jeg s Performance High performance products 800 345...

Страница 496: ...ld or sell completed or partially completed vehicles We are aware of a number of performance and hot rod shops that claim to specialize in building race cars and kit cars We have over the years compil...

Страница 497: ...496 www factoryfive com 508 291 3443 Appendix A Templates...

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Страница 510: ...509 www factoryfive com 508 291 3443 Appendix B Donor Parts List...

Страница 511: ...gine fuel rails Fuel evaporative canister solenoid and tubing Brakes Wheels Front and rear brake rotor drum calipers pads flexible lines etc Mount front and rear brake line riveted to donor Master cyl...

Страница 512: ...511 www factoryfive com 508 291 3443 Appendix C Big Block Installation 427 Shown here with fuel injection...

Страница 513: ...e sides The pickup can then be lifted out paying close attention to the alignment of the tubes so the new one can be mounted in the same location Larger fuel line is usually necessary for all carburet...

Страница 514: ...ate motor along with most stock oil pans is very deep and hangs downs below the frame we suggest the canton flat bottom pan which gives sufficient ground clearance and also provides extra baffling and...

Страница 515: ...ion we recommend is a Tremec TKO 500 or 600 heavy duty 5 speed that will fit the big block engines with a Lakewood or McLeod bellhousing and the spacer mentioned in the suggested parts list In order t...

Страница 516: ...are not using the spacer but still need a ball pivot an adjustable one is available also from Mcleod The Driveshaft will also vary in length depending on the transmission you select Before you have y...

Страница 517: ...lace Wait to mount the side pipes until after the body has been fitted The exhaust gaskets for the side pipes will need to be cut from the material provided it is all right to have excess material on...

Страница 518: ...se parts are not specifically required and some may be unnecessary depending on your combination Engine Ford Motorsports 460 M 6007 C460 SVO Intake Manifold 5066 Torker II Edelbrock Flat Bottom 9 Quar...

Страница 519: ...518 www factoryfive com 508 291 3443 Mustang Unlimited 800 243 7278 Holcomb Motorsports 800 475 7223...

Страница 520: ...519 www factoryfive com 508 291 3443 Appendix D Optional Rear Disc Brakes...

Страница 521: ...14903 The installation of this kit can be performed 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...

Страница 522: ...gear oil with GL 5 or GL 6 rating 4oz of Friction modifier Ford CM 19546 A1 Brake Fluid Remove the ten bolts that hold on the differential cover using a socket wrench Note If you are installing disc...

Страница 523: ...the differential until you see the small bolt Differential pinion shaft locking bolt that holds in the large center pin Remove the bolt using an 8mm socket and ratchet Reach behind the differential an...

Страница 524: ...he axles in toward the differential When you do this the C clips that hold the axles in will be visible and they may even fall out If the C clips do not fall out push them off with a small screw drive...

Страница 525: ...n not to damage inner wheel bearing oil seals when removing axle shafts from rear axle housing Install the brake caliper brackets so that the caliper will mount on the front side of the axle Use the f...

Страница 526: ...install the C clips When re installing the C clips it helps to use a small magnet to hold onto them as it is difficult to reach the axle and hold onto the clip Caution Care must be taken not to let a...

Страница 527: ...ld in place Install the center pin and the bolt that holds it It s a good idea to put Locktite on the bolt before installing it then torque it to 25 ft lbs Install the rear cover We recommend using a...

Страница 528: ...lace Make sure to clean the surface of the rotor with brake parts cleaner before installing the caliper Once the rotor is on put the brake pads in the caliper by pushing down on the pad to compress th...

Страница 529: ...3443 When installing the caliper make sure that the brake fluid bleed screw is on the top side of the caliper Do not worry about the LH RH markings on the calipers Torque the two 12mm mounting bolts...

Страница 530: ...of 75W 90 gear oil or until oil reaches the fill plug Replace the fill plug and tighten to 15 30 ft lbs Torque Specifications FASTENER TORQUE FT LBS DIFFERENTIAL PINION SHAFT LOCKING BOLT 15 30 BANJO...

Страница 531: ...530 www factoryfive com 508 291 3443 Appendix E Race car check sheet...

Страница 532: ...ht ___ Spring collars taped tight ___ Tire pressure set recommend 22 25 psi ___ Lug nuts tight 90 lb ft ___ Brakes Front Caliper bolts tight ___ Rear caliper bolts tight ___ Rotors clean no cracks or...

Страница 533: ...Driveshaft universal joints no bind or wear ___ Output shaft snug no bind ___ Drive shaft bolts tight ___ Transmission mount bolts tight ___ Bellhousing bolts tight ___ Starter tight ___ Engine Oil le...

Страница 534: ...533 www factoryfive com 508 291 3443 Appendix F Torque Specifications...

Страница 535: ...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...

Страница 536: ...535 www factoryfive com 508 291 3443 Appendix G Mustang Specifications...

Страница 537: ...02 Cobra DOHC 4 6L 320 5000 317 4750 Independent T 45 17 x8 00 Cobra R 331 5 4L 385 6250 385 4250 Independent T 56 18 x9 5 01 Bullitt SOHC 4 6L 265 5000 305 4000 Solid Axle T 45 17 x8 03 04 Cobra DOHC...

Страница 538: ...Most wheels fit the 59 25 width the best Make sure you know what axle you have before ordering wheels Front brakes 1987 to 1993 front rotors are 11 diameter and use a 4 25 4 lug bolt pattern They use...

Страница 539: ...FFR kits due to interference with the chassis For most disc brake applications we have found the 1994 Mustang Cobra master cylinder 15 16 to work the best From 1996 to 2004 Mustangs used a brake boost...

Страница 540: ...MS 0017271C M Mass Air Sensor Mass air sensors are devices used to measure air flow into the engine for the vehicles computer These started to be used in Mustangs in 1989 and are still being used 1986...

Страница 541: ...triangle shaped end as well as changing the inner and outer tie rod ends The 1994 to 2004 inner and outer tie rods are too long and do not work with an FFR kit The Factory Five 4 6L steering kit inclu...

Страница 542: ...all 4 link solid axle FFR kits and they are also used for independent rear suspension FFR kits There is a mounting bracket for the quad shock to mount to the Mustang chassis which is also used for so...

Страница 543: ...e spring control arm and spring chassis which are a required donor part for an FFR 4 link stock kit 1979 04 Production Spring Rates lbs in YEAR Mustang V 8 Cobra Cobra R 1979 F395 R160 1980 81 F370 R1...

Страница 544: ...9 93 Ron Francis has a harness for 96 04 engines For a carbureted car we recommend using an aftermarket chassis harness Accelerator Pedal The accelerator pedals remained unchanged from 1979 to 2004 an...

Страница 545: ...544 www factoryfive com 508 291 3443 Appendix H Fluid Specifications...

Страница 546: ...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...

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