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  5. Owner's Manual

Factory Five Racing Gen 3 Type 65 Coupe Owner's Manual

Summary of Gen 3 Type 65 Coupe

  • Page 1

    R e v i s i o n 4 b , o c t o b e r 2 0 1 7.

  • Page 2

    2017 factory five racing inc. 9 tow rd wareham, ma 02571 phone 508.291.3443 • fax 508.291.3883.

  • Page 3

    Ii www.Factoryfive.Com 508-291-3443 contents general information ................................................................ 11 foreword ....................................................................................... 11 safety notice ........................................................

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    Iii www.Factoryfive.Com 508-291-3443 front suspension .................................................................................... 34 fuel tank ................................................................................................ 35 rear end ..........................................

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    Iv www.Factoryfive.Com 508-291-3443 complete kit front brakes ...................................................................... 82 solid axle rear suspension .......................................................... 92 solid axle preparation .......................................................

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    V www.Factoryfive.Com 508-291-3443 complete kit accelerator pedal ............................................................. 185 cockpit aluminum ........................................................................ 190 rivet spacing tool ..........................................................

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    Vi www.Factoryfive.Com 508-291-3443 wiring harness ............................................................................. 270 complete kit chassis wiring harness ................................................... 270 led flashers .................................................................

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    Vii www.Factoryfive.Com 508-291-3443 frame preparation ....................................................................... 336 rear body mount ......................................................................... 338 body mounting ................................................................

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    Viii www.Factoryfive.Com 508-291-3443 headlights ................................................................................... 440 turn signals ................................................................................ 445 headlight covers ...................................................

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    Ix www.Factoryfive.Com 508-291-3443 alignment specifications ....................................................................... 522 optional parts .............................................................................. 524 performance reference material and technical support ...... 525 m...

  • Page 11

    X www.Factoryfive.Com 508-291-3443.

  • Page 12: General Information

    11 www.Factoryfive.Com 508-291-3443 general information foreword f you are reading this, you are embarking on a mission to build your own car, or at least considering doing so. I wanted to share with you some of my experiences and lessons learned while working with literally thousands of people who ...

  • Page 13

    12 www.Factoryfive.Com 508-291-3443 part of the very definition of always trying to go faster. The late carroll smith wrote something i really loved that speaks to this point. “there is no magic! The one basic truth of successful racecar preparation bears repeating. There is no magic. There is only ...

  • Page 14

    13 www.Factoryfive.Com 508-291-3443 five customers will also be there for you, as the one thing that really sets us above the crowd of other companies is the size, competence and enthusiasm of our customer community. When the baby arrives and when your car is done, there will still be more work. Wit...

  • Page 15

    14 www.Factoryfive.Com 508-291-3443 you have the skills to build your own vehicle, do not proceed. This project involves building a car from the bare frame all the way up to a finished vehicle. It is intended for individuals who have the skills and abilities commensurate with the scope of a project ...

  • Page 16

    15 www.Factoryfive.Com 508-291-3443 safety tips read the manual. It is at least a good guide and place to start. Don’t take short cuts. Before starting work, make sure you have the proper tools, the required parts, and sufficient space for the job. If you damage any parts, it will probably be becaus...

  • Page 17

    16 www.Factoryfive.Com 508-291-3443 how to use this book this assembly manual is intended to help you build your factory five kit. This book will not explain such things as engine or transmission building. A secondary purpose of this book is to use it as reference for owners that want to do maintena...

  • Page 18

    17 www.Factoryfive.Com 508-291-3443 rear end: 1987-2004 ford 8.8” rear axle. 1987-1993 width is best paint: most customers will send out the body and paint work to a professional body shop. Fuel pump: you are responsible for purchasing an external carbureted or fuel injected inline fuel pump. Batter...

  • Page 19

    18 www.Factoryfive.Com 508-291-3443 serial number identification factory five racing has included a certificate of origin along with a nameplate for your kit. The serial number from the certificate of origin matches the number engraved on the 1.50”x 1.50” tube going across the car at the front of th...

  • Page 20

    19 www.Factoryfive.Com 508-291-3443 tools list the following lists detail the tools and supplies that are needed to build your kit. The “helpful” items are not crucial to the assembly but make life easier. Home depot husky®, sears craftsman®, and snap-on tools are all guaranteed for life and we’ve f...

  • Page 21

    20 www.Factoryfive.Com 508-291-3443 required supplies stick with name brand products like eastwood , 3m , and duplicolor . The eastwood brand coatings are great for bringing weathered and oxidized parts up to show quality. Ppg brand and dupont brand paints are excellent. Engine degreaser silicone do...

  • Page 22: Donor Parts And Prep

    21 www.Factoryfive.Com 508-291-3443 donor parts and prep chapter 2.

  • Page 23

    22 www.Factoryfive.Com 508-291-3443 this chapter deals with the mustang parts needed in addition to our kit. Many people choose to use parts from a single mustang donor. If you are not going to use a donor car but choose to acquire parts separately, this section may still be useful. The complete lis...

  • Page 24

    23 www.Factoryfive.Com 508-291-3443 donor parts selection tips 87-93 mustang the following are a few tips we’ve picked up over the years when dealing with used parts. In addition to the parts that come with the kit, you have to provide the running gear and some other parts that can be taken directly...

  • Page 25

    24 www.Factoryfive.Com 508-291-3443 usa west coast all mustang performance phoenix, az 800-454-8387 tommy thompson www.Ampperformance.Com mustang village fontana, ca 909 823 7915 scott or tom www.Mustang-village.Com cypress auto berkley, ca 510 451 3034 mike percy www.Cypressautorecyclers.Com/factor...

  • Page 26

    25 www.Factoryfive.Com 508-291-3443 to verify mileage is by inspecting the drum brake shoes on the unit. The drum pulls straight out, off the axle. Rear shoes are never really replaced until about 60-100k miles unless there was severe duty (read abuse) placed on the car. The easiest way to avoid eng...

  • Page 27

    26 www.Factoryfive.Com 508-291-3443 radiator/cooling system metric sockets, extensions, large pliers, and waste container/bucket. Mustang radiator and fan shroud w/overflow reservoir. Refer to appendix b. Try to avoid spilling used coolant. Take care when handling the mustang radiator. When removing...

  • Page 28

    27 www.Factoryfive.Com 508-291-3443 mustang steering rack with lines removed with rubber bushings and fasteners. Engine bay sensors and electrical connections socket set, combination wrenches, phillips head screwdriver, slip joint pliers, tape, marker, and bucket. Mustang coil, egr assembly, vacuum ...

  • Page 29

    28 www.Factoryfive.Com 508-291-3443 interior socket set none. Remove the seats from the car. Remove the center consul cover the handle. Remove the carpet from the car. Computer socket set. Mustang computer and oem plastic cradle. If you are going to run the car with a carburetor you can disregard th...

  • Page 30

    29 www.Factoryfive.Com 508-291-3443 87-93 steering column (with ignition, turn signal stalk) remove the steering 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 s...

  • Page 31

    30 www.Factoryfive.Com 508-291-3443 87-93 dash harness with air bag and fuse panel attachments. Front wiring harness socket set, extension, regular, phillips head screwdrivers, needle nose pliers, hammer, and marker tape. Front wiring harnesses. Pull the rubber grommet out of the firewall into the e...

  • Page 32

    31 www.Factoryfive.Com 508-291-3443 87-93 front wiring harness with hookups for headlights, alternator, and horn. Speedometer sending unit socket set, duct tape. Speedometer sending unit. Remove the wiring harness plug from the sending unit. Remove the speedometer sending unit bolt using an 11mm soc...

  • Page 33

    32 www.Factoryfive.Com 508-291-3443 fuel inertia cut-off switch socket set, nut driver, phillips head screwdriver, wire cutters to cut plastic fasteners, marker pen, and tape. Fuel inertia cut-off switch. It is recommended that a fuel inertia cut-off switch be used in the car. Inertia cut-off switch...

  • Page 34

    33 www.Factoryfive.Com 508-291-3443 store the rear harness and transmission harness. Exhaust wrenches, 11 / 16 ” socket, socket extension, ratchet, adjustable wrench, hack saw. O 2 sensors. Handle the mustang catalytic converters with care since the honeycomb inside breaks easily. Some parts yards w...

  • Page 35

    34 www.Factoryfive.Com 508-291-3443 attach an engine hoist to the engine lift points at the driver’s front and passenger’s rear areas of the engine. One easy way to do this is with a chain and bolt on the other side of the hole. An alternative to this is to wrap chains through the back of the engine...

  • Page 36

    35 www.Factoryfive.Com 508-291-3443 lower a-arm w/bolts, brake caliper, spindle and brake rotor. Use a spring compression tool to remove the front springs or chain the spring to the chassis. Remove the three bolts that retain the struts to the top mounting plate. Slowly lower the jack and the strut ...

  • Page 37

    36 www.Factoryfive.Com 508-291-3443 remove the screws that hold the upper fuel cap and flange to the body of the car. Remove the set screw and metal ring collar retainer from the fuel neck where it meets the tank. Remove the fuel neck from the upper fuel fill area and slide the lower fuel tube out o...

  • Page 38

    37 www.Factoryfive.Com 508-291-3443 use a drill with a ¼” bit to drill out the rivets on the brake bracket, which retain it to the body above the differential. Keep this bracket for use later. Fuel filter and connectors socket set, small flat head screwdriver, tin snips or razor knife. Rear fuel lin...

  • Page 39

    38 www.Factoryfive.Com 508-291-3443 if not already done, fill the axle with gear oil. See appendix for specifications and capacities. If using a used rear axle, remove the lower shock mounts and the anti-vibration weight under the pinion. Drill the lower control arm holes out with a ½” drill bit..

  • Page 40

    39 www.Factoryfive.Com 508-291-3443 the lower shock mount brackets will get used on the front lower control arms to mount the front shocks front lower control arms hack saw, file grinder remove the area, near the center of the spring mount to prevent damage to the coil-over unit thru any contact wha...

  • Page 41

    40 www.Factoryfive.Com 508-291-3443 check clearance with the new shock and the new mount. These parts must move freely without contacting the control arm surface. Fuel filter fittings razor knife donor plastic fuel line fittings from fuel filter to body hard line and from return line from body hard ...

  • Page 42

    41 www.Factoryfive.Com 508-291-3443 fuel tank pliers fuel tank at the locations on the tank where the tank straps come near the tank, use a pair of pliers and bend the bent parts flat. Fuel filler neck hack saw fuel filler neck cut the mustang steel fuel neck in the mid-section after the 90 bend. Le...

  • Page 43

    42 www.Factoryfive.Com 508-291-3443 bend the fuel lines away from the engine block just at the point where they are held in place by the retaining clips. This is so that the fuel does not travel near the hot header. Don’t make tight bends here or it will affect your fuel flow. If you are using a lak...

  • Page 44

    43 www.Factoryfive.Com 508-291-3443 steering rack 11 / 16 ” and ⅝” wrenches, ruler, hack saw, marker. Remove the outer tie rods. Remove the inner tie rods. Cut 1.75” off the end of the inner tie rods. If you are planning on running power steering the next steps are not needed. Remove the hydraulic l...

  • Page 45

    44 www.Factoryfive.Com 508-291-3443 spark plug reveals about the engine's performance. When replacing the spark plugs, make sure you gap them before installing them..

  • Page 46: Disassembly Of The Kit

    45 www.Factoryfive.Com 508-291-3443 disassembly of the kit chapter 3.

  • Page 47

    46 www.Factoryfive.Com 508-291-3443 unpacking your kit boxes are numbered, when you read your packing list you will see that next to each assembly there is a number circled. This is the box number that the assembly was packaged in. The kit is packaged in the order that you will be using the parts. A...

  • Page 48

    47 www.Factoryfive.Com 508-291-3443 remove the duct tape from the kit. Remove the nose and rear hatch. Unscrew the body in the door openings using a 5 / 16 ” socket and ratchet or 5 / 16 ” nut driver..

  • Page 49

    48 www.Factoryfive.Com 508-291-3443 lift in the exhaust recess and the rear wheel well. Carefully pull the front sides of the body out and up around the door hinge mounts while at the same time lifting the rear of the body. Rotate the back of the body down and the front up once the back is clear of ...

  • Page 50

    49 www.Factoryfive.Com 508-291-3443 remove the body by walking towards the rear of the frame. The body can be stored on the ground outside. Area set-up jack stands, garage use jack-stands to position your frame in your workspace with plenty of room to move and walk around the whole frame. Aluminum p...

  • Page 51

    50 www.Factoryfive.Com 508-291-3443 using a marker trace along each tube on the aluminum panels where they contact the chassis. If you see a spot where a drill or rivet cannot be installed due to lack of space or interference then make a small note not to drill in that area. This is done to locate w...

  • Page 52

    51 www.Factoryfive.Com 508-291-3443 aluminum panel diagram.

  • Page 53

    52 www.Factoryfive.Com 508-291-3443 item no. Part number description alum/qty. 1 coupe frame coupe frame 1 2 60195 radiator duct back 1 3 60196 radiator duct side 2 4 60125 60149 - footbox outside wall, left 1 5 60501 left footbox front 1 6 60132 left footbox inside lower wall 1 7 60139 footbox insi...

  • Page 54: Chassis Assembly

    53 www.Factoryfive.Com 508-291-3443 chassis assembly chapter 4.

  • Page 55

    54 www.Factoryfive.Com 508-291-3443 steering rack needle nose pliers, ¾” wrench, ¾” socket, ratchet steering rack assembly, steering system hardware unpack the steering system hardware. Stock mustang power steering rack prep push the bushing sleeves into the stock mustang rack bushings. Steering rac...

  • Page 56

    55 www.Factoryfive.Com 508-291-3443 remove the inner tie rods and put a dot of thread lock on the threads of the steering rack. Attach the steering rack extension to the steering rack using a 1.50” wrench and tighten. Put a dot of thread lock on the threads of the steering rack extension and attach ...

  • Page 57

    56 www.Factoryfive.Com 508-291-3443 manual or optional power steering rack prep factory five manual and power racks are installed in a similar way. Unpack the steering rack assembly. Push the bushings into the mounting bosses on the rack..

  • Page 58

    57 www.Factoryfive.Com 508-291-3443 push the bushing sleeves into the rack bushings making them as flush as possible with the surface of the bushing. Screw the grease nipple into the outer tie rod end. Thread the outer tie rod and jam nut 1”-2” down onto the steering rack inner tie rod. The outer ti...

  • Page 59

    58 www.Factoryfive.Com 508-291-3443 steering rack install ¾” wrench, ¾” socket, ratchet. Lower the rack into the chassis right side first. Allow the rack to drop far enough into the opening to swing the other side down into its mounting bracket..

  • Page 60

    59 www.Factoryfive.Com 508-291-3443 locate the rack between the mounting brackets. Locate the ½” x 4” steering rack bolts, washers and locknuts. There are two sets of mounting holes, lower for standard street car ride height. Top for race car..

  • Page 61

    60 www.Factoryfive.Com 508-291-3443 for standard street car ride height use the lower set of holes to mount the steering rack. Use a ¾” wrench and ratchet to fully tighten the steering rack. Front suspension front lower control arm ⅞” socket, 5 / 16 ”, 15 / 16 ” wrenches, torque wrench front lower c...

  • Page 62

    61 www.Factoryfive.Com 508-291-3443 unpack the front lower control arms and hardware. Screw the grease fittings into the arms using a 5 / 16 ” wrench. There are two sets of mounting holes, lower for standard street car ride height. Top for race car..

  • Page 63

    62 www.Factoryfive.Com 508-291-3443 position the control arms one at a time so the lower set of holes line up with the control arm bushing sleeves and insert the front mounting bolt. The rear bushing mount on the chassis is wider, use one of the large washers as a shim to take up the extra space on ...

  • Page 64

    63 www.Factoryfive.Com 508-291-3443 while holding the arm parallel to the ground, torque the bolts to 135-149nm (100-110 lbft). Front coil-over shocks coil-over assembly snap ring pliers front shock set the front shocks are pre-valved at the factory in compression and rebound for good street use. Th...

  • Page 65

    64 www.Factoryfive.Com 508-291-3443 the coil-over hats have a snap ring which holds it in place. Remove this snap ring to assemble the coil over shock. Slide the rubber bumper about two inches down on the shaft. Put the spring and hat on the shock and rotate the spring seat back up the sleeve so tha...

  • Page 66

    65 www.Factoryfive.Com 508-291-3443 install the 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. Front shock installation if using the silver double adjustable shocks, these must be mounted with ...

  • Page 67

    66 www.Factoryfive.Com 508-291-3443 locate the coil-over mounting hardware in the kit. At the upper shock location using the longer 3.25” bolt and a washer thread it through the lower mounting hole in the frame and install one of the four longer (0.675”) spacers on it..

  • Page 68

    67 www.Factoryfive.Com 508-291-3443 if using the silver double adjustable shocks, these must be mounted with the body of the shock down in the top hole location for both street and race cars. For the stock red koni shocks, there are two sets of mounting holes, lower for standard street car ride heig...

  • Page 69

    68 www.Factoryfive.Com 508-291-3443 using the shorter (2.75”) bolt and shorter (0.40”) spacers repeat the process for the lower control arm mount and hand tighten the locknut to hold in place. The coil-over should now be holding the arm in place as shown..

  • Page 70

    69 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. Torque the upper and lower mounting bolts for the coil-overs to 40 ft-lbs and repeat for the other side of the frame..

  • Page 71

    70 www.Factoryfive.Com 508-291-3443 front upper control arm vise, thread locker, ⅜”, ¾” wrench, ¾” socket, torque wrench ifs components unpack the upper control arm assembly. Start threading the upper ball joints into the control arms so that the balljoint angles out on the bottom. The arms are the ...

  • Page 72

    71 www.Factoryfive.Com 508-291-3443 use a little red loctite on the balljoint threads. If you do not have a balljoint socket, clamp the balljoint in a vice and use the arm itself for leverage to tighten..

  • Page 73

    72 www.Factoryfive.Com 508-291-3443 screw the grease fittings in to the ball joints and tighten with a ⅜” wrench. Unpack the upper control arm mounting hardware..

  • Page 74

    73 www.Factoryfive.Com 508-291-3443 remove one of the inner bolts from the upper control arms and wrap the cross shaft of the arm around behind the coil-over. Slide the cross shaft in between the two mounting flanges and thread the mounting bolts into place with the nuts on finger tight..

  • Page 75

    74 www.Factoryfive.Com 508-291-3443 replace the bolt you removed to get the arm in place and flip over any remaining bolts that thread in from the bottom up so all the bolt heads are on top. Torque the two bolts that hold the arm to the frame to 135-149nm (100-110 lbft). Pivot endplay adjust the loc...

  • Page 76

    75 www.Factoryfive.Com 508-291-3443 slightly loosen the three pivot bolts using a ⅝” and 11 / 16 ” wrench. Loosen the jam nuts on both ends of each adjusting tubes using a 1⅛” wrench. Turn the adjusting tubes to lengthen or shorten the arm. After you have adjusted the arm to the desired length, tigh...

  • Page 77

    76 www.Factoryfive.Com 508-291-3443 unpack and lay out the hardware for the spindles assembly. The spindles are marked dss (driver side spindle) and pss (passenger side spindle). These refer to the way they are mounted on the ffr hot rod which is rear steer. The ffr coupe uses these as front steer s...

  • Page 78

    77 www.Factoryfive.Com 508-291-3443 place the spacer under the castle nut to ensure that the cotter pin is at the correct height. Torque to 106-149nm (80-110 lbft) and install the cotter pin. Attach the upper ball joint to the spindle and torque to 75 ft-lbs and install the cotter pin. The upper bal...

  • Page 79

    78 www.Factoryfive.Com 508-291-3443 bolt the steering arms to the spindles so the tie rod end will mount from the bottom (the taper on the hole will open out toward the bottom) and the kink in the arm angles the arm outward toward the rotor. Torque to 60 ft- lbs. The hub is a snug fit on the spindle...

  • Page 80

    79 www.Factoryfive.Com 508-291-3443 using a large socket or a flat head screwdriver and rubber mallet, hit the dust cap onto the hub. Ifs bracket ifs components, mustang strut bolts these are not used in the complete coupe kit.

  • Page 81

    80 www.Factoryfive.Com 508-291-3443 using the 87-93 spindles, use the hole closest 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 spindle adapter bracket to t...

  • Page 82

    81 www.Factoryfive.Com 508-291-3443 steering tie rod ends some tie rods have the nylon locknuts and others have the castle nuts with cotter pins, both are correct. Attach the tie rod to the spindle, torque the nut to 25 ft-lbs. If a castle nut is used, torque the nut then install the cotter pin..

  • Page 83

    82 www.Factoryfive.Com 508-291-3443 if the tie rod has a locknut instead of a castle nut, torque to 80nm (59 ft-lb). Front brakes sockets, ratchet, torque wrench, chassis grease, rags, brake cleaner, mustang front brake calipers and rotors make sure that your brake pads and rotors are in good condit...

  • Page 84

    83 www.Factoryfive.Com 508-291-3443 install the caliper slider pins on the caliper using the supplied bolts and a 16mm wrench and 12mm socket. Torque to 23-26 ft-lbs..

  • Page 85

    84 www.Factoryfive.Com 508-291-3443 install the slider grease boots on the slider pins..

  • Page 86

    85 www.Factoryfive.Com 508-291-3443.

  • Page 87

    86 www.Factoryfive.Com 508-291-3443 in the supplied hardware bag there are six steel clips that are designed to separate the pads from the caliper. These clips allow the pads to slide on a smooth surface and not wear on the caliper. The four clips that go on the ends of the hanger are different end ...

  • Page 88

    87 www.Factoryfive.Com 508-291-3443 the two clips that are left go in the center of the caliper with the tab sticking up through the center hole. Insert the clip from the inside of the caliper through the large center hole with the larger tab on the side facing the pistons then press down on the out...

  • Page 89

    88 www.Factoryfive.Com 508-291-3443 push the rubber boots over the lip on the caliper bracket to seal the slider bolts correctly. Look at the back side of each brake pad to find the inside pads and the outside pads. The difference is the location of the studs that are on the back of each pad. The st...

  • Page 90

    89 www.Factoryfive.Com 508-291-3443.

  • Page 91

    90 www.Factoryfive.Com 508-291-3443 install the brake pads in the caliper. Clean the rotor with brake cleaner and push it onto the hub..

  • Page 92

    91 www.Factoryfive.Com 508-291-3443 install the caliper on the spindle; make sure that the fluid bleeder is at the top of the caliper. Torque the caliper mounting bolts to 130nm (95 ft-lb)..

  • Page 93

    92 www.Factoryfive.Com 508-291-3443 solid axle rear suspension skip to the independent rear suspension if not installing a solid axle. Solid axle preparation ¾” sockets, ¾” wrench, ½” drill bit, drill, floor jack, jack stands, torque wrench 8.8” rear axle assembly, box 11 solid axle traction lok bra...

  • Page 94

    93 www.Factoryfive.Com 508-291-3443 if not already done, fill the axle with gear oil. See appendix for specifications and capacities. If using a used rear axle, remove the lower shock mounts and the anti-vibration weight under the pinion. Drill the lower control arm mount holes with a ½” drill bit..

  • Page 95

    94 www.Factoryfive.Com 508-291-3443 position the traction lok brackets on the rear end with the bolts provided (the two short bolts go on the sides). Axle bracket left side.

  • Page 96

    95 www.Factoryfive.Com 508-291-3443 axle bracket right side temporarily put the lower shock bolt through the traction lock bracket and stock shock hole on the axle..

  • Page 97

    96 www.Factoryfive.Com 508-291-3443 tighten the two short bolts. Torque to 75-95 nm (55-70 lbft). Attach the lower control arms to the brackets on the axle using the bolt provided. Torque to 101-111nm (75-82 lbft) the lower bolt holes provide more traction than the upper holes..

  • Page 98

    97 www.Factoryfive.Com 508-291-3443 4 link rear suspension 18mm sockets, ratchet, 15mm wrench mustang upper control arms and hardware. Attach the mustang upper rear control arms loosely to the rear end using the mustang hardware. Skip the 3 link section and continue on with the rear axle installatio...

  • Page 99

    98 www.Factoryfive.Com 508-291-3443 upper link axle mount if using the ffr moser axle skip to the next section since the upper link bracket is welded to the axle. Test fit the two halves of the upper arm mount together. If it is hard to put all of the bolts in the mount holes, put in as many as you ...

  • Page 100

    99 www.Factoryfive.Com 508-291-3443 the front attachment of the upper link axle mount attaches to the hole on the flange section of the pumpkin. This hole has some variance and may need to be drilled out from the bottom side using the mount as a guide. Attach the front of the upper link axle mount t...

  • Page 101

    100 www.Factoryfive.Com 508-291-3443 upper link install a jam nut on each of the rod ends, remembering that two of them are left hand thread. Insert the rod ends into the swedged tubes (one is right hand thread and one is left hand thread). The longer tube is the panhard bar and the shorter one is t...

  • Page 102

    101 www.Factoryfive.Com 508-291-3443 rear coil-over shock assembly snap ring pliers. Roadster/coupe rear shock kit the rear shocks are pre-valved at the factory in compression and rebound for good street use. The shocks can be adjusted in rebound as per koni’s instructions if so desired. The rear sp...

  • Page 103

    102 www.Factoryfive.Com 508-291-3443 the coil-over hats have a snap ring which holds it in place. Remove this snap ring to assemble the coil over shock. Slide the rubber bumper about two inches down on the shaft. Put the spring on the shock, then install the spring hat on the shaft end of the shock ...

  • Page 104

    103 www.Factoryfive.Com 508-291-3443 install the 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 hat. Assembled solid axle koni coil-over shock. Rea...

  • Page 105

    104 www.Factoryfive.Com 508-291-3443 use a floor jack to position the rear axle assembly under the frame. 3-link shown. Make sure that the rear jack stands are positioned under the frame as far back as possible to prevent the frame from tipping up once the axle is mounted do not hold the end of the ...

  • Page 106

    105 www.Factoryfive.Com 508-291-3443 with one person holding one side of the axle raise the axle so that the lower control arms can be bolted onto the frame. Attach the lower control arms to the frame mounts using the oem bolts or bolts supplied with the lower control arms.

  • Page 107

    106 www.Factoryfive.Com 508-291-3443 jack the rear axle up and attach the upper link(s) to the frame. If using the silver double adjustable shocks, these must be mounted with the body of the shock down in the top hole location for both street and race cars. For the stock red koni shocks, there are t...

  • Page 108

    107 www.Factoryfive.Com 508-291-3443 attach the body end of the shock to the frame using the lower shock mount hole, two 1.09”spacers along with the ½” x 4.00” bolts and locknuts. Jack the rear axle up so the rod end of the shocks can be mounted on the axle through the shock mount hole. Right side.

  • Page 109

    108 www.Factoryfive.Com 508-291-3443 left side install the kit ½”x 4” bolts are provided for each lower shock mount. From the rear, the bolt goes through the bracket, ⅛” shim, shock, then the long spacer (1.09”) followed by the bracket and axle. Use a ¾” socket and torque wrench to tighten both uppe...

  • Page 110

    109 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. 4 link rear suspension torque specs chart item nm lbft upper control arm to axle 101-111 75-82 upper control arm to frame 101-111 75-82 lower cont...

  • Page 111

    110 www.Factoryfive.Com 508-291-3443 for a 4 link car loosely mount all 4 arms and then lift axle until lower arms are flat to torque the mounting hardware..

  • Page 112

    111 www.Factoryfive.Com 508-291-3443 solid axle vent if using the ffr rear axle, attach the ¼” rubber fuel line to the vent tube on the rear axle or center section. Tie the top of the tube up high under the trunk allowing room for the axle to move. If running a 4 link, skip to the next section 3-lin...

  • Page 113

    112 www.Factoryfive.Com 508-291-3443 with the axle jacked up, attach the panhard bar frame mount to the inside of the quad shock brackets, the forward leg will attach to the back of the angled 2”x 3” tube. Do not tighten the quad shock bracket bolts yet..

  • Page 114

    113 www.Factoryfive.Com 508-291-3443 for the front mount, use a ½” drill bit and drill through the sleeve on the mount. Make sure before drilling that the hole is away from the side of the 2”x 3” tube so that a nut can be attached on the back of the bolt from the bottom of the tube. Install the ½”-1...

  • Page 115

    114 www.Factoryfive.Com 508-291-3443 lower the rear axle. With the rear end correctly installed with the 3-link, the rear axle will rest on the 3-link panhard bar mount with the suspension at full droop. Panhard bar the panhard bar mounts to the car using the ⅝”x 3” bolts and spacers. Install the pa...

  • Page 116

    115 www.Factoryfive.Com 508-291-3443 attach the panhard bar to the frame mount using the spacers provided. There should never be less than ¾” of threads screwed into either the panhard bar or the upper arm. To set the pinion angle, make sure that your ride height is where you want it, and then adjus...

  • Page 117

    116 www.Factoryfive.Com 508-291-3443 optional independent rear suspension l&r lower control arms, l&r upper control arms, toe arms, l&r cv axles, koni coil-over shocks, springs, fasteners, driveshaft adapter philips head screwdriver, 5 / 8 ” drill bit, 13 /16 ”, 15 / 16 ” wrenches, 13 /16 ”, 15 / 16...

  • Page 118

    117 www.Factoryfive.Com 508-291-3443 mustang irs specifications 2.3l eco boost 3.7l v6 5.0l coyote housing steel aluminum steel weight 93lb 78lb 93lb gear ratios 3.15:1, 3.31:1, 3.55:1 3.15:1, 3.55:1 3.15:1, 3.55:1 brakes 12.6" (320mm) solid rotor, 45mm single piston aluminum caliper 12.6" (320mm) s...

  • Page 119

    118 www.Factoryfive.Com 508-291-3443 mark the spindle starting at the top just to the inside of the top inside hole down to the corner of the small boss at the bottom of the ear. Use a saw to cut the ear off the spindle. If using a sawzall or similar, use a wood blade; a 14tpi blade or finer will ju...

  • Page 120

    119 www.Factoryfive.Com 508-291-3443 hubs hammer, vise, ratchet, ½”-20 lugnut, torque wrench. Rear wheel studs. Removal of the hub from the spindle is not necessary but can make things easier. Use a vise to lightly hold the side of the wheel stud head then use a hammer to bang out the mustang studs....

  • Page 121

    120 www.Factoryfive.Com 508-291-3443 insert one of the included wheel studs into the hub from the back and use a washer and lug nut on the front side. Use a ratchet to draw the wheel stud into the hub and torque the stud to 135nm (100lb-ft)..

  • Page 122

    121 www.Factoryfive.Com 508-291-3443 repeat for the other wheel studs. If the hub was removed, use loctite on the threads and reattach to the spindle. Torque the bolts to 133nm (98ft-lb)..

  • Page 123

    122 www.Factoryfive.Com 508-291-3443 center section 5 / 8 ” drill bit, drill. Use a 5 / 8 ” drill bit to chase the front mount holes on the center section. Frame rubber/plastic mallet differential mounting components.

  • Page 124

    123 www.Factoryfive.Com 508-291-3443 bushing locations. Use a plastic mallet to install the polyurethane bushings marked 2048 and the longer (3 1 / 16 ”) sleeves where the front of the center section will mount..

  • Page 125

    124 www.Factoryfive.Com 508-291-3443 use a plastic mallet to install the polyurethane bushings marked 2123 and the shorter (2.40”) sleeves where the rear of the center section will mount. Upper control arms upper control arm components grease gun.

  • Page 126

    125 www.Factoryfive.Com 508-291-3443 assemble each of the upper control arms as shown. Grease the control arms using chassis grease until the grease comes out of the flutes in the bushings next to the pivot sleeves. Lower control arms grease gun grease the control arms using chassis grease until the...

  • Page 127

    126 www.Factoryfive.Com 508-291-3443 toe adjustment arms assemble each of the toe adjustment arms as shown. Installation center section rubber/plastic mallet, torque wrench, 18mm, 13 / 16 ” sockets, 15 / 16 ” wrench. Differential mounting components. Use a friend to help with the heavy center sectio...

  • Page 128

    127 www.Factoryfive.Com 508-291-3443 use rags to protect between the front center section mount on the frame..

  • Page 129

    128 www.Factoryfive.Com 508-291-3443 with the help of a friend, lift the center section nose up into the frame and over the front mount..

  • Page 130

    129 www.Factoryfive.Com 508-291-3443 flatten the center section out so it is horizontal then back it up so it is above the mount locations and lower it down so the bolts can be installed. The smaller/shorter bolts are used for the rear mounts. The larger/longer bolts and nuts are used for the front ...

  • Page 131

    130 www.Factoryfive.Com 508-291-3443 toe adjustment arms irs toe adjustment arm components 13 / 16 ” socket, 15 / 16 ” wrench, torque wrench. If using the sway bar option, pass the bolt through the frame mount bracket when installing the toe arms. Attach the toe arms to the frame below the front low...

  • Page 132

    131 www.Factoryfive.Com 508-291-3443 attach the control arms to the frame with the shock mount towards the rear and spindle brackets up. Use the longer m16 x 110mm (~4 5 / 16 ”) bolts. Hold the arm horizontal and torque the bolts to 135nm (100 ft-lb). Upper control arms irs upper control arm compone...

  • Page 133

    132 www.Factoryfive.Com 508-291-3443 pass the upper control arm thick tube through the triangular area as shown in between the frame mounts. Use the longer m16 x 110mm (~4 5 / 16 ”) bolts. Hold the arm horizontal and torque the bolts to 135nm (100 ft-lb). Cv axle cv axles, spindles the inside cv joi...

  • Page 134

    133 www.Factoryfive.Com 508-291-3443 using the correct axle, push the inner cv joint into the center section. When fully installed there should be an 1 / 8 ” (~3mm) gap between the inside of the cv joint and the center section. If necessary, compress the cv axle and with the cv axle nut on the end h...

  • Page 135

    134 www.Factoryfive.Com 508-291-3443 slide the spindle onto the outer cv joint and start the nut on the end..

  • Page 136

    135 www.Factoryfive.Com 508-291-3443 spindle to lower arm connect the bottom of the spindle to the lower control arm using the m16 x 90mm bolts and locknuts. Right side shown. Wait to torque the bolts until after the other arms are installed..

  • Page 137

    136 www.Factoryfive.Com 508-291-3443 spindle to upper arm insert the angled mount adapter into the upper arm rod end. Reuse the 5 / 8 ” washer that was on the old bolt and place it on the new 5 / 8 ” x 4.25” bolt along with a misalignment spacer..

  • Page 138

    137 www.Factoryfive.Com 508-291-3443 attach the upper control arm to the spindle using the bolt with the misalignment spacer. Use a 15 / 16 ” wrench, 15 / 16 ” socket and ratchet to tighten the locknut. Wait to torque the bolts until after the other arms are installed..

  • Page 139

    138 www.Factoryfive.Com 508-291-3443 check the angle of the upper control arm rod end, make sure that the rod end is not touching the spindle and that it is aligned with the upper control arm..

  • Page 140

    139 www.Factoryfive.Com 508-291-3443 toe link attach the toe link arm to the spindle using the m14 x 80mm bolt and locknut. Repeat for the right hand side. Use the torque specifications page at the back of the instructions to torque the control arm to spindle bolts. Coil-over shock assembly snap rin...

  • Page 141

    140 www.Factoryfive.Com 508-291-3443 unpack the shocks, coil-over’s and hardware. Double check the jam nut under the rod end and bump stop to make sure that it is tight. Screw the spring seat down on the sleeve so it is closer to the unthreaded end. Slide the coil sleeve over the body of the damper ...

  • Page 142

    141 www.Factoryfive.Com 508-291-3443 the coil-over hats have a snap ring which holds it in place. Remove this snap ring to assemble the coil over shock. Slide the rubber bumper about two inches down on the shaft. Put the spring and hat on the shock and rotate the spring seat back up the sleeve so th...

  • Page 143

    142 www.Factoryfive.Com 508-291-3443 install the 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. Attach the rod end of the shock to the upper shock mount using the two equal length 1.09” kit spa...

  • Page 144

    143 www.Factoryfive.Com 508-291-3443 jack the spindle up so the body end of the shocks can be mounted on the shock mount on the control arm using the longer 1.09” spacer on the back and 7 / 16 ” spacer in front of the shock. Torque the lower shock bolt to 54nm (40 ft-lb). Remove the floor jack. Driv...

  • Page 145

    144 www.Factoryfive.Com 508-291-3443 apply loctite to the (6) m10 x 25mm socket head screws. Attach the driveshaft adapter to the center section pinion flange and torque the bolts in a star pattern to 55nm (41 ft-lb)..

  • Page 146

    145 www.Factoryfive.Com 508-291-3443 fluids name specification motorcraft® additive friction modifier (u.S.) xl-3 (u.S.) est-m2c118-a motorcraft® sae 75w-85 synthetic hypoid gear lubricant xy-75w85-ql wss-m2c942-a fill the rear axle with fluids. Capacities fluid amount sae 75w-85 synthetic hypoid ge...

  • Page 147

    146 www.Factoryfive.Com 508-291-3443 once the car has been aligned, use a 1 5 / 8 ” wrench to loosen the upper control arm large jam nut and put some loctite on the threads where the jam nut will sit. Retighten the jam nut. Optional irs brakes download the 2015 irs brake instructions from www.Factor...

  • Page 148

    147 www.Factoryfive.Com 508-291-3443 unpack the fuel strap fasteners. Unpack the ¾” square plastic end caps from the secondary body fasteners..

  • Page 149

    148 www.Factoryfive.Com 508-291-3443 push the two plastic end caps into the tubes hanging down in front of the gas tank area. Put the fuel tank bolts in the gas tank front frame mounts..

  • Page 150

    149 www.Factoryfive.Com 508-291-3443 hang the fuel tank straps from the rear mount of the chassis using two of the strap fasteners. The longer strap goes on the right side. Do not tighten the nuts fuel filler neck marker, tape measure, saw, razor knife.

  • Page 151

    150 www.Factoryfive.Com 508-291-3443 unpack the oem fuel tank components including the tank and straps. Insert the large rubber filler neck gasket in the side of the tank..

  • Page 152

    151 www.Factoryfive.Com 508-291-3443 use a ruler or wall and a tape measure to measure 6.50” and 8.50” up from the bottom edge of the filler tube and mark the tube. Cut the filler tube on the two places marked..

  • Page 153

    152 www.Factoryfive.Com 508-291-3443 fuel pick-up this install shows the set-up for a pick-up with an inline fuel pump. See www.Factoryfiveparts.Com/instructions for in-tank fuel pump set-up. Prep if the car will have a high horsepower fuel injected engine there are a few “tweaks” we recommend get d...

  • Page 154

    153 www.Factoryfive.Com 508-291-3443 starting with a ¼” drill bit drill out the end of the send line then change to a 9 / 32 ” or 19 / 64 ” drill bit, the pressed end is a little restrictive. Starting with a ¼” drill bit drill out the end of the return line then change to a 9 / 32 ” or 19 / 64 ” dri...

  • Page 155

    154 www.Factoryfive.Com 508-291-3443 install use the o-ring included with the kit not the square profiled o-ring sent with the pick-up set the rubber o-ring in place for the fuel pump pickup. Slide the pickup down into the tank; you will have to rotate as you go to get the tubes into the sump and li...

  • Page 156

    155 www.Factoryfive.Com 508-291-3443.

  • Page 157

    156 www.Factoryfive.Com 508-291-3443 with the pickup all the way down slide the mounting collar and tap tightly into place with a punch and hammer. Make sure that the lock ring is held by all three locking tabs on the tank or the sender will leak. Fuel gauge sender use the o-ring included with the k...

  • Page 158

    157 www.Factoryfive.Com 508-291-3443 set the rubber o-ring in place for the fuel level sending unit. Insert the fuel level sender into the tank..

  • Page 159

    158 www.Factoryfive.Com 508-291-3443 ] tap the locking ring tightly into place with a punch and hammer. Make sure that the lock ring is held by all three locking tabs on the tank or the sender will leak..

  • Page 160

    159 www.Factoryfive.Com 508-291-3443 fuel tank vent ¼”, 5 / 16 ” sockets, ratchet, 7 / 8 ” wrench, razor knife, vise. Screw the vent into the plastic bushing and tighten. Insert the small rubber vent gasket in the small hole on the top of the tank..

  • Page 161

    160 www.Factoryfive.Com 508-291-3443 push the vent into the grommet. A little oil or wd40 on the rubber gasket helps. Slide the lower filler tube section into the tank. A little oil or wd40 on the rubber gasket helps. Put masking tape over the end of the tube so that nothing drops into the tank..

  • Page 162

    161 www.Factoryfive.Com 508-291-3443 slide the retaining bracket down the filler tube and mark its mounting location on the tank. Move the retainer out of the way and make sure your mark is outside the weld that holds the two tank halves together..

  • Page 163

    162 www.Factoryfive.Com 508-291-3443 drill a ¼” hole through the tank flange on the mark made. Remove the filler neck tube. Fuel tank install 9 / 16 ” wrench, 9 / 16 ” deep socket, ratchet. At the locations on the tank where the tank straps come near the tank, use a pair of pliers and bend the bent ...

  • Page 164

    163 www.Factoryfive.Com 508-291-3443 put the metal tank in the plastic tank cover. With the help of a friend or using a jack in the center of the tank, raise the tank up into place on the chassis..

  • Page 165

    164 www.Factoryfive.Com 508-291-3443 bolt the straps in with the strap fasteners and drop the jack if used. Fuel filler neck insert the fuel filler neck into the fuel tank..

  • Page 166

    165 www.Factoryfive.Com 508-291-3443 use the ¼”bolt and locknut to attach the retainer to the tank. Fuel filter unpack the fuel filter and mounting hardware..

  • Page 167

    166 www.Factoryfive.Com 508-291-3443 open the hose clamp and slide it through the slots in the mount and start to tighten it back up into a hoop just bigger than the filter. Clamp the filter in place on the mount with the filter flange oriented as shown..

  • Page 168

    167 www.Factoryfive.Com 508-291-3443 attach the short nylon fuel line to the filter and the tank to show where your mounting location must be. The elbow end can attach to either end as shown here; we have attached it to the tank. Line the filter up to the chassis tube, the back of the bracket should...

  • Page 169

    168 www.Factoryfive.Com 508-291-3443 hard lines unpack the fuel lines 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 ¼” line provided for that as well. There a...

  • Page 170

    169 www.Factoryfive.Com 508-291-3443 the fuel line routing will depend on your style of fuel pump, whether it is in-line, in-tank, or mounted on the engine. The most important things are: to route the lines so that they are protected by the chassis; not close to any heat source or moving parts; and ...

  • Page 171

    170 www.Factoryfive.Com 508-291-3443 run the hard line up to the front of the transmission tunnel. Finish running your fuel system by hooking up either to your carburetor, fuel rail or fuel pressure regulator. Here we mounted a pressure regulator on the firewall and ran a single line over to the rai...

  • Page 172

    171 www.Factoryfive.Com 508-291-3443 connect the return line to the fuel tank. Vent hose attach a 25” section of 5 / 16 ” fuel line and fuel line clamp onto the vent then run the vent hose down to the tube near the vent and attach it to the tube using a zip tie..

  • Page 173

    172 www.Factoryfive.Com 508-291-3443 pedal box 7 / 16 ”, ½” sockets, ratchet, ¼”, ⅜”, 7 / 16 ”, ½” wrenches, 3 / 16 ”, ¼” drill bits, drill, philips head screwdriver, 3 / 16 ” hex key, snap ring pliers pedal components, pedal box hardware. This pedal box is set-up to use either a hydraulic clutch or...

  • Page 174

    173 www.Factoryfive.Com 508-291-3443 repeat the marking for the switch in front of the clutch pedal. Drill the two holes you have marked out with a 3 / 16 ” drill bit..

  • Page 175

    174 www.Factoryfive.Com 508-291-3443 attach the switch mounts to the pedal box using the black #10 screw and locknut. Connect the switches to the switch mount using a hex nut on each side of the mount bracket..

  • Page 176

    175 www.Factoryfive.Com 508-291-3443 clutch cable quadrant 3 / 16 ”, 5 / 16 ” hex keys, ½”, 9 / 16 ” wrenches, ½” socket, ratchet, file, external snap ring pliers. Assemble the clutch quadrant to the wilwood clutch pedal as shown above..

  • Page 177

    176 www.Factoryfive.Com 508-291-3443 use snap ring pliers to remove the clevis at the top of the clutch pedal. If necessary use a file to remove the forging centerline so the 3 / 8 ” bolt can go through the clutch pedal hole..

  • Page 178

    177 www.Factoryfive.Com 508-291-3443 frame installation 7 / 16 ” socket, ratchet, 7 / 16 ” wrench, ¼” drill bit, drill, 5 / 32 ” hex key pedalbox left side mount. Place the pedal box assembly in the driver’s footbox. Make sure that the left side of the pedalbox sits on top of the frame mount and the...

  • Page 179

    178 www.Factoryfive.Com 508-291-3443 attach the wilwood pedals to the mounting brackets using four 5 / 16 ” button head screws, locknuts, 3 / 16 ” hex key and ½” wrench. Attach the 60193 pedalbox top mount to the top of the pedalbox using the stainless ¼” x 0.50” flange head screws and a 5 / 32 ” he...

  • Page 180

    179 www.Factoryfive.Com 508-291-3443 drill through the 1” frame tube through the bracket mounting holes using a ¼” drill bit. Attach the pedalbox mount to the tube using the ¼” x 1.25” bolts and nuts along with a 7 / 16 ” socket, ratchet and wrench..

  • Page 181

    180 www.Factoryfive.Com 508-291-3443 master cylinders 6mm socket, ½” deep socket, ratchet, ½” wrench, saw master cylinders with the jam nut on the threaded shaft, cut 5 / 8 ” off each of the master cylinders. Screw the 90° brake line adapter into the end of the master cylinder making sure that the o...

  • Page 182

    181 www.Factoryfive.Com 508-291-3443 put one the ¾” master cylinder onto the brake left master cylinder mount location and turn the threaded shaft into the threaded mount on the brake pedal. As a starting point, thread the shaft in until you can see it is flush on the other side of the mount. Repeat...

  • Page 183

    182 www.Factoryfive.Com 508-291-3443 attach and tighten the locknuts using a ½” wrench and ½” deep socket holding the master cylinder to the pedal box then repeat for the other master cylinder. Put the plastic angled inlet adapter with hose clamp on the master cylinders. Use a 6mm socket and ratchet...

  • Page 184

    183 www.Factoryfive.Com 508-291-3443 tighten all the remaining hardware mounting the pedal box to the chassis. Balance bar adjustment the balance bar is an adjustable lever (usually a threaded rod), that pivots on a spherical bearing and uses two separate master cylinders for the front and rear brak...

  • Page 185

    184 www.Factoryfive.Com 508-291-3443 lever movement should be unimpeded throughout pedal travel. In the neutral position, clevises should have between .20” - .25” total clearance between the side of the pedal. The large washers between the pedal and clevis should remain loose. Make sure that the mas...

  • Page 186

    185 www.Factoryfive.Com 508-291-3443 check the full range of the accelerator pedal travel to ensure that there are no interferences with the pedal or travel. Complete kit accelerator pedal 5 / 64 ” hex key, ⅜”, 7 / 16 ”, ½” wrenches, wire cutter, ¼” drill bit, drill, marker, masking tape. Accelerato...

  • Page 187

    186 www.Factoryfive.Com 508-291-3443 attach the ball stud to the accelerator pedal. Use one ¼”x ¾” screw and locknut from the pedal box hardware position the accelerator pedal so that the pedal pad is at a comfortable height on your foot and there is still room at the top of the accelerator pedal on...

  • Page 188

    187 www.Factoryfive.Com 508-291-3443 bolt the pedal to the mount plate using the ¼”x ¾” screws and locknuts. Rotate the pedal so the top of the pedal where the accelerator cable will attach is 1.50” away from the front of the footbox and mark the front of the footbox directly in front of the ball st...

  • Page 189

    188 www.Factoryfive.Com 508-291-3443 unpack the throttle cable and cut the cylinder end off. Make sure your cutters are very sharp so as not to fray the cable. Pull the inner cable completely out of the sheath and thread it through hole in the top of the throttle pedal and then the cable retaining l...

  • Page 190

    189 www.Factoryfive.Com 508-291-3443 route the cable through the hole in the firewall and slide the sheath back over the cable. Tighten the cable sheath to the firewall with the retaining nut. A piece of tape on the end of the cable will help prevent it from backing out of the sheath. Check the full...

  • Page 191

    190 www.Factoryfive.Com 508-291-3443 cockpit aluminum rivet spacing tool packaged aluminum in most cases we use a 3” rivet spacing when mounting aluminum panels to the chassis and a 2” spacing when mounting panel to panel. The rivet spacing tool has this hole spacing marked. The distance from the ed...

  • Page 192

    191 www.Factoryfive.Com 508-291-3443 apply silicone to the backside of the panels or chassis (whichever is easier) in the areas where they will make contact. Locate and hold the right footbox aluminum panels (inside, front and outside) using the kit # 8 screws originally holding the aluminum to the ...

  • Page 193

    192 www.Factoryfive.Com 508-291-3443 drill through the rivet holes in the footbox front aluminum into the frame tubes using a 1 / 8 ” drill bit. Rivet the panel to the frame. Drill and rivet the inside footbox aluminum panels..

  • Page 194

    193 www.Factoryfive.Com 508-291-3443 run a bead of silicone along the inside bottom of the footbox. Silicone. Drill and rivet the outside footbox aluminum panel..

  • Page 195

    194 www.Factoryfive.Com 508-291-3443 silicone, drill and rivet the right door hinge inside cover to the frame. Left footbox aluminum ¼” nut driver, drill, 1 / 8 ” drill bit, rivet tool. Secondary body fasteners, kit aluminum. Do not rivet the panels together until everything fits together in the cor...

  • Page 196

    195 www.Factoryfive.Com 508-291-3443 locate and hold the left footbox front aluminum panel using the kit # 8 screws originally holding the aluminum to the frame. Locate and hold the left footbox inside top aluminum panel using the kit # 8 screws..

  • Page 197

    196 www.Factoryfive.Com 508-291-3443 locate and hold the left footbox inside bottom aluminum panel using the kit # 8 screws. Drill through the rivet holes in the aluminum into the frame tubes using a 1 / 8 ” drill bit. Rivet the panels to the frame. Do not attach the outside panel yet. Cockpit rear ...

  • Page 198

    197 www.Factoryfive.Com 508-291-3443 silicone the rear cockpit wall frame tubes. Use the #8 screws to hole the panel in place then drill and rivet the cockpit rear wall to the frame..

  • Page 199

    198 www.Factoryfive.Com 508-291-3443 cockpit floors silicone the tubes under the main floor areas. Set the floors in place. Use the #8 screws to hole the panel in place then drill and rivet the floors in place..

  • Page 200

    199 www.Factoryfive.Com 508-291-3443 riveted floors. Drivetrain install if installing a coyote engine, check our parts catalog www.Factoryfiveparts.Com/instructions/ for install instructions..

  • Page 201

    200 www.Factoryfive.Com 508-291-3443 frame prep on the right engine mount sand or grand any coating away around one of the hole shown above for the engine ground strap. Transmission prep 13mm, ¾” sockets, ratchet.

  • Page 202

    201 www.Factoryfive.Com 508-291-3443 remove the shifter handle for easier install using a 13mm socket and ratchet. Put masking tape over the hole. If not already attached, attach the transmission mount to the transmission using a ¾” socket and ratchet. 6speed magnum shown..

  • Page 203

    202 www.Factoryfive.Com 508-291-3443 engine prep engine hoist, chain, ¾”, 15 / 16 ” sockets, ratchet, extension engine, engine mounts, engine ground strap. The easiest method to install the drivetrain is with the engine and transmission already bolted together and lowered in as a unit. Also remove a...

  • Page 204

    203 www.Factoryfive.Com 508-291-3443 attach the engine ground strap (electrical completion parts for complete kit) to one of the engine mount bolts. Tighten all of the engine mount bolts. 87-95 oil filter relocator ⅞” wrench, razor knife, teflon tape, chassis grease, ⅜” hex key oil filter relocating...

  • Page 205

    204 www.Factoryfive.Com 508-291-3443 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 hold it in place while spinning on the adapter. Tighten ½ turn after solid resistance is felt. The outle...

  • Page 206

    205 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. Mount the oil filter relocator on the frame after the engine has been installed ..

  • Page 207

    206 www.Factoryfive.Com 508-291-3443 engine/transmission installation engine hoist, chain, 2-3 friends, 13 / 16 ” socket, ratchet and extension. Attach engine hoist chain to the engine..

  • Page 208

    207 www.Factoryfive.Com 508-291-3443 lower the engine and transmission into place. The more hands you have to help the better. Go very slowly. Install the engine mount to chassis nuts and tighten using a 13 / 16 ” socket, extension and ratchet. Make sure the alignment pins on the mounts are in the h...

  • Page 209

    208 www.Factoryfive.Com 508-291-3443 transmission mount 5 / 8 ”, ¾” sockets, ratchet, floor jack transmission mount/hardware use this transmission mount orientation for 302/351 with tko applications and all 6-speed applications..

  • Page 210

    209 www.Factoryfive.Com 508-291-3443 use this transmission mount orientation for the coyote with tko application jack the transmission up and place the transmission mount on top of the frame mount in the correct orientation. From the top pass the carriage bolts through the transmission mount plate a...

  • Page 211

    210 www.Factoryfive.Com 508-291-3443 attach the ground strap to the frame using a 5 / 16 ” x 1” stainless button head screw, locknut, 3 / 16 ” hex key, ½” socket and ratchet (complete kit only). Steering shaft 5 / 32 ”, 3 / 16 ” hex keys, ½”, 9 / 16 ” wrenches, marker, drill, 3 / 16 ” drill bit, phi...

  • Page 212

    211 www.Factoryfive.Com 508-291-3443 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. If running power steering, do not change the splined adapter; skip the next st...

  • Page 213

    212 www.Factoryfive.Com 508-291-3443 loosen the set screw, align the set screw with the flat side on the input shaft then slide the new adapter down onto the rack as far as possible. Slide the 1” flange bearing onto the upper shaft so that the locking collar is on the upper steering shaft side as sh...

  • Page 214

    213 www.Factoryfive.Com 508-291-3443 from the engine bay side insert the steering shaft into the footbox and mount the 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. Attach the flange to ...

  • Page 215

    214 www.Factoryfive.Com 508-291-3443 loosely mount the top pillow block to the chassis underside of the chassis mount with the set screw toward the rear of the car using the 60103 spacers, the 5 / 16 ” x 1.25” stainless button head screws, locknuts, 3 / 16 ” hex key and ½” wrench. Do not tighten the...

  • Page 216

    215 www.Factoryfive.Com 508-291-3443 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 down until the upper clip just disappears into the lower shaft. Line up the steering shaft and adapter and push the rack ada...

  • Page 217

    216 www.Factoryfive.Com 508-291-3443 tighten the set screws on both the upper and lower bearings. Clutch cable slide the clutch cable boss through the front of the driver footbox..

  • Page 218

    217 www.Factoryfive.Com 508-291-3443 hook the clutch cable over the quadrant. Attach the clutch cable to the front of the footbox using the small #8 screw provided and ¼” wrench..

  • Page 219

    218 www.Factoryfive.Com 508-291-3443 route the clutch cable down to the bellhousing. Make sure that the cable is clear of the hot exhaust header and the steering shaft or the cable may fail prematurely. Connect the clutch cable to the bellhousing and the clutch fork. Thread the cable end adjuster nu...

  • Page 220

    219 www.Factoryfive.Com 508-291-3443 accelerator cable accelerator cable components, insulated clip hardware the cable design is set up for a 96-04 4.6l mustang engine with an oem pedal but, using the supplied ball studs and retainers it can be adapted for all applications. Cut the barrel fitting of...

  • Page 221

    220 www.Factoryfive.Com 508-291-3443 attach the engine end of the cable sheath to the cable mount on the intake using ⅜” and 7 / 16 ” wrenches and push the cable wiper onto the remaining threads. There is a ball stud and retainer in the accelerator cable components to help attach to the throttle bod...

  • Page 222

    221 www.Factoryfive.Com 508-291-3443 push and twist the ball stud retainer onto the end of the cable and attach the ball stud retainer using a 5 / 64 ” hex key. Attach the engine end of the cable sheath to the cable mount on the engine using ⅜” and 7 / 16 ” wrenches and push the cable wiper onto the...

  • Page 223

    222 www.Factoryfive.Com 508-291-3443 unpack the hardware from the brake line components. The upper left laser cut pieces and the brake line adapter parts in the picture above are for the stock mustang flexible brake lines. The small black screws are for the e-brake boot if building the complete kit,...

  • Page 224

    223 www.Factoryfive.Com 508-291-3443 lay out the various lengths of brake line so you can see what you have to work with. Like the fuel lines, there are many ways to run these lines but you must be very careful to keep them protected from moving parts, heat, or being too close to the bottom of the c...

  • Page 225

    224 www.Factoryfive.Com 508-291-3443 run the brake line down the 1.50” tube to the bottom frame tube then up the front side of the angled rear suspension tube. When you are happy with the routing use the small insulated line clips and 3 / 16 ” rivets to hold the brake line in place..

  • Page 226

    225 www.Factoryfive.Com 508-291-3443 connect the brake line “t” adapter to the end of the brake line. The line will bend very easy but be careful not to kink it. Left flexible brake line the laser cut flexible brake line brackets attach to the rear angled chassis tube on the left front suspension. D...

  • Page 227

    226 www.Factoryfive.Com 508-291-3443 front right from the “t” fitting run a 60” brake line down the 1.50” tube, forward to the front of the frame and over to the right side of the frame. Run along the 1.50” tube behind the lower control arm and up the rear angled 1.50” tube..

  • Page 228

    227 www.Factoryfive.Com 508-291-3443 when you are happy with the routing use the small insulated line clips and 3 / 16 ” rivets to hold the brake line in place. Like the left side, push the flexible brake line through the bracket from the outside in, rivet the bracket in place and screw the flexible...

  • Page 229

    228 www.Factoryfive.Com 508-291-3443 make sure that your flex lines will not interfere with anything in the suspension, wheels during travel or turning full lock to lock. Rear brake line from the right ( 5 / 8 ”) master cylinder run a 60” brake line towards the center of the car then to the rear of ...

  • Page 230

    229 www.Factoryfive.Com 508-291-3443 at the back of the inside footbox, run down the 1” transmission tunnel tubes to the bottom 1.50” tube then to the back of the transmission tunnel. Stock rear brakes at this point your routing will depend on your rear brakes. 87-95 mustang solid axles have a singl...

  • Page 231

    230 www.Factoryfive.Com 508-291-3443 attach the brake line to the mustang mount. When you are happy with the routing use the small insulated line clips and 3 / 16 ” rivets to hold the brake line in place. Irs brakes at the back of the tunnel connect the 3 way female “t” adapter and an 8” brake line ...

  • Page 232

    231 www.Factoryfive.Com 508-291-3443 push the flexible brake line through the bracket from the outside in, screw the flexible line onto the brake line fitting, tighten by hand. Use channel lock pliers to install the clip that holds the flexible brake line in place. Locate, drill and rivet the bracke...

  • Page 233

    232 www.Factoryfive.Com 508-291-3443 at the end of the 20” line use a brake line union and an 8” brake line up the right side of the frame. Like the left side, push the flexible brake line through the bracket from the outside in, screw the flexible line onto the brake line fitting and tighten. Use c...

  • Page 234

    233 www.Factoryfive.Com 508-291-3443 reservoirs, one for each master cylinder. Additional reservoirs can be purchased at www.Factoryfiveparts.Com unpack the master cylinder reservoir fittings and the reservoir kit from the pedal-box assembly. Screw in the hose barb. Loosely screw the mounting bracke...

  • Page 235

    234 www.Factoryfive.Com 508-291-3443 decide where to mount the brake reservoir, it can go behind the engine (depending on the engine being used) or mount to the front of the footbox. Keep the reservoir high enough so that the lid is higher than master cylinder. This picture shows a coyote engine wit...

  • Page 236

    235 www.Factoryfive.Com 508-291-3443 decide the routing of your reservoir to master cylinder hose and drill a ½” hole through the aluminum for the bulkhead fitting. The fitting is slightly larger than ½” so wiggle the ½” bit around to oversize it. Insert the bulkhead fitting and spin the nut on the ...

  • Page 237

    236 www.Factoryfive.Com 508-291-3443 make sure to put the hose clamps on the hose before pushing onto the barb, it is hard to get the hose off the barb after. Route the hose from the reservoir to the bulkhead fitting, push a hose clamp onto the hose then onto the barb. Tighten using a 7mm socket and...

  • Page 238

    237 www.Factoryfive.Com 508-291-3443 from the bulkhead route to the master cylinders splitting it using the y provided. Make sure that the line cannot get in the way of moving parts..

  • Page 239

    238 www.Factoryfive.Com 508-291-3443 fill the system with dot 3 fluid and bleed being very thorough in checking for leaks. Emergency brake e-brake handle 5 / 32 ”, 3 / 16 ” hex keys, 7 / 16 ”, ½” wrenches, channellock pliers, wd-40 e-brake handle assembly, brake line components.

  • Page 240

    239 www.Factoryfive.Com 508-291-3443.

  • Page 241

    240 www.Factoryfive.Com 508-291-3443 unpack the emergency brake handle components. Some parts are not used for the coupe application push a nylon bushing into one side of the fixedgear..

  • Page 242

    241 www.Factoryfive.Com 508-291-3443 push the other bushing into the other side of the fixed gear. From the right side of one of the handle to ratchet mounts, insert the shoulder bolt through the ratchet mount and then the fixed gear..

  • Page 243

    242 www.Factoryfive.Com 508-291-3443 put the other ratchet to handle mount on shoulder bolt from the other side of the fixed gear. Using a 3 / 16 ” hex key and ½” wrench, tighten the shoulder bolt lock nut so that the ratchet to handle mount plates are against the bushings but they can still move up...

  • Page 244

    243 www.Factoryfive.Com 508-291-3443 slide the lower handle between the ratchet to handle mount plates and bolt the three pieces together using the two 5 / 16 ”x 1” button head screws. Put the ratchet tooth on the long anchor bolt as shown in the picture below..

  • Page 245

    244 www.Factoryfive.Com 508-291-3443 rotate the fixed gear out of the way and pass the anchor bolt up through the lower handle. Rotate the ratchet tooth between the handle to ratchet mount plates and align the mount holes..

  • Page 246

    245 www.Factoryfive.Com 508-291-3443 push the included spring pin through the ratchet mount plates and the ratchet tooth using a pair of channel lock pliers. Slide the 1” nylon spacer onto the end of the anchor bolt. There are two nylon spacers included. They provide preload on the spring so there i...

  • Page 247

    246 www.Factoryfive.Com 508-291-3443 spray a little wd-40 on the lower handle threads and screw the upper handle onto the lower handle. Insert the spring into the upper handle over the anchor bolt..

  • Page 248

    247 www.Factoryfive.Com 508-291-3443 screw the button onto the end of the anchor bolt. Screw the male and female rod ends together..

  • Page 249

    248 www.Factoryfive.Com 508-291-3443 use a wrench to spread the ears of the ratchet to handle mounts so that the rod end can just slide between them. Slide the male rod end between the ratchet to handle mount plates and attach it using the ¼” flange head bolt and locknut..

  • Page 250

    249 www.Factoryfive.Com 508-291-3443 attach the handle to the frame using the 5 / 16 ”x 1” button head bolts. Cables if there is a rubber washer on the end with the clip (frame end) of the cable shown, remove the rubber washer..

  • Page 251

    250 www.Factoryfive.Com 508-291-3443 check the fit of the emergency brake cable end in the brake cable clevis..

  • Page 252

    251 www.Factoryfive.Com 508-291-3443 if necessary, use a drill bit and drill or a dremel tool to open up the slot slightly. Push one of the cables through the bracket in the transmission tunnel until the sheath end clicks in place..

  • Page 253

    252 www.Factoryfive.Com 508-291-3443 push the second cable into the frame bracket. Solid axle route the cables back to the calipers and attach. Make sure your routing is out of the way of any moving parts and the cable has slack to move with the axle..

  • Page 254

    253 www.Factoryfive.Com 508-291-3443 on the end of the emergency brake cable sheath with no clip on, pull/push the cable so that 3” of cable sticks out of the sheath. From the bottom, insert the cable through the hole in the brake caliper..

  • Page 255

    254 www.Factoryfive.Com 508-291-3443 push the end of the sheath into the hole. The end of the sheath may or may not bottom on the flange. It is normal for the sheath to look like the picture, the end is being held in place and cannot move. Move the end of the cable around the spring bracket so it wi...

  • Page 256

    255 www.Factoryfive.Com 508-291-3443 push the cable so that the end of the cable sits on the spring bracket. Irs route the cable back behind the shock and towards the middle of the car..

  • Page 257

    256 www.Factoryfive.Com 508-291-3443 route the cable up over the center section and to the bracket in the transmission tunnel. Wilwood irs e-brake adapter.

  • Page 258

    257 www.Factoryfive.Com 508-291-3443 insert the cable end into the bent bracket then bolt the bracket to the e-brake lever. Handle and cable adjustment put the clevis brackets onto the end of the cables..

  • Page 259

    258 www.Factoryfive.Com 508-291-3443 squeeze the ends of the clevis’ with a pair of pliers. Facing the cable slots towards each other, attach one of the cable clevises to each side of the female rod end using the ¼”x 1.50” socket head bolt and locknut. Leave the locknut loose for now. Slowly pull up...

  • Page 260

    259 www.Factoryfive.Com 508-291-3443 release the brake and if necessary remove the ¼” clevis bolt and readjust the rod end so that the cable is tight. Reinstall the clevises and ¼” bolt then tighten the bolt so that the clevis ends are closed, this will prevent the cable ends from coming out..

  • Page 261

    260 www.Factoryfive.Com 508-291-3443 battery mounting and cable drill, 3 / 16 ”, ¼”, 5 / 16 ” drill bits, rivet gun, marker, 7 / 16 ” deep socket, ratchet, ½” wrench, 3 / 16 ” hex key. Secondary body fasteners, battery/tray components, insulated clip hardware, misc. Electrical components, battery, e...

  • Page 262

    261 www.Factoryfive.Com 508-291-3443 mark the corners of the battery on the tray. Drill (4) ¼” holes through the tray and 1” tubes in the front and the 1.50” cross tube so that the holes are outside where the battery will sit..

  • Page 263

    262 www.Factoryfive.Com 508-291-3443 remove the battery tray and on the 1” tube that is on the side of the negative post, remove any coating for the ground cable to connect. Use one or two of the ¼” washers between the battery tray and the frame on the side of the positive post, and the ground cable...

  • Page 264

    263 www.Factoryfive.Com 508-291-3443 use the ¼” x 2.25” bolts through the 1.50” tube and the ¼” x 1.75” bolts through the 1” tubes. Bolt from the bottom up using a 7 / 16 ” wrench, socket and ratchet..

  • Page 265

    264 www.Factoryfive.Com 508-291-3443 place the battery on the tray with the crossbar hold-down. Insert the j bolts through the battery tray and up through the hold-down..

  • Page 266

    265 www.Factoryfive.Com 508-291-3443 bolt the hold-down to the tray using the ¼” washers, locknuts, 7 / 16 ” deep socket and a ratchet. Battery cable attach the positive battery cable to the battery..

  • Page 267

    266 www.Factoryfive.Com 508-291-3443 run the battery cable down the right 1.50” tube to the starter attaching it to the frame using the 5 / 8 ” clamps and 3 / 16 ” rivets. Attach the battery cable to the battery post on the starter. Leave the ground cable off until after the wiring harness is instal...

  • Page 268

    267 www.Factoryfive.Com 508-291-3443 oil filter relocator razor knife, flathead screwdriver oil filter relocating kit, oil, oil filter this is needed for pushrod 302/351 engines running shorty headers and j pipes only. The coyote engine uses different exhaust and a different oil filter. Hook the oil...

  • Page 269

    268 www.Factoryfive.Com 508-291-3443 the finished firewall will sit with the windshield support flange facing toward the front of the car. Run a bead of silicone down the top of the frame tube the firewall sits on top of and lower it into place. The bottom flange faces toward the rear of the car and...

  • Page 270

    269 www.Factoryfive.Com 508-291-3443 drill and rivet the firewall to the frame so that the firewall is flush with the front of the tube. (upper flange not shown) trans tunnel top front position the trans tunnel top front aluminum panel, it can be used to pass wires through. Once the wiring is done, ...

  • Page 271

    270 www.Factoryfive.Com 508-291-3443 wiring harness complete kit chassis wiring harness the chassis wiring harness controls everything for the car except the engine. Route the front and rear harness through the transmission tunnel top front panel..

  • Page 272

    271 www.Factoryfive.Com 508-291-3443 attach the ground cable to the battery. Led flashers misc. Electrical components locate the electronic flashers in the kit pack. These must be used instead of the standard flashers because of the led rear lights. The flashers are located on the fuse block for the...

  • Page 273

    272 www.Factoryfive.Com 508-291-3443 make sure to ground the flashers. 1987-1993 mustang donor harness ⅜” socket, regular head screwdriver, slip joint pliers, ⅛”, 3 / 16 ” drill bits, drill, #8 nut driver, electrical tape, wire cutters. Misc. Electrical components, wiring harness mounting hardware, ...

  • Page 274

    273 www.Factoryfive.Com 508-291-3443 this is the harness layout using the stock mustang wiring harness only, not the optional chassis harness..

  • Page 275

    274 www.Factoryfive.Com 508-291-3443 rear harness run rear harness from the driver foot box inside wall, along inside the transmission tunnel straight back to the rear of the frame. Use zip ties, insulated line clips, and the wire loom to hold the wires and battery cable. At the rear of the frame, r...

  • Page 276

    275 www.Factoryfive.Com 508-291-3443 transmission harness run the harness up into the top of the foot box to its connector. Make sure that it does not get in the way of the steering shaft or accelerator pedal. Use the drilled holes and the zip tie trick to keep the harness in the corner along the fl...

  • Page 277

    276 www.Factoryfive.Com 508-291-3443 by removing the tape from the harness under the radiator, overlapping the wires, re-taping and using the loom material provided, a cleaner looking harness can be made. Attach the harness to the channel on the bottom of the radiator using zip ties. Dash harness da...

  • Page 278

    277 www.Factoryfive.Com 508-291-3443 old starter new starter when the wire harness is installed, mount the fuse panel to the 1.50” square tube going across the car in the left footbox. Leave the headlight and hazard switches hanging for now. Attach the harness across the 1.50” square tube, using the...

  • Page 279

    278 www.Factoryfive.Com 508-291-3443 engine harness ⅜” socket, regular head screwdriver, slip joint pliers, 3 / 16 ” and ⅛” drill bits, drill, #6 nut driver, electrical tape, wire cutters. Mustang engine harness, engine harness assembly if you are running a carbureted engine you do not need this sec...

  • Page 280

    279 www.Factoryfive.Com 508-291-3443 alternatively, the computer can be mounted to the inside of the right footbox. Use the drilled holes and cable tie trick to hold the extra harness to the top of the passenger foot box. The harness splits into two on top of the foot box. The short, smaller harness...

  • Page 281

    280 www.Factoryfive.Com 508-291-3443 computer ground near driver’s foot box ignition and turn signal stalk hack saw, 5 / 16 ” socket, 9 / 64 ” drill bits, drill. Misc. Electrical components, mustang ignition switch and turn signal stalk. The turn signal stalk can be cut shorter so that when it’s mou...

  • Page 282

    281 www.Factoryfive.Com 508-291-3443 cut the mustang plug in half using a pair of wire cutters or remove the female connectors from the housing and connect to the correct terminals on the switch. Speedometer sending unit 11mm deep socket, ratchet, wire crimping tool speedometer sending unit componen...

  • Page 283

    282 www.Factoryfive.Com 508-291-3443 install the gear on the end of the sender and hold it in place with the clip. Put a little oil on the o-ring and install the sender in your transmission. Use the original bolt to hold the sending unit in place..

  • Page 284

    283 www.Factoryfive.Com 508-291-3443 connect the plug and plug it into the sender. If you are running fuel injection you may also need to send this signal to the computer as well depending on your system. Horns 14mm wrench, wire cutters, wire crimpers, 5 / 32 ” hex key, drill, 3 / 16 ” drill bit, 3 ...

  • Page 285

    284 www.Factoryfive.Com 508-291-3443 attach one horn to the included bracket using one of the 14mm lock washers and nuts included. Note the orientation of the wire connectors when tightening the bracket so that it will be correct when installed. The flat horn outlet is pointed right. Mounting bracke...

  • Page 286

    285 www.Factoryfive.Com 508-291-3443 holding the horns the connectors should be spaced so that the wires will not hit each other. Locate the chassis harness horn wires on the front chassis harness. Cut 2” off the end of the chassis harness horn ground wire and strip the end of the chassis harness gr...

  • Page 287

    286 www.Factoryfive.Com 508-291-3443 twist the chassis harness ground wire and small wire ground together and insert them into one of the ¼” female connectors included then crimp the connector on. Cut the same 2”off the green horn power wire and strip the ends of both wires..

  • Page 288

    287 www.Factoryfive.Com 508-291-3443 twist the chassis harness green wire and small wire ground together and insert them into one of the ¼” female connectors included with the horns then crimp the connector on. Attach the chassis harness horn wires to one horn and push the jumper wires on to the oth...

  • Page 289

    288 www.Factoryfive.Com 508-291-3443 locate the horns on the frame so that the wires are not too tight. This picture show the 1.50” tube coming down from the footbox and drill a 3 / 16 ” mounting hole. Attach the two horns to the frame using a supplied #14 screw. Then drill a second 3 / 16 ” hole so...

  • Page 290

    289 www.Factoryfive.Com 508-291-3443 attach the second #14 screw. Fan wiring wire crimp tool fan mounting components, dash electrical components there are a few ways to run the electric fan. The kit includes a relay, wiring, and a thermostat switch to get used with the relay to turn the fan on and o...

  • Page 291

    290 www.Factoryfive.Com 508-291-3443 locate a coolant access point in your engine block or cylinder head to install the thermostat switch and thread it in. Ground the black electric fan wire to the frame. Connect the other electric fan wire to the #87 tab on the fan relay. Attach the #85 ground tab ...

  • Page 292

    291 www.Factoryfive.Com 508-291-3443 driveshaft 14mm wrench, thread lock driveshaft base kit - if not already done, the driveshaft should be shortened to the length specified in the appendix for the engine/transmission combination being used. Unpack the driveshaft and slip it up into the rear of the...

  • Page 293

    292 www.Factoryfive.Com 508-291-3443 solid axle the driveshaft bolts are in the box with the driveshaft and should have thread locker on them already. If thread lock is not there, put a small bead on each bolt. Fit the driveshaft snug against the yoke and install the bolts and tighten. You can put t...

  • Page 294

    293 www.Factoryfive.Com 508-291-3443 2015 irs bolt the rear flange to the driveshaft adapter and torque the bolts to 109nm (80 ft-lb). Cooling system marker, hack saw, insulated clip hardware, drill, ¼” drill bit, 3 / 16 ” hex key, 7 / 16 ”, ½” wrenches, ruler, flathead screwdriver, razor knife. Fan...

  • Page 295

    294 www.Factoryfive.Com 508-291-3443 aluminum duct silicone, drill and rivet the radiator duct back to the frame. Silicone, drill and rivet the radiator duct sides to the duct back and the nose hinge support tubes..

  • Page 296

    295 www.Factoryfive.Com 508-291-3443 fan mounting unpack the fan and push the four mounting brackets into the angled tab mounts. Center the fan on the radiator and mark the brackets to trim off the excess..

  • Page 297

    296 www.Factoryfive.Com 508-291-3443 remove and trim the brackets then bolt the assembly together using the hardware provided. Make sure and tighten the hardware that came pre-installed on the mounts. Radiator mounting use a razor knife and slit the 8.5” long sections of fuel line lengthwise. Push t...

  • Page 298

    297 www.Factoryfive.Com 508-291-3443 slide the cut rubber tubing over the radiator mount and install the radiator from above the frame. Attach some half-moon stick on weather stripping to the underside of the radiator top mount bracket. Position the top mount bracket so that the small tab sticking u...

  • Page 299

    298 www.Factoryfive.Com 508-291-3443 pass the mounting tabs through the holes in the side aluminum pieces. Drill the holes to mount the radiator top mount bracket to the two 1” nose tubes on the chassis. Attach the radiator top mount bracket to the frame using the 5 / 16 ” x 1.5” button head screws,...

  • Page 300

    299 www.Factoryfive.Com 508-291-3443 unpack the stainless radiator hose kit and remove the hose connectors from the boxes..

  • Page 301

    300 www.Factoryfive.Com 508-291-3443 use the smaller sections of tube inside the adapters to fit them to smaller fittings on the radiator and intake. Then fit the larger adapters over them..

  • Page 302

    301 www.Factoryfive.Com 508-291-3443 upper radiator hose starting at the engine, attach the inline filler to the engine exit. Attach stainless tube to the inline filler then route the tube under the angled frame tube and through the aluminum radiator duct hole to the upper radiator hose location. Ma...

  • Page 303

    302 www.Factoryfive.Com 508-291-3443 lower radiator hose connect the lower radiator hose to the radiator. Run the tube under the lower control arm mount and attach the stainless hose to the end using an adapter then to the engine..

  • Page 304

    303 www.Factoryfive.Com 508-291-3443 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 the cooling system. Overflow tank unpack the overflow assembly. Bolt the mounting tabs loosely onto the tank so they can be slid a...

  • Page 305

    304 www.Factoryfive.Com 508-291-3443 pick the mounting location for the tank and mark the holes. Make sure the tank is accessible and visible inside to check the level on the finished car then bolt it in place. Mount the overflow tank to the frame/aluminum. Attach the larger radiator hose to the inl...

  • Page 306

    305 www.Factoryfive.Com 508-291-3443 use the adapter and attach the smaller hose and route the overflow hose to the overflow tank. Make sure you attach the hose to the tube that runs off the bottom of the tank and not the one that extends up into the tank..

  • Page 307

    306 www.Factoryfive.Com 508-291-3443 aluminum panels drill, 1 / 8 ” drill bit, silicone, caulking gun, rivet gun roadster secondary body fasteners components, packaged aluminum, mounted aluminum trans tunnel sides aluminum drill and rivet the cockpit transmission side aluminum panels in place..

  • Page 308

    307 www.Factoryfive.Com 508-291-3443 transmission tunnel cover silicone and install the transmission tunnel top. Cockpit rear inside aluminum ¼” nut driver, drill, 1 / 8 ” drill bit, rivet tool. Secondary body fasteners, kit aluminum..

  • Page 309

    308 www.Factoryfive.Com 508-291-3443 silicone, drill and rivet the inside cockpit corner aluminum panels to the frame. Silicone, drill and rivet the driveshaft cover aluminum panel to the frame..

  • Page 310

    309 www.Factoryfive.Com 508-291-3443 left outside footbox aluminum ¼” nut driver, drill, 1 / 8 ” drill bit, rivet tool. Secondary body fasteners, kit aluminum. Make sure all of the clutch/brake switches and any other pedal adjustments are done before install. Silicone, drill and rivet the left footb...

  • Page 311

    310 www.Factoryfive.Com 508-291-3443 left door hinge inside covers silicone, drill and rivet the left door hinge inside cover to the frame. Hatch floor 1 / 8 ” drill bit, silicone, rivet gun, caulk gun. Mounted aluminum, packaged aluminum, secondary body fasteners.

  • Page 312

    311 www.Factoryfive.Com 508-291-3443 start with the hatch floor front panel. Silicone and rivet in place. To install, put the right side in as far as possible. “s” the panel so that the middle right side can clear the rollbar..

  • Page 313

    312 www.Factoryfive.Com 508-291-3443 bow the left side to get the left side to clear the rollbar. Final panel installed..

  • Page 314

    313 www.Factoryfive.Com 508-291-3443 insert, silicone and rivet the rear panel in place. Under door aluminum 1 / 8 ” drill bit, silicone, rivet gun, caulk gun. Packaged aluminum, secondary body fasteners.

  • Page 315

    314 www.Factoryfive.Com 508-291-3443 silicone drill and rivet in the under door aluminum panels. Exhaust headers and j-pipes 7 / 16 ”, 9 / 16 ” wrenches, 7 / 16 ” socket, ratchet, extension, 5 / 16 ” hex key.

  • Page 316

    315 www.Factoryfive.Com 508-291-3443 headers or straight tubes and shorty headers. Mount the headers to the engine. If you are using full length headers they bolt in place with the gaskets and hardware provided. Thread locker is recommended..

  • Page 317

    316 www.Factoryfive.Com 508-291-3443 if you are using shorty headers or stock manifolds bolt them back on. On a small block (302 or 351) the headers are switched side to side and on the coyote the headers also face forward if you are using the j-pipes bolt them to the headers. The shorter pipe will ...

  • Page 318

    317 www.Factoryfive.Com 508-291-3443 side exhaust 3 / 16 ”, 5 / 16 ” hex key, ⅜”, ½”, 9 / 16 ” socket, ratchet, 9 / 16 ” wrench, drill, 3 / 16 ”, 5 / 16 ” drill bits side exhaust bolt the mounting bracket to the pipe on the forward side of the bracket. Bolt the pipe and gasket to the header or j-pip...

  • Page 319

    318 www.Factoryfive.Com 508-291-3443 position the lap harnesses make sure to have the red release handle on the right side of the seat. Bolt the lap harnesses to the frame. Inside mount (left), outside mount (right)..

  • Page 320

    319 www.Factoryfive.Com 508-291-3443 remove the mounting tab from the harness. Loop the harness over the roll bar crossbar..

  • Page 321

    320 www.Factoryfive.Com 508-291-3443 the shoulder harnesses are side specific so make sure you have the sides correct. Follow the manufacturer’s directions inside the seat harness boxes on how to loop the harness straps through the slider bracket. Adjust the harnesses to where they fit you comfortab...

  • Page 322

    321 www.Factoryfive.Com 508-291-3443 seats 5 / 16 ” drill bit, drill, 3 / 16 ” hex key, ½” deep socket, marker seat mount hardware, seats unpack the seats and set them in the cockpit. Sit in the seats and locate them in the position you are most comfortable. This is a critical fitment so take your t...

  • Page 323

    322 www.Factoryfive.Com 508-291-3443 drill the remaining holes for mounting the seats and install the bolts. Nameplate 1 / 8 ” drill bit, rivet gun, drill secondary body fasteners, certificate of origin envelope factory five racing has included a certificate of origin along with a nameplate for your...

  • Page 324

    323 www.Factoryfive.Com 508-291-3443 gauges and dash tin snips, pliers, drill, 7 / 64 ”, 1/ 8 ” drill bit, silicone, caulking gun, rivet gun, wire crimper, wire stripper, philips screwdriver. Gauge set, dash electrical components, cut dash, packaged aluminum, dash electrical components, electrical s...

  • Page 325

    324 www.Factoryfive.Com 508-291-3443 wire the gauges according to the instructions provided with them and with the dash section of the chassis harness if using the ffr chassis harness. Install your switches in the dash. The horn button can be located where desired. The factory five coupe gps gauges ...

  • Page 326

    325 www.Factoryfive.Com 508-291-3443 push bulb weatherstrip on the front edge of the dash. Attach the dash onto the chassis by drill four 4 7 / 64 ” holes, two of them through the top gauge panel holes and using the black #6 screws and a philips screwdriver. Attach the gauge visor to the dash using ...

  • Page 327

    326 www.Factoryfive.Com 508-291-3443 locate the dash side panels. Right side shown. Attach the side panels to the ends of the dash and the frame using 1 / 8 ” rivets..

  • Page 328

    327 www.Factoryfive.Com 508-291-3443 steering wheel philips head screw driver, 10mm wrench, 5 / 16 ” hex key steering wheel/hardware unpack the steering wheel hardware..

  • Page 329

    328 www.Factoryfive.Com 508-291-3443 bolt the steering wheel to the boss. The pattern is not symmetrical so it will only line up in one direction. Bolt the steering wheel assembly to the steering shaft. Use thread-locker on this bolt..

  • Page 330

    329 www.Factoryfive.Com 508-291-3443 rolling chassis check front suspension double check all your hardware, make sure your wiring and hoses are away from extreme heat and moving parts, make sure the steering turns freely lock to lock, and make sure your brake flex lines have enough slack for the ful...

  • Page 331

    330 www.Factoryfive.Com 508-291-3443 have a friend sit in the car and step on the brakes. Torque the rear axle nuts to 175 ft-lbs. Wheels install and torque your wheels. Make sure they rotate freely and do not interfere with the brake calipers, lines, or any suspension components. Fluid levels and g...

  • Page 332

    331 www.Factoryfive.Com 508-291-3443 transmission fluid, rear axle gear oil, engine oil, coolant, water 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 axle...

  • Page 333

    332 www.Factoryfive.Com 508-291-3443 engine fill the engine with oil and coolant. Both these fluids should be rechecked after you have started the engine for the first time. Make sure there is some coolant in the overflow to start out, about 1 / 3 full is good..

  • Page 334

    333 www.Factoryfive.Com 508-291-3443 grease fittings all of the suspension and steering components that have grease fitting need to be greased. With a grease gun squeeze grease into each fitting on all the control arms, including rear lowers on a slid axle, and tie rods. Rattle patrol review the rac...

  • Page 335

    334 www.Factoryfive.Com 508-291-3443 brakes – plenty of fluid – pedal not bottoming- all fittings tight to reservoir dash – all gauges working - gauge lights work – indicators and switches working brake bias – if you have space adjust your brakes bias with the balance bar (the set up and adjustment ...

  • Page 336: Body Section

    335 www.Factoryfive.Com 508-291-3443 body section chapter 4.

  • Page 337

    336 www.Factoryfive.Com 508-291-3443 the body and panel mounting are a critical part of how your car will end up looking when it is finished. Whether you are having a body shop paint your car or doing it yourself, the best results will be from fully mounting the body, all the panels and getting them...

  • Page 338

    337 www.Factoryfive.Com 508-291-3443 push weather strip goes across the top of the firewall on either side of the windshield support flange. Push weatherstrip around the radiator aluminum..

  • Page 339

    338 www.Factoryfive.Com 508-291-3443 rear body mount rear body mount components (mounted) ½” socket, ratchet attach the rear body mounts to the frame using the 5 / 16 ” x ¾” carriage bolts, washers and locknuts using a ½” socket. Center them in the slots. Body mounting gloves body the body will be t...

  • Page 340

    339 www.Factoryfive.Com 508-291-3443 using three people, one on each side holding the door and side exhaust recess and one in the rear, move towards the frame from the rear with the back slightly lower than the front. Pull the sides of the body out to clear the frame. Watching the rear of the frame,...

  • Page 341

    340 www.Factoryfive.Com 508-291-3443 watch the door hinge mounts. Move forward until the rear hatch tubing is lined up with the lip on the body and put the body down in place. Locating ruler, long level, marker, floor jack, tape measure once the body is sitting down on the frame inside the door area...

  • Page 342

    341 www.Factoryfive.Com 508-291-3443 put a long level in the back of the hatch opening. Use masking tape to hold the level at the 7” marks..

  • Page 343

    342 www.Factoryfive.Com 508-291-3443 from the side of the hatch area, measure over 18” and mark the level. This should be the center of the opening. At the center point marked on the level, use a floor jack to raise or lower the body so that the bottom of the level is 10.25” up from the frame..

  • Page 344

    343 www.Factoryfive.Com 508-291-3443 in the rear wheel well area, measure horizontally from the frame shock mount over to the edge of the wheel well. This should be the same on both sides of the car. Rear body mount drill, 5 / 16 ” drill bit, ½” socket, ratchet, 5 / 32 ” hex key, friend.

  • Page 345

    344 www.Factoryfive.Com 508-291-3443 drill 5 / 16 ” holes through the middle of the rear body mounting bracket slot and into the recessed rear part of the body. Bolt the body to the bracket with the 5 / 16 ” x 1” button head stainless screws, washers, and locknuts using a ½” socket, 5 / 32 ” hex key...

  • Page 346

    345 www.Factoryfive.Com 508-291-3443 use a couple of the aluminum attachment screws through the bottom of the door opening into the tube..

  • Page 347

    346 www.Factoryfive.Com 508-291-3443 side body cuts drill 5 / 16 ” holes at the top side locations where the lower 1.50” frame tubes will hit the side of the body and cut the body for clearance..

  • Page 348

    347 www.Factoryfive.Com 508-291-3443 nose hinge 15 / 16 ” socket, 15 / 16 ” wrench. Nose fasteners screw the jam nut half way onto the rod end..

  • Page 349

    348 www.Factoryfive.Com 508-291-3443 put the end of the rod end up through the nose mount at the front of the frame loosely putting another jam nut ono the end of the rod end. Pass one of the 5 / 8 ” bolts through one side of the nose hinge bracket and place one of the 5 / 8 ” washers on the bolt..

  • Page 350

    349 www.Factoryfive.Com 508-291-3443 place one of the 3 / 8 ” spacers on the bolt. Hold the hinge bracket up to the rod end on the frame and pass the bolt through the rod end, another 3 / 8 ” spacer, 5 / 8 ” washer, the other side of the bracket and loosely put a locknut on the bolt..

  • Page 351

    350 www.Factoryfive.Com 508-291-3443 nose fitment 3 / 16 ” hex key, ½” socket, ratchet, tape measure, duct tape, paint sticks. Nose fasteners. With the latches unlatched, position the nose on the frame so that the nose mounts are seated on the body and the back side of the fog light holes. Use jack ...

  • Page 352

    351 www.Factoryfive.Com 508-291-3443 drill 5 / 16 ” holes in the marks made and attach the hinge brackets to the nose using 5 / 16 ” button head screws, locknuts, 3 / 16 ” hex key and ½” socket. Put the small bumpers around the edge of the nose opening and try closing the nose so that the nose heigh...

  • Page 353

    352 www.Factoryfive.Com 508-291-3443 use 1 / 8 ” long rivets to attach 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 panel in place, run a marker around ...

  • Page 354

    353 www.Factoryfive.Com 508-291-3443 measure back along the top outer tube behind the top shock mount 8.50” and mark the top of the tube. Hold the 90 degree strut mounting bracket on the top tube so the center hole is aligned with the mark made, the ball stud is pointed towards the outside of the ca...

  • Page 355

    354 www.Factoryfive.Com 508-291-3443 remove the bracket and drill the mounting hole with a 3 / 16 ” drill bit. Remove the tape and insert a rivet through the center bracket hole and frame hole then drill the rear mounting hole using the bracket as a guide..

  • Page 356

    355 www.Factoryfive.Com 508-291-3443 insert another rivet in the second hole then use a rivet tool to pull the rivets. Drill and rivet the last mounting hole..

  • Page 357

    356 www.Factoryfive.Com 508-291-3443 on the nose measure up from the center pivot of the nose hinge 16.50” and mark the nose liner flange. Hold the flat strut mounting bracket up to the outside of the flange on the nose. The point marked is center mounting hole again. Mark and the center mounting ho...

  • Page 358

    357 www.Factoryfive.Com 508-291-3443 insert one of the black button head mounting screws through the bracket and flange. Drill one of the other mounting holes then insert and tighten two of the button head screws using an 1 / 8 ” hex key, 3 / 8 ” socket and ratchet. Drill and attach the remaining sc...

  • Page 359

    358 www.Factoryfive.Com 508-291-3443 attach the rod end of the gas strut to the frame..

  • Page 360

    359 www.Factoryfive.Com 508-291-3443 nose side locator brackets drill, ⅛”, ⅜” drill bit, 1.25” hole saw, rivet gun, silicone, 5/16” hex key, 9/16” wrench. Nose locator bracket assembly, secondary body fastener assembly hold the outside of the nose behind the wheel opening so that it is flush with th...

  • Page 361

    360 www.Factoryfive.Com 508-291-3443 put the hatch hinge arms onto the button studs so that they point forward and the arms are on the inside..

  • Page 362

    361 www.Factoryfive.Com 508-291-3443.

  • Page 363

    362 www.Factoryfive.Com 508-291-3443 press a bushing into the hinge arms so that the bushings are on opposite sides..

  • Page 364

    363 www.Factoryfive.Com 508-291-3443 push a bushing into the rollbar clamp from the outside of the clamp, left side shown. Hand tighten the jam nuts on the bottom of the studs. Repeat for the other side..

  • Page 365

    364 www.Factoryfive.Com 508-291-3443 push the small 0.813” rubber washers on the small button studs. Push the small button studs through the holes on the sides of the glass. Push the medium 0.922” rubber washers onto the small button studs on the inside of the glass. Put a washer on the small button...

  • Page 366

    365 www.Factoryfive.Com 508-291-3443 carefully thread on and tighten a jam nut on the bottom of the small button stud. Thread on and tighten a ball stud on the small button stud. Repeat for the other side. Attach the hinge arm to the rollbar mount using the short shoulder bolts, wave washer, regular...

  • Page 367

    366 www.Factoryfive.Com 508-291-3443 at the area marked, measure 1” in each direction and draw a box leaving about ¼ in. Of the flange at the top. Cut along the line to give your opening. The trim looks best with a small radius at both the upper and lower corners as has been done on the right hand s...

  • Page 368

    367 www.Factoryfive.Com 508-291-3443 carefully place the hatch with the hinge arms onto the body and center in the opening. Loosely attach the hatch rollbar mount (plate welded to the outside) to the rollbar, rotate the mount so that the pivot point is as close to the roof as possible and slide the ...

  • Page 369

    368 www.Factoryfive.Com 508-291-3443 tighten the rollbar mount. Remove the hatch. Use a ½” drill bit to drill a hole at the point marked. Hatch struts the hatch will not sit correctly until the weatherstrip has been installed after painting the body..

  • Page 370

    369 www.Factoryfive.Com 508-291-3443 screw the ball stud into the tube collar using some locktite to prevent loosening. Attach the tube collar to the rollcage rear leg on the frame so the ball stud is 7” from the back of the rollbar as shown and push on the shaft end of the gas strut..

  • Page 371

    370 www.Factoryfive.Com 508-291-3443 attach the body side of the strut to the hatch ball stud. Hatch latch ⅜” socket, ratchet, flat head screwdriver, philips head screwdriver, 3 / 32 ” drill bit, drill rear glass hatch assembly.

  • Page 372

    371 www.Factoryfive.Com 508-291-3443 the hatch will not sit correctly until the weatherstrip has been installed after painting the body. Find the hatch latch and its striker plate insert the hatch latch into the hole..

  • Page 373

    372 www.Factoryfive.Com 508-291-3443 screw the plastic nut onto the latch and orient the latch so that the striker points towards the back of the car then use a set of slip joint pliers to tighten the nut. With the hatch raised, put tape on the back body flange inside the hatch area in the center wh...

  • Page 374

    373 www.Factoryfive.Com 508-291-3443 measure down from the body 1 3 / 16 ” and mark the location on the tape where the hatch latch is located. Hold the latch catch bracket against the flange so that the top of the bracket is aligned with the mark made then mark the mounting hole locations. Drill 3 /...

  • Page 375

    374 www.Factoryfive.Com 508-291-3443 use the aluminum 1 / 8 ” spacer and the black #6 x ½” philips head screws to hold the bracket inn place. An alternative would be to use the #10 x 5 / 8 ” black button head screws provided and rivnuts. Test the latch on the catch. Adjust the height of the catch if...

  • Page 376

    375 www.Factoryfive.Com 508-291-3443 rear spoiler sandpaper, ⅛” drill bit, drill, marker. Coupe rear spoiler. On the original car, this was a riveted on part but some customers have had their body shops fiberglass the spoiler into the body. Hold the rear spoiler up to the body. Sand or cut the flang...

  • Page 377

    376 www.Factoryfive.Com 508-291-3443 body cut-outs fuel filler drill, ⅛”, 7 / 32 ” drill bit, 3½” hole saw or air saw or jig saw, masking tape, scissors. Fuel filler template, aston lemans cap components..

  • Page 378

    377 www.Factoryfive.Com 508-291-3443 locate the template in the appendix and only cut out around the outside diameter of the circle. Tape the circle in the gas cap recess of the body. Use a ⅛” drill bit for all except one of the outer screw holes. Use a 7 / 32 ” bit drill for the last small hole. Us...

  • Page 379

    378 www.Factoryfive.Com 508-291-3443 tail light drill, 7 / 32 ” drill bit, 1” hole saw, file, scissors, masking tape, ruler. Tail light template, red rear light cut the rear mesh area out and tape the tail light template on the back of the body aligning the rear mesh area on the template and body. M...

  • Page 380

    379 www.Factoryfive.Com 508-291-3443 use a 7 / 32 ” bit to drill the outer holes for the taillight studs then cut out the center using a 1” hole saw. Test fit the tail light mounting plate and drill out the holes to fit if needed..

  • Page 381

    380 www.Factoryfive.Com 508-291-3443 license plate bracket drill, 3 / 16 ” drill bit, rivet tool, masking tape, marker, measuring tape. License plate bracket, secondary body fasteners. This kit is only a collection of parts designed for use primarily as a race car. Applying the license plate bracket...

  • Page 382

    381 www.Factoryfive.Com 508-291-3443 put a 3 / 16 ” rivet through the bracket and into the hole drilled then level the bracket and drill through the other mounting hole in the bracket into the body. License plate light drill, 1 7 / 8 ” hole saw, 11 / 64 ” drill bit, masking tape, marker license plat...

  • Page 383

    382 www.Factoryfive.Com 508-291-3443 put masking tape above the license plate bracket and mark 2” above and centered on the bracket. If possible use a 1 7 / 8 ” hole saw or if not available a 1¾” holes saw to drill the light location. Test fit the light so that it will sit flat on the body. If it wi...

  • Page 384

    383 www.Factoryfive.Com 508-291-3443 drill the screw holes in the light out using an 11 / 64 ” drill bit. Hold the light up to the body and use the light as a template to drill the 3 / 16 ” mounting holes..

  • Page 385

    384 www.Factoryfive.Com 508-291-3443 turn signal drill, ¾” hole saw, marker. Front turn signal light from the headlight mounting surface measure out and mark the bucket at 4” and 7” so that the turn signals will be lined up with the center of the headlight..

  • Page 386

    385 www.Factoryfive.Com 508-291-3443 drill the mounting holes with a ¾” hole saw. Headlights drill, 1 / 8 ”, ¼”, 7 / 16 ” drill bit, razor knife, masking tape, air saw or jig saw, level. Headlight template, headlight components,.

  • Page 387

    386 www.Factoryfive.Com 508-291-3443 cut out the headlight templates from the back of the manual on the outermost diameter and tape them in the center of the fender with the line level with the ground. Cut the center of the template out and trace the inner circle with a marker..

  • Page 388

    387 www.Factoryfive.Com 508-291-3443 drill the two smaller corner holes with a ¼” drill bit to mark their location. Follow this with a 7 / 16 ” drill bit. Using a jig saw, cut the inner hole out of the body, use a larger drill bit to make a hole to start your cut..

  • Page 389

    388 www.Factoryfive.Com 508-291-3443 put the rubber gasket on the light bucket. Push the rubber grommet into the bucket..

  • Page 390

    389 www.Factoryfive.Com 508-291-3443 test fit the light bucket making sure that they sit flat. Drill the four mounting screw holes with the bucket as a template using a 1 / 8 ” drill bit..

  • Page 391

    390 www.Factoryfive.Com 508-291-3443 side mesh/nose latch drill, ½” drill bit, jig saw or air saw, marker. Packaged aluminum hold the template up to the nose so that the bottom of the template is even with the bottom of the nose and the hood latch area is aligned with the finger recess..

  • Page 392

    391 www.Factoryfive.Com 508-291-3443 mark the template on the body. Use a jigsaw or hacksaw to cut the holes leaving the finger recess for the latch as shown..

  • Page 393

    392 www.Factoryfive.Com 508-291-3443 nose latch 7 / 32 ” drill bit, drill, ⅛” hex key, 5 / 16 ”, 9 / 16 ” wrench, 9 / 16 ” deep socket, chassis grease, rivet gun, masking tape, vise. Nose/trunk fastener assembly open the latches and apply a little bit of chassis grease to the sides of the latch. Wor...

  • Page 394

    393 www.Factoryfive.Com 508-291-3443 attach the latch mount plate to the front side of the latch as shown. Position the latch from the backside of the body; make sure the latch looks straight in the cutout from the outside then mark the back side of the body through the mounting holes. Drill 7 / 32 ...

  • Page 395

    394 www.Factoryfive.Com 508-291-3443 mount the latches to the nose. Use the washers on the backside of the body. Attach the “u” bolts to the nose latch striker mounts on the frame. Do not tighten them yet..

  • Page 396

    395 www.Factoryfive.Com 508-291-3443 radiator exit opening air saw or jig saw. Use a jigsaw to make sure the opening is straight and even. Side exhaust air saw or jig saw..

  • Page 397

    396 www.Factoryfive.Com 508-291-3443 the pattern for the side exhaust cut out is pre traced on the body. Use an air saw or jig saw to cut the area out. Hold up the side exhaust to make sure there is clearance especially the lower front corner. Locate the side exhaust rear mount parts..

  • Page 398

    397 www.Factoryfive.Com 508-291-3443 the mount will attach about half way back under the cockpit area. The body should be slotted for the hanger. Attach the long leg of the exhaust hanger to the back side of the side exhaust mount using a 5 / 16 ” x 1” button head screw. Attach the rubber mounts to ...

  • Page 399

    398 www.Factoryfive.Com 508-291-3443 attach the rubber hangers to the frame mount using the 5 / 16 ” locknuts. The body will have to be cut for the mounts to attach to the frame. Door hinge 9 / 16 ” socket, ratchet, 3 / 16 ” long drill bit, drill, air saw or jig saw, masking tape, ruler, measuring t...

  • Page 400

    399 www.Factoryfive.Com 508-291-3443 attach the door hinge mounts to the front of the frame mounts and center them up and down in the slots using the 3 / 8 ” carriage bolts, locknuts and 9 / 16 ” socket. On the door side, put masking tape over the whole hinge area..

  • Page 401

    400 www.Factoryfive.Com 508-291-3443 use a ruler to draw a line 0.25” in from the inner door recess. Use a long 3 / 16 ” drill bit directly above the door hinge and drill through the body..

  • Page 402

    401 www.Factoryfive.Com 508-291-3443 use a long 3 / 16 ” drill bit directly below the door hinge and drill through the body. Repeat this for the bottom hinge arm. On the inside of the door hinge area, draw a line 1.75” in from the edge of the body..

  • Page 403

    402 www.Factoryfive.Com 508-291-3443 use a tape measure to measure up from the lower door opening to the drill holes made and note the dimensions. On the inside of the door opening, mark these same heights..

  • Page 404

    403 www.Factoryfive.Com 508-291-3443 draw lines across connecting the drilled holes and inner marks made. Mark the area between the lines that will need to get cut for the hinge arms..

  • Page 405

    404 www.Factoryfive.Com 508-291-3443 cut the areas out using an air saw or jig saw. Door hinge door latch/hinge components.

  • Page 406

    405 www.Factoryfive.Com 508-291-3443 push the door hinge bushings into the door hinge arms. Left side door hinge..

  • Page 407

    406 www.Factoryfive.Com 508-291-3443 pass the hinge arms through the door hinge openings in the body and to the frame mounts. Attach the hinge arm assembly to the adjuster plate using the 2” shoulder bolts, washers and 5 / 16 ” nuts. It makes installing the shoulder bolts a bit easier if you grind a...

  • Page 408

    407 www.Factoryfive.Com 508-291-3443 tighten the nuts down until the arm is hard to move and then loosen slightly. If you tighten the nut down and you can still rotate the hinge easily then the washer is caught on the shoulder. Loosen slightly, adjust the washer and retighten. Door frame prep 3 / 8 ...

  • Page 409

    408 www.Factoryfive.Com 508-291-3443 latch locate the left door frame. Attach the door latch to the door frame using the ¼” flange bolts, washers, latch and 3 / 8 ” socket..

  • Page 410

    409 www.Factoryfive.Com 508-291-3443 attach the clevis to the release lever using the ¼” x ¾” screws, locknuts, philips head screwdriver and 7 / 16 ” wrench. Locate the cable mount tabs, ¼” jam nuts and release cable. Attach the cable mount to the cable in the center of the adjustment range by hand ...

  • Page 411

    410 www.Factoryfive.Com 508-291-3443 attach the other end of the release cable to the handle as shown. Insert the ball end into the clevis on the latch..

  • Page 412

    411 www.Factoryfive.Com 508-291-3443 locate the cable mount tab on the underside of the top tube so that the cable is tight but not pulling on the release lever and the mount tab does not stick out past the side of the frame that will touch the door liner (flat side). Mark the mounting holes. Drill ...

  • Page 413

    412 www.Factoryfive.Com 508-291-3443 attach the mounting tab using long 3 / 16 ” rivets and a rivet tool. Adjust the play in the cable then use some blue loctite and tighten the jam nuts using (2) 9 / 16 ” wrenches. Repeat this assembly for the right door latch..

  • Page 414

    413 www.Factoryfive.Com 508-291-3443 attach the doors to the hinge arms using ⅜” lock nuts, washers and 9 / 16 ” socket. Leave the locknuts loose enough so that the door frame can still slide. Doors drill, ⅛”, 5 / 16 ” drill bits, 1¼” hole saw, loctite, marker, air saw or jig saw, vise-grip clamps, ...

  • Page 415

    414 www.Factoryfive.Com 508-291-3443 trimming mark an even ½ inch flange around the door recess, you can use a washer or small block of wood to help keep an even spacing around the inside of the door area. Drill a 5 / 16 ” hole on the inside of the line marked to allow the saw blade to go into the d...

  • Page 416

    415 www.Factoryfive.Com 508-291-3443 cut the inside of the door out along the line leaving the flange..

  • Page 417

    416 www.Factoryfive.Com 508-291-3443 at the front of the door use the dimensions above to draw the area to remove to insert the door frame. Cut the marked area of the door front using an air saw or jig saw. Door frame install 5 / 16 ” drill bit, drill, 5 / 32 ” hex key, flashlight, ½” socket, ratche...

  • Page 418

    417 www.Factoryfive.Com 508-291-3443 with the door frame still on the car, start inserting the door onto the frame at the top rear corner then swing it down. Push the door onto the door. The door frame will self-locate around the door cut-out, clamp the door frame to the inner door liner..

  • Page 419

    418 www.Factoryfive.Com 508-291-3443 carefully close the door remove material from the doors if necessary to allow a good fit in the door opening. Allow an ⅛”- 3 / 16 ” gap on the bottom and front of the door. We usually use a paint stick as a guide, let the door sit on them and make sure it can fit...

  • Page 420

    419 www.Factoryfive.Com 508-291-3443 use a tape measure to measure on the inside of the door from the flange to the door frame. Add 0.50” to the measurement so that the mark will be in the center of the tube and mark the inside of the door so that there are four marks..

  • Page 421

    420 www.Factoryfive.Com 508-291-3443 rough locations of holes around door opening. Drill through the door and frame with a 3 / 16 ” bit then open it up to 5 / 16 ”..

  • Page 422

    421 www.Factoryfive.Com 508-291-3443 bolt the door to the door frame using the 5 / 16 ” x 1.50” button head screws, locknuts, 5 / 32 ” hex key and ½” socket..

  • Page 423

    422 www.Factoryfive.Com 508-291-3443 press the door latch so that it is in the locked position then use a flashlight to shine through the door opening at the back of the door so that you can see the circle of the door latch..

  • Page 424

    423 www.Factoryfive.Com 508-291-3443 mark the area to get cut for the door striker to go into the door. Allow room around the striker so that it will not hit the door fiberglass. Remove the door from the door frame and use an air saw or jig saw to cut out the area marked on the door. Reattach the do...

  • Page 425

    424 www.Factoryfive.Com 508-291-3443 reattach the striker to the frame. Test close the door to make sure there are no interferences between the door, latch, striker and body. Inside door handle marker, air saw, 3 / 32 ” drill bit, drill, philips head screwdriver. Make sure the hole will be above the...

  • Page 426

    425 www.Factoryfive.Com 508-291-3443 hold the template up to the door with the flat end of the cut-out area towards the back of the door. Use the cable and handle still hooked to the latch as a guide for the max reach of the cable. Having a bend in the cable is ok. Make sure the hole will be above t...

  • Page 427

    426 www.Factoryfive.Com 508-291-3443 remove the cable from the handle and insert the door handle into door hole just made and reattach the cable. Use the handle as a template to drill the 3 / 32 ” mounting screw holes. Attach the handle to the door using the #8 chrome oval head screws..

  • Page 428

    427 www.Factoryfive.Com 508-291-3443 door striker from inside the door reach through the center of the door latch with a marker and mark the body for the door striker. It is easier to get a good center if the latch has been closed so you have a hole instead of an open slot to trace. Use the 1¼” hole...

  • Page 429

    428 www.Factoryfive.Com 508-291-3443 bolt the striker plate to the frame and the striker to the plate using the center of the slot through the body as a starting point for adjustment. Adjust the latch striker on the mount plate until you have a nice fit on the door and tighten..

  • Page 430

    429 www.Factoryfive.Com 508-291-3443 nose scoops (optional) from ffr, the nose scoops are cosmetic; we do not include parts to make them fresh air ducts for the footboxes like the originals. If installing the optional nose scoops, drill the mounting holes for them now. Left side shown..

  • Page 431

    430 www.Factoryfive.Com 508-291-3443 right side duct. Final prep sand paper.

  • Page 432

    431 www.Factoryfive.Com 508-291-3443 all of the exterior body accessories, windshield and side exhaust must be mounted to the car to obtain the correct body location in order to create the correct gaps and opening sizes on the car before it is painted. One of the most important details in the bodywo...

  • Page 433

    432 www.Factoryfive.Com 508-291-3443 backside of body near exhaust area main radiator opening door hinge openings underside of nose and fender flange.

  • Page 434

    433 www.Factoryfive.Com 508-291-3443 hatch hinge area flange. The curled under side body edges are not as visible but just taking a little time here to get the lines straight and a small radius makes for a much nicer finish as well. The headlight, taillight, fuel cap, turn signal, quick jack, and tr...

  • Page 435

    434 www.Factoryfive.Com 508-291-3443 body painting remove all trim, doors, windshield etc. Before beginning body work the primer gel coat sands easily, and is a forgiving material to work with. The body comes out of the mold with a wax release compound and a thorough cleaning with a wax remover is t...

  • Page 436: Final Assembly

    435 www.Factoryfive.Com 508-291-3443 final assembly chapter 5.

  • Page 437

    436 www.Factoryfive.Com 508-291-3443 emergency brake boot 1 / 8 ” drill bit, drill, philips head screwdriver interior trim/carpet unpack the e-brake boot. Fit the boot over the handle and check the handle actuation. When you are in a position where the boot clears the handle movement drill through t...

  • Page 438

    437 www.Factoryfive.Com 508-291-3443 unpack the shift handle and bolt it to the transmission. These bolts have a tendency to rattle loose so use a little thread locker. Push the boot and trim rind down over the handle so it sits flush on the tunnel..

  • Page 439

    438 www.Factoryfive.Com 508-291-3443 using a silver marker or white paint marker, mark your screw holes on the tunnel. Remove the boot and drill 1 / 8 ” holes in the spots you marked..

  • Page 440

    439 www.Factoryfive.Com 508-291-3443 re-install the boot and screw down to the tunnel with the countersunk screws. A small screwdriver can help to locate the holes. Screw the two piece knob onto the shift handle and tighten so the shift pattern is in the correct orientation..

  • Page 441

    440 www.Factoryfive.Com 508-291-3443 headlights philips head screwdriver headlight components unpack the headlight mounting assembly. Headlight fasteners. 13419 13415 13418 13420 13416.

  • Page 442

    441 www.Factoryfive.Com 508-291-3443 screw the adjuster screws about halfway into the buckets. Push the grommet into the side of the bucket..

  • Page 443

    442 www.Factoryfive.Com 508-291-3443 screw the bucket onto the body. Run the light plug harness through from the inside.

  • Page 444

    443 www.Factoryfive.Com 508-291-3443 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 writing on the headlight should be right side up. Screw the mounting flange onto the light with the 3 small ta...

  • Page 445

    444 www.Factoryfive.Com 508-291-3443 plug the light into the connector. Mount the bulb to the bucket. The slotted parts of the mounting flange go onto the adjusting screws between the screw head and flange at the top and left side of the light. The bottom right screw attaches the bucket to the light...

  • Page 446

    445 www.Factoryfive.Com 508-291-3443 push the spring clip onto the boss near the bottom of the bucket. The trim ring hooks over the bucket on the top and gets a screw it in the bottom using the oval head screw. Drill a hole through the bottom of the nose headlight area so that a philips head screwdr...

  • Page 447

    446 www.Factoryfive.Com 508-291-3443 push the rubber bushing into the body hole. Slide the trim ring onto the light..

  • Page 448

    447 www.Factoryfive.Com 508-291-3443 pass the wires through the grommet. Push the light into the rubber bushing..

  • Page 449

    448 www.Factoryfive.Com 508-291-3443 headlight covers drill, ⅛” drill bit, philips head screwdriver, masking tape, marker, ruler, and sandpaper. Headlamp covers/fasteners put masking tape around the edge and on the inside around the edge of the headlight bucket so the paint will not get scratched..

  • Page 450

    449 www.Factoryfive.Com 508-291-3443 position the headlight cover in the opening with your hands as shown in the picture. Only press down at four points on the cover. Move your fingers as necessary so that the cover is flush with the body everywhere. If necessary use sandpaper on the edge of the pla...

  • Page 451

    450 www.Factoryfive.Com 508-291-3443 tape four of the mounting tabs in the bucket opening at the points marked. Mark the locations of the mounting tap holes..

  • Page 452

    451 www.Factoryfive.Com 508-291-3443 drill 3 / 16 ” holes into the bucket. Use 3 / 16 ” rivets to attach the tabs to the headlight bucket..

  • Page 453

    452 www.Factoryfive.Com 508-291-3443 reposition the cover carefully. If necessary, use a pair of pliers to bend the tabs to match the surface of the lens. A drill bit for plastic is suggested to prevent cracking.

  • Page 454

    453 www.Factoryfive.Com 508-291-3443 mark and drill 3 / 16 ” holes on the locations marked on the cover. Before final mounting the edges should be sanded to a smooth finish. Start with 400 grit paper and work down to 1200 grit before finishing with 3m plastic polish for a nice finished edge. Be extr...

  • Page 455

    454 www.Factoryfive.Com 508-291-3443 attach the cover to the mounting tabs using the #6 truss head screws and a philips head screwdriver. Tail lights pliers, masking tape, 3 / 8 ” socket, ratchet tail light components unpack the tail light components..

  • Page 456

    455 www.Factoryfive.Com 508-291-3443.

  • Page 457

    456 www.Factoryfive.Com 508-291-3443 put the light in the trim ring. Put the inner rubber gasket in on top of the light..

  • Page 458

    457 www.Factoryfive.Com 508-291-3443 put the mounting ring in on top of the gasket and orient the studs so that there is one stud at the top of the light and two at the bottom when looking at the text on the lens. Starting with the squared off end, push the snap ring into the retaining groove in the...

  • Page 459

    458 www.Factoryfive.Com 508-291-3443 put masking or duct tape or use a paint stick around one of the jaws on a set of pliers and squeeze the snap ring into the groove so that it is seated all the way. Put the rubber mounting gasket onto the light assembly. Cut the plug off the wires right next to th...

  • Page 460

    459 www.Factoryfive.Com 508-291-3443 push the wires through the body mounting hole then attach the light to the body using the 10-32 locknuts, 3 / 8 ” socket and ratchet. Mounted taillights..

  • Page 461

    460 www.Factoryfive.Com 508-291-3443 license plate bracket rivet gun, philips head screwdriver, 11 / 32 ” or 9mm wrench. Secondary body fasteners, license plate light/bracket components. If not already in, push the plastic license plate nuts into the bracket. Attach the license plate bracket to the ...

  • Page 462

    461 www.Factoryfive.Com 508-291-3443 on the backside of the body place the ground wire for the light on one of the screws and then place a washer and locknut and tighten using a philips head screwdriver and 11 / 32 ” or 9mm wrench. Gas cap philips head screwdriver.

  • Page 463

    462 www.Factoryfive.Com 508-291-3443 aston lemans cap unpack the fuel cap and mounting hardware. Put the gasket on the bottom surface of the cap..

  • Page 464

    463 www.Factoryfive.Com 508-291-3443 set the cap on the body and screw in using 5 of the countersunk screws. Leave the inside most forward hole open. The one remaining cap fastener is a longer screw and nut used for the ground strap, screw it in from the top then put the ground strap washer and nut ...

  • Page 465

    464 www.Factoryfive.Com 508-291-3443 nose side mesh silicone, caulking gun, duct tape coupe pressed mesh. Position the mesh screen behind the louver cut-out area on the nose to see where the mesh will touch. Apply silicone around the cut-out area on the nose that the mesh will touch..

  • Page 466

    465 www.Factoryfive.Com 508-291-3443 push the mesh into the silicone and use masking tape on the back to hold it in place or paint sticks and zip ties from the outside..

  • Page 467

    466 www.Factoryfive.Com 508-291-3443 rear mesh tin snips, marker coupe pressed mesh the rear mesh is a nice touch for looks but not necessary. There are different ways to mount the mesh, using spacers and fasteners or bend the sides and use silicone, it is up to you..

  • Page 468

    467 www.Factoryfive.Com 508-291-3443 headliner razor knife, tape, newspaper/large paper, spray glue, rags. Interior trim assembly. Put some clean rags on the ground to prevent scratching the roof of the body. With the help of a friend, turn the body upside down and place the roof on the rags. The ad...

  • Page 469

    468 www.Factoryfive.Com 508-291-3443 pre-fit the headliner to make sure you have it lined up so there will be no gaps. Rough trim if there is excessive material left over but the final trim is best after the liner is glued in place. The liner should follow the windshield pillars down to where they r...

  • Page 470

    469 www.Factoryfive.Com 508-291-3443 when laying out the liner, look for any high spots or bumps in the fiberglass that don’t allow the liner to sit flat. Using coarse sandpaper or a small sanding wheel, carefully bring these areas down flush to the roof. Starting with the liner in position, lift th...

  • Page 471

    470 www.Factoryfive.Com 508-291-3443 pay extra attention to the edges and tucking the material in tightly to the inside corners make sure the adhesive is nice and uniform and covers these areas completely as they are where separation is the most likely to happen. Spray and fit the windshield pillars...

  • Page 472

    471 www.Factoryfive.Com 508-291-3443 with the front glued in place and the rear half still loose check the fitment around the rear quarter window scoops and trim where needed to get the material to sit nice and flat. Making pie cuts around the tighter curves helps get the material to lay flat..

  • Page 473

    472 www.Factoryfive.Com 508-291-3443 due to the mold seam location this is also a likely spot for bumps or high spots, sand these away being careful not to go deeper than flush. Spray and stick the rear half of the liner also working from front to back and saving the quarter window edges until last..

  • Page 474

    473 www.Factoryfive.Com 508-291-3443 with the liner tight against all corners and edges you can now trim it very carefully with a razor knife. It is ok to leave a little extra around the window and pillar area as this will be covered up by weatherstripping. The windshield weather strip without the b...

  • Page 475

    474 www.Factoryfive.Com 508-291-3443 the weather stripping with the build is for the side windows, the bulb faces toward the outside of the car..

  • Page 476

    475 www.Factoryfive.Com 508-291-3443 the side window trim and windshield area trim will hide the rough cut edge of the liner. In order to get the liner to not get pushed off the body, start at an angle with the trim covering the liner side and then push it on so the body side edge is what is what is...

  • Page 477

    476 www.Factoryfive.Com 508-291-3443 final body mounting fit the body back on the chassis. Be very careful with the sides and slowly work it down into position. Pull the sides out around the chassis and make sure the body covers the rear cockpit wall and top of the dash without pulling the material ...

  • Page 478

    477 www.Factoryfive.Com 508-291-3443 reattach the nose latches to the nose. Door and latch mount reattach the doors and latches. Windshield mounting windshield windshield assembly. Handle the windshield with care and store in a safe place. We highly recommend having a professional windshield install...

  • Page 479

    478 www.Factoryfive.Com 508-291-3443 apply urethane around the windshield flange. Push the windshield into place. Tape it if necessary so that it will not slip down. Do not move/touch the windshield for 24 hours. Windshield mounted on the body without weatherstrip..

  • Page 480

    479 www.Factoryfive.Com 508-291-3443 windshield mounted on the body with 409 t 102 weatherstrip hatch side aluminum push weatherstrip onto the top edge of the hatch side aluminum. Right side shown..

  • Page 481

    480 www.Factoryfive.Com 508-291-3443 from the wheel well, push the hatch side aluminum into place so that the lower flange goes under the floor aluminum. Push the front bottom in so that the side panel touches the side of the floor..

  • Page 482

    481 www.Factoryfive.Com 508-291-3443 at the back, push the panel in again so that the side panel touches the side of the floor. Fuel filler neck razor knife, ⅜” socket, ratchet, 3 / 16 ” drill bit, drill aston lemans cap components.

  • Page 483

    482 www.Factoryfive.Com 508-291-3443 ground the fuel filler strap to the chassis using the screw that came in the cap hardware. This wire prevents any static charge build-up and must be used. Use a measuring tape and marker to mark the filler tube 3.50” up from the lower bent section and 3” up from ...

  • Page 484

    483 www.Factoryfive.Com 508-291-3443 cut the hose at the two places marked. Push the lower 90° hose section onto the gas cap along with a hose clamp. Rotate the hose so it points down towards the fuel tank filler..

  • Page 485

    484 www.Factoryfive.Com 508-291-3443 connect the other section of filler tube and hose to the fuel tube in the tank as shown. Assemble the pieces together before tightening the hose clamps..

  • Page 486

    485 www.Factoryfive.Com 508-291-3443 screw the plastic gas cap into the aston lemans style cap. Aluminum 1 / 8 ” drill bit, drill, rivet gun, silicone, caulking gun secondary body fasteners, packaged aluminum.

  • Page 487

    486 www.Factoryfive.Com 508-291-3443 firewall extension push weatherstrip around the curve of the panel and the horizontal area shown. Right side shown. Insert the panel into the area in front of the door hinge from the engine bay side..

  • Page 488

    487 www.Factoryfive.Com 508-291-3443 attach weatherstrip to the top and bottom of the inner firewall extension. Right side shown. Insert the inner extension panel and move the panels until they fit together. Trim the outer panel around the body if necessary..

  • Page 489

    488 www.Factoryfive.Com 508-291-3443 use the kit aluminum screws to attach the panels together; to the firewall; and to the outside of the footbox. Cockpit outside corners push weatherstrip on to the curve of the aluminum panels as shown..

  • Page 490

    489 www.Factoryfive.Com 508-291-3443 attach the panel to the chassis by putting the panel behind the body flange and so it rests against the rollbar tubes. Outside nose mount cover locate the outside nose mount covers..

  • Page 491

    490 www.Factoryfive.Com 508-291-3443 drill silicone and rivet the panel behind the nose latch mounts. Inside shock tower cover check the fit of the hatch area inside shock tower cover and note the locations available for rivets..

  • Page 492

    491 www.Factoryfive.Com 508-291-3443 silicone, drill and rivet the covers in place. Fuel tank access covers silicone and install the patch panels in the hatch area that cover the fuel sender and pickup access holes..

  • Page 493

    492 www.Factoryfive.Com 508-291-3443 hatch area rear wall put weatherstrip on the top edge of the aluminum leaving 3 / 8 ” at each end so the weatherstrip on the side panels does not hit the weatherstrip on this panel. Insert the panel through the hatch area..

  • Page 494

    493 www.Factoryfive.Com 508-291-3443 from the wheel well, push the hatch side aluminum flange behind the rear wall and use masking tape to hold it in place. Drill and rivet the panel to the floor panel and the side hatch flange aluminum..

  • Page 495

    494 www.Factoryfive.Com 508-291-3443 use a broom handle or similar to hold the aluminum panel against the body hatch area flange then drill and rivet the panel to the flange. Rear hatch final razor knife, ½” socket, ratchet. Secondary body fasteners. The rear hatch uses the weather stripping that ha...

  • Page 496

    495 www.Factoryfive.Com 508-291-3443 starting at the bottom in the middle, press the weather stripping onto the body with the longer leg towards the inside of the hatch to help prevent water getting to the hatch area. Remount the hatch by placing the glass back in the opening, set the gap around the...

  • Page 497

    496 www.Factoryfive.Com 508-291-3443 interior rearview mirror tape measure, marker, windshield rearview mirror glue, hex key set. Rearview mirrors use a ruler and marker pen to mark the center of the top windshield area mount on the windshield. Hold the mirror in place to find the best location up/d...

  • Page 498

    497 www.Factoryfive.Com 508-291-3443 unpack the side mirror assembly. Disassemble the mirror, removing the large base from the stand..

  • Page 499

    498 www.Factoryfive.Com 508-291-3443 the large base is replaced by the smaller insert and gasket. Temporarily bolt the mirror back together with the small insert. Sit in the seat to find a good location you can see it from and see clearly over the rear fender..

  • Page 500

    499 www.Factoryfive.Com 508-291-3443 mark the location and use the gasket to locate and drill the mounting holes. Disassemble the mirror and bolt the mounting insert with mounting bolt and the gasket to the body..

  • Page 501

    500 www.Factoryfive.Com 508-291-3443 slide the stand-off and upper gasket down the bolt and onto the mounting bracket. Bolt the main body of the mirror to the mounting stand-off..

  • Page 502

    501 www.Factoryfive.Com 508-291-3443 screw the mirror into the body and adjust it before tightening. Light wiring wire strippers, wire crimpers, chassis harness instructions headlight components, amber front turn signal lights, rear lights, license plate light, electrical system completion component...

  • Page 503

    502 www.Factoryfive.Com 508-291-3443 wire in the headlights to the chassis harness. On the headlight, there are three wires, black is ground, white is high beam and the red is low beam. Wire the turn signals up to the chassis harness. On the light, the white wire is the ground and the black wire is ...

  • Page 504

    503 www.Factoryfive.Com 508-291-3443 unpack the door check-straps. Drill and rivet the check-strap to the 1.50” vertical frame tube near the top of the tube using a 3 / 16 ” rivet. Put masking tape on the door near the front..

  • Page 505

    504 www.Factoryfive.Com 508-291-3443 open the door wide but not enough so that the door hits the body or the hinges hit the side of the cut-out. The straps will stretch slightly over time so allow enough room for this by closing the door slightly from the maximum. Use the check strap and mark the ho...

  • Page 506

    505 www.Factoryfive.Com 508-291-3443 with the steering wheel in the position that is most comfortable for you tighten the set screws on the upper steering bearing collar. Unwrap the steering wheel center section and push it into the steering wheel and boss, a little wd40 on the o- ring helps if it i...

  • Page 507

    506 www.Factoryfive.Com 508-291-3443 peel the backing off the badge and stick it in the center section making sure you are aligned with the top of the steering wheel. If necessary, file any flashing off the bottom edge of the emblem so that it will fit. Optional leather steering wheel..

  • Page 508

    507 www.Factoryfive.Com 508-291-3443 rear quarter side windows 5 / 32 ” drill bit, drill, sand paper, fine blade hack saw (finer the better), masking tape, marker quarter windows a drill bit designed for plastic with a 60° point instead of the standard 118° or 135° point will reduce the chance of cr...

  • Page 509

    508 www.Factoryfive.Com 508-291-3443 the bottom edge usually has the most overhang, make a mark on the window that lines up with the leading edge of the door. From your edge mark draw a straight line up to the top flange of the quarter window for trimming. Remove the window and evenly mark the windo...

  • Page 510

    509 www.Factoryfive.Com 508-291-3443 after trimming and rough edging drill holes and mount the window using the screws provided. Once you are happy with the mounted fit you can polish the finish edge. We usually start with 400 grit sand paper and step up to a 1200 grit before finishing with 3m plast...

  • Page 511

    510 www.Factoryfive.Com 508-291-3443 side exhaust 3 / 16 ”, 5 / 16 ” hex key, ⅜”, ½”, 9 / 16 ” socket, ratchet, 9 / 16 ” wrench, drill side exhaust attach the side exhaust using the kit fasteners, 5 / 16 ” hex key and 9 / 16 ” socket..

  • Page 512

    511 www.Factoryfive.Com 508-291-3443 attach the frame mounts to the underside of the 1.50” tubing using the #10 x 1” self-tapping screws. Aluminum splash guards 1 / 8 ”, 3 / 16 ” drill bit, drill, rivet gun, silicone, caulking gun, ¾” socket, ratchet, extension, marker secondary body fasteners, pack...

  • Page 513

    512 www.Factoryfive.Com 508-291-3443 front wheel, rear inside rivet the front wheel rear inside panel to the frame so that the exhaust goes through the hole it makes. Front wheel rear lower with the nose up, put a wheel and tire on the front and turn the steering so that the rear of the tire is as c...

  • Page 514

    513 www.Factoryfive.Com 508-291-3443 clamp the front lower splash guard to the inner splash panel and the outside to the front part of the body in front of the side exhaust. Use a level to make sure the surface that will be close to the nose is flat. Put a wheel and tire on the car and check for alu...

  • Page 515

    514 www.Factoryfive.Com 508-291-3443 front upper splash panels push weatherstrip on the outside of the upper splash panel to the bend only, not the thin part that goes forward. Right side shown. Close the nose and align the splash panel with the lower splash panel and clamp the front part to the fla...

  • Page 516

    515 www.Factoryfive.Com 508-291-3443 rear wheel push a piece of the bulb seal weather stripping around both rear splash guards where they will contact the body..

  • Page 517

    516 www.Factoryfive.Com 508-291-3443 fit the panels in place trimming the outside perimeter if needed. The small tab on the bottom faces towards the rear of the car and is on the bottom. Push the panel in so that the bulb of the weatherstrip is not visible from the outside. Silicone and rivet the pa...

  • Page 518

    517 www.Factoryfive.Com 508-291-3443.

  • Page 519

    518 www.Factoryfive.Com 508-291-3443 1 60560 left footbox inside carpet ea 1.00 2 60561 left footbox front carpet ea 1.00 3 60563 left footbox outside carpet ea 1.00 4 60562 left footbox outside triangle carpet ea 1.00 5 60564 left under door carpet ea 1.00 6 60566 left floor carpet ea 1.00 7 60569 ...

  • Page 520

    519 www.Factoryfive.Com 508-291-3443 the adhesive used to hold the carpet down is the same as we used on the dash pad. 3m ® super77™ or super90™ work best. Wipe down the bare aluminum with acetone or brake cleaner for good adhesion..

  • Page 521

    520 www.Factoryfive.Com 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 harness mounts poke through. Install the carpet pieces.

  • Page 522

    521 www.Factoryfive.Com 508-291-3443 finishing touches review the race car checklist in the appendix. Headlight alignment masking tape, marker, tape measure make sure that the car is at the correct ride height before the alignment procedure is done. Ride height should be 4½” at the front and 4½” at ...

  • Page 523

    522 www.Factoryfive.Com 508-291-3443 measurement a: from the ground to the geometric center of one of the headlight lenses measurement b: from one of the low beam headlights to the vehicle centerline. (also measure from high beam center to vehicle centerline for 4 headlight systems) note these measu...

  • Page 524

    523 www.Factoryfive.Com 508-291-3443 front for a car using a manual steering rack or the power rack without power use the following specifications: caster: 3 camber: -0.5 total toe: 1 / 16 ” in or 0.14 in for a car using power steering car use the following specifications: caster: 7 camber: -0.5 tot...

  • Page 525

    524 www.Factoryfive.Com 508-291-3443 there should never be more than 1” of thread showing past the tightened down jam nuts on either end of both adjusting tubes. The pivot bolts must be loosened while the car is being aligned and retightened afterwards 2015 irs once the car has been aligned, use a 1...

  • Page 526: Technical Support

    525 www.Factoryfive.Com 508-291-3443 performance reference material and technical support chapter 6.

  • Page 527

    526 www.Factoryfive.Com 508-291-3443 maintenance check the items on the car check sheet in the appendix on a yearly basis or before track days depending on how hard the car is driven. Wheels and tires if using a wheel wider than 7”, ffr front lower control arms are needed to prevent the wheels rubbi...

  • Page 528

    527 www.Factoryfive.Com 508-291-3443 if a modern look is what you’re after, you may want to try the 17” cobra™ r or fr style wheels. If using the standard width 1987-93 rear, it is possible to use aftermarket 10.5” wide, 27mm offset wheels. If using a rear end that has been converted to 5-lug using ...

  • Page 529

    528 www.Factoryfive.Com 508-291-3443 left: 15” ffr halibrand style. Right 17” ffr halibrand style performance modifications the following modifications and set-ups fall under the category of getting more horsepower from your engine and making your car perform better. You will find a hundred people a...

  • Page 530

    529 www.Factoryfive.Com 508-291-3443 turns is a 3.55 rear ratio, etc.… the other way to check the ratio out is to open the rear differential up and look on the ring gear. While the rear is open change the fluid. This never gets done enough on the car. Changing the gear ratio is one of the least expe...

  • Page 531

    530 www.Factoryfive.Com 508-291-3443 heads the 5.0l mustang aftermarket is full of 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 allows the use of o...

  • Page 532

    531 www.Factoryfive.Com 508-291-3443 steering rack the complete kit comes with an 18:1 manual steering rack. This is good for most driving situations. We have found that many customers prefer to use power steering. This can be done by using the stock 1987-1993 15:1 mustang power rack and power steer...

  • Page 533

    532 www.Factoryfive.Com 508-291-3443 installed edelbrock supercharger. Seats for the roadracers/autocrossers that want more side support, factory five offers a variety of different options. Check out www.Factoryfiveparts.Com helpful reference material must reads www.Thefactoryfiveforum.Com the large...

  • Page 534

    533 www.Factoryfive.Com 508-291-3443 catalogs/parts ford performance parts - catalog, current edition. Available at your local speed shop, an authorized ford racing distributor or www.Performanceparts.Ford.Com tire rack - tire and wheel source. 888-541-1777. Www.Tirerack.Com repair manuals - repair ...

  • Page 535: Appendix A – Templates

    534 www.Factoryfive.Com 508-291-3443 appendix a – templates.

  • Page 536

    535 www.Factoryfive.Com 508-291-3443.

  • Page 537

    536 www.Factoryfive.Com 508-291-3443.

  • Page 538

    537 www.Factoryfive.Com 508-291-3443.

  • Page 539

    538 www.Factoryfive.Com 508-291-3443.

  • Page 540

    539 www.Factoryfive.Com 508-291-3443 appendix b – donor parts list.

  • Page 541

    540 www.Factoryfive.Com 508-291-3443 in some cases not all parts listed below will be necessary, but it is suggested to obtain all parts to avoid future difficulties. Part name check engine /drive tra in engine engine mount, (l,r) w/nuts and bolts starter transmission, bell-housing, clutch, and shif...

  • Page 542: Sheet

    541 www.Factoryfive.Com 508-291-3443 appendix c – race / yearly check sheet.

  • Page 543

    542 www.Factoryfive.Com 508-291-3443 car_______________________________________ date___________ steering steering wheel tight ___ universal joint set screws tight ___ rack mount bolts tight ___ tie rod ends tight ___ tie rod to spindle bolts tight ___ steering free lock to lock ___ front suspension ...

  • Page 544

    543 www.Factoryfive.Com 508-291-3443 battery mount and connections secure ___ brake lights functioning ___ all wires free and clear of moving or hot parts ___ rear suspension ride height ___ shock mounting bolts tight ___ spring collars tight/taped ___ wheel bearings tight (irs) ___ tire pressure se...

  • Page 545

    544 www.Factoryfive.Com 508-291-3443 appendix d – torque specifications.

  • Page 546

    545 www.Factoryfive.Com 508-291-3443 general bolt torque specifications* thread sae english zinc plated ft-lb. ¼ -20 8 ¼ -28 10 5 / 16 -18 17 5 / 16 -24 19 ⅜ -16 30 ⅜ -24 34 7 / 16 -14 48 7 / 16 -24 54 ½ -13 75 ½ -20 83 9 / 16 -12 100 9 / 16 -18 100 ⅝ -11 100 ⅝ -14 100 thread sae metric zinc plated ...

  • Page 547

    546 www.Factoryfive.Com 508-291-3443 appendix e – mustang specifications.

  • Page 548

    547 www.Factoryfive.Com 508-291-3443 between 1996 and 1998 ford made 125,231 gt and 28,708 cobra versions of the mustang between 1999 and 2004 ford made ~200,000 gt, 5,582 bullitt, 9,652 mach 1 and 20,727 cobra versions of the mustang. (all information is based on v8 ford mustangs from 1979 to 2004)...

  • Page 549

    548 www.Factoryfive.Com 508-291-3443 1989-93 t-5 3.35 1.99 1.33 1.00 0.675 n/a 3.15 300 f(z,9,0)zr-7003- (a,aa) 75 1994-95 t-5 3.35 1.99 1.33 1.00 0.675 n/a 3.15 300 75 1995 tr3550 3.27 1.98 1.34 1.00 0.680 n/a 3.00 350 100 1996-98 t-45 3.37 1.99 1.33 1.00 0.670 n/a 3.22 325 109 1999-02 tr- 3650 3.3...

  • Page 550

    549 www.Factoryfive.Com 508-291-3443 that carry exhaust headers for the installation of a 351 windsor into a 1986-1993 mustang. These headers will work with factory five 1986-1995 j-pipes. Steering components power steering racks from 1987-2004 are 15:1. In 1994 the racks switched from having a spli...

  • Page 551

    550 www.Factoryfive.Com 508-291-3443 appendix f – fluid specifications.

  • Page 552

    551 www.Factoryfive.Com 508-291-3443 engine oil type capacity 302 10w-30 5.0 qts. 4.6l 5w-30 8.0 qts. W/ffr pan 5.0l coyote 5w-20 8.0 qts. W/ffr pan transmission oil type t-5 t-45 3650 tko t-56 mercon/dexron iii trans. Fluid 2.8 qts. 3.25 qts. 4.0 qts. 2.64 qts. 4.0 qts. 8.8 solid rear axle oil type...