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Factory Five Racing Mk3 Roadster Assembly Manual

Summary of Mk3 Roadster

  • Page 1

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

  • Page 2: Table of Contents

    Ii www.Factoryfive.Com 508-291-3443 table of contents t able of c ontents ................................................................................................................................................................... I f orward ......................................................

  • Page 3

    Iii www.Factoryfive.Com 508-291-3443 f uel n eck and g as c ap ...................................................................................................................................................... 136 w indscreen .........................................................................

  • Page 4: Forward

    Iv www.Factoryfive.Com 508-291-3443 forward by david smith president factory five racing, inc. If 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 lit...

  • Page 5

    V www.Factoryfive.Com 508-291-3443 the process of building a car is a lot like the process of having kids. As a matter of fact, it’s absolutely the best analogy i can find (apologies in advance to all of you without kids, try and bear with me). Both things are easy to get started. With a car project...

  • Page 6: Statement of Non-Liability

    Vi www.Factoryfive.Com 508-291-3443 president statement of non-liability while there are many things to love and be proud of in our country today there are a few things that we wish were different. With regret and a small amount of resentment we include the following warning and statement of non-lia...

  • Page 7: Safety Tips

    Vii 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...

  • Page 8: Tools and Supplies List

    Viii tools and supplies 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 found them to be ...

  • Page 9

    Ix 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. Required supplies engine degreaser silicone door and window sealant, ge silico...

  • Page 10

    10 www.Factoryfive.Com 508-291-3443 chapter 1 - donor parts and parts needed.

  • Page 11: Donor Part Selection Tips

    11 www.Factoryfive.Com 508-291-3443 if using a 4.6l engine or donor parts newer than 1995 call and ask for the 4.6l assembly manual this chapter deals with the donor parts needed in addition to the parts that we included with our kit. Many people choose to use parts from a single mustang donor. If y...

  • Page 12

    12 www.Factoryfive.Com 508-291-3443 crashed cars is very good. Where to look • junkyards – if they do not have one on the lot, usually they go to auctions weekly and can get what you want. • newspaper classifieds. • www.Ebaymotors.Com – search for wrecked mustang • the following is a list of compani...

  • Page 13

    13 www.Factoryfive.Com 508-291-3443 in order to make a wise choice on running gear, there are several things to look for. First, make sure that the vin numbers on the transmission and engine are present and match the numbers on the vehicle title (if available). If the numbers don’t match, (let’s say...

  • Page 14

    14 www.Factoryfive.Com 508-291-3443 slip yolk (transmission end) and the rear flange is important. The slip yolk must be smooth and clean without scores or gouges that can cause premature wear and develop leaks down the road. We recommend using only yokes from manual transmission cars; the automatic...

  • Page 15

    15 www.Factoryfive.Com 508-291-3443 10. Loosen the bolts on the brackets at the top of radiator. 11. Lift the radiator, shroud and the fan with clutch up and out of the engine bay. Discard or sell the fan. Keep the shroud. You won’t need the mustang fan since a 16” puller fan is included in the kit....

  • Page 16

    16 www.Factoryfive.Com 508-291-3443 2. Remove the lower steering column by taking off the two bolts at the flexible collar in the area where the splined steering rack shaft begins. 3. Remove the steering rack outer tie rod nuts and cotter pins. If the tie rod will not come out of the spindles easily...

  • Page 17

    17 www.Factoryfive.Com 508-291-3443 10. Remove the power steering lines from the pump, catching the fluid in a bucket. 11. Remove the braided ground strap from the rear driver’s side of the engine. 12. Follow the fuel lines off the engine and cut the lines 4” after they turn into the hard plastic li...

  • Page 18

    18 www.Factoryfive.Com 508-291-3443 computer attention: if you are going to run the car with a carburetor you can disregard the wiring harness part in this section. We still recommend the use of a fuel inertia cut off switch in your car if using an electric fuel pump. Tools: socket set parts: mustan...

  • Page 19

    19 www.Factoryfive.Com 508-291-3443 mustang gauges mounted in gauge pod . 5. The two gauge wiring connectors are removed from the gauge cluster by squeezing the outside clips. Remove the clear plastic gauge cover with a torx screwdriver and discard. Place the switches and gauge pod in your parts are...

  • Page 20

    20 www.Factoryfive.Com 508-291-3443 parts: dash wiring harnesses. Note: the wiring comes out in stages. Keep the sub-assemblies together as they are removed. Remember to identify both ends of every connector that you disassemble. The easy way to do this is to tape and number each side of the connect...

  • Page 21

    21 www.Factoryfive.Com 508-291-3443 front wiring harness with hookups for headlights, alternator, and horn . Speedometer and clutch cables tools: socket set, duct tape. Parts: speedometer cable and sending unit, clutch cable. 1. Pull the speedometer cable out from the dash area keeping the rubber gr...

  • Page 22

    22 www.Factoryfive.Com 508-291-3443 shifter and shifter handle attention: the kit comes with new bolts for the shifter handle so you don’t need the oem bolts. Save them anyway according to rule #85 of the car guys’ handbook which states “save any and all fasteners in rusty coffee cans”. This, of cou...

  • Page 23

    23 www.Factoryfive.Com 508-291-3443 parts: donor car rear wiring harness. 1. Remove bulb bases from the rear light housings if they are still on your donor. Use tape and a marker to label the wires. 2. Remove the rubber body plug from the fuel harness exit point in the base of the trunk area and unp...

  • Page 24

    24 www.Factoryfive.Com 508-291-3443 the plug with the square socket on it. Use a ⅜” ratchet handle to undo it. 5. Tape over the rear of the transmission so that it doesn’t leak or drip fluid. 6. Undo the transmission from the cross-member. 7. Loosen the cross-member attachment bolts. Attention: get ...

  • Page 25

    25 www.Factoryfive.Com 508-291-3443 lower a-arm w/bolts, brake caliper, spindle and brake rotor. 9. Use a spring compression tool to remove the front springs or chain the spring to the chassis. 10. Remove the three bolts that retain the struts to the top mounting plate. 11. Slowly lower the jack and...

  • Page 26

    26 www.Factoryfive.Com 508-291-3443 grommet on the side of the tank. 7. The fuel tank is held in place with two straps that go under the tank and bolt to the body in front. 8. Place a floor jack under fuel tank and loosen the strap bolts. 9. Remove the bolts and lower tank enough to reach the high-p...

  • Page 27: Donor Part Preparation

    27 www.Factoryfive.Com 508-291-3443 the body/chassis. 12. All of the arms should remain attached to the rear end assembly. Once off, place the oem bolts back into the arms and attach nuts so they do not get lost. 13. Remove the rear end from under the car. 14. Remove the brackets that secure the qua...

  • Page 28

    28 www.Factoryfive.Com 508-291-3443 3. Cut the upper rubber spring seat so that during assembly of the kit, it will conform to the spring mount on the frame. This is done with one cut across the part. Do not replace these bushings with aftermarket silicone pieces, as these will allow the springs to ...

  • Page 29

    29 www.Factoryfive.Com 508-291-3443 barbed fitting removed from plastic hose. Fuel tank tools: pliers parts: fuel tank 1. 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. Pedal box and accelerator pedal the ffr roadster uses a ...

  • Page 30

    30 www.Factoryfive.Com 508-291-3443 accelerator pedal modified . 3. Remove the bracket for the cruise control brake switch from the pedal box. 87-93 pedal box 1. Mark the mounting face of the 1” up from the bottom of the mounting plate. 87-93 pedalbox marked for cutting..

  • Page 31

    31 www.Factoryfive.Com 508-291-3443 2. Cut-off the marked area with a hack saw. This is necessary for steering shaft clearance. 1994-1995 pedal box 1. Cut the corner off the outside top of the pedal box. Top outside of pedal box. 2. Remove the cruise control switch located under the plastic clutch q...

  • Page 32

    32 www.Factoryfive.Com 508-291-3443 5. Remove the brake pedal spring from its mount hole and remove the plate on the front of the pedal box along with the round spacers. Brake pedal spring in mount hole and plate/spacers on pedal box front. 6. Relocate brake pedal spring to pedal box triangular open...

  • Page 33

    33 www.Factoryfive.Com 508-291-3443 3. Heater wires 4. Air bag blue boxes and wires 5. Electronic seat and window controls. 6. Remote trunk release wires not only does this take weight out of the car, it gives additional room behind the dash. Look at the plugs and compare them to a chilton’s manual ...

  • Page 34

    34 www.Factoryfive.Com 508-291-3443 tools: ⅜”, ¾”, 7 / 16 ” sockets, 5 / 16 ” hex keys, regular screwdriver, teflon tape, tube bender, 9 / 16 ” deep socket, ½”, 9 / 16 ” combination wrenches, 5 / 16 ” drill bit, drill. Bending the fuel lines on the engine. 1. Bend the fuel lines away from the engine...

  • Page 35: Cleaning and Detailing

    35 www.Factoryfive.Com 508-291-3443 transmission 1. If you are running a t-5 transmission, remove the casting tab with the hole in it that is sticking out on the passenger side with a hack saw. T-5 mounted in frame. Note the tab to be removed. Steering rack and shaft attention: if you are planning o...

  • Page 36: Not Using A Donor

    36 www.Factoryfive.Com 508-291-3443 electrical pieces. If the parts are really dirty, you can take the parts and assemblies to a do-it-yourself car wash. They usually have an engine degreaser as an option and most places run very high water temperature that helps loosen debris and grease. If doing t...

  • Page 37

    37 www.Factoryfive.Com 508-291-3443 becomes flush with the inspection cover. The internet has changed this part of the business forever. Parts are now much easier to find on-line. Check out a number of customer and enthusiast based forums for help and advice. If you are going to use donor parts from...

  • Page 38

    38 www.Factoryfive.Com 508-291-3443 chapter 2 - step by step chassis build-up.

  • Page 39: Unpacking Your Replica Kit

    39 www.Factoryfive.Com 508-291-3443 if using a 4.6l engine or donor parts newer than 1995 call and ask for the 4.6l assembly manual unpacking your replica kit please note that your boxes are numbered, when you read your packing list you will see that next to each assembly there is a number circled. ...

  • Page 40

    40 www.Factoryfive.Com 508-291-3443 5. When you store the body on the ground (unsupported) for long periods of time you may get slight distortion (bowing) around the walls forward of the doors. In order to avoid the chance of this happening, we recommend putting two short 2”x 4” braces (24” long) un...

  • Page 41

    41 www.Factoryfive.Com 508-291-3443 trace around the frame members, and then use a ruler to mark rivet locations . 3. Remove any screws holding the panel to the frame and remove the aluminum panels. Keep the #8 screws to help with aluminum positioning later during build-up. 4. Using a ruler and mark...

  • Page 42

    42 www.Factoryfive.Com 508-291-3443 note: if installing a heater/defroster, it is easier to make the necessary holes now before the firewall is installed. See the instructions included with the heater for hole size and location. 9. Run a silicone bead along the front of the horizontal 2”x 2” between...

  • Page 43

    43 www.Factoryfive.Com 508-291-3443 passenger side firewall extension in place. Front suspension installation tools: combination wrenches, coil-over adjusting tool (ffr# 10961), ⅜”, ⅝”, ¾”, 11 / 16 ”, 13 / 16 ”, ⅞”, 15 / 16 ”, 1⅛”, 18mm sockets. Rubber mallet, eye protection, drill w/#8 hex nut driv...

  • Page 44

    44 www.Factoryfive.Com 508-291-3443 5. Holding the dust boot in place, insert the ball joint into the spindle adapter bracket (ffr# 13819). This bracket replaces the mustang strut. Be sure to use the cotter pins included with the ball joint. Torque the ball joint to 95-122nm (70-90 lbft). If the top...

  • Page 45

    45 www.Factoryfive.Com 508-291-3443 note: the front lower control arm bolts may need to be trimed or use a washer under the head for the front bolts due to the manufacturing process of the bolt. Control arm mounts 8. While holding the arm parallel to the ground, torque the bolts to 135-149nm (100-11...

  • Page 46

    46 www.Factoryfive.Com 508-291-3443 1. If retro fitting the koni shocks, place the car on jack stands and remove the old shocks and springs. Save all of the fasteners and spacers, they will be reused. 2. Double check the jam nut under the rod end and bump stop to make sure that it is tight. 3. Screw...

  • Page 47

    47 www.Factoryfive.Com 508-291-3443 6. Slide the rubber bumper about two inches down on the shaft. 7. Put the spring on the shock, then install the spring hat on the shaft end of the shock and push the rubber bumper up against it. 8. Rotate the spring seat back up the sleeve so that the spring pushe...

  • Page 48

    48 www.Factoryfive.Com 508-291-3443 assembled koni coil-over shock. 10. Pass the shock assembly (with the body of the shock up) through the upper a-arm and attach them to the mustang rear shock bracket on the stock lower control arm using the 0.43” spacers that are supplied in the kit. 11. Check for...

  • Page 49

    49 www.Factoryfive.Com 508-291-3443 14. Fasten the shock to the top mount with the fasteners and 0.675” spacers provided. 15. Adjust the ride height of the car..

  • Page 50: Steering Shaft

    50 www.Factoryfive.Com 508-291-3443 16. Once the ride height is set, tighten the small set screw in the spring seat just until you feel it contact. The end of the set screw is plastic so that the threads are not destroyed. Not a lot of pressure is needed to prevent the seat from turning. Steering sh...

  • Page 51

    51 www.Factoryfive.Com 508-291-3443 6. Slide the 1” flange bearing onto the top of the shaft, the 1” dd tube end, with the set screw side of the bearing towards the top of the shaft. 7. Slide half of the flange bearing mount down over the shaft to the bearing. 8. Mount the 1” flange bearing on the f...

  • Page 52: Steering Rack Installation

    52 www.Factoryfive.Com 508-291-3443 steering rack installation tools: ¾” socket, ¾”, 1.50” wrench, needle nose pliers, adjustable wrench, thread lock parts: steering system hardware (ffr# 11073), 87-93 lower steering shaft (ffr# 13701), donor steering rack. Above: ford steering rack and fasteners (h...

  • Page 53

    53 www.Factoryfive.Com 508-291-3443 3. Insert the steering rack bolts through the frame mount, rack and rear frame mount and lock nut. Use the provided washers on the driver side (slotted) only. 4. Tighten the bolts to the bolt torque spec. Steering rack mounted to frame . Note: the inner tie rod ex...

  • Page 54

    54 www.Factoryfive.Com 508-291-3443 7. Put a dot of thread lock on the threads of the steering rack extension and attach the new inner tie rods to the steering rack. Inner tie rod attached to the steering rack. 8. Push the boot back onto the steering rack body and attach with zip ties. 9. The track ...

  • Page 55: Rear-End

    55 www.Factoryfive.Com 508-291-3443 steering rack installed. 11. Turn the steering wheel to make sure there is no bind in the u-joints. The steering should be smooth. Readjust the u-joints if necessary to prevent any binding. 12. Sit in the car and adjust the steering wheel to desired height by addi...

  • Page 56

    56 www.Factoryfive.Com 508-291-3443 10. Bolt on the perch using the ½” bolts provided. Spring perch mount bolted on frame. 11. Thread the cut rear springs onto the conical frame mounts all the way. 12. Insert the cut rubber spring mount between the spring and the steel seat. Make sure the end of it ...

  • Page 57

    57 www.Factoryfive.Com 508-291-3443 passenger side stock rear lower control arm in the frame mount . 18. Start raising the rear, taking care to position the two lower control arm rubber spring mounts and the springs in their correct seats on the lower control arms. Rear driver’s side quad shock moun...

  • Page 58

    58 www.Factoryfive.Com 508-291-3443 20. Suspension height adjustments are done in the rear by turning the spring from its normal position on the mount to a position higher or lower. Remember that the spring is located halfway to the arm mount, so any height changes at the spring will be multiplied b...

  • Page 59: Fuel Tank and Fuel Filter

    59 www.Factoryfive.Com 508-291-3443 item nm lbft front front lower control arm to frame 135-162 100-110 front lower ball joint to spindle 106-163 80-120 upper a-arm to frame 135-162 100-110 upper ball joint to ifs bracket 95-122 70-90 ifs bracket to spindle 135-162 100-110 rear upper control arm to ...

  • Page 60

    60 www.Factoryfive.Com 508-291-3443 3. Put a floor jack underneath the center of the gas tank with a friend holding one end of the gas tank for balance. 4. Raise the tank and hold it up to the ¾” vertical tubes while you get the straps positioned. 5. The straps install first at the rear of the frame...

  • Page 61: Pedals

    61 www.Factoryfive.Com 508-291-3443 3. Make sure that the fuel line will not get in the way of the tire. Use zip-ties or fasten the lines securely to make sure there is sufficient clearance. Fuel filter mounted to the passenger side 2”x 3” tube . Pedals tools: ⅜”, 9 / 16 ” sockets, 3 / 16 ”, 5 / 16 ...

  • Page 62

    62 www.Factoryfive.Com 508-291-3443 1. Position the mustang pedal box on the two angled ¾” tubes over the driver’s feet, and attach using two short ⅜” bolts and two washers to the front wall at the front of the foot box. Positioning the pedal box . 2. There are four holes on the mustang pedal assemb...

  • Page 63

    63 www.Factoryfive.Com 508-291-3443 pedal box positioned . Note corner to be removed on pedal box . 5. Remove the pedal assembly. 6. Drill ¼” holes completely through the ¾” tubing for the pedal box. 7. Use a 7 / 16 ” drill bit to drill the bolt hole in the pedal box for the master cylinder bolt. 8....

  • Page 64

    64 www.Factoryfive.Com 508-291-3443 tightening the master cylinder. Note the spacers directly behind it . 1. Use the ⅜”x 2” bolts provided to mount the master cylinder and spacers to the footbox front wall. The number of spacers used dictates the height of the brake pedal. Start with one spacer unle...

  • Page 65: Cockpit Aluminum

    65 www.Factoryfive.Com 508-291-3443 7. If you plan to race frequently, use some small springs and attach them to the brake pedal and pedal box to prevent the pedal from moving during severe acceleration. 8. The small aluminum piece packed in the assembly is not used for this application. Cockpit alu...

  • Page 66

    66 www.Factoryfive.Com 508-291-3443 transmission tunnel front vertical wall positioned. 4. Push the top front of the floor transmission tunnel sides in against the front vertical wall then, while holding it in place, use your other hand in the transmission tunnel to position the bottom of the front ...

  • Page 67

    67 www.Factoryfive.Com 508-291-3443 1. Position the foot box floor. The front edge sits on top of the front wall bottom tab and the back gets attached to the 2”x 2” tube. 10. Mark where the rivets will go. 11. Remove the panel and apply silicone to the frame. 12. Attach the panel with self-tapping s...

  • Page 68

    68 www.Factoryfive.Com 508-291-3443 28. Take a look at the completed foot box and floor for gaps between the panels and around the seat harness mounts. Use silicone to fill these gaps. Drivers inside footbox passenger foot box 1. Position the foot box floor. The front edge sits on top of the front w...

  • Page 69

    69 www.Factoryfive.Com 508-291-3443 passenger inside wall assembled . 15. Position the front wall with self-tapping screws. 16. Mark where the rivets will go, remove the panel and apply silicone to the panels. 17. Rivet the panel in place. 18. Position the outside wall with self-tapping screws. 19. ...

  • Page 70

    70 www.Factoryfive.Com 508-291-3443 cockpit rear wall 1. Position the panel on the frame. The panel sits on top of the floors. 2. Mark where the rivets will go. 3. Remove the panel and apply silicone to the frame and aluminum tabs. 4. Attach the panels with self-tapping screws. 5. Rivet the panel in...

  • Page 71

    71 www.Factoryfive.Com 508-291-3443 • it is a good idea to make a small loop at the end of the lines (where they secure to the brake line mounts or master cylinder). This loop will provide good adjustment for any small variances without bending or crimping the line and provide protection from vibrat...

  • Page 72

    72 www.Factoryfive.Com 508-291-3443 3. Run the line up along the backside of the 2”x 3” frame members and across to the ¾” tubing that runs down forward to the transmission rear mount. 4. Attach the line to the frame with the small size insulated line clips (ffr# 10970) and 3 / 16 ” rivets provided ...

  • Page 73

    73 www.Factoryfive.Com 508-291-3443 brake distribution block line routing. Right is towards front of car . 6. From the distribution block, run the line forward along the ¾” tubing to the front side of the “x” member for a clean engine appearance. Go down along the “x” and up again then along the ¾” ...

  • Page 74

    74 www.Factoryfive.Com 508-291-3443 fuel line routing in front of the passenger foot box . 3. From the passenger outer corner, go towards the first 2”x 2” frame outrigger alongside the 4” round tube. 4. Fasten the lines to the 2”x 2” square cockpit outriggers with the insulated line clips. 5. In a s...

  • Page 75

    75 www.Factoryfive.Com 508-291-3443 rubber fuel line and mustang connector on fuel filter 11. Attach the connectors onto the fuel filter and fuel pump. 12. Run the vapor line to the plastic connector on the fuel tank along with the hard line to the fuel canister, which will be mounted later to about...

  • Page 76

    76 www.Factoryfive.Com 508-291-3443 2. Place the battery in the battery box and mark the height of the flat top of the battery on the box. 3. Remove the battery and use a ruler and marker to mark a line 3 / 16 ” below the point marked previously. Mark this all the way around the box. 4. Using a razo...

  • Page 77

    77 www.Factoryfive.Com 508-291-3443 marking the bolt locations on the box top. 17. Drill ¼” holes through the top of the ¾” tubes only, at the bolt locations marked. 18. Insert the “j” bolts into the tubes so that the threaded part sticks straight up. 19. Position the battery box with battery betwee...

  • Page 78: Alternate Drive Pulley

    78 www.Factoryfive.Com 508-291-3443 3. Install the block off plugs (with a ⅜” hex key) in the adapter holes not being used. Use the teflon tape on the threads of the plugs as you tighten them. Wrap the teflon tape so it stretches when you attach the plug into the threaded socket. Max torque for the ...

  • Page 79

    79 www.Factoryfive.Com 508-291-3443 assembling pulley on mount sleeve 5. Install the bolt assembly on the a/c bracket (previously drilled in the disassembly section), using the lock nut provided. 6. Pull the tension pulley back with a pry bar carefully and install the fan belt. If the belt does not ...

  • Page 80

    80 www.Factoryfive.Com 508-291-3443 1. If you are using a tko transmission, the rear of the transmission needs to be modified. The rear of the transmission needs to be trimmed to fit over the 4” crossmember. The mount hanging off the bottom of the housing is for a torque arm and must be trimmed off ...

  • Page 81

    81 www.Factoryfive.Com 508-291-3443 transmission mount bolted to frame. 3. Lift the engine using the two factory brackets that are on the 5.0 engine (make sure that the brackets are turned the correct way). Sometimes people put these lift brackets on backwards since they are removed when removing th...

  • Page 82

    82 www.Factoryfive.Com 508-291-3443 lowering engine into frame. Friends are helpful here . 7. Lower the transmission mount bolts into the rear transmission mount plate on the cross member and then lower the engine onto the frame engine mounts. Make sure that the passenger’s side engine mount hole is...

  • Page 83: Accelerator Cable

    83 www.Factoryfive.Com 508-291-3443 11. Fill the engine with oil. Use the stock dip stick line as a fill level. See appendix i for specifications and capacities. 12. Before installing the driveshaft, the rear axle should be allowed to hang with the frame being supported and the transmission should b...

  • Page 84

    84 www.Factoryfive.Com 508-291-3443 ball stud retainer pushed onto cable. 5. Insert the pedal end of the cable into the foot box. 6. Screw on and tighten the 5 / 16 ” locknut on the cable sheath inside the foot box using two ½” wrenches. 7. Hold the accelerator pedal up to the mount on the ¾” tube a...

  • Page 85

    85 www.Factoryfive.Com 508-291-3443 accelerator cable attached to engine. 13. Push the ball stud retainer onto the ball on the bottom of the throttle body. 14. Push/pull the cable into the retainer so that the cable is tight. 15. Tighten the set screw in the retainer using a 5 / 64 ” hex key. 16. Ch...

  • Page 86

    86 www.Factoryfive.Com 508-291-3443 stop tab on accelerator pedal. 94-95 fuel injected applications use the accelerator cable without modification. Follow the installation instructions above. Carburated applications 1. Insert the pedal end of the cable into the foot box. 2. Screw on and tighten the ...

  • Page 87: Clutch Cable

    87 www.Factoryfive.Com 508-291-3443 16. 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 remaining threads. 17. Push the ball stud retainer onto the ball stud. 18. Push/pull the cable into the retainer so that...

  • Page 88

    88 www.Factoryfive.Com 508-291-3443 mass air mounting note: if your engine is a 1989 or newer, follow this procedure for mounting the mass air meter and air filter. 1. Flatten the outer edge of the mounting bracket using a hammer or vise. Use the top oem hole and mount to the front side of the verti...

  • Page 89

    89 www.Factoryfive.Com 508-291-3443 3. The fan will be attached to the fan shroud via the mount strips. Position fan assembly in the mouth of the fan shroud so that the fan and shroud are flush. Fan attached to mount strips mustang fan shroud with kit fan and mount strips 4. Bend the tabs on the mou...

  • Page 90

    90 www.Factoryfive.Com 508-291-3443 mounting the radiator . 13. The aluminum nosepieces that form a picture frame-like support for the entire lower edge of the radiator will be installed after the body is in place. 14. Use the corrugated hose provided for the upper and lower radiator hoses to the ra...

  • Page 91

    91 www.Factoryfive.Com 508-291-3443 adapter hose pushed onto the tube. 19. Connect the lower radiator hose to the engine. 20. Run the hose next to the 4” main rail and under the steering rack. 21. Route the tube to the radiator. 22. Mark the tube where it needs to be cut so that the tube will just t...

  • Page 92

    92 www.Factoryfive.Com 508-291-3443 upper radiator tube. Note, the “f” panel would already be riveted in place. 37. When filling the radiator, use the upper hose for coolant filling. Make sure to get as much air out of the system as possible. 38. Connect the fan after the wiring harness has been ins...

  • Page 93

    93 www.Factoryfive.Com 508-291-3443 rear harness 1. Run rear harness along left side of the frame trunk extensions. 2. Use the inertia cut-off switch as a template and drill two holes in the trunk aluminum on the far corner of the driver’s side. Mount the inertia fuel cut-off switch on the inside. M...

  • Page 94

    94 www.Factoryfive.Com 508-291-3443 rear trunk wiring harness attached along frame . 5. From the battery forward, use some of the black plastic wire loom (included with kit) to cover and protect the rear harness and the battery cable. 6. Replace the cable ties that were used earlier during the batte...

  • Page 95

    95 www.Factoryfive.Com 508-291-3443 1. Push the harness plugs through the hole in the driver's side floor aluminum. Harness plug in floor aluminum 2. Run the harness forward into the corner to the ¾” tube at the foot box front. Then go up and along the angled ¾” tube to its connector. Make sure that...

  • Page 96

    96 www.Factoryfive.Com 508-291-3443 6. Using a 87-93 harness, wire the black electric fan wire to the frame. It serves as the ground. 7. Connect the other electric fan wire to one of the dash toggle switches through the relay provided. The fan is not needed all of the time. The 2-position toggle wil...

  • Page 97

    97 www.Factoryfive.Com 508-291-3443 dash harness going through laser cut hole . 7. The dash harness can then be run on top of the 2”x 2” square tube over to the computer side. Run everything loosely so that final positioning can be done. 8. The starter wires can be hooked up now. There are two diffe...

  • Page 98

    98 www.Factoryfive.Com 508-291-3443 aluminum fuse panel (87-98 only) mounted to the frame. 10. Mount the headlight and hazard switches using the aluminum pieces (ffr #’s 10566, 10638) in the center of the car just to the left of the transmission front cover. 11. Attach the harness across the 2”x 2” ...

  • Page 99

    99 www.Factoryfive.Com 508-291-3443 engine harness engine harness. 1. On the passenger’s side, the engine harness begins in the passenger foot box. The computer plug is pushed through the oval shaped hole on the passenger’s foot box top from the engine bay side. 2. Attach the computer to the undersi...

  • Page 100

    100 www.Factoryfive.Com 508-291-3443 engine harness plug mounted in firewall..

  • Page 101

    101 www.Factoryfive.Com 508-291-3443 engine harness passing through firewall extension. 5. Use screws provided with kit to mount the vacuum controls and bap (barometric air pressure) sensor to the firewall. Attention: note: the bap sensor is similar to a map sensor used on speed density cars except ...

  • Page 102: Gauge Pod Installation

    102 www.Factoryfive.Com 508-291-3443 gauge pod installation attention: if you are using aftermarket gauges, skip this section. Tools: wire stripper, crimping tool, electrical tape, wire cutters, phillips head screw driver, ⅜” socket head and socket wrench, razor knife, spray adhesive, silicone, caul...

  • Page 103

    103 www.Factoryfive.Com 508-291-3443 mustang gauge pod mounted to firewall . Note: mk. Ii frame shown . 11. Use the pod as a template to mark and drill the mounting holes in the aluminum using a ⅛” drill bit. 12. Mount using the screws provided in the kit. Use flat nuts on the back of each screw. A ...

  • Page 104

    104 www.Factoryfive.Com 508-291-3443 front trunk side wall. 2. The rear trunk sidewall is mounted to the outside of the frame. Rear trunk side wall..

  • Page 105

    105 www.Factoryfive.Com 508-291-3443 trunk front and rear side walls. 3. Place the mid-trunk floor panel (ffr# 10560) over the roll bar tube mounts by arching the panel up in the middle lengthwise and passing it from the cockpit side into the upper trunk. This can be tricky, but take your time and i...

  • Page 106

    106 www.Factoryfive.Com 508-291-3443 7. Apply silicone to the flat surfaces of the frame where the aluminum will contact. 8. Re-install the aluminum panel. 9. Use #8 screws to hold the panel in place. 10. Drill through the aluminum rivet holes into the frame. 11. Wipe and clean the aluminum. 12. Riv...

  • Page 107

    107 www.Factoryfive.Com 508-291-3443 brake cables in mount bracket. 3. Push the cable through the holes, and snap in the cable retainers. 4. If using 87-92 cables, after the sheath is snapped into the bracket, and run the cable down and under the 4” cross member and up to the “t” cable. The cable ru...

  • Page 108

    108 www.Factoryfive.Com 508-291-3443 brake cables running under the 4” crossmember. Brake cables attached to the t cable.

  • Page 109

    109 www.Factoryfive.Com 508-291-3443 emergency brake handle 5. Push the captive nuts onto the handle so the screw can be attached from the underside. 6. On 99-04 handles, remove the small bracket and screw that prevents the ratcheting adjustment gear from turning. Ratchet gear stop bracket and screw...

  • Page 110: Transmission Top Cover

    110 www.Factoryfive.Com 508-291-3443 2003 e-brake handle mounted. 8. Attach the 2-into-1 cable with the “t” connector to the handle if it is not already there. 9. Release the emergency brake handle using the button and make sure it is all the way in the down position. 10. Pull on the cables one at a...

  • Page 111

    111 www.Factoryfive.Com 508-291-3443 1. Slide the top cover under the rear u-joint cover, then forward and down as much as possible on top of the front wall tab. 2. Use a marker and ruler to mark rivet positions. 3. Remove the panel and silicone where the panel will touch the already mounted panels....

  • Page 112

    112 www.Factoryfive.Com 508-291-3443 6. Check for shock clearance on brake lines, emergency brake cables, brake calipers, frame and control arms. Checking the running gear 1. Secure loose and unused wires with cable ties. Look up the function of the wires in your chilton’s manual before you tape. Ne...

  • Page 113

    113 www.Factoryfive.Com 508-291-3443 rack. This effectively changes (reducing) your steering travel and turning radius, but it’s a good trick to remember if you use oversize tires or have bought custom wheels (not from us!) and the wheels rub slightly. Foot box top cover attention: check for electri...

  • Page 114: Roll Bar Drilling

    114 www.Factoryfive.Com 508-291-3443 kit driver footbox aluminum roll bar drilling tools: drill, 5 / 16 ” long drill bit, vise grips 1. Assemble the roll bar on the frame. Put the rear leg on, then slide the front hoop on all the way down to the small knobs on the holders. Push the rear leg up onto ...

  • Page 115: Body Cut-Outs

    115 www.Factoryfive.Com 508-291-3443 roll bar from inside trunk view. Assembled and bolted in place . Body cut-outs at this time you should be finished with the rolling chassis. This is an exciting time because the bulk of the real difficult work is behind you. From here on out, the time is really i...

  • Page 116

    116 www.Factoryfive.Com 508-291-3443 roll bar holes cut out with roll bar installed . Gas filler hole tools: 3.50” hole saw 1. Use the template in appendix a. 2. Cut the large circle out of the template. 3. Center the circle in the gas cap location. 4. Drill the 3.50” hole in the center of the cutou...

  • Page 117

    117 www.Factoryfive.Com 508-291-3443 connect the two holes with a jig saw to form the windshield slot 3. Repeat on the other side of the body. These ovals will be the slots through which the windshield bars will insert. Side exhaust cut-outs attention: use caution when cutting. Go slowly measure twi...

  • Page 118

    118 www.Factoryfive.Com 508-291-3443 driver's side exhaust cut out turn signal and tail light cut-outs tools: 1.25”holesaw, 3 / 16 ” drill bit, drill. 1. Use a 1.25” hole saw at the turn signal mount location to make the center hole. 2. Use the rubber gasket as a template to mark the locations of th...

  • Page 119

    119 www.Factoryfive.Com 508-291-3443 side louver cut out . Headlight cut-outs tools: hand jigsaw, drill, marker, tape, 7 / 16 ” drill bit. 1. Using a 7 / 16 ” drill bit, drill the two holes marked at the headlight mount locations. 2. On the headlight template that follows, cut out the two small hole...

  • Page 120

    120 www.Factoryfive.Com 508-291-3443 hood scoop cut-out tools: hand jigsaw, ¾” hole saw. A painted hood with the hood scoop cut out. 1. Use a ¾” hole saw in the upper corners of the hood scoop leaving room on the edge slightly more than the thickness of the material. 2. Cut out the scoop making sure...

  • Page 121: Hood Pins

    121 www.Factoryfive.Com 508-291-3443 trunk license plate light hole cut-outs attention: this kit is only a collection of parts designed for use primarily as a race car. Applying the license plate bracket does not mean that this vehicle is street legal. Factory five racing does not build completed or...

  • Page 122

    122 www.Factoryfive.Com 508-291-3443 top hood pin plate ready for drilling and riveting . 2. Bolt the top mounting plates to the side mounting plates. (be sure to line the top plate with the front ¾” tube. Top hood pin plate mounted to side plate . 3. Drill a 3 / 16 hole in the front ¾” tube. 4. Riv...

  • Page 123

    123 www.Factoryfive.Com 508-291-3443 1. Position the rear l-shaped handles (part of the three lock set ffr# 10624) in the holes near the rear of the hood. Point the handles to the rear of the hood. 2. Use a small square file to make room for the tabs on the handles. 3. Using a ⅛” drill bit, drill ho...

  • Page 124

    124 www.Factoryfive.Com 508-291-3443 10. Using a pen, mark the location of the bracket holes on the hood lip. 11. Remove the bracket and drill the holes. 12. Countersink the holes on the body's hood lip a little by turning a philips head screwdriver in the hole. 13. Mount the brackets with the angle...

  • Page 125

    125 www.Factoryfive.Com 508-291-3443 lowering a painted body down onto the completed chassis. 4. Raise the body up above the rolling chassis. 5. While holding the rear end of the body above the rear of the chassis, lower the nose section down, making sure that the 1 / 16 ” bent steel plates (the fro...

  • Page 126

    126 www.Factoryfive.Com 508-291-3443 slide the nose on first with the body up in the air . Rear quick jack bumpers attention: if you ordered the optional chrome bumper assembly, follow the instructions for these under the optional accessories section near the end of this manual. The quick jack bolts...

  • Page 127

    127 www.Factoryfive.Com 508-291-3443 tools: 5 / 16 ” drill bit, 3 / 16 ” hex key, drill, ½” wrench. Parts: secondary body fasteners (ffr# 10788). 1. Drill the holes at the points marked on the side of the body. 2. Push the u-nuts onto the side body mount plates. 3. Install the stainless side bolts (...

  • Page 128: Body Prep and Painting

    128 www.Factoryfive.Com 508-291-3443 3. If, after tightening the bolt, the spacer hits the body, move it so that it does not. The mounting plate will bend to accommodate. Body prep and painting attention: the door, hood and trunk panels are molded without flanges (edges), and then they are cut by a ...

  • Page 129

    129 www.Factoryfive.Com 508-291-3443 refer to appendix a for a drawing on how to make a wooden buck to hold the body. A body buck diagram is in the appendix. The dimensions do not have to be exact. A rough shape is all that is needed to hold the body. Tools: 80, 220, 400 grit sand paper, sanding blo...

  • Page 130: Rubber Seal On Aluminum

    130 www.Factoryfive.Com 508-291-3443 impossible to keep looking perfect if you are going to put miles on the car. If the car will sit in a protected garage all its life then yes, spend the $5000.00 on the show car paint. If you are like the rest of the world, try to control the expense of the projec...

  • Page 131: Final Body Mounting

    131 www.Factoryfive.Com 508-291-3443 press on bulb seal on trunk sidewall . 2. The top edge of the aluminum cockpit rear wall (ffr# 10823) does not have a rubber seal since it does not go all the way to the body seat, but is covered with the rear lip flange of the body. 3. Use the small adhesive bac...

  • Page 132

    132 www.Factoryfive.Com 508-291-3443 upper splash panel. 5. Position the lower splash panels in place on top of the upper panel and in front of the floor lip..

  • Page 133: Trunk Hinges

    133 www.Factoryfive.Com 508-291-3443 rear cockpit lower splash panel. 6. Hold the panels in place with #8 screws. 7. Use a marker and ruler to mark the rivet holes on the aluminum panel. 8. Note where the panels touch each other and where they touch the frame. Remove the panels. 9. Apply silicone to...

  • Page 134: Trunk Latch

    134 www.Factoryfive.Com 508-291-3443 attention: the hinges are marked left and right on the underside with a little (r) and (l). The hinges will bind and can damage the paint if mounted incorrectly. Tools: ⅜”, ½” wrenches. Parts: hood/trunk fasteners (ffr# 10646) 1. Mount the hinges to the trunk lid...

  • Page 135: Side Louvers

    135 www.Factoryfive.Com 508-291-3443 trunk latch pin mounted in trunk. 4. Pass the pin through pre-drilled hole in the body, then the pin sleeve and on through the aluminum and the 1 / 16 " plate on the frame. 5. Put the washer and nut on the pin and tighten with a ⅜” wrench and regular screwdriver....

  • Page 136

    136 www.Factoryfive.Com 508-291-3443 side louver attached to body. Fuel neck and gas cap attention: when you’re finished, double check the hose clamps that connect the rubber fuel neck to tank to cap. Previously the fuel neck hole was cut out of the body using the template. In 1999, ford changed the...

  • Page 137

    137 www.Factoryfive.Com 508-291-3443 87-98 mustang fuel tank neck with kit extension tube . Optional stainless steel filler neck 3. Use a hose clamp to attach the fuel neck extension tubing to the lower half of the mustang filler neck..

  • Page 138

    138 www.Factoryfive.Com 508-291-3443 stock fuel tank filler neck with extension . Optional stainless steel filler neck with extension. 4. Insert the neck back into the tank to prevent gas fume leakage and point the tube towards the ground to prevent anything from falling into the tank. 5. Place the ...

  • Page 139

    139 www.Factoryfive.Com 508-291-3443 gas cap located to open towards the center of the body. Note the ¼ turn gas cap. 7. Remove the gas cap leaving the rubber gasket. Use a marker through the gasket holes on the gas cap flange to mark the drill hole locations then remove the gasket. 8. Use an 1 / 8,...

  • Page 140

    140 www.Factoryfive.Com 508-291-3443 underside view of installed fuel filler neck extension. Windscreen attention: handle the windshield with care. This piece costs close to $645. Store in a safe place. Use caution while installing the screws into the windshield, they strip the brass strip very easi...

  • Page 141

    141 www.Factoryfive.Com 508-291-3443 inserting the windshield into the body. 3. Line up the windshield mount bars with the frame mount brackets below the body surface. Open up the slots in the body to get the correct angle if necessary. 4. Press the windshield down onto the body so that the rubber a...

  • Page 142: Hood Pins

    142 www.Factoryfive.Com 508-291-3443 inserting the windshield with the base plates in place . 11. Fasten the base plates to the body using the enclosed small screws and a matching drill bit to start the hole. Base plate screwed to body. Hood pins tools: drill, 3 / 32 ”, 7 / 16 ” drill bits, phillips...

  • Page 143: Doors and Hinges

    143 www.Factoryfive.Com 508-291-3443 6. Center the hood in the opening and press down. 7. This should leave a couple of small silicone marks on the underside of the hood. 8. Drill two 7 / 16 ” holes in the hood where the marks are located. 9. Raise the height of the posts so that they stick through ...

  • Page 144

    144 www.Factoryfive.Com 508-291-3443 latch without cover mounted to door. 5. Bolt the door to the car and do a rough alignment (bolt in the center of the slot) at the hinge end. Top backside of door hinge.

  • Page 145

    145 www.Factoryfive.Com 508-291-3443 door hinge. 6. Remove the striker bolt from the striker plate. 7. Loosely bolt the striker bolt to the frame. Door striker mounted. Note, seat and carpet are mounted in photo which would not have been done at this time..

  • Page 146: Check Straps

    146 www.Factoryfive.Com 508-291-3443 8. Shut the door slowly adjusting the striker to where it lines up with the latch. It may be necessary to shim the striker with washers to get the best alignment. 9. Finish the alignment of the door. Tighten down the striker once you achieve a good fit between th...

  • Page 147

    147 www.Factoryfive.Com 508-291-3443 under-door side impact protection. 1. Position the under door aluminum pieces. 2. Mark the rivet locations on the aluminum panel. 3. Remove the panel and silicone the frame. 4. Rivet the panel in place. Finished lower under door aluminum. 5. Test fit the upper un...

  • Page 148

    148 www.Factoryfive.Com 508-291-3443 passenger side upper under door aluminum. Passenger side upper under door aluminum positioned. 6. Remove the panel and silicone the frame. 7. Use the self tapping screws to hold the aluminum in place. 8. Rivet the panel in place. Side view mirror tools: ½” wrench...

  • Page 149

    149 www.Factoryfive.Com 508-291-3443 parts: rear view mirrors/fasteners (ffr# 11066) 1. The side view mirror location must be determined from sitting inside the car, so place one of your seats in the driver’s side. 2. The mirror must be positioned to clear the door when it is fully open. If you have...

  • Page 150: Radiator Aluminum

    150 www.Factoryfive.Com 508-291-3443 standard side view polished mirror installed . Radiator aluminum attention: use care when handling aluminum, the edges are sharp and can cut you. Tools: drill, #8 nut driver, ⅛”, 3 / 16 ” drill bits, rivet tool, floor jack, marker, ruler, silicone, caulk gun. Par...

  • Page 151

    151 www.Factoryfive.Com 508-291-3443 radiator nose aluminum mounted . 8. Line up the edge of the radiator fins with the edge of the side aluminum. 9. The top angle of the sidepieces will not go all the way down to the top of the quick jack mount. 10. From the wheel well side of the radiator, mark th...

  • Page 152: Side Exhaust

    152 www.Factoryfive.Com 508-291-3443 14. Insert and attach the radiator floor aluminum using either the screws provided or ⅛” rivets every 2”. Drilling the radiator and aluminum nose panels . 15. Apply silicone to the ¾” tubing where it will contact the aluminum sidepieces. 16. Install the sidepiece...

  • Page 153

    153 www.Factoryfive.Com 508-291-3443 exhaust mount cut in half. 2. Mount the straight pipes to the mustang headers. The passenger straight pipe is shorter. Aftermarket headers may require “ovaling” the holes on the two-bolt flange. 3. Leave the bolts hand tight in order to locate the side pipes prop...

  • Page 154

    154 www.Factoryfive.Com 508-291-3443 side exhaust mount post and its relative position to the front side body mount bolts side exhaust mounted on car . 8. Tighten the straight pipe bolts to the header. 9. Tighten the straight pipe to side exhaust bolts. 10. Check the alignment of the side exhaust ag...

  • Page 155

    155 www.Factoryfive.Com 508-291-3443 11. Using the rear exhaust mount as a guide drill a 5 / 16 ” hole through the inner most hole through the 2”x 2” tube. 12. Insert the rubber hanger into the side exhaust mount so that the female threaded part faces the 2”x 2”. 13. Attach a locknut and tighten the...

  • Page 156

    156 www.Factoryfive.Com 508-291-3443 installing the roll bar . Rearview mirror tools: drill, philips head screwdriver, ⅛”, 9 / 64 ” drill bits, tape measure, marker. Parts: rearview mirrors/fasteners (ffr# 11066) 1. Use a tape measure and marker to mark the center of the dash area on the ¾” dash tub...

  • Page 157

    157 www.Factoryfive.Com 508-291-3443 the rear view mirror, looking at it from the front of the car into the cockpit. Gauges and dash attention: • this assembly should be done carefully to avoid damage to the instruments. If you are using aftermarket, this section does not apply. The dash should only...

  • Page 158

    158 www.Factoryfive.Com 508-291-3443 odometer and trip meters. 3. Cut the gauges apart, using a hacksaw. It is best to put the gauges in a vise facing you and to only use a downward motion, with the hack saw, to avoid tearing the gauge face label. 4. With the gauges separated center them in their de...

  • Page 159

    159 www.Factoryfive.Com 508-291-3443 1994-1998 6. Drill the scribe marks on the gauges with the 5 / 32 ” drill bit. 7. The speedometer and tachometer holes in the dash are designed to work for two different size gauges. You will see a fine laser cut dashed line surrounding the cut out. These lines a...

  • Page 160

    160 www.Factoryfive.Com 508-291-3443 10. If you would like to install the three lights that are included in the kit, the original roadster’s had them positioned directly over the steering column in a straight line. Use a ½” drill bit for the holes. 11. The blue light will light when the high beams a...

  • Page 161

    161 www.Factoryfive.Com 508-291-3443 15. Cover each gauge face with paper so that spray adhesive does not get on the gauge faces. 16. Spray 3m super 77  adhesive over the front of the clean aluminum dash panel as well as the back surface of the vinyl or leather dash cover. 17. Remove the paper that...

  • Page 162

    162 www.Factoryfive.Com 508-291-3443 connecting the wire extensions from the dash to the gauge pod . 31. Hold and center the dash by using the steering shaft and steering hole then adjust the vertical height by raising the dash. Put the collar on the front side of the bearing. Do this after the shaf...

  • Page 163

    163 www.Factoryfive.Com 508-291-3443 1. Put some of the press-on bulb seal around the outside edge of the aluminum front splash guards (they look like large elephant ears). 2. Use the tin snips to cut the length and a pair of pliers to squeeze the bulb so that it will grip the aluminum. 3. Hold the ...

  • Page 164

    164 www.Factoryfive.Com 508-291-3443 rear splash guard mounted. Headlight assemblies tools: phillips head screwdriver, drill, ⅛”drill bit, wire strippers, wire cutters, electrical tape, marker, chilton’s manual. Parts: headlamp components (ffr# 11043)..

  • Page 165

    165 www.Factoryfive.Com 508-291-3443 headlight fasteners. 1. Insert the grommet in the hole in the side of the bucket. Grommet installed. 2. Push the headlight chrome clip (ffr#13415) onto the bucket bracket. 13419 13415 13418 13420 13416.

  • Page 166

    166 www.Factoryfive.Com 508-291-3443 chrome ring clip mounted. 3. Screw the two headlight adjustment screws (ffr# 13420) half way into the bucket using a philips head screwdriver. Adjustment screws installed. 4. Turn retaining ring over and positioned so that one tab is at the top and one is to the ...

  • Page 167

    167 www.Factoryfive.Com 508-291-3443 retaining ring. 5. Position the headlight in the retaining ring so that the light is the correct way up and the electrical tabs are as shown below. 6. Screw (ffr# 13418) the retaining ring clips (ffr# 13416) to the retaining ring. See the picture below for the co...

  • Page 168

    168 www.Factoryfive.Com 508-291-3443 pigtail wires and covering pulled through grommet. 9. Slide the retaining ring slots around the adjustment screws. Adjustment screw in slot. 10. Attach the retaining ring to the bucket using the last philips head screw (ffr# 13419)..

  • Page 169

    169 www.Factoryfive.Com 508-291-3443 retaining ring screw mounted. 11. Push the rubber gasket on the back of the bucket. 12. Hold a headlight up to the body holes cut earlier and use the bucket holes as a template to mark the screw holes. 13. Drill ⅛” mounting holes. 14. Screw on each headlight with...

  • Page 170

    170 www.Factoryfive.Com 508-291-3443 turn signal lights tools: 8mm deep socket, wire strippers, wire cutters, electrical tape, marker, chilton’s manual. Parts: front turn signals and hardware (ffr# 11044). 1. Mount the light to the body with the provided fasteners and an 8mm deep socket and ratchet....

  • Page 171

    171 www.Factoryfive.Com 508-291-3443 parts: tail-lights and hardware (ffr# 11042). 1. Insert the taillights into the holes made earlier. 2. Use a 13 / 64 ” deep well socket and the kit supplied nylon lock-nuts and washers to fasten the lights to the body. 3. Wire the taillights into the mustang harn...

  • Page 172: Seat Installation

    172 www.Factoryfive.Com 508-291-3443 use a couple of the small insulated line clips, with screws or rivets, to hold it to the trunk lid to hold the wires. 2. Pass the two wires from the license plate light through into the trunk. 3. Insert the rear license plate lamp into the trunk holes drilled ear...

  • Page 173

    173 www.Factoryfive.Com 508-291-3443 seat mounting area on frame. 2. Mark on the floor the location of the 4” round tube, the 2”x 2” tubes, and where the frame steel mount plate is located (between the x tubes under the seat). A. Use a marker and a ruler and measure 2” towards the outside of the car...

  • Page 174

    174 www.Factoryfive.Com 508-291-3443 7. If the seat can not get mounted in four places, reposition the seat. Note: the further apart the mounting locations are, the more solid the seat will feel. 8. Drill 13 / 64 ” holes, through the seat frame into the chassis..

  • Page 175

    175 www.Factoryfive.Com 508-291-3443 9. Remove the seat and drill through the seat frame holes only with a 9 / 32 ” drill bit so the screws can pass through the seat easily. 10. Re-align the seat in the cockpit and fasten the seat using an 8mm socket, ratchet and fasteners included with the seats. D...

  • Page 176

    176 www.Factoryfive.Com 508-291-3443 clean the aluminum cockpit floor before final assembly . 4. Use the following for the order of installation for all the carpet except the main floor pieces: rear cockpit corners rear cockpit wall transmission top cover u-joint cover passenger side footbox outside...

  • Page 177

    177 www.Factoryfive.Com 508-291-3443 carpet installed. Seat harness installation attention: these seat belts are frame mounted in three locations. Never drill a hole and attach these to aluminum alone. If you are not wearing a helmet, make sure that the roll bar is padded for adequate rear head prot...

  • Page 178

    178 www.Factoryfive.Com 508-291-3443 attaching harness to frame mounts. 4. Position the brackets at the correct angle before tightening. Use a ¾” socket and ¾” combination wrench to tighten the bolts. 5. The seat belt quick release latch should be on the right side if you are right handed, left if y...

  • Page 179: Shifter Installation

    179 www.Factoryfive.Com 508-291-3443 emergency brake boot installed. Shifter installation 1. Install the shifter handle onto the transmission neck using the shifter bolts provided. 2. Slide the boot over the shifter to determine where the holes need to be for the screws to hold it in place. 3. Drill...

  • Page 180: Nameplate

    180 www.Factoryfive.Com 508-291-3443 completed interior. You cannot see any of the aluminum. Nameplate factory five racing has included a nameplate for your kit. This can be engraved at any trophy or mall engraver. Below is an example of how the nameplate can be engraved with the serial number from ...

  • Page 181: Finishing Touches

    181 www.Factoryfive.Com 508-291-3443 finishing touches headlight alignment tools: marker, masking tape, tape measure. Note: • make sure that the car is at the correct ride height before the alignment procedure is done. Ride height should be 4 ½” at the front and 4 ½” at the back measured to the bott...

  • Page 182

    182 www.Factoryfive.Com 508-291-3443 6. On a piece of masking tape, draw one horizontal line on the wall at a height exactly 2 inches lower than measurement a. 7. On the line, make vertical marks both to the right and left of the vehicle centerline mark at the distance of measurement b from the vehi...

  • Page 183

    183 www.Factoryfive.Com 508-291-3443 alignment specifications take your new car to an alignment shop and have the car aligned properly before hitting the track. A minor flaw in alignment can cause very “twitchy” handling. Avoid temptation and never drive a car without proper alignment. For a manual ...

  • Page 184: Technical Support

    184 www.Factoryfive.Com 508-291-3443 chapter 3 - performance reference material and technical support.

  • Page 185: Technical Support

    185 www.Factoryfive.Com 508-291-3443 technical support our success depends on you being able to build your kit without problems or frustration. We are counting on you to build and drive this car and in so doing, provide us with the most important advertising of all. If you have purchased a kit, we w...

  • Page 186: Wheels

    186 www.Factoryfive.Com 508-291-3443 steps for you to complete when seeking registration of your vehicle. Provided with your factory five racing coupe kit is a manufacturer’s certificate of origin. This document records the origin of the vehicle and is not a vehicle title. The component kit that we ...

  • Page 187

    187 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 t...

  • Page 188: Performance Modifications

    188 www.Factoryfive.Com 508-291-3443 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 day that will tell you what you’ve got to have. We just want...

  • Page 189

    189 www.Factoryfive.Com 508-291-3443 rear end gears . Induction/fuel injection there are three things an engine needs; air, fuel and spark. If you allow more of each of these into the engine, it will make more power. Throttle body stock size: 58mm a 65mm throttle body work well up to 350hp. Ford mot...

  • Page 190

    190 www.Factoryfive.Com 508-291-3443 upper intake the next logical step for breathing is a more free flowing intake manifold. There are a number of intakes available from different companies (e.G. Edelbrock, trick flow). Ford also makes a good intake, the cast 1993 cobra intake from ford motorsport ...

  • Page 191

    191 www.Factoryfive.Com 508-291-3443 block cars. For big block cars, #10 lines are recommended to prevent a drop in oil pressure. High horsepower transmissions stock: t-5 the stock t-5 is good for the stock engine. If the engine is going to have some work done to it then an upgrade to a heavy duty, ...

  • Page 192

    192 www.Factoryfive.Com 508-291-3443 ffr competition bump steer kit . Rear suspension the standard solid axle rear suspension works well, is low maintenance and is reliable. The next step in performance is the 3-link upgrade for the solid axle. This is for the more serious driver that goes to more t...

  • Page 193

    193 www.Factoryfive.Com 508-291-3443 • we highly recommend using porterfield r-4, carbotech panther plus, or hawk blue brake pads. Though costly, you will find a significant difference in your cars ability to stop. If these pads are out of your price range, next in line would be performance friction...

  • Page 194

    194 www.Factoryfive.Com 508-291-3443 1984 jeep cherokee manual brakes 15 / 16 ” master cylinder (all steel) • the cobra brakes do not clear most halibrand style wheels. • when using this setup, the ’94 and newer rear axles have a hub-to-hub distance of 61.125” compared to the ’93 and older rear axle...

  • Page 195

    195 www.Factoryfive.Com 508-291-3443 miscellaneous brake information • the caliper from either lincoln will bolt on to the mustang spindle although the piston is 73mm in diameter, so it would not be well suited for the recommended brake setups above. If this caliper is used, a 1” master cylinder fro...

  • Page 196: Helpful Reference Material

    196 www.Factoryfive.Com 508-291-3443 factory five racing customers have successfully installed kenne bell, vortech, and powerdyne superchargers in their cars. The key to any supercharger installation seems to be the side that the supercharger is hooked up on. Use the ones that mount on the passenger...

  • Page 197

    197 www.Factoryfive.Com 508-291-3443 2. Helpful 3. Catalogs/parts 4. Factory five aftermarket 5. Insurance 6. Other at the end of each of the books are reference lists that the authors recommend. Smith and alexander give excellent sources for more information. Must reads • chilton’s 1989-93 ford mus...

  • Page 198

    198 www.Factoryfive.Com 508-291-3443 • very cool parts - distributor of the coolest parts available for your ffr. 760-403-6266. Www.Verycoolparts.Com tools • automotive equipment and supply - (a division of northern tools) serves autobody and repair shops nationwide. 800-468-8298. Www.Northernautosu...

  • Page 199: Appendix A – Templates

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

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

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

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

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

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

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

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

  • Page 207

    207 www.Factoryfive.Com 508-291-3443 86 3/4" 64 5/8" 75" 51" 39 1/4" 30" 6" 32 1/4" 37 3/8" 42 1/4" 13 7/8" 16 5/16" 48" 96" r10 5/8" r8 1/2" 1 1/2" 10 1/2" roadster a initial release 1998 b redrawn 1/21/04 revisions description rev. Date approved body buck b 11190 sheet 2 of 2 unless otherwise spec...

  • Page 208

    208 www.Factoryfive.Com 508-291-3443 length a initial release 12/18/00 1993 or earlier ford engine using t-5 or tko trans. 302 using 1994-1995 bellhousing and t-5 trans. 4.6l engine using t-45 or 3650 transmission mk. Iii roadster mk. Iii roadster mk. Iii roadster coupe/spyder 13.00" 12.50" 10.375" ...

  • Page 209

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

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    210 www.Factoryfive.Com 508-291-3443 87-98 fusepanel cut-out 99-04 fusepanel cut-out not to scale revisions description rev. Date approved fuse panel mount b sheet 3 of 3 unless otherwise specified: scale: 1:2 weight: rev dwg. No. A size title: name date comments: q.A. Mfg appr. Eng appr. Checked dr...

  • Page 211

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

  • Page 212

    212 www.Factoryfive.Com 508-291-3443 donor parts from ford mustang 5.0, 1987 to 1993 removed assembly name part name quantity from donor engine/drivetrain clutch cable 1 engine, 5.0l ford & t-5 trans, w/bolts/nuts 1 transmission mount w/bolts 1 driveshaft and 4 original bolts 1 speedometer cable 1 c...

  • Page 213

    213 www.Factoryfive.Com 508-291-3443 different donor vehicle options we highly recommend not using these different donor cars for the average build. This list will help with those parting out individual items, and possibly for those not using all of the donor parts. 1982-1986 8 donors • front brakes...

  • Page 214

    214 www.Factoryfive.Com 508-291-3443 appendix c – roadster standard pack list.

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    215 www.Factoryfive.Com 508-291-3443 customer:_______________________________________________________ box 1a primary chassis components (roadster) ffr # part name uni t qty check -off status 10632 ’87-’95 roadster build manual ea 1.00 11074 roadster ifs components 13819 ‘87-‘04 spindle adapter brack...

  • Page 216

    216 www.Factoryfive.Com 508-291-3443 box 2a secondary chassis components (roadster) ffr # part name unit qty check- off status 10788 roadster secondary body fasteners 11061 rubber bumper, small, (hood post) ea 10.00 10701 rubber bumper, large, (hood post) ea 10.00 10983 screw, #8 x 3/4", (hood post)...

  • Page 217

    217 www.Factoryfive.Com 508-291-3443 10972 ¾” flexible wire loom ft 10.00 12754 ½” flexible wire loom ft 10.00 10942 wire extension, 16 gauge ft 16.00 10940 butt connector, red ea 30.00 10973 flexible serrated polyethylene grommeting ft 4.00 11070 wiring harness mounting hardware 10984 bolt, #14 x 1...

  • Page 218

    218 www.Factoryfive.Com 508-291-3443 end of box 2a box 3a body finish components ffr # part name unit qty check- off statu s 14636 factory five badge ea 3.00 11043 headlamp components ea 2.00 included with above part# mount gasket bucket, black plastic 5 #8 x ½” screws retainer ring, chrome 3 retain...

  • Page 219

    219 www.Factoryfive.Com 508-291-3443 11024 bolt, 5/16"-18 x 1" ea 4.00 11005 washer, 5/16" uss ea 8.00 13963 lock nut, nylon, 5/16"-18 ea 4.00 10813 hood pin set ea 1.00 included with above part# 2 hood pins 2 hood pin plates 4 jam nuts 8 pan head screws 2 hood pin clip 10553 quick jack bumper compo...

  • Page 220

    220 www.Factoryfive.Com 508-291-3443 10833 bolt, 1/2"x 1.25" ea 2.00 10834 lock nut, nylon, 1/2"-13 ea 2.00 10520 bolt, 3/8"x 1.00" ea 2.00 13964 lock nut, nylon, 3/8"-16 ea 2.00 11080 alternate drive pulley components 10775 pulley wheel, (to replace a/c) ea 1.00 10952 pulley spacer, machined alumin...

  • Page 221

    221 www.Factoryfive.Com 508-291-3443 4 1373 8 brake line, 3/16" o.D. X 60" ea 4.00 1374 0 brake line, 3/16" o.D. X 20" ea 1.00 1469 2 brake line, 3/16" o.D. X 8” ea 1.00 1475 1 fuel line, ¼” o.D. X 60” ea 2.00 1475 2 fuel line, 5/16” o.D .X 60” ea 2.00 end of box 5a box 6a mkiii packaged aluminum ff...

  • Page 222

    222 www.Factoryfive.Com 508-291-3443 1314 1 aluminum patch cover, small half, (optional use) ea 1.00 1484 2 engine bay packaged aluminum 1371 3 aluminum panel, engine bay pass. "f" block-off ea 1.00 1086 5 aluminum panel, front nose floor ea 1.00 1227 3 aluminum panel, engine harness block-off plate...

  • Page 223

    223 www.Factoryfive.Com 508-291-3443 1391 9 carpet, lh floor, cockpit ea 1.00 1392 0 carpet, rh floor, cockpit ea 1.00 1392 3 carpet, lh sub-door section ea 1.00 1392 4 carpet, rh sub-door section ea 1.00 1392 5 carpet, lh outside footbox wall ea 1.00 1462 1 carpet, lh front footbox wall ea 1.00 139...

  • Page 224

    224 www.Factoryfive.Com 508-291-3443 14019 rh traction-lok bracket ea 1.00 14021 lh traction-lok bracket ea 1.00 10833 bolt, 1/2"-13 x 1.25", (upper, rear traction-lock extention) ea 4.00 10834 lock-nut, nylon, 1/2"-13, (upper, rear traction lock bracket) ea 4.00 13706 bolt, m12 x 110mm, (control ar...

  • Page 225

    225 www.Factoryfive.Com 508-291-3443 12776 bolt, 5/16"-18 x 1.5", (outside exhaust mount) ea 2.00 11024 bolt, 5/16"-18 x 1", (outside exhaust mount) ea 4.00 13963 lock nut, nylon, 5/16"-18 ea 8.00 13778 rubber exhaust mount ea 2.00 10851 screw, #14 x 1 1/2", (rubber hanger to chassis) ea 2.00 10829 ...

  • Page 226

    226 www.Factoryfive.Com 508-291-3443 10859 aluminum panel, lh footbox, top/inside section ea 1.00 10858 aluminum panel, lh footbox, top/outside section ea 1.00 10905 aluminum panel, lh footbox, vertical wall, inside ea 1.00 10904 aluminum panel, lh footbox, vertical wall, front ea 1.00 10554 aluminu...

  • Page 227

    227 www.Factoryfive.Com 508-291-3443 appendix d – big block instructions.

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    228 www.Factoryfive.Com 508-291-3443 part number: 12401 revision: d effective date: 03/12/03 by/date: j. Camire document type (indicate): ° bill of materials ° drawing (may be attached) ° specification • assembly instructions ° operating procedure °other big block 390/427/428/429/460 installation in...

  • Page 229

    229 www.Factoryfive.Com 508-291-3443 i. Disassembly of the mustang the following parts will not be required off of the mustang donor parts list. 1. Engine and t-5 transmission 2. Motor mounts 3. Mass air sensor 4. Oxygen sensors 5. Headers 6. Radiator 7. High pressure fuel line 8. Fuel evaporative c...

  • Page 230

    230 www.Factoryfive.Com 508-291-3443 fuel line and pressure regulator mounted at rear of engine (for carbureted applications) 3. The electric fuel pump should be mounted to a frame rail as close to the tank as is practical. The 2”x 3” is a good solid location, however, some pumps must be mounted bel...

  • Page 231

    231 www.Factoryfive.Com 508-291-3443 2. The throttle cable from the mustang donor car can be used with a carburetor and most holleys come with the correct linkage ball to snap on the cable. Use a universal throttle linkage bracket from holley or equivalent to hook the cable up to the intake. 3. The ...

  • Page 232

    232 www.Factoryfive.Com 508-291-3443 bellhousing and spacer lined up to mark pivot hole 17. The driveshaft will also vary in length depending on the transmission you select. Before you have your driveshaft shortened, measure the distance between the end of the transmission and the rear axle flange w...

  • Page 233

    233 www.Factoryfive.Com 508-291-3443 clutch fork installed awaiting transmission 19. The transmission mount to the crossmember must also be fitted with spacers. Two ¾” spacers need to be fit between the mount and the transmission, which raises the entire assembly. Even with this raise, the rear of t...

  • Page 234

    234 www.Factoryfive.Com 508-291-3443 torque arm mount removed for crossmember clearance 20. Level the motor using the intake manifold or the back of the bellhousing, this is important in order for the side exhaust to line up correctly with the body as well as for valve cover clearance on the drivers...

  • Page 235

    235 www.Factoryfive.Com 508-291-3443 engine ford motorsport 460 m-6007-c460 (svo) intake manifold 5066/torker ii (edelbrock) flat bottom 9 quart oil pan 13-766 (canton) oil pickup 13-767 (canton) starter 86 ford f350 460 5 speed aluminum v belt pulleys 1810 (march) alternator (single wire) sum-g1667...

  • Page 236

    236 www.Factoryfive.Com 508-291-3443 appendix e – 3-link instructions.

  • Page 237

    237 www.Factoryfive.Com 508-291-3443 3 link rear suspension installation instructions – initial build with frame prepared at factory parts included in kit: 1326 9 3 link hardware ea 1.00 1083 3 1/2"-13 x 1.25" bolt ea 4.00 1397 6 1/2" washer ea 10.00 1238 7 5/8" washer ea 4.00 1238 3 5/8"-11 nylon l...

  • Page 238

    238 www.Factoryfive.Com 508-291-3443 1083 4 1/2"-13 nylon lock nut ea 1.00 1414 8 upper link kit ea 1.00 1321 1 upper link tube ea 1.00 1221 7 1/2"-13 x 3" bolt ea 4.00 1221 8 clamp locknut, 1/2"-20 ea 4.00 1238 0 jam nut, right hand thread ea 1.00 1234 8 rod end, right hand thread ea 1.00 1406 5 ro...

  • Page 239

    239 www.Factoryfive.Com 508-291-3443 1. Remove the traction lock bracket from each side of the mustang rear-end. Replace with the competition driver’s side and competition passenger’s side bracket using the ½” bolts provided in the kit. You may need a rubber mallet as they are purposely a snug fit. ...

  • Page 240

    240 www.Factoryfive.Com 508-291-3443 driver's side competition traction-lok bracket 5. Once the hole has been drilled, install the panhard mount. Tighten all nuts. 6. Install a jam nut on each of the rod ends, remembering that two of them are left hand thread. 7. Thread each rod end into the panhard...

  • Page 241

    241 www.Factoryfive.Com 508-291-3443 panhard bar axle mount 9. Attach the panhard bar to the frame mount. 10. Test fit the two halves of the upper arm mount together. If it is hard to put all of the bolts in the mount holes, put in as many as you can then use a ½” drill bit through the remaining bol...

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

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    243 www.Factoryfive.Com 508-291-3443 13. Install the rod ends with jam nuts in the upper control arm and bolt the arm in place. One end bolts to the axle bracket just installed and the other end to the bracket welded in at the factory on the passenger side of the 2”x 3” frame rail. Use the spacers a...

  • Page 244

    244 www.Factoryfive.Com 508-291-3443 drill through mount into back of frame 15. Bolt the panhard bar frame mount to the back of the frame using the supplied ½”x 2.5” bolt and locknut. 16. To set the alignment, make sure that your ride height is where you want it, then adjust the pinion angle. We usu...

  • Page 245

    245 www.Factoryfive.Com 508-291-3443 appendix f – independent rear suspension.

  • Page 246

    246 www.Factoryfive.Com 508-291-3443 independent rear suspension installation instructions note: • these instructions are designed to supplement the assembly manual where the assembly process is different from the build using a solid axle. Sections of the manual that deal with the assembly of the re...

  • Page 247

    247 www.Factoryfive.Com 508-291-3443 • spindles and attaching hardware • brakes with flexible lines and mounting brackets • rear 10.50” brake rotors. Donor bolts/fasteners needed. (upper) spindle attaching bolts. (lower left) center section front mounts. (lower right) center section rear mount bolts...

  • Page 248

    248 www.Factoryfive.Com 508-291-3443 rear brake pads stainless braided brake lines 11.65” rear brake rotors rear caliper adapter brackets iv. Tools needed drill 3 / 16 ” drill bit ⅜”, ¾”, 15 / 16 ” sockets ⅜”, ¾”, 15 / 16 ” wrenches ⅜”- 7 / 16 ” brake line box wrench brake line bender snap ring plie...

  • Page 249

    249 www.Factoryfive.Com 508-291-3443 when selecting a donor vehicle, there are several important things to look for to avoid problems. Ford used the same irs set-up for a few different cars. Thunderbirds between 1989 and 1997, lincoln mark viii’s between 1992 and 1999, and mercury cougar xr7’s betwe...

  • Page 250

    250 www.Factoryfive.Com 508-291-3443 • there are only three differentials that will work in either the mark viii or t-bird center section, the stock supercoupe traction-lok, an auburn gear differential and a torsen differential. Auburn offers two units that will work. The high performance unit (part...

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    251 www.Factoryfive.Com 508-291-3443 • rotors once the spindles have been re-drilled, the rotors must be made to fit the new lug pattern. The easiest way to do this is using a dremel tool or grinder to oval out the existing stud holes. Mustang 5 lug rotors can not be used as they have a different wh...

  • Page 252

    252 www.Factoryfive.Com 508-291-3443 1. Using the thunderbird flexible brake line with the “t” connection on it, hold it up to the ¾” tubing on the driver’s side that connects the two 2”x3” frame rails. Mark the location of the mount hole and the locating pin hole on the tube as shown in the picture...

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    253 www.Factoryfive.Com 508-291-3443 brake line fittings 7. Attach the brake line going from the master cylinder to the rear brakes to the “t”. 8. Using the 60” brake line provided, make a line to run between the two flexible line mounts. Run the line along the 2”x 3” tube. Use the insulated line cl...

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    254 www.Factoryfive.Com 508-291-3443 5. Tighten the rear differential bolts. 6. Fill the differential with 3.25 pints gear oil and 4oz. Friction modifier. • lower control arm installation 1. Screw the jam nuts all the way onto the rod ends. 2. Screw the rod ends into the lower arms so that there is ...

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    255 www.Factoryfive.Com 508-291-3443 alignment shims in place. 6. Tighten the control arm bolts to spec. Tighten the jam nuts on the rod ends making sure that the rod ends are vertical and have room to articulate as the control arm moves. Koni irs coil-over shock assembly tools: snap ring pliers, ¾”...

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    256 www.Factoryfive.Com 508-291-3443 1. If retro fitting the koni shocks, place the car on jack stands and remove the old shocks and springs. Save all of the fasteners and spacers, they will be reused. 2. Double check the jam nut under the rod end and bump stop to make sure that it is tight. 3. Scre...

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    257 www.Factoryfive.Com 508-291-3443 6. Slide the rubber bumper about two inches down on the shaft. 7. Put the spring on the shock, then install the spring hat on the shaft end of the shock and push the rubber bumper up against it. 8. Rotate the spring seat back up the sleeve so that the spring push...

  • Page 258

    258 www.Factoryfive.Com 508-291-3443 assembled koni coil-over shock. 10. Position the shock so that the shock body is on top and the rod end is in the triangle of the lower control arm that the shock mount is in. 11. Fasten the shock to the top mount with the fasteners, washers and spacers provided ...

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    259 www.Factoryfive.Com 508-291-3443 (left) lower shock-mounting fasteners/spacers. (right) upper shock mounting fasteners/spacers. 12. Fasten the shock to the bottom mount with the fasteners and spacers provided. The longer spacer goes towards the front of the car..

  • Page 260

    260 www.Factoryfive.Com 508-291-3443 lower shock mount. 13. Check for clearance on brake lines, emergency brake cables, brake calipers, frame and control arm parts. 14. Run zip ties through the holes in the spring hat and around the spring to prevent the spring from becoming unseated. 15. Adjust the...

  • Page 261

    261 www.Factoryfive.Com 508-291-3443 note: on pin drive irs suspensions it may be necessary to move the shock snap ring to the upper groove to allow for correct ride height adjustment depending on the desired ride height and tire height combination. See the picture below: 16. Once the ride height is...

  • Page 262

    262 www.Factoryfive.Com 508-291-3443 2. Attach the shaft end of the quad shock to the rear quad shock bracket hole on the frame using the washer on the outside of the quad shock as shown in the picture. Quadshock mounted to frame bracket. • spindle installation attention: the caliper is mounted on t...

  • Page 263

    263 www.Factoryfive.Com 508-291-3443 • rear calipers and rotors 1. Push the slotted rotor onto the spindle. 2. Attach the caliper to the spindle using the oem t-bird bolts. • emergency brake cable installation 1. Release the emergency brake handle using the button and make sure it is all the way in ...

  • Page 264

    264 www.Factoryfive.Com 508-291-3443 e-brake cables attached to triangles emergency brake cable next to mounting bracket. 4. Pull on the “t” connector attached to the emergency brake handle and slide on the cables one at a time. 5. Pull up on the emergency brake handle, so that the automatic tension...

  • Page 265

    265 www.Factoryfive.Com 508-291-3443 old hose slit and covering new hose. Zip tied in place. Xi. Final assembly 1. Double check that all of the bolts are tight. 2. Mount your wheels and tires. 3. Lower the car off the jack stands. 4. Set the ride height in the car as specified in the manual 5. Once ...

  • Page 266

    266 www.Factoryfive.Com 508-291-3443 initial testing at new hampshire international speedway mark drag racing the twin turbo/irs prototype car at run & gun 1999. 10.91 seconds at 127mph.

  • Page 267

    267 www.Factoryfive.Com 508-291-3443 appendix g – torque specifications.

  • Page 268

    268 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 269

    269 www.Factoryfive.Com 508-291-3443 appendix h – mustang specifications.

  • Page 270

    270 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 2003 ford made 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) special ...

  • Page 271

    271 www.Factoryfive.Com 508-291-3443 1983.5 t-5 2.95 1.94 1.34 1.00 0.725 n/a 2.76 265 e3zr-7003-a 75 1984 t-5 2.95 1.94 1.34 1.00 0.625 n/a 2.76 265 e4zr-7003-da 75 1985-89 t-5 3.35 1.93 1.29 1.00 0.675 n/a 3.15 265 e(5,6)zr-7003-(fa,fb) 75 1989-93 t-5 3.35 1.99 1.33 1.00 0.675 n/a 3.15 300 f(z,9,0...

  • Page 272

    272 www.Factoryfive.Com 508-291-3443 called a hydro-boost system. This system utilized pressurized power steering fluid to assist in pedal pressure. This unit works with ffr kits with an adaptor bracket which comes standard with ffr 96-04 efi kits (more brake component information can be found in th...

  • Page 273

    273 www.Factoryfive.Com 508-291-3443 1983-98 19 tooth pink c0dz-00017271-b 1983-98 20 tooth black c1dz-00017271-a 1983-98 21 tooth red c40z-00017271-a 1983-98 23 tooth white e6ms-0017271c-m mass air sensor mass air sensors are devices used to measure air flow into the engine for the vehicles compute...

  • Page 274

    274 www.Factoryfive.Com 508-291-3443 from 1986 to 1993 the mustang upper and lower radiator hoses, as well as the firewall heater hoses remained the same, and are a required donor part for ffr 87-93 efi kits. The bypass hose, engine to thermostat housing hose, and the thermostat to overflow tank hos...

  • Page 275

    275 www.Factoryfive.Com 508-291-3443 quad shocks are attached between the axle and the chassis of solid axle mustangs from 1983.5 to 2004 to prevent wheel hop. This is a required donor part for all solid axle ffr kits, and they are also used for independent rear suspension ffr kits. There is a mount...

  • Page 276

    276 www.Factoryfive.Com 508-291-3443 0 0 1994 f400/r165 f500/r265 f400/r16 0 1995 f400/r165 f500/r265 f400/r16 0 f700/r20 0 f850/r26 0 1996-98 f400/r165 f500/r265 f400/r16 0 1999 f450/r210 f500/r47 0 2000 f450/r210 f800/r75 0 2001-02 f450/r210 f500/r470* 2003 f450/r210 f600/r600* 2004 f450/r210 *con...

  • Page 277

    277 www.Factoryfive.Com 508-291-3443 appendix i - fluid specifications and capacities engine oil type capacity 302 10w-30 5.0 qts. 4.6l 5w-30 8.0 qts w/ffr pan transmission oil type t-5 t-45 3650 tko t-56 mercon/dexron iii trans. Fluid 2.8 qts. 3.25 qts. 4.0 qts. 2.64 qts. 4.0 qts 8.8 solid rear axl...