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Factory Five Racing Mk4 Roadster Assembly Manual

Other manuals for Mk4 Roadster: Assembly Manual, Assembly Manual, Assembly Manual
Manual is about: Complete Kit

Summary of Mk4 Roadster

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    R e v i s i o n 3 o , j a n u a r y 2 0 1 2.

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     2012 factory five racing inc. 9 tow rd wareham, ma 02571 phone 508.291.3443 • fax 508.291.3883.

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    Ii www.Factoryfive.Com 508-291-3443 table of contents table of contents.......................................................................................Ii general information ................................................................... 8 foreword ...........................................

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    Iii www.Factoryfive.Com 508-291-3443 cv axles ................................................................................................. 92 spindles .................................................................................................. 93 upper control arms...........................

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    Iv www.Factoryfive.Com 508-291-3443 clutch cable ............................................................................... 227 accelerator cable ....................................................................... 229 87-93 5.0l fuel injected applications.......................................

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    V www.Factoryfive.Com 508-291-3443 front quick jacks ................................................................................. 325 hood fitment and bumpers ......................................................... 326 hood hinge ..................................................................

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    Vi www.Factoryfive.Com 508-291-3443 rollbar mounting ................................................................................... 439 door and latch mount .......................................................................... 440 windshield mounting ..........................................

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    Vii www.Factoryfive.Com 508-291-3443 high performance manual braking systems ............................... 489 miscellaneous brake information .......................................................... 489 superchargers ............................................................................ 4...

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    8 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 h...

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    9 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 l...

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    10 www.Factoryfive.Com 508-291-3443 all the way thru the process, as you build your car, the seasoned guys at factory five in tech support will help you. The larger community of factory five customers will also be there for you, as the one thing that really sets us above the crowd of other companies...

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    11 www.Factoryfive.Com 508-291-3443 safety notice 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-liability at the advice of...

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    12 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...

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    13 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...

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    14 www.Factoryfive.Com 508-291-3443 cooling system/parts: electric cooling fan and mounting hardware, aluminum radiator w/cap and in-line filler neck, stainless steel radiator hose kit incl. Adapter kits, fasteners, overflow tank w/cap, hoses, hose clamps, mounting hardware, 185° thermostat switch. ...

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    15 www.Factoryfive.Com 508-291-3443 rear end: 1987-2004 ford 8.8” rear axle. 1987-1993 width is optimal 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. Bat...

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    16 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 2”x 2” tube going across the car at the front of the cock...

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    17 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...

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    18 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 d...

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    19 www.Factoryfive.Com 508-291-3443 pizza and beer for previous line item.

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    20 www.Factoryfive.Com 508-291-3443 disassembly of the kit chapter 2.

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    21 www.Factoryfive.Com 508-291-3443 unpacking your 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. This is the box number that the assembly was packaged in. The kit is packaged in the order that you will...

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    22 www.Factoryfive.Com 508-291-3443 unbolt the quick jacks and remove the body. Two people can do this but it is much easier with a third person to pull the sides clear of the chassis..

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    23 www.Factoryfive.Com 508-291-3443 aluminum removal # ¼” nut driver, jack stands, marker. , do one panel at a time. Be careful of the sharp aluminum edges, they can cut you. Using a marker outline the underside of each panel where it contacts the chassis. This is done to locate where to drill rivet...

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    24 www.Factoryfive.Com 508-291-3443 mark each panel and take pictures of how the panels fit together (i.E. Which is on top). Remove each panel after it has been marked until the chassis is bare. Keep the #8 screws to help with aluminum positioning later during build-up. Use jack-stands to position y...

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    25 www.Factoryfive.Com 508-291-3443 chassis assembly 3.

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    26 www.Factoryfive.Com 508-291-3443 rivet spacing tool p 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 edge of the tool t...

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    27 www.Factoryfive.Com 508-291-3443 drill the panels using a 1 / 8 ” bit then clean the marker lines and labeling off using acetone or brake cleaner..

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    28 www.Factoryfive.Com 508-291-3443 apply silicone to the panel or chassis (whichever is easier) in the areas where they will make contact. Use the original #8 screws to remount the panel then drill the 1 / 8 ” rivet holes through the panel holes into the chassis..

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    29 www.Factoryfive.Com 508-291-3443 rivet the panel in place using 1 / 8 ” short rivets, then remove the screws and replace them with rivets. Repeat for the other side..

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    30 www.Factoryfive.Com 508-291-3443 front suspension front lower control arm # ⅞” socket, 5 / 16 ”, 15 / 16 ” wrenches, torque wrench p front lower control arm assembly unpack the front lower control arms and hardware. Screw the grease fittings into the arms using a 5 / 16 ” wrench..

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    31 www.Factoryfive.Com 508-291-3443 mount the lower control arms using the outer set of holes on the chassis using the supplied hardware. The rear bushing mount on the chassis is wider to be able to accept oem arms so use the large shim washers provided to take up the extra space..

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    32 www.Factoryfive.Com 508-291-3443 while holding the arm parallel to the ground, torque the bolts to 135-149nm (100-110 lbft). Front upper control arm # vise, thread locker, ⅜”, ¾” wrench, ¾” socket, torque wrench p ifs components , the bolts and no flange locknuts for the rear bolt location are pa...

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    33 www.Factoryfive.Com 508-291-3443 put thread locker on the upper balljoint threads. Screw the upper ball joints into the control arms; make sure to screw the ball joints in from opposite sides to give a right and left arm. Tighten the balljoint using the arm for leverage with a vice holding the ba...

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    34 www.Factoryfive.Com 508-291-3443 screw the grease fittings in to the ball joints and tighten with a ⅜” wrench. Mount the upper control arms to the chassis with the solid corner facing the front. Use the mount holes that are vertical on the side of the 2”x 3” tube, not the top horizontal ones..

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    35 www.Factoryfive.Com 508-291-3443 , the bolts and lock nuts for the rear control arm mount are packed with the spindles. The locknut without the flange is used on the rear mounting hole. Torque the two bolts that hold the arm to the frame to 135-149nm (100-110 lbft)..

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    36 www.Factoryfive.Com 508-291-3443 adjusting the upper control arm , use the diagram below for reference. 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 short...

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    37 www.Factoryfive.Com 508-291-3443 , the front shocks extended measurement is 15.15” center to center. They are 2.50” shorter than the rear shocks unpack the front 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 spr...

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    38 www.Factoryfive.Com 508-291-3443 slide the rubber bumper about two inches down on the shaft. Put the spring and hat on the shock and rotate the spring seat back up the sleeve so that the spring pushes the hat tight against the end of the shock..

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    39 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. Pass the shock assembly (with the body of the shock up) through the upper a-arm and attach them to...

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    40 www.Factoryfive.Com 508-291-3443 check for shock clearance on brake lines, emergency brake cables, brake calipers, frame and axle parts. Check to make sure that the spring is seated correctly on the shock. Run zip ties through the holes in the spring hat and around the spring to prevent the sprin...

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    41 www.Factoryfive.Com 508-291-3443 fasten the shock to the top mount with the fasteners and 0.675” spacers provided and torque both upper and lower mounts to 40 ft-lbs..

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    42 www.Factoryfive.Com 508-291-3443 spindles # 13 / 16 ” socket, torque wrench, needle nose pliers, rubber mallet p spindle assembly, ifs components. Unpack and lay out the hardware for the spindles assembly. , the spindles are marked dss (driver side spindle) and pss (passenger side spindle). These...

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    43 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..

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    44 www.Factoryfive.Com 508-291-3443 attach the upper ball joint to the spindle and torque to 75 ft-lbs and install the cotter pin. , the upper ball joint boot will look crushed and out of shape when the car is in the air, this is ok. The boot will seat when the car is on the ground. Bolt the steerin...

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    45 www.Factoryfive.Com 508-291-3443 the hub is a snug fit on the spindle and may require a light tap with a soft mallet to get in place. Torque the hub nut to 305-338nm (225-250 ft-lbs). Using a large socket or a flat head screwdriver and rubber mallet, hit the dust cap onto the hub..

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    46 www.Factoryfive.Com 508-291-3443 front suspension torque specs chart item nm lbft 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 spindle 95-122 70-90 spindle hub nut 305-338 225-250 front b...

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    47 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. Install the slider grease boots on the slider pins..

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    48 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 ...

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

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    50 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...

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    51 www.Factoryfive.Com 508-291-3443 grease the slide pins using the supplied grease. Slide the caliper hanger onto the caliper..

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    52 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...

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

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    54 www.Factoryfive.Com 508-291-3443 install the brake pads in the caliper..

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    55 www.Factoryfive.Com 508-291-3443 clean the rotor with brake cleaner and push it onto the hub. Install the caliper on the spindle; make sure that the fluid bleeder is at the top of the caliper. Torque the caliper mounting bolts to 130nm (95 ft-lb)..

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

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    57 www.Factoryfive.Com 508-291-3443 solid axle rear suspension , skip to the independent rear suspension if not installing a solid axle. , two bolts are included with the control arms, the other two are included in the kit with the traction lok brackets. Solid axle preparation # ¾” sockets, ¾” wrenc...

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    58 www.Factoryfive.Com 508-291-3443 if using a used rear axle, remove the lower shock mounts and the anti vibration weight under the pinion. Drill the lower control arm mount holes with a ½” drill bit..

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    59 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 driver's side.

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

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    61 www.Factoryfive.Com 508-291-3443 tighten the two short bolts. Torque to ford specs 75-95 nm (55-70 lbft)..

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    62 www.Factoryfive.Com 508-291-3443 attach the lower control arms to the brackets on the axle using the bolt provided. Torque to 101-111nm (75-82 lb-ft) the lower bolt holes provide more traction than the upper holes. 3 link rear suspension # 3 / 16 ”, ⅜”, ½” drill bits, ⅝”, ¾”, 15 / 16 ”, 1” wrench...

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    63 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 yo...

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    64 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..

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    65 www.Factoryfive.Com 508-291-3443 install a jam nut on each of the rod ends, remembering that two of them are left hand thread..

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    66 www.Factoryfive.Com 508-291-3443 insert the rod ends into the swedged tubes (one is right hand thread and one is left hand thread). The longer tube is the panhard bar and the shorter one is the upper link. Upper link attach the short upper link tube to the axle upper link mount using the ¼” space...

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    67 www.Factoryfive.Com 508-291-3443 rear axle , have someone help with this step, the rear axle is very heavy and mistakes can result in serious injury. Use a floor jack to position the rear axle assembly under the frame..

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    68 www.Factoryfive.Com 508-291-3443 , make sure that the rear jack stands are positioned under the 4” round tube as far back as possible to prevent the frame from tipping up once the axle is mounted , do not hold the end of the axle from the bottom of the disc, if the axle falls, the axle can crush ...

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    69 www.Factoryfive.Com 508-291-3443 attach the lower control arms to the frame mounts..

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    70 www.Factoryfive.Com 508-291-3443 jack the rear axle up and attach the upper link to the frame. Rear coil-over shock assembly # snap ring pliers, ¾” wrench, ¾” socket, ratchet, ruler, marker, hack saw. P roadster/coupe rear shock kit , the rear shocks are pre-valved at the factory in compression a...

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    71 www.Factoryfive.Com 508-291-3443 unpack the rear 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. The center high part of the set should be poin...

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

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    73 www.Factoryfive.Com 508-291-3443 use zip ties to hold the spring to the spring hat. Assembled solid axle koni coil-over shock. Attach the body end of the shock to the upper shock mount using the two equal length (1.09”) spacers..

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    74 www.Factoryfive.Com 508-291-3443 jack the rear axle up so the rod end of the shocks can be mounted on the axle through the shock mount hole. 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...

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    75 www.Factoryfive.Com 508-291-3443 passenger side driver side.

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    76 www.Factoryfive.Com 508-291-3443 check for shock clearance on brake lines, emergency brake cables, brake calipers, frame and axle parts. Check to make sure that the spring is seated correctly on the shock. Run zip ties through the holes in the spring hat and around the spring to prevent the sprin...

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

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

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    79 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..

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    80 www.Factoryfive.Com 508-291-3443 install the ½”-13 x 2.5” bolt and tighten. Tighten the bolts on the quad shock brackets..

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    81 www.Factoryfive.Com 508-291-3443 the panhard bar mounts to the car using the ⅝”x 3” bolts and spacers. Install the panhard bar to the passenger side traction lock bracket. Three spacers are used in the front (2) 0.375" (ffr# 14064) and (1) 0.25" (ffr# 14065). The rear uses the thin 0.0625" shim (...

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    82 www.Factoryfive.Com 508-291-3443 attach the panhard bar to the frame mount using the spacers provided..

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    83 www.Factoryfive.Com 508-291-3443 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 adjust the upper arm until the desired angle is reached. We usually run abou...

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    84 www.Factoryfive.Com 508-291-3443 unpack the rear suspension box and the irs completion parts. Irs center section mount the rear center section to the chassis. It installs from the bottom with the driveshaft flange pointing straight up and the axle holes lined up front to back with the chassis. Us...

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    85 www.Factoryfive.Com 508-291-3443 slide the bushing sleeves into the bushings from the top. Through bolt the two front bushings and the remaining rear mount with the mounting hardware and tighten..

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    86 www.Factoryfive.Com 508-291-3443 lower control arms screw the rod ends with jam nuts into the lower control arm. Screw the forward joint in all the way then back out 4 turns..

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    87 www.Factoryfive.Com 508-291-3443 mount the lower arms to the chassis with the shock mount hanging down below the arm. The rear bolt can be slip in place with no shims for now. Shim the front bolts using 3 shims on the front side of the rod end on both the left and right arms..

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    88 www.Factoryfive.Com 508-291-3443 tighten the front bolts for both lower control arms. It is also a good idea to snug the rear bolts even though they will be removed again for alignment. Irs rear coil-over shock assembly # snap ring pliers, ¾” wrench, ¾” socket, ratchet, ruler, marker, hack saw. P...

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    89 www.Factoryfive.Com 508-291-3443 unpack the rear 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. The center high part of the set should be pointed away...

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

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    91 www.Factoryfive.Com 508-291-3443 assembled solid axle koni coil-over shock. Use zip ties to hold the spring to the spring hat. Mount the coil-over to the chassis mount using the two of the smaller length spacers on either side. The body of the shock goes toward the top..

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    92 www.Factoryfive.Com 508-291-3443 mount the lower control arm to the coil-over with the remaining large and small spacers. The large spacer goes toward the rear. Cv axles push the cv joints into the rear axle and let them rest on the lower arm..

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    93 www.Factoryfive.Com 508-291-3443 spindles slide the splined end of the outer cv joint into the hub and mount the spindle to the lower arm..

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    94 www.Factoryfive.Com 508-291-3443 upper control arms screw in the rod end and jam nut into the upper arm and attach it to the chassis using a short equal length spacer on either side of the rod end..

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    95 www.Factoryfive.Com 508-291-3443 attach the upper arm to the spindle and tighten all of the spindle mounting hardware..

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    96 www.Factoryfive.Com 508-291-3443 irs brakes # ¾” wrench, ¾” socket, ratchet, ¾”, 5 / 16 ” hex key, flat head screwdriver, torque wrench, thread locker. The rear brake caliper bracket needs to be loosely attached to the adapter plate with just the upper bolt and spacer. This bolt and all others on...

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    97 www.Factoryfive.Com 508-291-3443 put the nuts on the back of the adapter bracket mounting bolts and tighten the bracket to the spindle..

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    98 www.Factoryfive.Com 508-291-3443 lift the caliper bracket up and slide the rotor under it and into place. You can use a lug nut to hold it in position. Mount the other caliper bracket bolt and spacer. This bolt is a button head to allow clearance for the e- brake cable..

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    99 www.Factoryfive.Com 508-291-3443 tighten both caliper bracket mounting bolts..

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    100 www.Factoryfive.Com 508-291-3443 put the brake pads in place on the rotor and slide the caliper down over the top of them. Make sure you use the correct side caliper and the bleeder screw is at the top. Install the caliper to bracket bolts and tighten..

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    101 www.Factoryfive.Com 508-291-3443 firewall & driver front footbox aluminum # drill, 1 / 8 ” drill bit, rivet tool, caulk gun, silicone p firewall and driver footbox front aluminum, secondary body fasteners. , if you are installing a heater/defroster it is much easier to cut the firewall before in...

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    102 www.Factoryfive.Com 508-291-3443 rivet the firewall in position on the chassis. Mark, drill, and rivet in place the driver’s side footbox front panel, leave the lower section that attaches to the ¾” tube un-siliconed and un-riveted for the inside wall to slip underneath later..

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    103 www.Factoryfive.Com 508-291-3443 pedal box # ½”, 9 / 16 ” sockets, ⅜”, 11 / 32 ”, ½”, 9 / 16 ” wrenches, drill, 3 / 16 ”, ¼”, ½” drill bit, 1 / 8 ”, 9 / 32 ”, 3 / 16 ”, 5 / 16 ” hex keys, hammer, vise or 2 pieces of 2 x 4, razor knife or file or grinder, snap ring pliers. P pedal components, ped...

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    104 www.Factoryfive.Com 508-291-3443 use snap ring pliers to remove one of the retaining clips from the brake pedal pivot sleeve and pull the sleeve to remove the pedal. Place the brake switch mount between the brake pedal mount tabs on the side closest to the brake pedal pivot holes and drill a 3 /...

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    105 www.Factoryfive.Com 508-291-3443 attach the brake switch mount to the pedal box using the black #8 screw and locknut..

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    106 www.Factoryfive.Com 508-291-3443 clutch cable quadrant using snap ring pliers, remove one of the retaining clips from the clutch pedal pivot sleeve. Push the pivot sleeve out and remove the pedal and remove the second snap ring from the clutch pedal pivot sleeve..

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    107 www.Factoryfive.Com 508-291-3443 using snap ring pliers, attach one of the snap rings to the new longer pivot sleeve provided. Push the pivot sleeve through the clutch quadrant from the left side. If necessary, chase the quadrant hole with a ½” drill bit so that the quadrant can slide on the piv...

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    108 www.Factoryfive.Com 508-291-3443 put one of the wilwood pedal washers on the pivot sleeve next to the quadrant..

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    109 www.Factoryfive.Com 508-291-3443 remove the snap ring holding the master cylinder mount to the clutch pedal, push the pivot sleeve out and remove the master cylinder mount. Attach the wilwood pedals to the underside of the mounting bracket using three button head screws and locknuts and the stud...

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    110 www.Factoryfive.Com 508-291-3443 the stud should get mounted on the left side next to the clutch pedal pivot sleeve boss. A tap in with a hammer and punch will get the stud to stick while tightening. Attach the clutch pedal stop mount to the bottom of the pedal box using two ¼” socket head screw...

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    111 www.Factoryfive.Com 508-291-3443 put the remaining thin washer and snap ring on the pivot sleeve..

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    112 www.Factoryfive.Com 508-291-3443 insert the 2” aluminum spacer between the quadrant and the clutch pedal lining up the small hole in the quadrant and the hole in the clutch pedal..

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    113 www.Factoryfive.Com 508-291-3443 insert the long ⅜” socket head screw from the quadrant side through the small hole in the quadrant then the spacer and the clutch pedal, screw on the locknut and tighten. , check that the clutch moves freely and does not contact the stud. If needed file the top o...

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    114 www.Factoryfive.Com 508-291-3443 place the pedal box assembly in the drivers footbox. Make sure that the brake pedal goes in front of the ¾” cross tube on the frame. Unpack the pedal box hardware from the secondary chassis components box..

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    115 www.Factoryfive.Com 508-291-3443 insert three ⅜” x 1” socket head screws from the pedal box hardware assembly and the one included in this pedal assembly through the front of the footbox and through the pedal box mount..

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    116 www.Factoryfive.Com 508-291-3443 push the rear pedal box mount onto the master cylinder mount studs and use a few of the jam nuts from the wilwood pedal assembly to temporarily hold the rear mount in place..

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    117 www.Factoryfive.Com 508-291-3443 tighten two of the front ⅜” screws then use a marker to mark the locations of the rear mount holes on the ¾” tubes..

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    118 www.Factoryfive.Com 508-291-3443 loosen the bolts and remove the pedal box assembly from the footbox then use a ¼” drill bit and drill to drill through the ¾” tubes at the locations marked for the rear mount. Reinstall the pedal box assembly in the driver’s footbox; use the ¼”x 1.50” screws from...

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    119 www.Factoryfive.Com 508-291-3443 master cylinders place a jam nut from the wilwood pedals onto each of the master cylinder threaded shafts. Put one of the master cylinders onto one of the brake master cylinder mounts and turn the threaded shaft into the threaded mount on the brake pedal. As a st...

  • Page 121

    120 www.Factoryfive.Com 508-291-3443 attach and tighten the locknuts holding the master cylinder to the pedal box then repeat for the other master cylinder..

  • Page 122

    121 www.Factoryfive.Com 508-291-3443 tighten all the remaining hardware mounting the pedal box to the chassis. Thread the jam nut onto the ⅜”x 1.25” screw provided in the quadrant box..

  • Page 123

    122 www.Factoryfive.Com 508-291-3443 from the underside, push the screw through the quadrant pedal stop mount plate and hand tighten the locknut on the screw..

  • Page 124

    123 www.Factoryfive.Com 508-291-3443 clutch cable and firewall adjuster push the firewall adjuster into the front of the footbox and attach to the front of the pedal box using the screws provided and a 9 / 64 ” hex key and an 11 / 32 ” wrench. Pull the rubber mount off the end of the clutch cable..

  • Page 125

    124 www.Factoryfive.Com 508-291-3443 use a razor knife, file or grinder to remove the plastic barbs from the plastic shaft. Slide the clutch cable boss through the adjuster and loop the cable over the quadrant..

  • Page 126

    125 www.Factoryfive.Com 508-291-3443 accelerator pedal # 5 / 64 ” hex key, ⅜”, 7 / 16 ”, ½” wrenches, wire cutter, ¼” drill bit, drill, marker, masking tape. P accelerator cable components, accelerator pedal components, pedal box hardware. , the accelerator cable is designed to be used with all type...

  • Page 127

    126 www.Factoryfive.Com 508-291-3443 use one ¼”x ¾” screw and locknut from the pedal box hardware position the accelerator pedal using the top hole in the accelerator pedal mount so that the top of the pedal lines up with the accelerator cable hole so the cable will come out straight. Mark the lower...

  • Page 128

    127 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..

  • Page 129

    128 www.Factoryfive.Com 508-291-3443 thread the inner cable through the cable retaining lock nut from the accelerator cable components assembly. Route the cable through the hole in the firewall and slide the sheath back over the cable..

  • Page 130

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

  • Page 131

    130 www.Factoryfive.Com 508-291-3443 steering shaft # 5 / 32 ”, 3 / 16 ”, 5 / 16 ” hex keys, ½”, 9 / 16 ”, 10mm wrenches, marker, drill, 3 / 16 ” drill bit, philips head screwdriver, 15mm deep socket, ratchet. P steering bearings/hardware, steering shaft, manual steering rack and adapter. Unpack the...

  • Page 132

    131 www.Factoryfive.Com 508-291-3443 loosely 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..

  • Page 133

    132 www.Factoryfive.Com 508-291-3443 loosely mount the top pillow block to the chassis with the set screw toward the rear of the car. Slide the steering shaft into the footbox from the engine bay through the lower bearing..

  • Page 134

    133 www.Factoryfive.Com 508-291-3443 steering rack # needle nose pliers, ¾” wrench, ¾” socket, ratchet p steering rack assembly, steering system hardware , the inner tie rod extensions are for stock power steering racks only, not for manual steering racks. Unpack the manual steering rack and the mou...

  • Page 135

    134 www.Factoryfive.Com 508-291-3443 push the bushings and sleeves into the mounting bosses on the rack. Center the steering rack. Line up the steering shaft and adapter and push the rack onto the steering shaft..

  • Page 136

    135 www.Factoryfive.Com 508-291-3443 bolt the rack into the frame. It is easier to do the driver side first then swing the passenger side down into the mount..

  • Page 137

    136 www.Factoryfive.Com 508-291-3443 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. Attach the tie rod to the spindle, torque the castle nut to 25 ft-lbs and install the cotter pin..

  • Page 138

    137 www.Factoryfive.Com 508-291-3443 use thread locker on all the steering shaft screws that do not have jam nuts and the adapter screws. Upper steering shaft # 5 / 32 ”, 3 / 16 ”, 5 / 16 ” hex keys, ½” wrench, rubber mallet p steering system hardware unpack the upper steering shaft from the primary...

  • Page 139

    138 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..

  • Page 140

    139 www.Factoryfive.Com 508-291-3443 tighten the upper and lower bearings. Also tighten the set screw on the upper shaft. Fuel tank # 9 / 16 ” and 5 / 16 ” deep sockets, ratchet, 7 / 16 ” wrench, rubber mallet, hammer, marker, punch or flathead screwdriver, 3 / 16 ”, 5 / 16 ” hex key, floor jack, fr...

  • Page 141

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

  • Page 142

    141 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 143

    142 www.Factoryfive.Com 508-291-3443 insert the small rubber vent gasket in the small hole on the top of the tank..

  • Page 144

    143 www.Factoryfive.Com 508-291-3443 use a small amount of wd40 to lubricate the inside of the vent gasket and push the white plastic vent down into the gasket. Set the rubber o-ring gaskets in place for the fuel pump pickup..

  • Page 145

    144 www.Factoryfive.Com 508-291-3443 slide the pickup down into the tank; you will have to rotate as you go to get the tubes into the sump and line up the tabs on the pick-up and slots on the tank. You can see this looking through the filler neck hole..

  • Page 146

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

  • Page 147

    146 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. Repeat this process for the level sender..

  • Page 148

    147 www.Factoryfive.Com 508-291-3443 slide the filler neck tube into the tank. A little oil on the rubber gasket helps. Slide the retaining bracket down the filler tube and mark its mounting location on the tank..

  • Page 149

    148 www.Factoryfive.Com 508-291-3443 move the retainer out of the way and make sure your mark is outside the weld that holds the two tank halves together. Drill a ¼” hole through the tank flange on the mark made..

  • Page 150

    149 www.Factoryfive.Com 508-291-3443 use the ¼”bolt and locknut to attach the retainer to the tank. Push the four plastic end caps into the tubes hanging down in front and behind the gas tank..

  • Page 151

    150 www.Factoryfive.Com 508-291-3443 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. Hang the fuel tank straps from the rear mount of the chassis using two of the strap fasteners. The longer strap goes on the passenger side..

  • Page 152

    151 www.Factoryfive.Com 508-291-3443 using a jack, raise the tank up into place on the chassis. Make sure the plastic cover is in position below the tank..

  • Page 153

    152 www.Factoryfive.Com 508-291-3443 bolt the straps in with the strap fasteners and drop the jack..

  • Page 154

    153 www.Factoryfive.Com 508-291-3443 tighten only the driver’s side strap as the passenger one will be removed for aluminum fitment later on. Cockpit aluminum # drill, ⅛” drill bit, rivet tool, silicone, caulking gun, #8 self tapping screws, #8 hex nut driver, ruler, marker, acetone or carburetor cl...

  • Page 155

    154 www.Factoryfive.Com 508-291-3443 silicone this panel where it meets the chassis and rivet along the bottom of the 2” square frame crossbar only. Use one of the original screws to temporarily hold it to the other small chassis tube. Drill the tunnel front a-shaped piece where it meets the chassis...

  • Page 156

    155 www.Factoryfive.Com 508-291-3443 mark and drill the two vertical edges of the passenger footbox inside wall. Silicone and rivet the panel to the front tunnel “a” and the footbox top..

  • Page 157

    156 www.Factoryfive.Com 508-291-3443 mark the holes in the passenger footbox front panel upper and outer edges but do not drill yet..

  • Page 158

    157 www.Factoryfive.Com 508-291-3443 silicone the panel and install with the temporary screws then drill through both panels and rivet it in place. Silicone the flanges for the passenger footbox floor then install and rivet it in place. The floor sits on top of the flanges from the footbox walls..

  • Page 159

    158 www.Factoryfive.Com 508-291-3443 mark and drill all three flanges on the passenger outer footbox top. Silicone the flange between the outer top and the outer wall and attach the two pieces together using the temporary screws..

  • Page 160

    159 www.Factoryfive.Com 508-291-3443 silicone the remaining flanges then install the outer wall/top on the footbox with rivets. Make sure the rear edge is flush to the chassis and not caught up on the door hinge before you start riveting..

  • Page 161

    160 www.Factoryfive.Com 508-291-3443 passenger floor drill the passenger side floor where it was marked to attach to the chassis. Mark the two front flanges but do not drill yet..

  • Page 162

    161 www.Factoryfive.Com 508-291-3443 silicone the chassis where the aluminum floor will touch. The main chassis rails are not riveted to but still need a bead of silicone run along the tops. The top edge of the tunnel is not riveted yet but gets silicone as well..

  • Page 163

    162 www.Factoryfive.Com 508-291-3443 drill and rivet the floor in place to the chassis. Use a couple clamps or tape to hold the tunnel top to the tunnel until the silicone sets. Drill, silicone, and rivet the passenger outside wall in place. Leave the rivets out of the rear vertical flange for now..

  • Page 164

    163 www.Factoryfive.Com 508-291-3443 driver floor drill silicone and install the driver’s footbox floor. The outer flange does not get drilled yet..

  • Page 165

    164 www.Factoryfive.Com 508-291-3443 silicone, drill, and install the driver side floor. Install the drivers side outer wall same as the passenger..

  • Page 166

    165 www.Factoryfive.Com 508-291-3443 the inner wall for the driver side is different for a 4.6l engine than for any of the others. The 4.6 panel is pictured on the left. It has an extra bend about 10” in from the front. Drill, silicone and install the inner footbox wall. The front flange tucks in be...

  • Page 167

    166 www.Factoryfive.Com 508-291-3443 u-joint cover mark the rear tunnel cover where it meets the chassis then silicone and rivet it in place..

  • Page 168

    167 www.Factoryfive.Com 508-291-3443 transmission tunnel rear corners the inner rear corner pieces tuck behind the tunnel sides and sit on top of the floor. Mark the rivet spacing on the top edge and silicone and rivet the three flanges that make contact..

  • Page 169

    168 www.Factoryfive.Com 508-291-3443 cockpit rear corners the outer cockpit corners get marked on the bottom flange and where they meet the chassis. Drill silicone and rivet these in place..

  • Page 170

    169 www.Factoryfive.Com 508-291-3443 cockpit rear wall mark and drill the rear cockpit wall. Silicone the chassis and aluminum flanges where it attaches and rivet it into place..

  • Page 171

    170 www.Factoryfive.Com 508-291-3443 fuel system # tube bender, 3 / 16 ”drill bit, drill, rivet tool, marker, tape measure, flat head screwdriver p insulated clip hardware, fuel line components, ¼”, 5 / 16 ” fuel lines, oem fuel tank components. Unpack the fuel filter and mounting hardware..

  • Page 172

    171 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..

  • Page 173

    172 www.Factoryfive.Com 508-291-3443 clamp the filter in place on the mount with the filter flange oriented as shown..

  • Page 174

    173 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. Hold the filter up to the 2”x 3” chassis tube, mark the holes, then dr...

  • Page 175

    174 www.Factoryfive.Com 508-291-3443 , 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 are barbed fittings provided for both sizes..

  • Page 176

    175 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; ...

  • Page 177

    176 www.Factoryfive.Com 508-291-3443 from the filter we generally run the lines down the 2”x 3” tube behind the rear cockpit wall and alongside the outside of the main 4” frame tube. , which side you run down may depend on where you are hooking up to your fuel rail, carburetor, or pressure regulator...

  • Page 178

    177 www.Factoryfive.Com 508-291-3443 fasten the lines to the 2”x 2” square cockpit outriggers with the insulated line clips and 3 / 16 ” rivets..

  • Page 179

    178 www.Factoryfive.Com 508-291-3443 brake system # tube bender, 3 / 16 ”, ¼”, 7 / 16 ”, ⅝” drill bits, drill, rivet gun, marker, tape measure, razor knife, round file or sand paper, brake fluid. P pedal components, insulated clip hardware, brake line components, 3 / 16 ” brake lines, front caliper/...

  • Page 180

    179 www.Factoryfive.Com 508-291-3443 the brake reservoir mounts to the front of the footbox just inside the hood opening. Take the reservoir with cap and line it up so the top is in line with the top of the hood support tube and mark the holes. Make sure your hole location is low enough fit a nut on...

  • Page 181

    180 www.Factoryfive.Com 508-291-3443 drill a ⅝” hole one inch down from the bottom of the reservoir. This hole is for the fluid line to run through so take extra time with a file and round all the edges making sure there are no burrs left or sharp spots..

  • Page 182

    181 www.Factoryfive.Com 508-291-3443 route the fluid line for the master cylinders through the hole and press onto the bottom of the reservoir. Loosely install the banjo fittings on each master. Make sure there is a crush washer on either side of the fitting..

  • Page 183

    182 www.Factoryfive.Com 508-291-3443 route the line from the reservoir to the master cylinders splitting it using the t provided. Make sure that the line cannot get in the way of moving parts, especially the brake pedal!.

  • Page 184

    183 www.Factoryfive.Com 508-291-3443 use insulated clips from the secondary chassis box or zip ties to hold in place and tighten the banjo fittings on the master cylinders. Front flexible brake lines unpack the hardware from the brake line components..

  • Page 185

    184 www.Factoryfive.Com 508-291-3443 , the crossed off parts in the picture above are for the stock mustang master cylinder and flexible brake lines so are not used. The u-nuts, washers and button head screws are for the e-brake handle mounting. The small black screws are for the e-brake boot unpack...

  • Page 186

    185 www.Factoryfive.Com 508-291-3443 , which side you run down may depend on where you are hooking up to your fuel rail, carburetor, or pressure regulator. We usually run the fuel lines on the passenger side of the car and the brake lines on the driver side of the car. The laser cut stainless bracke...

  • Page 187

    186 www.Factoryfive.Com 508-291-3443 attach the front brake line to the caliper making sure there is a crush-washer on either side of the fitting and then screw the other end of the line to the fitting on the chassis. Hand tight is fine on all these for now..

  • Page 188

    187 www.Factoryfive.Com 508-291-3443 screw the brake line t fitting into the end of the drivers side brake adapter and tighten..

  • Page 189

    188 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. Torque the front flexible brake line to caliper banjo bolts to 29 ft-lbs. Hard brake lines run one of the longer 60” brake lines ...

  • Page 190

    189 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 it in place. Use another of the long 60” brake lines and route from the drivers side adapter back to the master cylinder. Either master cylinder can be used for fro...

  • Page 191

    190 www.Factoryfive.Com 508-291-3443 mount the line clips and seal with silicone anywhere you pass into the passenger compartment..

  • Page 192

    191 www.Factoryfive.Com 508-291-3443 use a long 60” brake line and route from the second master cylinder toward the rear of the car. You can either run down the outside or inside front of the footbox, in this case we have run inside which is cleaner, just be careful to keep the line firmly attached ...

  • Page 193

    192 www.Factoryfive.Com 508-291-3443 use a union to attach the remaining 60” brake line. Run the brake line up the back of the 2”x 3” tube. , at this point your routing will depend on your rear brakes. 87-93 mustang solid axles have a single flex line that runs to the middle of the axle then out to ...

  • Page 194

    193 www.Factoryfive.Com 508-291-3443 using the ffr rear brakes, we attached the flexible brake line mount to the driver side diagonal ¾” tube with the brake line clip. Attach the “t” adapter to the flexible brake line and route the hard brake line coming from the front to the “t”..

  • Page 195

    194 www.Factoryfive.Com 508-291-3443 run a 60” brake line from the “t” up the ¾” tube to the front fuel tank mount tubes and over to the passenger side ¾” tube. An alternative to running it this way would be to run it across the backside of the 2”x 3” tube..

  • Page 196

    195 www.Factoryfive.Com 508-291-3443 attach the passenger side flexible brake line mount to the ¾” tube and attach the flexible brake line to the bracket with the brake line clip..

  • Page 197

    196 www.Factoryfive.Com 508-291-3443 attach the hard brake line to the flexible brake line. When your system is finished being plumbed, go back and check all the fittings for tightness. Fill the system with fluid and bleed being very thorough in checking for leaks..

  • Page 198

    197 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. Banjo bolt torque specs front brake hose to caliper banjo bolt – (39nm) 29lbft rear brake caliper hose to caliper banjo bolt – (4...

  • Page 199

    198 www.Factoryfive.Com 508-291-3443 route the harness according to the instructions. The brake light switch plug in the harness gets cut off and replaced with spade connectors. It is not important which terminal on the switch has which wire..

  • Page 200

    199 www.Factoryfive.Com 508-291-3443 trunk aluminum # 1 / 8 ” drill bit, silicone, rivet gun, caulk gun, 9 / 16 ” wrench, 5 / 16 ” hex key. P mounted aluminum, packaged aluminum, secondary body fasteners silicone and rivet in the trunk side panels..

  • Page 201

    200 www.Factoryfive.Com 508-291-3443 remove the rear bolt of the passenger side gas tank strap. With the rear taillight harness tied up and secure, silicone and install the lower trunk floor. Silicone and install the lower trunk floor..

  • Page 202

    201 www.Factoryfive.Com 508-291-3443 re-install the gas tank strap and tighten. Silicone and install the trunk inner corner pieces..

  • Page 203

    202 www.Factoryfive.Com 508-291-3443 silicone and rivet the fuel tank strap patch panel from the packaged aluminum assembly..

  • Page 204

    203 www.Factoryfive.Com 508-291-3443 drill and silicone the upper trunk floor. The rivets along the front 2”x 3” tube should be close to the back as possible for drill and rivet gun access. Bend it in the middle to get it into position. Work the corners of the panel down over the roll bar mounts and...

  • Page 205

    204 www.Factoryfive.Com 508-291-3443 battery mounting and cable # drill, 1” hole saw, 3 / 16 ”, ¼”, 5 / 16 ” drill bits, rivet gun, marker, 7 / 16 ” deep socket, ratchet, ½” wrench, 3 / 16 ” hex key. P secondary body fasteners, battery mounting kit, insulated clip hardware, misc. Electrical componen...

  • Page 206

    205 www.Factoryfive.Com 508-291-3443 drop the j-bolts in the mounting holes and mark where they hit the trunk floor. Drill the ¼” mounting holes in the floor..

  • Page 207

    206 www.Factoryfive.Com 508-291-3443 hook the j-bolts through the floor and bolt the battery down. Hold the j-bolts with a vice grip and be careful not to over tighten and crack or distort the battery..

  • Page 208

    207 www.Factoryfive.Com 508-291-3443 remove the powder coating from the small circle in the trunk closer to the ground terminal of your battery. Drill through the center of the circle and put a washer down in the cut out..

  • Page 209

    208 www.Factoryfive.Com 508-291-3443 bolt the ground strap to the chassis, the battery terminal is left off for now while the rest of the system is being routed..

  • Page 210

    209 www.Factoryfive.Com 508-291-3443 drill out the hole you didn’t use for the ground with a 1” hole saw. Install one of the grommets in the hole..

  • Page 211

    210 www.Factoryfive.Com 508-291-3443 route the small end of the batter cable from through the floor from the top and hook to the battery terminal. Attach the battery positive terminal and leave enough slack to be able to remove the terminal easily..

  • Page 212

    211 www.Factoryfive.Com 508-291-3443 cover the remaining positive cable that runs underneath the car with the provided conduit to protect it from the elements..

  • Page 213

    212 www.Factoryfive.Com 508-291-3443 drivetrain install transmission prep # hack saw or reciprocating saw, ¾” socket, ratchet p transmission, polyurethane engine/transmission mount kit if you are using a tremec 3550, tko 500 or, a tko 600 you will need to trim off the unused mounting boss on the bot...

  • Page 214

    213 www.Factoryfive.Com 508-291-3443 trim it flush or just below the pad for the transmission mount. Engine prep # engine hoist, chain, ¾”, 15 / 16 ” sockets, ratchet, extension p engine, polyurethane engine/transmission mount kit , the easiest method to install the drivetrain is with the engine and...

  • Page 215

    214 www.Factoryfive.Com 508-291-3443 if using a 4.6l or coyote engine remove the stock oil pan and install a shallow oil pan. Unpack the engine and transmission mounts and attach to the engine but leave the bolts loose enough to be able to wiggle the mounts around for alignment. 87-95 oil filter rel...

  • Page 216

    215 www.Factoryfive.Com 508-291-3443 install the oil filter relocate base plate on the engine. 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 attac...

  • Page 217

    216 www.Factoryfive.Com 508-291-3443 thread the short end of the threaded nipple into the relocator..

  • Page 218

    217 www.Factoryfive.Com 508-291-3443 mark the hole locations for the oil filter relocator on the old ac bracket or on the front frame x member (preferred location). If you’re going to mount the relocate bracket on the x member. Drill the mounting holes for the relocator. , make sure to drill this be...

  • Page 219

    218 www.Factoryfive.Com 508-291-3443 engine/transmission installation lower the engine and transmission into place. The more hands you have to help the better. Go very slowly and make sure the transmission tail-shaft is above the rear cross-member..

  • Page 220

    219 www.Factoryfive.Com 508-291-3443 install the engine mount to chassis nuts and tighten down all the engine mount hardware. Make sure the alignment pins on the mounts are in the holes on the chassis pads..

  • Page 221

    220 www.Factoryfive.Com 508-291-3443 transmission mount # 5 / 16 ” hex key, 9 / 16 ”, ¾” socket, ratchet, ¾” wrench, floor jack p transmission mount/hardware unpack the a-frame transmission mount and hardware. Jack the transmission up and mount the a-frame underneath it. Normally this mounts above t...

  • Page 222

    221 www.Factoryfive.Com 508-291-3443 install the bolts that hold the transmission to the mount and tighten all the hardware on the mount and a- frame..

  • Page 223

    222 www.Factoryfive.Com 508-291-3443 driveshaft # 14mm wrench, thread locker p driveshaft unpack the driveshaft and slip it up into the rear of the transmission. The most room to do this is usually to hold the shaft just above the center section and come in from the driver’s side. The driveshaft bol...

  • Page 224

    223 www.Factoryfive.Com 508-291-3443 fit the driveshaft snug against the yoke and install the bolts and tighten. You can put the transmission in gear to stop the driveshaft from turning while you tighten..

  • Page 225

    224 www.Factoryfive.Com 508-291-3443 headers and j-pipes # 7 / 16 ”, 9 / 16 ” wrenches, 7 / 16 ” socket, ratchet, extension, 5 / 16 ” hex key p headers or straight tubes and shorty headers or catalytic convertors and shorty headers mount up your headers to the engine. If you are using full length he...

  • Page 226

    225 www.Factoryfive.Com 508-291-3443 also if you are using the cats or j-pipes bolt them to the headers. The shorter pipe will go on the passenger side..

  • Page 227

    226 www.Factoryfive.Com 508-291-3443 fuel system # flat head screwdriver p fuel line components, external fuel pressure regulator (if used) finish running your fuel system by hooking up either to your carburetor or fuel rail. Here we mounted a pressure regulator on the firewall and ran a single line...

  • Page 228

    227 www.Factoryfive.Com 508-291-3443 clutch cable p clutch cable, insulated clip hardware route the clutch cable down to the bellhousing. Using zip ties or insulated clips tie the cable safely away from the headers and the moving steering components. It can be fastened to the engine using the bracke...

  • Page 229

    228 www.Factoryfive.Com 508-291-3443 connect the clutch cable to the bellhousing and the clutch fork..

  • Page 230

    229 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. 87-93 5.0l fuel injected a...

  • Page 231

    230 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. Push the ball stud retainer onto the ball on the bottom of the throttle body. Make sure the accelerator cable is tied up and out of the way...

  • Page 232

    231 www.Factoryfive.Com 508-291-3443 check the idle screw underneath the throttle body to see if the throttle arm is hitting it. If it is not, either loosen the ball stud retainer set screw and readjust the cable or, bend the small tab behind the accelerator pedal until the idle screw hits the throt...

  • Page 233

    232 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 234

    233 www.Factoryfive.Com 508-291-3443 tighten the accelerator cable locknut. Push the ball stud retainer onto the throttle pedal. While pulling the cable tight, push the accelerator pedal up until it hits the frame and align the ball stud retainer with the cable. Mark on the cable where the retainer ...

  • Page 235

    234 www.Factoryfive.Com 508-291-3443 the hole in the firewall extension can be used to pass wires through from the engine to behind the dash and we often mount the computer inside the cockpit with the wires running through here. There is a cover plate that can be drilled to a smaller hole as well..

  • Page 236

    235 www.Factoryfive.Com 508-291-3443 silicone and rivet the dash extension in position..

  • Page 237

    236 www.Factoryfive.Com 508-291-3443 cooling system # marker, hack saw, insulated clip hardware, drill, ¼” drill bit, 3 / 16 ” hex key, 7 / 16 ”, ½” wrenches, ruler, flathead screwdriver. P fan mounting components, stainless radiator hose kit, roadster cooling system, insulated clip hardware, packag...

  • Page 238

    237 www.Factoryfive.Com 508-291-3443 center the fan on the radiator and mark the brackets to trim off the excess..

  • Page 239

    238 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 zip tie the radiator in place on the chassis. The bottom section can just hang by...

  • Page 240

    239 www.Factoryfive.Com 508-291-3443 mark the center of the radiator and the center of the chassis and offset the radiator by ⅝”. Drill the holes to mount the radiator top flange to the two small mounting tubes on the chassis..

  • Page 241

    240 www.Factoryfive.Com 508-291-3443 mount the radiator top to the flange with the hardware provided. The bottom stays zip tied for now..

  • Page 242

    241 www.Factoryfive.Com 508-291-3443 stainless radiator hoses unpack the stainless radiator hose kit and remove the hose connectors from the boxes. Use the smaller sections of tube inside the adapters to fit them to smaller fittings on the radiator and intake..

  • Page 243

    242 www.Factoryfive.Com 508-291-3443 then fit the larger adapters over them..

  • Page 244

    243 www.Factoryfive.Com 508-291-3443 upper radiator hose start at the engine and route the tube above the “x” and to the upper radiator hose location. The inline filler neck goes in the upper hose. Mark the tube where it needs to be cut so that the tube will just touch the attaching location. Remove...

  • Page 245

    244 www.Factoryfive.Com 508-291-3443 mark the tube where it needs to be cut so that the tube will just touch the attaching location. Remove the tube/hose assembly from the vehicle. Cut the tube using a hack saw or if available a cut-off wheel. If necessary clean the end up with tin snips or a grinde...

  • Page 246

    245 www.Factoryfive.Com 508-291-3443 bolt the mounting tabs loosely onto the tank so they can be slid around to fit. 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...

  • Page 247

    246 www.Factoryfive.Com 508-291-3443 route the overflow hose from the filler 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 248

    247 www.Factoryfive.Com 508-291-3443 put the radiator cap in place on the filler for now so it doesn’t get lost. If you did not use the hole in the f-panel for your hose routing then silicone and rivet the cover panel in place. For a cleaner look run the rivets you can get to from the engine bay out...

  • Page 249

    248 www.Factoryfive.Com 508-291-3443 there is a thermostatic fan switch provided to activate the fan. In your engine block or cylinder head locate a coolant access point to install the thermostat switch and thread it in..

  • Page 250

    249 www.Factoryfive.Com 508-291-3443 fan wiring # wire crimp tool p misc. Electrical components. Cut the two wires that ground the fan control relay and extend one of them from the relay out to the engine bay and connect to the temp sender. You can use the wire extension from the misc. Electrical co...

  • Page 251

    250 www.Factoryfive.Com 508-291-3443 when you cut these wires you will need to reconnect the fuel pump relay ground..

  • Page 252

    251 www.Factoryfive.Com 508-291-3443 in the dash harness the fan switch lead can now be spliced into the gauge positive feed circuit (12 volts switched positive) so the fan will run only with the ignition on. Connect the fan wires to the harness. Speedometer sending unit # 11mm deep socket, ratchet,...

  • Page 253

    252 www.Factoryfive.Com 508-291-3443 install the gear on the end of the sender and hold it in place with the clip..

  • Page 254

    253 www.Factoryfive.Com 508-291-3443 put a little oil on the o-ring and install the sender in your transmission. Use the original bolt to hold the sending unit in place. The plug for the sending unit gets wired into the harness to send a signal to the speedometer. Looking at the plug head on with th...

  • Page 255

    254 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..

  • Page 256

    255 www.Factoryfive.Com 508-291-3443 emergency brake e-brake handle # 5 / 32 ”, 3 / 16 ” hex keys, 7 / 16 ”, ½” wrenches, channel lock pliers, wd-40 p e-brake handle assembly, brake line components.

  • Page 257

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

  • Page 258

    257 www.Factoryfive.Com 508-291-3443 unpack the emergency brake handle components. Push a nylon bushing into one side of the fixedgear..

  • Page 259

    258 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 260

    259 www.Factoryfive.Com 508-291-3443 put the other ratchet to handle mount on shoulder bolt from the other side of the fixed gear..

  • Page 261

    260 www.Factoryfive.Com 508-291-3443 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 and down. Make sure the ratchet to handle mount plate next to the locknut does not get caught...

  • Page 262

    261 www.Factoryfive.Com 508-291-3443 put the ratchet tooth on the long anchor bolt as shown in the picture below. Rotate the fixed gear out of the way and pass the anchor bolt up through the lower handle..

  • Page 263

    262 www.Factoryfive.Com 508-291-3443 rotate the ratchet tooth between the handle to ratchet mount plates and align the mount holes..

  • Page 264

    263 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..

  • Page 265

    264 www.Factoryfive.Com 508-291-3443 , there are two nylon spacers included. They provide preload on the spring so there is more force holding the ratchet tooth to the fixed gear and making the release button harder to push. Try using the 1” long spacer first. After the handle is assembled, try the ...

  • Page 266

    265 www.Factoryfive.Com 508-291-3443 screw the male and female rod ends together. Use a wrench to spread the ears of the ratchet to handle mounts so that the rod end can just slide between them..

  • Page 267

    266 www.Factoryfive.Com 508-291-3443 slide the male rod end between the ratchet to handle mount plates and attach it using the ¼” flange head bolt and locknut. Insert a 5 / 16 ” carriage bolt into one of the bent mount brackets so the square shoulder is in the square hole..

  • Page 268

    267 www.Factoryfive.Com 508-291-3443 attach the mount brackets to the fixed gear using a ½” wrench. Leave the locknut slightly loose so positioning can be done on the frame later..

  • Page 269

    268 www.Factoryfive.Com 508-291-3443 check the fit of the emergency brake cable end in the brake cable clevis. If necessary, use a drill bit and drill or a dremel tool to open up the slot slightly..

  • Page 270

    269 www.Factoryfive.Com 508-291-3443 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. Just start the nut for now, do not tighten it..

  • Page 271

    270 www.Factoryfive.Com 508-291-3443 attach the handle to the frame using the 5 / 16 ” carriage bolts. Leave the locknuts loose enough so that the mount bracket can still slide on the frame mount. The front mount bracket goes under the frame bracket while the rear goes on top. The fixed gear straddl...

  • Page 272

    271 www.Factoryfive.Com 508-291-3443 tighten the mount bracket to fixed gear carriage bolts..

  • Page 273

    272 www.Factoryfive.Com 508-291-3443 cables , your e-brake cables should be from the same car as your rear brakes. , 87-92 mustang cables or the ffr cables mount to the bracket up near the 2”x 3” tube. 93-04 mustang cables mount to the bracket near the handle. For 87-92 and ffr cables route them thr...

  • Page 274

    273 www.Factoryfive.Com 508-291-3443 , the following pictures are shown without aluminum for easier viewing. For 87-92 and ffr cables route the inner cable down under the chassis 4” crossmember..

  • Page 275

    274 www.Factoryfive.Com 508-291-3443 handle and cable adjustment remove the cable clevises from the rod end and attach them to the cable ends. Adjust the rod end so that the ¼” bolt goes through the rod end and both clevises and the cable is tight..

  • Page 276

    275 www.Factoryfive.Com 508-291-3443 put the locknut back on the ¼” bolt hand tight..

  • Page 277

    276 www.Factoryfive.Com 508-291-3443 slowly pull up on the handle to set the brake pads and remove any slack from the brake cables. Release the brake and if necessary remove the ¼” clevis bolt and readjust the rod end so that the cable is tight..

  • Page 278

    277 www.Factoryfive.Com 508-291-3443 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 279

    278 www.Factoryfive.Com 508-291-3443 engine ground # sand paper or grinder bit, ½” socket, ratchet, 3 / 16 ” hex key p electrical system completion components clean the powder coating from the hole in the engine mount..

  • Page 280

    279 www.Factoryfive.Com 508-291-3443 bolt the ground strap to the hole and then run the other end to a boss on the block. In this case we used an engine mount bolt..

  • Page 281

    280 www.Factoryfive.Com 508-291-3443 axle and fuel tank vents # razor knife p oem fuel tank components, insulated clip hardware 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 roo...

  • Page 282

    281 www.Factoryfive.Com 508-291-3443 aluminum panels transmission tunnel cover # drill, 1 / 8 ” drill bit, silicone, caulking gun, rivet gun p roadster secondary body fasteners components, packaged aluminum, mounted aluminum silicone and install the transmission tunnel top..

  • Page 283

    282 www.Factoryfive.Com 508-291-3443 silicone and install the shifter hole cover. Make sure it does not interfere with the movement of the shift lever. Silicone and install the tunnel plug patch panel..

  • Page 284

    283 www.Factoryfive.Com 508-291-3443 driver footbox side aluminum # 1 / 8 ” drill bit, drill, rivet gun, caulking gun, silicone p mounted aluminum, packaged aluminum, secondary body fasteners silicone and install the drivers side footbox outer wall. The front flanges tuck in behind the footbox front...

  • Page 285

    284 www.Factoryfive.Com 508-291-3443 silicone and install the front patch panel..

  • Page 286

    285 www.Factoryfive.Com 508-291-3443 seats # 5 / 16 ” drill bit, drill, 3 / 16 ” hex key, ½” deep socket, marker p 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 yo...

  • Page 287

    286 www.Factoryfive.Com 508-291-3443 drill the first hole for the seat mounting and install the bolt..

  • Page 288

    287 www.Factoryfive.Com 508-291-3443 drill the remaining holes for mounting the seats and install the bolts..

  • Page 289

    288 www.Factoryfive.Com 508-291-3443 nameplate p 1 / 8 ” drill bit, rivet gun, drill p secondary body fasteners, certificate of origin envelope , 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...

  • Page 290

    289 www.Factoryfive.Com 508-291-3443 , depending on which gauges you are using you may need to open up the dash holes for the tachometer and speedometer. If you need the larger holes the take a tin snip and cut through from the smaller hole to the tracing for the larger one halfway between all the t...

  • Page 291

    290 www.Factoryfive.Com 508-291-3443 take a pair of pliers and snap the tabs off to get the larger opening..

  • Page 292

    291 www.Factoryfive.Com 508-291-3443 the ignition switch hole also needs opened up the same way. File the hole smooth and test fit the switch..

  • Page 293

    292 www.Factoryfive.Com 508-291-3443 clean the dash off with some brake cleaner or acetone and spray the front surface and the back surface of the dash pad with adhesive. (3m super 77 or super 90 work great). Stick the dash to the pad leaving about an inch border all around the top, the bottom will ...

  • Page 294

    293 www.Factoryfive.Com 508-291-3443 cut the dash pad in angle shaped cuts every 2” (even closer in the corners) up to about ¼” from the dash. Wrap the dash pad around to the back and glue it. Use some heavy books to hold the pad in place until the adhesive has a chance to dry..

  • Page 295

    294 www.Factoryfive.Com 508-291-3443 if you are having trouble getting the pad to stick on the bottom of the dash you can screw the corners down using some of the trim screws provided with the dash hardware. Using a razor knife, cut the gauge holes and switch holes out of the dash pad, cut the holes...

  • Page 296

    295 www.Factoryfive.Com 508-291-3443 using the razor knife cut a “+” sign pattern into the middle of the steering shaft hole. With the dash lying face down on a clean tabletop, bend the edges of the dash down 1.25” in from the ends so they are at a 45° angle. Install the gauges in the dash..

  • Page 297

    296 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. Line the dash up with the hoop on the chassis. The corners of the dash support tube are 3 / 16 ” below the top edge of the dash. The tube will be lo...

  • Page 298

    297 www.Factoryfive.Com 508-291-3443 drill for the dash mounting screws (5 evenly spread) through the dash and chassis with a 1 / 8 ” drill bit then drill back through the dash only with a 3 / 16 ” bit and screw the dash to the chassis. Push the ends of the dash behind the top of the door hinge and ...

  • Page 299

    298 www.Factoryfive.Com 508-291-3443 unpack the dash support panels from the packaged aluminum. Rivet the panels to the chassis and then use the trim screws to attach them to the bottom of the dash..

  • Page 300

    299 www.Factoryfive.Com 508-291-3443 install your switches and horn button. Mount the turn signal switch and high low beam switch as well as indicators in the dash. These can be mounted wherever you like, use a ½” drill bit for the holes on both the switches and indicator lights. Steering wheel # ph...

  • Page 301

    300 www.Factoryfive.Com 508-291-3443 bolt the steering wheel to the boss. The pattern is not symmetrical so it will only line up in one direction..

  • Page 302

    301 www.Factoryfive.Com 508-291-3443 bolt the steering wheel assembly to the steering shaft. Use thread-locker on this bolt..

  • Page 303

    302 www.Factoryfive.Com 508-291-3443 rollbar # ½” wrench, 3 / 16 ” hex key, 5 / 16 ” drill bit, drill p driver side rollbar assembly unpack the rollbar and mounting hardware. Slide the rear leg of the bar down into the chassis mount..

  • Page 304

    303 www.Factoryfive.Com 508-291-3443 slide the main hoop into the chassis mounts and wiggle or tap with a soft mallet until it lines up with the rear leg..

  • Page 305

    304 www.Factoryfive.Com 508-291-3443 slide the rear leg up over the mount on the hoop and make sure it comes all the way up flush. Clamp the rear leg up with a pair of vise grips. The front hoop will angle back about 6° or so..

  • Page 306

    305 www.Factoryfive.Com 508-291-3443 drill a hole all the way through each of the lower mounts and rollbar main hoop. , with the thick tubing and curved surface it is much easier to start small and work your way up to a 5 / 16 ” drill bit. , insert one of the bolts after drilling each hole to ensure...

  • Page 307

    306 www.Factoryfive.Com 508-291-3443 make sure the rear leg is tight up against the main hoop and drill the upper hole. This bolt will be visible so keep this in mind when deciding the orientation. Install the bolt loosely to keep the leg in place..

  • Page 308

    307 www.Factoryfive.Com 508-291-3443 drill the remaining mount and install and tighten all of the bolts..

  • Page 309

    308 www.Factoryfive.Com 508-291-3443 rolling chassis check front suspension now is a good time to double check all your hardware, make sure your wiring and hoses are away from extreme heat and moving parts, make sure the steering turns freely lock to lock, and make sure your brake flex lines have en...

  • Page 310

    309 www.Factoryfive.Com 508-291-3443 transmission fill the transmission with fluid and install the shifter assembly. Leave the shift handle and knob off for now..

  • Page 311

    310 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 312

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

  • Page 313

    312 www.Factoryfive.Com 508-291-3443 irs axle nuts # torque wrench, 36mm socket p irs components have a friend sit in the car and step on the brakes. Torque the rear axle nuts to 175 ft-lbs..

  • Page 314

    313 www.Factoryfive.Com 508-291-3443 wheels install and torque your wheels. Make sure they rotate freely and do not interfere with the brake calipers, lines, or any suspension components..

  • Page 315

    314 www.Factoryfive.Com 508-291-3443 rattle patrol get the engine up to temperature and check for leaks and make sure the fan is working. After running the car for the first time once coolant is added and while the system is still warm, retighten the hose clamps used on the cooling system. If you ne...

  • Page 316

    315 www.Factoryfive.Com 508-291-3443 • 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 procedure is detailed in the paperwork that came with the pedal-box) set up ...

  • Page 317

    316 www.Factoryfive.Com 508-291-3443 different shoes can make a large difference in foot room. Driver footbox aluminum rivet the remaining inner cockpit wall flange to the firewall. Silicone and install the footbox inside top panel. Leave the top flange un-riveted for now; use some clamps or tape to...

  • Page 318

    317 www.Factoryfive.Com 508-291-3443 silicone and install the outer footbox top section. Your rolling chassis is now complete!.

  • Page 319

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

  • Page 320

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

  • Page 321

    320 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 322

    321 www.Factoryfive.Com 508-291-3443 the rectangular adhesive backed weatherstrip runs along the top of the chassis tubes on either side of the hood opening and the top of the curved trunk hoop. The push-on weather strip needs to run across the top of the firewall and the trunk walls and rear floor..

  • Page 323

    322 www.Factoryfive.Com 508-291-3443 mounting the body rear quick jacks # ⅝” wrench, ⅝” socket, ratchet p quick jack bumper components , the main locating points for the body are the rear quick jack mounts; these will set the body in the correct position front to back as well as locating the rear ha...

  • Page 324

    323 www.Factoryfive.Com 508-291-3443 , when bolting the body down the first time to do the fitment you can leave the quick jacks off and only use the hardware, this makes it easier to maneuver around and safer when crawling out from under the car. Find the quick jack hardware that came mounted on th...

  • Page 325

    324 www.Factoryfive.Com 508-291-3443 even with the quick jacks removed, it is still a good idea to wrap the bolts with some rags and duct-tape to save yourself from painful cuts or bruises..

  • Page 326

    325 www.Factoryfive.Com 508-291-3443 front quick jacks # ⅝” wrench, ⅝” socket, ratchet p quick jack bumper components the front quick jacks mount the same as the rears except for the angled spacers and rubber backed washers that line up with the nose. You can also mount the body and hardware leaving...

  • Page 327

    326 www.Factoryfive.Com 508-291-3443 hood fitment and bumpers # orbital sander, air saw, 1 / 8 ” drill bit, drill, rivet gun p hood, secondary body fasteners the hood has been trimmed slightly oversized to allow the panel gaps to be sanded down to fit. Set the hood in place and make sure it will fit...

  • Page 328

    327 www.Factoryfive.Com 508-291-3443 , the bumpers are used to get the hood to the correct plane with the body, you can shave small amounts off either or put washers as shims to fine tune as needed. Put the small bumpers around the edge of the hood opening and try closing the hood. If it is too low ...

  • Page 329

    328 www.Factoryfive.Com 508-291-3443 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 the edge of the panel so that it tubs the body lip all of the way around. This will...

  • Page 330

    329 www.Factoryfive.Com 508-291-3443 repeat this gap procedure later after mounting the doors and the trunk. Hood hinge # 3 / 16 ”, 7 / 64 ”, ⅝” drill bits, drill, measuring tape, rivet gun, marker, 3 / 16 ” hex key, ½” wrench p hood hinge.

  • Page 331

    330 www.Factoryfive.Com 508-291-3443 the hood hinge pivot mounts attach to the hood using rivets, the holes are predrilled in the hood liner but you may need to clean them out with a 3 / 16 ” drill bit. This is the initial install so you only need a few rivets if you are going to remove the hinge br...

  • Page 332

    331 www.Factoryfive.Com 508-291-3443 press the bronze bushings into the holes in the hinge arms as shown. The short hinge arms are both the same. Drivers side long arm with bushings pressed in passenger side long arm with bushings pressed in short arm with bushings pressed in. Attach the hinge arms ...

  • Page 333

    332 www.Factoryfive.Com 508-291-3443 drivers side arm plate with arms attached driver side hinge assembled. Attach the hinges to the chassis using the carriage bolts, these push in from the outside for easier adjustment..

  • Page 334

    333 www.Factoryfive.Com 508-291-3443 leave the bolts loose enough so that the hinge assembly can be positioned to match the hood. Set the hood in place and attach the two arms to the brackets from the underside of the body..

  • Page 335

    334 www.Factoryfive.Com 508-291-3443 install the threaded ball studs in the hole on the long hinge arms with the ball pointed toward the outside of the car using a 5 / 16 ” locknut. Then snap the gas piston shaft onto the ball..

  • Page 336

    335 www.Factoryfive.Com 508-291-3443 attach the piston body end to the ball on the hood. Hood handles # 1 / 8 ”, 7 / 64 ”, 3 / 16 ”, ⅝” drill bits, drill, measuring tape, philips head screwdriver, pliers, marker, 2.5mm hex key, file. P three lock set and fasteners measure the center of the hood line...

  • Page 337

    336 www.Factoryfive.Com 508-291-3443 measure out from the hood center 12” on each side and mark the middle of the hood liner rib for the hood handle location. Drill through the hood and the liner starting with smaller bits working up to a ⅝” hole. The larger bits sometimes work better by running the...

  • Page 338

    337 www.Factoryfive.Com 508-291-3443 remove the hood handles from the three lock set and break off the bottom small tabs with a pair of pliers..

  • Page 339

    338 www.Factoryfive.Com 508-291-3443 set the handles in the holes drilled in the hood so that they are lined up squarely with the edge and mark the screw holes on the hood. Drill the holes with a 7 / 64 ” bit then screw the handles down using the screws from the set..

  • Page 340

    339 www.Factoryfive.Com 508-291-3443 shut the hood and mark the body where the hood handles line up. Open the hood and drill two 3 / 16 ” holes in the hood opening recess ¼” on either side of the centerline and ¼” back from the edge of the opening. These are for mounting the hood catch brackets..

  • Page 341

    340 www.Factoryfive.Com 508-291-3443 the latch brackets are in the handle assembly, center them on the line with the corner edge up against the inner radius of the hood opening and mark the two holes..

  • Page 342

    341 www.Factoryfive.Com 508-291-3443 drill the two holes just marked with a 7 / 64 ” bit and file the edged of the bracket round with a file or grinder for a nice finish. The four remaining screws are used to hold these brackets in place. They can either be countersunk into the body or used to hold ...

  • Page 343

    342 www.Factoryfive.Com 508-291-3443 attach the cam wedge to the underside of the hood handles and adjust for tightness using a 2.5mm hex key..

  • Page 344

    343 www.Factoryfive.Com 508-291-3443 windshield # philips head screwdriver, marker, ½” drill bit, drill, hack saw, ¾” wrench, ratchet, ¾” socket, friend. P windscreen box. , the strips along the sides of the windshield that the screws go into are brass. The brass threads strip easily so take your ti...

  • Page 345

    344 www.Factoryfive.Com 508-291-3443 remove the windshield from the car and then remove the sidebars from the windshield. At the marks made on the sidebar, measure and mark the center of the sidebar to give the correct angle adjustment on the windshield. Drill the holes with a ½” bit. Remount the si...

  • Page 346

    345 www.Factoryfive.Com 508-291-3443 doors # 3 / 16 ” hex key, marker, ⅝” socket, ratchet, air saw, orbital sander, 3 / 16 ” drill bit, drill, rivet gun p door hinges, doors, secondary body fasteners. If you have removed them, remount the door hinges on the chassis. The square nuts sit along side th...

  • Page 347

    346 www.Factoryfive.Com 508-291-3443 position the door in the body to see where it may need to be trimmed to fit the opening. Mark the door and only remove enough material to get it to fit..

  • Page 348

    347 www.Factoryfive.Com 508-291-3443 hold or tape the door in position and attach the hinge to the studs. Adjust the door with the hinge until the panel surfaces are lined up with the body. Start at the top of the door and match the curved surfaces..

  • Page 349

    348 www.Factoryfive.Com 508-291-3443 once the top of the door is good, you can adjust the bottom of the body in and out to help fit the bottom edge of the door. When you are happy with the fit of the door, rivet the bottom lip of the body to the chassis using the long 3 / 16 ” rivets. Set the gaps o...

  • Page 350

    349 www.Factoryfive.Com 508-291-3443 door latch # ½” wrench, 1 / 8 ” drill bit, drill, philips head screwdriver, marker, lithium or silicone grease. P door components remove the door latch striker from the original mounting bracket and keep only the striker and the washers. The bracket and nut will ...

  • Page 351

    350 www.Factoryfive.Com 508-291-3443 latch the door latch onto the striker and close the door. Adjust the striker if needed to fit the latch to the door cut out. You can also use the door latch spacers to help with this alignment..

  • Page 352

    351 www.Factoryfive.Com 508-291-3443 with the door lined up and the striker in place, mark and drill the 1 / 8 ” holes for the door latch..

  • Page 353

    352 www.Factoryfive.Com 508-291-3443 lubricate the moving parts of the latch using lithium or silicone grease. This will make the latches easier to use and prevent any binding. Bolt everything together to double check fit and operation. The door latches will be tight at first but break in quickly wi...

  • Page 354

    353 www.Factoryfive.Com 508-291-3443 trunk hinge # ½” wrench, 3 / 16 ” hex key p trunk hinge components. Press the bushings into the hinge arms from either side. Use the carriage bolts and 5 / 16 ” locknuts to bolt the mounting pads to the arms leaving them just snug so they can be moved without loo...

  • Page 355

    354 www.Factoryfive.Com 508-291-3443 hang the hinge arms on the chassis using the shoulder bolts. You do not need the nuts for just doing fitment..

  • Page 356

    355 www.Factoryfive.Com 508-291-3443 screw the trunk to the mounting pads also leaving them loose enough that they will just move..

  • Page 357

    356 www.Factoryfive.Com 508-291-3443 close the trunk and wiggle it into position then open and tighten the bolts. This may take a little adjustment to get the trunk to sit down right. You can also use some of the rubber bumpers from the hood opening as a temporary means of holding the surfaces level...

  • Page 358

    357 www.Factoryfive.Com 508-291-3443 screw the trunk latch to the holder with the short #14 screws lining the small square hole with the hole for the handle..

  • Page 359

    358 www.Factoryfive.Com 508-291-3443 bolt the handle to the trunk running the bolts through the trunk and the latch mount..

  • Page 360

    359 www.Factoryfive.Com 508-291-3443 the long bolt that holds the latch pin in place goes through the plastic cap then the body then the sleeve and into the chassis plate. Test fit to make sure the trunk is held snug. If it is loose you can bend the catch with channel lock pliers to snug it down..

  • Page 361

    360 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. P fuel filler template, aston lemans cap components. Locate the template in the appendix and only cut out around the outside diameter of the cir...

  • Page 362

    361 www.Factoryfive.Com 508-291-3443 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. Use a 3½” hole saw for the center opening, drill out the holes for the filler. If you do not have a hole saw this size, you can cut the center circle...

  • Page 363

    362 www.Factoryfive.Com 508-291-3443 tail light # drill, 7 / 32 ” drill bit, 1¼” hole saw, file, scissors. P tail light template, red rear light use a 7 / 32 ” bit to drill the two outer holes for the taillight studs then cut out the center using a 1¼” hole saw. There are marks on the body that loca...

  • Page 364

    363 www.Factoryfive.Com 508-291-3443 test fit the lights and file the holes to fit if needed..

  • Page 365

    364 www.Factoryfive.Com 508-291-3443 turn signal # drill, 7 / 32 ” drill bit, 1¼” hole saw, marker. P turn signal template, amber front turn signal lights remove the gasket from the turn signal box and use it to center and trace the mounting holes and large center hole for the turn signal. Drill the...

  • Page 366

    365 www.Factoryfive.Com 508-291-3443 test fit a light and adjust if needed..

  • Page 367

    366 www.Factoryfive.Com 508-291-3443 license plate light # drill, ¼”, ⅜” drill bits, scissors, masking tape, marker p license plate light template, license plate light and bracket. , this kit is only a collection of parts designed for use primarily as a race car. Applying the license plate bracket d...

  • Page 368

    367 www.Factoryfive.Com 508-291-3443 side exhaust # drill, 2½” hole saw, air saw or jig saw. P side exhaust template the pattern for the standard exhaust cut out is pre traced on the body. Using a 2½” hole saw cut the upper two corners of the pattern out..

  • Page 369

    368 www.Factoryfive.Com 508-291-3443 using a jig saw cut the remaining straight sections and radius on the lower rear corner..

  • Page 370

    369 www.Factoryfive.Com 508-291-3443 headlights # drill, 1 / 8 ”, ¼”, 7 / 16 ” drill bit, razor knife, masking tape, air saw or jig saw, level. P headlight template, headlight components, cut out the headlight templates from the back of the manual on the outermost diameter and tape them in the cente...

  • Page 371

    370 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..

  • Page 372

    371 www.Factoryfive.Com 508-291-3443 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. Test fit the light bucket and rubber gasket making sure that they sit flat and the bucket is centered on the fender. Mark and drill the four mounting scr...

  • Page 373

    372 www.Factoryfive.Com 508-291-3443 side louver # drill, 1¼” hole saw, jig saw or air saw, measuring tape, marker p side louver template use the template and measurements in the picture below to locate the template on the body..

  • Page 374

    373 www.Factoryfive.Com 508-291-3443 use a 1¼” hole saw to cut the corners on the traced opening for the side louver. Connect the flush surfaces of the holes with a jig saw..

  • Page 375

    374 www.Factoryfive.Com 508-291-3443 hood and scoop # drill, 3 / 16 ”, ⅜” drill bits, marker, ruler, tape measure, jig saw or air saw, rivet gun. P hood scoop, hood, secondary body fasteners. The scoop needs to be trimmed so that there is an even ¾” flange around the sides and the back and a ¼” flan...

  • Page 376

    375 www.Factoryfive.Com 508-291-3443 on the underside of the hood on the liner, trace the opening for the cut out in the hood 1½” in from the side and rear edges and 4” back from the front edge of the scoop recess..

  • Page 377

    376 www.Factoryfive.Com 508-291-3443 use a larger drill bit to start the blade for the saw then cut the opening in the hood using a jig saw..

  • Page 378

    377 www.Factoryfive.Com 508-291-3443 to locate the scoop, measure from the leading edged of the hood back 19” on either side of the opening and draw a straight line across the width of the hood. On the line just marked, measure in 8” from each of the outside edges of the hood and mark on the line..

  • Page 379

    378 www.Factoryfive.Com 508-291-3443 center the scoop using the straight edge and two marks. Double check by measuring in from the rear edges of the hood to make sure that it is centered..

  • Page 380

    379 www.Factoryfive.Com 508-291-3443 drill two of the rivet holes on opposite sides for the scoop and install a couple rivets to hold the panels together. Drill out the remaining rivet holes and then separate the two pieces for painting..

  • Page 381

    380 www.Factoryfive.Com 508-291-3443 roll bar # drill, 1¾” hole saw, air saw or jig saw, file p 1.50” driver side rollbar. The roll bar holes are marked on the body and need to be cut out using a 1¾” holes saw. The front two holes are cut centering the saw in the marked circle and drilling verticall...

  • Page 382

    381 www.Factoryfive.Com 508-291-3443 to cut the rear roll bar leg, make 2 holes overlapping so that they form the right length. Use the same 1¾” hole saw centered in the front of the traced opening and with the drill leaning at a 45° angle toward the inner front leg. Stop the drill when it has cut t...

  • Page 383

    382 www.Factoryfive.Com 508-291-3443 the rear of the hole is then finished using the whole saw vertically. Trim the remaining flash on the opening with a file or jig saw and test fit the bar..

  • Page 384

    383 www.Factoryfive.Com 508-291-3443 final prep # sand paper , 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. , refer to appendix a...

  • Page 385

    384 www.Factoryfive.Com 508-291-3443 • brake duct openings • main radiator opening • oil cooler opening • hood opening • roll bar cut outs • door openings • cockpit edges 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 radi...

  • Page 386

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

  • Page 387

    386 www.Factoryfive.Com 508-291-3443 radiator aluminum # drill, ¼” nut driver, ⅛”, 3 / 16 ” drill bits, rivet tool, floor jack, marker, ruler, silicone, caulk gun. P secondary body fasteners, engine bay aluminum. , use care when handling aluminum, the edges are sharp and can cut you. The radiator an...

  • Page 388

    387 www.Factoryfive.Com 508-291-3443 position the radiator floor aluminum so that it goes under the body lip and goes across to the bottom of the radiator. Clamp the floor piece to the nose..

  • Page 389

    388 www.Factoryfive.Com 508-291-3443 attach the radiator floor piece to the bottom of the radiator with a couple of self-tapping screws on the marks or use a couple of clamps. Drill, silicone and rivet the radiator floor aluminum to the bottom radiator lip..

  • Page 390

    389 www.Factoryfive.Com 508-291-3443 silicone and rivet the aluminum to the nose lip using three 3 / 16 ” rivets..

  • Page 391

    390 www.Factoryfive.Com 508-291-3443 pass the radiator sidepieces through the nose and put them on their respective sides. , trimming aluminum may be necessary if you use the press-on rubber bulb seal weather- stripping..

  • Page 392

    391 www.Factoryfive.Com 508-291-3443 line up the edge of the radiator fins with the edge of the side aluminum and attach the piece to the ¾” tube using a self tapping screw..

  • Page 393

    392 www.Factoryfive.Com 508-291-3443 from the backside of the panel, mark the location of the ¾” tube..

  • Page 394

    393 www.Factoryfive.Com 508-291-3443 , if using the press on bulb weatherstrip, make sure there is ⅜”-½” of gap between the edge of the panel and the body. Remove the side panel then measure, mark, drill rivet locations where the ¾” tube is located and press on the bulb weatherstrip. Reinsert the si...

  • Page 395

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

  • Page 396

    395 www.Factoryfive.Com 508-291-3443 repeat this procedure for the driver side panel. Carpet # razor knife, silicone, caulking gun, spray glue, brake cleaner or acetone. P interior trim/carpet , the adhesive used to hold the carpet down is the same as we used on the dash pad. 3m ® super77™ or super9...

  • Page 397

    396 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..

  • Page 398

    397 www.Factoryfive.Com 508-291-3443 start with the large rear cockpit wall of carpet. Position it before gluing so you understand where it will go then, apply the adhesive and glue it into position..

  • Page 399

    398 www.Factoryfive.Com 508-291-3443 the cockpit rear corners go on next. Be very careful spraying the adhesive once some carpet is mounted. Guard the carpet with masking tape or cardboard..

  • Page 400

    399 www.Factoryfive.Com 508-291-3443 test fit the rear and main tunnel covers. While you are fitting cut the handle opening for the e-brake and shifter..

  • Page 401

    400 www.Factoryfive.Com 508-291-3443 glues down the tunnel top..

  • Page 402

    401 www.Factoryfive.Com 508-291-3443 the tunnel rear section is slightly oversized to make sure it can cover small variances in the way the other pieces lay down. Trim it for a perfect fit then glue it in place. Fit and glue the passenger outside footbox wall carpet section. The carpet tucks in behi...

  • Page 403

    402 www.Factoryfive.Com 508-291-3443 fit and glue the driver’s side footbox outer carpet section. This piece also tucks behind the footbox tubing..

  • Page 404

    403 www.Factoryfive.Com 508-291-3443 fit and glue the tunnel/firewall section of carpet. Fit and glue the lower floor sections..

  • Page 405

    404 www.Factoryfive.Com 508-291-3443 fit and glue the under door sections. The floors are the last pieces to go in. They may also need a slight trim for the best fit. Glue them down and vacuum the carpet prior to the seats going in..

  • Page 406

    405 www.Factoryfive.Com 508-291-3443 seats harness lap belt # ¾” wrench, ¾” socket, ½” drill bit, drill, ratchet p seat harness/fasteners unpack the seat harnesses and hardware. Drill through the inner lap belt mount into the tunnel with a ½ in. Bit..

  • Page 407

    406 www.Factoryfive.Com 508-291-3443 bolt the lap harness in position with the inner most nut inside the transmission tunnel..

  • Page 408

    407 www.Factoryfive.Com 508-291-3443 emergency brake boot # 1 / 8 ” drill bit, drill, philips head screwdriver p interior trim/carpet unpack the e-brake boot and a few of trim screws. Fit the boot over the handle and check the handle actuation. When you are in a position where the boot clears the ha...

  • Page 409

    408 www.Factoryfive.Com 508-291-3443 seat final install drill back up through your seat mounting holes to put holes through the carpet and re-mount the seats..

  • Page 410

    409 www.Factoryfive.Com 508-291-3443 seat harness shoulder belts # razor knife, ¾” wrench, ¾” socket, ½” drill bit, drill, ratchet p seat harness/fasteners, misc. Electrical components use some of the serrated grommeting from the electrical assembly to cover the edge where the harness passes through...

  • Page 411

    410 www.Factoryfive.Com 508-291-3443 cut the carpet with a single slit to allow the harness to pass through..

  • Page 412

    411 www.Factoryfive.Com 508-291-3443 remove the mounting tab and slider from the harness. Slide the harness through the rear wall from the front. The shoulder harnesses are side specific so make sure you have the sides correct..

  • Page 413

    412 www.Factoryfive.Com 508-291-3443 replace the slider and mounting tab and bolt the tab to the chassis. Adjust the harnesses to where they fit you comfortably..

  • Page 414

    413 www.Factoryfive.Com 508-291-3443 shifter handle and boot # ½” wrench, 1 / 8 ” drill bit, drill, philips head screwdriver, marker, thread lock p shifter handle components unpack the shift handle and bolt it to the transmission. These bolts have a tendency to rattle loose so use a little thread lo...

  • Page 415

    414 www.Factoryfive.Com 508-291-3443 push the boot and trim rind down over the handle so it sits flush on the tunnel. Using a silver marker or white paint marker, mark your screw holes on the tunnel..

  • Page 416

    415 www.Factoryfive.Com 508-291-3443 remove the boot and drill 1 / 8 ” holes in the spots you marked. Re-install the boot and screw down to the tunnel with the countersunk screws. A small screwdriver can help to locate the holes..

  • Page 417

    416 www.Factoryfive.Com 508-291-3443 screw the two piece knob onto the shift handle and tighten so the shift pattern is in the correct orientation..

  • Page 418

    417 www.Factoryfive.Com 508-291-3443 headlights # philips head screwdriver p headlight components unpack the headlight mounting assembly..

  • Page 419

    418 www.Factoryfive.Com 508-291-3443 # headlight fasteners. Screw the adjuster screws about halfway into the buckets. 13419 13415 13418 13420 13416.

  • Page 420

    419 www.Factoryfive.Com 508-291-3443 push the grommet into the side of the bucket. Run the light plug harness through from the inside.

  • Page 421

    420 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..

  • Page 422

    421 www.Factoryfive.Com 508-291-3443 screw the mounting flange onto the light with the 3 small tabs and small screws. The tabs are bent to fit around the bosses on the light..

  • Page 423

    422 www.Factoryfive.Com 508-291-3443 put the gasket on the bucket with the adjuster bosses poking through the 2 larger holes. Screw the bucket to the body using the screw that came in the mounting assembly..

  • Page 424

    423 www.Factoryfive.Com 508-291-3443 plug the light into the connector and mount the bulb to the bucket. The slotted parts of the mounting flange go onto the adjusting screws between the screw head and flange..

  • Page 425

    424 www.Factoryfive.Com 508-291-3443 push the spring clip onto the boss near the bottom of the bucket..

  • Page 426

    425 www.Factoryfive.Com 508-291-3443 mount the trim ring hooking it over the bucket on the top and screwing it into the bottom using the countersunk screw. Turn signals # 5 / 16 ” deep socket, ratchet p amber front turn signal lights mount the turn signals to the body being careful not to over tight...

  • Page 427

    426 www.Factoryfive.Com 508-291-3443 tail lights # 5 / 16 ” deep socket, ratchet p red rear lights mount the taillights, also being careful with the mounting hardware..

  • Page 428

    427 www.Factoryfive.Com 508-291-3443 gas cap # philips head screwdriver p aston lemans cap unpack the fuel cap and mounting hardware..

  • Page 429

    428 www.Factoryfive.Com 508-291-3443 put the gasket on the bottom surface of the cap..

  • Page 430

    429 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 431

    430 www.Factoryfive.Com 508-291-3443 side louvers # silicone, caulking gun, duct tape p side louvers unpack the side louvers. Holding the top and bottom flanges, bend the fins in so they are roughly at a 45° angle..

  • Page 432

    431 www.Factoryfive.Com 508-291-3443 hold them up to the body to see how they fit. They are designed to allow air to exit the engine bay so the flanges point from the rear edge in..

  • Page 433

    432 www.Factoryfive.Com 508-291-3443 apply silicone down the top and bottom flange on the side facing the body..

  • Page 434

    433 www.Factoryfive.Com 508-291-3443 line up the louvers and tape them in place to hold them until the silicone dries. Weatherstripping # razor knife, tin snips p secondary body fasteners if you haven’t already run the bulb seal up the sides and rear of the trunk and bolt the trunk hinges back in pl...

  • Page 435

    434 www.Factoryfive.Com 508-291-3443 cut out a section of the c channel where the hoop comes across to allow one piece to run the whole way. If you removed any of the other weatherstrip on the firewall or hood support tubes replace it now..

  • Page 436

    435 www.Factoryfive.Com 508-291-3443 when you are ready to mount the body, unpack the expanding foam and run a small section up the outside of each footbox just forward of the door hinge..

  • Page 437

    436 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 he dash without pulling the material o...

  • Page 438

    437 www.Factoryfive.Com 508-291-3443 re-mount the nose with the front quick jacks. Hood mounting rivet the scoop back in position on the hood..

  • Page 439

    438 www.Factoryfive.Com 508-291-3443 re-install the hood latch plates and replace the bumpers you used before on the body to line up the hood..

  • Page 440

    439 www.Factoryfive.Com 508-291-3443 re-install the hood and latches. Rollbar mounting re-mount the roll bar through the body. Make sure that the rear leg is in the correct orientation so that your holes will line up..

  • Page 441

    440 www.Factoryfive.Com 508-291-3443 door and latch mount reattach the doors and latches..

  • Page 442

    441 www.Factoryfive.Com 508-291-3443 once you are happy with the door fit install the covers on the door latches. Windshield mounting position the windshield trim plates with gaskets on the body so that the notch faces the inside front corner..

  • Page 443

    442 www.Factoryfive.Com 508-291-3443 re-mount the windshield..

  • Page 444

    443 www.Factoryfive.Com 508-291-3443 fuel filler neck # razor knife, ⅜” socket, ratchet, 3 / 16 ” drill bit, drill p aston lemans cap components 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...

  • Page 445

    444 www.Factoryfive.Com 508-291-3443 install the hose between the filler neck and gas cap with the clamps that came in the cap hardware..

  • Page 446

    445 www.Factoryfive.Com 508-291-3443 screw the plastic gas cap into the aston lemans style cap. Fuel tank access covers # 1 / 8 ” drill bit, drill, rivet gun, silicone, caulking gun p secondary body fasteners, packaged aluminum silicone and install the patch panels in the trunk that cover the fuel s...

  • Page 447

    446 www.Factoryfive.Com 508-291-3443 final trunk mounting # tin snips, 3 / 16 ” hex key p secondary body fasteners push the side mount weatherstrip on the trunk opening starting at the bottom next to the latch pin hole and working all the way around just leaving a small gap for the head of the latch...

  • Page 448

    447 www.Factoryfive.Com 508-291-3443 re-mount the license plate light and trunk handle. Re-mount the trunk to the hinges and re install the latch pin..

  • Page 449

    448 www.Factoryfive.Com 508-291-3443 interior rearview mirror # philips head screwdriver, drill, 3 / 32 ”, 3 / 16 ” drill bits, marker, measuring tape p rearview mirrors/fasteners use a tape measure and marker to mark the center of the dash area about ¼” in from the body lip. Line up the rearview mi...

  • Page 450

    449 www.Factoryfive.Com 508-291-3443 sit in the seat and make sure you are comfortable with the position. Drill the body with a 3 / 32 ” bit and screw the mirror in position..

  • Page 451

    450 www.Factoryfive.Com 508-291-3443 side mirror # philips head screwdriver, drill, 3 / 32 ”, 3 / 16 ” drill bits, marker, ⅜” wrench. P rearview mirrors/fasteners. , only a driver side mirror is included with the kit. A passenger side one is available if desired. Unpack the side mirror assembly. Dis...

  • Page 452

    451 www.Factoryfive.Com 508-291-3443 the large base is replaced by the smaller insert and gasket..

  • Page 453

    452 www.Factoryfive.Com 508-291-3443 temporarily bolt the mirror back together with the small insert. Sit in the seat to find a good location you can see it from and see clearly over the rear fender..

  • Page 454

    453 www.Factoryfive.Com 508-291-3443 mark the location and use the gasket to locate and drill the mounting holes..

  • Page 455

    454 www.Factoryfive.Com 508-291-3443 disassemble the mirror and bolt the mounting insert with mounting bolt and the gasket to the body. Slide the stand-off and upper gasket down the bolt and onto the mounting bracket..

  • Page 456

    455 www.Factoryfive.Com 508-291-3443 bolt the main body of the mirror to the mounting stand-off. Screw the mirror into the body and adjust it before tightening..

  • Page 457

    456 www.Factoryfive.Com 508-291-3443 light wiring # wire strippers, wire crimpers, chassis harness instructions p headlight components, amber front turn signal lights, rear lights, license plate light, electrical system completion components wire in the headlights to the chassis harness. On the head...

  • Page 458

    457 www.Factoryfive.Com 508-291-3443 wire the taillights according to the wiring harness instructions. We normally run the upper lights in the rear for brakes and the lower for turn signals. Wire the license plate light. Check straps # 3 / 16 ” drill bit, drill, rivet tool, marker p secondary body f...

  • Page 459

    458 www.Factoryfive.Com 508-291-3443 rivet the check-strap to the door hinge using a 3 / 16 ” rivet..

  • Page 460

    459 www.Factoryfive.Com 508-291-3443 open a door wide but not enough so that the door hits the body. The straps will stretch slightly over time so allow enough room for this by closing the door slightly from the maximum. While holding the door open, pull the check strap tight and mark the location o...

  • Page 461

    460 www.Factoryfive.Com 508-291-3443 under door aluminum # drill, 1 / 8 ” drill bit, rivet tool, silicone, caulking gun, spray glue, tin snips. P packaged aluminum, interior trim/carpet, secondary body fasteners unpack the under door aluminum panels. They are shaped to fit around the bottom of the d...

  • Page 462

    461 www.Factoryfive.Com 508-291-3443 test fit and then glue in the remaining carpet sections under the doors. Cut a section of the large c channel weatherstrip to fit from the bottom of the door hinge to the door latch and push it in place over the body, aluminum and carpet to finish the edges off. ...

  • Page 463

    462 www.Factoryfive.Com 508-291-3443 steering wheel center section # wd40, 5 / 32 ” hex key p steering wheel/hardware, factory five badge 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 is tight..

  • Page 464

    463 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..

  • Page 465

    464 www.Factoryfive.Com 508-291-3443 with the steering wheel in the position that is most comfortable for you tighten the set screws on the collar of the upper steering bearing. Side exhaust # 3 / 16 ”, 5 / 16 ” hex key, ⅜”, ½”, 9 / 16 ” socket, ratchet, 9 / 16 ” wrench, drill, 3 / 16 ”, 5 / 16 ” dr...

  • Page 466

    465 www.Factoryfive.Com 508-291-3443 bolt the mounting bracket to the pipe on the forward side of the bracket. Bolt the pipe and gasket to the header or j-pipe flange with using the shorter ⅜” bolts and mechanical locknuts..

  • Page 467

    466 www.Factoryfive.Com 508-291-3443 drill a 3 / 16 ” hole in the 2”x 2” outrigger tube directly above the middle hole in the mounting bracket. You want this hole as high as you can get it while still being able to mount the rubber exhaust hanger. About ½” down from the aluminum floor..

  • Page 468

    467 www.Factoryfive.Com 508-291-3443 screw the rubber hanger onto the chassis with the sheet metal mounting screw using one of the washers between the rubber and the head of the screw. Bolt the bottom section of the hanger to the side exhaust mounting bracket using the middle length 5 / 16 ” button ...

  • Page 469

    468 www.Factoryfive.Com 508-291-3443 using the inner hole of the bracket as a guide, drill the 2”x 2” outrigger all the way through both of the tube walls and into the footbox area with a 5 / 16 ” bit..

  • Page 470

    469 www.Factoryfive.Com 508-291-3443 insert the rubber standoff between the bracket and outrigger and put the nut on finger tight then run the long 5 / 16 ” bolt through from inside the footbox into the threads in the standoff. Tighten the whole assembly together..

  • Page 471

    470 www.Factoryfive.Com 508-291-3443 aluminum splash guards # 1 / 8 ”, 3 / 16 ” drill bit, drill, rivet gun, silicone, caulking gun, ¾” socket, ratchet, extension, marker p secondary body fasteners, packaged aluminum, front wheel and tire front wheel put some of the press-on bulb seal around the out...

  • Page 472

    471 www.Factoryfive.Com 508-291-3443 hold the splashguards up against the rear bent lip of the engine bay “f” aluminum. Overlap the two lips. Fit the splash guards in position. If needed, trim them to fit around the outside edge, the weatherstrip will cover the trimming..

  • Page 473

    472 www.Factoryfive.Com 508-291-3443 put a wheel and tire on the car and check for aluminum clearance. If necessary push the aluminum in and mark the inside of the body at the outer edge of the splashguards. Remove the wheel. Silicone and rivet the panels in place down the length of the flange..

  • Page 474

    473 www.Factoryfive.Com 508-291-3443 use one of the 3 / 16 ” rivets to attach to the bottom of the fender just forward of the exhaust cut-out..

  • Page 475

    474 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. Fit the panels in place and trim the outside perimeter if needed. The small tab on the bottom faces towards the rear of the car and is on t...

  • Page 476

    475 www.Factoryfive.Com 508-291-3443 silicone and rivet the panels in place. Bend the lower tab by hand to fit up flush with the body..

  • Page 477

    476 www.Factoryfive.Com 508-291-3443 use a long 1 / 8 ” rivet as low as possible to attach the tab to the lower fender..

  • Page 478

    477 www.Factoryfive.Com 508-291-3443 finishing touches 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 the back measured to the bottom of the 4” r...

  • Page 479

    478 www.Factoryfive.Com 508-291-3443 make the following two measurements: 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 ...

  • Page 480

    479 www.Factoryfive.Com 508-291-3443 turn the headlights on and adjust the vertical aim of the headlights so that the top horizontal cutoff of each of the beams is located along the horizontal line drawn on the wall. Adjust the horizontal aim of the low beam headlights so that the point at which the...

  • Page 481

    480 www.Factoryfive.Com 508-291-3443 caster: 7 ° camber: -0.5 ° total toe: 1 / 16 ” adjusting the upper control arm , use the diagram below for reference. 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” wrenc...

  • Page 482

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

  • Page 483

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

  • Page 484

    483 www.Factoryfive.Com 508-291-3443 wheels , only 7”-9” wheels are recommended for the front. If using a wheel wider than 7”, ffr front lower control arms are needed to prevent the wheels rubbing the control arms. Below is a chart indicating the rear wheel sizes and backspacing that are possible us...

  • Page 485

    484 www.Factoryfive.Com 508-291-3443 17”x 9” and 17”x 10.5” fr style wheels. For a more vintage look, take a look at our halibrand style wheels. Our online parts catalog: factoryfiveparts.Com has more views of these wheels on cars. Left: 15” ffr halibrand style. Right 17” ffr halibrand style 1994-19...

  • Page 486

    485 www.Factoryfive.Com 508-291-3443 1999-2003 rear end because of the width of this rear end, custom wheels are needed if 10” or wider wheels are wanted. Use two (2) 9” wide, 5.95” backspace wheels in the front. See the table above for different width wheel backspacing. Performance modifications th...

  • Page 487

    486 www.Factoryfive.Com 508-291-3443 rear end gears. Efi engines , 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 mustang size: 58mm a 65mm throttle body work well up to 350hp. Ford racing,...

  • Page 488

    487 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 racing. Hea...

  • Page 489

    488 www.Factoryfive.Com 508-291-3443 4.6l 4 valve frpp headers. Timing most computer chips simply change the timing of the engine and slightly enrich the mixture. Using a timing light, advancing the base timing to 14 ° will do the same. Higher octane fuel will be needed. Under-drive pulleys yes. The...

  • Page 490

    489 www.Factoryfive.Com 508-291-3443 using the stock 1987-1993 15:1 mustang power rack and power steering pump. If changing to a power 15:1 rack, a universal joint with a different number of splines will be necessary in order to connect the steering shaft to the steering rack. High performance manua...

  • Page 491

    490 www.Factoryfive.Com 508-291-3443 kenne bell supercharger. Installed supercharger. Seats for the roadracers/autocrossers that want more side support, factory five offers a variety of different options. Check out www.Factoryfive.Com.

  • Page 492

    491 www.Factoryfive.Com 508-291-3443 helpful reference material must reads • www.Ffcobra.Com . The largest discussion forum for factory five racing kits. Also has many vendor links. Helpful • 5.0l ford dyno tests. By richard holdener. Published by sa design, cartech. 11605 kost dam rd., north branch...

  • Page 493

    492 www.Factoryfive.Com 508-291-3443 tools • craftsman tools - sears brand “guaranteed forever” tools. 800-549-4505. Www.Craftsman.Com • husky tools – home depot “guaranteed forever” tools. Www.Homedepot.Com • kobalt tools – lowe’s “guaranteed forever” tools. Www.Lowes.Com • eastwood - unique automo...

  • Page 494

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

  • Page 495

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

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

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

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

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

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

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

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

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

  • Page 504

    503 www.Factoryfive.Com 508-291-3443 appendix b – pack list.

  • Page 505

    504 www.Factoryfive.Com 508-291-3443 customer:_______________________________________________________ box 1a primary chassis components (mk4 roadster) ffr # part name unit qty check- off status 10632 ’87-’95 roadster build manual ea 1.00 11074 roadster ifs components 13819 ‘87-‘04 spindle adapter br...

  • Page 506

    505 www.Factoryfive.Com 508-291-3443 box 2a secondary chassis components (mk4 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 po...

  • Page 507

    506 www.Factoryfive.Com 508-291-3443 11070 wiring harness mounting hardware 10984 bolt, #14 x 1/2" ea 7.00 13979 screw with countersunk washer, #8 x 3/4" ea 8.00 10995 screw, #10 x 1" , (inertia cut-off switch) ea 2.00 10851 screw, #14 x 1 1/2", (vacuum controls) ea 2.00 11217 ring connector, 16 gau...

  • Page 508

    507 www.Factoryfive.Com 508-291-3443 box 3a body finish components – mk4 roadster ffr # part name unit qty check-off status 14636 factory five badge ea 3.00 12612 vinylester hood scoop ea 1.00 14671 headlamp components ea 2.00 included with above part# mount gasket 2 #8 x ¾” screws bucket, black pla...

  • Page 509

    508 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 510

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

  • Page 511

    510 www.Factoryfive.Com 508-291-3443 box 4a ancillary components ffr # part name unit qty check- off status 10789 air filter, conical ea 1.00 10781 fan belt, six rib, single ea 1.00 13661 a-frame transmission mount /hardware 13929 transmission bolt on mount, a-frame, powder coated ea 1.00 10833 bolt...

  • Page 512

    511 www.Factoryfive.Com 508-291-3443 box 5a lower steering shaft / cut dash / brake-fuel line ffr # part name unit qty check- off status 14553 lower steering shaft with 1987-1993 rack adapter (3/4”-36 spline) ea 1.00 13544 mkiii cut dash board ea 1.00 13738 brake line, 3/16" o.D. X 60" ea 4.00 13740...

  • Page 513

    512 www.Factoryfive.Com 508-291-3443 box 7a mkiv interior trim / carpet ffr # part name unit qty check- off status 10948 padded black vinyl dash cover ea 1.00 14922 emergency brake boot, black leather ea 1.00 15049 mkiv black carpet kit 15050 carpet, lh footbox floor, outside/front ea 1.00 15051 car...

  • Page 514

    513 www.Factoryfive.Com 508-291-3443 box 10 a lh mk4 rollbar (powder) ffr # part name unit qty check- off status 15084 lh 1.50” powder coated rollbar components 15082 lh main hoop, roll bar, 1.50”, 180 deg, powder coated black ea 1.00 15083 rollbar rear leg, 1.50”, powder coated black ea 1.00 15099 ...

  • Page 515

    514 www.Factoryfive.Com 508-291-3443 box 11b 3-link deluxe rear suspension ffr # part name unit qty check- off status 14676 roadster/coupe koni solid axle coil over kit 14623 damper, (koni 30-1721) ea 2.00 25621 2.5” koni spring hat ea 2.00 25622 2.5” koni threaded spring seat ea 2.00 25623 2.5” kon...

  • Page 516

    515 www.Factoryfive.Com 508-291-3443 box 12 a ‘87-‘95 straight tubes ffr # part name unit qty check- off status 13847 lh straight pipe, long, ‘87-’95 ea 1.00 13848 rh straight pipe, short, ‘87-’95 ea 1.00 13961 o2 sensor plug ea 2.00 end of box 12a box 13 a roadster side exhaust (uncoated) ffr # par...

  • Page 517

    516 www.Factoryfive.Com 508-291-3443 chassis number:_____________________________________________________ mkiv m o u n t e d c o m p o n e n t s ffr # part name unit qty check- off status 13029 mkiv roadster frame, complete ea 1.00 33050 3 link frame mount ea 1.00 12385 2.5” lower frame mount bolt (...

  • Page 518

    517 www.Factoryfive.Com 508-291-3443 14841 cockpit mounted aluminum 14627 screws, self tappers, kit building ea 50.00 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 ...

  • Page 519

    518 www.Factoryfive.Com 508-291-3443 tubular front lower arms ffr # part name unit qty check- off status 12066 lh/rh tubular front lower control arm 12306 front suspension, lower a-arm ea 2.00 14925 bolt, m16-2mm x 110mm, (front lower control arm) ea 4.00 14515 nut, m16 x 2.0mm, (front lower control...

  • Page 520

    519 www.Factoryfive.Com 508-291-3443 accelerator pedal ffr # part name unit qty check- off status 14481 accelerator pedal components 14486 accelerator pedal ea 1.00 included with above part# accelerator pedal allen wrench 13975 ball stud retainer ea 1.00 included with above part# stud retainer ball ...

  • Page 521

    520 www.Factoryfive.Com 508-291-3443 option manual steering rack ffr # part name unit qty check- off status 12619 15:1 aluminum manual steering rack assembly 14688 15:1 aluminum manual steering rack w/jam nuts ea 1.00 12620 steering rack polyurethane bushings ea 4.00 13651 outer tie-rod end ea 2.00 ...

  • Page 522

    521 www.Factoryfive.Com 508-291-3443 oem e-brake handle ffr # part name unit qty check- off status 14616 e-brake handle components 14548 e-brake handle ea 1.00 14549 e-brake t-junction ea 1.00 option oem mk4 front spindles ffr # part name unit qty check- off status 33048 front spindles ea 1.00 inclu...

  • Page 523

    522 www.Factoryfive.Com 508-291-3443 oem fuel tank components ffr # part name unit qty check- off status 14472 oem fuel tank components 14469 fuel tank ea 1.00 14624 fuel tank straps ea 1.00 included with above part# rh fuel tank mounting strap lh fuel tank mounting strap 14470 fuel tank cover ea 1....

  • Page 524

    523 www.Factoryfive.Com 508-291-3443 pedal box roadster/coupe ffr # part name unit qty check- off status 14724 clutch quadrant assembly ea 1.00 included with above part# clutch quadrant threaded firewall adjuster 4 #8-32 x 0.75" socket head screw 4 #8-32 nylon locknut quadrant spacer 3/8"-16 x 3.5" ...

  • Page 525

    524 www.Factoryfive.Com 508-291-3443 roadster cooling system ffr # part name unit qty check- off status 14031 roadster aluminum radiator ea 1.00 12912 inline filler neck ea 1.00 14576 threaded barb ea 1.00 12757 lower fan mount bracket ea 4.00 13127 185 degree thermostat switch ea 1.00 11180 0.25" f...

  • Page 526

    525 www.Factoryfive.Com 508-291-3443 wiper kit (roadster) ffr # part name unit qty check- off status 12041 boxed wiper components ea 1.00 included with above part# wiper motor, lucas cable, wiper motor gear, wiper motor wheelbox, lucas ferrule, threaded insert nut, ferrule gasket, rubber, wiper base...

  • Page 527

    526 www.Factoryfive.Com 508-291-3443 appendix c – big block installation 427 shown here with fuel injection..

  • Page 528

    527 www.Factoryfive.Com 508-291-3443 , these instructions are designed to supplement the assembly manual where the assembly process is different from the build up using a small block. Sections of the manual that deal with wiring and motor preparation of the small block will not apply and can be skip...

  • Page 529

    528 www.Factoryfive.Com 508-291-3443 460 single plane manifold with 850 cfm carburetor the throttle cable from the kit 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 th...

  • Page 530

    529 www.Factoryfive.Com 508-291-3443 427 engine mount with rubber isolator. The transmission we recommend is a tremec tko heavy duty 5 speed that will fit the big block engines with a lakewood bellhousing and the spacer mentioned in the suggested parts list. In order to use any manual transmission t...

  • Page 531

    530 www.Factoryfive.Com 508-291-3443 bellhousing and spacer lined up to mark pivot hole 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 with ...

  • Page 532

    531 www.Factoryfive.Com 508-291-3443 clutch fork installed awaiting transmission the transmission mount to the crossmember must also be fitted with spacers due to the higher centerline of the big block crankshaft. Two one-inch spacers are fit between the mount and the transmission, which raises the ...

  • Page 533

    532 www.Factoryfive.Com 508-291-3443 suggested parts the following parts are suggestions based on a combination of parts that we know to work. These parts are not specifically required and some may be unnecessary depending on your combination. Engine ford motorsports 460 m-6007-c460 (svo) intake man...

  • Page 534

    533 www.Factoryfive.Com 508-291-3443 appendix d – optional rear disc brakes.

  • Page 535

    534 www.Factoryfive.Com 508-291-3443 installation instructions , these instructions apply to any 1986-2004 ford mustang 8.8 rear axle with traction-lok differential (ffr#s 14319,14970) using 1994-2004 oem mustang style disc brakes (ffr#s 14834, and 14903). , the installation of this kit can be perfo...

  • Page 536

    535 www.Factoryfive.Com 508-291-3443 non-synthetic gear oil with gl-5 or gl-6 rating, 4oz of friction modifier (ford# cm-19546- a1), brake fluid. Remove the ten bolts that hold on the differential cover using a ½” socket wrench. Note: if you are installing disc brakes on a used rear axle, leave one ...

  • Page 537

    536 www.Factoryfive.Com 508-291-3443 reach behind the differential and push out the center pin from the back side..

  • Page 538

    537 www.Factoryfive.Com 508-291-3443 once the pin is removed, push the axles in toward the differential. When you do this the c -clips that hold the axles in will be visible and they may even fall out. If the c-clips do not fall out, push them off with a small screw driver or needle nose pliers. Sli...

  • Page 539

    538 www.Factoryfive.Com 508-291-3443 install the brake caliper brackets so that the caliper will mount on the front side of the axle. Use the four 3 / 8 ”-16 flange bolts provided and torque them to 45-50 ft/lbs..

  • Page 540

    539 www.Factoryfive.Com 508-291-3443 slide the axles back into the differential and re-install the c-clips. When re-installing the c-clips it helps to use a small magnet to hold onto them as it is difficult to reach the axle and hold onto the clip. , caution: care must be taken not to let axle shaft...

  • Page 541

    540 www.Factoryfive.Com 508-291-3443 once the c-clips are in, pull the axle back out until it stops so the clips are held in place. Install the center pin and the bolt that holds it. It’s a good idea to put locktite on the bolt before installing it, then torque it to 25 ft/lbs..

  • Page 542

    541 www.Factoryfive.Com 508-291-3443 install the rear cover. We recommend using a high temp oil safe rtv silicone rather than a paper gasket. Use a liberal amount, and tighten the bolts to 28-38 ft/lbs. Next install the brake rotor using one lug nut to hold it in place. Make sure to clean the surfac...

  • Page 543

    542 www.Factoryfive.Com 508-291-3443 once the rotor is on, put the brake pads in the caliper by pushing down on the pad to compress the wire springs on the top of the pad, and then slide them into the slots in the caliper hanger..

  • Page 544

    543 www.Factoryfive.Com 508-291-3443 when installing the caliper make sure that the brake fluid bleed screw is on the top side of the caliper. Do not worry about the lh/rh markings on the calipers. Torque the two 12mm mounting bolts to 55ft/lbs using a 16mm socket. Allow the silicone on the cover to...

  • Page 545

    544 www.Factoryfive.Com 508-291-3443 torque specifications fastener torque (ft./lbs.) differential pinion shaft locking bolt 15-30 banjo bolts 30-40 wheel nuts 85-105 axle adapter/rearbacking plate bolts 45-50 axle housing cover bolts 25-35 axle fill plug 15-30 caliper mounting bolts 70-95.

  • Page 546

    545 www.Factoryfive.Com 508-291-3443 appendix e – torque specifications.

  • Page 547

    546 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 548

    547 www.Factoryfive.Com 508-291-3443 appendix f – mustang specifications.

  • Page 549

    548 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 550

    549 www.Factoryfive.Com 508-291-3443 rear axle ratio manual optional automatic 2004 3.55 2.49 2003 3.55 3.27 1996-2002 3.27 3.27 1995 3.08 3.27 1994 3.08 3.27 1987-1993 2.73 3.08 3.27 from 1986 to 2004 8.8” rear axles were used in mustangs. In 1994 they went from a 4.25” 4-lug bolt pattern to a 4.5”...

  • Page 551

    550 www.Factoryfive.Com 508-291-3443 with an ffr kit. The factory five 4.6l steering kit includes the correct inner and outer tie rod ends along with the correct steering adapter..

  • Page 552

    551 www.Factoryfive.Com 508-291-3443 appendix e – fluid specifications.

  • Page 553

    552 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 transmission oil type t-5 t-45 3650 tko t-56 mercon/dexron iii trans. Fluid 2.8 qts. 3.25 qts. 4.0 qts. 2.64 qts. 4.0 qts 8.8 solid rear axle oil type capacity friction modifier 80w-90 gear...