1. DL manuals
  2. Factory Five Racing
  3. Automobile
  4. Mk4 Roadster
  5. Assembly Manual

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

  • Page 1

    R e v i s i o n 3 x , a u g u s t 2 0 1 7.

  • Page 2

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

  • Page 3: Table Of Contents

    Ii www.Factoryfive.Com 508-291-3443 table of contents general information ............................................................... 12 foreword ....................................................................................... 12 safety notice ................................................

  • Page 4

    Iii www.Factoryfive.Com 508-291-3443 speedometer and clutch cables ............................................................ 42 shifter and shifter handle ....................................................................... 43 emergency brake handle ...............................................

  • Page 5

    Iv www.Factoryfive.Com 508-291-3443 aluminum removal ....................................................................... 81 chassis assembly .................................................................. 86 rivet spacing tool .....................................................................

  • Page 6

    V www.Factoryfive.Com 508-291-3443 wilwood brake routing .......................................................................... 163 wilwood e-brake adapter ...................................................................... 164 firewall & driver front footbox aluminum ...........................

  • Page 7

    Vi www.Factoryfive.Com 508-291-3443 gauge pod installation ................................................................ 235 ignition and turn signal stalk ...................................................... 237 trunk aluminum ......................................................................

  • Page 8

    Vii www.Factoryfive.Com 508-291-3443 radiator mounting................................................................................. 291 96-04 additional steps ........................................................................... 292 stainless radiator hoses ...................................

  • Page 9

    Viii www.Factoryfive.Com 508-291-3443 door latch .................................................................................. 386 trunk ........................................................................................... 389 trunk hinge .....................................................

  • Page 10

    Ix www.Factoryfive.Com 508-291-3443 fuel tank access covers .............................................................. 469 final trunk mounting .................................................................. 470 interior rearview mirror ...........................................................

  • Page 11

    X www.Factoryfive.Com 508-291-3443 helpful reference material .......................................................... 518 must reads ........................................................................................... 518 helpful ...............................................................

  • Page 12

    Xi www.Factoryfive.Com 508-291-3443 accelerator pedal.................................................................................. 548 gauge cluster ....................................................................................... 548 pedal box ...............................................

  • Page 13: General Information

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

  • Page 14

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

  • Page 15

    14 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...

  • Page 16

    15 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...

  • Page 17

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

  • Page 18

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

  • Page 19

    18 www.Factoryfive.Com 508-291-3443 gauges and dash and electrical assembly: base kit parts are included to adapt the mustang wiring harness. The kit comes with components to build your car with an authentic original street style dash. Complete assembly comes with aluminum dash, padded vinyl dash co...

  • Page 20

    19 www.Factoryfive.Com 508-291-3443 driveshaft: 1987-2004 ford mustang. 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. Radiator and fan shroud: 1987-2004 ford mustang. Steering rack: 1987-20...

  • Page 21

    20 www.Factoryfive.Com 508-291-3443 wheels and tires: see the appendix for complete recommended sizes. 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 engrav...

  • Page 22

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

  • Page 23

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

  • Page 24: Donor Parts And Prep

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

  • Page 25

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

  • Page 26

    25 www.Factoryfive.Com 508-291-3443 the 4.6l engine is quiet while cruising and loud upon acceleration where the 5.0l is loud all the time. The 4.6l gets better mpg for the same horsepower level. The 4.6l engine is more expensive to upgrade parts. You have to buy two or four cams vs. One, etc... The...

  • Page 27

    26 www.Factoryfive.Com 508-291-3443 when you attempt to start the vehicle, the computer sends out a rf signal that is picked up by the transponder in the key. The transponder then returns a unique rf signal to the vehicle's computer, giving it the ok for the vehicle to start and continue to run. The...

  • Page 28

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

  • Page 29

    28 www.Factoryfive.Com 508-291-3443 axles (from rollovers or hard side hits). These are not too hard to fix but it’s good to know up front when you’re planning your budget. A quick way to verify mileage is by inspecting the drum brake shoes on the unit. The drum pulls straight out, off the axle. Rea...

  • Page 30

    29 www.Factoryfive.Com 508-291-3443 transmission mount, and the drive shaft). Think of this job as a reverse assembly line and it will go faster. If you are getting ready to disassemble a mustang, please refer to the “donor parts list” appendix. A chilton’s repair manual has quite good step-by-step ...

  • Page 31

    30 www.Factoryfive.Com 508-291-3443 87-95 brake power booster socket set, wrenches or box wrenches for brake lines, tube cutter, tape, and marker pen. Mustang power booster push rod, brake light switch/spacer/clip. Remove the brake rod retainer clip from the top of the brake pedal. Remember the orde...

  • Page 32

    31 www.Factoryfive.Com 508-291-3443 brake switch parts. Place a bucket under the hydro-booster. Label all hoses that attach to the hydro booster. Disconnect the hoses draining them into the bucket. Attach tape to the brake lines and mark their positions on the master cylinder and distribution block....

  • Page 33

    32 www.Factoryfive.Com 508-291-3443 1997 hydro-booster, master cylinder, hydro-boost retaining nut and snap ring. 1996-2004 abs brakes if power brakes are going to be used, an addition that is optional and not necessary but is very useful is the use of the abs system from the mustang. This does comp...

  • Page 34

    33 www.Factoryfive.Com 508-291-3443 never heat or lubricate the tie rod end to make removal easier. Remove the two bolts that secure the steering rack to the frame and lower the rack out of the car. Mustang steering rack with lines removed with rubber bushings and fasteners. 96-04 steering rack and ...

  • Page 35

    34 www.Factoryfive.Com 508-291-3443 mustang coil, egr assembly, vacuum lines, starter solenoid, mass air meter, and throttle cable. Remember to identify both ends of every connector disassembled. The easy way to do this is to tape and number each side of the connector the same. The connectors will o...

  • Page 36

    35 www.Factoryfive.Com 508-291-3443 remove and discard the front driver’s side plastic wheel well using a 7mm socket to loosen it from the body. Disconnect and remove the horns. They are located just forward of the wheel well on the driver’s side (accessed from the wheel well). Label and mark the co...

  • Page 37

    36 www.Factoryfive.Com 508-291-3443 while moving the cable wheel toward the firewall. The clutch cable can be easily released from the grooved wheel at this point. Unbolt and remove the pedal box. 94-04 pedal box assembly computer socket set. Mustang computer and oem plastic cradle. If you are going...

  • Page 38

    37 www.Factoryfive.Com 508-291-3443 eec-iv computer and cradle. Eec-v computer. Remove the kick panel in the passenger footbox. Disconnect the ground strap in the footbox next to the computer. Remove the computer and its plastic holder from the passenger footbox area. Gauge cluster and speedometer c...

  • Page 39

    38 www.Factoryfive.Com 508-291-3443 87-93 mustang gauges mounted in gauge pod. Remove the two gauge wiring connectors from the gauge cluster by squeezing the outside clips. Remove the clear plastic gauge cover with a torx screwdriver and discard. Place the switches and gauge pod in your parts area, ...

  • Page 40

    39 www.Factoryfive.Com 508-291-3443 96-04 steering column (with ignition, turn signal stalk) remove the steering column mounts located under the dash above the driver floor. Allow the column to fall down. Remove the wiring connectors have from the turn signal and ignition switches. Remove the turn s...

  • Page 41

    40 www.Factoryfive.Com 508-291-3443 key and anti-theft module dash wiring harness socket set, extension, regular, torx and phillips head screwdrivers, needle nose pliers, hammer, and marker tape. Dash wiring harnesses, 96-04 traction control switch the wiring comes out in stages. Keep the sub-assemb...

  • Page 42

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

  • Page 43

    42 www.Factoryfive.Com 508-291-3443 87-93 front wiring harness with hookups for headlights, alternator, and horn. Speedometer and clutch cables socket set, duct tape. Speedometer cable and sending unit, clutch cable. Pull the speedometer cable out from the dash area keeping the rubber grommet that i...

  • Page 44

    43 www.Factoryfive.Com 508-291-3443 clutch cable and retainer circlip. Shifter and shifter handle socket set, phillips head screwdriver. Shifter the kit comes with new bolts for the shifter handle so you don’t need the oem bolts. Save them anyway according to rule #85 of the car guys’ handbook which...

  • Page 45

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

  • Page 46

    45 www.Factoryfive.Com 508-291-3443 the transmission harness must be removed along with the rubber plug. This runs along the driver’s side of the transmission tunnel. Store the rear harness and transmission harness. Exhaust wrenches, 11 / 16 ” socket, socket extension, ratchet, adjustable wrench, ha...

  • Page 47

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

  • Page 48

    47 www.Factoryfive.Com 508-291-3443 2003 4.6l dohc engine and 3650 transmission there is an exhaust h-pipe tube holder plate sandwiched between the transmission mount and the transmission that must be removed. All you need is the transmission mount with the two bolts sticking down. Front suspension ...

  • Page 49

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

  • Page 50

    49 www.Factoryfive.Com 508-291-3443 loosen the rear wheel lug nuts. Raise the rear of the car and place on jack stands. Open the gas cap to relieve any pressure built up in the tank. Remove the screws that hold the upper fuel cap and flange to the body of the car. Remove the set screw and metal ring...

  • Page 51

    50 www.Factoryfive.Com 508-291-3443 lower the jack slowly with the rear end so that they come down together. When the rear end has dropped down low enough, you can easily remove the coil springs and upper rubber spring mount. Save the rubber bushings above and below the springs. Remove the bolts and...

  • Page 52

    51 www.Factoryfive.Com 508-291-3443 96-98 donor fuel system parts. Donor part preparation rear coil springs hack saw or chop saw rear coil spring. Remove the rubber tubular spacer from inside the coil..

  • Page 53

    52 www.Factoryfive.Com 508-291-3443 cut one full coil from the top of the spring for correct ride height setting. Cut the upper rubber spring seat so that during assembly of the kit, it will conform to the spring mount on the frame. This is done with one cut across the part. Do not replace these bus...

  • Page 54

    53 www.Factoryfive.Com 508-291-3443 stock 94-04 front lower. If using the stock 94-04 front lower control arms, drill a ½” hole in the spring seat area shown in the picture below using the rear end shock mount as a guide for height. If the hole is drilled too low, you will have to clearance the midd...

  • Page 55

    54 www.Factoryfive.Com 508-291-3443 drilled and modified front lower control arm. Attach the rear shock mount to the control arm through the hole in the spring seat with the small leg sticking up. Check clearance with the new shock and the new mount. These parts must move freely without contacting t...

  • Page 56

    55 www.Factoryfive.Com 508-291-3443 coil-over mounted in lower arm with clearance hole. Fuel filter fittings razor knife donor plastic fuel line fittings from fuel filter to body hard line and from return line from body hard line to fuel tank. Carefully with out damaging the plastic barb, cut the ha...

  • Page 57

    56 www.Factoryfive.Com 508-291-3443 fuel tank pliers fuel tank at the locations on the tank where the tank straps come near the tank, use a pair of pliers and bend the bent parts flat. Fuel filler neck hack saw fuel filler neck 87-98 - cut the mustang steel fuel neck in the mid-section after the 90 ...

  • Page 58

    57 www.Factoryfive.Com 508-291-3443 uncut filler neck cut filler neck 99-04 – cut the donor filler neck just above the crimp line below the mounting flange..

  • Page 59

    58 www.Factoryfive.Com 508-291-3443 cut the filler neck above the bend but below where the small fuel tubes attach to the side of the larger tube making sure to leave enough room to attach a fuel filler hose and hose clamp. Brake pedal hack saw if you are not using the hydro-boost/power brakes, it i...

  • Page 60

    59 www.Factoryfive.Com 508-291-3443 cut the brake pedal between the mounting bolt and the master cylinder push rod attachment stud. Remove 1.5” from the middle and mig weld the pedal back together. Make sure the top piece where the bolt is located is oriented correctly, as the spacer on each side of...

  • Page 61

    60 www.Factoryfive.Com 508-291-3443 trim the accelerator pedal as shown, just above the plastic pedal support pad. It is possible to mount the original plastic pedal piece onto the shortened pedal if desired. This can be accomplished by squeezing the bottom of the trimmed pedal and drilling a hole f...

  • Page 62

    61 www.Factoryfive.Com 508-291-3443 mark the mounting face of the 1” up from the bottom of the mounting plate. Cut-off the marked area (bottom of the front mount flange) with a hack saw. This is necessary for steering shaft clearance. 1994-2004 pedal box drill, drill bits.

  • Page 63

    62 www.Factoryfive.Com 508-291-3443 drill out the four spot welds on the front face of the pedal box. Cut off the lower corner of clutch quadrant stop shown in the picture for accelerator pedal clearance. Cut line.

  • Page 64

    63 www.Factoryfive.Com 508-291-3443 remove the brake pedal spring from its mount hole and remove the plate on the front of the pedal box along with the round spacers. Relocate brake pedal spring to pedal box triangular opening. Wiring harness razor knife, electrical tape. Many people choose to cut d...

  • Page 65

    64 www.Factoryfive.Com 508-291-3443 heater wires air bag blue boxes and wires electronic seat and window controls. Remote trunk release wires not only does this take weight out of the car, it gives additional room behind the dash. Look at the plugs and compare them to a chilton’s manual to make sure...

  • Page 66

    65 www.Factoryfive.Com 508-291-3443 move the harness grommet backwards on the harness behind the short wiring “branch with the large rectangular plug on it. All of the remaining plugs should be pulled back behind the firewall plug. Rewrap the harness with electrical tape from where the grommet was b...

  • Page 67

    66 www.Factoryfive.Com 508-291-3443 87-95 brake power booster push-rod remove the master cylinder from the power booster. The power brake assembly is changed to a manual brake assembly for this kit. This simple modification is done on many scca mustangs for improved brake feel. In a 2,100 lb. Car, t...

  • Page 68

    67 www.Factoryfive.Com 508-291-3443 87-95 - bend the fuel lines away from the engine block just at the point where they are held in place by the retaining clips. This is so that the fuel does not travel near the hot header. Don’t make tight bends here or it will affect your fuel flow. If you are usi...

  • Page 69

    68 www.Factoryfive.Com 508-291-3443 96-04 driver side manifold. 96-04 passenger side manifold. Note the casting touches the block..

  • Page 70

    69 www.Factoryfive.Com 508-291-3443 96-04 - install the headers, leave the header on the correct side of the engine but flip them over so that they point forward alternate drive pulley preparation cordless drill, ½” drill bit, needle nose pliers alternate drive pulley template on 87-93 efi cars, the...

  • Page 71

    70 www.Factoryfive.Com 508-291-3443 insert the spring pins back into the two front holes on the block. It may be helpful to put a dab of silicone to hold the pins in place until the bolts are installed. 87-95 transmission hack saw.

  • Page 72

    71 www.Factoryfive.Com 508-291-3443 if you are running a t-5 transmission, remove the casting tab with the hole in it that is sticking out on the passenger side with a hack saw. Steering rack 11 / 16 ” and ⅝” wrenches, ruler, hack saw, marker. Remove the outer tie rods. Cut 1.75” off the end of the ...

  • Page 73

    72 www.Factoryfive.Com 508-291-3443 old style cut half of the passenger side power steering mount off. Drill a mounting hole in the bracket using a 3 / 16 ” drill bit. Intake tube the year and type of engine may give a different style intake tube. Similar modifications can be done to different style...

  • Page 74

    73 www.Factoryfive.Com 508-291-3443 uncut 1997 dohc cobra™ intake hose cut the intake hose in the crease on the intake side of the bellow section marked in the picture. Make sure not to cut the large bellow section. 96-04 air filter housing unclamp the air filter housing from the mass air meter..

  • Page 75

    74 www.Factoryfive.Com 508-291-3443 mark the housing around the base of the dome. Cut the flange off the housing. Keep in mind, the flange is the part you want to keep..

  • Page 76

    75 www.Factoryfive.Com 508-291-3443 re-assemble the air filter and cut flange clamping them together with the stock clamp. Cleaning and detailing before you start assembling your car, cleaning is the best way to assess what needs to be done to the donor parts. Based on your close-up inspection you m...

  • Page 77

    76 www.Factoryfive.Com 508-291-3443 wait until the wiring harness is installed and the car is running before you cover the harness up with a nice wrapping of electrical tape. If it’s dirty, wipe it off gently with a moist (not wet) rag. Use common sense when cleaning these parts; don’t use a wire wh...

  • Page 78: Disassembly Of The Kit

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

  • Page 79

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

  • Page 80

    79 www.Factoryfive.Com 508-291-3443 body removal ⅝” socket, ratchet, ⅝” wrench, gloves, 2 friends. Be careful of the raw fiberglass edges, they can splinter into your skin unbolt the door from the hinge leaving the hinge attached to the chassis. Cut the zip ties in the door latch area. Remove the ho...

  • Page 81

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

  • Page 82

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

  • Page 83

    82 www.Factoryfive.Com 508-291-3443 using a marker outline the underside of each panel where it contacts the chassis. This is done to locate where to drill rivet holes when the panels are permanently mounted later on. Mark each panel and take pictures of how the panels fit together (i.E. Which is on...

  • Page 84

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

  • Page 85

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

  • Page 86

    85 www.Factoryfive.Com 508-291-3443 use jack-stands to position your frame in your workspace with plenty of room to move things around..

  • Page 87: Chassis Assembly

    86 www.Factoryfive.Com 508-291-3443 chassis assembly chapter 3.

  • Page 88

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

  • Page 89

    88 www.Factoryfive.Com 508-291-3443 the “f” shaped aluminum panels that mount behind the suspension are mounted first. Locate them and mark your rivet pattern in the location you traced. Drill the panels using a 1 / 8 ” bit then clean the marker lines and labeling off using acetone or brake cleaner..

  • Page 90

    89 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 #6 screws to remount the panel then drill the 1 / 8 ” rivet holes through the panel holes into the chassis..

  • Page 91

    90 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. Front suspension front lower control arm ⅞” socket, 15 / 16 ” wrenches, torque wrench mustang lower control arms and fasteners.

  • Page 92

    91 www.Factoryfive.Com 508-291-3443 87-93 - mount the lower control arms using the outer set of holes on the chassis using the supplied hardware. 94-04 - stock lower control arms, use the inner set of bolt holes. Ffr tubular lower control arms - use the outer mounting holes. While holding the contro...

  • Page 93

    92 www.Factoryfive.Com 508-291-3443 put thread locker on the upper balljoint threads. Screw the upper ball joints into the control arms so that the balljoint angles out on the bottom.

  • Page 94

    93 www.Factoryfive.Com 508-291-3443 tighten the balljoint using the arm for leverage with a vice holding the ball joint. Screw the grease fittings in to the ball joints and tighten with a ⅜” wrench..

  • Page 95

    94 www.Factoryfive.Com 508-291-3443 mount the upper control arms to the chassis with the grease fittings pointed up. Use the mount holes that are horizontal on the top of the 2”x 3” tube, not the side vertical ones. Torque the two bolts that hold the arm to the frame to 135-149nm (100-110 lbft). The...

  • Page 96

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

  • Page 97

    96 www.Factoryfive.Com 508-291-3443 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 spring seat down on the sleeve so it is closer to the unthreaded end. Slide the coil sleeve over the body of the da...

  • Page 98

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

  • Page 99

    98 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 control arm and attach t...

  • Page 100

    99 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. Spindles 13 / 16 ” socket, torque wrench, needle nose pliers, rubber mallet ifs components, mustang spindles. Make sure the grease...

  • Page 101

    100 www.Factoryfive.Com 508-291-3443 using the 87-93 spindles, use the hole closest to the ball joint and the third hole down. Using a 94-04 spindles, attach the bracket using the bottom and third hole up so that the ball joint is further away from the spindle. Attach the upper ball joint to the spi...

  • Page 102

    101 www.Factoryfive.Com 508-291-3443 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. Front suspension torque specs chart item nm lbft front lower control arm to frame 135-162 100-110 front lower ba...

  • Page 103

    102 www.Factoryfive.Com 508-291-3443 94-04 front brakes clean the rotor with brake cleaner and push it onto the hub..

  • Page 104

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

  • Page 105

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

  • Page 106

    105 www.Factoryfive.Com 508-291-3443 if not already done, fill the axle with gear oil. See appendix for specifications and capacities. If using a used rear axle, remove the lower shock mounts and the anti vibration weight under the pinion. 87-98 axle – drill the lower control arm holes out with a ½”...

  • Page 107

    106 www.Factoryfive.Com 508-291-3443 99-04 axle - drill the lower control arm holes out with a 9 / 16 ” drill bit. Position the traction lok brackets on the rear end with the bolts provided (the two short bolts go on the sides). Axle bracket driver's side.

  • Page 108

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

  • Page 109

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

  • Page 110

    109 www.Factoryfive.Com 508-291-3443 spring perch mounts ½” drill bit, drill, ¾” wrench, ¾” socket, ratchet rear spring perches, mustang springs and rubber isolator mounts hold the spring perches up to the frame so the vertical perch mount is in between the 2”x 3” tube and the vertical frame mount. ...

  • Page 111

    110 www.Factoryfive.Com 508-291-3443 skip the 3 link section and continue on with the rear axle section. Optional 3 link rear suspension 3 / 16 ”, ⅜”, ½” drill bits, ⅝”, ¾”, 15 / 16 ”, 1” wrenches, ⅜”, ⅝”, ¾”, 15 / 16 ” sockets, 5 / 16 ” hex key, ratchet, torque wrench, drill, ruler/tape measure, pl...

  • Page 112

    111 www.Factoryfive.Com 508-291-3443 test fit the two halves of the upper arm mount together. If it is hard to put all of the bolts in the mount holes, put in as many as you can then use a ½” drill bit through the remaining bolt holes. Attach the upper link bracket onto the axle using the fine hardw...

  • Page 113

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

  • Page 114

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

  • Page 115

    114 www.Factoryfive.Com 508-291-3443 rear axle installation 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. Make sure that the rear jack stands are positioned under the 4” ro...

  • Page 116

    115 www.Factoryfive.Com 508-291-3443 with one person holding a side of the axle, raise the axle so that the lower control arms can be bolted onto the frame. Attach the lower control arms to the frame mounts. Jack the rear axle up..

  • Page 117

    116 www.Factoryfive.Com 508-291-3443 if using a 4 link, attach the upper control arms to the frame. If using a 3 link, attach the upper link to the frame. Optional 3-link panhard bar frame mount the panhard bar frame mount is mounted to the chassis during shipping.

  • Page 118

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

  • Page 119

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

  • Page 120

    119 www.Factoryfive.Com 508-291-3443 panhard bar 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...

  • Page 121

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

  • Page 122

    121 www.Factoryfive.Com 508-291-3443 optional rear coil-over shock assembly snap ring pliers, ¾” wrench, ¾” socket, ratchet, ruler, marker, hack saw. Roadster/coupe rear shock kit the rear shocks are pre-valved at the factory in compression and rebound for good street use. The shocks can be adjusted...

  • Page 123

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

  • Page 124

    123 www.Factoryfive.Com 508-291-3443 install the snap ring on the spring hat so that it holds onto the shock end. Make sure that the slot in the snap ring and the slot in the spring hat are not aligned. Use zip ties to hold the spring to the spring hat. Assembled solid axle koni coil-over shock..

  • Page 125

    124 www.Factoryfive.Com 508-291-3443 attach the body end of the shock to the upper shock mount using the two equal length (1.09”) spacers. Jack the rear axle up so the rod end of the shocks can be mounted on the axle through the shock mount hole. Passenger side.

  • Page 126

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

  • Page 127

    126 www.Factoryfive.Com 508-291-3443 run zip ties through the holes in the spring hat and around the spring to prevent the spring from becoming unseated..

  • Page 128

    127 www.Factoryfive.Com 508-291-3443 rear shocks torque wrench, ratchet, ¾” socket, 15mm wrench mustang vertical shocks, quad shocks, quad shock brackets, quad shock fasteners assembly, rear spring perches, rear traction lok brackets/fasteners. Attach the rear vertical shocks at the top through the ...

  • Page 129

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

  • Page 130

    129 www.Factoryfive.Com 508-291-3443 tighten the bolts on the quad shock brackets. 4 link rear suspension torque specs chart item nm lbft upper control arm to axle 101-111 75-82 upper control arm to frame 101-111 75-82 lower control arm to axle 101-111 75-82 lower control arm to frame 101-111 75-82 ...

  • Page 131

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

  • Page 132

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

  • Page 133

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

  • Page 134

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

  • Page 135

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

  • Page 136

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

  • Page 137

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

  • Page 138

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

  • Page 139

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

  • Page 140

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

  • Page 141

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

  • Page 142

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

  • Page 143

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

  • Page 144

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

  • Page 145

    144 www.Factoryfive.Com 508-291-3443 center section vent pliers, wire cutters, hammer vent hose, vent nipple, insulated clips, secondary body fasteners. Remove the plug at the top of the rear cover..

  • Page 146

    145 www.Factoryfive.Com 508-291-3443 use a hammer on the end of the barb to put the nipple in the rear cover. Push the 12.00” piece of 5 / 16 ” fuel hose onto the barb..

  • Page 147

    146 www.Factoryfive.Com 508-291-3443 run the hose up to the 1” tube that goes across the back of the irs and use one of the kit 5 / 8 ” insulated clips and 3 / 16 ” rivet to hold it in place. Toe adjustment arms irs toe adjustment arm components 13 / 16 ” socket, 15 / 16 ” wrench, torque wrench. If ...

  • Page 148

    147 www.Factoryfive.Com 508-291-3443 attach the toe arms to the frame below the front lower arm mount using the 1 / 8 ” thick spacer in the back and the ¼” spacer on the front side of the rod end. Use the 5 / 8 ” x 2.25” bolts to attach them to the frame. Torque bolts to 135nm (100 ft-lb). Lower con...

  • Page 149

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

  • Page 150

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

  • Page 151

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

  • Page 152

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

  • Page 153

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

  • Page 154

    153 www.Factoryfive.Com 508-291-3443 spindle to upper arm insert the angled mount adapter into the upper arm rod end. Attach the upper control arm to the spindle using the 5 / 8 ” x 3.50” bolt and locknut. Wait to torque the bolts until after the other arms are installed..

  • Page 155

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

  • Page 156

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

  • Page 157

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

  • Page 158

    157 www.Factoryfive.Com 508-291-3443 install the snap ring on the spring hat so that it holds onto the shock end. Make sure that the slot in the snap ring and the slot in the spring hat are not aligned. Attach the rod end of the shock to the upper shock mount using the two equal length 1.09” kit spa...

  • Page 159

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

  • Page 160

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

  • Page 161

    160 www.Factoryfive.Com 508-291-3443 insert the driveshaft into the transmission, bolt the rear flange to the driveshaft adapter and torque the bolts to 109nm (80 ft-lb). Fluids name specification motorcraft® additive friction modifier (u.S.) xl-3 (u.S.) est-m2c118-a motorcraft® sae 75w-85 synthetic...

  • Page 162

    161 www.Factoryfive.Com 508-291-3443 alignment specs camber: -0.5 to -0.75° total toe: 1/8” toe in torque specifications lb-ft nm center section to frame front 129 175 center section to frame rear 129 175 brake caliper to caliper bracket 24 32 brake caliper bracket to spindle 129 175 brake hose banj...

  • Page 163

    162 www.Factoryfive.Com 508-291-3443 e-brake cables make sure the ffr cables go through the upper bracket in the transmission tunnel until the sheath end clicks in place..

  • Page 164

    163 www.Factoryfive.Com 508-291-3443 wilwood brake routing run the left e-brake cable over the top of the center section and left rear mount then down and over to the brake caliper. Run the right cable over the center section and right rear mount then down and over to the brake caliper..

  • Page 165

    164 www.Factoryfive.Com 508-291-3443 wilwood e-brake adapter insert the cable end into the bent bracket then bolt the bracket to the e-brake lever..

  • Page 166

    165 www.Factoryfive.Com 508-291-3443 make sure to run the other end of the brake cables under the 4” crossmember and connect them to the e- brake handle and adjust. Firewall & driver front footbox aluminum drill, 1 / 8 ” drill bit, rivet tool, caulk gun, silicone firewall and driver footbox front al...

  • Page 167

    166 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..

  • Page 168

    167 www.Factoryfive.Com 508-291-3443 pedal box ⅜”, 9 / 16 ” sockets, 3 / 16 ”, 5 / 16 ” hex key, drill, 9 / 16 ” wrench, ⅛”, ¼”, 7 / 16 ” drill bits, silicone, rivet tool, marker. Mustang pedal box, pedal box hardware, cockpit aluminum. 87-93 pedal box.

  • Page 169

    168 www.Factoryfive.Com 508-291-3443 position the mustang pedal box on the two angled ¾” tubes over the driver’s feet, and attach using two short ⅜” bolts and two washers to the front wall at the front of the foot box..

  • Page 170

    169 www.Factoryfive.Com 508-291-3443 there are four holes on the mustang pedal assembly on top of the ¾” tubing. Mark these holes on the tubes. The right hole for the master cylinder must also be marked on the pedal box. Use the laser cut hole in the foot box steel as a guide to mark the mustang ped...

  • Page 171

    170 www.Factoryfive.Com 508-291-3443 drill ¼” holes completely through the ¾” tubing for the pedal box. Use a 7 / 16 ” drill bit to drill the bolt hole in the pedal box for the master cylinder bolt. Trim the corner off the pedal box using a hacksaw. The front foot box aluminum panel can now be silic...

  • Page 172

    171 www.Factoryfive.Com 508-291-3443 reinstall the pedal box assembly in the driver’s footbox; use the ¼”x 1.50” screws from the pedal box fastener assembly with a fender washer next to the head. Leave all the hardware hand tight. 94-04 pedal box position the mustang pedal box over the two angled ¾”...

  • Page 173

    172 www.Factoryfive.Com 508-291-3443 install the pedal box with the two ⅜” bolts and washers at the top as before. They go through existing holes in the front of the foot box. Accelerator cable 5 / 64 ” hex key, ⅜”, 7 / 16 ”, ½” wrenches, wire cutters..

  • Page 174

    173 www.Factoryfive.Com 508-291-3443 pedal box hardware, accelerator cable components. The cable design is set up for a 96-04 4.6l mustang engine with an oem pedal but using the supplied ball studs and retainers it can be adapted for all applications. 87-93 fuel injected and carbureted applications ...

  • Page 175

    174 www.Factoryfive.Com 508-291-3443 screw on and tighten the 5 / 16 ” locknut on the cable sheath inside the foot box using two ½” wrenches. The engine end will get installed later. 94-04 fuel injected applications loosen the nut on the engine end of the accelerator cable with the cylinder slug on ...

  • Page 176

    175 www.Factoryfive.Com 508-291-3443 accelerator cable mounted on ‘98 4 valve intake. Accelerator cable mounted on ’96 2 valve intake. Run the cable from the mount plate, tightly against the intake and over to the driver’s foot box front panel. Insert the pedal end of the cable into the foot box. Sc...

  • Page 177

    176 www.Factoryfive.Com 508-291-3443 cut the accelerator pedal capture in the corner using a pair of wire cutters. Slip the accelerator cable through the cut so that the ball will sit in the recess. Push the capture into the end of the throttle pedal. Check the idle screw underneath the throttle bod...

  • Page 178

    177 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. Loosely mount the top pillow block to the chassis with the set screw toward the rear ...

  • Page 179

    178 www.Factoryfive.Com 508-291-3443 slide the steering shaft into the footbox from the engine bay through the lower bearing. 87-93 power steering racks have a different spline than a manual steering rack and the 94-04 power rack uses a “pyramid” shaped end. All of these lower adapters are available...

  • Page 180

    179 www.Factoryfive.Com 508-291-3443 87-93 steering rack and fasteners (hydraulic lines removed). If not already in, insert the stock rubber bushings and kit spacer sleeves into the rack. Pull back the rubber boot on the inner tie rod and remove the inner tie rod from the steering rack. Line up the ...

  • Page 181

    180 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. Use thread locker on all of the steering shaft screws that do not have jam nuts and the adapter screws. The inner tie rod extensions are for ...

  • Page 182

    181 www.Factoryfive.Com 508-291-3443 if using the power rack and you have not already done this in the donor prep stage, cut 1.75” off the end of the inner tie rod. Put a dot of thread lock on the threads of the steering rack and attach the steering rack extension to the steering rack using a 1.50” ...

  • Page 183

    182 www.Factoryfive.Com 508-291-3443 94-04 - put a dot of thread lock on the threads of the steering rack extension and attach the new inner tie rods to the steering rack. Push the boot back onto the steering rack body and attach with zip ties. The track of the ffr roadster front end is a little nar...

  • Page 184

    183 www.Factoryfive.Com 508-291-3443 steering rack installed. Upper steering shaft 5 / 32 ”, 3 / 16 ”, 5 / 16 ” hex keys, ½” wrench, rubber mallet steering system hardware unpack the upper steering shaft from the primary chassis components box..

  • Page 185

    184 www.Factoryfive.Com 508-291-3443 slide the steering shaft through the upper bearing and start it in the lower shaft. Turn the steering shaft so the recessed bosses for the spring washers are facing up and set the washers in place. Then tap the upper shaft down until the upper clip just disappear...

  • Page 186

    185 www.Factoryfive.Com 508-291-3443 tighten the upper and lower bearings. Also tighten the set screw on the upper shaft. Cockpit aluminum drill, ⅛” drill bit, rivet tool, silicone, caulking gun, #8 self tapping screws, #8 hex nut driver, ruler, marker, acetone or carburetor cleaner, rags. Packaged ...

  • Page 187

    186 www.Factoryfive.Com 508-291-3443 passenger footbox locate the passenger footbox top and drill and mark the holes in the top flat surface only. Silicone this panel where it meets the chassis and rivet along the bottom of the 2” square frame crossbar only. Use one of the original screws to tempora...

  • Page 188

    187 www.Factoryfive.Com 508-291-3443 drill the tunnel front a-shaped piece where it meets the chassis and silicone and rivet it in place. Mark and drill the two vertical edges of the passenger footbox inside wall..

  • Page 189

    188 www.Factoryfive.Com 508-291-3443 silicone and rivet the panel to the front tunnel “a” and the footbox top. Mark the holes in the passenger footbox front panel upper and outer edges but do not drill yet..

  • Page 190

    189 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..

  • Page 191

    190 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 192

    191 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. Passenger floor drill the passenger side floor where it was m...

  • Page 193

    192 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. Drill and rivet the floor in place t...

  • Page 194

    193 www.Factoryfive.Com 508-291-3443 drill, silicone, and rivet the right side under door piece in place. Leave the rivets out of the rear vertical flange for now. Driver floor drill silicone and install the driver’s footbox floor. The outer flange does not get drilled yet..

  • Page 195

    194 www.Factoryfive.Com 508-291-3443 silicone, drill, and install the driver side floor. Install the left side under door aluminum like the right side..

  • Page 196

    195 www.Factoryfive.Com 508-291-3443 drill, silicone and install the inner footbox wall. The front flange tucks in behind the front wall that was left unriveted. Put a little silicone on both sides of this flange. U-joint cover mark the rear tunnel cover where it meets the chassis then silicone and ...

  • Page 197

    196 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 198

    197 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. Fuel system fuel tank 9 / 16 ” deep socket, ratchet, hammer, 5 / 16 ” hex key, floor jack, friend. Mustang fue...

  • Page 199

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

  • Page 200

    199 www.Factoryfive.Com 508-291-3443 push the four plastic end caps into the tubes hanging down in front and behind the gas tank. 87-93 - hang the fuel tank straps from the rear mount of the chassis using two of the strap fasteners. The longer strap goes on the passenger side..

  • Page 201

    200 www.Factoryfive.Com 508-291-3443 94-04 - hang the fuel tank straps from the rear mount of the chassis using two of the strap fasteners. The strap with both flat ends goes on the passenger side (shown). Using a jack, raise the tank up into place on the chassis. Make sure the plastic cover is in p...

  • Page 202

    201 www.Factoryfive.Com 508-291-3443 bolt the straps in with the strap fasteners and drop the jack. Tighten only the driver’s side strap as the passenger one will be removed for aluminum fitment later on..

  • Page 203

    202 www.Factoryfive.Com 508-291-3443 fuel filter tube bender, 3 / 16 ”drill bit, drill, rivet tool, marker, tape measure, flat head screwdriver, 9 / 16 ” wrenches insulated clip hardware, fuel line components, ¼”, 5 / 16 ” fuel lines, mustang fuel filter and mount, mustang tank to filter nylon hose,...

  • Page 204

    203 www.Factoryfive.Com 508-291-3443 fuel lines unpack the fuel lines and the fuel line assembly which is in the secondary chassis components box. The larger 5 / 16 ” line is the send fuel line to the engine. If you are running a return system then there is ¼” line provided for that as well. There a...

  • Page 205

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

  • Page 206

    205 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. Fasten the lines to the 2”x 2” s...

  • Page 207

    206 www.Factoryfive.Com 508-291-3443 if you are going to use the mustang fuel vapor line, run it along with the other fuel lines. Brake system tube bender, 3 / 16 ”, ¼” drill bits, drill, rivet gun, marker, tape measure, razor knife, round file or sand paper, brake fluid, 5 / 16 ” hex key, ½”, 9 / 1...

  • Page 208

    207 www.Factoryfive.Com 508-291-3443 manual brake master cylinder and pushrod use the ⅜”x 2” bolts provided to mount the master cylinder and spacers to the footbox front wall. The number of spacers used dictates the height of the brake pedal. Start with one spacer unless you are 6’ or taller then us...

  • Page 209

    208 www.Factoryfive.Com 508-291-3443 tighten all of the mounting bolts for the pedal box and master cylinder. Install the push rod from the power booster into the master cylinder and insert the white plastic bushing in the ring end. Hold the rod between the two ears of the brake light switch and sli...

  • Page 210

    209 www.Factoryfive.Com 508-291-3443 put the clip through the hole in the pedal so that the push rod will not come off. Tighten all the remaining hardware mounting the pedal box to the chassis. If you plan to race frequently, use some small springs and attach them to the brake pedal and pedal box to...

  • Page 211

    210 www.Factoryfive.Com 508-291-3443 put the clip through the hole in the pedal so that the push rod will not come off. Front flexible brake lines unpack the hardware from the brake line components..

  • Page 212

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

  • Page 213

    212 www.Factoryfive.Com 508-291-3443 push the brake line adapters through the brackets from the outside in and install the clips that hold them in place. If removed, attach the front brake line to the caliper making sure there is a crush-washer on either side of the fitting. Hand tight is fine on al...

  • Page 214

    213 www.Factoryfive.Com 508-291-3443 from the distribution block, run one of the longer 60” brake lines over to the passenger side brake hose mount. The line will bend very easy but be careful not to kink it. When you are happy with the routing use the small insulated line clips and 3 / 16 ” rivets ...

  • Page 215

    214 www.Factoryfive.Com 508-291-3443 use a union to attach a second 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. 87-95 mustang solid axles have a single flex line that runs to the middle of the axle then out to the cal...

  • Page 216

    215 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 217

    216 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. Attach the passenger side flexible brake l...

  • Page 218

    217 www.Factoryfive.Com 508-291-3443 attach the hard brake line to the flexible brake line. Make sure that your flex lines will not interfere with anything in the suspension, wheels during travel or turning full lock to lock. Tighten the banjo bolts on the calipers banjo bolt torque specs 87-95 fron...

  • Page 219

    218 www.Factoryfive.Com 508-291-3443 manuals for the model year you are using are invaluable. They cost between $30-$55 ea. But are well worth the money. Www.Helminc.Com if you did not take the harness out of the car yourself, when connecting the plugs together, check the wire colors going into and ...

  • Page 220

    219 www.Factoryfive.Com 508-291-3443 use the inertia cut-off switch as a template and drill two holes in the trunk aluminum on the far corner of the driver’s side. Mount the inertia fuel cut-off switch on the inside. Run (2) wires (using the blue wire extensions in the misc. Electrical components) f...

  • Page 221

    220 www.Factoryfive.Com 508-291-3443 transmission harness push the harness plugs through the hole in the driver's side floor aluminum. Run the harness forward into the corner to the ¾” tube at the foot box front. Then go up and along the angled ¾” tube to its connector. Make sure that it does not ge...

  • Page 222

    221 www.Factoryfive.Com 508-291-3443 headlight harness 87-93 headlight harness. 87-95 - the headlight harness is started at the alternator and runs forward to the passenger headlight area, then goes under the fan shroud to the driver’s side headlight area and then rearward to the coil and starter re...

  • Page 223

    222 www.Factoryfive.Com 508-291-3443 96-04 - mount the engine bay fuse box using the stock mount in the front driver side corner of the engine bay to the “x” leaving room for the hood pin or hood hinge mount and the power steering reservoir. The mustang is wider than the ffr roadster in front and th...

  • Page 224

    223 www.Factoryfive.Com 508-291-3443 87-95 dash harness the dash harness begins at the coil area and goes rearward to the large hole in the front of the driver’s side foot box. The key to routing the dash harness is to start on the inside of the foot box and push the smaller items through the large ...

  • Page 225

    224 www.Factoryfive.Com 508-291-3443 run the harness over the pedal box and through the large hole in the firewall. Dash harness going through laser cut hole. The dash harness can then be run on top of the 2”x 2” square tube over to the computer side. Run everything loosely so that final positioning...

  • Page 226

    225 www.Factoryfive.Com 508-291-3443 old starter new starter.

  • Page 227

    226 www.Factoryfive.Com 508-291-3443 when the wire harness is installed, mount the fuse panel (use the diagram in appendix a to determine the correct shape) to the 2”x 2” dash hoop support and between the two ¾” x ¾” frame tubes in the driver’s side footbox using the aluminum bracket provided and a ...

  • Page 228

    227 www.Factoryfive.Com 508-291-3443 dash wiring showing computer mounted on the passenger side of the firewall. Either modify the dash harness as described in the donor parts modification section at the beginning of the manual or cut a hole in the top outer footbox panel for the rectangular plug so...

  • Page 229

    228 www.Factoryfive.Com 508-291-3443 run the harness over the pedal box and steering shaft and through the large slot in the firewall. The connectors for the rest of the harness easily fit through this hole and the big rubber grommet on the harness press fits into the laser cut hole. Attach the rect...

  • Page 230

    229 www.Factoryfive.Com 508-291-3443 when the wire harness is installed, mount the fuse panel (use the diagram in appendix a to determine the correct shape) to the 2”x 2” dash hoop support and between the two ¾” x ¾” frame tubes in the driver’s side footbox using the aluminum bracket provided and a ...

  • Page 231

    230 www.Factoryfive.Com 508-291-3443 attach the pats module pigtail to the dash harness and zip-tie the ignition cylinder assembly to the dash harness. 87-95 engine harness.

  • Page 232

    231 www.Factoryfive.Com 508-291-3443 silicone and rivet the dash extension in position. The engine harness begins in the passenger foot box. The computer plug is pushed through the oval shaped hole on the firewall extension from the engine bay side..

  • Page 233

    232 www.Factoryfive.Com 508-291-3443 attach the computer to the underside of the top of the passenger foot box using the plastic bracket from the mustang and the screws provided. Alternatively the computer can be mounted to the inside of the firewall if the optional heater/defroster is not being use...

  • Page 234

    233 www.Factoryfive.Com 508-291-3443 attach the computer connectors to the starter solenoid and the ground to the backside of the solenoid against the ¾” tubing. The ground looks like a female stereo jack (sort of). The other half of the connector is on the battery negative cable, so just cut the co...

  • Page 235

    234 www.Factoryfive.Com 508-291-3443 run the other larger bundle forward to the front of the frame. Connectors shown at the front of the footbox are not needed using the fuel pump resistor as a template, hold it against the firewall and mark the firewall where the mount hole and tab hole. Drill 3 / ...

  • Page 236

    235 www.Factoryfive.Com 508-291-3443 attach the constant control relay to the top of the passenger footbox using ⅛” rivets. Gauge pod installation wire stripper, crimping tool, electrical tape, wire cutters, phillips head screwdriver, hack saw, razor knife, marker, 1 / 8 ”, 11 / 64 ” drill bits, dri...

  • Page 237

    236 www.Factoryfive.Com 508-291-3443 remove the mustang gauges from the white gauge pod with a small torx screwdriver. Cut the locating pins for the gauges off the white gauge pod with a hack saw so that the pod will lie flush against the firewall when mounted. Use an 11 / 64 ” drill bit and a stead...

  • Page 238

    237 www.Factoryfive.Com 508-291-3443 with a razor knife, cut the other end of the blue plastic on the female blue butt connectors that overhangs so that the metal part is flush with the end of the connector. This will give more contact area for the gauges to grab. Push the male bullet connectors on ...

  • Page 239

    238 www.Factoryfive.Com 508-291-3443 mount the turn signal stalk with the stalk pointed towards the seat as high as possible between the plate steel that also holds the windshield and the vertical ¾” tubing next to it. The switch spans the gap. Use two 1” screws and a 5 / 16 ” socket and 9 / 64 ” dr...

  • Page 240

    239 www.Factoryfive.Com 508-291-3443 with the rear taillight harness tied up and secure, silicone and install the lower trunk floor. Re-install the gas tank strap and tighten. Silicone and install the trunk inner corner pieces..

  • Page 241

    240 www.Factoryfive.Com 508-291-3443 silicone and rivet the fuel tank strap patch panel from the packaged aluminum assembly. Drill and silicone the upper trunk floor. Bend it in the middle to get it into position..

  • Page 242

    241 www.Factoryfive.Com 508-291-3443 work the corners of the panel down over the roll bar mounts and seat harness tabs a little at a time on each side. Once the panel lies flat, finish rivet it into place. The rivets along the front 2”x 3” tube should be close to the back as possible for drill and r...

  • Page 243

    242 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. Battery mounting and cable drill, 1” hole saw, 3 / 16 ”, ¼”, 5/ 16 ” drill bits, rivet gun, marker, 7 / 16 ” deep socket, ...

  • Page 244

    243 www.Factoryfive.Com 508-291-3443 unpack the battery mounting kit. Position the battery with mounting bracket in the trunk for mounting. It is centered side to side with just enough room for the mounting bracket between it and the front of the trunk..

  • Page 245

    244 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 246

    245 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. Remove the powder coating from the small circle in the trunk closer to the ground terminal of your...

  • Page 247

    246 www.Factoryfive.Com 508-291-3443 drill through the center of the circle and put a washer down in the cut out. Bolt the mustang ground cable to the chassis, leave the battery terminal off for now while the rest of the system is being routed..

  • Page 248

    247 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 249

    248 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 250

    249 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. Drivetrain preparation if installing a coyote engine, call or check our parts catalog online for install instructions. Aftermarket tko 500 a...

  • Page 251

    250 www.Factoryfive.Com 508-291-3443 trim off the unused mounting boss on the bottom of the case. Trim it flush or just below the pad for the transmission mount. 99-04 transmission mount transmission mount adapter (ffr# 13969)..

  • Page 252

    251 www.Factoryfive.Com 508-291-3443 if using a 99-04 engine, the transmission mount adapter bracket shown and provided in the kit must be used when using the stock transmission mount. Drill the rivets out of the stock mount. Locate the stock mount on the adapter so that the bottom edge of the mount...

  • Page 253

    252 www.Factoryfive.Com 508-291-3443 bolt the transmission side of the mount to the bracket provided as shown. 99-04 transmission mount on the adapter bracket. 87-93 alternate drive pulley ¾” socket, ¾” wrench. Alternate drive pulley components (ffr# 11080) if you are using under-drive pulleys or el...

  • Page 254

    253 www.Factoryfive.Com 508-291-3443 place a washer onto the bolt. Place the pulley wheel on the bolt. Place the aluminum sleeve on the bolt with the flange towards the pulley wheel, so that it slides inside the pulley. Install the bolt assembly on the a/c bracket (previously drilled in the disassem...

  • Page 255

    254 www.Factoryfive.Com 508-291-3443 check the pulley wheel for alignment with the other pulleys so that premature belt wear does not occur. With one eye, carefully align the front side of the pulley with the front side of the other pulleys. If the new pulley is not lined up properly and is too far ...

  • Page 256

    255 www.Factoryfive.Com 508-291-3443 use teflon tape on the threaded barbs and thread them into the oil filter relocator. Thread the short end of the threaded nipple into the relocator..

  • Page 257

    256 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 befo...

  • Page 258

    257 www.Factoryfive.Com 508-291-3443 place the aluminum sleeve on the bolt with the flange towards the pulley wheel, so that it slides inside the pulley. Attach the pulley to the bracket to using the included ½” bolt..

  • Page 259

    258 www.Factoryfive.Com 508-291-3443 attach the a/c eliminator bracket to the engine. Use double washers for the two front bolts that have the sleeves in the holes. Pull the tension pulley back using a ratchet in the square hole and install the serpentine belt using the picture for reference if usin...

  • Page 260

    259 www.Factoryfive.Com 508-291-3443 if not using power steering, use the following picture for routing. 96-98 dohc belt routing without power steering. 99-03 dohc serpentine belt routed on engine using power steering..

  • Page 261

    260 www.Factoryfive.Com 508-291-3443 96-04 heater bypass hose use the heater bypass hose provided to loop between the inlet and outlet on the back of the engine. 96-04 oil pan 9 / 16 ” deep socket, 9 / 16 ”, ½” wrenches. If you are installing aftermarket gauges, some of the gauge sending units will ...

  • Page 262

    261 www.Factoryfive.Com 508-291-3443 the easiest method to install the drivetrain is with the engine and transmission already bolted together and lowered in as a unit. Also remove anything that will make your job easier (shifter assembly, headers, power steering pump, etc…). Lower the engine and tra...

  • Page 263

    262 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. Transmission mount 5 / 16 ” hex key, 9 / 16 ”, ¾” socket, ratchet, ¾” wrench, floor jack tran...

  • Page 264

    263 www.Factoryfive.Com 508-291-3443 unpack the a-frame transmission mount and hardware. Jack the transmission up and mount the a-frame underneath it. Normally this mounts above the frame tabs but can be mounted underneath if extra clearance is needed..

  • Page 265

    264 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. Driveshaft 14mm wrench, thread locker mustang driveshaft and fasteners if not already done, the driveshaft should be shortened to the length specifie...

  • Page 266

    265 www.Factoryfive.Com 508-291-3443 slip the shortened driveshaft 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 mustang driveshaft bolts should have thread locker on them already. If ...

  • Page 267

    266 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. 87-95 oil filter relocator razor knife, flathead screwdriver oil filter relocating kit, oil, oi...

  • Page 268

    267 www.Factoryfive.Com 508-291-3443 headers and j-pipes 7 / 16 ”, 9 / 16 ” wrenches, 7 / 16 ” socket, ratchet, extension, 5 / 16 ” hex key mustang shorty headers, straight tubes catalytic convertors and full length headers are available if required or preferred. Mount the headers to the engine. Thr...

  • Page 269

    268 www.Factoryfive.Com 508-291-3443 mount the straight pipes to the mustang headers. The shorter pipe will go on the passenger side. Leave the bolts hand tight in order to locate the side pipes properly. Aftermarket headers may require “ovaling” the holes on the two-bolt flange..

  • Page 270

    269 www.Factoryfive.Com 508-291-3443 fuel lines to engine flat head screwdriver fuel line components finish running your fuel system by hooking up either to your carburetor or fuel rail. Here we mounted a pressure regulator on the firewall and ran a single line over to the rail. 96-04 connections ¼”...

  • Page 271

    270 www.Factoryfive.Com 508-291-3443 insert one end of the 5 / 16 ”x 16” onto the inlet side of the fuel pulse dampener. Slide and attach the fuel injection clamp over the end of the pulse dampener end. Slide another fuel injection clamp onto the hose and push the inlet end onto the 5 / 16 ” hard li...

  • Page 272

    271 www.Factoryfive.Com 508-291-3443 hydro-boost lines shown in stock location. Lines must be bent and re-routed to fit behind aluminum tubes bent around inside of master cylinder..

  • Page 273

    272 www.Factoryfive.Com 508-291-3443 lines in bent and routed in final locations. Lines running from booster, along steering shaft to steering rack..

  • Page 274

    273 www.Factoryfive.Com 508-291-3443 hose routing for 96-2000 power steering cooler. Power steering line for steering rack. Note stock line bent..

  • Page 275

    274 www.Factoryfive.Com 508-291-3443 power steering oil cooler (if applicable) drill, 3 / 16 ” drill bit, ⅜” wrench. Power steering cooler and hoses. 1996-1999 version mount the power steering cooler to the 3 / 16 ” plate on the front of the 4” main rails. Use the original mount on the passenger sid...

  • Page 276

    275 www.Factoryfive.Com 508-291-3443 location of power steering cooler inlet/outlet if using tubular control arms. 2000-2004 version this cooler is the replacement for the older coolers. There are a couple of different locations that the cooler can be mounted: to the bottom of the radiator so it is ...

  • Page 277

    276 www.Factoryfive.Com 508-291-3443 drill and temporarily mount the driver side mount. Measure the distance from the radiator and make a bracket to mount the passenger side mount such as the one shown. Note the 90 degree bent mount bracket..

  • Page 278

    277 www.Factoryfive.Com 508-291-3443 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 bracket on the cable ...

  • Page 279

    278 www.Factoryfive.Com 508-291-3443 connect the clutch cable to the bellhousing and the clutch fork. Speedometer sending unit 11mm deep socket, ratchet. Mustang speedometer sending unit..

  • Page 280

    279 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. Plug the wire harness connector into the sender. Accelerator cable 5 / 64 ” hex key, ⅜”, 7 / 16 ” wrenches insulated clip hardware...

  • Page 281

    280 www.Factoryfive.Com 508-291-3443 fuel injected application attach the engine end of the cable sheath to the cable mount on the intake using ⅜” and 7 / 16 ” wrenches. Put a dab of silicone on the rear edge of the rubber wipe then push the rubber wipe back onto the threads. 87-93 mounted accelerat...

  • Page 282

    281 www.Factoryfive.Com 508-291-3443 accelerator cable mounted on ‘98 4 valve intake. Accelerator cable mounted on ’96 2 valve intake. 87-93 - push the ball stud retainer onto the ball on the bottom of the throttle body. Push/pull the cable into the retainer so that the cable is tight. Tighten the s...

  • Page 283

    282 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 284

    283 www.Factoryfive.Com 508-291-3443 carbureted applications if necessary, attach the supplied ball stud to the carburetor in the appropriate location. Refer to the carburetor instructions for placement. Attach the ball stud retainer to the ball stud. Pull the cable tight holding the cable against t...

  • Page 285

    284 www.Factoryfive.Com 508-291-3443 attach the engine end of the cable sheath to the cable mount on the engine using ⅜” and 7 / 16 ” wrenches. Put a dab of silicone on the rear edge of the rubber wipe then push the rubber wipe back onto the threads. Push the ball stud retainer onto the ball stud. P...

  • Page 286

    285 www.Factoryfive.Com 508-291-3443 modified 2003 intake tube. Mass air meter drill, 3 / 16 ” drill bit, ⅜” socket wire harness mounting hardware, mustang mass air sensor mass air meters are used on 1989 and newer mustangs. 89-93 mounting flatten the outer edge of the mounting bracket using a hamme...

  • Page 287

    286 www.Factoryfive.Com 508-291-3443 attach the mass air mount to the backside of the vertical ¾” tube on the passenger side as shown in the picture below using two 3 / 16 ” rivets. Attach the mass air meter to the mount using the stock nuts. Attach the intake hose to the engine and the mass air met...

  • Page 288

    287 www.Factoryfive.Com 508-291-3443 87-95 mounting drill two 3 / 16 ” holes through the canister bracket oem holes. Mount with two #14 screws. Attach the vent hose from the gas tank to the canister and the hose leading to the engine..

  • Page 289

    288 www.Factoryfive.Com 508-291-3443 96-04 mounting if you are going to run a vapor line and a fuel evaporative canister (charcoal can), mount the can at the back of the car on the driver side using the stock bracket so that the stock plastic line will still reach the correct connection. Note: splas...

  • Page 290

    289 www.Factoryfive.Com 508-291-3443 fan mount bracket 87-93 fan mounting remove the radiator reservoir using a 5 / 16 ” socket. Attach the 1 / 16 ” steel strips to the electric fan using the phillips head screws provided..

  • Page 291

    290 www.Factoryfive.Com 508-291-3443 position the fan assembly in the mouth of the fan shroud so that the fan and shroud are flush, if necessary, bend the tabs on the mount strips outwards slightly to hold it in place. Mark the position of the mounting strip holes and drill guide holes into fan shro...

  • Page 292

    291 www.Factoryfive.Com 508-291-3443 radiator mounting zip tie the radiator in place on the chassis. The bottom section can just hang by a couple ties looped around the lower outlet and the drain. Move the radiator towards passenger side until the filling cap just clears the frame. Drill the holes t...

  • Page 293

    292 www.Factoryfive.Com 508-291-3443 mount the radiator top to the flange with the hardware provided. The bottom stays zip tied for now. 96-04 additional steps hold the upper radiator mount plate up to the frame, and line up the bend with the bend in the ¾” tube. Mark rivet locations every 3”- 4”. D...

  • Page 294

    293 www.Factoryfive.Com 508-291-3443 drill and rivet the upper mount plate to the radiator using ⅛” rivets. Position the stock overflow tank so that it is centered across the front radiator mount plate. Dohc overflow front overflow mounts positioned on the radiator mount..

  • Page 295

    294 www.Factoryfive.Com 508-291-3443 mount the rear of the overflow tank to the front side of the 2”x 2” frame tube using the bracket included and 3 / 16 ” rivets. Mk 3 shown. Mount the front of the overflow tank to the radiator mount using #14x ½” screws provided..

  • Page 296

    295 www.Factoryfive.Com 508-291-3443 96-04 - if you prefer to use rubber radiator hoses, use napa # 7575 for the top hose. Use the stock lower hose to the thermostat housing then use gates #21383 to attach to the radiator going under the steering rack..

  • Page 297

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

  • Page 298

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

  • Page 299

    298 www.Factoryfive.Com 508-291-3443 upper radiator hose start at the engine and using the stock mustang radiator the radiator hose should be routed through the “f” panel to the radiator. If the ffr radiator is being used, the upper radiator hose should be routed above the “x” to the radiator. If us...

  • Page 300

    299 www.Factoryfive.Com 508-291-3443 push some grommeting onto the passenger side aluminum “f” panel slot to prevent any chaffing of the tube. Pass the upper radiator tube through the passenger side “f” panel and route the tube to the radiator. Mark the tube where it needs to be cut so that the tube...

  • Page 301

    300 www.Factoryfive.Com 508-291-3443 run the tube next to the 4” main rail and under the steering rack to the radiator. Route the lower tube with enough slack to be able to adjust the radiator for the nose aluminum. Make sure that the lower hose is not hanging down. If necessary, zip tie the hose to...

  • Page 302

    301 www.Factoryfive.Com 508-291-3443 standard on/off switch using this set-up, the driver must watch the water temperature gauge and manually turn the fan on when the water temperature gets to 212°f. The fan should only be needed while going less than 35mph or in traffic. This set-up will only power...

  • Page 303

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

  • Page 304

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

  • Page 305

    304 www.Factoryfive.Com 508-291-3443 silicone and install the tunnel plug patch panel. Driver footbox side aluminum ⅛” drill bit, drill, rivet gun, caulking gun, silicone mounted aluminum, packaged aluminum, secondary body fasteners silicone and install the drivers side footbox outer wall. The front...

  • Page 306

    305 www.Factoryfive.Com 508-291-3443 emergency brake e-brake handle 3 / 16 ” hex key mustang e-brake handle, brake line components. The 99-04 parking brake handle has different mounting locations and “t” cable length than the older 87-98 handles. Push the u-nuts from the brake line components onto t...

  • Page 307

    306 www.Factoryfive.Com 508-291-3443 on 99-04 handles, remove the small bracket and screw that prevents the ratcheting adjustment gear from turning. Bolt the handle to the mount bracket using the kit fasteners. The holes are slotted so the handle can get positioned properly to allow room for your ha...

  • Page 308

    307 www.Factoryfive.Com 508-291-3443 e-brake 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...

  • Page 309

    308 www.Factoryfive.Com 508-291-3443 for 87-92 and ffr cables, route the inner cable down under the chassis and hook them to the t cable..

  • Page 310

    309 www.Factoryfive.Com 508-291-3443 solid axle route the remaining cable back to the calipers and attach. Make sure your routing is out of the way of any moving parts and the cable has slack to move with the axle. Pull up on the handle a few times to make sure the self tensioner works and there are...

  • Page 311

    310 www.Factoryfive.Com 508-291-3443 irs bend and route the cables over the center section so that they curves to the rear of the lower control arm and attach the cable to the arm using zip ties from the kit. Emergency brake cable in caliper bracket. Pull up on the handle a few times to make sure th...

  • Page 312

    311 www.Factoryfive.Com 508-291-3443 optional irs 11.65” brakes attach the emergency brake cable to the caliper by pulling on the back of the caliper slightly and pushing the cable into the mount. The cable will be very close to or touch the adapter bracket. If necessary, file a small angled recess ...

  • Page 313

    312 www.Factoryfive.Com 508-291-3443 bend and route the cables over the center section so that they curves to the rear of the lower control arm and attach the cable to the arm using zip ties from the kit. Engine ground sand paper or grinder bit, ½” socket, ratchet, 3 / 16 ” hex key mustang engine gr...

  • Page 314

    313 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. Seats 5 / 16 ” drill bit, drill, 3 / 16 ” hex key, ½” deep socket, marker seat mount hardware, seats unpack the seats and set them in t...

  • Page 315

    314 www.Factoryfive.Com 508-291-3443 lift up the bottom of the cushion to reveal the seat frame. Using the rivet heads as a guide mark where the rails of the seat frame are above the seat mounting plates..

  • Page 316

    315 www.Factoryfive.Com 508-291-3443 drill the first hole for the seat mounting and install the bolt. Drill the remaining holes for mounting the seats and install the bolts. Nameplate 1 / 8 ” drill bit, rivet gun, drill.

  • Page 317

    316 www.Factoryfive.Com 508-291-3443 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 number engraved on the 2”x 2” tube going across the...

  • Page 318

    317 www.Factoryfive.Com 508-291-3443 1987-1993 1994-1998.

  • Page 319

    318 www.Factoryfive.Com 508-291-3443 1999-2004 with 1994-1995 versions, cut the trip meter off from the odometer as shown before cutting. Retain the odometer to reattach to the speedometer later. With the gauges separated center them in their designated dash holes from the back side and scribe a mar...

  • Page 320

    319 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 tab...

  • Page 321

    320 www.Factoryfive.Com 508-291-3443 take a pair of pliers and snap the tabs off to get the larger opening. Countersink the gauge mounting holes in the dash. To do this take one of the 1.5” long phillips head screws included in the kit, and use a drill to screw the screws into all of the gauge mount...

  • Page 322

    321 www.Factoryfive.Com 508-291-3443 gauge installation there are multiple gauge mounting holes for the different years, so there will be some unused holes in the dash, which will be covered by the padded dash. 87-93 gauges installed, note the screw holes used. 94-98 gauges installed, note the screw...

  • Page 323

    322 www.Factoryfive.Com 508-291-3443 countersink the spacers to match the countersunk holes for a good fit and so they lay flat against the dash. If you would like to install the three lights that are included in the kit, one possible layout is similar to the original roadsters, positioned directly ...

  • Page 324

    323 www.Factoryfive.Com 508-291-3443 install the large gauges with the taller spacers and the smaller gauges with the shorter spacers that are included with the kit so that the faces of the gauges stand away from the back face of the aluminum dash panel. This distance has been pre-set at the factory...

  • Page 325

    324 www.Factoryfive.Com 508-291-3443 the turn signal light uses a three prong flasher unless two lights are used, one for each direction. Using the one light in the kit, remove the two-prong flasher from above the passenger compartment. Break/cut the connector for it in half and connect the purple/p...

  • Page 326

    325 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 327

    326 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 328

    327 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 329

    328 www.Factoryfive.Com 508-291-3443 using the razor knife cut a “+” sign pattern into the middle of the steering shaft hole. Press fit the 4” and 2” bezels into the dash by pressing on the outer rim section only. For 1987-1993 gauges pull out the trip counter button. Install the switches in the das...

  • Page 330

    329 www.Factoryfive.Com 508-291-3443 use the wiring extension pins to connect the gauges to the white master panel (the dash pod). This was previously mounted on the firewall behind the dash. Connect the electric fan wires to the fan switch if being used. Connect the horn wires to the horn button..

  • Page 331

    330 www.Factoryfive.Com 508-291-3443 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 lower as it goes to the middle. Make sure the gauges do not hit the ¾” tubing. Drill for the dash mounting screws (5 ...

  • Page 332

    331 www.Factoryfive.Com 508-291-3443 push the ends of the dash behind the top of the door hinge and screw through the hinge into the dash end. Unpack the dash support/headlight/hazard brackets from the packaged aluminum. Rivet the panels to the chassis and then use the trim screws to attach them to ...

  • Page 333

    332 www.Factoryfive.Com 508-291-3443 install the mustang headlight and hazard switches in the aluminum brackets. Installation of the dash with mustang gauge conversion set. Steering wheel phillips head screw driver, 10mm wrench, 5 / 16 ” hex key.

  • Page 334

    333 www.Factoryfive.Com 508-291-3443 steering wheel/hardware unpack the steering wheel hardware..

  • Page 335

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

  • Page 336

    335 www.Factoryfive.Com 508-291-3443 rollbar ½” wrench, 3 / 16 ” hex key, 5 / 16 ” drill bit, drill driver side rollbar assembly unpack the rollbar and mounting hardware..

  • Page 337

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

  • Page 338

    337 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. Drill a hole all the way through each of the lower mounts and rollbar mai...

  • Page 339

    338 www.Factoryfive.Com 508-291-3443 insert one of the bolts after drilling each hole to ensure that the rollbar does not move. Make sure the rear leg is tight up against the main hoop and drill the upper hole. This bolt will be visible so keep this in mind when deciding the orientation. Install the...

  • Page 340

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

  • Page 341

    340 www.Factoryfive.Com 508-291-3443 fluid levels and grease grease gun, chassis grease, ratchet, rags transmission fluid, rear axle gear oil, engine oil, coolant, water.

  • Page 342

    341 www.Factoryfive.Com 508-291-3443 irs fill the rear differential with gear oil. Any 8.8 in. Ford has a fill plug that is removed and filled until the oil just reaches that level. The irs has it in the rear cover and the solid axle has it in the front..

  • Page 343

    342 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 344

    343 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 345

    344 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. Irs axle nuts torque wrench, 36mm...

  • Page 346

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

  • Page 347

    346 www.Factoryfive.Com 508-291-3443 turn the steering wheel all the way to the left. Fill the reservoir to the full cold level and leave the cap off. Turn the steering wheel lock to lock 20 times checking the fluid level every few times. Top off if necessary. Start the engine and check the fluid le...

  • Page 348

    347 www.Factoryfive.Com 508-291-3443 wiring – loose wires – close to heat sources or moving parts – loose grounds suspension – all hardware tight – no binding or clearance issues chassis – all hardware double checked – nothing loose or sharp steering – all set screws tight – steering wheel tight – t...

  • Page 349

    348 www.Factoryfive.Com 508-291-3443 racing seats with less padding give more room, the more upright the angle of the seat the more room to straighten out your legs. Driver footbox aluminum rivet the remaining inner cockpit wall flange to the firewall..

  • Page 350

    349 www.Factoryfive.Com 508-291-3443 silicone and install the footbox inside top panel. Leave the top flange un-riveted for now; use some clamps or tape to hold it in place. Silicone and install the outer footbox top section. Your rolling chassis is now complete!.

  • Page 351: Body Section

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

  • Page 352

    351 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 353

    352 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..

  • Page 354

    353 www.Factoryfive.Com 508-291-3443 the push-on weather strip needs to run across the top of the firewall and the trunk walls and rear floor. Mounting the body rear quick jacks ⅝” wrench, ⅝” socket, ratchet quick jack bumper components the main locating points for the body are the rear quick jack m...

  • Page 355

    354 www.Factoryfive.Com 508-291-3443 the long sleeves go between the body and chassis with washers on both ends of all sleeves..

  • Page 356

    355 www.Factoryfive.Com 508-291-3443 the nut and bolt use a ⅝” wrench and socket to attach the rear quick jack bolts to the frame and body. Even with the quick jacks removed, it is still a good idea to wrap the bolts with some rags and duct-tape to save yourself from painful cuts or bruises..

  • Page 357

    356 www.Factoryfive.Com 508-291-3443 front quick jacks/front mounts ⅝” wrench, ⅝” socket, ratchet quick jack fasteners do not tighten the bolts until directed to do so. The body mounting bracket goes on the back side of the frame front mount..

  • Page 358

    357 www.Factoryfive.Com 508-291-3443 assemble the quick jack parts in the order shown, the bolts can be installed either way around depending on personal preference. Use the shipping carriage bolt through the turn signal mounting hole until the turn signals are mounted..

  • Page 359

    358 www.Factoryfive.Com 508-291-3443 center the body over the frame using a tape measure to measure from the lip of the body to the rear mounting plate of the front coil-over bracket. Check the alignment to make sure the tape measure is going straight across the car by lining it up with the front “x...

  • Page 360

    359 www.Factoryfive.Com 508-291-3443 check the outside corners of the dash tube. Make sure there is a ½” or so gap between the body and frame. Try pushing down on the body here, it should move. If the tube touches it will affect the door front corner fitment. Use an adjustable or ¾” wrench to bend t...

  • Page 361

    360 www.Factoryfive.Com 508-291-3443 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 the opening in the body, if needed sand or file the edges to allow the panel to just fit with a very small gap all aroun...

  • Page 362

    361 www.Factoryfive.Com 508-291-3443 use ⅛” long rivets to attach the bumpers through the body and into the frame. Once you are happy with the alignment you can set the panel gap and radius the edges. An easy way to set the gap is by using a marker. With the panel in place, run a marker around the e...

  • Page 363

    362 www.Factoryfive.Com 508-291-3443 hood pin mount loosely attach the hood pin mount plates to the chassis using the carriage bolts. The bolts push in from the outside..

  • Page 364

    363 www.Factoryfive.Com 508-291-3443 position the hood pin plates on the frame. Attach the hood pin vertical posts hand tight to the mounting plate. One nut goes on each side of the plate. Drill 3 / 16 ” holes in the front ¾” tube through the mounting plate holes..

  • Page 365

    364 www.Factoryfive.Com 508-291-3443 rivet the plate to the front ¾” tube. Change the angle of the mounting plate so that the hood pin post is perpendicular to the body hood lip. Bend the front tab if necessary so that it sits flat on the radiator mount tube. Tighten the carriage bolts holding the m...

  • Page 366

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

  • Page 367

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

  • Page 368

    367 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 369

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

  • Page 370

    369 www.Factoryfive.Com 508-291-3443 drivers side arm plate with arms attached driver side hinge assembled. Attach the hinge arms to the arm support plate as shown using the ⅜” shoulder bolts, spacers, nylon lock nuts and washers. The spacer fits over the bronze bushing after it is pressed into the ...

  • Page 371

    370 www.Factoryfive.Com 508-291-3443 attach the hinges to the chassis using the carriage bolts, these push in from the outside for easier adjustment. Leave the bolts loose enough so that the hinge assembly can be positioned to match the hood..

  • Page 372

    371 www.Factoryfive.Com 508-291-3443 set the hood in place and attach the two arms to the brackets from the underside of the body. Install the threaded ball studs in the hole on the long hinge arms with the ball pointed toward the outside of the car using a 5 / 16 ” locknut. Then snap the gas piston...

  • Page 373

    372 www.Factoryfive.Com 508-291-3443 attach the piston body end to the ball on the hood. Hood handles ⅛ ”, 7 / 64 ”, 3 / 16 ”, ⅝” drill bits, drill, measuring tape, phillips head screwdriver, pliers, marker, 2.5mm hex key, file. Three lock set and fasteners.

  • Page 374

    373 www.Factoryfive.Com 508-291-3443 measure the center of the hood liner rib along the trailing edge of the hood and mark it. Measure out from the hood center 12” on each side and mark the middle of the hood liner rib for the hood handle location..

  • Page 375

    374 www.Factoryfive.Com 508-291-3443 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 drill in reverse so they do not tear the fiberglass. Remove the hood handles from the three lock set and break off the bo...

  • Page 376

    375 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 377

    376 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 378

    377 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. Drill the two holes just marked with a 7 / 64 ” bit and file the edged of the bracket round with a ...

  • Page 379

    378 www.Factoryfive.Com 508-291-3443 the four remaining screws are used to hold these brackets in place. They can either be countersunk into the body or used to hold down the hood bumpers to hide them completely. Attach the cam wedge to the underside of the hood handles and adjust for tightness usin...

  • Page 380

    379 www.Factoryfive.Com 508-291-3443 windshield phillips head screwdriver, marker, ½” drill bit, drill, hack saw, ¾” wrench, ratchet, ¾” socket, friend. 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 time an...

  • Page 381

    380 www.Factoryfive.Com 508-291-3443 with the help of a friend, slide the windshield down through the slots in the body until the bottom edge is resting on the body and mark the chassis mounting holes on the arms. If the arms are too long and prevent the windshield from sitting down then pull them b...

  • Page 382

    381 www.Factoryfive.Com 508-291-3443 slide the windshield into position and bolt in place using the windshield mounting hardware. The windshield should remain bolted down while you fit the doors. Doors 3 / 16 ” hex key, marker, ⅝” socket, ratchet, air saw, orbital sander, 3 / 16 ” drill bit, drill, ...

  • Page 383

    382 www.Factoryfive.Com 508-291-3443 if you have removed them, remount the door hinges on the chassis. The square nuts sit alongside the tube so only one hex wrench is needed for adjustment..

  • Page 384

    383 www.Factoryfive.Com 508-291-3443 use a jack under the side of the car to make sure the body is up against the bottom of the frame. Leave the jack so that the body can be moved in and out when pulled. Start with the body all the way in. Position the door in the body to see where it may need to be...

  • Page 385

    384 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 386

    385 www.Factoryfive.Com 508-291-3443 once the front of the door is good, reuse one of the #10 self-tapping screws that the body was originally mounted with to lock the location in. Screw it up into the 2”x 2” tube near the front of the door. Push or pull the back of the body to line it up with the d...

  • Page 387

    386 www.Factoryfive.Com 508-291-3443 once the body is painted and final mounted rivet the bottom lip of the body to the chassis using the long 3 / 16 ” rivets. Set the gaps on the doors as you did with the hood using a marker. Door latch ½” wrench, 1 / 8 ” drill bit, drill, philips head screwdriver,...

  • Page 388

    387 www.Factoryfive.Com 508-291-3443 remove the door latch striker from the original mounting bracket and keep only the striker and the washers. The bracket and nut will not be used. Bolt the striker onto the chassis putting enough shims on the striker to bring the base of the striker head flush wit...

  • Page 389

    388 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. With the door lined up and the striker in place, mark and drill the 1...

  • Page 390

    389 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 391

    390 www.Factoryfive.Com 508-291-3443 trim the trunk lid edges enough so that it just fits into the opening. Trunk hinge ½” wrench, 3 / 16 ” hex key trunk hinge components. Press the bushings into the hinge arms from either side..

  • Page 392

    391 www.Factoryfive.Com 508-291-3443 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 loosening the bolts. Hang the hinge arms on the chassis using the shoulder bolts. You do not need the nuts for just doing fitmen...

  • Page 393

    392 www.Factoryfive.Com 508-291-3443 screw the trunk to the mounting pads also leaving them loose enough that they will just move. Close the trunk and wiggle it into position then open and tighten the bolts. This may take a little adjustment to get the trunk to sit down right. You can also use some ...

  • Page 394

    393 www.Factoryfive.Com 508-291-3443 trunk latch ⅜” socket, ratchet, flat head screwdriver, philips head screwdriver 3 lock set and fasteners find the trunk latch and components in the 3 lock set..

  • Page 395

    394 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. Bolt the handle to the trunk running the bolts through the trunk and the latch mount..

  • Page 396

    395 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 397

    396 www.Factoryfive.Com 508-291-3443 body cut-outs fuel filler drill, ⅛”, 7 / 32 ” drill bit, 3½” hole saw or air saw or jig saw, masking tape, scissors. Fuel filler template, aston lemans cap components. Locate the template in the appendix and only cut out around the outside diameter of the circle....

  • Page 398

    397 www.Factoryfive.Com 508-291-3443 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 out of the template and use the remaining template to mark for a jig-saw instead. Tail light drill, 7 / 32 ” dril...

  • Page 399

    398 www.Factoryfive.Com 508-291-3443 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 locate these holes. If the marks do not show there is also a template in the back of the manual. Test fit the li...

  • Page 400

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

  • Page 401

    400 www.Factoryfive.Com 508-291-3443 drill the outer holes with a 7 / 32 ” drill bit and the inner with a 1¼” hole saw. Test fit a light and adjust if needed. License plate light drill, ¼”, ⅜” drill bits, scissors, masking tape, marker.

  • Page 402

    401 www.Factoryfive.Com 508-291-3443 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 does not mean that this vehicle is street legal. Factory five racing does not build ...

  • Page 403

    402 www.Factoryfive.Com 508-291-3443 test fit the light with a license plate and adjust the holes with the drill bit if needed. Side exhaust drill, 2½” hole saw, air saw or jig saw. Side exhaust template.

  • Page 404

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

  • Page 405

    404 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. Headlight template, headlight components, cut out the headlight templates from the back of the manual on the outermost diameter and tape them in the center of...

  • Page 406

    405 www.Factoryfive.Com 508-291-3443 cut the center of the template out and trace the inner circle with a marker. Drill the two smaller corner holes with a ¼” drill bit to mark their location. Follow this with a 7 / 16 ” drill bit..

  • Page 407

    406 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 408

    407 www.Factoryfive.Com 508-291-3443 side louver drill, 1¼” hole saw, jig saw or air saw, measuring tape, marker side louver template use the template and measurements in the picture below to locate the template on the body. Use a 1¼” hole saw to cut the corners on the traced opening for the side lo...

  • Page 409

    408 www.Factoryfive.Com 508-291-3443 connect the flush surfaces of the holes with a jig saw. Hood and scoop drill, 3 / 16 ”, ⅜” drill bits, marker, ruler, tape measure, jig saw or air saw, rivet gun. Hood scoop, hood, secondary body fasteners. Mark and drill around the edge of the scoop for rivets. ...

  • Page 410

    409 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. Use a larger drill bit to start the blade for the saw then cut the opening in the hoo...

  • Page 411

    410 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 412

    411 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. Drill two of the rivet holes on opposite sides for the scoop and install a couple rivets to hold the panels toge...

  • Page 413

    412 www.Factoryfive.Com 508-291-3443 drill out the remaining rivet holes and then separate the two pieces for painting. Roll bar drill, 1¾” hole saw, air saw or jig saw, file 1.50” driver side rollbar..

  • Page 414

    413 www.Factoryfive.Com 508-291-3443 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 vertically to match the angle the bar comes through the body. To cut the rear roll bar leg, mak...

  • Page 415

    414 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. Final prep sand paper.

  • Page 416

    415 www.Factoryfive.Com 508-291-3443 all of the exterior body accessories, windshield and side exhaust must be mounted to the car to obtain the correct body location in order to create the correct gaps and opening sizes on the car before it is painted. Refer to appendix a for a drawing on how to mak...

  • Page 417

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

  • Page 418: Final Assembly

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

  • Page 419

    418 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. Secondary body fasteners, engine bay aluminum. Use care when handling aluminum, the edges are sharp and can cut you. The radiator and its ...

  • Page 420

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

  • Page 421

    420 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..

  • Page 422

    421 www.Factoryfive.Com 508-291-3443 drill, silicone and rivet the radiator floor aluminum to the bottom radiator lip. Silicone and rivet the aluminum to the nose lip using three 3 / 16 ” rivets..

  • Page 423

    422 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 424

    423 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. From the backside of the panel, mark the location of the ¾” tube..

  • Page 425

    424 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..

  • Page 426

    425 www.Factoryfive.Com 508-291-3443 reinsert the side panel then silicone and rivet the panel to the ¾” tube and the radiator floor aluminum..

  • Page 427

    426 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. Interior trim/carpet the adhesive used to hold the carpet down is the same as we used on the dash pad. 3m ® super77™ or super90™ wor...

  • Page 428

    427 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 429

    428 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. The cockpit rear corners go on next. Be very careful spraying the adhesive once some carpet is mount...

  • Page 430

    429 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 431

    430 www.Factoryfive.Com 508-291-3443 glues down the tunnel top. The tunnel rear section is slightly oversized to make sure it can cover small variances in the way the other pieces lay down. Trim it for a perfect fit then glue it in place..

  • Page 432

    431 www.Factoryfive.Com 508-291-3443 fit and glue the passenger outside footbox wall carpet section. The carpet tucks in behind the footbox protection tube. Taping off the tube helps prevent getting the adhesive on it. Fit and glue the driver’s side footbox outer carpet section. This piece also tuck...

  • Page 433

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

  • Page 434

    433 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. Seats harness lap belt ¾” wrench, ¾” socket, ½” drill bit, drill, r...

  • Page 435

    434 www.Factoryfive.Com 508-291-3443 unpack the seat harnesses and hardware. Drill through the inner lap belt mount into the tunnel with a ½ in. Bit..

  • Page 436

    435 www.Factoryfive.Com 508-291-3443 bolt the lap harness in position with the inner most nut inside the transmission tunnel. Emergency brake boot 1 / 8 ” drill bit, drill, phillips head screwdriver interior trim/carpet.

  • Page 437

    436 www.Factoryfive.Com 508-291-3443 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 handle movement drill through the material into the tunnel and screw it into place..

  • Page 438

    437 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. Seat harness shoulder belts razor knife, ¾” wrench, ¾” socket, ½” drill bit, drill, ratchet seat harness/fasteners, misc. Electrical componen...

  • Page 439

    438 www.Factoryfive.Com 508-291-3443 use some of the serrated grommeting from the electrical assembly to cover the edge where the harness passes through. Cut the carpet with a single slit to allow the harness to pass through..

  • Page 440

    439 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 441

    440 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. Shifter handle and boot ½” wrench, 1 / 8 ” drill bit, drill, philips head screwdriver, marker, thread lock.

  • Page 442

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

  • Page 443

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

  • Page 444

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

  • Page 445

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

  • Page 446

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

  • Page 447

    446 www.Factoryfive.Com 508-291-3443 run the light plug harness through from the inside line up the headlight with the bucket to get the proper orientation. The bottom of the bucket is the only screw boss that comes in from the side and the writing on the headlight should be right side up..

  • Page 448

    447 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. Put the gasket on the bucket with the adjuster bosses poking through the 2 larger holes. Screw the bucket to the body using t...

  • Page 449

    448 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 450

    449 www.Factoryfive.Com 508-291-3443 push the spring clip onto the boss near the bottom of the bucket. Mount the trim ring hooking it over the bucket on the top and screwing it into the bottom using the countersunk screw. Turn signals 5 / 16 ” deep socket, ratchet amber front turn signal lights.

  • Page 451

    450 www.Factoryfive.Com 508-291-3443 mount the turn signals to the body being careful not to over tighten the locknuts. Tail lights 5 / 16 ” deep socket, ratchet red rear lights.

  • Page 452

    451 www.Factoryfive.Com 508-291-3443 mount the taillights, also being careful with the mounting hardware. Gas cap phillips head screwdriver aston lemans cap.

  • Page 453

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

  • Page 454

    453 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 455

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

  • Page 456

    455 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. Apply silicone down the top and bottom flange on the side facing the body..

  • Page 457

    456 www.Factoryfive.Com 508-291-3443 line up the louvers and tape them in place to hold them until the silicone dries. Weatherstripping razor knife, tin snips secondary body fasteners.

  • Page 458

    457 www.Factoryfive.Com 508-291-3443 if you haven’t already run the bulb seal up the sides and rear of the trunk and bolt the trunk hinges back in place and tighten. Cut out a section of the c channel where the hoop comes across to allow one piece to run the whole way..

  • Page 459

    458 www.Factoryfive.Com 508-291-3443 if you removed any of the other weatherstrip on the firewall or hood support tubes replace it now. When you are ready to mount the body, unpack the expanding foam and run a small section up the outside of each footbox just forward of the door hinge..

  • Page 460

    459 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 461

    460 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 462

    461 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. Re-install the hood and latches. Rollbar mounting a popular option are the roll bar grommets. If installing them, do it now..

  • Page 463

    462 www.Factoryfive.Com 508-291-3443 re-mount the roll bar through the body. Make sure that the rear leg is in the correct orientation so that your holes will line up. Door and latch mount reattach the doors and latches..

  • Page 464

    463 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 465

    464 www.Factoryfive.Com 508-291-3443 re-mount the windshield. Fuel filler neck razor knife, ⅜” socket, ratchet, 3 / 16 ” drill bit, drill aston lemans cap components.

  • Page 466

    465 www.Factoryfive.Com 508-291-3443 ground the fuel filler strap to the chassis using the screw that came in the cap hardware. This wire prevents any static charge build-up and must be used. 87-98 fuel filler neck attach the 2” fuel filler hose to the bottom section of the mustang filler neck. Stoc...

  • Page 467

    466 www.Factoryfive.Com 508-291-3443 optional stainless steel filler neck with extension. Install the hose between the filler neck and gas cap with the clamps that came in the cap hardware..

  • Page 468

    467 www.Factoryfive.Com 508-291-3443 screw the plastic gas cap into the aston lemans style cap. 99-04 filler neck 99-04 fuel filler tube assembly push on and attach the 1” fuel filler hose to the lower part of the filler neck using the included hose clamps. Insert the upper part of the fuel filler n...

  • Page 469

    468 www.Factoryfive.Com 508-291-3443 unpack the 2” fuel filler hose and cut a 5” long section out of one end. Use the short section of hose to connect the upper part of the stock filler neck to the aston fuel cap.

  • Page 470

    469 www.Factoryfive.Com 508-291-3443 screw the plastic gas cap into the aston lemans style cap. Fuel tank access covers ⅛” drill bit, drill, rivet gun, silicone, caulking gun secondary body fasteners, packaged aluminum.

  • Page 471

    470 www.Factoryfive.Com 508-291-3443 silicone and install the patch panels in the trunk that cover the fuel sender and pickup access holes. Final trunk mounting tin snips, 3 / 16 ” hex key secondary body fasteners push the side mount weatherstrip on the trunk opening starting at the bottom next to t...

  • Page 472

    471 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. Interior rearview mirror philips head screwdriver, drill, 1 / 16 ”, 1 / 8 ”, 3 / 16 ” drill bits, marker, measuring tape rearview mirrors/fasteners u...

  • Page 473

    472 www.Factoryfive.Com 508-291-3443 use a tape measure to measure in from the body lip to roughly the center of the dash tube. On top of the boy measure in and mark the body for the center tube location..

  • Page 474

    473 www.Factoryfive.Com 508-291-3443 line up the rearview mirror with the center mark and mark the holes in the body. Use a 1 / 16 ” drill bit and slowly (so the bit doesn’t walk off the tube) drill through the body into the tube at the mirror hole locations. Follow this with a 1 / 8 ” drill bit int...

  • Page 475

    474 www.Factoryfive.Com 508-291-3443 put the plastic spacers between the dash tube and the body so the screws can go through them. Put the mirror screws through the mirror, body and spacers and screw them into the dash tube..

  • Page 476

    475 www.Factoryfive.Com 508-291-3443 side mirror philips head screwdriver, drill, 3 / 32 ”, 3 / 16 ” drill bits, marker, ⅜” wrench. 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..

  • Page 477

    476 www.Factoryfive.Com 508-291-3443 disassemble the mirror, removing the large base from the stand. The large base is replaced by the smaller insert and gasket..

  • Page 478

    477 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 479

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

  • Page 480

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

  • Page 481

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

  • Page 482

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

  • Page 483

    482 www.Factoryfive.Com 508-291-3443 unpack the door check-straps. Rivet the check-strap to the door hinge using a 3 / 16 ” rivet. Open a door wide but not enough so that the door hits the body. The straps will stretch slightly over time so allow enough room for this by closing the door slightly fro...

  • Page 484

    483 www.Factoryfive.Com 508-291-3443 while holding the door open, pull the check strap tight and mark the location of the mount holes on the inside face of the 2”x 2” tube. Drill 3 / 16 ” holes at the marked locations and rivet the mount to the chassis..

  • Page 485

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

  • Page 486

    485 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 487

    486 www.Factoryfive.Com 508-291-3443 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. Peel the backing off the badge and stick it in the center section making sure you ...

  • Page 488

    487 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 ” dril...

  • Page 489

    488 www.Factoryfive.Com 508-291-3443 unpack the hardware for mounting the side exhaust. Bolt the mounting bracket to the pipe on the forward side of the bracket..

  • Page 490

    489 www.Factoryfive.Com 508-291-3443 bolt the pipe and gasket to the header or j-pipe flange with using the shorter ⅜” bolts and mechanical locknuts. Drill a 3 / 16 ” hole in the 2”x 2” outrigger tube directly above the middle hole in the mounting bracket. You want this hole as high as you can get i...

  • Page 491

    490 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 492

    491 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. Insert the rubber standoff between the bracket and outrigger and put the nut on finger tight then ...

  • Page 493

    492 www.Factoryfive.Com 508-291-3443 tighten the whole assembly together. Aluminum splash guards ⅛”, 3 / 16 ” drill bit, drill, rivet gun, silicone, caulking gun, ¾” socket, ratchet, extension, marker secondary body fasteners, packaged aluminum, front wheel and tire.

  • Page 494

    493 www.Factoryfive.Com 508-291-3443 front wheel put some of the press-on bulb seal around the outside edge of the aluminum front splash guards (they look like large elephant ears)where they will contact the body. Hold the splashguards up against the rear bent lip of the engine bay “f” aluminum. Ove...

  • Page 495

    494 www.Factoryfive.Com 508-291-3443 fit the splash guards in position. If needed, trim them to fit around the outside edge, the weatherstrip will cover the trimming. Put a wheel and tire on the car and check for aluminum clearance. If necessary push the aluminum in and mark the inside of the body a...

  • Page 496

    495 www.Factoryfive.Com 508-291-3443 silicone and rivet the panels in place down the length of the flange. Use one of the 3 / 16 ” rivets to attach to the bottom of the fender just forward of the exhaust cut-out..

  • Page 497

    496 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 498

    497 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 499

    498 www.Factoryfive.Com 508-291-3443 use a long 1 / 8 ” rivet as low as possible to attach the tab to the lower fender. Finishing touches review the race car checklist in the appendix..

  • Page 500

    499 www.Factoryfive.Com 508-291-3443 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” round tube with the nor...

  • Page 501

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

  • Page 502

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

  • Page 503

    502 www.Factoryfive.Com 508-291-3443 there should never be more than 1” of thread showing past the tightened down jam nuts on either end of both adjusting tubes. The pivot bolts must be loosened while the car is being aligned and retightened afterwards optional parts check out factoryfive.Com for th...

  • Page 504: Technical Support

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

  • Page 505

    504 www.Factoryfive.Com 508-291-3443 maintenance check the items on the race car check sheet in the appendix on a yearly basis or before track days depending on how hard the car is driven. Wheels only 7”-9” wheels are recommended for the front. If using a wheel wider than 7”, ffr front lower control...

  • Page 506

    505 www.Factoryfive.Com 508-291-3443 left: ffr car using late model 17” cobra™ r rims. Right: ford racing cobra™ r 17” wheels and 12” cobra™ brakes. 17”x 9” and 17”x 10.5” fr style wheels. For a more vintage look, take a look at our halibrand style wheels. Our online parts catalog: factoryfiveparts....

  • Page 507

    506 www.Factoryfive.Com 508-291-3443 left: 15” ffr halibrand style. Right 17” ffr halibrand style 1994-1998 rear end use two (4) 9” wide, 5.95” backspace wheels in the front and the rear. If you would like a wider tire than this in the rear it is possible to use aftermarket 10.5” wide, 27mm offset w...

  • Page 508

    507 www.Factoryfive.Com 508-291-3443 gears the mustang 5.0 manual transmission car comes with either 2.73 or 3.08 rear end gear ratios from the factory. If you can get a rear from an automatic car it will have 3.27 gears. There is an id tag on the rear differential. If you find that your rear end is...

  • Page 509

    508 www.Factoryfive.Com 508-291-3443 in order to increase the flow of air above 5000 rpm, upgrade from the stock mass air sensor. Aftermarket 70 mm or 75 mm mass air units are an excellent choice and have proven effective. If the mass air meter is changed make sure it is calibrated for the injectors...

  • Page 510

    509 www.Factoryfive.Com 508-291-3443 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. They work well on all cars. Oil ...

  • Page 511

    510 www.Factoryfive.Com 508-291-3443 feature of the tremec tko is it allows the shifter to be relocated 8” forward of the normal shifter location if a vertical shifter is desired verses a forward angled shifter. Steering rack stock: 15:1 once the car is rolling either a 15:1 or 18:1 rack will yield ...

  • Page 512

    511 www.Factoryfive.Com 508-291-3443 ffr two piece spindles (ffr#14850) – 5 lug, many wheels and brakes plus improved suspension geometry, improved steering feel and more adjustability over 94-04 spindles. Rear suspension the standard solid axle 4-link rear suspension works well, is low maintenance ...

  • Page 513

    512 www.Factoryfive.Com 508-291-3443 3-link suspension - this is for the more serious driver that goes to more road course track events and wants to start exploring the limit without giving up the “off the line” bite of a solid axle. Irs suspension – good everyday driving suspension. The irs is best...

  • Page 514

    513 www.Factoryfive.Com 508-291-3443 front: the stock front arms work well all round. The factory five tubular lower control arms with polyurethane bushings are lighter, eliminate the rubber and look better than the stock mustang arms. Rear: using tubular control arms with polyurethane bushings help...

  • Page 515

    514 www.Factoryfive.Com 508-291-3443 shocks/springs using the mustang rear coil springs and shocks gives a comfortable ride. For a slightly stiffer suspension, replace the stock rear shocks with aftermarket units. We have found that kyb makes an inexpensive good replacement that roughly 20% stiffer ...

  • Page 516

    515 www.Factoryfive.Com 508-291-3443 11”front spindle oem 87-93 v8 mustang front spindle rotor oem 87-93 v8 mustang 11” rotor caliper oem 87-93 v8 mustang 60mm caliper 10.5”rear stainless steel brake corp. 87-93 mustang disc brake conversion kit (part #a-112-1) or disc brakes r’ us - select ford and...

  • Page 517

    516 www.Factoryfive.Com 508-291-3443 rotor oem 94-98 mustang cobra™ 11.65” rotor caliper oem 94-98 mustang cobra™ single piston 1.4375” caliper bracket ffr 11.65” caliper mount brackets (ffr#14571, 14572) irs master cylinder – ffr 15 / 16 ” master cylinder/proportioning valve (ffr#14739) the rear di...

  • Page 518

    517 www.Factoryfive.Com 508-291-3443 6.3 to 7.6 max 1⅛ factory five racing 508-291-3443 www.Factoryfiveparts.Com disc brakes r’ us 888-558-5757 www.Discbrakesrus.Com mustang part’s specialties, inc. 770-867-2644 www.Stangparts.Com porterfield enterprises ltd. 800-537-6842 www.Porterfield-brakes.Com ...

  • Page 519

    518 www.Factoryfive.Com 508-291-3443 helpful reference material must reads www.Thefactoryfiveforum.Com the largest discussion forum for factory five racing kits. Also has many vendor links. Helpful 5.0l ford dyno tests. By richard holdener. Www.Cartechbooks.Com building 4.6/5.4l ford horsepower. By ...

  • Page 520

    519 www.Factoryfive.Com 508-291-3443 spinap - fred benedict. Eastern us. 914-946-9300. A final note about completed cars and car builders if you are reading this manual then you must be at least contemplating the task of building your own race car. Many component car companies offer services to thos...

  • Page 521: Appendix A – Templates

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

  • Page 522

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

  • Page 523

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

  • Page 524

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

  • Page 525

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

  • Page 526

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

  • Page 527

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

  • Page 528

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

  • Page 529

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

  • Page 530

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

  • Page 531

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

  • Page 532

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

  • Page 533

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

  • Page 534

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

  • Page 535

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

  • Page 536

    535 www.Factoryfive.Com 508-291-3443 appendix c – race car check sheet.

  • Page 537

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

  • Page 538

    537 www.Factoryfive.Com 508-291-3443 electrical battery charged ___ battery mount and connections secure ___ brake lights functioning ___ all wires free and clear of moving or hot parts ___ rear suspension ride height ___ shock mounting bolts tight ___ spring collars tight/taped ___ wheel bearings t...

  • Page 539

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

  • Page 540

    539 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 541

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

  • Page 542

    541 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 200...

  • Page 543

    542 www.Factoryfive.Com 508-291-3443 transmission year type 1st 2nd 3rd 4th 5th 6th r torque capacity lbs-ft part number weight 1983.5 t-5 2.95 1.94 1.34 1.00 0.725 n/a 2.76 265 e3zr-7003-a 75 1984 t-5 2.95 1.94 1.34 1.00 0.625 n/a 2.76 265 e4zr-7003-da 75 1985-89 t-5 3.35 1.93 1.29 1.00 0.675 n/a 3...

  • Page 544

    543 www.Factoryfive.Com 508-291-3443 rear brakes 1987 to1993 mustangs used a 4.25” 4-lug bolt pattern drum brake. From 1994 to 2004 mustangs switched to have a 10.5”diameter 4.5” 5-lug bolt pattern solid rear rotor with a single piston cast iron caliper. All cobra™ and the cobra™ r versions of the m...

  • Page 545

    544 www.Factoryfive.Com 508-291-3443 speedometer cable from 1983.5 to 1993 mustangs used a mechanical speedometer with a cable which had a plastic gear c- clipped on to its end, which was inserted into the driver side of the transmission. This plastic gear is designed to translate the proper vehicle...

  • Page 546

    545 www.Factoryfive.Com 508-291-3443 measurement of all of the cylinders can be taken. All oxygen sensors are recommended to be used when placing a fuel injected engine into a factory five kit. Exhaust headers 1986 to 1993 mustang headers have 1.5” tubes, and remained the same shape. From 1994 to 19...

  • Page 547

    546 www.Factoryfive.Com 508-291-3443 from 1988 to 1993 fuel pumps were 88 liters/hr., and the 1994 to 2004 pumps were 110 liters/hr. The fuel filler neck is also a donor part required for an ffr kit.. In 1999, the tank filler hole and the filler neck changed to 1” from 2”. The pump also changed so t...

  • Page 548

    547 www.Factoryfive.Com 508-291-3443 though they increased in length by approximately ¾”. This arm can also be used by following the same modifications as the 1979 to 1993 arms. There are two sets of holes on the factory five chassis to mount the lower control arms. The inner holes are for the 1994 ...

  • Page 549

    548 www.Factoryfive.Com 508-291-3443 selection tips at the beginning of this manual) so more of the harness parts must be kept or the computer will need to be flashed. In 1999 ford added to the pats so that the gauge cluster needs to be present to start the car. An alternative to using the donor har...

  • Page 550

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

  • Page 551

    550 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...