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Factory Five Racing Type 65 Coupe Assembly Manual

Summary of Type 65 Coupe

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

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     2013 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 ..................................................................................... 11 foreword ............................................................................................................ 11 safety notice .....

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    Iii www.Factoryfive.Com 508-291-3443 exhaust ........................................................................................................................ 35 engine removal ........................................................................................................... 35 front...

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    Iv www.Factoryfive.Com 508-291-3443 front brakes ....................................................................................................... 73 donor front brakes ...................................................................................................... 73 complete kit front ...

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    V www.Factoryfive.Com 508-291-3443 driver floor ................................................................................................................ 167 u-joint cover ............................................................................................................. 168 transmi...

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    Vi www.Factoryfive.Com 508-291-3443 fuel injected application ............................................................................................. 217 carbureted applications .............................................................................................. 218 mass air meter, a...

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    Vii www.Factoryfive.Com 508-291-3443 hood latch ................................................................................................................. 273 nose mounting ................................................................................................. 277 hinge ...............

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    Viii www.Factoryfive.Com 508-291-3443 fuel filler neck ................................................................................................. 342 nose mounting ........................................................................................................... 345 door final fit .....

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    Ix www.Factoryfive.Com 508-291-3443 fuel injectors .............................................................................................................. 392 upper intake ............................................................................................................... 392 heads...

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    X www.Factoryfive.Com 508-291-3443 engine ........................................................................................................................ 432 transmission .............................................................................................................. 432 rear ...

  • Page 12: General Information

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

  • Page 13

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

  • Page 14

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

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    14 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 16

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

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

  • Page 18

    17 www.Factoryfive.Com 508-291-3443 engine/exhaust parts: kit comes with alternate drive pulley assembly, oil filter relocate kit, and exhaust assembly to adapt mustang engine and headers to vintage side exit exhausts. Gauges and dash and electrical assembly: kit parts are included to adapt the must...

  • Page 19

    18 www.Factoryfive.Com 508-291-3443 rear end: 1987-1998 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. Steering rack: 1987-2004 ford mustang. Fuel tank/pump and filter: 1987-2004 ford mustang. Electrical: 1987-...

  • Page 20

    19 www.Factoryfive.Com 508-291-3443 serial number identification factory five racing has included a certificate of origin along with a nameplate for your kit. The serial number from the certificate of origin matches the number engraved on the 2”x 2” tube going across the car at the front of the cock...

  • Page 21

    20 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 ...

  • Page 22

    21 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 23: Donor Parts And Prep

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

  • Page 24

    23 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...

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

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    25 www.Factoryfive.Com 508-291-3443 all mustang performance phoenix, az 800-454-8387 tommy thompson www.Ampperformance.Com mustang village fontana, ca 909 823 7915 scott or tom www.Mustang-village.Com cypress auto berkley, ca 510 451 3034 mike percy www.Cypressautorecyclers.Com/factory5.Html mustang...

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    26 www.Factoryfive.Com 508-291-3443 shoes on the unit. The drum pulls straight out, off the axle. Rear shoes are never really replaced until about 60-100k miles unless there was severe duty (read abuse) placed on the car.  the easiest way to avoid engine work is to buy a donor car with an engine th...

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    27 www.Factoryfive.Com 508-291-3443 when in doubt, don’t throw it out. That one little oem bolt could save you a trip to the auto parts store. 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 ligh...

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    28 www.Factoryfive.Com 508-291-3443 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. Engine bay sensors and electrical connections socket set, combination wrenches, phillips...

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    29 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...

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    30 www.Factoryfive.Com 508-291-3443 unbolt and remove the pedal box. Computer socket set. Mustang computer and oem plastic cradle. If you are going to run the car with a carburetor you can disregard the efi wiring harness part in this section. We recommend the use of a fuel inertia cut off switch in...

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    31 www.Factoryfive.Com 508-291-3443 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 signal stalk dash wiring harness socket set, extension, re...

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    32 www.Factoryfive.Com 508-291-3443 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 engine bay. Remove the front light harness from the engine ba...

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    33 www.Factoryfive.Com 508-291-3443 release the cable sheath retainer clip. Pull the cable out and replace the clip on the cable. You may even want to tape it in place. Clutch cable and retainer circlip. Shifter and shifter handle socket set, phillips head screwdriver. Shifter the kit comes with new...

  • Page 35

    34 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...

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    35 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...

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    36 www.Factoryfive.Com 508-291-3443 use duct tape or zip ties to secure the lower radiator hose up to the power steering pump area so that it will not spill fluid as the engine is removed later. Get help with the next few steps, as the parts involved are heavy! Attach an engine hoist to the engine l...

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    37 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 39

    38 www.Factoryfive.Com 508-291-3443 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 collar retainer from the fuel neck where it meets the tank. Remove the fuel neck fr...

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    39 www.Factoryfive.Com 508-291-3443 remove the bolts and nuts from the lower rear mustang control arm, where the arms are mounted to the body/chassis. Remove the bolts and nuts from the upper mustang control arm, where the arms are mounted to the body/chassis. All of the arms should remain attached ...

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    40 www.Factoryfive.Com 508-291-3443 remove the rubber tubular spacer from inside the coil. 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...

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

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

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    43 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...

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

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    45 www.Factoryfive.Com 508-291-3443 accelerator pedal remove the plastic part of accelerator pedal by pushing out the pin. 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...

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    46 www.Factoryfive.Com 508-291-3443 87-93 pedal box marked for cutting. Cut-off the marked area (bottom of the front mount flange) with a hack saw. This is necessary for steering shaft clearance. Wiring harness razor knife, electrical tape. Many people choose to cut down the wiring harness to use on...

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    47 www.Factoryfive.Com 508-291-3443 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, the fee...

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    48 www.Factoryfive.Com 508-291-3443 if you are using a lakewood bell housing, trim the area around the starter so that is flush with the inspection cover. If you are not running emissions equipment, the only engine controls that need vacuum are the pcv valve in the valve cover and the fuel pressure ...

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    49 www.Factoryfive.Com 508-291-3443 top: trimmed handle. Bottom: untrimmed handle. Trim the handle with grinder, it is very hard steel. Alternate drive pulley preparation cordless drill, ½” drill bit, needle nose pliers alternate drive pulley template on 87-93 efi cars, the pulley and fan belt suppl...

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    50 www.Factoryfive.Com 508-291-3443 remove the hydraulic lines. Drain all fluid by turning it, lock to lock, upside down over a collection pan. Dispose of the fluid properly. The rack is greased on the gears at the ends. The mustang power rack is converted to a manual rack by removing the hydraulic ...

  • Page 52: Disassembly Of The Kit

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

  • Page 53

    52 www.Factoryfive.Com 508-291-3443 unpacking your kit customer picking up a kit at our wareham, ma facility in june 2000. Please note that your boxes are numbered, when you read your packing list you will see that next to each assembly there is a number circled. This is the box number that the asse...

  • Page 54

    53 www.Factoryfive.Com 508-291-3443 lift in the exhaust recess and the rear wheel well. Body with sides supported. Aluminum removal ¼” nut driver, jack stands, marker. Do one panel at a time. Be careful of the sharp aluminum edges, they can cut you..

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    54 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...

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    55 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 57: Chassis Assembly

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

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    57 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 ...

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    58 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.

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    59 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. If assembling a complete coupe kit with the ffr spindles, skip to the next section. Front upper contr...

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    60 www.Factoryfive.Com 508-291-3443 front upper control arm mounting with ffr spindles mount the upper control arms to the chassis with the grease fittings pointed up. Use the mount holes that are vertical on the side of the 2”x 3” tube, not the top horizontal ones..

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    61 www.Factoryfive.Com 508-291-3443 use a washer with the front locknut. Do not use a washer on the rear locknut. Torque the two bolts that hold the arm to the frame to 135-149nm (100-110 lbft)..

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    62 www.Factoryfive.Com 508-291-3443 pivot endplay adjust the locknuts on the ends of the pivot shaft so that there is minimal endplay but so the pivots can still rotate easily on the shaft. The pivots may be a little stiff at first but once on the car they will loosen slightly. Adjusting the upper c...

  • Page 64

    63 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 65

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

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    65 www.Factoryfive.Com 508-291-3443 install the snap ring on the spring hat so that it holds onto the shock end. Make sure that the slot in the snap ring and the slot in the spring hat are not aligned. Pass the shock assembly (with the body of the shock up) through the upper control arm and attach t...

  • Page 67

    66 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 if assembling a complete coupe kit with the ffr spindles, skip to the next section..

  • Page 68

    67 www.Factoryfive.Com 508-291-3443 donor spindles 13 / 16 ” socket, torque wrench, needle nose pliers, rubber mallet ifs components, mustang spindles. Make sure the grease boot is in place on the lower ball joint then mount the spindle to the lower control arm. Attach the castle nut and torque the ...

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

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    69 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. Bolt the steering arms to the spindles with the taper facing down. Torque to 60 ft-lbs..

  • Page 71

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

  • Page 72

    71 www.Factoryfive.Com 508-291-3443 front suspension torque specs chart item nm lbft front lower control arm to frame 135-162 100-110 front lower ball joint to spindle 106-163 80-120 upper a-arm to frame 135-162 100-110 upper ball joint to spindle 95-122 70-90 spindle hub nut 305-338 225-250 ifs bra...

  • Page 73

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

  • Page 74

    73 www.Factoryfive.Com 508-291-3443 front brakes sockets, ratchet, torque wrench, chassis grease, rags, brake cleaner, mustang front brake calipers and rotors make sure that your brake pads and rotors are in good condition. Donor front brakes make sure that the hub bearings are greased correctly and...

  • Page 75

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

  • Page 76

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

  • Page 77

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

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

  • Page 79

    78 www.Factoryfive.Com 508-291-3443 grease the slide pins using the supplied grease. Slide the caliper hanger onto the caliper. Push the rubber boots over the lip on the caliper bracket to seal the slider bolts correctly..

  • Page 80

    79 www.Factoryfive.Com 508-291-3443 look at the back side of each brake pad to find the inside pads and the outside pads. The difference is the location of the studs that are on the back of each pad. The studs on the inside pads are out near the ends of the pad, while the studs on the outside pads a...

  • Page 81

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

  • Page 82

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

  • Page 83

    82 www.Factoryfive.Com 508-291-3443 solid axle rear suspension ¾” sockets, ¾” wrench, ½” drill bit, drill, floor jack, jack stands, torque wrench.

  • Page 84

    83 www.Factoryfive.Com 508-291-3443 8.8” rear axle assembly, box 11 solid axle traction lok brackets, rear control arms. Use caution when working with the rear end assembly, it weights 225 lbs. Skip to the independent rear suspension if not installing a solid axle. See the donor parts prep section i...

  • Page 85

    84 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 86

    85 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..

  • Page 87

    86 www.Factoryfive.Com 508-291-3443 if using rear coil-over shocks, skip the next section. 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 ...

  • Page 88

    87 www.Factoryfive.Com 508-291-3443 thread the cut rear springs onto the conical frame mounts all the way. Insert the cut rubber spring mount between the spring and the steel seat. Make sure the end of it is flush with the end of the spring mount. Suspension height adjustments are done in the rear b...

  • Page 89

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

  • Page 90

    89 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..

  • Page 91

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

  • Page 92

    91 www.Factoryfive.Com 508-291-3443 upper link attach the short upper link tube to the axle upper link mount using the ¼” spacers on either side of the rod end. 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...

  • Page 93

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

  • Page 94

    93 www.Factoryfive.Com 508-291-3443 attach the lower control arms to the frame mounts. Jack the rear axle up. If using a 4 link, attach the upper control arms to the frame..

  • Page 95

    94 www.Factoryfive.Com 508-291-3443 if using a 3 link, attach the upper link to the frame. If using the stock mustang shocks, skip the next section. 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...

  • Page 96

    95 www.Factoryfive.Com 508-291-3443 unpack the rear shocks, coil over’s and hardware. Double check the jam nut under the rod end and bump stop to make sure that it is tight. Screw the spring seat down on the sleeve so it is closer to the unthreaded end. The center high part of the set should be poin...

  • Page 97

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

  • Page 98

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

  • Page 99

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

  • Page 100

    99 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 h...

  • Page 101

    100 www.Factoryfive.Com 508-291-3443 passenger side driver side check for shock clearance on brake lines, emergency brake cables, brake calipers, frame and axle parts. Check to make sure that the spring is seated correctly on the shock..

  • Page 102

    101 www.Factoryfive.Com 508-291-3443 mount the quad shocks and their brackets to the rectangular frame plate hanging under the 2”x 3” tube behind the axle. Attach the rear end axle straps (included with the kit). These cables will prevent drive shaft binding if you happen to achieve airborne status....

  • Page 103

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

  • Page 104

    103 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 105

    104 www.Factoryfive.Com 508-291-3443 the panhard bar mounts to the car using the ½” bolts and spacers. Install the panhard bar to the passenger side traction lock bracket. Three spacers are used in the front (2) 0.375" and (1) 0.25". The rear uses the thin 0.125" shim. It will be necessary to adjust...

  • Page 106

    105 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..

  • Page 107

    106 www.Factoryfive.Com 508-291-3443 to set the pinion angle, make sure that your ride height is where you want it, and then adjust the upper arm until the desired angle is reached. We usually run about 2° up on the rear axle, but you can adjust this to fit your particular set-up. The panhard bar ca...

  • Page 108

    107 www.Factoryfive.Com 508-291-3443 irs center section mount the rear center section to the chassis. It installs from the bottom with the driveshaft flange pointing straight up and the axle holes lined up front to back with the chassis. Use one rear bolt through the rear cover to hold it in place. ...

  • Page 109

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

  • Page 110

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

  • Page 111

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

  • Page 112

    111 www.Factoryfive.Com 508-291-3443 irs 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 in r...

  • Page 113

    112 www.Factoryfive.Com 508-291-3443 screw the spring seat down on the sleeve so it is closer to the unthreaded end. The center high part of the set should be pointed away from the unthreaded end. Slide the coil sleeve over the body of the damper beginning at the end which has the rubber bump stop. ...

  • Page 114

    113 www.Factoryfive.Com 508-291-3443 put the spring on the shock, then install the spring hat on the shaft end of the shock and push the rubber bumper up against it. Rotate the spring seat back up the sleeve so that the spring pushes the hat tight against the end of the shock. Install the snap ring ...

  • Page 115

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

  • Page 116

    115 www.Factoryfive.Com 508-291-3443 cv axles push the cv joints into the rear axle and let them rest on the lower arm. Spindles slide the splined end of the outer cv joint into the hub and mount the spindle to the lower arm..

  • Page 117

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

  • Page 118

    117 www.Factoryfive.Com 508-291-3443 quad shock installation attach the body end of the quad shock to the upper arm of the irs with the supplied metric bolt. Attach the shaft end of the quad shock to the rear quad shock bracket hole on the frame using the washer on the outside of the quad shock as s...

  • Page 119

    118 www.Factoryfive.Com 508-291-3443 rear calipers and rotors push the slotted rotor onto the spindle. Attach the caliper to the spindle using the oem t-bird bolts. Width adjustment mount your wheels and tires. Lower the frame off the jack stands. With the car on the ground, check theride height of ...

  • Page 120

    119 www.Factoryfive.Com 508-291-3443 place a straight edge on the rotor wheel mounting surface on each side of the suspension and measure across the car to find the suspension width. With these axles, it is recommended that the rear suspension should measure 59.00” for the standard width or 54.00” f...

  • Page 121

    120 www.Factoryfive.Com 508-291-3443 adjust the rod ends the same number for turns for the front and rear rod ends on the lower control arm and upper control arm as required so that if the number of turns done is the same for all control arms on one side of the suspension, an alignment is not needed...

  • Page 122

    121 www.Factoryfive.Com 508-291-3443 insert a hex head bolt through the caliper mount bracket hole so that the threads will point out..

  • Page 123

    122 www.Factoryfive.Com 508-291-3443 from the outside in, insert two hex head bolts through the spindle caliper mount holes then through the caliper mount bracket. Torque the bolts to 87-101nm (64-75 lbft). Place the caliper mount spacers on the bolts facing out..

  • Page 124

    123 www.Factoryfive.Com 508-291-3443 place the brake rotor on the spindle load the caliper with the brake pads put a dot of locktite on the threads of the two bolts with the spacers on. Attach the caliper to the caliper mount bracket. Hand tighten both bolts starting with the top on first. Keep the ...

  • Page 125

    124 www.Factoryfive.Com 508-291-3443 tighten the top mount bolt with a ¾” wrench. Driver front footbox aluminum drill, 1 / 8 ” drill bit, rivet tool, caulk gun, silicone firewall and driver footbox front aluminum, secondary body fasteners. If you are installing a heater/defroster it is much easier t...

  • Page 126

    125 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..

  • Page 127

    126 www.Factoryfive.Com 508-291-3443 mustang pedal box.

  • Page 128

    127 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. There are four holes on the mustang pedal assembly on top of the ¾” tubing. Mark ...

  • Page 129

    128 www.Factoryfive.Com 508-291-3443 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 pedal box. Remove the pedal assembly. Drill ¼” holes completely through the ¾” tubing for the pedal box. Use a...

  • Page 130

    129 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. Complete kit pedal box ½”, 9 / 16 ” sockets, ⅜”, 11 / 32 ”, ½”, 9 / 1...

  • Page 131

    130 www.Factoryfive.Com 508-291-3443 this pedal box is set-up to use either a hydraulic clutch or a cable clutch. The parts and instructions required for a cable clutch installation are included in this kit. Unpack the pedal box assembly. Now is a good time to paint all of the bare steel brackets. U...

  • Page 132

    131 www.Factoryfive.Com 508-291-3443 place the brake switch mount between the brake pedal mount tabs on the side closest to the brake pedal pivot holes and drill a 3 / 16 ” hole through the brake switch mount hole and the pedal box. Attach the brake switch mount to the pedal box using the black #10 ...

  • Page 133

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

  • Page 134

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

  • Page 135

    134 www.Factoryfive.Com 508-291-3443 put one of the wilwood pedal washers on the pivot sleeve next to the quadrant. Remove the snap ring holding the master cylinder mount to the clutch pedal, push the pivot sleeve out and remove the master cylinder mount..

  • Page 136

    135 www.Factoryfive.Com 508-291-3443 attach the wilwood pedals to the underside of the mounting bracket using three button head screws and locknuts and the stud. The stud should get mounted on the left side next to the clutch pedal pivot sleeve boss. A tap in with a hammer and punch will get the stu...

  • Page 137

    136 www.Factoryfive.Com 508-291-3443 attach the clutch pedal stop mount to the bottom of the pedal box using two ¼” socket head screws, spacers and locknuts. Put the actuator in a vise and snug up the bolts with a 5 / 16 ” hex key. Do not overtighten and strip the threads..

  • Page 138

    137 www.Factoryfive.Com 508-291-3443 slide the quadrant and new pivot sleeve assembly through the hole in the side of the wilwood pedal bracket and remount the clutch pedal. Put the remaining thin washer and snap ring on the pivot sleeve..

  • Page 139

    138 www.Factoryfive.Com 508-291-3443 put locktite on the 5 / 16 ” bolt threads. Insert the 5 / 16 ” bolt through the clutch pedal and thread into the actuator. Snug up the bolt using a 3 / 16 ” hex key. This 5 / 16 ” bolt is only used to hold the pedal in position when the pedal is not being pushed ...

  • Page 140

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

  • Page 141

    140 www.Factoryfive.Com 508-291-3443 insert three ⅜” x 1” socket head screws from the pedal box hardware assembly and the one included in this pedal assembly through the front of the footbox and through the pedal box mount. Push the rear pedal box mount onto the master cylinder mount studs and use a...

  • Page 142

    141 www.Factoryfive.Com 508-291-3443 tighten two of the front ⅜” screws then use a marker to mark the locations of the rear mount holes on the ¾” tubes. Loosen the bolts and remove the pedal box assembly from the footbox then use a ¼” drill bit and drill to drill through the ¾” tubes at the location...

  • Page 143

    142 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. Master cylinders place a jam nut from the wilwood pedals onto each of...

  • Page 144

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

  • Page 145

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

  • Page 146

    145 www.Factoryfive.Com 508-291-3443 from the underside, push the screw through the quadrant pedal stop mount plate and hand tighten the locknut on the screw. Accelerator cable 5 / 64 ” hex key, ⅜”, 7 / 16 ”, ½” wrenches, wire cutters. Pedal box hardware, accelerator cable components. The cable desi...

  • Page 147

    146 www.Factoryfive.Com 508-291-3443 using a pair of wire cutters, cut the cable at the location marked. Remove and discard the included ball stud. It is for carbureted applications push and twist the included ball stud retainer onto the end of the cable. Do not tighten the set screw yet. Insert the...

  • Page 148

    147 www.Factoryfive.Com 508-291-3443 the engine end will get installed later. Accelerator pedal 3 / 16 ” hex key, 7 / 16 ” wrench, pliers oem accelerator pedal, accelerator cable components hold the accelerator pedal up to the mount on the ¾” tube at the front of the foot box. The higher you can mou...

  • Page 149

    148 www.Factoryfive.Com 508-291-3443 the accelerator cable is designed to be used with all types of engines, carbureted or fuel injected. The stock cable has the barrel end on it for the 4.6l throttle body and the ball for a mustang accelerator pedal. Unpack the throttle pedal and separate the arms....

  • Page 150

    149 www.Factoryfive.Com 508-291-3443 bolt the pedal to the mount plate using the ¼”x ¾” screws and locknuts unpack the throttle cable and cut the cylinder end off. Make sure your cutters are very sharp so as not to fray the cable..

  • Page 151

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

  • Page 152

    151 www.Factoryfive.Com 508-291-3443 tighten the cable sheath to the firewall with the retaining nut. A piece of tape on the end of the cable will help prevent it from backing out of the sheath. Check the full range of the accelerator pedal travel to ensure that there are no interferences with the p...

  • Page 153

    152 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 154

    153 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 155

    154 www.Factoryfive.Com 508-291-3443 steering rack needle nose pliers, ¾” wrench, ¾” socket, ratchet, 1.50” wrench or adjustable wrench. Mustang power steering rack, steering system hardware 87-93 steering rack and fasteners (hydraulic lines removed). If not already in, insert the stock rubber bushi...

  • Page 156

    155 www.Factoryfive.Com 508-291-3443 use thread locker on all of the steering shaft screws that do not have jam nuts and the adapter screws..

  • Page 157

    156 www.Factoryfive.Com 508-291-3443 the inner tie rod extensions are for stock power steering racks only, not for manual steering racks. 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 th...

  • Page 158

    157 www.Factoryfive.Com 508-291-3443 put a dot of thread lock on the threads of the steering rack extension and attach the mustang 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 coupe front end is narrower than the m...

  • Page 159

    158 www.Factoryfive.Com 508-291-3443 the outer tie rods may come with either a castle nut and cotter pin or a nylon locknut. Attach the tie rod to the spindle, torque the nut to 25 ft-lbs. If a castle nut is used, torque the nut then install the cotter pin..

  • Page 160

    159 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. Slide the steering shaft through the upper bearing and ...

  • Page 161

    160 www.Factoryfive.Com 508-291-3443 turn the steering shaft so the recessed bosses for the spring washers are facing up and set the washers in place. Then tap the upper shaft down until the upper clip just disappears into the lower shaft. Tighten the upper and lower bearings. Also tighten the set s...

  • Page 162

    161 www.Factoryfive.Com 508-291-3443 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 aluminum, mounted aluminum, secondary body fasteners. Do one panel at a time. Be care...

  • Page 163

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

  • Page 164

    163 www.Factoryfive.Com 508-291-3443 mark and drill the two vertical edges of the passenger footbox inside wall. Silicone and rivet the panel to the front tunnel “a” and the footbox top. Mark the holes in the passenger footbox front panel upper and outer edges but do not drill yet. Silicone the pane...

  • Page 165

    164 www.Factoryfive.Com 508-291-3443 silicone the flanges for the passenger footbox floor then install and rivet it in place. The floor sits on top of the flanges from the footbox walls. Silicone the remaining flanges then install the outer wall/top on the footbox with rivets. Make sure the rear edg...

  • Page 166

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

  • Page 167

    166 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 168

    167 www.Factoryfive.Com 508-291-3443 driver floor drill silicone and install the driver’s footbox floor. The outer flange does not get drilled yet. Silicone, drill, and install the driver side floor. Drill, silicone and install the inner footbox wall. The front flange tucks in behind the front. Put ...

  • Page 169

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

  • Page 170

    169 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. Cockpit rear wall mark and drill the rear co...

  • Page 171

    170 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 172

    171 www.Factoryfive.Com 508-291-3443 unpack the ¾” square plastic end caps from the secondary body fasteners. Push the four plastic end caps into the tubes hanging down in front and behind the gas tank..

  • Page 173

    172 www.Factoryfive.Com 508-291-3443 hang the fuel tank straps from the rear mount of the chassis using two of the strap fasteners. The longer strap goes on the passenger side. Using a jack, raise the tank up into place on the chassis. Make sure the plastic cover is in position below the tank..

  • Page 174

    173 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 175

    174 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 176

    175 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 177

    176 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 178

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

  • Page 179

    178 www.Factoryfive.Com 508-291-3443 fasten the lines to the 2”x 2” square cockpit outriggers with the insulated line clips and 3 / 16 ” rivets. If you are going to use the mustang fuel vapor line, run it along with the other fuel lines..

  • Page 180

    179 www.Factoryfive.Com 508-291-3443 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 / 16 ” wrenches. Pedal box hardware, insulated clip hardware, brake line components, 3 / 16 ” br...

  • Page 181

    180 www.Factoryfive.Com 508-291-3443 tighten all of the mounting bolts for the pedal box and master cylinder..

  • Page 182

    181 www.Factoryfive.Com 508-291-3443 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 slide it over the brake pedal post. Put the clip through the hole in the ped...

  • Page 183

    182 www.Factoryfive.Com 508-291-3443 the small aluminum piece packed in the assembly is not used for this application. Tighten all the remaining hardware mounting the pedal box to the chassis. Front flexible brake lines unpack the hardware from the brake line components. Lay out the various lengths ...

  • Page 184

    183 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 185

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

  • Page 186

    185 www.Factoryfive.Com 508-291-3443 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 calipers. Newer axles and the ffr rear brakes run ...

  • Page 187

    186 www.Factoryfive.Com 508-291-3443 attach the “t” adapter to the flexible brake line and route the hard brake line coming from the front to the “t”..

  • Page 188

    187 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 189

    188 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 190

    189 www.Factoryfive.Com 508-291-3443 wiring harness ⅜” socket, regular head screwdriver, slip joint pliers, ⅛”, 3 / 16 ” drill bits, drill, #8 nut driver, electrical tape, wire cutters. Misc. Electrical components, wiring harness mounting hardware, insulated clip hardware if during this section, you...

  • Page 191

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

  • Page 192

    191 www.Factoryfive.Com 508-291-3443 transmission harness transmission harness push the harness plugs through the hole in the driver's side floor aluminum. Harness plug in 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” ...

  • Page 193

    192 www.Factoryfive.Com 508-291-3443 headlight harness 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 relay area. The mustang is wider th...

  • Page 194

    193 www.Factoryfive.Com 508-291-3443 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 hole from the insid...

  • Page 195

    194 www.Factoryfive.Com 508-291-3443 (+) battery cable yellow wire green wire orange/dark blue wire red/blue wire black cable to starter starter solenoid wiring old starter.

  • Page 196

    195 www.Factoryfive.Com 508-291-3443 new starter 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 pro...

  • Page 197

    196 www.Factoryfive.Com 508-291-3443 engine harness ⅜” socket, regular head screwdriver, slip joint pliers, 3 / 16 ” and ⅛” drill bits, drill, #6 nut driver, electrical tape, wire cutters. Mustang engine harness, engine harness assembly the aluminum is laser cut for the efi (electronic fuel injectio...

  • Page 198

    197 www.Factoryfive.Com 508-291-3443 use the drilled holes and cable tie trick to hold the extra harness to the top of the passenger foot box. The harness splits into two on top of the foot box. The short, smaller harness goes forward and connects to the mass air sensor and to the harness on the eng...

  • Page 199

    198 www.Factoryfive.Com 508-291-3443 if you are running efi without emissions equipment, the vacuum/electrical solenoids located on top of the foot box along with the vacuum reservoir on the firewall are not necessary. Plug the vacuum outlets on the intake remove the unused parts. Use screws provide...

  • Page 200

    199 www.Factoryfive.Com 508-291-3443 computer ground near driver’s foot box ignition and turn signal stalk hack saw, 5 / 16 ” socket, 9 / 64 ” drill bits, drill. Dash electrical components, mustang ignition switch and turn signal stalk. Mount the turn signal stalk with the stalk pointed towards the ...

  • Page 201

    200 www.Factoryfive.Com 508-291-3443 on the driver’s side at the rear of the trunk area. This can be used if the coupe fuel cell kit is used. Place the battery tray, on top of the trunk floor, with half of the plate on each side of the cross brace located on the driver side of the trunk. Mark where ...

  • Page 202

    201 www.Factoryfive.Com 508-291-3443 battery tray mounted in rear trunk corner for fuel cell. Duct tape the hooks into the holes to help in the assembly process. Place the battery onto the tray with the positive terminal on the driver’s side. One by one, wipe clean of any grease/oil on the hook bolt...

  • Page 203

    202 www.Factoryfive.Com 508-291-3443 if the starter solenoid was mounted behind the engine, run the cable up the transmission tunnel front wall behind where the engine will sit and to the solenoid. If the starter solenoid was mounted to the 1” tube near the master cylinder, run the cable to the fron...

  • Page 204

    203 www.Factoryfive.Com 508-291-3443 rear wall 1 / 8 ” drill bit, silicone, rivet gun, caulk gun, 9 / 16 ” wrench, 5 / 16 ” hex key. Mounted aluminum, packaged aluminum, secondary body fasteners position the panel on the frame overlapping the side wall tabs. Mark where the rivets will go by tracing ...

  • Page 205

    204 www.Factoryfive.Com 508-291-3443 floor with the rear taillight harness tied up and secure, silicone and install the lower trunk floor. Drivetrain preparation aftermarket tko 500 and tko 600 prep hack saw or reciprocating saw, ¾” socket, ratchet transmission, polyurethane engine/transmission moun...

  • Page 206

    205 www.Factoryfive.Com 508-291-3443 trim off the unused mounting boss on the bottom of the case..

  • Page 207

    206 www.Factoryfive.Com 508-291-3443 trim it flush or just below the pad for the transmission mount. 87-93 alternate drive pulley ¾” socket, ¾” wrench. Alternate drive pulley components if you are using under-drive pulleys or eliminating the smog pump do not drill the a/c bracket according to the di...

  • Page 208

    207 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. Install the bolt assembly on the a/c bracket (previously drilled in the disassembly section), using the lock nut provided. Pull the tension pulley...

  • Page 209

    208 www.Factoryfive.Com 508-291-3443 new pulley is not lined up properly and is too far in, use the arbor shims included with the kit to go between the aluminum sleeve and the pulley wheel, effectively pushing the assembly outwards. Engine/transmission installation engine hoist, chain, ¾”, 15 / 16 ”...

  • Page 210

    209 www.Factoryfive.Com 508-291-3443 tighten the transmission mount to the frame. Driveshaft 14mm wrench, thread locker mustang driveshaft and fasteners if not already done, the driveshaft should be shortened to the length specified in the appendix for the engine/transmission combination being used....

  • Page 211

    210 www.Factoryfive.Com 508-291-3443 the mustang driveshaft bolts should have thread locker on them already. If thread locker is not there, put a small bead on each bolt. Fit the driveshaft snug against the yoke and install the bolts and tighten. You can put the transmission in gear to stop the driv...

  • Page 212

    211 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..

  • Page 213

    212 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 214

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

  • Page 215

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

  • Page 216

    215 www.Factoryfive.Com 508-291-3443 use a razor knife, file or grinder to remove the plastic barbs from the plastic shaft. Slide the clutch cable boss through the adjuster and loop the cable over the quadrant. Speedometer sending unit 11mm deep socket, ratchet. Mustang speedometer sending unit..

  • Page 217

    216 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..

  • Page 218

    217 www.Factoryfive.Com 508-291-3443 accelerator cable 5 / 64 ” hex key, ⅜”, 7 / 16 ” wrenches insulated clip hardware. 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 r...

  • Page 219

    218 www.Factoryfive.Com 508-291-3443 stop tab on accelerator pedal. After driving the car for the first time you may want to adjust the pedal locations for optimum heal/toe and shoe size differences. Make sure the accelerator cable is tied up and out of the way of moving or hot parts as well. Carbur...

  • Page 220

    219 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 and push the cable wiper onto the remaining threads. Push the ball stud retainer onto the ball stud. Push/pull the cable into the retainer so that the cable ...

  • Page 221

    220 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. Fuel vapor canister drill, 3 / 16 ” drill bit, ⅜” socket wire harness mounting hardware, mustang fuel vapor canister.

  • Page 222

    221 www.Factoryfive.Com 508-291-3443 the emissions canister can be mounted to the right side of the engine bay on outside of the 1” horizontal tubing just behind the mass air meter. Drill two 3 / 16 ” holes through the canister bracket oem holes. Mount with two #14 screws. Attach the vent hose from ...

  • Page 223

    222 www.Factoryfive.Com 508-291-3443 angle the lower mounting tabs at a 45 angle outward then adjust them so that the mounting bolts will again go through the flange and the nut will go on the bolt. Mark the upper and lower mount tab holes on the radiator flanges. Mark where the lower mount tabs ca...

  • Page 224

    223 www.Factoryfive.Com 508-291-3443 trim the excess off the lower fan mount tabs. Attach the fan to the radiator using the black #10 x 1” screws on the top and the #10 x 5 / 8 ” screws on the bottom. Make sure that the fan blades do not hit the sides of the fan housing once the fan is attached to t...

  • Page 225

    224 www.Factoryfive.Com 508-291-3443 install the radiator from above the frame. Attach some stick on weather stripping to the underside of the radiator top mount bracket. Position the top mount bracket so that the small tab sticking up is on the rearward side of the bracket..

  • Page 226

    225 www.Factoryfive.Com 508-291-3443 while holding the bracket on top of the radiator, mark the location of the mount bracket holes on the 1”x 1” tubes. Do not let the end of the bracket overhang the tube, another piece of aluminum will be attached to the outside of the tube later (see picture below...

  • Page 227

    226 www.Factoryfive.Com 508-291-3443 large radiator duct mounted. Insert the radiator duct aluminum from behind the radiator. Attach the driver and passenger side duct brackets to the top of the 1”x 1” tubes and the sides of the main duct using ⅛” rivets and silicone..

  • Page 228

    227 www.Factoryfive.Com 508-291-3443 passenger side bracket driver side bracket.

  • Page 229

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

  • Page 230

    229 www.Factoryfive.Com 508-291-3443 then fit the larger adapters over them. Upper radiator hose start at the engine and route the tube along the top of the passenger side duct bracket..

  • Page 231

    230 www.Factoryfive.Com 508-291-3443 the kit includes a remote fill adapter that should be installed at the highest point in the cooling system which is the return hose back to the radiator..

  • Page 232

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

  • Page 233

    232 www.Factoryfive.Com 508-291-3443 fan mounting components, dash electrical components there are a few ways to run the electric fan. The kit includes a relay, wiring, and a thermostat switch to get used with the relay to turn the fan on and off at 185°f. The alternative way is to use the relay wit...

  • Page 234

    233 www.Factoryfive.Com 508-291-3443 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 to the thermostat switch. Connect the #86 and #30 tabs to a +12v 30a fuse in the fuse panel..

  • Page 235

    234 www.Factoryfive.Com 508-291-3443 emergency brake ½” deep socket, 3 / 16 ” hex key, marker, scissors, hacksaw. Mustang e-brake handle, brake line components push the u-nuts from the brake line components onto the e-brake handle. Bolt the handle to the mount bracket using the kit fasteners. The ho...

  • Page 236

    235 www.Factoryfive.Com 508-291-3443 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. Route the cables through the upper bracket in the transmission tunnel until the sheath end clicks in place..

  • Page 237

    236 www.Factoryfive.Com 508-291-3443 route the inner cable down under the chassis and hook them to the t cable..

  • Page 238

    237 www.Factoryfive.Com 508-291-3443 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 no problem...

  • Page 239

    238 www.Factoryfive.Com 508-291-3443 interior aluminum transmission tunnel cover drill, ⅛” drill bit, silicone, caulking gun, rivet gun secondary body fasteners components, packaged aluminum, mounted aluminum remove the seats, roll bar, and harnesses and silicone and install the transmission tunnel ...

  • Page 240

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

  • Page 241

    240 www.Factoryfive.Com 508-291-3443 driver footbox silicone and install the front patch panel. Seats harness ¾” wrench, ¾” socket, ½” drill bit, drill, ratchet seat harness/fasteners unpack the seat harnesses and hardware..

  • Page 242

    241 www.Factoryfive.Com 508-291-3443 bolt the lap harness in position. Remove the mounting tab from the harness. Loop the harness over the roll bar crossbar..

  • Page 243

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

  • Page 244

    243 www.Factoryfive.Com 508-291-3443 adjust the harnesses to where they fit you comfortably. Shifter handle and boot ½” wrench, ⅛”drill bit, drill, phillips head screwdriver, marker, thread lock shifter handle components unpack the shift handle and bolt it to the transmission. These bolts have a ten...

  • Page 245

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

  • Page 246

    245 www.Factoryfive.Com 508-291-3443 remove the boot and drill ⅛” holes in the spots you marked. Re-install the boot and screw down to the tunnel with the countersunk screws. A small screwdriver can help to locate the holes..

  • Page 247

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

  • Page 248

    247 www.Factoryfive.Com 508-291-3443 seats 5 / 16 ” drill bit, drill, 3 / 16 ” hex key, ½” deep socket, marker seat mount hardware, seats these instructions show the install of the more popular roadster street seat. Racing seats with less padding give more room, the more upright the angle of the sea...

  • Page 249

    248 www.Factoryfive.Com 508-291-3443 using the rivet heads as a guide mark where the rails of the seat frame are above the seat mounting plates. Drill the first hole for the seat mounting and install the bolt..

  • Page 250

    249 www.Factoryfive.Com 508-291-3443 drill the remaining holes for mounting the seats and install the bolts. Nameplate 1 / 8 ” drill bit, rivet gun, drill.

  • Page 251

    250 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 252

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

  • Page 253

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

  • Page 254

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

  • Page 255

    254 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 256

    255 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. Get the engine up to temperature and c...

  • Page 257

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

  • Page 258

    257 www.Factoryfive.Com 508-291-3443 power steering system bleeding if not running power steering, skip this section. Raise the front wheels off the ground if they are not already turn the steering wheel all the way to the left. Fill the reservoir to the full cold level and leave the cap off. Turn t...

  • Page 259

    258 www.Factoryfive.Com 508-291-3443 if you just can’t get comfortable with the standard configuration some things you can do to increase room or comfort include:  trim the pedal pads for more room between pedals.  cut down or remove altogether the gas pedal pad.  add a dead pedal to the outside ...

  • Page 260: Body Section

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

  • Page 261

    260 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 262

    261 www.Factoryfive.Com 508-291-3443 the push-on weather strip needs to run across the top of the firewall. Body mounting gloves body the body will be trial fit/adjusted along with the doors to ensure everything fits before the body and parts are painted. All of the trim accessories will also be tri...

  • Page 263

    262 www.Factoryfive.Com 508-291-3443 pull the sides of the body out to clear the frame. Watching the rear of the frame, move the body forward slowly lowering the front. Watch the door latch posts. Pull the body out to get around the hinges. Move forward until the rear hatch tubing is lined up with t...

  • Page 264

    263 www.Factoryfive.Com 508-291-3443 tail lights drill, 1¼” hole saw, 7 / 32 ” drill bit, ⅜” socket, flat head screwdriver, razor knife, marker, ruler, level. Tail light template, tail lights and hardware. Be careful with the lenses, they are glass and can break if dropped from a fairly low height. ...

  • Page 265

    264 www.Factoryfive.Com 508-291-3443 the lights mount from the outside of the body without the lenses and trim rings in place. Test fit the lights. You may have to bend the ground tab slightly or file away a bit at the hole to make it fit perfectly. Mount the lights using the supplied hardware. This...

  • Page 266

    265 www.Factoryfive.Com 508-291-3443 side rear body mount. 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 d...

  • Page 267

    266 www.Factoryfive.Com 508-291-3443 use a ⅛” drill bit for all except one of the outer screw holes. Use a 7 / 32 ” bit drill for the last small hole. Use a 3½” hole saw for the center opening, drill out the holes for the filler. If you do not have a hole saw this size, you can cut the center circle...

  • Page 268

    267 www.Factoryfive.Com 508-291-3443 side exhaust air saw or jig saw. Side exhaust template cut out the side exhaust template. The template goes down to the top edge of the body. Tape or hold the template and mark around it with a pen. Use a jigsaw to cut out the marked area. The template is slightl...

  • Page 269

    268 www.Factoryfive.Com 508-291-3443 radiator exit opening air saw or jig saw. Use a jigsaw to cut out the area..

  • Page 270

    269 www.Factoryfive.Com 508-291-3443 turn signal drill, 1” hole saw, marker. Turn signal template, front turn signal light only cut the outer lines of the shapes out. Position templates on the body in their correct locations and tape in place. Drill the holes with a 1” hole saw. Test fit a light and...

  • Page 271

    270 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 272

    271 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 273

    272 www.Factoryfive.Com 508-291-3443 side louver drill, ½” drill bit, jig saw or air saw at the corners of the louver indentation, use a ½” drill bit. Use a jigsaw or hacksaw for the straight edges..

  • Page 274

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

  • Page 275

    274 www.Factoryfive.Com 508-291-3443 cut the area for the latch on the nose leaving the lower finger recess for the bottom of the latch. Tape the outside of the body around the latch area..

  • Page 276

    275 www.Factoryfive.Com 508-291-3443 position the latch from the backside of the body. Make sure the latch looks straight in the cutout and compared to the rear edge of the nose. Drill 7 / 32 ” holes for the mounting screws..

  • Page 277

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

  • Page 278

    277 www.Factoryfive.Com 508-291-3443 nose mounting hinge nose bracket 5 / 16 ” drill bit, drill, 3 / 16 ” hex key, ½” wrench, tape measure, marker. Nose/trunk fastener assembly, body, mustang fog lights. Have some help when doing this step. The fiberglass edges can be very sharp. Wear gloves when li...

  • Page 279

    278 www.Factoryfive.Com 508-291-3443 line the hinge plates up against the openings with the angled supports as vertical as possible. These need to be as vertical as possible to prevent binding in the hinge. Mark the brackets through the mount holes. Remove and drill the hinge brackets. Bolt the hing...

  • Page 280

    279 www.Factoryfive.Com 508-291-3443 raise or lower the front of the nose so that the bottom edge of the hood is parallel with the bottom edge of the body above the exhaust area. Align the rear of the wheel well of the nose with the front of the body. Move the nose around so there is a small gap (i....

  • Page 281

    280 www.Factoryfive.Com 508-291-3443 either through the nose or from under the car, look at the alignment of the rod ends and the location of the rod ends (left to right) in the brackets. Screw the rod ends in/out as necessary to align the hole with the slots. The nose gaps may also have to be adjus...

  • Page 282

    281 www.Factoryfive.Com 508-291-3443 with the frame at 4” ride height in the front and the help of a friend, open the nose until the fog light area of the nose is parallel with the ground. Use a ratchet strap or some rope to hold the nose in this position until the struts are in place. The taller st...

  • Page 283

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

  • Page 284

    283 www.Factoryfive.Com 508-291-3443 underside view, nose locator mounted scoops sandpaper, ⅛” drill bit, drill, marker coupe scoops the original coupe had three scoops, two small ones mounted on the body and one larger one mounted on the nose..

  • Page 285

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

  • Page 286

    285 www.Factoryfive.Com 508-291-3443 hold the scoops up to the body in the locations desired and sand or cut the outside of them as needed to fit in the location. Make sure to keep about ½” of flange for the ⅛” rivets that will hold them on. Mark the rivet locations on the scoop flanges. Drill throu...

  • Page 287

    286 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. Rivet and silicone th...

  • Page 288

    287 www.Factoryfive.Com 508-291-3443 from the secondary body fastener assembly, use some press-on weather stripping on the three top sides, the sides that will contact the radiator, and along the lower front edge of the large radiator duct. Insert the radiator duct aluminum from behind the radiator..

  • Page 289

    288 www.Factoryfive.Com 508-291-3443 attach the driver and passenger side duct brackets to the top of the 1”x 1” tubes and the sides of the main duct using ⅛” rivets and silicone. Passenger side bracket driver side bracket.

  • Page 290

    289 www.Factoryfive.Com 508-291-3443 exhaust ½” sockets, ½” wrench, jack stands, jack, ¼”, 5 / 16 ” hex key. Headers, side exhaust, locktite. Try not to drop the side exhaust assembly as it will probably land on the outer curved surface and dent (if it sounds like this has happened to us, it has). T...

  • Page 291

    290 www.Factoryfive.Com 508-291-3443 slide the band clamps for the side pipes onto the headers. The small diameter goes first. Side exhaust cut the large exhaust hanger in half lengthwise. Attach one half of the rubber exhaust mount to the side pipe mount using a 5 / 16 ”x 1.5” button head screw, wa...

  • Page 292

    291 www.Factoryfive.Com 508-291-3443 mount the side exhaust mount to the frame using four 3 / 16 ” long rivets. Bolt through the top hole of the rubber and the frame bracket using a 5 / 16 ”x 1.5” button head screw. Line the bottom hole up with the slot on the side exhaust and tighten the bolt. Whit...

  • Page 293

    292 www.Factoryfive.Com 508-291-3443 on the inside of the body at the center of the car, there is a body mount in the middle at the top and bottom of the windshield. Use the windshield mount spacers in these areas between the frame and the body. Add or subtract the number of spacers as needed before...

  • Page 294

    293 www.Factoryfive.Com 508-291-3443 using a jig saw or other reciprocating saw cut out the area traced. Draw a line ⅝” from the edge of the recessed area on the inside of each door. Drill a ⅜” hole in one corner and use this as a starting point to begin cutting. Cut and remove the inside face of th...

  • Page 295

    294 www.Factoryfive.Com 508-291-3443 attach the latch to the door frame using the 3 phillips head screws. Door handle drill, 3 / 32 ”, 3 / 16 ” drill bits, drill, rivet tool, air saw or jig saw, philips screwdriver, marker, scissors. Interior door handle components, secondary body fasteners attach t...

  • Page 296

    295 www.Factoryfive.Com 508-291-3443 push the other end of the cable into the cable mount tab. Place the clevis on the end of the cable and attach it to the door latch using the black button head screw. Tighten the screw enough so that the clevis is not sloppy but so that it can rotate on the latch....

  • Page 297

    296 www.Factoryfive.Com 508-291-3443 using a straight edge draw a line along the top and bottom edges of the recessed area. Draw a line parallel to this line ⅝” above the top line and ¾” below the bottom line. Mark the door for drilling using the diagram for locations. Drill through the door and fra...

  • Page 298

    297 www.Factoryfive.Com 508-291-3443 remove the clamps. Move the door handle around inside the door and find an approximate location that you would like to mount the handle. Make sure that the cable will be able to reach. Do not go forward of the cut out in the door as this will hit the window frame...

  • Page 299

    298 www.Factoryfive.Com 508-291-3443 through the hole, insert the cable barrel fitting into its hole and slide cable sheath end in into the angled slot. Mount the handle using the #8 sheet metal screws. Door hinge using the door hinge diagram in the appendix, mark the cut out locations on the body a...

  • Page 300

    299 www.Factoryfive.Com 508-291-3443 drill a ⅜” hole in each of the cut out locations and cut out with a jig saw. Install the adjuster plates to the frame using the ⅜” square head bolts with nuts and washers but do not tighten yet..

  • Page 301

    300 www.Factoryfive.Com 508-291-3443 press the bronze bushings into the ½” holes in the hinge arms. Attach the hinge arm assembly to the adjuster plate using the 2” shoulder bolts, washers and 5 / 16 ” nuts. It makes installing the shoulder bolts a bit easier if you grind an angle on the end of the ...

  • Page 302

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

  • Page 303

    302 www.Factoryfive.Com 508-291-3443 hinge arm mounted to adjuster plate. (note: this photo was taken before the door was mounted to the frame to clearly illustrate the frame mounting procedure) attach the doors to the hinge arms using ⅜” lock nuts and washers..

  • Page 304

    303 www.Factoryfive.Com 508-291-3443 align the door in the opening with 3 / 16 ” spacers under it. Tighten the nuts in the door, check the alignment, then tighten the nuts holding the adjuster plate. Check door gaps and movement, adjust if necessary. Striker mounting from inside the rear wheel well ...

  • Page 305

    304 www.Factoryfive.Com 508-291-3443 use a jig saw to cut out the area marked on the door. Attach the latch striker to the mount plate on the frame using two ⅜” washers next to the striker flange to space it out and one washer next to the locknut..

  • Page 306

    305 www.Factoryfive.Com 508-291-3443 firewall extension aluminum marker, drill, ¼” hex drive bit, tin snips self tapping sheet metal screws, engine bay packaged aluminum. Insert the aluminum pieces outside first into the area between the body and the footboxes in the engine bay and hold in place. Tr...

  • Page 307

    306 www.Factoryfive.Com 508-291-3443 right side left side.

  • Page 308

    307 www.Factoryfive.Com 508-291-3443 side windows 7 / 32 ” drill bit, drill, ⅛” hex key, 5 / 16 ” wrench, marker, hacksaw blade, phillips head screwdriver. Side window assembly, secondary body fasteners assembly. The driver is different than the passenger side window, the driver side is 7 / 16 ” sho...

  • Page 309

    308 www.Factoryfive.Com 508-291-3443 front window frame mount. Remove the window and drill the mounting holes with a 7 / 32 ” drill bit. Cut a slot in the recess at the top rear of the door for the rear weather strip mount (looks like a number “1”) using a hack saw blade. Trial fit the weather strip...

  • Page 310

    309 www.Factoryfive.Com 508-291-3443 top of weather strip mount. Push the rubber on side weather stripping onto the flange going around the door opening. The window tracks mount on the outside of the window. Push the “u” window weather stripping onto each of the side windows. The weather stripping m...

  • Page 311

    310 www.Factoryfive.Com 508-291-3443 a drill bit designed for plastic with a 60° point instead of the standard 118° or 135° point will reduce the chance of cracking during drilling. They can be found at mcmaster.Com in their specialty drill bit section. Put masking tape on the front edge of the quar...

  • Page 312

    311 www.Factoryfive.Com 508-291-3443 attach the latch striker square bolt to the frame using the locknuts and washers provided. Leave it adjusted as high as possible. Do not tighten it down yet it will need some adjustment..

  • Page 313

    312 www.Factoryfive.Com 508-291-3443 hatch hinge.

  • Page 314

    313 www.Factoryfive.Com 508-291-3443 7 / 16 ”, 9 / 16 ”, 11 / 16 ” wrench, ⅛”, 3 / 16 ” hex key, marker, drill, 7 / 32 ”, 7 / 16 ” drill bit, hack saw, philips head screwdriver, ruler, friend rear glass hatch components, glass hatch. Push the large 1.32” rubber washers onto the large button studs. F...

  • Page 315

    314 www.Factoryfive.Com 508-291-3443 push the small button studs through the holes on the sides of the glass. Push the medium 0.922” rubber washers onto the small button studs on the inside of the glass. Put a washer on the small button stud. Carefully thread on and tighten a jam nut on the bottom o...

  • Page 316

    315 www.Factoryfive.Com 508-291-3443 push plastic bushings into both sides of the hatch frame hinge bracket. Use a vise to push them in evenly if necessary. Insert the bronze bushings into the frame mounts on the roll bar. From the inside of the rollbar, attach the frame side hatch hinge arm using t...

  • Page 317

    316 www.Factoryfive.Com 508-291-3443 rotate the hinge arm up so that it touches the body and mark the body where it hits. Use a 7 / 16 ” drill bit to drill a hole just below the rear hatch flange. Cut the sides of the hole with a hack saw so the hinge arm has clearance..

  • Page 318

    317 www.Factoryfive.Com 508-291-3443 hatch struts the strut bracket should be positioned with the bracket starting ⅜” from the top corner of the hatch support area. The bracket should be on the inside of the hatch area with the strut ball pointing in. Make sure all of the mount holes land on the tub...

  • Page 319

    318 www.Factoryfive.Com 508-291-3443 hatch with the help of a friend, place the glass hatch in the opening. Locate the glass so that the gap is even all the way around the hatch opening. Use coins or washers, etc… along the bottom and sides so that the hatch is held in position. The hatch should be ...

  • Page 320

    319 www.Factoryfive.Com 508-291-3443 carefully try opening the hatch. Attach the rod side of the gas strut to the ball stud mounted on the hatch..

  • Page 321

    320 www.Factoryfive.Com 508-291-3443 remove the hatch by unbolting the two halves of the hinge arms..

  • Page 322

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

  • Page 323

    322 www.Factoryfive.Com 508-291-3443 tape some sheets of newspaper or large pieces of paper together matching the size of the headliner. The paper will be used as a template for the headliner. Put some clean rags on the ground to prevent scratching the roof of the body. With the help of a friend, tu...

  • Page 324: Final Assembly

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

  • Page 325

    324 www.Factoryfive.Com 508-291-3443 headlights phillips head screwdriver, drill, 5 / 16 ” drill bit headlight components unpack the headlight mounting assembly..

  • Page 326

    325 www.Factoryfive.Com 508-291-3443 screw the adjuster screws about halfway into the buckets. Push the grommet into the side of the bucket. 13419 13415 13418 13420 13416.

  • Page 327

    326 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 328

    327 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..

  • Page 329

    328 www.Factoryfive.Com 508-291-3443 temporarily put the bucket in the hole. The trim ring is held on by a screw on the bottom. Mark the bottom of the headlight area where the screw mount is. Remove the bucket and drill a 5 / 16 ” hole through the bottom of the bucket. Screw the bucket to the body u...

  • Page 330

    329 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 331

    330 www.Factoryfive.Com 508-291-3443 make the following two measurements: measurement a: from the ground to the geometric center of one of the headlight lenses measurement b: from one of the low beam headlights to the vehicle centerline. (also measure from high beam center to vehicle centerline for ...

  • Page 332

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

  • Page 333

    332 www.Factoryfive.Com 508-291-3443 turn signals 5 / 16 ” deep socket, ratchet amber front turn signal lights screw the turn signal lights into their holes..

  • Page 334

    333 www.Factoryfive.Com 508-291-3443 headlight covers drill, ⅛” drill bit, philips head screwdriver, masking tape, marker, ruler, and sandpaper. Headlamp covers/fasteners stick masking tape around the edge of the headlight bucket so the paint will not be scratched. Position the headlight cover in th...

  • Page 335

    334 www.Factoryfive.Com 508-291-3443 reposition the cover carefully, the tabs may need additional bending to match the surface of the plastic. Drill and rivet the tabs to the headlight bucket. Drill and mark the location of the tab holes on the cover. Drill the holes marked for the mounting screws. ...

  • Page 336

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

  • Page 337

    336 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 338

    337 www.Factoryfive.Com 508-291-3443 side louver mesh silicone, caulking gun, duct tape side louver mesh position the mesh screen behind the louver cut-out area on the nose..

  • Page 339

    338 www.Factoryfive.Com 508-291-3443 apply silicone around the cut-out area on the nose that the mesh will touch. Duct tape around the outside of the mesh..

  • Page 340

    339 www.Factoryfive.Com 508-291-3443 line up the mesh on the nose and tape them in place to hold them until the silicone dries (usually over night). Weatherstripping razor knife, tin snips secondary body fasteners replace any weatherstrip that was damaged during body removal. Put additional weathers...

  • Page 341

    340 www.Factoryfive.Com 508-291-3443 pull the sides of the body out to clear the frame. Watching the rear of the frame, move the body forward slowly lowering the front. Watch the door latch posts. Move forward until the rear hatch tubing is lined up with the lip on the body and put the body down in ...

  • Page 342

    341 www.Factoryfive.Com 508-291-3443 side body mounts drill, 5 / 16 ” drill bit, 3 / 16 ” hex key, ½” wrench, marker, ruler. Secondary body fasteners the body sides are mounted using four stainless 5 / 16 ”x 1” bolts with a washer next to the head. The rear most side body mount needs 7 / 16 ” worth ...

  • Page 343

    342 www.Factoryfive.Com 508-291-3443 side rear body mount. Fuel filler neck razor knife, ⅜” socket, ratchet, 3 / 16 ” drill bit, drill aston lemans cap components ground the fuel filler strap to the chassis using the screw that came in the cap hardware. This wire prevents any static charge build-up ...

  • Page 344

    343 www.Factoryfive.Com 508-291-3443 attach the 2” fuel filler hose to the bottom section of the mustang filler neck. Stock fuel tank filler neck with extension..

  • Page 345

    344 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. Screw the plastic gas cap into the aston lemans style cap..

  • Page 346

    345 www.Factoryfive.Com 508-291-3443 nose mounting re-install the hinge brackets on the nose. Replace the bumpers you used before on the body to line up the nose..

  • Page 347

    346 www.Factoryfive.Com 508-291-3443 re-install the hood and latches. Door final fit ½” deep socket, (2) 9/16” wrenches, 3 / 16 ”, 5 / 16 ” hex key, phillips head screwdriver, masking tape. Take your time to align the doors properly. Hinge reattach the door hinge to the frame. Attach the door frame ...

  • Page 348

    347 www.Factoryfive.Com 508-291-3443 door use masking tape around the body opening to prevent scratching or chipping..

  • Page 349

    348 www.Factoryfive.Com 508-291-3443 bolt the door skin to the door frame using the 1½” long 5 / 16 ” screws. If washers were used to space the skin away from the steel don’t forget to put them on the screws. Slowly try closing the door. Adjust the hinge if necessary. Handles remount the door handle...

  • Page 350

    349 www.Factoryfive.Com 508-291-3443 rear front splash guards position the rear front splash panels so that they are flat against the rear cockpit wall and the corner is against the aluminum panels. Hold the panels in place with #6 screws..

  • Page 351

    350 www.Factoryfive.Com 508-291-3443 use a marker and ruler to mark the rivet holes on the aluminum panel. Note where the panels touch each other and where they touch the frame. Remove the panels. Apply silicone to the upper splash panels. Install the upper splash panels with #6 screws. Apply silico...

  • Page 352

    351 www.Factoryfive.Com 508-291-3443 license plate light and bracket drill, ⅛”, 3 / 16 ” drill bits, 2” hole saw, marker, level, phillips head screwdriver, file. License light/ bracket assembly. This kit is only a collection of parts. Applying the license plate bracket does not mean that this vehicl...

  • Page 353

    352 www.Factoryfive.Com 508-291-3443 use the license plate bracket as a template for the mounting screws. Use a level to make sure the bracket is level since there are no straight lines on the rear of the car. Use a ¼” drill bit for the mount screws. Attach the bracket to the body using the two flat...

  • Page 354

    353 www.Factoryfive.Com 508-291-3443 windshield windshield assembly. Handle the windshield with care and store in a safe place. We highly recommend having a professional windshield installation shop do this installation. Most glass shops prefer to use their own weather strip and materials to install...

  • Page 355

    354 www.Factoryfive.Com 508-291-3443 prime the windshield flange for the urethane. Apply urethane around the windshield flange. Attach the weather stripping to the windshield..

  • Page 356

    355 www.Factoryfive.Com 508-291-3443 push the windshield into place. Do not move/touch the windshield for 24 hours. Windshield mounted on the body..

  • Page 357

    356 www.Factoryfive.Com 508-291-3443 final hatch mounting razor knife, ½” socket, ratchet. Secondary body fasteners. The rear hatch uses the weather stripping that has two legs on it, one longer than the other and has no adhesive on the back. Press the double stick tape around the rear hatch recess ...

  • Page 358

    357 www.Factoryfive.Com 508-291-3443 for a cleaner wiring set-up. Mount the gauges in the dash before connecting the gauges to the engine. The dash has been cut for the larger vintage style gauge speedometer and tach. If using the autometer gauges, use the autometer gauge mount plate for the large g...

  • Page 359

    358 www.Factoryfive.Com 508-291-3443 attach the dash sides to the dash. Push some of the push-on weather-stripping onto the top edge of the dash sides and around the front edge of the dash..

  • Page 360

    359 www.Factoryfive.Com 508-291-3443 position the dash in the cockpit. Mark four screw locations across the front face of the dash along the top, for the mounting screws and two in each of the dash side pieces into the 2”x 2” tube. Use the self-tapping #6 screws to screw the dash to the ¾”x ¾” dash ...

  • Page 361

    360 www.Factoryfive.Com 508-291-3443 lower switch panel decide the layout of the lower switch panel. Below is the layout we chose. If installing a radio keep it in mind as well. The layout shown uses optional switches that are included in the carbureted harness option and wiper option. Top row left ...

  • Page 362

    361 www.Factoryfive.Com 508-291-3443 side of switch panel riveted to transmission tunnel. Gauges the electrical hook-ups for the gauges referenced in these instructions are provided for all years, where there are differences the different years are indicated. For 5.0l cars, the pin numbers are for 1...

  • Page 363

    362 www.Factoryfive.Com 508-291-3443 remove the dash from the car. Remove the gauges from the dash. Cover/coat the dash, a matte finish or non-reflective finish is suggested. We chose spray on truck bed liner from wal-mart for its finish and ease of use. Powder coating would also be a good choice. M...

  • Page 364

    363 www.Factoryfive.Com 508-291-3443 starting at the 4” mark, place one of the drilled tap connectors on the wire along with one of the 8” wires. Center the 8” wire on the connector and squeeze the connector with a pair of pliers. Snap the cover on the connector with your fingers. Repeat steps 4 and...

  • Page 365

    364 www.Factoryfive.Com 508-291-3443 wire leads for dash lights and speedo use zip ties from the kit to tie all three wires together. Attach the loose end of the red wire to the mustang gauge gray plug pin #7 (warning lamps feed). Attach the loose end of the blue wire to the mustang brown gauge plug...

  • Page 366

    365 www.Factoryfive.Com 508-291-3443 ring connector attached to gauge light ground and wire harness ground. Wire the tach lighting when wiring the remainder of the tach. If after hooking everything up, there are no lights or they are dim, check the mustang dimmer switch for adjustment. If dimmer swi...

  • Page 367

    366 www.Factoryfive.Com 508-291-3443 pick a color wire for the sending unit wire and connect it to the gauge using a ring connector. Attach the other end of the same color wire to the mustang brown plug #8 (oil pressure feed). Oil temperature gauge there are many ways to mount the oil temperature se...

  • Page 368

    367 www.Factoryfive.Com 508-291-3443 pick a color wire for the sending unit wire and connect it to the gauge using a ring connector. Attach the other end of the same color wire to the mustang brown plug # 10 (gas tank sending unit). Battery charging in order for the battery to charge, solder a 510 o...

  • Page 369

    368 www.Factoryfive.Com 508-291-3443 rivet the panels to the chassis and then use the trim screws to attach them to the bottom of the dash. Install the mustang headlight and hazard switches in the aluminum brackets. Interior rearview mirror tape measure, marker, windshield rearview mirror glue, hex ...

  • Page 370

    369 www.Factoryfive.Com 508-291-3443 mustang interior rearview mirror. Use a ruler and marker pen to mark the center of the top windshield area mount on the windshield. Hold the mirror in place to find the best location up/down and mark this on the windshield. Follow the directions on the glue for a...

  • Page 371

    370 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 372

    371 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. Mark the location and use the gasket to locate and drill the mounting holes..

  • Page 373

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

  • Page 374

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

  • Page 375

    374 www.Factoryfive.Com 508-291-3443 check straps 3 / 16 ” drill bit, drill, rivet tool, marker secondary body fasteners, door latch/hinge components unpack the door check-straps..

  • Page 376

    375 www.Factoryfive.Com 508-291-3443 sitting inside with the door closed, hold the check straps up to the door and the 2”x 2” tube and position the strap so that it will hit the framework in the door. Use a marker and one of the check straps to mark the two mounting holes on the middle of the inside...

  • Page 377

    376 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..

  • Page 378

    377 www.Factoryfive.Com 508-291-3443 optional leather steering wheel. Side exhaust 3 / 16 ” hex key, ⅜”, ½”socket, ratchet side exhaust remount the side exhaust..

  • Page 379

    378 www.Factoryfive.Com 508-291-3443 aluminum splash guards ⅛”, 3 / 16 ” drill bit, drill, rivet gun, silicone, caulking gun, ¾” socket, ratchet, extension, marker, clamps secondary body fasteners, packaged aluminum, front wheel and tire front wheel with the nose up, put a wheel and tire on the fron...

  • Page 380

    379 www.Factoryfive.Com 508-291-3443 adjust the clamp on the frame so that the aluminum splash guard will not contact the tire. Put some of the press-on bulb seal around the outside edge of the upper aluminum splash guards. Clamp the splashguard up against the nose. The upper splashguard attaches to...

  • Page 381

    380 www.Factoryfive.Com 508-291-3443 make sure that the nose and the body sides are aligned with each other. Look at the two splash guard pieces and move them forward or back so they are aligned. Use a marker and tin snips or move the lower splash guard if necessary to create an even gap between the...

  • Page 382

    381 www.Factoryfive.Com 508-291-3443 mark the lower splash guard where it will touch the 1”x 1” tube for rivets. Drill and rivet the lower splash guard to the tube using ⅛” rivets. The lower splash guard on the outside can either mount on the inside of the body or on the outside of the body as shown...

  • Page 383

    382 www.Factoryfive.Com 508-291-3443 make sure that the front of the lower section of body is even with the nose when it is down. Apply silicone to the outside of the lower splash guard then mark and rivet the outside of the lower splash guard to the body. Note the push some bulb weather-stripping o...

  • Page 384

    383 www.Factoryfive.Com 508-291-3443 use some of the self-tapping #6 screws to hold it in place. Remove the panel and silicone where it will contact the trunk side and along the inside of the flange on the body. Drill and rivet the panel in place along the trunk side and through the bottom corner of...

  • Page 385

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

  • Page 386

    385 www.Factoryfive.Com 508-291-3443 hold the mesh up to the rear vent area and mark the outline on the mesh. Bend the mesh to the shape or use tin snips to cut the shape of the vent. If bending, cut the depth you would like the mesh to sit at otherwise cut or find spacers and fasteners to get the c...

  • Page 387

    386 www.Factoryfive.Com 508-291-3443 total toe: 1 / 16 ” rear (irs only) camber: -1 total toe: 1 / 16 ” adjusting the upper control arm use the diagram below for reference. Slightly loosen the three pivot bolts using a ⅝” and 11 / 16 ” wrench. Loosen the jam nuts on both ends of each adjusting tube...

  • Page 388: Technical Support

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

  • Page 389

    388 www.Factoryfive.Com 508-291-3443 wheels and tires if using a wheel wider than 7”, ffr front lower control arms are needed to prevent the wheels rubbing the control arms. The front of the car can accommodate up to a 10” wheel with 315/35r-17. The rear of the car can accommodate up to a 12” wheel ...

  • Page 390

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

  • Page 391

    390 www.Factoryfive.Com 508-291-3443 17”x 9” and 17”x 10.5” fr style wheels. Our online parts catalog: factoryfiveparts.Com has more views of these wheels on cars. Left: 15” ffr halibrand style. Right 17” ffr halibrand style performance modifications seats for the roadracers/autocrossers that want m...

  • Page 392

    391 www.Factoryfive.Com 508-291-3443 train. Remember that a 2,100 lb. Car stresses the parts less than a 3,100 lb. Mustang does, so all of the components will last longer and can take more abuse than they did on the mustang. Check out www.Factoryfive.Com to see what we offer. Gears the mustang 5.0 m...

  • Page 393

    392 www.Factoryfive.Com 508-291-3443 throttle body stock mustang size: 58mm a 65mm throttle body work well up to 350hp. Ford racing, bbk, jegs, summit racing etc… sell many other sizes. Mass air meter stock mustang size: 55mm in order to increase the flow of air above 5000 rpm, upgrade from the stoc...

  • Page 394

    393 www.Factoryfive.Com 508-291-3443 if using a 351w engine there are two options, use 351w engine swap headers from ford racing (m- 9430-a58) or mac (e358692) or if smog/catalytic converters are not necessary, use our full length 4 into 4 headers. Ford racing offers 1⅝” unequal length stainless ste...

  • Page 395

    394 www.Factoryfive.Com 508-291-3443 high horsepower transmissions stock: t-5 the stock t-5 is good for the stock 302 engine. If the engine is going to have some work done to it then an upgrade to a heavy duty, ford racing “z” t-5 is all that is needed. An additional change to a tremec tko 500 or 60...

  • Page 396

    395 www.Factoryfive.Com 508-291-3443 rear suspension the standard solid axle 4-link rear suspension works well, is low maintenance and is reliable. Which rear suspension you choose depends on the type of driving you do a majority of the time. Each one is best for one application and is good in other...

  • Page 397

    396 www.Factoryfive.Com 508-291-3443 irs suspension – good everyday driving suspension. The irs is best for rough surfaces control arms stock: stamped steel with rubber bushings. Front: the stock front arms work well all round. The factory five tubular lower control arms with polyurethane bushings a...

  • Page 398

    397 www.Factoryfive.Com 508-291-3443 rear: using tubular control arms with polyurethane bushings helps to locate the solid axle and hook up better on the drag launches..

  • Page 399

    398 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 400

    399 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 401

    400 www.Factoryfive.Com 508-291-3443 11.65” rear factory five performance 11.65” brake set (ffr#14834) or 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 ...

  • Page 402

    401 www.Factoryfive.Com 508-291-3443 baer brakes 602-233-1411 www.Baer.Com stainless steel brakes corporation 800-448-7722 www.Ssbrakes.Com disc brakes r’ us 888-558-5757 www.Discbrakesrus.Com afco racing products (supplier of cnc components) 812-897-0900 www.Afcoracing.Com mustang part’s specialtie...

  • Page 403

    402 www.Factoryfive.Com 508-291-3443 factory five aftermarket  breeze automotive - products, kits & parts to streamline ffr assembly. 508-533-6455. Www.Breezeautomotive.Com  ff metal - custom metal components for your ffr roadster. 703-550-2777. Www.Ffmetal.Com  finish line - large selection of v...

  • Page 404

    403 www.Factoryfive.Com 508-291-3443 please know that there is no connection between ffr and those outside shops. There are no authorized ffr dealerships, and we cannot recommend any of the particular businesses that are on our lists, nor do we warrantee their work. They are provided simply to help ...

  • Page 405: Appendix A – Templates

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

  • Page 406

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

  • Page 407

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

  • Page 408

    407 www.Factoryfive.Com 508-291-3443 ji a coupe tail light template u se a l ev e l o n t his line 7 .50 " t o o ute r e dge of bo dy 7 .3 75 " to o ut er e dg e of body w ei g h t : 13022 proprieta ry a n d c on f iden tia l the in f or m ation con tain ed in this d r awin g is the sole pr oper ty ...

  • Page 409

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

  • Page 410

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

  • Page 411

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

  • Page 412

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

  • Page 413

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

  • Page 414

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

  • Page 415

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

  • Page 416

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

  • Page 417

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

  • Page 418

    417 www.Factoryfive.Com 508-291-3443 ffr coupe donor parts from ford mustang 5.0, 1987 to 1993 efi removed assembly name part name qty only from donor drivetrain clutch cable and circlip 1 engine, 5.0l ford 1 bellhousing w/ mount bolts 1 t-5 transmission w/ mount bolts 1 transmission mount w/mount b...

  • Page 419: Brakes

    418 www.Factoryfive.Com 508-291-3443 appendix c – optional rear disc brakes.

  • Page 420

    419 www.Factoryfive.Com 508-291-3443 11.65” rear brakes installation instructions revision: c  these instructions apply to any 1986-2004 ford mustang 8.8 rear axle with traction-lok differential (ffr#s 14319,14970) using 1994-2004 oem mustang style disc brakes (ffr#s 14834, and 14903).  the instal...

  • Page 421

    420 www.Factoryfive.Com 508-291-3443 instructions place the caliper “c” shaped caliper axle mount bracket over the axle so that the open part of the bracket is facing down..

  • Page 422

    421 www.Factoryfive.Com 508-291-3443 insert the caliper axle mount bracket bolts from the outside in. Torque the caliper bracket to 45-50 ft-lbs..

  • Page 423

    422 www.Factoryfive.Com 508-291-3443 insert the caliper mount bracket bolts from the outside in through the four remaining bracket holes. Slide the caliper mount bracket onto the four bolts..

  • Page 424

    423 www.Factoryfive.Com 508-291-3443 torque the mounting bolts to the same 45-50 ft-lbs. Next install the brake rotor using one lug nut to hold it in place. Make sure to clean the surface of the rotor with brake parts cleaner before installing the caliper..

  • Page 425

    424 www.Factoryfive.Com 508-291-3443 put the brake pads in the caliper by pushing down on the pad to compress the wire springs on the top of the pad, and then slide them into the slots in the caliper bracket. When installing the caliper make sure that the brake fluid bleed screw is on the top side o...

  • Page 426

    425 www.Factoryfive.Com 508-291-3443 make sure the caliper bracket is centered over the rotor then check to see if a spacer is needed between the caliper bracket and the caliper mount bracket or between the two brackets. If needed remove the caliper and slide the shim onto the bolt..

  • Page 427

    426 www.Factoryfive.Com 508-291-3443 recheck the clearance between the caliper bracket and rotor. Tighten and torque the two 12mm mounting bolts to 55ft/lbs using a 16mm socket..

  • Page 428

    427 www.Factoryfive.Com 508-291-3443 if not already done, fill the rear axle with fluid and seal the cover with rtv silicone. Torque specifications: fastener torque (ft./lbs.) differential pinion shaft locking bolt 15-30 banjo bolts 30-40 wheel nuts 85-105 axle adapter/rearbacking plate bolts 45-50 ...

  • Page 429

    428 www.Factoryfive.Com 508-291-3443 appendix d – different donor vehicles.

  • Page 430

    429 www.Factoryfive.Com 508-291-3443 we highly recommend not using these different donor cars for the average build. This list will help with those parting out individual items, and possibly for those not using all of the donor parts. 1982-1986 v8 donors  front brakes are 10” in diameter compared t...

  • Page 431

    430 www.Factoryfive.Com 508-291-3443  rear axle is 61.125” from hub to hub, where as the pre-93 donors were 59.25”. (a different wheel offset could be used to make up the difference).  front spindles are shorter (if you specify, we have brackets to make them work).  wiring harness will not work. ...

  • Page 432

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

  • Page 433

    432 www.Factoryfive.Com 508-291-3443 (all information is based on v8 ford mustangs from 1979 to 1995) special version mustangs with specifications year & model engine hp torque rear susp. Transmission wheels 93' mustang cobra 302, 5.0l 235@4600 280@4000 solid axle t-5 17"x8" 93' mustang cobra "r" 30...

  • Page 434

    433 www.Factoryfive.Com 508-291-3443 front brakes 1987 to 1993 front rotors are 11” diameter, and use a 4.25” 4-lug bolt pattern. They use a cast iron single piston caliper. These rotors also contain the hub that carries the wheel bearings cast in as a one piece rotor/hub assembly (1982 lincoln cont...

  • Page 435

    434 www.Factoryfive.Com 508-291-3443 clutch cable, quadrant clutch cables and quadrants remain the same from 1982 to 1995. From 1996 to 2002 cables and quadrants changed. Speedometer cable from 1983.5 to 1993 mustangs used a mechanical speedometer with a cable which had a plastic gear c- clipped on ...

  • Page 436

    435 www.Factoryfive.Com 508-291-3443 remain very hot, and an average 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. Steering components power steering racks from 1987 - 2004 are mostly all 1...

  • Page 437

    436 www.Factoryfive.Com 508-291-3443 they are thicker and are designed for a smaller 10” rotor. To use them, one of the shims tack welded into the standard ifs bracket needs to be removed. Rear 4 link control arms upper control and lower control arms stay the same from 1979 to 1998. Front lower cont...

  • Page 438

    437 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 439

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

  • Page 440

    439 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...

  • Page 441

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

  • Page 442

    441 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 ...