Factory Five Racing Gen 3 Type 65 Coupe User manual

R E V I S I O N 4 B , O C T O B E R 2 0 1 7

2017 Factory Five Racing Inc.
9 Tow Rd
Wareham, MA 02571
Phone [phone] • Fax [phone]

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Contents
General Information................................................................11
Foreword .......................................................................................11
Safety Notice.................................................................................13
Safety Tips.....................................................................................15
How to use This Book....................................................................16
What you need for all kits ..............................................................16
Serial Number Identification ..........................................................18
Optional part Instructions...............................................................18
Tools List.......................................................................................19
Required Supplies.........................................................................20
Helpful Tools..................................................................................20
Donor Parts and Prep.............................................................21
The 5.0L Mustang..........................................................................22
Not using a donor..........................................................................22
Donor Parts Selection Tips............................................................23
87-93 Mustang........................................................................................23
Other Donor years...................................................................................23
Where to look..........................................................................................23
Price........................................................................................................24
Running Gear..........................................................................................24
Disassembly of a Mustang Donor for Parts ...................................25
Radiator/Cooling System ........................................................................26
87-93 Steering Rack ...............................................................................26
Engine Bay Sensors and Electrical Connections....................................27
Interior.....................................................................................................28
Computer ................................................................................................28
Turn Signal and Ignition Switches...........................................................28
Dash Wiring Harness..............................................................................29
Front Wiring Harness..............................................................................30
Speedometer sending unit......................................................................31
Shifter and Shifter handle .......................................................................31
Fuel Inertia cut-off switch........................................................................32
Rear and Transmission Wiring Harnesses .............................................32
Exhaust ...................................................................................................33
Engine Removal......................................................................................33

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Front Suspension....................................................................................34
Fuel Tank ................................................................................................35
Rear End.................................................................................................36
Fuel filter and connectors........................................................................37
Donor Part Preparation..................................................................37
Solid Axle................................................................................................37
Front Lower Control Arms.......................................................................39
Fuel Filter Fittings....................................................................................40
Fuel Tank ................................................................................................41
Fuel Filler Neck.......................................................................................41
Driveshaft................................................................................................41
Engine Preparation .................................................................................41
Alternate Drive Pulley Preparation..........................................................42
Steering Rack..........................................................................................43
Cleaning and Detailing ..................................................................43
Disassembly of the kit.............................................................45
Unpacking Your Kit........................................................................46
Kit Parts Prep ................................................................................46
Headliner and Optional Carpet......................................................46
Body Removal...............................................................................46
Area set-up....................................................................................49
Aluminum Prep and removal .........................................................49
Aluminum panel diagram...............................................................51
Chassis Assembly ..................................................................53
Steering Rack................................................................................54
Stock Mustang power steering rack prep ...............................................54
manual or optional power steering rack prep..........................................56
Steering rack install.................................................................................58
Front Suspension ..........................................................................60
Front lower control arm...........................................................................60
Front Coil-Over Shocks...........................................................................63
Front upper control arm ..........................................................................70
Pivot endplay...........................................................................................74
Adjusting the upper control Arm..............................................................74
Spindles ..................................................................................................75
IFS Bracket .............................................................................................79
Front Suspension Torque Specs Chart...................................................80
Steering Tie Rod Ends ..................................................................81
Front Brakes..................................................................................82
Donor Front Brakes.................................................................................82

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Complete kit Front Brakes ......................................................................82
Solid Axle Rear Suspension..........................................................92
Solid Axle Preparation ............................................................................92
4 Link Rear Suspension..........................................................................97
Optional 3-Link Rear Suspension ...........................................................97
Rear Coil-Over Shock Assembly ..........................................................101
Rear Axle installation ............................................................................103
4 link Rear Suspension Torque Specs Chart........................................109
Solid axle vent.......................................................................................111
3-link Panhard Bar Frame mount..........................................................111
Panhard Bar..........................................................................................114
3 link Rear Suspension Torque Specs Chart........................................115
Optional Independent Rear Suspension......................................116
Parts needed.........................................................................................116
Mustang IRS Specifications..................................................................117
Parts preparation...................................................................................117
Installation.............................................................................................126
Fluids.....................................................................................................145
Capacities .............................................................................................145
Alignment specs....................................................................................145
Torque Specifications............................................................................145
Optional IRS Brakes....................................................................146
Fuel System.................................................................................146
Frame prep............................................................................................146
Fuel filler neck.......................................................................................149
Fuel Pick-up ..........................................................................................152
Fuel Gauge Sender...............................................................................156
Fuel Tank install....................................................................................162
Fuel filler neck.......................................................................................164
Fuel filter ...............................................................................................165
Hard lines..............................................................................................168
Vent hose..............................................................................................171
Pedal Box....................................................................................172
Brake and clutch safety switch mounts.................................................172
Clutch Cable Quadrant .........................................................................175
Frame Installation..................................................................................177
Master Cylinders...................................................................................180
Balance Bar adjustment........................................................................183
Accelerator Pedal........................................................................184
OEM Mustang .......................................................................................184

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Complete kit Accelerator Pedal.............................................................185
Cockpit aluminum........................................................................190
Rivet Spacing Tool................................................................................190
Right footbox aluminum ........................................................................190
Left footbox aluminum...........................................................................194
Cockpit rear wall....................................................................................196
Cockpit floors ........................................................................................198
Drivetrain Install...........................................................................199
Frame prep............................................................................................200
Transmission prep.................................................................................200
Engine Prep ..........................................................................................202
Engine/Transmission Installation ..........................................................206
Transmission Mount....................................................................208
Engine ground.............................................................................209
Steering Shaft..............................................................................210
Upper Steering Shaft.............................................................................214
Clutch Cable................................................................................216
Accelerator Cable........................................................................219
87-93 5.0L Fuel Injected Applications...................................................219
Carbureted applications........................................................................220
Cable adjustment..................................................................................221
Brake System..............................................................................221
Left front................................................................................................223
Front right..............................................................................................226
Rear brake line......................................................................................228
Stock rear brakes..................................................................................229
IRS brakes ............................................................................................230
Banjo bolt torque specs ........................................................................232
Brake reservoir and hose......................................................................232
Emergency Brake........................................................................238
E-brake Handle .....................................................................................238
Cables...................................................................................................249
Handle and Cable Adjustment ..............................................................257
Battery Mounting and Cable........................................................260
Battery tray............................................................................................260
Battery cable.........................................................................................265
Oil Filter Relocator.......................................................................267
Aluminum panels.........................................................................267
Firewall..................................................................................................267
Trans tunnel top front............................................................................269

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Wiring harness.............................................................................270
Complete Kit Chassis wiring harness ...................................................270
LED Flashers...............................................................................271
1987-1993 Mustang Donor Harness.....................................................272
Speedometer Sending Unit .........................................................281
Horns...........................................................................................283
Fan Wiring.............................................................................................289
Driveshaft ....................................................................................291
Solid axle...............................................................................................292
2015 IRS ...............................................................................................293
Cooling System ...........................................................................293
Aluminum Duct......................................................................................294
Fan Mounting ........................................................................................295
Radiator Mounting.................................................................................296
Radiator Hoses .....................................................................................298
Overflow Tank.......................................................................................303
Aluminum panels.........................................................................306
Trans tunnel sides aluminum................................................................306
Transmission Tunnel Cover..................................................................307
Cockpit rear inside aluminum................................................................307
Left outside footbox aluminum..............................................................309
Left door hinge inside covers................................................................310
Hatch floor.............................................................................................310
Under door aluminum............................................................................313
Exhaust .......................................................................................314
Headers and J-pipes.............................................................................314
Side Exhaust.........................................................................................317
Seats Harness.............................................................................317
Seats...........................................................................................321
Nameplate...................................................................................322
Gauges and Dash........................................................................323
Steering Wheel............................................................................327
Rolling Chassis Check.................................................................329
Front Suspension..................................................................................329
IRS Axle Nuts........................................................................................329
Wheels ..................................................................................................330
Fluid Levels and Grease.......................................................................330
Rattle Patrol ..........................................................................................333
Footbox Fitment....................................................................................334
Body Section ........................................................................335

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Frame preparation.......................................................................336
Rear body mount.........................................................................338
Body Mounting.............................................................................338
Locating.................................................................................................340
Rear body mount...................................................................................343
Side body cuts.......................................................................................346
Nose Hinge..................................................................................347
Nose fitment ................................................................................350
Nose gas Struts.....................................................................................352
Nose Side Locator Brackets .................................................................359
Hatch Hinge.................................................................................359
Hatch Struts ..........................................................................................368
Hatch Latch...........................................................................................370
Rear Spoiler.................................................................................375
Body Cut-outs..............................................................................376
Fuel filler................................................................................................376
Tail light.................................................................................................378
License plate bracket............................................................................380
License plate light .................................................................................381
Turn Signal............................................................................................384
Headlights .............................................................................................385
Side Mesh/Nose latch...........................................................................390
Nose Latch............................................................................................392
Radiator Exit opening............................................................................395
Side exhaust .........................................................................................395
Door hinge.............................................................................................398
Door hinge...................................................................................404
Door frame prep ..........................................................................407
Latch .....................................................................................................408
Doors...........................................................................................413
Trimming...............................................................................................414
Door frame install..................................................................................416
Inside door handle.................................................................................424
Door Striker...........................................................................................427
Nose Scoops (Optional) ..............................................................429
Final Prep....................................................................................430
Body Painting ..............................................................................434
Final Assembly .....................................................................435
Emergency Brake Boot................................................................436
Shifter Handle and Boot ..............................................................436

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Headlights ...................................................................................440
Turn Signals ................................................................................445
Headlight Covers.........................................................................448
Tail lights .....................................................................................454
License plate bracket...................................................................460
License plate light........................................................................460
Gas Cap ......................................................................................461
Nose side mesh...........................................................................464
Rear mesh...................................................................................466
Headliner.....................................................................................467
Final Body Mounting....................................................................476
Nose mounting......................................................................................476
Door and Latch mount ..........................................................................477
Windshield Mounting.............................................................................477
Windshield...................................................................................477
Hatch side aluminum...................................................................479
Fuel Filler Neck............................................................................481
Aluminum ....................................................................................485
firewall extension...................................................................................486
Cockpit outside corners ........................................................................488
Outside nose mount cover....................................................................489
Inside shock tower cover ......................................................................490
Fuel tank access covers .......................................................................491
Hatch area rear wall..............................................................................492
Rear hatch final ...........................................................................494
Interior Rearview Mirror...............................................................496
Side Mirror...................................................................................496
Light wiring ..................................................................................501
Check straps................................................................................502
Steering wheel center section......................................................504
Rear Quarter side windows .........................................................507
Side Exhaust ...............................................................................510
Aluminum Splash guards.............................................................511
Front wheel, rear inside ........................................................................512
Front wheel rear lower ..........................................................................512
Front upper splash panels ....................................................................514
Rear Wheel...........................................................................................515
Carpet (Optional).........................................................................516
Finishing Touches .......................................................................521
Headlight Alignment..............................................................................521

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Alignment Specifications.......................................................................522
Optional Parts..............................................................................524
Performance Reference Material and Technical Support......525
Maintenance................................................................................526
Wheels and Tires.........................................................................526
Wheel specifications .............................................................................526
Performance Modifications..........................................................528
Gears ....................................................................................................528
EFI Engines...........................................................................................529
Oil Cooler ..............................................................................................530
High Horsepower Transmissions..........................................................530
Steering Rack........................................................................................531
High Performance Manual Braking Systems...............................531
Miscellaneous Brake Information..........................................................531
Superchargers.............................................................................531
Seats...........................................................................................532
Helpful Reference Material..........................................................532
Must Reads...........................................................................................532
Helpful...................................................................................................532
Catalogs/Parts.......................................................................................533
Factory Five Aftermarket.......................................................................533
Tools .....................................................................................................533
Insurance ..............................................................................................533
A Final Note about Completed Cars and Car Builders ................533
Appendix A –Templates.......................................................534
Appendix B –Donor Parts List..............................................539
Appendix C –Race / Yearly check sheet..............................541
Appendix D –Torque Specifications.....................................544
General Bolt torque specifications*..............................................545
Appendix E –Mustang Specifications...................................546
Special Version Mustangs with Specifications......................................547
Engine...................................................................................................547
Transmission.........................................................................................547
Rear Axle Ratio.....................................................................................548
Oxygen Sensors....................................................................................548
Exhaust headers...................................................................................548
Steering components............................................................................549
Appendix F –Fluid Specifications.........................................550