Factory Five Racing Mk4 Roadster User manual

R E V I S I O N 4 L , 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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Table of Contents
General Information..................................................................8
Foreword .........................................................................................8
Safety Notice.................................................................................10
Safety Tips.....................................................................................12
How to use This Book....................................................................13
What You Get................................................................................13
What You Need.............................................................................14
Serial Number Identification ..........................................................16
Optional part Instructions...............................................................16
Tools List.......................................................................................17
Required Supplies.........................................................................18
Helpful Tools..................................................................................18
Disassembly of the kit.............................................................19
Unpacking Your Kit........................................................................20
Kit Parts Prep ................................................................................20
Carpet and Dash ...........................................................................20
Body Removal...............................................................................21
Aluminum Removal .......................................................................24
Chassis Assembly ..................................................................28
Rivet Spacing Tool ........................................................................29
Engine bay F panel aluminum.......................................................29
Front Suspension ..........................................................................32
Front lower control arm...........................................................................32
Front upper control arm ..........................................................................34
Pivot endplay...........................................................................................38
Adjusting the upper control Arm..............................................................38
Front Coil-Over Shock Assembly............................................................39
Spindles ..................................................................................................44
Front Suspension Torque Specs Chart...................................................47
Front Brakes..................................................................................48
Solid Axle Rear Suspension..........................................................58
Solid Axle Preparation ............................................................................58
3 Link Rear Suspension..........................................................................63
Rear Axle ................................................................................................66
Panhard Bar Frame mount .....................................................................69
Rear Coil-Over Shock Assembly ............................................................71
Panhard Bar............................................................................................78

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3 link Rear Suspension Torque Specs Chart..........................................79
Optional Independent Rear Suspension –Standard width............80
Parts needed...........................................................................................80
Mustang IRS Specifications....................................................................81
Parts preparation.....................................................................................81
Installation...............................................................................................90
Fluids.....................................................................................................110
Capacities .............................................................................................110
Alignment specs....................................................................................111
Torque Specifications............................................................................111
Optional IRS Brakes....................................................................112
E-brake cables ......................................................................................113
Wilwood brake routing ..........................................................................114
Wilwood e-brake adapter......................................................................115
Firewall & Driver Front Footbox Aluminum..................................116
Pedal Box....................................................................................118
Brake switch mount...............................................................................118
Clutch safety switch mount ...................................................................119
Clutch Cable Quadrant .........................................................................120
Clutch Quadrant stop............................................................................125
Frame Installation..................................................................................126
Master Cylinders...................................................................................129
Balance Bar adjustment........................................................................133
Accelerator Pedal........................................................................134
Steering System..........................................................................138
Steering Rack........................................................................................138
Steering Shaft .......................................................................................143
Upper Steering Shaft.............................................................................148
Cockpit Aluminum........................................................................150
Passenger Footbox...............................................................................151
Passenger Floor....................................................................................156
Driver Floor ...........................................................................................158
U-Joint Cover ........................................................................................160
Transmission Tunnel rear corners ........................................................161
Cockpit rear corners..............................................................................162
Fuel System.................................................................................162
Frame prep............................................................................................162
Fuel Tank Vent......................................................................................165
Fuel Pick-up ..........................................................................................168
Fuel Gauge Sender...............................................................................173

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Fuel filler neck.......................................................................................175
Fuel tank install.....................................................................................177
Fuel filter ...............................................................................................179
Hard lines..............................................................................................182
Brake System..............................................................................186
Brake reservoir......................................................................................186
Front flexible brake lines.......................................................................193
Hard brake lines....................................................................................197
Banjo bolt torque specs ........................................................................206
Chassis wiring harness................................................................207
Trunk Aluminum ..........................................................................207
Cockpit rear wall..........................................................................211
Battery Mounting and Cable........................................................212
Drivetrain Install...........................................................................219
Transmission Prep................................................................................219
Engine Prep ..........................................................................................220
Engine/Transmission Installation ..........................................................225
Engine Ground ............................................................................226
Transmission Mount....................................................................227
Driveshaft ....................................................................................229
Solid axle...............................................................................................230
2015 IRS ...............................................................................................231
Headers and J-pipes ...................................................................231
Fuel line to engine.......................................................................233
Oil Filter Relocator.......................................................................234
Clutch Cable................................................................................235
Accelerator Cable........................................................................237
87-93 5.0L Fuel Injected Applications...................................................237
Carbureted applications........................................................................239
Interior Fitment......................................................................................240
Engine Wiring..............................................................................241
Cooling System ...........................................................................243
Fan Mounting ........................................................................................244
Radiator Mounting.................................................................................245
Stainless Radiator Hoses......................................................................247
Overflow Tank.......................................................................................252
Fan Wiring.............................................................................................256
Speedometer Sending Unit .........................................................256
Emergency Brake........................................................................258
E-brake Handle .....................................................................................258

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Cables...................................................................................................273
Handle and Cable Adjustment ..............................................................276
Axle and Fuel Tank Vents ...........................................................279
Aluminum panels.........................................................................281
Transmission Tunnel Cover..................................................................281
Driver Footbox Side Aluminum .............................................................282
Seats...........................................................................................283
Nameplate...................................................................................285
Gauges and Dash........................................................................286
Horns...........................................................................................296
Steering Wheel............................................................................302
Rollbar.........................................................................................304
Rolling Chassis Check.................................................................309
Front Suspension..................................................................................309
Fluid Levels and Grease.......................................................................309
IRS Axle Nuts........................................................................................312
Wheels ..................................................................................................313
Rattle Patrol ..........................................................................................313
Footbox Fitment....................................................................................314
Driver Footbox Aluminum............................................................316
Body Section ........................................................................318
Frame preparation.......................................................................319
Mounting the Body.......................................................................321
Rear Quick Jacks..................................................................................321
Front Quick Jacks/Front mounts...........................................................324
Hood............................................................................................327
Fitment and bumpers............................................................................327
Hood Hinge...........................................................................................331
Hood Handles .......................................................................................339
Hood Scoop.................................................................................344
Windshield...................................................................................350
Doors...........................................................................................352
Door Latch...................................................................................357
Trunk...........................................................................................360
Trunk Hinge...........................................................................................361
Trunk Latch...........................................................................................363
Body Stripes/centerline................................................................373
Body Cut-outs..............................................................................374
Fuel filler................................................................................................374
Tail light.................................................................................................378

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Turn Signal............................................................................................379
License plate light .................................................................................381
Side exhaust .........................................................................................385
Headlights .............................................................................................386
Side louver ............................................................................................389
Hood......................................................................................................391
Roll bar..................................................................................................401
Final Prep....................................................................................410
Body Painting ..............................................................................412
Final Assembly .....................................................................413
Radiator Aluminum......................................................................414
Carpet..........................................................................................422
Seats Harness lap belt ................................................................429
Emergency Brake Boot................................................................431
Seat Final Install..........................................................................433
Seat Harness Shoulder Belts.......................................................433
Shifter Handle and Boot ..............................................................437
Headlights ...................................................................................440
Turn Signals ................................................................................446
Tail lights .....................................................................................447
Gas Cap ......................................................................................448
Side Louvers................................................................................451
Weatherstripping .........................................................................453
Final Body Mounting....................................................................456
Quick Jack Mounting.............................................................................456
Hood mounting......................................................................................457
Rollbar mounting...................................................................................458
Door and Latch mount ..........................................................................459
Windshield Mounting.............................................................................460
Fuel Filler Neck............................................................................461
Fuel tank access covers..............................................................463
Final Trunk Mounting...................................................................464
Interior Rearview Mirror...............................................................466
Side Mirror...................................................................................470
Light wiring ..................................................................................475
Check straps................................................................................476
Under door Aluminum..................................................................479
Steering wheel center section......................................................480
Side Exhaust ...............................................................................482
Aluminum Splash guards.............................................................487

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Front Wheel...........................................................................................488
Rear Wheel...........................................................................................491
Finishing Touches .......................................................................493
Headlight Alignment..............................................................................494
Alignment Specifications.......................................................................495
Optional Parts..............................................................................497
Performance Reference Material and Technical Support......498
Maintenance................................................................................499
Wheels ........................................................................................499
1994-1998 rear end...............................................................................500
1999-2003 rear end...............................................................................501
Performance Modifications..........................................................501
Gears ....................................................................................................501
EFI Engines...........................................................................................502
Oil Cooler ..............................................................................................503
High Horsepower Transmissions..........................................................503
Steering Rack........................................................................................503
High Performance Manual Braking Systems...............................503
Miscellaneous Brake Information..........................................................504
Superchargers.............................................................................504
Seats...........................................................................................504
Helpful Reference Material..........................................................505
Must Reads...........................................................................................505
Helpful...................................................................................................505
Catalogs/Parts.......................................................................................505
Factory Five Aftermarket.......................................................................505
Tools .....................................................................................................505
Insurance ..............................................................................................505
A Final Note about Completed Cars and Car Builders ................505
Appendix A –Templates.......................................................507
Appendix B –Race car check sheet .....................................518
Appendix C –Torque Specifications.....................................521
Appendix D –Fluid Specifications.........................................522

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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 have
completed this
undertaking with
us. The lessons learned
here are important and
will hopefully help
with your decisions as
well as with the project
and the completed car.
First of all, the idea of
building your own car
is NOT for
everyone. It is a
serious endeavor that should be undertaken with care and consideration. The
desire to build your own custom car goes way back. It is part of our uniquely
American car-centric culture, and those who build their own cars are at the
very center of this. Since the earliest days of Hot Rodding, literally tens of
thousands of people have built their own cars. Even more have done
restorations and major customizations to existing cars. As fun as this project
is, a person should be candid about their abilities turning a wrench. This is
not a place for novices. That is even truer in racing, where danger and risk are
Chapter
1
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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 logic, common sense,
forethought, vast amounts of hard work, and a fanatic dedication to the task at
hand”.
Carroll Smith
“Prepare to Win”
I can’t think of anything more appropriate to say about the right way to
approach the serious work of building your own car. Carroll passed away not
too long ago, but his accomplishments behind the Ford Lemans victories and
his contributions to the motorsports community continues in his writings that
are all at the top of my list of recommended readings for the car builder or
racer.
After being honest about the skills, responsibility, and dedication required to
build a car, I feel the need to talk about the PROCESS of building a car in an
equally candid manner.
The process of building a car is a lot like the process of having kids. As a
matter of fact, it’s absolutely the best analogy I can find (apologies in
advance to all of you without kids, try and bear with me). Both things are
easy to get started. With a car project you order a manual, talk to car guys,
get all excited over glossy photos and perhaps order a kit from us. With the
whole pregnancy thing, well for most folks that’s even easier to get started…
When my wife was pregnant with our first daughter I was sure we would
never have any more children. From the swollen ankles to the morning
sickness, to the delivery room scene from the movie “Alien”, the whole
process was difficult, and while she didn’t complain too much thru the nine
months, it was obviously hard work. Another thing, she wouldn’t have been
the best salesman for others considering getting started on the baby thing.
When it comes to the car project, once the kit arrives and the process begins
it is much the same as pregnancy. Frankly the degree to which a person
breezes thru the project or languishes is commonly a factor of skill, but still,
building a car for anyone is a tough job and there are inevitably issues. How
many times have you gotten the wrong part at NAPA, gotten home to realize
the alternator has a six ribbed pulley not five…? You will meet challenges
building this car and you will be frustrated at times. Thankfully there are
internet discussion forums where you can vent your frustrations and complain
about the idiots who designed this kit. We smile when reading these posts
because we know that while the pregnant woman complains, the mother
loves her children in an unreasonable and perhaps even undeserved way!