Factory Five Racing Type 65 Coupe User manual

REVISION 3J, APR IL 2013

2013 Factory Five Racing Inc.
9 Tow Rd
Wareham, MA 02571
Phone [phone] • Fax [phone]

ii
www.factoryfive.com 508-291-3443
Tableof Contents
General Information.....................................................................................11
Foreword............................................................................................................ 11
Safety Notice...................................................................................................... 14
Safety Tips.......................................................................................................... 15
How to use This Book......................................................................................... 16
What You Get.....................................................................................................16
What You Need.................................................................................................. 17
Major Components.......................................................................................................17
Serial Number Identification................................................................................ 19
Tools List............................................................................................................20
Required Supplies.............................................................................................. 21
Helpful Tools....................................................................................................... 21
Donor Parts and Prep..................................................................................22
The 5.0L Mustang............................................................................................... 23
Not using a donor............................................................................................... 23
Donor Parts Selection Tips................................................................................. 24
87-93 Mustang .............................................................................................................24
Other Donor years........................................................................................................24
Where to look...............................................................................................................24
Price.............................................................................................................................25
Running Gear...............................................................................................................25
Disassembly of a Mustang Donor for Parts........................................................ 26
87-95 Brake Power Booster..........................................................................................27
87-93 Steering Rack.....................................................................................................27
Engine Bay Sensors and Electrical Connections...........................................................28
Interior..........................................................................................................................29
Pedal Box, Accelerator Pedal and Clutch Cable............................................................29
Computer.....................................................................................................................30
Turn Signal and Ignition Switches.................................................................................30
Dash Wiring Harness....................................................................................................31
Front Wiring Harness....................................................................................................32
Speedometer and Clutch Cables..................................................................................32
Shifter and Shifter handle.............................................................................................33
Emergency Brake Handle.............................................................................................33
Fuel Inertia cut-off switch..............................................................................................34
Rear and Transmission Wiring Harnesses....................................................................34

iii
www.factoryfive.com 508-291-3443
Exhaust........................................................................................................................35
Engine Removal...........................................................................................................35
Front Suspension .........................................................................................................36
Fuel Tank.....................................................................................................................37
Rear End......................................................................................................................38
Fuel filter and connectors..............................................................................................39
Donor Part Preparation....................................................................................... 39
Rear Coil Springs .........................................................................................................39
Solid Axle.....................................................................................................................40
Front Lower Control Arms.............................................................................................42
Fuel Filter Fittings.........................................................................................................43
Fuel Tank.....................................................................................................................43
Fuel Filler Neck ............................................................................................................44
Brake Pedal..................................................................................................................44
Accelerator Pedal.........................................................................................................45
Pedal Box.....................................................................................................................45
Wiring Harness.............................................................................................................46
Brake Power Booster Push-rod.....................................................................................47
Driveshaft.....................................................................................................................47
Engine Preparation.......................................................................................................47
Emergency Brake Handle.............................................................................................48
Alternate Drive Pulley Preparation................................................................................49
Steering Rack...............................................................................................................49
Cleaning and Detailing ....................................................................................... 50
Disassembly of the kit .................................................................................51
Unpacking Your Kit............................................................................................. 52
Body Removal....................................................................................................52
Aluminum Removal ............................................................................................ 53
Chassis Assembly.......................................................................................56
Rivet Spacing Tool ............................................................................................. 57
Front Suspension ............................................................................................... 57
Front lower control arm.................................................................................................57
Front upper control arm................................................................................................57
Pivot endplay................................................................................................................62
Adjusting the upper control Arm....................................................................................62
Front Coil-Over Shock Assembly..................................................................................62
Spindles.......................................................................................................................66
Front Suspension Torque Specs Chart.........................................................................71
IFS Bracket ..................................................................................................................71

iv
www.factoryfive.com 508-291-3443
Front Brakes.......................................................................................................73
Donor Front Brakes......................................................................................................73
Complete kit Front Brakes............................................................................................73
Solid Axle Rear Suspension...............................................................................82
Spring Perch mounts....................................................................................................86
4 Link Rear Suspension................................................................................................87
Optional 3 Link Rear Suspension..................................................................................87
Rear Axle installation....................................................................................................91
Optional Rear Coil-Over Shock Assembly.....................................................................94
Rear shocks.................................................................................................................99
4 link Rear Suspension Torque Specs Chart...............................................................101
Panhard Bar Frame mount .........................................................................................102
3 link Rear Suspension Torque Specs Chart...............................................................106
Optional Independent Rear Suspension – Standard width............................... 106
IRS Center Section.....................................................................................................107
Lower Control Arms....................................................................................................109
IRS Rear Coil-Over Shock Assembly..........................................................................111
CV Axles....................................................................................................................115
Spindles.....................................................................................................................115
Upper Control arms....................................................................................................116
Quad shock Installation ..............................................................................................117
Rear Calipers and Rotors...........................................................................................118
Width Adjustment .......................................................................................................118
Optional IRS Brakes......................................................................................... 120
Driver Front Footbox Aluminum........................................................................ 124
Pedal Box......................................................................................................... 125
Mustang Pedal Box ....................................................................................................126
Complete kit pedal box...............................................................................................129
Accelerator Cable............................................................................................. 145
87-93 Fuel Injected and Carbureted Applications........................................................145
Accelerator Pedal............................................................................................. 147
Complete kit Accelerator pedal...................................................................................147
Steering System............................................................................................... 151
Steering Shaft.............................................................................................................151
Steering Rack.............................................................................................................154
Upper Steering Shaft..................................................................................................159
Cockpit Aluminum............................................................................................. 161
Passenger Footbox ....................................................................................................161
Passenger Floor.........................................................................................................165

v
www.factoryfive.com 508-291-3443
Driver Floor ................................................................................................................167
U-Joint Cover.............................................................................................................168
Transmission Tunnel rear corners...............................................................................169
Cockpit rear wall.........................................................................................................169
Cockpit rear corners...................................................................................................170
Fuel System...................................................................................................... 170
Fuel Tank...................................................................................................................170
Fuel Filter...................................................................................................................174
Fuel Lines...................................................................................................................175
Brake System................................................................................................... 179
Manual Brake Master Cylinder and pushrod................................................................179
Front flexible brake lines.............................................................................................182
Hard brake lines.........................................................................................................183
Banjo bolt torque specs..............................................................................................188
Wiring Harness................................................................................................. 189
Rear Harness.............................................................................................................190
Transmission Harness................................................................................................191
Headlight Harness......................................................................................................192
Dash Harness.............................................................................................................192
Starter Solenoid..........................................................................................................193
Engine Harness..........................................................................................................196
Ignition and Turn signal stalk ......................................................................................199
Battery.............................................................................................................. 199
Mount.........................................................................................................................199
Battery Cables............................................................................................................201
Trunk Aluminum ............................................................................................... 202
Side Walls..................................................................................................................202
Rear Wall...................................................................................................................203
Floor...........................................................................................................................204
Drivetrain Preparation....................................................................................... 204
Aftermarket TKO 500 and TKO 600 prep....................................................................204
87-93 Alternate Drive Pulley.......................................................................................206
Engine/Transmission Installation...................................................................... 208
Driveshaft ......................................................................................................... 209
Fuel Lines to engine......................................................................................... 211
Clutch Cable..................................................................................................... 212
Complete kit Clutch Cable and Firewall Adjuster.........................................................214
Speedometer Sending Unit............................................................................... 215
Accelerator Cable............................................................................................. 217

vi
www.factoryfive.com 508-291-3443
Fuel Injected application.............................................................................................217
Carbureted applications..............................................................................................218
Mass air meter, Air filter and Intake hose......................................................... 219
Engine Ground ................................................................................................. 219
Fuel Vapor Canister.......................................................................................... 220
Cooling System ................................................................................................ 221
Fan Mounting.............................................................................................................221
Radiator Mounting......................................................................................................223
Radiator Aluminum.....................................................................................................225
Stainless Radiator Hoses............................................................................................228
Fan Wiring..................................................................................................................231
Emergency Brake............................................................................................. 234
Emergency Brake Boot...............................................................................................237
Interior Aluminum ............................................................................................. 238
Transmission Tunnel Cover........................................................................................238
Driver Footbox............................................................................................................240
Seats Harness.................................................................................................. 240
Shifter Handle and Boot ................................................................................... 243
Seats................................................................................................................ 247
Nameplate........................................................................................................ 249
Steering Wheel................................................................................................. 250
Rolling Chassis Check...................................................................................... 253
Front Suspension .......................................................................................................253
Fluid Levels and Grease.............................................................................................253
Rattle Patrol ...............................................................................................................257
Footbox Fitment .........................................................................................................257
Left footbox aluminum...................................................................................... 258
Body Section .............................................................................................259
Weatherstrip..................................................................................................... 260
Body Mounting.................................................................................................. 261
Tail lights....................................................................................................................263
Side Body Mounts......................................................................................................264
Body Cut-outs................................................................................................... 265
Fuel filler ....................................................................................................................265
Side exhaust ..............................................................................................................267
Radiator Exit opening.................................................................................................268
Turn Signal.................................................................................................................269
Headlights..................................................................................................................269
Side louver.................................................................................................................272

vii
www.factoryfive.com 508-291-3443
Hood Latch.................................................................................................................273
Nose Mounting ................................................................................................. 277
Hinge .........................................................................................................................277
Nose Side Locator Brackets........................................................................................282
Scoops ............................................................................................................. 283
Rear Spoiler...................................................................................................... 285
Radiator Aluminum........................................................................................... 286
Exhaust ............................................................................................................ 289
Headers .....................................................................................................................289
Side Exhaust..............................................................................................................290
Windshield area................................................................................................ 291
Doors................................................................................................................ 292
Door handle................................................................................................................294
Door hinge..................................................................................................................298
Striker Mounting.........................................................................................................303
Firewall Extension Aluminum............................................................................ 305
Side Windows................................................................................................... 307
Rear Quarter windows...................................................................................... 309
Rear Hatch....................................................................................................... 310
Hatch Latch striker......................................................................................................310
Hatch Hinge ...............................................................................................................312
Hatch Struts ...............................................................................................................317
Hatch .........................................................................................................................318
Final Prep......................................................................................................... 321
Body Removal .................................................................................................. 321
Headliner Fitting ............................................................................................... 321
Body Painting ................................................................................................... 322
Final Assembly..........................................................................................323
Headlights......................................................................................................... 324
Headlight Alignment ...................................................................................................329
Trim Ring ...................................................................................................................331
Turn Signals ..................................................................................................... 332
Headlight Covers.............................................................................................. 333
Gas Cap........................................................................................................... 334
Side Louver mesh............................................................................................. 337
Weatherstripping .............................................................................................. 339
Final Body Mounting......................................................................................... 339
Final Tail light install......................................................................................... 340
Side body mounts............................................................................................. 341

viii
www.factoryfive.com 508-291-3443
Fuel Filler Neck................................................................................................. 342
Nose mounting...........................................................................................................345
Door final fit ...................................................................................................... 346
Hinge .........................................................................................................................346
Door Weather-Stripping..............................................................................................346
Door...........................................................................................................................347
Handles......................................................................................................................348
Under door aluminum....................................................................................... 348
Rear front splash guards.................................................................................. 349
Headlight/Turn signal wiring ............................................................................. 350
License Plate Light and Bracket....................................................................... 351
Windshield........................................................................................................ 353
Final Hatch Mounting........................................................................................ 356
Dash and Gauges............................................................................................. 356
Dash ..........................................................................................................................356
Lower Switch Panel....................................................................................................360
Gauges ......................................................................................................................361
Interior Rearview Mirror.................................................................................... 368
Side Mirror........................................................................................................ 369
Check straps..................................................................................................... 374
Steering wheel center section........................................................................... 375
Side Exhaust .................................................................................................... 377
Aluminum Splash guards.................................................................................. 378
Front Wheel................................................................................................................378
Rear Wheel................................................................................................................382
Scoops ............................................................................................................. 383
Rear mesh........................................................................................................ 384
Finishing Touches ............................................................................................ 385
Alignment Specifications.............................................................................................385
Adjusting the upper control Arm..................................................................................386
Optional Parts................................................................................................... 386
Performance Reference Material and Technical Support.........................387
Wheels and Tires.............................................................................................. 388
Performance Modifications............................................................................... 390
Seats..........................................................................................................................390
Gears.........................................................................................................................391
EFI Engines................................................................................................................391
Throttle Body..............................................................................................................392
Mass Air Meter...........................................................................................................392

ix
www.factoryfive.com 508-291-3443
Fuel Injectors..............................................................................................................392
Upper Intake...............................................................................................................392
Heads.........................................................................................................................392
Cams .........................................................................................................................392
Headers .....................................................................................................................392
Timing........................................................................................................................393
Under-drive Pulleys....................................................................................................393
Oil Cooler...................................................................................................................393
Bellhousing.................................................................................................................393
High Horsepower Transmissions ................................................................................394
Steering Rack.............................................................................................................394
Spindles.....................................................................................................................394
Rear Suspension........................................................................................................395
Control Arms..............................................................................................................396
Shocks/Springs ..........................................................................................................398
High Performance Manual Braking Systems.................................................... 398
4-lug (4.25” pattern)....................................................................................................398
5-Lug (4.5”pattern)......................................................................................................399
IRS.............................................................................................................................400
Miscellaneous Brake Information...................................................................... 400
Helpful Reference Material............................................................................... 401
Must Reads................................................................................................................401
Helpful........................................................................................................................401
Catalogs/Parts............................................................................................................401
Factory Five Aftermarket.............................................................................................402
Tools..........................................................................................................................402
Insurance ...................................................................................................................402
Others........................................................................................................................402
A Final Note about Completed Cars and Car Builders ..................................... 402
Appendix A – Templates...........................................................................404
Appendix B – Donor Parts List..................................................................416
Appendix C – Optional Rear Disc Brakes.................................................418
Torque Specifications:................................................................................................427
Appendix D – Different Donor Vehicles ....................................................428
1982-1986 V8 Donors................................................................................................429
1982-1993 4 Cylinder Donors....................................................................................429
1994 and 1995 Donors...............................................................................................429
Appendix E – Mustang Specifications.......................................................431
Special Version Mustangs with Specifications.................................................. 432