SALEEN SPEEDLAB BODY KIT

Transcription

1 SALEEN SPEEDLAB BODY KIT INSTALLATION MANUAL: 2005 to 2009 Mustang 4.6 3V P/N: C11404D Saleen Performance, Inc East Maple Rd. Troy, MI

2 IF YOU ARE NOT EXPERIENCED IN THE AREA OF AUTOMOTIVE MECHANICS, WE STRONGLY URGE THAT YOU REFER THIS INSTALLATION TO A CERTIFIED INSTALLER OR TECHNICIAN 2

3 Saleen Speedlab Body Kit Installation Guide for 2005 to 2009 Mustang 4.6 3V WELCOME! Thank you for buying the Saleen Speedlab Body Kit for the '05 to '09 Mustang with the 4.6- liter, 3-valve motor. We appreciate your business, and we hope you enjoy your product. For your benefit, please read the following instructions completely and thoroughly before attempting to install the body kit. Many questions have been received from customers about the installation of our products could have been easily solved by information listed in the accompanying installation guide. We want you to enjoy the product in its fully functional state, and reading this tutorial is the first step to getting you on your way to a more rare and attractive Mustang. NOTE: Please keep all hardware you remove from your stock Mustang, as much of it will be reused to install the new body kit. YOU ARE RESPONSIBLE FOR PAINTING THE BODY KIT. SALEEN RECOMMENDS HIRING A PROFESSIONAL PAINTER WHO IS FAMILIAR WITH TPO PLASTIC, AND THAT YOU PAINT THE BODY KIT BEFORE ATTEMPTING ANY SUBASSEMBLY. IF YOU CHOOSE TO PAINT BODY PIECES BEFORE DOING SUBASSEMBLY OPERATIONS, LAY THE PAINTED PARTS ON A SOFT CLOTH DURING SUBASSEMBLY. IF YOU PAINT THE PIECES AFTER SUBASSEMBLY OPERATIONS, BE CAREFUL NOT TO SPRAY THE UNDERSIDE OF THE PARTS, ESPECIALLY WHERE TAPE IS USED; SPRAYING THE TAPE MAY DAMAGE THE BOND TO THE BODY PIECE, WHICH MAY CAUSE THE BODY KIT TO FALL OFF THE CAR A SHORT TIME AFTER INSTALLATION. Again, thank you for choosing Saleen! 3

4 Table of Contents I Front Fascia Removal..7 II Front Shroud Removal and Modification...10 III Rear Badge, Trunk Latch Cover and Brake Light Removal 11 IV Rear Fascia Removal 12 V Tail Lights Removal 15 VI Rocker Panels Removal VII Front Air Splitter Repositioning. 17 VIII Front Bumper Painting..19 IX Front Fascia Subassembly...20 X Front Turn Signal Harness Installation XI Front Turn Signal Bracket Modification. 27 XII Modified Front Shroud Installation XIII Front Fascia Installation XIV Rivnut Installation for Flip-down License Plate XV Rear Grille Appliqué and Tail Light Covers Subassembly.. 33 XVI Rear Fascia Subassembly XVII Rear Bumper Painting

5 Table of Contents cont d XVIII Rear Fascia Installation XIX Rocker Panels Subassembly XX Rocker Panels Installation XXI Three-Piece Rear Wing End Caps Subassembly XXII Three-Piece Rear Wing End Caps Hole Drilling...49 XXIII Three-Piece Rear Wing Center Support Installation...50 XXIV Center Spoiler Installation XXV Three Piece Rear Wing End Caps Installation...53 XXVI Third Brake Light Connector Replacement..55 XXVII License Plate Lights Harness Installation 57 XXVIII Third Brake Light and License Plate Lights Installation...59 XXIX Rear Grille Appliqué and Tail Light Covers Installation 60 XXX Door Cladding Subassembly XXXI Door Cladding Installation XXXII Flip-Down License Plate Installation

6 OBTAIN THE FOLLOWING TOOLS: ¼ drive ratchet ¼ drive socket ¼ drive standard sockets: ¼ ; 5/16 ; 15/16 ¼ drive 4 extension ¼ drive metric sockets: 5.5mm shallow wobbly ; 10mm ; 10mm shallow socket ; 11mm deep socket ¼ drive 8 extension 9/64 Allen wrench #4 Allen wrench Drill Metric drill bits: 6mm bit Standard drill bits: 1/8 bit ; 13/64 ; 3/8 ; 25/64 ; 7/16 Black touchup paint Wax and grease cleaner Glass cleaner Philips head screwdriver Heat Gun Electrical Tape Tin Snips Crimpers 10mm wrench CLEAR RTV Silicone Counter sink Rivet gun Rivnut gun 20 Oz. Pneumatic Gun (Cox Ltd.: Item# ) Glass & Pinchweld Primer (C.R. Laurence Co. Catalog.# PWR4P) High Viscosity Windhsield Adhesive (urethane); (C.R. Laurence Co. Catalog.# PWR615HV) Masking Tape 80 grit Sand paper AM902 or equivalent plastic prep and cleaner 3M Automotive adhesion promoter #06396 Razor blade ¾ Wide x 0.04 Thick Double Sided Tape, Clear (3M Vendor# 4910) Wire clippers Semi-flat black spray paint Panel Pullers Hack saw 6

7 I Front Fascia Removal Obtain the following tools: 10mm shallow wobbly socket, ¼ drive ¼ drive air ratchet Philips #2 socket, ¼ drive 8 extension, ¼ drive 5.5mm shallow wobbly socket, ¼ drive Order of Operations: 1. Turn the steering wheel all the way to the right (clockwise). Starting on the left side of the car remove the three screws from each wheel well using the short Phillips #2 ¼ drive with the ¼ drive air ratchet. See FIGURE 1 for location of screws. 2. Once the screws are removed, pull the fender liner out enough (see FIGURE 2) to insert a 10 mm shallow wobbly socket on an 8 extension. Use the ¼ drive air ratchet with the extension and 10mm socket to remove the two hex swivel nuts. Make sure to keep the hex swivel nuts because they will be used when installing the new fascia. FIGURE 3 is a different view of FIGURE 2 with the nuts removed. Figure 2 Figure 3 7

8 3. Underneath the front fascia in FIGURE 4, there are four screws that need to be removed. Use the ¼ drive air ratchet with a 5.5 mm shallow socket. 4. Remove the bolt shown in FIGURE 5. There are two of these bolts, one on each side of the car. Use the ¼ drive air ratchet with a 10 mm shallow wobbly socket. Keep these bolts as they will be reused in the new fascia. 5. Repeat steps 1 and 2 on the right side of the car, but turn the steering wheel all the way to the left. 6. Remove the fascia by placing the palm of your hand on the side of the front fascia (see FIGURE 6 for location) and push down until the fascia loosens. See FIGURE 3. Let the fascia sit on the front frame in order to disconnect harnesses. Figure 4 Figure 5 Figure 6 8

9 7. Disconnect the running lights, the fog lights, and the side markers. FIGURE 7 is the fog light connector and FIGURE 8 shows both the turn signal and side marker. FIGURE 9 shows a close up of the running/turn signal connector. Figure 7 Figure 8 Figure 9 9

10 II Front Shroud Removal and Modification Obtain the following tools: Panel puller Angle press or plastic cutters 1. Remove six Christmas trees (). Don t break the Christmas trees: save them, because they will be used in the reinstallation of the shroud. 2. Remove shroud. 3. Starting at front of shroud, cut in 1+1/8 as shown by vertical white lines in. 4. Starting at left of shroud, cut in 1+3/4 as shown by horizontal white line in ; repeat on right side. 1 1/8 1 3/4 Figure 2 10

11 III Rear Badge, Trunk Latch Cover and Third Brake Light Removal 1. With a piece of fishing wire, saw back and forth behind the Mustang badge located on the back of the trunk lid to remove the badge (Figure 1). 2. Carefully remove black plastic cover from the inside of the trunk lid. (Figure 2) There are two plastic plugs (Figure 3) which are inserted tightly into the metal of the trunk lid. The plastic cover is fragile, so be careful. 3. Disconnect wiring harness from trunk latch cover. (Figure 4) 4. Remove third brake light by squeezing on four clear plastic tabs (two of them are indicated in Figure 5). Figure 2 Figure 3 Figure 4 Figure 5 11

12 IV Rear Fascia Removal Obtain the Following Tools: Phillips head screwdriver 11 mm deep socket, ¼ drive Panel puller ¼ drive ratchet Order of operations: 1. Remove top two trees from trunk liner. () 2. Remove two lower trees inside trunk. (Figure 2: view from inside trunk, looking back to the rear of the car) 3. Remove liner from trunk. (Figure 3: view looking down into trunk, after all trunk liners - including the vertical plastic piece which covers the back of the trunk - have been removed). 4. Remove 4 nuts in little holes under trunk liner. (Figure 4) Figure 2 Figure 3 Figure 4 12

13 5. Remove the two screws in each wheel well (under the cut line for the front fascia) with the Phillips screwdriver. Note the picture is sideways, lower portion is rear wheels and arrows are pointing to rear of car. (Figure 5) 6. Remove all three Christmas trees on bottom of bumper. Note Figure 6 is taken from under the vehicle looking up. (Figure 6) 7. Pull out the left corner of the front fascia, then push away from the vehicle. Do the same on the right side. Do not completely pull the front fascia off until step 8 (Figure 7) * Make sure to pull the fascia off with care because the plastic tabs are fragile. Rear of car Figure 5 Figure 6 Figure 7 13

14 8. Disconnect light harness and the main support bracket (to which the harness is attached) inside the trunk (Figure 8: side view of the back of the trunk). KEEP THE HARNESS AND SUPPORT BRACKET BECAUSE YOU WILL REINSTALL THEM ON THE NEW REAR FASCIA. 9. Pull rear fascia straight off the car. (Figure 9) Figure 8 Figure 9 14

15 V Tail Lights Removal Obtain the Following Tools: ¼ drive ratchet 11 mm deep socket, ¼ drive Order of Operations: 1. Remove three 11 mm nuts. (Figure 1) 2. Pull out left tail light assembly (Figure 3). 3. Remove electrical plug from back of the light bulb that is nearest the center of trunk (see arrow in Figure 3). 4. Remove that light bulb and push plug back into the tail light assembly. Put tail light assembly back into place. 5. Repeat on right side. 6. Push tail light assembly back into place and secure by tightening three nuts. Figure 2 Figure 3 15

16 VI Rocker Panels Removal Obtain the Following Tools: Panel puller Order of Operations: 1. Remove 8 Christmas trees under rocker panel; keep all these for installation of the new rocker panels. (three of the push screws are indicated in ) 2. Remove two push screws from front wheel well. (Figure 2) Make sure to keep the push screws they will be reused. 3. Grab rocker panel firmly from rear wheel and pull down, then out away from the car 4. Figure 3 is a picture of the end result. Make sure to remove the eight white plastic clips from the rocker panel because they will be reused. Figure 2 Figure 3 16

17 VII Front Air Splitter Repositioning Part Number Description Qty C10013* Rivet Dome Std Blind 3/16"Dia Al-Al C10991C BRACKET DRIVER FRONT FASCIA C10992C BRACKET PASS FRONT FASCIA 1 Obtain the following tools: Screwdriver rivet puller Drill ¼ drive impact gun 5.5 mm socket, ¼ drive 5/16 socket, ¼ drive 1. Using the ¼ drive impact gun with the 5.5 mm socket, remove three 5.5mm screws from locations indicated in. Keep two of the screws; they will be reused. 2. Loosen the brackets on the front of the outer ends of the radiator with the 5/16 socket and ¼ drive ratchet. 3. Reposition the shroud so that the tabs shown line up with the front of the crossmember, as shown in Figure Drill out holes in shroud so that shroud can be screwed on to the bottom of the crossmember; attachment point for the crossmember is the slot indicated in Figure 3. Figure 2 Figure 3 17

18 5. Reattach shroud with two original screws (Figure 4). 6. Using two of the original screws that attached the stock brackets to the radiator (one on each side), attach two L-brackets, one to each side of the radiator, as shown in Figure Attach front of shroud to the bottom of the L-brackets with one rivet ( C10013*) on each side (Figure 6). Drill a hole for each bracket before installing the rivets. Figure 4 Figure 5 Figure 6 18

19 VIII Front Bumper Painting Obtain the following tools: Semi-flat black spray paint 1. Paint both front bumper mounts (Figure 3 shows the bumper mounts, which are located directly behind the bumper foam on the outboard ends of the bumper assembly). 2. Paint the front of the blue box that is mounted behind the passenger side front bumper mount (left arrow in Figure 3). 3. Paint the two lines that go across the front of the lower radiator (Figure 4). Minimize overspray onto radiator. 4. Paint center of frame member above radiator (). Do not paint over yellow part of hood release latch! 5. Paint both vertical structural pieces on either side of the radiator (Figure 2). Figure 2 Figure 4 Figure 3 19

20 IX Front Fascia Subassembly Part Number Description Qty C11462* Screw, Sheet Metal, Pan Head, #8, 3" Long 18-8 Ss C11463* Screw, Sheet Metal, Flat Head, #8 3.5" Long 18-8 Ss C10013* Rivet Dome Std Blind 3/16"Dia Al-Al C09563 Front Fascia C09876 Front Grille 05 Mustang C11452 Screen Mesh Front Fascia RH 05 S C11453 Screen Mesh Front Fascia LH 05 S C09763* Turn Signal, Front Fascia LH C09782* Turn Signal, Front Fascia RH C09988 Front Grille Badge 2005 S C11182* Screw Plastic Thrd Pan Hd Round Washer Blk Ox C11634* Screw Phil HD Flatp Top #4x3/8" Blck Oxide C11532 Turn Signal Light Spacer 3.178" Long C11533 Turn Signal Light Spacer 3.055" Long 2 Obtain the Following Tools: Wire clippers Drill 1/8 drill bit Masking tape ¾ x 0.04 Double sided tape, clear (3M Vendor# 4910) Philips head screwdriver Hack saw 20

21 Order of Operations: 1. Using a hack saw, cut off the bottom of the turn signal ¼ below the hole indicated in. Note the cut line shown in. 2. Tape the top of the turn signal ( C09763*) into place with masking tape in the orientation shown in Figure 2 (passenger light shown). The turn signals are directional, so put the light for the driver s side on the driver side; the surface of the turn signal must be flush with the contour of the fascia. (Figure 3). 3. Insert long spacer ( C11532A) on the inboard side and the short spacer ( C11533A) on the outboard side of the turn signal. The spacers go over the long screws ( C11463* and C11462*) (Figure 4). 4. Insert two screws (one of each length) into the two upper holes in the mini turn signal and tighten to the fascia. Be sure you hand-tighten the screws to a snug fit and DO NOT OVERTIGHTEN; you should have a 1/8 gap from the tip of the screw to the backside of the fascia when screws are fully tightened. (Figure 4) Hole Figure 2 Turn signal Spacers Figure 3 Figure 4 21

22 4. Tighten bottom of mini turn signal into place with bolt ( C11634*) Be sure you hand-tighten the screws to a snug fit and DO NOT OVERTIGHTEN; you should have an 1/8 gap from the tip of the screw to the backside of the fascia when screws are fully tightened (Figure 4) 5. Repeat steps 1-4 for passenger side turn signal ( C09782*). 6. Fit the screens to the left and right openings in the front fascia. With wire clippers, clip off any bits of the screen that are inhibiting a proper fit. A proper fit means that the screen tab and fascia tab are parallel, such that you can insert the small screws (Figure 6). 7. Hold screens in place with channel locks, and drill two holes in each fascia tab with a 1/8 drill bit. The holes should be ¼ in from each edge, centered on the tab (Figures 5,6) 8. Fasten screens with 2 screws ( C11182*) per tab. (Figure 6) Fascia tabs Figure 4 Figure 5 Figure 6 22

23 9. On passenger side, rivet side marker light bracket into place using existing holes and rivets ( C10013*) as shown in Figure 7. Repeat on driver side. 10. Insert tab on side marker light into the slot provided on the fascia. (Figure 9) 11. Secure each side marker by clicking outboard end into place over two white plastic clips on the side marker bracket (0) 12. Check that the hole in the fascia indicated in Figure 8 lines up with hole in side bracket; the wheel well screw will go in here on installation. Figure 7 Figure 8 Figure

24 11. Orient the grille as shown in Hand-fasten the grille with 10 screws ( C11634*) (2, 13). 13. Apply adhesion promoter onto the closed out rectangle of the grill. 14. Remove backing from badge. 15. Refer to 1. Grill badge is installed in the only closed out rectangle on grill (1). Center grill badge within rectangle. There should be a 1/8 gap forming a perimeter between the badge and the grill rectangle. Grill badge

25 X Front Turn Signal Harness Installation Part Number Description Qty B10316 Turn Signal Harness Drv./Pass Side C11337* CONNECTOR, 3 PIN FEMALE HSING 2 Obtain the Following Tools: Electrical Tape Wire cutters Heat gun Crimper Brown connector Order of Operations: 1. Locate the existing turn signal harness in front of the driver side front wheel well it is the brown connector indicated in. 2. Remove the pins from stock 3-pin connector. () Using a pick, pull the plastic wedgelock out of the inside of the connector the wedgelock is gray. Figure 2 shows the connector with the wedgelock, Figure 3 shows the connector without the wedgelock. 3. The wedgelock is removed in order to remove the wire terminals from the connector so you can insert the wire terminals into the new connector. 4. Note the color of each wire and the pin it is connected to; the wires will go into pins of the same numbers in the new connector. 5. Once the wedgelock is out, CAREFULLY remove the wire terminals. Figure 2 Figure 3 25

26 6. The wedgelock in the new black connector must be pulled out in order to insert the pins; the wedgelock here is white. Figure 4 shows the new 3-pin turn signal connector. Use a pick and press the tab in order to release the wedgelock. 7. The two connectors have the same pin ID numbers: 1, 2, and 3. The wire terminal goes into the same pin in the new connector as in the stock connector. 8. Insert the terminals into the pin locations, which are on the opposite end of the connector from the white wedgelock. The pins will click when properly set into the new black 3-pin connector. 9. When all the pins are in place, push the wedgelock back into place until it clicks. 10. Figure 5 shows the finished product. 11. Plug the three-pin connector from the new turn signal harness ( B10316) into the driver side connector that was just attached to the stock harness. (Figure 6) 12. Zip tie the harness onto the underbody. 13. Repeat the operations on the passenger side with the passenger side connector ( C11653). Tab to release the wedgelock Figure 4 Figure 5 Figure 6 26

27 XI Front Turn Signal Bracket Modification Obtain the Following Tools: 10 mm socket, ¼ drive 8 Extension, ¼ drive Band saw Calipers Order of Operations: 1. Remove bolts from the bracket with a ¼ drive ratchet with a 10 mm socket and an extension. Do not throw away hardware; it will be used to reinstall the brackets. (Figure 1) 2. Each bracket is still held in place by one press-release tab. Locate these tabs through the front of the engine bay and squeeze gently with needle nose pliers while pulling the bracket forward. The tab may break; however, the part may still be used. 3. Measure 1 3/8 down from the top of the bracket (Figure 3). From this height, you will make a cut into the bracket (cut A ). 4. Make cut A 1 7/8 deep, measuring from the center of the top bolt-hole (bolt-hole shown in Figure 2; cut shown in Figure 3). 5. After cut A is made, make cut B vertically straight down through the bracket (). Deburr edges after cutting!! 6. Reinstall brackets with stock hardware. Bolthole, step 4 Figure 2 1 3/8 A B 1 7/8 Figure 3 27

28 XII Modified Front Shroud Installation Order of Operations: 1. Reinstall shroud with six stock Christmas trees. (FIGURE 1) 28

29 XIII Front Fascia Installation Part Number Description Qty C11967* Weather stripping 3 ft. Obtain the Following Tools: 10mm socket, ¼ drive ¼ drive air ratchet Short Philips head screwdriver 5.5mm shallow wobbly socket, ¼ drive Order of Operations: 1. Remove the backing from the adhesive on the weather stripping ( C11967*), and place along the outboard, inboard, and bottom edges of each headlight (). 2. Obtain the assembled and painted front fascia. 3. Line the fascia up with the front of the car. Let the fascia rest on the front bumper. 4. On the passenger side, plug in the connector for the wiring harness for the side marker lamp (Figure 2) and the two harness connectors for the mini turn signal lamp (Figure 3). Repeat on driver side. 5. Line up the top mounts of the fascia with the bolt holes on either side of the grille (Figure 4). 6. Secure fascia with the two stock 10mm bolts using the 10mm socket and ¼ drive ratchet (Figure 4). Figure 2 Figure 3 Figure 4 29

30 7. Line up the holes in the tab on the inboard side of the fascia with the bolts hanging from the car body underneath the passenger side front quarter panel (Figure 5). 8. Use the two stock nuts and a 10mm socket with 8 extension on a ¼ drive air ratchet to secure the passenger side of the fascia. 9. Repeat steps 6 and 7 on the driver side. 10. Underneath the front fascia in Figure 6, there are four screws that need to be put back in (two in the center, and one on each side of the car). Use the ¼ drive air ratchet with a 5.5 mm shallow socket. 11. Reattach the wheel well liners using the three stock screws. Make sure to plate the fender liner behind the fascia. Use the ¼ drive air ratchet and the Philips #2 drill bit. (Figure 7). 12. Replace the front shroud, which was removed and modified on page 10. Secure shroud with the original 6 Christmas trees. Figure 5 Figure 6 Figure 7 30

31 XIV Rivnut Installation for Flip-down License Plate Part Number Description Qty C08604* Rivnut 1/4-20 knurled st 2 Obtain the Following Tools: Drill 25/64 drill bit Rivnut gun Order of Operations: 1. Mark two holes for the rivnuts. Make sure the holes are 11 3/8 in from either end of the bottom rear portion of the deck lid (the section below the center spoiler mount) deck lid end, 1 ½ above the bottom of the lid; most importantly, the hole centers must be 7 ½ apart. (). 11 3/8 7 ½ 11 3/8 1 ½ 31

32 2. Drill the two holes with the 25/64 bit. () NOTE: If you do not have a rivnut gun, you can borrow one from your local tool lending service; many Auto Zone locations provide this service. 3. Place the two rivnuts ( C08604*) into the holes on the back of the vehicle where the GT emblem went. Figure 2 Screw the rivnut onto the rivnut gun. Insert in the hole and squeeze rivnut gun handle until the rivnut is firmly attached. The rivnut should sit flush and level with the surface of the trunk lid; it should not be tilted. (Figure 2) Figure 2 Existing holes 32

33 XV Rear Grille Appliqué and Tail Light Covers Subassembly Part Number Description Qty C09836B Rear grille 05 Mustang C09834B Tail light coverup LH C09835B Tail light coverup RH 1 Obtain the Following Tools: 80 Grit Sand Paper AM902 plastic prep and cleaner ¾ x 0.04 Double sided tape, clear 3M Automotive adhesion promoter #06396 Razor Blade Order of Operations: 1. Using the 80 grit sand paper rough up the locations indicated by Figure 2 (left and right tail light covers, C09834B and C09835B) and Figure 3 (rear grille, C09836B). Use the spray can (AM902) to clean those areas with paper towel. 2. Use 3M-adhesion promoter on the areas that were sanded. Remove protective red backing from one side of the double sided tape. Follow the patterns in Figures 2 and 3. Figure 2 Figure 3 33

34 XVI Rear Fascia Subassembly Part Number Description Qty C09574 Rear fascia cntr exhaust 05 Mustang C11454 Screen mesh rear fascia outside 05 S C11455 Screen mesh rear fascia center 05 S C10013* Rivet dome std blind 3/16"dia al-al C11634* Screw Phil HD flat TOP #4x3/8" blck oxide C11052 Bracket Rr fascia to wing end cap RH C11054 Bracket Rr fascia to wing end cap LH 1 Obtain the Following Tools: Rivet gun Tin snips 1/8 drill bit drill Order of Operations: 1. Using the rivet gun and two rivets per side ( C10013*), install C11052B on the top of the right side ledge of the rear fascia; install C11054B on the left side. (). 2. Have the unit painted. 3. Obtain the painted rear fascia. 34

35 4. shows the stock support beam and attached stock wiring harness installed. With bolts in the support beam facing away from the rear fascia (towards the interior of the car, if you were holding the rear fascia in its proper orientation up to the rear of the car), slide beam in from behind the four holes. There are four rivet locations along the beam and a set of two at each end. (Figure 2) 5. Once the rivets are in place, slide the two marker lamps (one per side) into their correct side. 6. Insert the stock side marker light by first inserting the tail end of the lamp and push the front of the light assembly into place. There will be a click. (Figure 3) 7. Connect the wire from the stock rear side marker light harness to the back of the side marker lamp. (Figure 4) 8. For better fitment, minor modifications of the screens may be necessary. Use wire cutters to trim increase the size of the tab cutouts or move any obstructive material. Figure 2 Rear of car Figure 3 35

36 8. Position screens so that the screen tabs line up with the fascia tabs. 9. Hold screens in place with clamps (Figure 5). 10. With a 1/8 drill bit, drill pilot holes for each of the screws. (Figure 6) 11. Fasten the screens in place with screws. (Figure 7) Use 2 screws ( C11634*) per tab. Fasten the screws as tight as you can without breaking them, so that they are not visible through the screens. 12. Fasten the center screen in the same way, using two screws ( C11634*) per tab. Figure 4 Figure 5 Figure 6 Figure 7 36

37 XVII Rear Bumper Painting Obtain the following tools: Semi-flat Black spray paint 1. Cover the tips of the exhaust pipes. 2. Paint rear bumper as shown in Figure Paint rear of gas tank (Figure 2). Figure 2 37

38 XVIII Rear Fascia Installation Obtain the Following Tools: ¼ drive air ratchet ¼ drive 4 extension ¼ drive 10mm socket ¼ drive 11 mm deep socket Phillips screw driver ¼ drive ratchet Order of Operations: NOTE: YOU MUST INSTALL THE NEW SALEEN EXHAUST BEFORE INSTALLING THE REAR FASCIA. THE STOCK EXHAUST DOES NOT FIT PROPERLY WITH THE SALEEN REAR FASCIA. 1. Remove the bolt that holds the bracket on each end of the back of the car, under the tail light, and expand the hole to the right so that the bracket can be slid to the left. The bracket should be repositioned so the farthest right point on the top (see arrow in Figure 2) lines up with the weld seam in the metal; the seam is indicated by the dashed lines in Figure 2. Figure 2 is a closeup of Figure Remove the tail lights if not already removed. Refer to page Put bumper close enough to the car so you can run the rear fascia harness through the factory hole. Make sure that you place the rubber grommet back in the hole. (Figure 4) 4. From the rear, slide the bumper onto the car; line up the 4 studs with their corresponding holes on the vehicle. (Figure 4) Figure 2 Figure 3 38

39 5. From the rear, slide the bumper onto the car; line up the 4 studs with their corresponding holes on the vehicle. (Figures 5,6) 6. On the sides, make sure the fascia is flush with the wheel well and that the holes in the front line up with the holes in the rear of the wheel well liners. A little force may be required. (Figures 5,7) 7. Screw in the two screws in each wheel well. (arrows in Figure 7) 8. Tighten the four nuts over the studs back in the trunk using the ¼ drive ratchet with 4 extension and 11 mm socket. These are take-off parts from the stock Mustang. The studs can be located through holes in the sheetmetal in the back of the trunk. 9. Inside the trunk plug the rear fascia harness back into the factory system. (Figure 8). Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 39

40 XIX Rocker Panels Subassembly Part Number Description Qty C11094 Perf scrn rocker 2005 S C09588 Body rockers LH 05 Mustang C11634* #4 screws for screens C09589 Body rockers RH 05 Mustang 1 Obtain the Following Tools: 80 grit Sand paper AM902 plastic prep and cleaner 3M Adhesion promoter #06396 ¾ Double sided tape, clear (8ft.) Razor blade Order of Operations: 1. IF the rocker panel is already painted, use paint thinner on the edge of the rocker panel as specified by the line in Figure 5, and along the top edge as shown in. 2. For all rocker panels, painted and unpainted, use sand paper to rough up the surfaces indicated in Figures 1 and 5. Use the spray can (AM902) and paper towels to clean those areas that were sanded. Make sure the area is dry before proceeding. Rough entire surface Figure 2 40

41 3. Use one swipe of 3M-adhesion promoter on the areas that were sanded. (Figures 2 and 4) 4. Apply double-sided tape to the top edge of the rocker panel; don t go over the top edge. Double over the tape where necessary to ensure a secure fit. Make sure that the tape is pressed against the ribbed edge. (Figure 3) 5. Install one rocker panel screen ( C11094) onto each opening on each rocker panel there will be two screens per rocker. Attach each screen with two screen screws ( C11634*). Figure 3 41

42 XX Rocker Panels Installation Part Number Description Qty C09588 Body Rockers LH 05 Mustang C09589 Body Rockers RH 05 Mustang C10219* Fastener Christmas Tree.276"-.286" Dia 2.73" C11424 Rocker Panel Spacer 1.5" Long C11425 Rocker Panel Spacer 1.75" Long C11426 Rocker Panel Spacer 2" Long 6 Obtain the Following Tools: Urethane gun (see p.6) Urethane primer (see p.6) 3M Automotive adhesion promoter #06396 High Viscosity Windhsield Area 1 Area 2 Adhesive (urethane; see p.6) Masking tape Order of Operations: 1. Clean the areas shown with a wet rag. () Figures 2 & 3 are close ups. Urethane below this line Urethane below this line Area 1 Figure 3 Area 2 Figure 2 42

43 2. Urethane primer must be applied to the car. The primer goes under the crease in the fenders. Refer to Figures 2 & 3. Refer to Figures 4 & 5 for finished product. Make sure to stop the primer ½ inch from each door jam. (Figure 6) Adhesive promoter above primer Figure 4 Adhesive promoter above primer ½ gap Figure 5 Figure 6 43

44 3. Remove the backing on the double-sided tape. Below the double-sided tape put a bead of urethane in the groove the runs the entire length of the inside of the rocker panel. Figure 7 shows the entire area and Figure 8 shows a close up of the amount of urethane used. Make sure the bead of urethane stands a quarter of an inch off the groove so it will reach the body panels; if the bead is not thick enough it will not adhere to the car. 4. First make sure all the stock Christmas trees are removed. (Figure 9) 5. Make sure the white clips (0) are secure in the rocker panel. If any of the brackets are loose place foam behind it to stiffen it up (1). 6. With the car door open, line up the white clips with the slots in the car. (2) You only need 5 clips from each old rocker panel (10 for the pair) to install the new one. (0) Figure 7 Figure 8 Figure

45 7. Gently tap the clips in place by hand. Then push the each side into place. (Figures 13 and 14). Make sure the gaps are even in each wheel well, and that the door does not hit the rocker when opened and closed. 8. Underneath the rocker panel there are eight attachment points; the first three are indicated in Obtain Christmas trees C10219* (eight per side). You will place spacers over each of the Christmas trees, and then install them into the locations indicated by 5. For the first three holes, obtain three spacers C11425 (1.8 ) and insert into the first three holes behind the front wheel. Spacers C11424 (1.5 ) go in the next two holes. Spacers C11426 (2.0 ) go in the last three holes. Push the Christmas trees until they are flush with the bottom of the rocker panel. 10. Secure rocker panel with masking tape while urethane dries. Leave masking tape on for at least 24 hours before removing. Allow the urethane to cure for 24 hours before pulling on it. Make sure to clean any residue off the car and the rocker panel. 3 4 Insert Christmas tree here

46 XXI Three-Piece Rear Wing End Caps Subassembly Part Number Description Qty C09728 Rear Quarter Panel Spoiler Extension LH C09729 Rear Quarter Panel Spoiler Extension RH C10779 Bracket Rear End Cap Spoiler 2005 S C10892* Rivet Blind 1/8x0.337" Lngth AL-AL 2 Obtain the Following Parts: Drill gun 3/8 and 1/8 drill bits Counter sink Rivet gun 1 ½ ¾ Order of Operations: 1. Using a 1/8 th inch drill bit, drill a hole ¾ from the inboard edge of the end cap and 1 ½ from the bottom edge of the top section (). 2. Use the countersink (Figure 2) to countersink the hole. Not too deep, just enough for the rivet to be flush with the surface, as shown in Figure Counter sink the hole by hand. (Figure 3) Figure 2 46

47 4. Stick the rivet in place and check the depth of the hole. Figure 4. Make sure the head is flat before continuing. 5. Place the bracket on the inside surface of the end cap. Align rivet, and the bracket with the hole in the end cap. Figure 5 6. Pull the rivet with a hand held rivet gun. Figure 6 Figure 3 Figure 4 Figure 5 Figure 6 47

48 7. Drill three 3/8 holes as shown. The top arrow in Figure 7 shows a hole that is centered with respect to the rectangular depression in the quarter panel extension; the bottom left arrow shows a hole centered the same way within its own rectangular depression. 8. The bottom right arrow in Figure 7 shows a hole centered vertically on the crossmember of the quarter panel extension, and the hole center is located one inch from the center of the hole that is on the left (1 hole center to hole center; see Figure 8, which is a close-up of Figure 7). Figure 7 Crossmember Figure 8 48

49 XXII Three-Piece Rear Wing End Caps Hole Drilling Part Number Description Qty C piece spoiler end caps hole template 1 Tools need: Drill 3/8 bit 7/16 bit 1/8 drill bit tabs *2 1. Use the provided template (P/N C11723) when making holes for attaching three piece spoiler. (). 2. Tape the templates into place. Make sure each guide lines up with the bodywork, (). Give special priority when lining up the small rounded corners (circled in Figure 1) of the paper jig. Note: the outer rectangles on the jigs are pointed out in. The tabs to be folded over. 3. Drill a 1/8 pilot hole in the top inboard hole and the two bottom holes. Note that the top outboard hole (this will be the top left hole on the driver side jig) is blacked out because the hole should not be drilled. 4. Use the 3/8 bit for the inboard top hole and 7/16 bit for the bottom two holes. () tabs 49

50 XXIII Three-Piece Rear Wing Center Support Installation Part Number Description Qty C10996 Spoiler Center Support C10936* Nut Nyloc M6 10mm Width 6mm Height C11723 Hole Pattern, Flat, S281 Rear Spoiler Assembly C11132* Washer, #10 ID 2 OD sealing neoprene 4 Tools need: Drill ¼ bit 13/64 bit CLEAR RTV Silicone Black touchup paint 1/4 ratchet 6mm socket, ¼ drive 1. Clamp paper hole guides for center spoiler to the deck lid. Make sure each guide is flush with respect to the end of the deck lid (Figure 4), and with hole from the third brake light (Figures 1, 4). 2. Give special attention when lining up the small rounded corners of the jig with their respect to the corners on the trunk. Note: the outer rectangles on the jig are to be folded over; 3. Drill holes on outer ends of the deck lid with ¼ bit (Figure 4). 4. There are two groups of four holes in the jig. The two holes (specified by box A in Figure 4) are for the spoiler mount, and the two holes on the two 13/64 holes specified as B in Figure 4 are for the center spoiler. Clear RTV Figure 2 50

51 4. Check to make sure the studs in the back of the mount line up with the holes specified as A in the template; adjust template for best fit. 5. Drill holes for center spoiler with 13/64 drill bit. (Figure 4) 6. Drill holes for center spoiler mount with ¼ bit. 7. Spray a bead of RTV CLEAR Silicone around the edges of the removed third stock brake light, as shown in. Wipe off excess RTV. 8. Slide the mount into place, so it is oriented as shown in Figure 3. Make sure holes in deck lid line up with open tabs in center support. 9. If the studs do not line up with the drilled holes, drill the holes out to accommodate the studs, but DO NOT EXCEED 7/16 in DIAMETER. 10. Secure mount with four M6 nuts ( C10936*), four washers ( C11132*) and a ¼ drive 10 mm socket (Figure 4). 11. Figure 3 shows the finished product. Figure 3 13/64 (B) ¼ A ¼ Figure 4 13/64 (B) 51

52 XXIV Center Spoiler Installation Part Number Description Qty C09730 Rear Spoiler 05 Mustang C10320* CAPSCRW SCKT HD 8-32x0.75 Bl Ox ST C10321* Nut 8-32 Tapped Hole C11921* Screw Phil HD FLATP Washer #8x3/4" Zn Pl St C11133* Tools need: ¼ drive ratchet ¼ drive 9/64 Allen socket Philips head screwdriver Drill Standard bits: 1/8 ; ¼ ; 7/6 ; 3/8 bit Washer 1/4"Id 2.75"Od 3/4" Sealing Neoprene- Bonded Galv St 4 1. Slide wing into place over the mount () 2. Drill 13/64 holes through the tabs in the inside of the spoiler to match the holes drilled in the back of the deck lid (Figure 3). 3. Line up center spoiler so the ends are flush with the deck lid. The top of the wing should also be flush with the top of the deck lid, and the bottom flush with the bottom of the section of the deck lid to which it is mounted line in Figure 5 denotes bottom edge of this section 4. Drill ¼ holes in the center spoiler to match the ¼ holes on the outer ends of the deck lid. 5. Pull the center spoiler away from the car. Insert a tapped hole nut ( C10321*) over each of the four 13/64 holes. 6. Using the 9/64 Allen tool, secure spoiler with four bolts ( C10882*) and four washers ( C11133*) in the four 13/64 holes. (Figure 2 shows one side of the trunk with the 2 passenger side bolts for the wing indicated by arrows). NOTE: You may need to expand holes to allow better fitment of spoiler. 7. Secure the outer ends of the spoiler with 2 screws ( C11921*) on each end. Figure 2 Figure 3 52

53 XXV Three Piece Rear Wing End Caps Installation Part Number Description Qty C10320* Capscrw Sckt HD 8-32x0.75 Bl Ox ST C09728 Rear Quarter Panel Spoiler Extension LH C09729 Rear Quarter Panel Spoiler Extension RH C10321* Nut 8-32 Tapped Hole C11132* Washer #10 ID 2.0" OD 5/8" Sealing Neoprene- Bonded Galv St 8 Tools needed: Drill 3/8 bit ¼ drive 8 extension 9/64 Allen socket (¼ drive) or wrench ¼ drive small ratchet End cap Brake light Order of operations: 1. Position the end cap above the passenger side of the rear fascia, in line with the passenger side rear quarter panel. 2. Insert a tapped hole nut ( C10321*) onto the end cap tabs, over the holes drilled in the subassembly section. 3. Insert an Allen head bolt ( C10320*) with a washer ( C11132*) into each of the bottom holes and tighten lightly. Figure 2 53

54 4. Check the end cap to ensure it is flush with the adjacent quarter panel (Figure 3) and the centerpiece for the rear wing (Figure 4). 5. Insert the remaining two bolts and washers. 6. Tighten all 4 bolts. NOTE: You may need to expand the holes to allow better fitment and positioning of the end caps. Figure 3 Figure 4 54

55 XXVI Third Brake Light Connector Replacement Part Number Description Qty C11336* CONNECTOR, 2 PIN FEMALE HSING 1 Tools needed: Heat Gun Electrical Tape Tin Snips Crimpers Order of operations: 1. You need to remove the two wire terminals from the stock black 2- pin connector for the 3 rd brake light harness. First, using a small pick, push in the tab to release the red wedgelock in the center of the connector, on the end opposite where the wire terminals are. FIGURE 1 shows the wedgelock pried loose. 2. Remove the wedgelock and release the wire terminals; there are tabs inside the connector which hold the terminals in place; pry each tab up while simultaneously pushing the wire tabs out the back of the connector. (FIGURE 2) 3. Pry the white wedgelock loose from the inside of the new 2-pin connector. (FIGURE 3) Figure 2 Figure 3 55

56 4. Insert the wire terminals into the back of the connector ( C11336*; opposite end from the wedgelock) until they click into place the balck wire (gorund) goes into pin 1, and the colored wire goes into pin 2. (FIGURE 4) Figure 4 56

57 XXVII License Plate Lights Harness Installation Part Number Description Qty B10845 Harness Extension License Plate Light Zip Tie C08956* Polyefin Heat Shrink 3/16" Black 2 x 1 piece Tools needed: Razor blade Black electrical tape Heat gun Crimper 1. Remove trunk liner from passenger side of trunk. 2. Cut open 6 of convoluted sleeving on rear side marker harness at about midway through the trunk, as indicated in Figures 1 and 2 ( is a close up of Figure 2). Make the cut along the length of the sleeving, such that 6 of the wire are exposed. 3. Cut the green and black wires at the location indicated in Figure 2. Strip ½ off both ends of the green and black wires in the rear side marker harness (Four wire ends total). 4. Strip ½ off ends of license plate lights harness wires that don t have metal connectors attached. 5. Slip a 1 piece of 3/16 heat shrink ( C08956*) over each of the two wire ends that lead to the back of the car. 6. Place butt connectors over the bare ends of the black and green wires which lead to the rear of the car and crimp the butt connectors. Figure 3). Inner wall To lights To rear Figure 2 Rear of car Front of car Butt conn. Figure 3 57

58 7. Insert the green wires from the license plate lights harness and the front end of the stock harness into the open end of the butt connector (Figure 3). Make sure you match green wires to green wires. 8. Crimp the other end of the butt connectors. 9. Repeat steps 7 and 8 for black wires. 10. Slide heat shrink over butt connectors, and shrink with heat gun (Figure 3). 11. Cover heat shrink with electrical tape. 12. Close up convoluted sleeving with electrical tape. 13. Run license plate lights harness up inner wall of passenger side of trunk and zip tie into place (Figure 2). 14. Run license plate lights harness along third brake light harness up to deck lid (Figure 4) and across deck lid (Figure 5) to the opening that leads to the center spoiler. 15. Zip tie third brake light and license plate lights harnesses together. 16. And pull each wire connector out its respective hole in the spoiler (Figure 6). Figure 4 Figure 5 Figure 6 58

59 XXVIII Third Brake Light and License Plate Lights Installation Part Number Description Qty C10313* Lamp Assy License Plate B Third Brake Light Pigtail C11921* screw phil hd flatp top washer #8x3/4" zn pl st 4 Tools need: Philips head screwdriver 1. Insert the electrical connector for the third brake light in the large center opening in the rear center spoiler. Attach the connector to the new connector installed on pages Insert the third brake light into the large opening at the back-center of the center spoiler. 3. Secure third brake light with four screws ( C11921*). (Figure 1) 4. Insert copper tabs of license plate lights into the wire ends shown in Figures 2 and 3. The tabs and wire ends only fit one way. 5. Push the license plate wires and lights into place through the holes in the center spoiler. Figure 2 Figure 3 59

60 XXIX Rear Grille Appliqué and Tail Light Covers Installation Part Number Description Qty C09836 Rear Grille 05 Mustang C09834 Tail Light Coverup LH C09835 Tail Light Coverup RH 1 Obtain the Following Tools: 3M Automotive adhesive promoter #06396 Wax and grease cleaner Glass cleaner Order of Operations: 1. Clean (outside) rear of trunk with wax and grease cleaner. Clean tail lamps with glass cleaner. Wipe dry and clean all surfaces. 2. Apply adhesive promoter to the areas of the back of the trunk lid where the tape on the rear grille will attach. 3. Remove adhesive backing from tape on the back of the rear grille (Figure 1). 4. Figure 2 shows the finished product. Figure 2 60

61 5. Place grille over trunk as shown in Figure 2. There is a very small amount of overlap; make sure the grill is centered side to side, and check that the holes in the grille line up with the key hole for the trunk and the two installed rivnuts (Figure 4). Press firmly into place. 6. Apply automotive adhesive promoter to areas of inboard tail lights where the tape on the back of the tail light covers will attach. 7. Remove adhesive backing from tail light covers and place over respective taillight; the curved top corner will be on the inboard side and the cutout will go around the white backup light (Figure 3). Press firmly into place. Figure 3 Figure 4 61

62 XXX Door Cladding Subassembly Part Number Description Qty C09733C Door Cladding LH 05 Mustang C09734C Door Cladding RH 05 Mustang 1 Obtain the Following Tools: 80 grit sandpaper AM209 plastic prep and cleaner 3M Automotive adhesion promoter Order of Operations: 1. Using 80-grit sandpaper, sand the two tabs that run the length of the door cladding. 2. Clean the tabs with AM209 plastic surface prep and cleaner and paper towels. 3. Apply 3M automotive adhesion promoter to the cleaned tabs. 4. Cut a section of 3M double sided clear tape ( C08519*) to fit on each tab. (Figures 1,2) 5. Remove backing from one side of 3M double sided clear tape and apply to tab. Figure 2 62

63 XXXI Door Cladding Installation Part Number Description Qty C09733C Door Cladding LH 05 Mustang C09734C Door Cladding RH 05 Mustang 1 Obtain the Following Tools: Urethane Gun Urethane 2 Order of Operations: 1. Obtain the passenger side door cladding ( C10863A). 2. Create a cylinder shaped pile of urethane ¾ inch tall, and about the size of a quarter in diameter. Center the pile midway between the two tabs, and 2 inches from the front of the cladding. (). 3. With the door open, place passenger side door cladding on the passenger door, aligning the bottom edge of the cladding with the bottom edge of the door, and the front and rear ends of the cladding with the front and rear ends of the door. (Figures 2,3). 4. Repeat steps 2 and 3 for the driver side cladding ( C10862A). Figure 2 Figure 3 63

64 XXXII Flip-Down License Plate Installation Part Number Description Qty C11046* Screw, License Plate, #14 X 5/8, 5/8 Washer Head, Black E-Coat C11047* Nut, License Plate, #14 Screw Size C10092* Flip Down License Plate Bracket C11049* Screw, But Hd. Cap. 1/4-20, 3/4 Lgth, Ss. Blk-Oxide 2 Obtain the Following Tools: ¼ drive ratchet ¼ drive #4 Allen socket (or wrench) ¼ drive 5/16 socket Order of Operations: 1. The license plate bracket ( C10092*) is shown in, with mount shown in proper orientation. 2. Line up the holes shown by the bottom arrows in with the installed rivnuts. Make sure arms are in proper orientation, as shown in Figure Secure the mount with two screws ( C11049*) (Figure 2). 4. Place the two nuts ( C11047*) into the two top holes of the license plate mount (top arrows, ; see also Figure 3). Figure 2 Proper orientation for arm 64

65 5. Place the plastic license plate frame and the paper SALEEN insert over the bracket, and line up the top holes. Insert the two screws ( C11046*) through the plastic frame and into the nuts. Tighten top bolts with a 5/16, ¼ drive socket. 6. Finished product shown in Figure Inside the trunk, reattach the wiring harness (Figure 5) to the trunk latch cover that was removed on page 11, and reinstall the trunk latch cover (Figure 6). Figure 3 Figure 4 Figure 5 Figure 6 65