Exhaust Headers; Steering Components; Radiator And Overflow Tank; Fan And Fan Shroud - Factory Five Racing MK4 ROADSTER Assembly Manual

measurement of all of the cylinders can be taken. All oxygen sensors are recommended to be used when
placing a fuel injected engine into a Factory Five kit.

Exhaust headers

1986 to 1993 Mustang headers have 1.5" tubes, and remained the same shape. From 1994 to 1995
Mustang headers still have 1.5" headers, but the collector flanges have a larger ball and socket joint.
1996 to 2004 Mustangs used cast exhaust manifolds. SOHC engines had circular exhaust ports, and the
DOHC had oval ports; however the collector flange changed in 2003 and 2004. Factory Five Produces
J-pipes to connect stock Mustang headers in a reversed position to Roadster 4 port side pipes for the
following years: 1986-1995, 1996-2004. 4 into 4 headers are also available from Factory Five for the
following applications: pre 1995 289/302, 96-04 SOHC 4.6L, 96-04 DOHC 4.6L, 351W, 390/427/428
big blocks, and 429/460 big blocks. For those installing 351 Windsor engines there are a few companies
including Ford Motorsport that carry exhaust headers for the installation of a 351 Windsor into a 1986-
1993 Mustang. These headers will work with Factory Five 1986-1995 J-pipes.

Steering components

Power steering racks from 1987 - 2004 are mostly all 15:1. In 1994 the racks switched from having a
splined shaft for attachment to the steering column to a triangle shaped end, as well as changing the
inner and outer tie rod ends. The 1994 to 2004 inner and outer tie rods are too long and do not work
with an FFR kit. The Factory Five 4.6L steering kit includes the correct inner and outer tie rod ends
along with the correct steering adapter.

Radiator and overflow tank

Radiators were painted brass 2 core radiators from 1986-1993. 1994 through 2004 used an aluminum
single core radiator with plastic side tanks. All work with Factory Five Roadster kits. Overflow tanks
are a required donor part for all FFR Roadster kits. In 86-93 Mustangs, the overflow was directly
attached to the fan shroud. From 94-04 the overflow tank design was changed and was attached to the
chassis.

Fan and fan shroud

1986 to 1993 Mustangs had a clutch fan attached to the water pump and the fan shroud was attached to
the radiator which also had the overflow tank attached to it. The fan shroud, and overflow tank are
required for Roadster kits using 87-93 donors. This version of the kit also comes with an electric
1300cfm. fan and brackets to attach it to the shroud. The clutch fan is eliminated. 1994 to 2004
Mustangs had a shroud with an electric fan built in, which is a required donor part.

Fuel tank, pump, pick ups, vents

1986-2004 Mustang fuel tanks were stamped steel with a plastic under tray, and had two straps that held
them to the chassis. All driver side straps are the same however in 1994 the passenger side strap
changed. Factory Five kits can accept all versions of the strap. The fuel pumps are all in the tank.
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