Ford Racing Boss 302S Owner's Manual

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Ford Racing Boss 302S

This is a Racing Vehicle!! This vehicle is intended for off-road use

ONLY and is not legal for on-road use!

The Boss 302S is a turn-key, or in this case a push button, racing vehicle and requires proper race

preparation. Please read and understand the owner's guide and the detailed instructions for the various

components supplied with your Boss 302S. Beyond component specific maintenance we recommend that

you regularly "nut and bolt" your Boss 302S. This is a process of checking all the nuts, bolts, wiring, belts,

hoses, tires, etc...on your vehicle. Your Race Car should be checked before every session of use...it is

also equally important to inspect your vehicle after each use: this includes checking all mechanical

components as well as checking for codes using your Ford Pro-Cal tool. In addition you should also

review the data in your AIM data acquisition system outlined later in this manual. Please be diligent

with the care of your vehicle!

Section 1

Ford Racing Boss 302S Specifications

Section 2

Driver Information / AIM system

Section 3

Ford Pro-cal Instructions

Section 4

Electrical Information

Section 5

Torque Sheets

Section 6

Brake/Chassis/Setup information

Section 7

Safety Equipment/Maintenance/Part numbers

In addition to this manual there are several file on this jump drive for your use:

• Sachs tuning guide

• Dynamics tuning guide

• DTC Error list

• Ford Racing wiring diagrams

• Aim Configuration File Boss302S FACTORYAIM.cfn (already preloaded on your car)

• Aim GPS track coordinates Boss_302_S_GpsMngr_2011_06_13_174017.mpl (already

preloaded on your car)

Only after reviewing Pro-cal tool DTC codes and AIM data should further support be

required. Please call the Ford Racing Tech Line at 800-FORD788.

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Summary of Contents for Ford Racing Boss 302S

Page 1 Boss 302S. Beyond component specific maintenance we recommend that you regularly "nut and bolt" your Boss 302S. This is a process of checking all the nuts, bolts, wiring, belts, hoses, tires, etc…on your vehicle. Your Race Car should be checked before every session of use…it is also equally important to inspect your vehicle after each use: this includes checking all mechanical components as well as checking for codes using your Ford Pro-Cal tool.
Page 2 FORD RACING WARRANTY DISCLAIMER FORD RACING PERFORMANCE PARTS AND VEHICLES ARE SOLD “AS IS”, “WITH ALL FAULTS”, “AS THEY STAND” AND WITHOUT ANY EXPRESS WARRANTY WHATSOEVER. TO THE FULLEST EXTENT ALLOWED BY THE STATE AND FEDERAL LAW, FORD MOTOR COMPANY EXPRESSLY DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND OF FITNESS FOR A PARTICULAR PURPOSE, EVEN IF A PARTICULAR PURPOSE IS MENTIONED HEREIN.
Page 3: Section 1 Ford Racing Boss 302S Specifications
Section 1 Ford Racing Boss 302S Specifications Engine 5.0L Ford Racing Motorsport Engine, based on 2012 Mustang Boss 302 engine Ford Racing Oil Pan, M-6675-M50BR Ford Racing Oil Filter, CM-6731-FL820 Engine Oil: Motorcraft 5W50 full synthetic or equivalent Setrab ProLine Engine oil cooler...
Page 4: Section 2 Driver Information/ Aim System
Driver Information/ AIM system Your Boss 302S includes a MXL Pista which is a digital dash, gauge, and race data acquisition system featuring a tachometer, 8 analog inputs, 1 speed input, CAN/serial ECU connector, gear position indicator (From ECU), internal lateral G sensor, and lap timer.
Page 5 RPM 2-STEP / PIT LANE SPEED CONTROL (PLSC) The Boss 302S has a RPM 2-STEP feature that will maintain a set engine speed while the accelerator pedal is depressed. This feature is built into the powertrain control module (PCM) and does not require aftermarket components.
Page 6: Section 3 Ford Pro-Cal Instructions
2. The RPM point is adjusted by moving the toggle switch up or down. The RPM will change in 100 RPM increments. The user range for the launch control is 2000 rpm to 7000 rpm and the PCM will not allow any settings beyond these limits.
Page 7: Section 4 Electrical Information
Section 4 Electrical Information Additional information about the Boss Crate Motor harness used on the 302S can be found on the Ford Racing website at http://www.fordracingparts.com/download/instructionsheets/FordInstShtM-6017-A504V_A54SC.pdf OBDII Connector Located on the passenger side air vent.
Page 8 Controls Pack Power Distribution Box The Controls Pack Power Distribution Box (PDB) is responsible for base engine electrical functions and is located under the passenger side air bag cover. Fuse and relay locations in this PDB are indicated on the circuit board. Refer to the circuit board picture below for clarification of fuse/relay locations in the Controls Pack PDB.
Page 9 Vehicle Power Distribution Box The Vehicle PDB shown in the following picture contains the fuses/relays used for headlights, taillights and other vehicle functions. This PDB is located in the passenger side kick panel. Fuse and relay locations for this PDB are shown below.
Page 10 Splice Circuit # Description Relay Pin Circuit # Description Fuse Type Source Amps Circuit # Description 12V HAAT 30A (F22) 300B C1200 35 Ground HAAT BATT C1200 3 T1 - 12V HAAT High Beam Feed C1200 14 High Beam Switch HAAT BATT C1200 5...
Page 11: Section 5 Torque Sheets
Section 5 Torque Sheets Bolt Torque Spec. Sheet Location: Type of Fastener Torque in Nm Torque in Ft Lbs Engine Mount to Crossmember Bolt 55.0 40.5 Engine Mount to Engine Block Bracket 62.5 46.1 Engine Block Bracket to Engine Block Bolt 55.0 40.5...
Page 12: Section 6 Brake/Chassis/Setup Information
Brakes Your Boss 302S comes equipped with Brembo road race brakes, a Ford Racing brake booster, PFC racing pads and a TRW Race ABS system that is uniquely tuned to the car. Changing any of these components from the intended design will degrade brake system performance.
Page 13 • Changes to ride heights, corner weights, and alignment will have effects on each other. Getting these settings correct is an iterative process. If you are making a major change or a new installation/re-installation, make a rough setup of height and alignment before starting with fine adjustments Measuring and setting front ride height: •...
Page 14 Measuring and setting rear ride height: • Rear ride height is defined by the "D" dimension, which is the distance between the top of the axle tube and the flat surface on the inboard side of the spring pocket. This measurement is used because it is a consistent measure of suspension position, independent of wheels, tires, bodywork, etc.
Page 15 Adjusting corner weights: • Once initial ride heights are set, use corner scales to measure and adjust corner weights so that the diagonal (RF+LR and LF+RR) weights are 50% (OR AS CLOSE TO 50% AS POSSIBLE). The "Cross Weight %" (shown on many scales) is the RF+LR Percentage •...
Page 16: Maintenance
Safety Equipment/Maintenance/Part numbers General Safety items The seat belts and window nets in the Boss 302S are NOT PRE SET. Before driving the vehicle, set belt lengths. They will need to be adjusted for each individual that races this vehicle.
Page 17 Wheel/Tires Front; Pirelli P Zero 255/40ZR19 Rear; Pirelli P Zero 285/35ZR19 Wheel torque: 95 ft-lbs For World Challenge competition the following wheel and tires are required…. Wheels 18x10" Ford Racing M-1007-R1810 (requires unique lug nuts) Part Allstar-ALL44102 Number: Product Photo:...
Page 18: Part Number Listing
Part number listing Part description Part number Button, Start Engine M-11572-GT Shock Mount, Rear M-18197-A Booster, Race Brake M-2005-R Pad, Rear Brake Kit M-2200-R Differential M-4204-T31H Kit, Ring & Pinion Install M-4210-B1 Crossbrace, Trans Cooler Air Scoop M-5025-MBR Muffler, SVT Kit M-5230-MGTCA1 Bar, Front Anti Roll M-5490-A...