SALEEN SPEEDLAB BODY KIT

SALEEN SPEEDLAB
BODY KIT
INSTALLATION MANUAL: 2005 to 2009 Mustang 4.6 3V
P/N: 10-8002-C11404D
Saleen Performance, Inc. 1225 East Maple Rd. Troy, MI 48083 248-743-4800
www.saleen.com
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
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 4.6liter, 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
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……………………………………….……...16
VII Front Air Splitter Repositioning………………………………….…17
VIII Front Bumper Painting……………………………………………..19
IX Front Fascia Subassembly………………………………………….....20
X Front Turn Signal Harness Installation…………….………………...25
XI Front Turn Signal Bracket Modification………………………….…27
XII Modified Front Shroud Installation……..…...…….……………….28
XIII Front Fascia Installation..………………………….……………….29
XIV Rivnut Installation for Flip-down License Plate…...………….…..31
XV Rear Grille Appliqué and Tail Light Covers Subassembly..………33
XVI Rear Fascia Subassembly…….………………….……………..…...34
XVII Rear Bumper Painting.....….…………………….…………….…..37
4
Table of Contents cont’d
XVIII Rear Fascia Installation…..….……..………………………….…38
XIX Rocker Panels Subassembly……..………………………...………..40
XX Rocker Panels Installation……..……………………..…….……..…42
XXI Three-Piece Rear Wing End Caps Subassembly………...………..46
XXII Three-Piece Rear Wing End Caps Hole Drilling…………..…….49
XXIII Three-Piece Rear Wing Center Support Installation.…………..50
XXIV Center Spoiler Installation…………...………………….………..52
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..……………………………………...62
XXXI Door Cladding Installation. ………..……………………………..63
XXXII Flip-Down License Plate Installation ……….………………......64
5
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# 61006-20)
• 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
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 1
Figure 2
Figure 3
7
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.
Figure 4
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 5
Figure 6
8
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
II Front Shroud Removal and Modification
Obtain the following tools:
•
•
Panel puller
Angle press or plastic cutters
1. Remove six Christmas trees (Figure 1). 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 Figure 1.
4. Starting at left of shroud, cut in 1+3/4” as shown by
horizontal white line in Figure 1; repeat on right side.
Figure 1
1 1/8”
1 3/4”
Figure 2
10
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 4
Figure 1
Figure 3
Figure 5
11
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.
(Figure 1)
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 1
Figure 2
Figure 3
Figure 4
12
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
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
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 1
Figure 2
Figure 3
15
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 Figure 1)
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 1
Figure 2
Figure 3
16
VII Front Air Splitter Repositioning
Part Number
Description
Qty.
00-9006-C10013*
Rivet Dome Std Blind 3/16"Dia .251-.375 Al-Al
2
06-1101-C10991C
BRACKET DRIVER FRONT FASCIA
1
06-1101-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
Figure 1
1. Using the ¼” drive impact gun with the
5.5 mm socket, remove three 5.5mm
screws from locations indicated in
Figure 1. 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 2.
4. 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
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 5.
7. Attach front of shroud to the bottom of
the L-brackets with one rivet (00-9006C10013*) on each side (Figure 6). Drill
a hole for each bracket before installing
the rivets.
Figure 4
Figure 5
Figure 6
18
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 (Figure 1). 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 1
Figure 2
Figure 4
Figure 3
19
IX Front Fascia Subassembly
Part Number
Description
Qty.
00-9001-C11462*
Screw, Sheet Metal, Pan Head, #8, 3" Long 18-8 Ss
2
00-9001-C11463*
Screw, Sheet Metal, Flat Head, #8 3.5" Long 18-8 Ss
2
00-9006-C10013*
Rivet Dome Std Blind 3/16"Dia .251-.375 Al-Al
4
06-1101-C09563
Front Fascia
1
06-1101-C09876
Front Grille 05 Mustang
1
06-1101-C11452
Screen Mesh Front Fascia RH 05 S281
1
06-1101-C11453
Screen Mesh Front Fascia LH 05 S281
1
00-1202-C09763*
Turn Signal, Front Fascia LH
1
00-1202-C09782*
Turn Signal, Front Fascia RH
1
06-9101-C09988
Front Grille Badge 2005 S281
1
00-9001-C11182*
Screw Plastic Thrd Pan Hd Round Washer Blk Ox
12
00-9001-C11634*
Screw Phil HD Flatp Top #4x3/8" Blck Oxide
12
06-1101-C11532
Turn Signal Light Spacer 3.178" Long
2
06-1101-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
Order of Operations:
1. Using a hack saw, cut off the bottom of
the turn signal ¼” below the hole
indicated in Figure 1. Note the cut line
shown in Figure 1.
2. Tape the top of the turn signal (00-1202C09763*) 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).
Hole
Figure 1
3. Insert long spacer (06-1101-C11532A)
on the inboard side and the short spacer
(06-1101-C11533A) on the outboard side
of the turn signal. The spacers go over
the long screws (00-9001-C11463* and
00-9001-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)
Figure 2
Turn signal
Figure 3
Spacers
Figure 4
21
4. Tighten bottom of mini turn signal
into place with bolt (00-9001C11634*) 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 (00-1202-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 (009001-C11182*) per tab. (Figure 6)
Figure 4
Fascia tabs
Figure 5
Figure 6
22
9. On passenger side, rivet side marker
light bracket into place using existing
holes and rivets (00-9006-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 (Figure 10)
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 9
Figure 10
23
11. Orient the grille as shown in Figure 11.
12. Hand-fasten the grille with 10 screws
(00-9001-C11634*) (Figure 12, 13).
13. Apply adhesion promoter onto the closed
out rectangle of the grill.
14. Remove backing from badge.
15. Refer to Figure 11. Grill badge is
installed in the only closed out rectangle
on grill (Figure 11). Center grill badge
within rectangle. There should be a 1/8”
gap forming a perimeter between the
badge and the grill rectangle.
Grill badge
Figure 11
Figure 13
Figure 12
24
X Front Turn Signal Harness Installation
Part Number
Description
Qty.
06-1704-B10316
Turn Signal Harness Drv./Pass Side
2
00-1704-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 Figure 1.
2. Remove the pins from stock 3-pin
connector. (Figure 1) 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 1
Figure 2
Figure 3
25
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 (061704-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 (06-1703-C11653).
Tab to release the wedgelock
Figure 4
Figure 5
Figure 6
26
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
(Figure 1). Deburr edges after cutting!!
6. Reinstall brackets with stock hardware.
Figure 1
Bolthole,
step 4
Figure 2
“A”
1 3/8”
“B”
1 7/8”
Figure 3
27
XII Modified Front Shroud Installation
Order of Operations:
1. Reinstall shroud with six stock Christmas trees. (FIGURE 1)
Figure 1
28
XIII Front Fascia Installation
Part Number
Description
Qty
00-9502-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 (00-9502-C11967*),
and place along the outboard, inboard, and
bottom edges of each headlight (Figure 1).
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 3
Figure 1
Figure 2
Figure 4
29
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
Figure 71
30
XIV Rivnut Installation for Flip-down License Plate
Part Number
Description
Qty.
00-9006-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. (Figure 1).
7 ½”
11 3/8”
11 3/8”
1 ½”
Figure 1
31
2. Drill the two holes with the 25/64” bit.
(Figure 1)
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 (00-9006-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)
Existing
holes
Figure 2
32
XV Rear Grille Appliqué and Tail Light Covers Subassembly
Part Number
Description
Qty.
06-1101-C09836B
Rear grille 05 Mustang
1
06-1101-C09834B
Tail light coverup LH
1
06-1101-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, 06-1101-C09834B
and 06-1101-C09835B) and Figure 3
(rear grille, 06-1101-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 1
Figure 2
Figure 3
33
XVI Rear Fascia Subassembly
Part Number
Description
Qty.
06-1101-C09574
Rear fascia cntr exhaust 05 Mustang
1
06-1103-C11454
Screen mesh rear fascia outside 05 S281
2
06-1103-C11455
Screen mesh rear fascia center 05 S281
1
00-9006-C10013*
Rivet dome std blind 3/16"dia .251-.375 al-al
12
00-9001-C11634*
Screw Phil HD flat TOP #4x3/8" blck oxide
22
06-1108-C11052
Bracket Rr fascia to wing end cap RH
1
06-1108-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 (00-9006-C10013*), install 06-1108C11052B on the top of the right side
ledge of the rear fascia; install 06-1108C11054B on the left side. (Figure 1).
2. Have the unit painted.
3. Obtain the painted rear fascia.
Figure 1
34
4. Figure 1 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 1
Figure 2
Rear of car
Figure 3
35
8.
9.
10.
11.
12.
Position screens so that the screen tabs line
up with the fascia tabs.
Hold screens in place with clamps (Figure
5).
With a 1/8” drill bit, drill pilot holes for each
of the screws. (Figure 6)
Fasten the screens in place with screws.
(Figure 7) Use 2 screws (00-9001-C11634*)
per tab. Fasten the screws as tight as you can
without breaking them, so that they are not
visible through the screens.
Fasten the center screen in the same way,
using two screws (00-9001-C11634*) per
tab.
Figure 4
Figure 5
Figure 6
Figure 7
36
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
1.
3. Paint rear of gas tank (Figure 2).
Figure 1
Figure 2
37
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.
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 3.
2. Remove the tail lights if not already
removed. Refer to page 15.
3. 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 1
1.
Figure 2
Figure 3
38
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
XIX Rocker Panels Subassembly
Part Number
Description
Qty.
06-1102-C11094
Perf scrn rocker 2005 S281
4
06-1101-C09588
Body rockers LH 05 Mustang
1
00-9001-C11634*
#4 screws for screens
8
06-1101-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
Rough
entire
surface
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 Figure 1.
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.
Figure 1
Figure 2
40
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 (06-1102C11094) onto each opening on each
rocker panel – there will be two screens
per rocker. Attach each screen with two
screen screws (00-9001-C11634*).
3.
Figure 3
41
XX Rocker Panels Installation
Part Number
Description
Qty.
06-1101-C09588
Body Rockers LH 05 Mustang
1
06-1101-C09589
Body Rockers RH 05 Mustang
1
00-9006-C10219*
Fastener Christmas Tree .276"-.286" Dia 2.73"
16
06-1102-C11424
Rocker Panel Spacer 1.5" Long
4
06-1102-C11425
Rocker Panel Spacer 1.75" Long
6
06-1102-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
Adhesive (urethane; see p.6)
• Masking tape
Area 1
Area 2
Figure 1
Order of Operations:
1. Clean the areas shown with a wet rag.
(Figure 1) Figures 2 & 3 are close ups.
Urethane below this
line
Urethane
below this line
Area 2
Area 1
Figure 3
Figure 2
42
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
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 (Figure 10)
are secure in the rocker panel. If any of
the brackets are loose place foam behind
it to stiffen it up (Figure 11).
6. With the car door open, line up the white
clips with the slots in the car. (Figure 12)
You only need 5 clips from each old
rocker panel (10 for the pair) to install
the new one. (Figure 10)
Figure 10
Figure 7
Figure 8
Figure 9
Figure 11
Figure 12
44
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 Figure 15.
9. Obtain Christmas trees 00-9006C10219* (eight per side). You will place
spacers over each of the Christmas trees,
and then install them into the locations
indicated by Figure 15. For the first three
holes, obtain three spacers 06-1102C11425 (1.8”) and insert into the first
three holes behind the front wheel.
Spacers 06-1102-C11424 (1.5”) go in the
next two holes. Spacers 06-1102-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.
Figure 13
Figure 14
Insert
Christmas
tree here
Figure 15
Figure 16
45
XXI Three-Piece Rear Wing End Caps Subassembly
Part Number
Description
Qty.
06-1101-C09728
Rear Quarter Panel Spoiler Extension LH
1
06-1101-C09729
Rear Quarter Panel Spoiler Extension RH
1
06-1108-C10779
Bracket Rear End Cap Spoiler 2005 S281
2
00-9006-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
Order of Operations:
1. Using a 1/8th 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 (Figure 1).
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 4.
3. Counter sink the hole by hand. (Figure
3)
¾”
1 ½”
Figure 1
Figure 2
46
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
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).
Crossmember
Figure 7
Figure 8
48
XXII Three-Piece Rear Wing End Caps Hole Drilling
Part Number
Description
Qty.
10-3103-C12151
3-piece spoiler end caps hole template
1
Tools need:
• Drill
• 3/8” bit
• 7/16” bit
• 1/8” drill bit
*2
1. Use the provided template (P/N 103103-C11723) when making holes
for attaching three piece spoiler.
(Figure 1).
2. Tape the templates into place. Make
sure each guide lines up with the
bodywork, (Figure 1). 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 Figure 1. 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. (Figure 1)
tabs
tabs
Figure 1
49
XXIII Three-Piece Rear Wing Center Support Installation
Part Number
Description
Qty.
06-1102-C10996
Spoiler Center Support
1
00-9003-C10936*
Nut Nyloc M6 10mm Width 6mm Height
4
10-3103-C11723
Hole Pattern, Flat, S281 Rear Spoiler Assembly
1
00-9004-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 1
Figure 2
50
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 Figure 1. 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 (009003-C10936*), four washers (009004-C11132*) and a ¼” drive 10
mm socket (Figure 4).
11. Figure 3 shows the finished product.
Figure 3
¼” “A”
13/64”
(B)
¼”
Figure 4
13/64”
(B)
51
XXIV Center Spoiler Installation
Part Number
Description
Qty.
06-1101-C09730
Rear Spoiler 05 Mustang
1
00-9001-C10320*
CAPSCRW SCKT HD 8-32x0.75 Bl Ox ST
4
00-9003-C10321*
Nut 8-32 Tapped Hole
4
00-9011-C11921*
Screw Phil HD FLATP Washer #8x3/4" Zn Pl St
4
00-9004-C11133*
Washer 1/4"Id 2.75"Od 3/4" Sealing NeopreneBonded Galv St
4
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
1. Slide wing into place over the mount (Figure 1)
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 (00-9001-C10321*) over each of
the four 13/64” holes.
6. Using the 9/64” Allen tool, secure spoiler with
four bolts (00-9001-C10882*) and four washers
(00-9004-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 (00-9011-C11921*) on each end.
Figure 1
Figure 2
Figure 3
52
XXV Three Piece Rear Wing End Caps Installation
Part Number
Description
Qty.
00-9001-C10320*
Capscrw Sckt HD 8-32x0.75 Bl Ox ST
8
06-1101-C09728
Rear Quarter Panel Spoiler Extension LH
1
06-1101-C09729
Rear Quarter Panel Spoiler Extension RH
1
00-9003-C10321*
Nut 8-32 Tapped Hole
8
00-9004-C11132*
Washer #10 ID 2.0" OD 5/8" Sealing NeopreneBonded 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
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 (00-9003C10321*) onto the end cap tabs, over
the holes drilled in the subassembly
section.
3. Insert an Allen head bolt (00-9001C10320*) with a washer (00-9004C11132*) into each of the bottom holes
and tighten lightly.
Brake
light
End
cap
Figure 1
Figure 2
53
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
XXVI Third Brake Light Connector Replacement
Part Number
Description
Qty.
00-1704-C11336*
CONNECTOR, 2 PIN FEMALE HSING
1
Tools needed:
• Heat Gun
• Electrical Tape
• Tin Snips
• Crimpers
Order of operations:
1.
2.
3.
You need to remove the two wire
terminals from the stock black 2pin connector for the 3rd 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.
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)
Pry the white wedgelock loose
from the inside of the new 2-pin
connector. (FIGURE 3)
Figure 1
Figure 2
Figure 3
55
4. Insert the wire terminals into the back of
the connector (00-1704-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
XXVII License Plate Lights Harness Installation
Part Number
Description
Qty.
06-1704-B10845
Harness Extension License Plate Light
1
069-700
4” Zip Tie
12
00-1704-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 (Figure 1 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 (001704-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).
Figure 1
Rear of
car
Inner
wall
Figure 2
To lights
Front of car
Butt
conn.
To rear
Figure 3
57
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
XXVIII Third Brake Light and License Plate Lights Installation
Part Number
Description
Qty.
00-1202-C10313*
Lamp Assy License Plate
2
06-1704-B10625
2005 Third Brake Light Pigtail
1
00-9011-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 48-49.
2. 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 (00-9011-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 1
Figure 2
Figure 3
59
XXIX Rear Grille Appliqué and Tail Light Covers Installation
Part Number
Description
Qty.
06-1101-C09836
Rear Grille 05 Mustang
1
06-1101-C09834
Tail Light Coverup LH
1
06-1101-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 1
Figure 2
60
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
XXX Door Cladding Subassembly
Part Number
Description
Qty.
06-1101-C09733C
Door Cladding LH 05 Mustang
1
06-1101-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.
2.
3.
4.
5.
Using 80-grit sandpaper, sand the two
tabs that run the length of the door
cladding.
Clean the tabs with AM209 plastic
surface prep and cleaner and paper
towels.
Apply 3M automotive adhesion
promoter to the cleaned tabs.
Cut a section of 3M double sided
clear tape (00-9006-C08519*) to fit
on each tab. (Figures 1,2)
Remove backing from one side of 3M
double sided clear tape and apply to
tab.
Figure 1
Figure 2
62
XXXI Door Cladding Installation
Part Number
Description
Qty.
06-1101-C09733C
Door Cladding LH 05 Mustang
1
06-1101-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 (06-1102-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. (Figure 1).
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 (06-1102-C10862A).
Figure 1
Figure 2
Figure 3
63
XXXII Flip-Down License Plate Installation
Part Number
Description
Qty.
00-9001-C11046*
Screw, License Plate, #14 X 5/8, 5/8 Washer Head ,
Black E-Coat
2
00-9003-C11047*
Nut, License Plate, #14 Screw Size
2
00-1103-C10092*
Flip Down License Plate Bracket
1
00-9001-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 (00-1103C10092*) is shown in Figure 1, with
mount shown in proper orientation.
2. Line up the holes shown by the bottom
arrows in Figure 1 with the installed
rivnuts. Make sure arms are in proper
orientation, as shown in Figure 2.
3. Secure the mount with two screws (009001-C11049*) (Figure 2).
4. Place the two nuts (00-9003-C11047*)
into the two top holes of the license plate
mount (top arrows, Figure 1; see also
Figure 3).
Figure 1
Proper
orientation
for arm
Figure 2
64
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 (00-9001C11046*) through the plastic frame and
into the nuts. Tighten top bolts with a
5/16”, ¼” drive socket.
6. Finished product shown in Figure 4.
7. 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