INSTALLATION INSTRUCTIONS
Mustang Body Kit
Application: Mustang
1999 Through Current Model Year
Roush Performance
12447 Levan Road
Livonia, MI 48150
For Technical Assistance Call:
1-800-59-ROUSH
Information contained in this publication was in effect at the time of publication, was approved for printing and is subject to change without notice or liability. ROUSH Performance reserves the right to revise the information presented or discontinue the production of parts described at any time.
Part # RMBINST02
Printed in USA
Roush Performance 1999
Please Recycle
1-800-59-ROUSH
The ROUSH Mustang. It has been a dream of ours for years to bring you the same level of performance and engineering from our racing program to the streets. If you don’t already know ROUSH, we’ve spent the last 20 years building Ford race cars. In that time, we’ve held our own winning 180+ races and 23 National titles—in top series like NASCAR Winston Cup, Bush Grand National, Craftsman Truck, SCCA Trans-Am and IMSA GTO.
Now it’s on to the American road.
The Roush Body Styling you are about to install was designed specifically for the 1999 through current model year Ford Mustang enthusiast. These components were developed, tested, and manufactured to our race winning standards. Properly installed, the
Roush Body Styling will enhance the appearance of your Mustang.
If you have any questions regarding installation or would like to learn about other ROUSH Performance Products, please call us at:
1-800-59-ROUSH
Part #RMBINST02
Printed in USA
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STOP! READ IMPORTANT SAFETY CAUTIONS AND
WARNINGS BEFORE PROCEEDING.
IMPORTANT SAFETY CAUTIONS AND WARNINGS
It is strongly recommended that someone with actual automotive mechanical experience perform this installation.
Obtain assistance when removing or installing large and/or heavy components to prevent possible personal injury.
Most importantly, read each step of the installation manual before starting the actual installation.
IMPORTANT SAFETY NOTICE
Appropriate disassembly, assembly methods and procedures are essential to ensure the personal safety of the individual doing the work. Improper installation due to the failure to properly follow these instructions could cause personal injury or death. Read each step of the installation manual carefully before starting the actual installation.
NOTES, CAUTIONS, IMPORTANTS AND WARNINGS
Reading through the procedures, you will be referencing NOTES, CAUTIONS, IMPORTANTS & WARNINGS.
NOTES
give added information that will help complete a procedure or as a reminder to install or remove a specific component.
CAUTIONS
are presented to prevent you form making a mistake or damaging your supplied parts or vehicle.
IMPORTANTS
are to ensure that all procedures are followed and components are present during a specific removal or assembly procedure.
WARNINGS
remind you to be extremely careful in those areas where carelessness can cause personal injury.
Read the following bullet points, as they contain general WARNINGS that we recommend be followed when working on your vehicle.
• Always wear safety glasses for eye protection.
• Place ignition switch in the OFF position.
• Always apply the parking brake when working on the vehicle.
• Block front and rear tire surface to prevent unexpected vehicle movement.
• Operate the engine only in well ventilated areas to avoid exposure to carbon monoxide.
• Do not smoke or use flammable items near or around the vehicle fuel system.
• Use chemicals and cleaners in well ventilated areas.
• Batteries produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or flammable substances to come near the battery.
• Keep hands and any other objects away from the radiator fan blades.
• Keep yourself and your clothing away from moving parts when the engine is running.
• Do not wear loose clothing or jewelry that can get caught in rotating parts.
Part #RMBINST02
Printed in USA
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Tools Required:
Acetone
5/16” Drill Bit
Hammer
Clean Rags
Part #RMBINST02
Printed in USA
Adhesion Promoting
Primer
#2 Phillips Screw Driver
Utlity Knife
Tape Measure
Drill Motor
Ratchet w/ 7/16” socket
Wax Pencil
Scotch-Brite / #220
Sand Paper
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Kit Contents:
RFFM02: Front Valance, RFFM02HDW: Hardware Kit
Part #
A
B
C
D
E
F
Description
3M Mounting Tape 10’
1/4-20 Screw SS
1/4ID Washer SS
1/4-20 Nylock Nut SS
1-1/8”LG Aluminum Spacer
#8 X 1-1/2”LG Screw Black Oxide
QTY
1
2
6
2
2
4
4
RLSM03 & RRSM03: Side Skirts L & R, RSSM03HDW: Hardware Kit
Part #
H
F
Description
3M Mounting Tape 8’
#8 X 1-1/2LG Screw Black Oxide
QTY
2
8
4
2
RRFM03L &RRFM03R: Rear Valance L & R, RRFM03HDW: Hardware Kit
Part #
A
F
Description
3M Mounting Tape 10’
#8 X 1-1/2LG Screw Black Oxide
QTY
1
2
6
Part #RMBINST02
Printed in USA
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Urethane Component Preparation Procedures
IMPORTANT: This procedure must be followed for all ROUSH urethane components installed on this vehicle!
CAUTION: These instructions must be followed to ensure proper tape adhesion to the part. Mask the tape groove areas on the parts prior to painting.
NOTE: All components should be painted prior to installation. Handle the components gently to prevent damage to the vehicle surface and/or the cover. It is recommended to place the components on a soft, non-abrasive surface for all installation operations. For best results and ease of installation, the body components can be placed in the sunlight or warm area to stabilize. Installation should occur in ambient conditions of 70-100 degrees F.
The following steps may require the help of an additional person. Prior to installation, the vehicle should be washed with mild soap and water and thoroughly dried.
Step 1: Inspect the back sides of each component. Remove any masking tape as a result of the painting process.
Step 2:
Using Scotch-brite, scuff the entire tape groove for each component if needed. If necessary, smooth any imperfections or seams in the tape groove only.
WARNING: Chemicals/Cleaners such as acetone must be used in well ventilated areas and discarded of properly. Improper use can cause severe injury or death. Follow manufacturer’s
instructions for proper usage.
Step 3: Using clean cloth, wipe all tape groove surfaces with acetone to remove any dirt, debris, or contaminants.
Step 4: Wipe all tape groove surfaces with an adhesion promoter such as Pro-Bond or 3-M #4298. Let all components dry.
Step 5: Install supplied mounting tape
A,H
along the tape grooves in the back of applicable body components.
Step 6: In preparation for final installation, pull back 2” to 3” of tape backing on each end of the tape section.
The tape backing should peel upward allowing access to backing once components are installed.
Part # RMBINST02
Printed in USA
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Roush Mustang Removal Procedures
NOTE: Installation of the front valance and the rear valances will not require removal of factory installed body components.
IMPORTANT: It is imperative that all vehicle surfaces be dry and free from dirt, debris and contaminants
during the installation process.
WARNING:
The installation of the rear valances will require installation of the Roush Side skirts.
Modifications of the factory exhaust system other than that which is recommended by
Roush, can cause serious injury or death.
NOTE: For installation of Roush Side skirts, removal of the factory side skirts is necessary.
Step 1: Locate vehicle safely on a hoist and remove all four tire and wheel assemblies. Save for reinstallation.
WARNING: Follow the directions in the vehicle owner’s manual for proper removal and installation techniques.
Step 2: Remove the factory side skirt fasteners located in each wheel opening using a Phillips hand screwdriver.
Step 3: Remove all the plastic fasteners along the pinch rail and body. (This is the area between the front and rear wheel openings.) Open vehicle doors and remove black “Mustang” trim piece by lifting upward. Remove the side skirt from each side of the vehicle by pulling out and downward on the side skirt (The factory side skirt consists of two interlocking pieces).
Step 4: After the factory side skirts have been removed, be sure to remove any additional fasteners from vehicle surface which may have pulled free from the side skirts during removal.
Step 5: Wash all of the exterior vehicle surfaces, including the door returns, with mild soap and water. It may be necessary to re-install the tire and wheel assemblies during this process.
NOTE: It is imperative that all vehicle surfaces be dry and free from debris during the installation process.
Part # RMBINST02
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Roush Mustang Pre-Assembly Procedures
IMPORTANT: Follow this procedure for all urethane components to be installed on the vehicle!
CAUTION: If components have been pre-painted, handle them gently to prevent damage to the vehicle surface or the component. It is recommended to place all components on a soft surface for all installation operations.
Step 1: Inspect the tape groove of each component. Remove any masking in the tape groove as a result of the painting process. Using a Scotch-brite sanding pad or #220 sandpaper, scuff the entire tape groove on each component. If necessary, smooth any imperfections or seams in the tape groove only. Be careful not to touch or remove material on the top edge of the body components, as this will be visible when installed.
Step 2: Using a clean cloth, wipe all of the tape groove surfaces with acetone to remove any mold release or contaminants. Let all components dry. Wipe all of the tape groove surfaces with an adhesion promoter such as Pro-Bond or 3M #4298. Let all components dry.
WARNING:
Chemicals/Cleaners such as acetone must be used in a well ventilated area and discarded properly. Improper use can cause severe injury or death. Follow manufactures instructions for proper usage.
Step 3: Install 3M mounting tape
A,H
along the tape groove of each applicable component. Un-roll the tape and secure it just below the top edge of the body component by pressing firmly. It will be necessary to trim the 3M mounting tape to the appropriate lengths using a pair of scissors or razor knife.
NOTE: The tape groove is slightly recessed to prevent exposure of the tape after installation is complete.
Part # RMBINST02
Printed in USA
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Roush Mustang Installation Procedure
Step 1: Pre-fit all body components to the vehicle and using a wax pencil, mark a guide line on the vehicle surface along the top edge of the body component being installed. This will be used during the final installation step. See figures 1-5 for part locations.
IMPORTANT: For best results, request the assistance of another skilled individual to help.
Attachment between rear fender and OEM valance.
Fig. 1
8-1/4”
Fit the REAR valances to the body at the measurement shown and to the inward landings of the components. Mark with wax pencil.
3” from lowest point on license plate landing to new valance.
Fig. 2
3”
Fig. 3
6-1/4”
7”
Attachment between front fender and OEM valance.
Part # RMBINST02
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Fig. 4
Fig. 4& 5: Install Rocker’s 1/4” below body contour line.
Fig. 5
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Printed in USA
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Step 2: Using a Scotch brite pad, scuff a 1” wide section of the vehicle surface (clear coat) 1/8” below the guide line defined in STEP 11.
Step 3: Using a clean cloth, wipe all of the vehicle surfaces with acetone which will come in contact with the 3M mounting tape. Do not remove the wax guideline. Allow surfaces to dry. Wipe the vehicle surfaces with an adhesion promoter such as Pro-Bond or 3M #4298. Allow surfaces to dry.
IMPORTANT: The vehicle surface must be free from debris and contaminants for proper mounting tape adhesion.
NOTE: For best results and ease of installation, the body components can be placed in the sunlight or warm area to stabilize. Installation should occur in ambient conditions of 70 to 100 degrees F.
Step 4: In preparation for final installation, pull back approximately 1” of the orange tape backing at each end of the mounting tape run. It should extend above the top edge of the body component when it is held in place. To assist with this portion of the installation, it is common to crease the orange backing at a 45 degree angle.
Step 5: Remove screw from wheel well opening where part is to be installed. Install (1) plastic push-pin fastener
G
per wheel return and rear valance, and (1) screw
F
per wheel return. For the push-pin fastener
G
, drill a 5/16” hole through the component into the wheel well flange/rear valance. Be sure to drill a pilot hole to properly center the plastic fastener in the wheel well flange. For the screw, drill 1/8” hole through the component to match up with the factory hole in the fender.
Step 6: Install each component by re-aligning its top edge with the wax pencil guide line on the vehicle and pressing the exposed mounting tape surface to the vehicle. Holding the orange backing tape, pull it gently along the top edge of the component at approximately a 45 degree angle. Be careful not to break the backing tape. Continue to press the component and exposed tape surface to the vehicle until all of the orange backing tape has been removed and the component is securely in place. Be certain all corners are tight.
CAUTION: The plastic fastener should penetrate the component and the factory wheel well flange.
Step 7: Insert the plastic fastener through the drilled holes, then screw or tap the center pin flush with the fastener
surface. Modify push-pin fasteners
G
to 3/8” overall length as shown in Figure 6. Install screws
F
through the modified push-pin retainer.
Fig. 6
Modify retainer to 3/8” overall length. Use supplied screws through the center.
Part # RMBINST02
Fig. 6
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Fig. 7
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Fig. 8
Step 8: For the front & rear valance inboard attachment, drill through pre-drilled holes with a 5/16” drill. Install screws
B
, washers
C
, spacers
E
, and nut
D
in front valance (Figure 7). Install push-pin fasteners
G
in rear valance as shown in Figure 8.
Fig. 7
Install with washers on both sides of spacer plus in between OEM valance and nylock nut.
Fig. 8
After drill operation, install fastener on inward side of rear valance.
Step 9: Install the two Roush logos
K
. The recessed area is located in the side skirts just ahead of the rear wheels (two places).
IMPORTANT: Do not wash vehicle for 72 hours. Do not allow moisture to come in contact with mounting tape.
Step 10: Re-install the tire and wheel assemblies per the manufacture’s directions located in the vehicle owner’s manual.
Part # RMBINST02
Printed in USA
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ROUSH PERFORMANCE PRODUCTS: LIMITED WARRANTY
Who is Covered:
Original Purchasers (“Purchaser”) of genuine Roush parts and components (“Roush Part(s)”) from Ford
Dealers.
Warranty Period for Roush Part(s) and Coverage:
From the date of installation by an authorized installer, the warranty periods will be the first to occur of:
12 months or 12,000 miles for Roush Chrome Wheels, and 3 years or 36,000 miles for all other
Roush Part(s).
When installed, Roush Part(s) will void the Ford warranty as it pertains to that specific part or component (i.e. a
Roush suspension package will void the Ford suspension warranty only). Notwithstanding this fact, Roush’s warranty covers defects in material and workmanship of Roush Part(s) and their installation from the date/mileage the vehicle is put in service. During the warranty period Roush will repair, replace, or adjust any defective Roush Part(s) on the vehicle or other substantially damaged areas that arise as a direct result of its interaction with the defective Roush
Part(s). To activate Roush’s warranty coverage the Ford Dealer must receive Roush’s written authorization prior to beginning any work to be billed to Roush. (Roush’s warranty does not cover the cost of rental cars during any repair, replacement, or adjustment of Roush Part(s).)
What is Not Covered:
The following circumstances are intended to parallel standard Ford warranty exclusions and are not covered by this limited warranty: (i) road hazards, misuse, abuse, neglect, accidents, collision, fire, theft, freezing, vandalism, riot, explosion, or objects striking the vehicle; (ii) misusing the vehicle, such as driving over curbs, overloading, racing, or using the vehicle as a stationary power source; (iii) altering, disassembling or modifying the Roush Part(s) after the vehicle leaves the Ford Dealer's or other
Authorized Installer's control; (iv) tampering with the vehicle or with other parts that affect the Roush Part(s); (v) defects caused or induced by failures, breakdowns, or damage by other parts, components or the vehicle; (vi) vehicle recall or service campaign warranty claims negotiable on an incident-by-incident basis; (vii) subjecting the Roush Part(s) to excessive moisture or water or any motor vehicle fluids (e.g.: oil, anti-freeze, battery acid, break fluid, etc.); (viii) acts of God, natural disasters and other similar causes beyond the reasonable control of Roush; (ix) customer application of chemicals that affect the Roush Part(s). This limited warranty does not cover surface deterioration of paint, trim, and appearance items that result from use and/or exposure to the elements, such as stone chips, scratches, bird droppings, lightning, hail, windstorm, dings, dents, earthquake, road salt, tree sap, water or flood.
ROUSH SHALL NOT BE LIABLE FOR INCIDENTIAL OR CONSEQUENTIAL DAMAGES RESULTING FROM THE INSTALLATION
AND USE OF ROUSH PART(S) OR ARISING OUT OF ANY BREACH OF THIS WARRANTY. ALL EXPRESS AND IMPLIED
WARRANTIES INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PUPOSE, ARE
LIMITED TO THE WARRANTY PERIOD SET FORTH ABOVE. DURATION OF IMPLIED WARRANTIES, IF ANY, ARE LIMITED
TO THE WARRANTY PERIOD. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF IMPLIED
WARRANTIES OR THEIR DURATION, OR LIABILITY FOR INCIDENTIAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE
EXCLUSIONS OR LIMITATIONS MAY NOT APPLY TO YOU.
How to Get Service:
Purchaser should bring the vehicle to a Ford Dealership that to sell Roush Performance Products. The Ford Dealership will review all claims for defects in, or damage arising from, Roush Part(s) or their faulty installation. Upon the Ford Dealer's recommendation, a Roush representative will promptly assess the claim and make and/or authorize the repair, replacement, or adjustment accordingly. The final action will be determined by a combined analysis of the Ford Dealership, Ford Motor Co. (if necessary, particularly where the Ford Warranty is involved) and a Roush representative. For further information about Roush Performance
Products call 1-800-597-6874, or locate us on the World Wide Web at: www.roushracing.com or www.roushperf.com.
How State Law Applies:
This limited warranty gives you specific legal rights, and you may have other rights, which vary, from state to state.
Part # RMBINST02
Printed in USA
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