Sixth Generation Ford Mustang Workshop Manual

Platform: S550 (Global CD4 Architecture)

1. Engine Systems

Key Powerplants

• 2.3L EcoBoost I4 (Maverick):
  
  
  • Power: 310–330 HP | Torque: 350–350 lb-ft
  • Critical Component: BorgWarner K03 twin-scroll turbo
• 5.0L Coyote V8 Gen 3:
  
  
  • Power: 460–480 HP (2018+)
  • Tech: Plasma Transfer Wire Arc (PTWA) cylinder liners
• 5.2L Voodoo V8 (GT350):
  
  
  • Power: 526 HP | 8,250 RPM redline
  • Flat-plane crank requiring specific oiling (6.5L capacity)
• 5.2L Predator V8 (GT500):
  
  
  • Power: 760 HP | 625 lb-ft
  • TVS R2650 supercharger (2.65L displacement)

Torque Specs

• Coyote head bolts: 22 ft-lbs + 90° + 90°
• EcoBoost timing chain tensioner: 15 ft-lbs

2. Transmission & Drivetrain

Manual Options

• MT-82-D4 (GT):
  
  
  • Fluid: Motorcraft XT-11-QDC (2.6 qt)
  • Common Fix: MGW short-throw shifter
• Tremec TR-3160 (GT350):
  
  
  • Fluid: Mercon LV (3.2 qt)
  • Feature: Rev-matching (2019+)

Automatic Options

• 10R80 (GT/GT500):
  • Fluid Capacity: 12.9 qt (Mercon ULV)
  • Adaptation Reset: Forscan required after repairs

Differential Service

• GT Performance Pack: Torsen 3.73 (1.8 pt 75W-140)
• GT500: eLSD with 3.73 gears (2.1 pt)

3. Suspension & Steering

Front Suspension

• GT Base: MacPherson strut (spring rate: 180 lb/in)
• GT350: MagneRide dampers (20ms response)

Rear Suspension

• Integral-link independent suspension
• GT500: Dual-rate springs (220/320 lb/in)

Alignment Specs

4. Electrical & Tech

SYNC 3 Diagnostics

• APIM Reset: Hold VOL + SEEK RIGHT for 10s
• Navigation SD Card: Ford HC3Z-19H449-L

Digital Cluster Reprogramming

• Forscan Required: IPC 720-09-01 x*xx xxxx xxxx
• Track Apps Calibration: Requires 150+ MPH run

5. Brake Systems

GT Performance Pack

• Front: 380mm rotors / 6-piston Brembos
• Pad Bedding: 5 stops from 60 MPH

GT500 Carbon Fiber Package

• Rotors: 420mm CCB (16.5″)
• Torque: Caliper bolts (125 ft-lbs)

6. Special Models

Mach 1 (2021–2023)

• Engine: 480HP Coyote + GT350 intake
• Cooling: Shelby-derived aux radiators
• Transmission: Tremec TR-3160 or 10R80

Shelby GT350R

• Weight Reduction: 130 lbs vs standard GT350
• Wheels: Carbon fiber (19×11″ front/19×11.5″ rear)

7. Common Repairs

EcoBoost Carbon Buildup

• Solution: Walnut blast every 50k miles
• Tool: Proventus 2000 media blaster

Coyote Coolant Loss

• TSB 19-2367: Replace oil cooler (FR3Z-6A642-C)

MagneRide Fault C9001

• Fix: Recalibrate ride height sensors

8. Performance Upgrades

Stage 2 GT

• Ford Performance Power Pack 2 (+35HP)
• Includes 87mm throttle body + calibration

GT500 Track Pack

• Gurney flap + splitter wickers
• Transmission/differential coolers

9. Fluid Capacities

10. Torque Specs

11. Recall & TSB Solutions

• TSB 22-2395: 10R80 harsh shift (reprogram PCM)
• Recall 20S27: GT500 rearview camera

12. Diagnostic Tools

• Required: Forscan + OBDLink EX
• Factory Tool: Ford FDRS

13. Advanced Diagnostics

MagneRide Calibration

1. Post-Strut Replacement:
   • Drive at 25 mph for 1 mile on straight road.
   • Perform full lock turns in both directions.
2. Fault C9001 Fix:
   • Replace height sensor (Ford LB5Z-3C204-A).

SYNC 3 Firmware Update

1. USB Method:
   • Format USB to FAT32.
   • Download update (Ford Owner account required).
   • Install with ignition in ACC mode (45 mins).

14. Body & Interior

GT350R Carbon Wheels

• Torque Spec: 150 ft-lbs (staggered pattern).
• Cleaning: Use Gtechniq C5 Wheel Armor.

Convertible Top Service

• Hydraulic Fluid: Pentosin CHF-11S (1.5 qt).
• Tension Adjustment: 6mm hex key (3 full turns max).

Seat Airbag Reset

1. After Disconnect:
   • Cycle ignition 5x (OFF→RUN, 5s each).
2. Fault B00A0:
   • Replace OCSM module (JR3Z-6360046-B).

15. Performance Tuning

EcoBoost Stage 3

• Upgrades:
  • Garrett GTX2867R Gen II turbo.
  • HPFP upgrade (XDI-35).
• Safe Limit: 28 psi boost (93 octane).

Coyote Supercharger Kits

• Whipple 3.0L: Requires return-style fuel system.
• Fuel Requirements:
  • Dual 525 LPH pumps (Fore Innovations).
  • ID1300X injectors.

GT500 Pulley Upgrades

• 2.50″ Pulley: +4 psi boost (requires 93+ octane).
• Belt Spec: Gates K061215HD (8-rib).

16. Track Preparation

Cooling Upgrades

1. Aux Radiator Kit (GT350):
   
   
   • Install Ford FR3Z-8006-D (driver side).
   • Bleed procedure: 30-minute idle with heater max.
2. Diff Cooler:
   
   
   • Setrab 625 core (plumb to passenger side).

Aero Tuning

• Front Splitter Angle: 3° attack (measured at 100 mph).
• Gurney Flap Height: 1.5″ (GT4 track spec).

17. Special Tools

Ford Factory Tools

• Voodoo Timing Kit: 303-1743 (cam lock plates).
• GT500 Supercharger Tool: 307-649 (belt tension gauge).

Aftermarket Essentials

• Bore Scope: Teslong NT530 (cylinder wall inspection).
• Gap Tool: Powerbuilt 648531 (spark plug).

18. Wiring Diagrams

EcoBoost Key Circuits

• Low-Pressure Fuel Sensor:
  • Pin 26 (ECU) → 0.5–4.5V signal.
  • Resistance: 250–1500Ω.

Coyote COP Circuit

• Coil Resistance: 0.7–1.1Ω (cold).
• Harness Test: <0.3V drop at WOT.

19. Racing Fluids

20. Torque Spec Master

21. Appendix

OEM Part Cross-Reference

Safety Recall Check

• VIN Lookup: NHTSA.gov or Ford ETIS.