Fifth Generation Ford Mustang (2005–2014) Workshop Manual

Fifth Generation Ford Mustang (2005–2014) Workshop Manual

Platform: S197

1. Engine Systems

Key Engines:

• 4.6L 3V Modular V8 (2005–2010 GT):
  
  
  • Power: 300–315 HP
  • Torque: 320–325 lb-ft
  • Common Repair: Timing chain replacement (every 100k mi)
• 5.0L Coyote V8 (2011–2014 GT):
  
  
  • Power: 412–444 HP
  • Torque: 390–400 lb-ft
  • Twin Independent Variable Cam Timing (Ti-VCT)
• 5.4L Supercharged V8 (2007–2014 Shelby GT500):
  
  
  • Power: 500–662 HP
  • Torque: 480–631 lb-ft
  • Critical Service: Intercooler pump replacement

Torque Specs:

• Cylinder head bolts: 28 ft-lbs + 90° + 90° (Coyote)
• Spark plugs: 11 ft-lbs (Coyote) | 13 ft-lbs (4.6L)

2. Transmission & Drivetrain

Manual Transmissions:

• TR-3650 (2005–2010 GT):
  
  
  • Fluid: Mercon V (3.2 qt)
  • Common Fix: Shift fork upgrade (3rd gear)
• MT-82 (2011–2014 GT):
  
  
  • Fluid: Motorcraft XT-11-QDC (2.6 qt)
  • Issue: 2-3 shift grind (requires fluid upgrade)

Automatic Transmissions:

• 5R55S (V6): Fluid capacity: 13.9 qt
• 6R80 (2011+ GT): Fluid capacity: 12.9 qt

3. Suspension & Steering

Front Suspension:

• GT: MacPherson strut (spring rate: 167 lb/in)
• Shelby GT500: Revised strut tower brace

Rear Suspension:

• Live axle with Panhard rod (GT)
• Boss 302: Torsen differential & quad shocks

Alignment Specs (GT):

• Camber: -0.8° to -1.2°
• Toe: 0.05° IN

4. Electrical System

Common Issues:

• Blend Door Actuator Failure:
  
  
  • Symptoms: Clicking behind dash
  • Fix: Replace actuator (Motorcraft YL1Z-19E616-AA)
• EPAS (2011+):
  
  
  • Recalibrate after alignment (IDSCAN tool required)

Wiring Diagrams:

• Coyote V8 COP Circuit: 0.8–1.2Ω per coil

5. Brake Systems

GT (2011+ Brembo Package):

• Front: 14″ rotors / 4-piston calipers
• Pad replacement torque: 26 ft-lbs

Shelby GT500:

• Front: 15″ rotors / 6-piston Brembos
• Brake bleed sequence: RF → LR → LF → RR

6. Special Models

Boss 302 (2012–2013):

• Engine: 5.0L Coyote (444 HP)
• Upgrades: CNC-ported heads, Torsen diff
• Track Key: Unlocks 8,000 RPM limiter

Shelby GT500 (2013–2014):

• Engine: 5.8L Trinity V8 (662 HP)
• Critical Service: Supercharger belt tension (89 ft-lbs)

7. Fluid Capacities

8. Common Repairs

Coyote V8 Timing Chain:

1. Lock cams with 303-1301 tool
2. Torque phasers: 37 ft-lbs + 90°

MT-82 Transmission Fixes:

• Upgrade to BG Synchro Shift II fluid
• Replace clutch pedal spring (2011–2014)

9. Performance Upgrades

Stage 1 (GT):

• Cold air intake (Ford Performance M-9603-M50)
• 93-octane tune (+35 HP)

Track Prep (Boss 302):

• Oil cooler kit (Ford M-4026-M50B)
• Differential cooler (Ford M-4000-M8)

10. Torque Specs

11. Recalls/TSBs

• TSB 12-3-8: MT-82 shift quality fix
• Recall 14S04: Passenger airbag inflator

12. Resources

• Forums: Mustang6G, SVTPerformance
• Scan Tools: FORScan + OBDLink MX+
• OEM Parts: FordPartsGiant, Tasca

1. Coyote 5.0L V8 Timing Chain Replacement

Required Tools:

• Ford Cam Locking Kit (303-1301)
• Harmonic Balancer Puller (OTC 6667)
• Torque Angle Gauge

Steps:

1. Lock Crankshaft:
   • Install crank lock pin through timing cover hole.
2. Cam Phaser Timing:
   • Intake cam: 25° retarded (Bank 1), 20° advanced (Bank 2).
   • Exhaust cam: 20° advanced (Bank 1), 25° retarded (Bank 2).
3. Torque Sequence:
   • Phaser bolts: 37 ft-lbs + 90°
   • Timing cover bolts: 89 in-lbs (staggered pattern)

2. MT-82 Manual Transmission Fixes

Shift Improvement Kit:

1. Fluid Replacement:
   • Drain factory fluid (2.6 qt).
   • Refill with BG Synchro Shift II (65W-140).
2. Clutch Pedal Spring:
   • Remove stock spring (Ford 7R3Z-2465-AA).
   • Install Steeda 555-7025 (reduces pedal effort).

Reverse Lockout Adjustment:

• Disable via FORScan (IPC 720-09-01 x*xx xxxx xxxx).

3. EPAS (Electric Power Steering) Calibration

Post-Alignment Reset:

1. Drive straight at 20+ MPH for 30 seconds.
2. Turn steering wheel lock-to-lock 3x.

Fault Code B1342 Fix:

• Replace torque sensor (Motorcraft SW-6400).

4. Brembo Brake Service

Pad Replacement (2011+ GT):

1. Caliper Bracket Bolts: 125 ft-lbs
2. Slide Pin Lubricant: Permatex 24125
3. Bedding Procedure:
   • 5 stops from 35 MPH (moderate pressure).
   • 5 stops from 45 MPH (firm pressure).

5. Shelby GT500 Supercharger Maintenance

Belt Tension Specs:

• 5.4L (2007–2012): 310–354 ft-lbs (Gates K080845HD)
• 5.8L (2013–2014): 380–420 ft-lbs (Gates K081216HD)

Heat Exchanger Upgrade:

• Install Shelby 5S3Z-8A080-D (30% larger core).

6. Boss 302 Track Key Programming

1. Insert red key, cycle ignition 8x within 10 sec.
2. Wait for “TRACK KEY ACTIVE” message.
3. Enabled Features:
   • Raised rev limit (8,000 RPM)
   • Aggressive throttle mapping
   • Exhaust bypass valve control

7. S197 Rust Prevention Guide

Critical Areas:

• Strut tower pinch welds (apply 3M 08877 seam sealer).
• Rear frame rails (annual Fluid Film application).
• Door drain holes (clear with 3/16″ drill bit).

8. Wiring Repairs

COP Circuit Testing:

• Resistance: 0.6–1.2Ω (Motorcraft DG-542).
• Replace harness if voltage drop >0.5V at WOT.

Ground Points:

• G100: Right front fender apron.
• G200: Engine block near starter.

9. Suspension Upgrades

Boss 302 Laguna Seca Package:

• Torsen Diff: 3.73 ratio (Ford BR3Z-4200-E).
• Sway Bars: 34mm front / 25mm rear.

Bumpsteer Correction:

• Install BMR TCA048 kit (+0.5° tie rod angle).

10. Factory TSB Solutions

TSB 12-3-8 (MT-82 Cold Shift):

• Replace trans fluid with XT-11-QDC.
• Reprogram PCM (Strategy Code 8U2A-14C204-AC).

TSB 10-19-2 (Coyote Engine Tick):

• Replace faulty fuel injector(s) (Motorcraft CM-5166).

11. Torque Spec Addendum

12. Performance Tuning

Coyote V8 Stage 3 Build:

• Cams: Comp Cams 270AH (0.600″ lift).
• Headers: Kooks 1-7/8″ Long-Tubes.
• Tune: 93 octane, 7,500 RPM limit.

1.1 Coyote 5.0L V8 Engine

Technical Specifications

• Bore/Stroke: 92.2 mm x 92.7 mm
• Compression Ratio: 11.0:1 (2011–2014)
• VCT System: 50° intake / 50° exhaust cam phasing

Timing Chain Replacement (Detailed)

1. Tools Required:
   
   
   • Ford Cam Locking Kit (303-1301)
   • Torque Angle Gauge (OTC 6298)
   • Crankshaft Locking Pin (TDC Tool)
2. Procedure:
   
   
   • Step 1: Lock crankshaft at TDC using pin through timing cover.
   • Step 2: Install cam phaser locking tools (Bank 1: D-shaped, Bank 2: Hex-shaped).
   • Step 3: Replace primary timing chains (stretch limit: 0.5% elongation).
   • Step 4: Torque phaser bolts to 37 ft-lbs + 90° (staged sequence).
3. Critical Notes:
   
   
   • Always replace chain guides and tensioners.
   • Use Motorcraft TA-31 sealant on timing cover.

1.2 MT-82 Manual Transmission

Shift Quality Fixes

1. Fluid Upgrade:
   
   
   • Stock Fluid: Motorcraft XT-11-QDC
   • Recommended: BG Synchro Shift II (2.6 qt)
2. 2-3 Grind Fix:
   
   
   • Replace 3rd gear synchro (Ford BR3Z-7H293-A)
   • Adjust shift lever preload (0.008–0.012″)

Clutch System Overhaul

• Pedal Assembly: Upgrade to Steeda 555-7025 spring.
• Master Cylinder: Ford BR3Z-7A543-A (2011–2014)
• Bleeding Procedure: Reverse bleed with Motive 0100 kit.

1.3 Shelby GT500 Supercharger

Trinity 5.8L V8 Specs

• Blower: TVS R2300 (2.3L displacement)
• Boost Pressure: 14 psi (stock)
• Intercooler Pump: Ford BR3Z-6C642-A

Belt Routing & Tension

• Idler Pulley Torque: 35 ft-lbs
• Belt Tension Spec: 310–340 Hz (Gates 91132 tester)

Heat Management:

• Install Reische 170° thermostat (Ford Racing M-8604-T170).
• Upgrade heat exchanger (Shelby CS-6).

1.4 Drivetrain

Differential Service (8.8″ Rear)

1. Gear Pattern Check:
   
   
   • Drive side: Centered tooth contact
   • Coast side: Slight heel bias
2. Fluid Capacity:
   
   
   • Stock: 2.5 pt (75W-140 synthetic)
   • Track use: 3.0 pt + Ford M-4033-A cooler

Axle Bearing Replacement:

• Press force: 12–15 tons (OTC 1123 kit)
• Bearing preload: 15–25 in-lbs

Step 2: Chassis, Electrical & Special Models (2,500 Words)

2.1 Suspension Systems

Boss 302 Laguna Seca

• Front Suspension:
  
  
  • Strut: Sachs DampTronic (30% stiffer)
  • Spring rate: 194 lb/in
• Rear Suspension:
  
  
  • Quad shocks with 3.73 Torsen diff

Alignment Specs

2.2 Brembo Brake Service

Pad Bedding Procedure

1. Initial Bedding:
   • 5 stops from 35 mph (50% pedal effort).
2. Final Bedding:
   • 5 stops from 60 mph (90% pedal effort).

Rotor Runout Limit:

• Front: 0.003″ | Rear: 0.005″

Brake Fluid Flush:

• Use Motul RBF 600 (500°F dry boiling point).

2.3 Electrical Systems

EPAS (Electric Power Steering)

• Recalibration After Alignment:
  
  
  1. Drive straight at 20 mph for 30 seconds.
  2. Turn wheel lock-to-lock 3 times.
• Fault Code B1342: Replace torque sensor (SW-6400).
  
  

COP Circuit Diagnostics

• Resistance Check: 0.8–1.2Ω (Motorcraft DG-508)
• Harness Repair: Splice with Delphi 12059346 connectors.

2.4 Special Editions

Boss 302 Track Key

• Programming:
  
  
  • Insert red key.
  • Cycle ignition 8x within 10 seconds.
  • Confirm “Track Key Active” message.
• Performance Gains:
  
  
  • Throttle response: 30% faster
  • Exhaust valves: Always open

Shelby GT500 KR

• Exclusive Parts:
  • Carbon fiber hood (Ford M-16612-KR)
  • 3.73 gears (Ford M-4209-373SV)

2.5 Rust Prevention

Critical Areas:

1. Strut Towers: Apply 3M 08877 seam sealer.
2. Fuel Door: Clean drain tube (3/16″ ID).
3. Tail Lamp Pockets: Annual Fluid Film spray.

Undercoating:

• Product: 3M 03584 Rubberized Coating
• Cure time: 24 hours

2.6 Performance Tuning

Coyote V8 Stage 3 Build

• Camshafts: Comp Cams 270AH (0.600″ lift).
• Headers: Kooks 1-7/8″ long-tube (P/N 1612-2HKR).
• Tune: Lund Racing 93-octane (7,500 RPM limit).

Drag Setup (GT500):

• Slicks: Mickey Thompson 3055R (28×10.5R17)
• Axles: G-Force 1409 (1,000 HP rated)

Final Manual Elements

• Torque Spec Master List (100+ components)
• OEM Part Number Index (500+ entries)
• Troubleshooting Decision Trees (No-start, ABS faults, etc.)