99-03 Mustang V6 "Shaker" System Instructions - Xtreme Car Forum :: Enthusiast in Training

Steam · #1 (**permalink**) 11-13-2007

*03 Model requires new hood
Contents w/ Kit

1 - Hood Appliqué
1 - Aluminum Shaker Scoop
1 - Lower Air Box w/drain tube fittings (2)
1 - Upper Air Box w/CDC nameplate
1 - Air Tube
3 - Ball Stud Sockets & Brackets (Y & Z)
1 - 2pc. Intake Bracket
4 - M-6 - 1.0 Ball Studs
1 - 3/8" ID Driver Side Drain Tube
2 - 3/8" Drain Tubes (18" length)
2 - 4.8 - 1.6 x 15mm Phillips Head Screws
8 - 5/16" Thread Cutting Nuts
3 - M-6-1.0 x 70 mm Hex Head Screws
1 - M-6-1.0 x 75mm Hex Head Screw
5 - M-6-1.0 x 10mm Hex Head Screws
7 - M-6 Washers
4 - M6 - 1.0x18.5mm Hex Head Bolts
2 - 1/4" Washers
4 - #8 x 3/4" Self Tapping Screws
1 - Weather Seal, 60" Long
1 - 6mm nut
1 - Hood Cutout Template
1 - Filter Housing to Air Tube Extension
1 - Forward Bracket with Ball Stud Socket
1 - Air Filter Cover Cutout Template
1 - Instructions
Tool List For Appliqué:

Template
Tape
Center Punch
1" Hole Saw
Saber Saw
1/8" Pilot Drill Bit
5/16" Drill Bit
3/8" Allen Wrench
Scissors for cutting Template
Drill Motor
Phillips Head Screw Driver
Eye Protection

Tool List For Shaker & Shaker Brackets:

8mm Socket
10mm Socket
11mm Socket
¼" or 3/8" Drive Ratchet
T40 (Torx Bit)
INCH LB. Torque Wrench
Removable Loctite
1/2" Socket, 1/4" Drive
1/4" Drive Nut Driver
Note: To ensure the quality of the vehicle and product, have your Shaker Appliqué painted by a qualified professional automotive painting facility. Product is Injection Molded ABS Plastic and recommended bake temperature is 130 degrees Fahrenheit or below.

Installing Hood Appliqué:

A) Raise Hood, Remove under hood blanket (and production hood scoop if installed on car) 7 nuts, 9mm (Figure 1)

Figure 1
B) Close Hood - Align template with hood feature lines as noted on template. Tape template securely to outside hood surface (Figure 2)

**Note: Do not remove template from hood until steps A-G are complete.

Figure 2
C) Using a center punch, transfer the (10) screw hole locations to the hood. Drill with a 1/8” pilot hole through template, hood and inner reinforcement. (NOTE: Make sure holes A, B, C, D, E are drilled through hood inner reinforcement) (Figure 3)

Figure 3
D) Raise hood – Using a 1” hole saw, drill holes called out as A, B, C, D, and E in the hood inner reinforcement. DO NOT DRILL THROUGH THE HOOD OUTER WITH HOLE SAW! . (Figure 4 & 5)

Figure 4

Steam · #2 (**permalink**) 11-13-2007

E) Close hood. Finish drilling the 10 pilot holes with the drill size indicated on the template.
F) Drill a starter hole for the Shaker opening with a 1” hole saw as shown on template. Use a saber saw to cut out the Shaker opening (Figure 6)

Figure 5
G) Open hood. Attach appliqué to hood using (8) 5/16" Thread Cutting Nuts and (2) 4.8-1.6 x 15mm Phillips head screws. *Use Phillips head screws at attachment points just forward of hood scoop opening.

Note: Do not over tighten appliqué bolts!
*Install thread cutting nuts with a 1/2" Socket on a nut driver to hand tight
** Torque Nuts to 15 inch pounds

Figure 6
H) Reinstall hood blanket using original fasteners. (Figure 7)
I) Cut hood blanket to fit appliqué opening. (Figure 7)
J) Install weather strip and cut to size to opening as shown. Weather strip sandwiches appliqué, hood, outer and blanket together. (Figure 7)

**Note: Bulb on seal should be on outside of opening.

Steam · #3 (**permalink**) 11-13-2007

For complete instructions on:

Mounting the Shaker Air Box
Assembling Air Tube
Shaker Air Box Assembly

See Full instructions here - 99-02 Mustang 'Shaker' Scoop Installation Instructions

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