Paxton Superchargers Shelby Mustang GT User Manual
DP/N: 4809660 - v1.0 Shelby 02/27/07
Owner’s Installation Guide for the
Paxton Automotive
Novi 1200 Supercharger
for the
2005-2007 4.6L Mustang GT
Paxton Automotive . 1300 Beacon Place . Oxnard CA 93033
805 604-1336 . FAX (805) 604-1337
P/N: 4809660
©2007 Paxton Automotive
All Rights Reserved, Intl. Copr.Secured
27FEB07 v1.0 05-07ShelbyMusGT(4809660v4.0)
ii
FOREWORD
Take note of the following before proceeding:
1. Proper installation of this supercharger kit requires general automotive
mechanic knowledge and experience.Please browse through each step of
this instruction manual prior to beginning the installation to determine if you
should refer the job to a professional installer/technician.Please contact
your dealer or Paxton Automotivefor possible installers in your area.
2. This product was designed for use on stock (un-modified, OEM) vehicles. The
PCM (computer), engine, transmission, drive axle ratios and tire O.D.must be stock. If
the vehicle or engine has been modified in any way, check with Paxton prior to installation and use of this product.
3. Use only premium grade fuel with a minimum of 91 octane (R+M/2).
4. Always listen for any sign of detonatlion (knocking/pinging) and discontinue hard use
(no boost) until problem is resolved.
5. Paxton is not responsible for any clutch, transmission, drive-line or engine damage.
Exclusions from Paxton warranty coverage considerations include, but
not limited to:
1. Neglect, abuse, lack of maintenance, abnormal operation or improper installation.
2. Continued operation with an impaired vehicle or sub-system.
3. The combined use of Paxton components with other modifications such as, but not limit-
ed to, exhaust headers, aftermarket camshafts, nitrous oxide, third party PCM programming or other such changes.
©
2007 PAXTON AUTOMOTIVE
All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, or translated
into another language in any form, by any means without written permission of Paxton Automotive.
T
his manual provides information on the installation, maintenance and service of the
Paxton supercharger kit expressly designed for this vehicle.All information, illustra-
tions and specifications contained herein are based on the latest product information
available at the time of this publication.Changes to the manual may be made at any time
without notice. Contact Paxton Automotive for any additional information regarding this kit
and any of these modifications at (805) 247-0228 8:00am-4:30pm PST.
STOP
P/N: 4809660
©2007 Paxton Automotive
All Rights Reserved, Intl. Copr.Secured
27FEB07 v1.0 05-07ShelbyMusGT(4809660v4.0)
iii
TABLE OF CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii
TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv
TOOL & SUPPLY REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
PA RTS LIST (2005-2006 Mustang GT, H.O.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii
PA RTS LIST (2007 Mustang GT, H.O.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .x
1. PREPARATION/REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2. OIL FEED INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3. OIL DRAIN ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4. POWER STEERING RELOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
5.1 COOLANT TUBE RELOCATION (2005-2006 Models Years Only) . . . . . . . . . . . . . . . . . .7
5.2 THERMOSTAT HOUSING/RADIATOR HOSE MODIFICATION (2007 Model
Year Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
6. SUPERCHARGER MOUNTING PLATE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .12
7. THERMOSTAT HOUSING RELOCATION (2005-2006 Only) . . . . . . . . . . . . . . . . . . . . .15
8. CHARGE AIR COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
8.A BUMPER COVER AND SPLASH PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
8.B CHARGE AIR COOLER ASSEMBLY INSTALLATION . . . . . . . . . . . . . . . . . . . . .20
8.C ENGINE COOLANT RESERVOIR INSTALLATION (2005-20006
Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8.D RADIATOR HOSE MODIFICATIONS (2005-2006 Models Only) . . . . . . . . . . . . .30
8.E ENGINE COOLANT RESERVOIR INSTALLATION (2007 Models Only) . . . . . . .31
8.F COOLER CORE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
8.G COOLANT RESERVOIR FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
8.H COMPRESSOR BYPASS VALVE ASSEMBLY INSTALLATION . . . . . . . . . . . . . .36
9. CRANK CASE BREATHER AND PCV INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .37
10. AIR INLET ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
11. FUEL PUMP UPGRADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
12. REFLASH COMPUTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
13. FINAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
P/N: 4809660
©2007 Paxton Automotive
All Rights Reserved, Intl. Copr.Secured
27FEB07 v1.0 05-07ShelbyMusGT(4809660v4.0)
iv
IMPORTANT NOTES
NOTICE
This product is protected by state common law, copyright and/or patent.
All legal rights therein are reserved. The design, layout, dimensions,
geometry, and engineering features shown in this product are the exclusive property of Shelby/Paxton Automotive, LLC.This product may not
be copied or duplicated in whole or part, abstractly or fundamentally,
intentionally or fortuitously, nor shall any design, dimension, or other
information be incorporated into any product or apparatus without prior
written consent of Shelby/Paxton Automotive, LLC.
P/N: 4809660
©2007 Paxton Automotive
All Rights Reserved, Intl. Copr.Secured
27FEB07 v1.0 05-07ShelbyMusGT(4809660v4.0)
v
Before beginning this installation, please read through this entire instruction booklet and the Street
Supercharger System Owner’s Manual which includes the Limited Warranty Program, the
Warranty Registration form and return envelope.
Paxton supercharger systems are performance improving devices. In most cases, increases in torque
of 30-35% and horsepower between 35-45% can be expected with the boost levels specified by
Paxton
Automotive.This product is intended for use on healthy, well maintained engines. Installation
on a worn-out or damaged engine is not recommended and may result in failure of the engine as
well as the supercharger.Paxton
Automotive
is not responsible for engine damage.
Installation on new vehicles will not harm or adversely affect the break-in period so long as factory
break-in procedures are followed.
For best performance and continued durability, please take note of the following key points:
1. Use only premium grade fuel 91 octane or higher (R+M/2).
2. The engine must have stock compression ratio.
3. If the engine has been modified in any way, check with Paxton prior to using this product.
4. Always listen for any sign of detonation (pinging) and discontinue hard use (no boost) until
problem is resolved.
5. Perform an oil and filter change upon completion of this installation and prior to test driving
your vehicle.Thereafter, always use a high grade SF rated engine oil or a high quality synthetic, and change the oil and filter at least every 3,000 miles. Never attempt to extend the
oil change interval beyond 3,000 miles, regardless of oil manufacturer’s claims as potential
damage to the supercharger may result.
6. Before beginning installation, replace all spark plugs that are older than 1-year or 15,000
miles with original heat range plugs as specified by the manufacturer and reset timing to factory specifications (follow the procedures indicated within the factory repair manual and/or
as indicated on the factory underhood emissions tag). Do not use platinum spark plugs
unless they are original equipment. Change spark plugs every 20,000 miles.
TOOL & SUPPLY REQUIREMENTS
• Factory repair manual
• 3/8" socket and drive set:SAE & metric
• 1/2" socket and drive set:SAE & metric
• 3/8"NPT tap, 3/8-18 tap & handle
• Adjustable wrench
• Open end wrenches: 3/8", 7/16", 1/2", 9/16"
• Center punch and a 5/8" tapered punch
• 6 quarts (or what is specified in your owner’s manual)
SF rated quality engine oil, oil filter and wrench
If it has been 15,000 miles or more since your vehicle’s last spark plug change, then you will also need:
• Spark plug socket
• NEW spark plugs
2005-2007 Mustang GT
Installation Instructions
Congratulations on selecting the best performing and best backed automotive
supercharger available today... the PAXTON® supercharger!
S U P E R C H A R G E R S
P/N: 4809660
©2007 Paxton Automotive
All Rights Reserved, Intl. Copr.Secured
27FEB07 v1.0 05-07ShelbyMusGT(4809660v4.0)
vi
P/N: 4809660
©2007 Paxton Automotive
All Rights Reserved, Intl. Copr.Secured
27FEB07 v1.0 05-07ShelbyMusGT(4809660v4.0)
vii
PART NO. DESCRIPTION QTY. PART NUMBER DESCRIPTION QTY.
IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts
immediately.
2005-2006 Mustang GT, H.O.
Part No. 1001860
SUPERCHARGERS
PARTS LIST
1016140 S/C ASY, SHELBY '05-'07 V8 MUS 1
4FU130-036 OIL DRAIN ASY, '05 MUS GT 1
7U030-036 1/2" OIL DRAIN HOSE 2.5'
7R001-008 #8 STNLS HOSE CLAMP 2
7P375-017 3/8"NPT x 1/2" BEADED HSE BRB 1
4FU130-026 OIL FEED ASY, G5 MUS GT 1
7U250-090-260 OIL FEED HSE, 26" x -4 x 90° 1
7P125-005 1/8"NPT STR. x -4 JIC FTG STL 1
7P250-091 1/4"NPT x 90° x -4 JIC FTG STL 1
9P250-034 1/4"NPT x 1/4"NPT STRT T 1
4FU112-010 AIR INLET ASY, '05 MUS GT 1
4FU012-010 INLET DUCT, “A”, '05 MUS GT 1
4FU012-015 INLET DUCT, “B”, '05 MUS GT 1
7R002-056 #56 SAE TYPE “F” SS HOSE CLAMP 1
7S400-200 SLEEVE, 4" x 2", BLUE 2
7S400-351 REDUCER SLV 4.00" x 3.5" x 2.35"L 1
7R002-064 #64 SAE TYPE “F” SS HOSE CLAMP 5
8H040-235 AIR FILTER, 4.0"FLG x 7.0"L 1
8A003-071 MAF, 3/8"ID, '05 MUS GT 1
7P750-102 3/4"NPT x 1" x 90° HSE FIT 1
7P250-047 1/4"NPT TO 3/8" BARB x90° 1
4FU010-071 BRKT, INTAKE SUPPORT 1
7U032-016 3/8" EFI FUEL HSE HI-PRSR 4.0'
4FU013-010 COVER, AIR FILTER, '05 MUS GT 1
7C040-008 M4-7 x 8mm SHCD SS 2
4FU111-044 S/C MTG BRKT ASY, '05 MUS GT 1
4FU010-044 S/C MOUNT PLT, '05 MUS GT 1
4FU010-034 IDLER MOUNT PLATE, '05 MUS 1
4FU017-011 SPACER, STUDDED '05 MUS GT 2
2A017-750-05 SPACER, .750"OD x 2.691"LONG 2
2A017-750-06 SPACER, .750"OD x 2.712"LONG 1
2A017-879-08 SPACER, .879"OD x 1.776"LONG 1
2A017-750-07 SPACER, .750"OD x .097"LONG 1
4FU017-021 SPACER, IDLER, '05 MUS GT 1
4PCS016-160 PULLEY, IDLER, SRT10 TRUCK 1
2A046-120 BELT, GATES K061203 1
7A375-375 3/8-16 x 3-3/4" HXHD 1
7C080-150 M8-1.25 x 150mm HXHD CL10.9 1
7C080-140 M8-1.25 x 140 HXHD CL8.8 2
7A375-100 3/8-16 x 1" G5 HHCS, PLT 7
7K312-030 5/16"AN WASHER, SS 2
7K375-040 3/8"AN960 FLAT WASHER PLATED 10
4FU214-021 COOL BYPASS HOSE RELOC ASY, '05 GT 1
4FU114-021 ASY, WATER OUTLET, '05 MUS GT 1
7J875-010 7/8" SEALING WASHER 1
7F875-010 NUT, 7/8-14, SHORT/JAM 1
7U133-050 1.5" x 90° HOSE, LONG LEG 1
7U133-190 HOSE. COOLANT DRIVER’S SIDE, '05 MUS 1
7U038-000 3/4" HEATER HOSE 3.5'
7P375-075 3/4" HOSE BARB UNION, BRASS 1
7R002-020 #20 SAE TYPE “F” SS HOSE CLAMP 4
7R002-024 #24 SAE TYPE “F” SS HOSE CLAMP 2
7P125-002 FREEZE PLUG, Ø1.25" x .25"TALL 1
7R002-010 #10 SAE TYPE “F” SS HOSE CLAMP 4
7P125-016 1/8"NPT PLUG 1
4FU110-010 P/S RESERV. RELOC. '05 MUS GT 1
7P375-075 3/4" HOSE BARB UNION, BRASS 1
7P375-050 3/8" HOSE UNION, BRASS 1
7R001-004 #4 HOSE CLAMP 2
7R001-008 #8 STNLS HOSE CLAMP 2
7U038-030 HOSE, P/S, 3/4"ID 3'
7U032-016 3/8" EFI FUEL HOSE, HI-PRSR 3'
7A250-075 1/4-20 x .75" SHCS PLTD 1
7J250-001 1/4" WASHER, SAE PLTD 2
7F250-021 1/4-20 NYLOCK NUT, ZINC PLATED 1
4FU010-010 P/S RELOC BRKT, '05 MUS GT 1
7U100-055 TIE-WRAPS, 7.5" NYLON 4
8N101-290 WELDED CORE ASY, '05 MUS GT 1
8N155-080 COOLANT RES.RELOC. '05 MUS 1
8N055-080 TANK, RAD OVERFLOW, '05 MUS 1
4FU010-051 MTG BRKT “A”, RES.RELOC. '05 MUS 1
4FU010-061 BRKT “B”, COOL RES.RELOC. '05 MUS 1
7A250-051 1/4-20 x .50" HHCS ZINC PLTD 4
7P250-045 1/4" MALE NPT x 3/8" MALE BARB 1
7J006-093 6mm WASHER, PLATED 4
7R002-010 #10 SAE TYPE “F” SS HOSE CLAMP 1
7P375-050 3/8" HOSE UNION, BRASS 1
7U030-056 3/8" PCV/VAC RUBBER HOSE 2.5'
7R004-002 STEPLESS.CLAMP, 17.0-70 3
7C060-020 M6-1.0 x 20mm HHCS ZN 3
7J006-093 6mm WASHER, PLATED 3
4FU139-096 PCV/MAF MOD ASY, '05 GT 1
7P375-106 PCV VALVE, FORD, 3/8" HOSE 1
7P625-375 REDUCER, 5/8" BARB TO 3/8" BARB 1
7R001-006 #6 STNLS HOSE CLAMP, NARROW 2
7R001-008 #8 STNLS HOSE CLAMP 3
7R002-010 #10 SAE TYPE “F” SS HOSE CLAMP 1
7U032-016 3/8" EFI FUEL HOSE HI-PRSR .5'
5W018-030 18GA STRD WIRE GREY 1.0'
5W018-010 18GA STRD WIRE RED 1.0'
5W018-020 18GA STRD WIRE BLK, UL1015 1.0'
5W018-080 18GA STRD WIRE BLUE BULK 1.0'
5W018-090 18GA STRD WIRE BROWN BULK 1.0'
5W018-100 18GA STRD WIRE PURPLE 1.0"
5W001-007 3/16" HEAT SHRINK TUBING 1.5'
5W001-005 3/8" PLASTIC WIRE LOOM 1.5'
5W001-012 18-22 GA BUTT CONN RED INSUL 12
7U033-020 HOSE, 5/8"ID CLASS 1 EMISSIONS 0.066'
8F060-048 FUEL INJ, 39lb EV6, OEM '03 COB 8
3863515 DECAL, PAXTON COLOR, 9" x 3" 2
008575 S/C STRT INFO PKG ASY PAXTON 1
4809660 INSTR MANUAL, '05 MUS GT 1
4FU114-010 RAD PIPE RELOC ASY, '05 MUS GT 1
4FU014-010 RADIATOR PIPE, '05 MUS GT 1
7R002-024 #24 SAE TYPE “F” SS HOSE CLAMP 2
8F101-262 FUEL PUMP ASY, '05 MUS TWIN INTA 1
7U032-016 3/8" EFI FUEL HSE, HI-PRESS. .23'
7U100-055 TIE-WRAPS, 7.5" NYLON 4
7R004-002 STEPLESS CLAMP, 17.0-70 2
8F001-255 255 INTANK FUEL PUMP, '86-'97 1
7R002-044 #44 SAE TYPE “F” SS HOSE CLAMP 1
7R004-006 STEPLESS CLAMP, 11.3"x 5mm WIDE 4
5W001-022 T-TAP CONNECTOR 14-16AWG 2
5W001-009 16-14GA MALE SLIDE INSULATED 2
5W001-080 FUSE, 20AMP MINI BLADE 1
7P375-099 Y-UNION, 3/8" BARBED, TEFLON 1
7U032-025 HOSE, 5/16"ID x 3/8"OD x 1"W 0.125"
7U032-030 HOSE, SPIRAL, 3/8" CUFF ID, 1"L 2
P/N: 4809660
©2007 Paxton Automotive
All Rights Reserved, Intl. Copr.Secured
27FEB07 v1.0 05-07ShelbyMusGT(4809660v4.0)
viii
PART NO. DESCRIPTION QTY. PART NUMBER DESCRIPTION QTY.
IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts
immediately.
2005-2006 Mustang GT, H.O.
cont’d
Part No. 1001860
SUPERCHARGERS
PARTS LIST
5A003-035 PREDATOR, '05 MUS 1
5A001-025 DIABLO MAFia, '05 MUS 1
8N104-125 SUPPORT PCS.'05 GT MUS CLR GEN2 1
8N056-061 SURGE TANK, INTEGRA GSR MODIFIED 1
8N055-050 PLASTIC CAP, SURGE TANK 1
8N010-160 SURGE TANK BRKT, '05 MUS GT 1
7R007-001 NYLON RATCHET CLAMP, 1-1/8" 16
7P500-026 1.2"NPT x 3/4" BARB x 90° BRASS 2
7U038-012 HOSE, Ø3/4" x 90°, 4" x 12" LEGS 1
7U038-000 3/4" HEATER HOSE 12'
7U030-065 3/4" x 90° RUBBER HOSE, SHORT 1
7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 2
7S275-055 ELBOW, Ø2.75" x 55° SILICONE 1
7S450-200 SLEEVE, 4-1/2" x 2", BLUE 1
7R002-044 #44 SAE TYPE “F” SS HOSE CLAMP 2
7R002-072 #72 SAE TYPE “F” SS HOSE CLAMP 2
7P375-075 3/4" HOSE BARB UNION, BRASS 3
7J006-093 6mm WASHER, PLATED 5
7A250-050 1/4-20 x .50" SHCS ZINC PLTD 3
7A250-051 1/4-20 x .50" HHCS ZINC PLTD 2
7U038-020 HOSE, Ø3/4" “S” MOLDED RUBBER 1
8F001-403 PUMP, WATER, BOSCH 1
7R003-028 ADEL CLAMP, 2-3/8" x .26" HOLE 2
5W018-010 18GA STRD WIRE, RED 5'
5W001-009 16-14GA MALE SLIDE, INSULATED 1
5W001-011 16-14GA RING TERM. .26" HOLE 1
5W001-022 T-TAP CONN. 14-16AWG 1
5W001-032 1/4" PLASTIC WIRE LOOM 60"
7U100-055 TIE-WRAPS, 7.5" NYLON 6
7R002-016 #16 SAE TYPE “F” SS HOSE CLAMP 4
7P156-082 5/32" TEE 1
7U030-046 5/32" VACUUM LINE 5'
8D001-001 STD COMPRESS BYPASS VALVE 1
7U034-016 1" GS HEATER HOSE 1'
7U034-016 1" GS HEATER HOSE 1.25'
5W001-071 FUSE HOLDER, 16GA WIRE 1
5W001-015 FUSE, BLADE, TYPE 20AMP 1
008341 PAXTON CHARGE COOLER DECAL 1
7U375-054 3/4" VINYL CAP 1
7P218-156 VAC.TEE, 7/32", 7/32", 5/32" 1
5W001-050 HARNESS, FUEL INJ. PLUG w/WIRES 1
7R003-016 ADEL CLAMP, 1.0" 1
7A250-074 1/4-20 x .75" HHCS PLTD 2
7J250-001 1/4" WASHER, SAE, PLTD 4
7F250-020 1/4-20 HEX NUT 2
7u038-150 HOSE, 3/4" x 150° MOLDED HOSE 1
8N010-220 MTG BRKT, '05-'07 MUS BOSCH PUMP 1
8N106-135 WATER CLR ASY, '05 MUS GEN II 1
8N006-020 WATER COOLR, FLDYN DUAL PASS 1
8N010-171 BRACKET, DRVR’S SIDE CLR MNT. PLT 1
8N010-173 BRACKET, PASS’S SIDE CLR MNT. 1
2A017-036 SPACER, PLT. BRG.HSG., 0.186" 4
7C080-030 M8-1.25 x 30 HXHD CL10.9 6
7F008-020 NUT, M8-1.25 6
7J312-000 5/16" FLAT WASHER, SAE 12
7A250-051 1/4-20 x .50 HHCS ZINC PLATED 4
7J250-001 1/4" WASHER, SAE PLATED 4
P/N: 4809660
©2007 Paxton Automotive
All Rights Reserved, Intl. Copr.Secured
27FEB07 v1.0 05-07ShelbyMusGT(4809660v4.0)
ix
P/N: 4809660
©2007 Paxton Automotive
All Rights Reserved, Intl. Copr.Secured
27FEB07 v1.0 05-07ShelbyMusGT(4809660v4.0)
x
PART NO. DESCRIPTION QTY. PART NUMBER DESCRIPTION QTY.
IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts
immediately.
PARTS LIST
2007 Mustang GT, H.O.
Part No. 1001859
1016140 S/C ASY, SHELBY '05-'07 V8 MUS 1
8FU130-036 OIL DRAIN ASY, '05 MUS GT 1
7U030-036 1/2" OIL DRAIN HOSE 2.5'
7R001-008 #8 STNLS HOSE CLAMP 2
7P375-017 3/8"NPT x 1/2" BEADED HSE BRB 1
4FU130-026 OIL FEED ASY '05 MUS GT 1
7U250-090-260 OIL FEED HOSE, 26' -4 x 90° 1
7p125-005 1/8"NPT STR x -4 JIC FTG STL 1
7P250-091 1/4"NPT x 90° x -4 JIC FTG STL 1
7P250-034 1/4"NPT x 1/4"NPT STRT T 1
4FU112-010 AIR INLET ASY, '05 MUS GT 1
4FU012-010 INLET DUCT, “A”, '05 MUS GT 1
4FU012-015 INLET DUCT, “B”, '05 MUS GT 1
7R002-056 #56 SAE TYPE “F” SS HOSE CLAMP 1
7S400-200 SLEEVE, 4" x 2" BLUE 2
7S400-351 REDUCER SLV 4.0" x 3.5" x 2.35"L 1
7R002-064 #64 SAE TYPE “F” SS HOSE CLAMP 5
8H040-235 AIR FILTER, 4.0" FLG x 7.0"L 1
8A003-071 MAF, 3.8"ID, '05 MUS GT 1
7P750-102 3/4"NPT x 1" x 90° HSE FIT 1
7P250-047 1/4"NPT x 3/8" BARB x 90° 1
4F010-071 BRKT, INTAKE SUPPORT 1
7U032-016 3/8"EFI FUEL HSE HI-PRSR 4'
4FU013-010 COVER, AIR FILTER, '05 MUS GT 1
7C040-008 M4-7 x 8mm SHCD SS 2
4FU111-044 S/C MTG BRKT ASY, '05 MUS GT 1
4FU010-044 S/C MOUNT PLT, '05 MUS GT 1
4FU010-034 IDLER MOUNT PLATE, '05 MUS 1
4FU017-011 SPACER, STUDDED '05 MUS GT 2
2A017-750-05 SPACER, .750"OD x 2.691"L 2
2A017-750-06 SPACER, .750"OD x 2.712"L 1
2A017-879-08 SPACER, .875"OD x 1.776"L 1
2A017-750-07 SPACER, .750"OD x .097"L 1
4FU017-021 SPACER, IDLER, '05 MUS GT 1
4PCS016-160 PULLEY, IDLER, SFT10 TRUCK 1
2A046-120 BELT, GATES K061203 1
7A375-375 3/8-16 x 3-3/4" HXHD 1
7C080-150 M8-1.25 x 150mm HXHD CL10.9 1
7C080-140 M8-1.25 x 140mm HXHD CL8.8 2
7A375-100 3/8-16 x 1"GS HHCS, PLT 7
7K312-030 5/16"AN WASHER, SS 2
7K372-040 3/8"AN960 FLAT WASHER PLATED 10
4FU110-010 P/S RESERV RELOC, '05 MUS GT 1
7P375-075 3/4" HOSE BARB UNION, BRASS 1
7P375-050 3/8" HOSE UNION, BRASS 1
7R001-004 #4 HOSE CLAMP 2
7R001-008 #8 STNLS HOSE CLAMP 2
7U038-030 HOSE, P/S, 3/4"ID 3'
7U032-016 3/8" EFI FUEL HOSE HI-PRSR 3'
7A250-075 1/4-20 x .75" SHCS PLTD 1
7J250-001 1/4" WASHER, SAE, PLTD 2
7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 11
4FU010-010 P/C RELOC BRKT, '05 MUS GT 1
7U100-055 TIE-WRAP, 7.5" NYLON 4
8N155-082 COOLANT RES RELOC, '07 MUS 1
8N055-080 TANK, RAD OVERFLOW, '05 MUS 1
4FU010-061 BRKT “B”, COOL RES RELOC '05 MUS 1
7A250-051 1/4-20 x .50" HHCS ZINC PLTD 4
7P250-045 1/4" MALE NPT x 3/8" MAKE BARB 1
7J006-093 6mm WASHER, PLATED 10
7P375-050 3/8" HOSE UNION, BRASS 1
7U030-056 3/8" PCV/VAC RUBBER HOSE 2.5'
7R004-002 STEPLESS CLAMP, 17.0-70 3
4FU010-091 BRKT. COOL RES RELOC, '07 GT 1
7A250-074 1//4-20 x .75" HHCS PLTD 3
7F250-021 1/4-20 NYLOCK NUT ZINC PLATED 3
7R002-010 #10 SAE TYPE “F” SS HOSE CLAMP 2
7U038-000 3/4 HEATER HOSE 1.83"
7P100-076 HOSE REDUCER, 1" - 3/4" PLASTIC 1
4FU139-096 PCV/MAF MOD ASY, '05 GT 1
7P375-106 PCV VALVE, FORD, 3/8" HOSE 1
7P625-375 REDUCER, 5/8" BARB x 3/8" BARB 1
7R001-006 #6 STNLS HOSE CLAMP, NARROW 2
7R001-008 #8 STNLS HOSE CLAMP 3
7R002-010 #10 SAE TYPE “F” SS HOSE CLAMP 1
7U032-016 3/8" EFI FUEL HSE HI-PSR .5'
5W018-030 18GA STRD WIRE GREY 1'
5W018-010 18GA STRD WIRE RED 1'
5W018-020 18GA STRD WIRE BLK, UL1015 1'
5W018-080 18GA STRD WIRE BLUE BULK 1"
5W018-090 18GA STRD WIRE BROWN BULK 1"
5W018-100 18GA STRD WIRE PURPLE 1'
5W001-007 3/16" HEAT-SHRINK TUBING 1.5'
SW001-005 3/8" PLASTIC WIRE LOOM 2.5'
5W001-012 18-22GA BUTT CONN RED INSUL 12
7U033-020 HOSE, 5/8"ID CLASS 1 EMISSIONS .066'
8F060-048 FUEL INJ. 39LB EV6, OEM '03 COB 8
3863515 DECAL, PAXTON COLOR, 9" x 3" 1
008575 S/C STRT INFO PKG ASY PAXTON 1
4809660 INSTR MANUAL '05 MUS GT 1
4FU114-030 WATER PIPE ASY, '07 MUS GT 1
4FU014-051 HOUSING, THRST RELC '07 MUS GT 1
7C060-015 M6-1.0 x 16mm SHCS CL10.9 + 2 2
7U012-018 O-RING, '07 MUS GT THERM HSG 1
4FU014-060 WATER PIPE, Ø1.5" x 90°, '07 MUS 1
7R002-024 #24 SAE TYPE “F” SS HOSE CLAMP 3
5W001-085 SLEEVE, FLEX BRD Ø1.5" NOM .83'
7C060-025 M6-1.0" x 25mm HX 2
7J006-094 6mm WASHER SS 2
4FE014-010 RADIATOR PIPE, STAINLESS 1
8N106-135 WATER COOLER ASY, '05 MUS 1
8N006-020 WATER COOLER, FELDYN DUAL PA 1
8N010-171 BRACKET, DRVR’S SIDE, CLR MNT 1
8N010-173 BRACKET, PASS’S SIDE, CLR MNT 1
2A017-036 SPACER, PLT, BRG HSG, 0.186" 4
7C080-030 M8-1.25 x 30mm HXHD CL10.9 6
7F008-020 NUT, M8-1.25 6
7J312-000 5/16" FLAT WASHER-SAE 12
7A250-051 1/4-20 x .50" HHCS ZINC PLTD 4
7J250-001 1/4" WASHER, SAE, PLTD 4
8F101-262 FUEL PMP ASY, '05 MUS TWIN INTA 1
7U032-016 3/8" EFI FUEL HSE HI-PSR .23'
7U100-055 TIE-WRAP, 7.5" NYLON 4
7R004-002 STEPLESS CLAMP, 17.0-70 2
8F001-255 255 INTANK FUEL PUMP '86-'97 1
7R002-044 #44 SAE TYPE “F” SS HOSE CLAMP 1
7R004-006 STEPLESS CLAMP, 11.3 x 5mm WIDE 4
5W001-022 T-TAP CONN, 14-16AWG 2
5W001-009 16-14GA MALE SLIDE INSULATED 2
5W001-080 FUSE, 20AMP MINI BLADE 1
7P375-099 Y-UNION, 3/8" BARBED TEFLON 1
7U032-025 HOSE, 5/16"ID, 3/8"OD, 1/32"W .125'
7U032-030 HOSE, SPIRAL 3/8" CUFF ID, 1"L 2
SUPERCHARGERS
P/N: 4809660
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All Rights Reserved, Intl. Copr.Secured
27FEB07 v1.0 05-07ShelbyMusGT(4809660v4.0)
xi
2007 Mustang GT, H.O. cont’d
Part No. 1001859
5A003-038 PREDATOR, '07 MUS 1
5A001-025 DIABLO MAFia, '05 MUS 1
8N104-125 SUPRT PCS, '05 MUS GT CLR GEN2 1
8N056-061 SURGE TANK, INTEGRA GSR MODIFIED 1
8N055-050 PLASTIC CAP, SURGE TANK 1
8N010-160 SURGE TANK BRKT, '05 MUS GT 1
7R007-001 NYLON RATCHET CLAMP, 1-1/8" 16
7P500-026 1.2"NPT x 3/4" BARB x 90° BRASS 2
7U038-012 HOSE, Ø3/4" x 90°, 4" x 12" LEGS 1
7U038-000 3/4" HEATER HOSE 12'
7U030-065 3/4" x 90° RUBBER HOSE, SHORT 1
7P500-078 1/2"NPT x 3/4" HOSE FIT STRT 2
7S275-055 ELBOW, Ø2.75" x 55° SILICONE 1
7S450-200 SLEEVE, 4-1/2" x 2", BLUE 1
7R002-044 #44 SAE TYPE “F” SS HOSE CLAMP 2
7R002-072 #72 SAE TYPE “F” SS HOSE CLAMP 2
7P375-075 3/4" HOSE BARB UNION, BRASS 3
7J006-093 6mm WASHER, PLATED 5
7A250-050 1/4-20 x .50" SHCS ZINC PLTD 3
7A250-051 1/4-20 x .50" HHCS ZINC PLTD 2
7U038-020 HOSE, Ø3/4" “S” MOLDED RUBBER 1
8F001-403 PUMP, WATER, BOSCH 1
7R003-028 ADEL CLAMP, 2-3/8" x .26" HOLE 2
5W018-010 18GA STRD WIRE, RED 5'
5W001-009 16-14GA MALE SLIDE, INSULATED 1
5W001-011 16-14GA RING TERM. .26" HOLE 1
5W001-022 T-TAP CONN. 14-16AWG 1
5W001-032 1/4" PLASTIC WIRE LOOM 60"
7U100-055 TIE-WRAPS, 7.5" NYLON 6
7R002-016 #16 SAE TYPE “F” SS HOSE CLAMP 4
7P156-082 5/32" TEE 1
7U030-046 5/32" VACUUM LINE 5'
8D001-001 STD COMPRESS BYPASS VALVE 1
7U034-016 1" GS HEATER HOSE 1'
7U034-016 1" GS HEATER HOSE 1.25'
5W001-071 FUSE HOLDER, 16GA WIRE 1
5W001-015 FUSE, BLADE, TYPE 20AMP 1
008341 VORTECH CHARGE COOLER DECAL 1
7U375-054 3/4" VINYL CAP 1
7P218-156 VAC.TEE, 7/32", 7/32", 5/32" 1
5W001-050 HARNESS, FUEL INJ. PLUG w/WIRES 1
7R003-016 ADEL CLAMP, 1.0" 1
7A250-074 1/4-20 x .75" HHCS PLTD 2
7J250-001 1/4" WASHER, SAE, PLTD 4
7F250-020 1/4-20 HEX NUT 2
7u038-150 HOSE, 3/4" x 150° MOLDED HOSE 1
8N010-220 MTG BRKT, '05-'07 MUS BOSCH PUMP 1
8N101-290 WELDED CORE ASY, .05 MUS GT 1
PART NO. DESCRIPTION QTY. PART NUMBER DESCRIPTION QTY.
IMPORTANT: Before beginning installation, verify that all parts are included in the kit. Report any shortages or damaged parts
immediately.
SUPERCHARGERS
PARTS LIST
P/N: 4809660
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All Rights Reserved, Intl. Copr.Secured
27FEB07 v1.0 05-07ShelbyMusGT(4809660v4.0)
xii
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P/N: 4809660
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27FEB07 v1.0 05-07ShelbyMusGT(4809660v4.0)
1
A. Disconnect the battery before proceeding.
B. Loosen the hose clamp at the throttle body.
Disconnect the plastic 3/8" tube assembly
attached to the passenger’s side valve cover.
Remove the plastic 3/8" x 90° connector from the
plastic tube that was connected at the passenger’s
side valve cover. Set this connector aside to be reused in a later step. Discard the remainder of the
hose assembly, as it will not be re-used. (See Fig.
1-c.)
C. Disconnect the mass air flow (MAF) sensor plug
and remove the inlet duct and upper air filter
cover from the car. (See Figs. 1-a, 1-b, 1-c.)
D. Remove the 10mm headed bolt (located next to
the inner fender) which secures the lower portion
of the air filter enclosure. Remove the lower portion from the car - it will not be reused. (See Fig.
1-d.)
E. Remove the six plastic push pins securing the
radiator cover. Remove the cover and set aside to
be reinstalled later. (See Fig. 1-e.)
1. PREPARATION/REMOVAL
Fig. 1-a
Fig. 1-b
MAF CONNECTOR
Fig. 1-c
CRANKCASE
BREATHER HOSE
RETAIN THIS
90° HOSE END
Fig. 1-d
10mm HEADED BOLT
THROTTLE
BODY CLAMP
NOTE: The preferred method of removing the
90° connector from its original plastic
tube is to apply a small amount of heat
to the tube and slide the connector free.
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27FEB07 v1.0 05-07ShelbyMusGT(4809660v4.0)
2
F. Locate the coolant drain plug on the passenger’s
side of the radiator. Next drain the coolant into a
clean container. This coolant will be reused in a
later step.
G. Remove the two 8mm headed bolts securing the
coolant overflow reservoir to the plastic fan
shroud. (See Fig. 1-f.)
H. Disconnect the small overflow hose (running
across the top of the radiator) from the overflow
reservoir. (See Fig. 1-f.)
I.1 (2007 Models Only) Remove the large hose
connected to the bottom of the coolant overflow
reservoir. (See Fig. 1-g.)
2007 Models Skip to 1.m.
I.2 (2005-2006 Only) Remove the large hose con-
necting the thermostat housing to the bottom of the
overflow reservoir. Set the hose and reservoir aside
to be reinstalled in a later step. (See Fig. 1-g.)
J. Remove the two upper radiator hoses from the
engine coolant crossover tube and set aside. The
radiator hose located on the driver’s side will not
be reused. (See Fig. 1-g.)
K. Remove the thermostat housing from the large
formed hose leading to the engine block and the
lower outlet of the radiator. (See Fig. 1-h.) Set
the thermostat housing aside to be reinstalled in a
later step.
L. Remove the lower hose on the radiator and set the
hose aside, as it will not be reused.
M. Drain and remove the power steering reservoir.
This reservoir will be relocated in a later step.
N. Disconnect and remove the factory 5/8" plastic
breather hose assembly attached to the driver’s
side valve cover and intake manifold. Remove the
two fittings from the ends of the plastic tube for
re-use. Discard the striped plastic tube. (See Fig.
1-i.)
NOTE: If you are installing H.O. (charge cooled)
kit, the coolant reservoir will not be
reused. Retain only the fill cap for reuse.
Fig. 1-f
Fig. 1-e
Fig. 1-g
8mm HEADED BOLTS
COOLANT
OVERFLOW HOSE
TWO UPPER
RADIATOR HOSES
HOSE TO
THERMOSTAT
NYLON CLIPS
1. PREPARATION/REMOVAL, cont’d
P/N: 4809660
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27FEB07 v1.0 05-07ShelbyMusGT(4809660v4.0)
3
Fig. 1-h
LARGE FORMED
HOSE TO
ENGINE BLOCK
O. The installation of this supercharger system
requires the removal, in part or whole, of the
intake manifold so that modifications can be made
to the coolant crossover tube or thermostat housing depending on year of application:
1. (2005-2006 Only) Unplug the wire connec-
tors from each of the eight injectors. Remove
all of the vacuum hoses and connectors located at the front and rear of the intake manifold.
Remove the connector attached to the intake
manifold runner control (IMRC) unit located
at the rear of the manifold on the passeger’s
side.
2. (2007 Only): Unplug the wire connectors
from each of the eight injectors.
3. Remove the four 8mm headed bolts securing
the injector rails to the intake manifold. Do
not remove the small clips that retain the
injectors to the fuel rails. Using a 5/8" spring
lock tool, disconnect the fuel feed line from
the fuel rail. Remove the vacuum line from
the fuel regulator. Remove the rails and injectors as a complete unit and set aside. New
injectors will be installed in a later step. (See
Figs. 1-i, 1-j.)
4. Locate and remove the remaining 10mm
headed bolts retaining the intake manifold to
the cylinder heads. There are five on each
side.
5. (2005-2006 Only): Remove the intake man-
ifold and set aside so it can be reinstalled after
modifications to the coolant crossover tube
are made.
Fig. 1-j
Fig. 1-i
8mm HEADED SCREWS
RETAIN FACTORY
HOSE ENDS
NOTE: Modification to the crossover tube
will be completed in a later step
REMOVED IN STEP “G”
1. PREPARATION/REMOVAL, cont’d
THERMOSTAT
HOUSING
6. (2007 Only): It is not necessary to remove
the intake manifold from the vehicle completely. Raise the front of the manifold 3-4"
and support between the throttle-body and
alternator.
NOTE: Modification to the thermostat will
be completed in a later step.
P/N: 4809660
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All Rights Reserved, Intl. Copr.Secured
27FEB07 v1.0 05-07ShelbyMusGT(4809660v4.0)
4
Fig. 1-o
Fig. 1-r
Fig. 1-r1
Fig. 1-s
STUD BOLT
MODIFY STUD
REMOVE 13mm
HEADED BOLT
REMOVE
STUD BOLT
P. Using a 1/2" ratchet, release the tension from the
accessory drive belt and remove it from the car.
This drive belt will be replaced with a longer one
later in the installation.
Q. Locate and remove the stud bolt that secures the
alternator in place as well as the bolt located to
the right of the alternator. (See Fig. 1-o.) Using a
15mm socket or wrench, remove the nut that
secures the capacitor, resistor and coolant hose
support bracket to the stud bolt. Using an 18mm
socket or wrench, remove the stud bolt, it will be
modified and replaced in a later step.
R. There is a small tab that secures the wiring har-
ness in place on the valve cover that will need to
be removed to gain clearance for the supercharger
belt. This tab is best removed with a small air saw
but a grinder will work. After removal, smooth the
area to prevent damage to the belt. (See Figs. 1-r,
1-r1.)
S. As seen in Fig. 1-o, the upper bolt is removed
from the timing chain cover. This bolt will have to
be modified by cutting off the threaded end where
the resistor attaches. Modify and reinstall the bolt.
(See Fig. 1-s.)
T. Disconnect the plug to the cam position sensor.
Remove the wiring harness from the retaining
clips that hold it to the valve cover. Move the harness out of the way. This harness will have to be
relocated to gain clearance for the supercharger.
REMOVE TAB
TAB REMOVED
1. PREPARATION/REMOVAL, cont’d
MODIFIED
STUD BOLT
P/N: 4809660
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27FEB07 v1.0 05-07ShelbyMusGT(4809660v4.0)
5
A. Locate the factory oil sensor on the driver’s side
of the vehicle near the oil filter.
B. Remove the sending unit and set aside.
C. Locate the supplied 1/4"NPT street TEE fitting.
Install the TEE in the same location as the factory
sending unit with the 1/4" x –4 x 90° installed on
the TEE at the location noted. (See Fig. 2-a.)
D. Attach the stainless steel –4 hose to the –4 fitting
installed in the street TEE. (See Fig. 2-a.)
E. Route the hose away from hot, sharp or moving
parts and move to the top of the engine where it
will be attached to the supercharger oil feed.
F. Reinstall the factory sensor in the branch of the
TEE as shown. (See Fig. 2-a.)
A. To provide an oil drain for the supercharger, it is
necessary to make a hole in the oil pan. It is best
to punch the hole rather than to drill it.
B. Remove paint from the area around the hole.
C. Mark the oil pan 5/8" down from the oil pan
mounting rail on the driver’s side of the engine.
Measure forward 3/4" from the first bolt on the
side of the oil pan. (See Fig. 3-a.)
D. Use a small center punch to perforate the pan and
expand the hole. Switch to a larger diameter
punch and expand the hole further to approximately Ø9/16". Most punches are made from
hexagon material and may be placed in a socket
with an extension to make this procedure easier.
E. Tap the hole with a 3/8"NPT tap approximately
1/4" deep. Pack the flutes of the tap with heavy
grease to hold chips. Use a small magnet to check
for any stray chips.
3. OIL DRAIN ASSEMBLY INSTALLATION
Fig. 2-a
Fig. 3-a
Fig. 3-b
NOTE: The oil feed hose to the S/C will be
installed in a later step of the installation. Temporarily cap the open end of
the hose to prevent contamination to
the inside of the hose.
3/4"
5/8"
NOTE: This method of rolling over the lip of the
hole and tapping it works very well if
carefully done and should cause no
problems.
F. Thoroughly clean the threaded area. Apply a small
amount of silicone sealer or teflon paste to the
new threads. Apply more sealer to the 3/8"NPT
hose fitting and secure in the hole. Make sure a
seal is formed all around the fitting. (See Fig. 3-
b.)
G. Drain the engine oil and change the filter.
2. OIL FEED INSTALLATION
P/N: 4809660
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27FEB07 v1.0 05-07ShelbyMusGT(4809660v4.0)
6
4. POWER STEERING RELOCATION
A. Locate the power steering assembly 4FU110-010.
B. Attach the power steering (P/S) relocation bracket
4FU010-010 with the hardware provided to the
P/S reservoir removed in an earlier section. (See
Fig.4-a.)
C. Attach the 3/4" P/S hose along with the 3/8" P/S
hose to the outlets of the reservoir with the clamps
provided. (See Fig. 4-b.)
D. Attach the 3/4" and the 3/8" hose barb unions to
the factory hoses using the factory clamps.
E. Attach the reservoir to the passenger’s side radia-
tor core support using one of the factory ground
strap retaining bolts. (See Fig. 4-c.)
F. Attach the hoses from the reservoir to the factory
P/S hoses and secure with the supplied clamps.
Trim for best fit. Secure the hose to the fan shroud
away from heat and moving objects.
G. It will be necessary to trim the corner of the radia-
tor core support cover to clear the relocated P/S
reservoir. (See Fig. 4-d..)
Fig. 4-a
Fig. 4-b
Fig. 4-c
Fig. 4-d
TRIMMED AREA
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