Anyone have some pics or the instructions for installing the brake cooling duct kit M-2004-MB on the standard Boss - what's invloved?
Thanks,
Rick

 

Sorry, no pictures.
But, having installed them on my Boss, these are some of the items you'll run into.

Plan on cutting the wheel well liners.
You will find it is easier to do a test fit with the liner after the hose is installed, remove the liner and cut it on a piesce of wood using a blade. The plastic cuts pretty easy.

Plan on removing, (cutting, the plastic brackets that are used to hold the factory fog lights. They putrude about 3 inches into the cavity where you will need to work the hose around the other stuff.

The 'other stuff'.
On the driver side, the horn is going to be in the way. I read where someone turned the horn upside down. In my case I just bent the brackets holding the horn out of the way.

Passenger side; the windshield resevoir will be in the way. You'll have to bend the hose around that as well.

I tried everything to get the hose to slide onto the metal ducting backing disk that attaches to the rotor. I gave up and just cut 2 or 3 of the wire rings slid the casing onto the plate and tightened down with the supplied clamp.

The hose will not clamp down and stay affixed to the front ducts. Use electrical tape around the the plastic duct to aid in giving the hose some bite. ( I think this was Cloud9's idea..it works!)

 

Good to hear I'm not the only one! I bought a Kenny Brown spindle-mounted duct kit, and it was a royal pain getting a 3" hose on it, the opening is oval shaped on mine making it even harder. Used WD40, windex, etc to try to grease it up. Found that cutting out the first 4-6" of wire completely allowed the silicone hose to be started on it, then slowly rotating until the wire engaged the opening. Had to be done completely off the car, though, so that's an idea as well -- mount hose to the spindle/backing piece, then mount spindle piece, then thread hose to the front.

I ended up using large 3" hose clamps on both ends to make sure it stays put -- tried zipties on my front fascia ducts, and slipped off at the track.

 

Paging Cloud9!

 

I found for the most part the brake duct kit was easy to install except for the aforementioned difficulty of getting the duct over the back of the plate mounted on the brakes themselves. After trying on and off the car finally took everything off and let my dealer do it. Never thought of cutting the wire in the duct. Sounds like the answer. If you have issues with the inner fender liner just leave it off. That's what I did.

I just sanded the plastice where the duct mounts on the for light opening and this made is stay on without much problem although the aforementioned electrical tape obviously works.

If your kit comes without the plastic fog light inserts (with the opening already cut) like mine did just call Ford Performance. They sent me a set out with no additional cost. Good Luck!!

 

Pics start on Post #23

http://bossmustangsonline.com/boss-3...angsonline/15/

 

I searched bossmustanonline and mustangsource before I did mine and did not find this. Wish I had known about removing the wire. Oh well live and learn.

 

It's not in a great spot.....I just put it in the middle of Boss pics. I'll go move it to its own thread.

 

Sound like a good plan. Thanks for all of your help and input!!!

 

The inserts are supposed to be part of the kit?? GT*O.

 

I didn't know that either.

 

The instructions that came with my kit showed the inserts as part of it and to install them. I called Ford Performance parts and they said they would look into it. Faxed them my sales receipt and address and they sent out the inserts out at no charge. Got them within 3 or 4 days. I was really surprised and pleased. Don't know if it matters if you have a Boss or not. Before you cut yours (if you haven't already) give them a call.

 

I had ordered a separate set so I wouldn't have to cut mine. that's what I get for not reading the instructions yet. I'll make my call tomorrow.

 

I think I'll install mine later this week...

 

What are the 'inserts' you speak of? I havent' received the kit yet but seems I will still have to cut the fog light holes regardless. What am I missing here?
Will I need to order the California Special lower facia or is the Boss the same thing?
Rick

 

I installed the kit yesterday. Not the best designed kit. A couple of issues. I believe the tires are going to hit the tubing when turned in fully. I havent got it of the lift yet to see if this is going to happen. I may have to crush the ducting so the tires don't tear it up. Has anyone else addressed this issue? Also, as mentioned, the windshield washer bottle is in the way on the right side. Instead of cutting away the fog light plastic and bending and crushing the duct to get by the bottle and the cooler line, I just removed the washer bottle. Three bolts hold it on. I have not used the washers yet so I thought I might as well get rid of it (less weight too). And I can't believe the made the metal tube that the duct attaches too so big. Yea, I had to get rid of the wire inside the duct. I also removed the horn assembly and reversed the horns and the bracket so it was facing up. I would like to see how this was all done on the LS?

 

Check posts #91 and #93 http://bossmustangsonline.com/boss-3...angsonline/90/

You should be able to route the hose far enough inside so you don't rub it with the tire. You have to remove (or cut bottom 1/3 off) the plastic shield on the driver side and cut the vertical triangular shaped piece of plastic on the passenger side. You should be able to route the hose around the washer bottle without removing it. It's a snug fit, but it will go and it still flows well. Or just get rid of it like you did.

 

Here's the mod to get around the washer bottle:

 

Here's the piece you have to trim to route the passenger side hose far enough inboard to avoid rubbing the tire:

 

Remove this piece (or cut off bottom 1/3) so you can route the driver side hose inboard under the swaybar to avoid tire rubbing: