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How-I-Did-It: Roush Front Fascia Installation
Posted June 19, '03
Written by Audie Cleaveland (folome)

 

Roush Front Fascia Installation for 1999+ Mustangs

The majority of the information presented here is from the Roush Mustang Front Fascia Installation Instructions.  These instructions were provided by Roush Performance with the purchase of my Roush front fascia.  Any additional comments that I thought were needed were added in red. I didn't add pictures that I thought were unnecessary.  If you can't pull a headlight out, you might want to reconsider having this installed by a body shop.  The instructions state that "This kit is intended for professional installation."  I had the fascia professionally prepped and painted, but I installed it myself in less than 1 ½ hours.

The kit was well packaged and came with all parts required to accomplish the installation.  I found very few things in the documentation that needed clarification.  During a test fitting before sending the fascia to be painted, it was determined that the fascia needed no trimming.

Included Parts:

  • 1 -front cover
  • 2 - side mounting brackets
  • 11 - grille clips
  • 1 - grille panel
  • 2 - fog lights
  • 2 - fog light brackets
  • 6 - pop rivets
  • 2 - screws for attaching the fascia inside the fender opening
  • 1 - horse/corral mounting bracket
  • 6 - tinnerman nuts
  • 2 - screws for the horse/corral mounting bracket
  • 1 - set of installation instructions

Procedure:

Stock Fascia Removal:

  1. Disconnect the fog lights.
  2. Remove the headlamp assemblies (two retainers per side) and disconnect the electrical connections. (Don't try to pry off the headlamp connector, remove the retaining ring first, then remove the connector.  It will keep you from breaking a connector)
  3. Remove the two radiator sight shield pins. (I had four of these to remove)
  4. Remove the two grille retainer pins. 
  5. Remove the two bumper cover retainer pins.
  6. Remove one retainer screw from each front fender opening.
  7. Remove the two retainers from the front underside of the bumper cover. (I missed getting a picture here, but they're easy enough to find.  Pull on the center pin, and then the rest of the retaining clip will come out.)
  8. Remove the two nuts from each bracket (left and right side) at the front inner fenders. (This can be done without placing the car on ramps or a lift.)
  9. Carefully remove the front fascia assembly.  (You may want to get another set of hands for this part)


Click image for larger view

(everything removed, fog light wiring extensions in place)


Roush Fascia Installation Preparation: 
(After you have it painted)

  1. Install the lower grille assembly onto the fascia using the 11 supplied clips.  (I used all 11 clips to fit it in nice and snug and close up all the gaps.)
    NOTE:  Do not mount the clips on the thick grille tabs.


Click image for larger view

(grill insert clip placement)

  1. Install the left and right fascia support brackets onto the fascia.  Each bracket requires three supplied pop rivets.


Click image for larger view
(pop rivets in place)

3. Remove and discard the hard shell connectors from the factory fog lamp wiring harness.

NOTE:  De-pin the connectors. DO NOT clip the wires.  Only remove the hard shells.  Replace the hard shell connectors with the supplied hard shells. (This was the only part of the install that I would consider difficult.)

4. Install the fog lights into the brackets with four supplied screws per fog light.


(fog lights and grill in place)


Roush Fascia Installation:

  1. Position the front fascia over the grille area.  (This was the only part of the install that required two people.)
  2. Install the two upper bumper pin-type retainers.
  3. Connect the parking light and headlamp electrical connectors for each side, then install the left and right headlamp assemblies.
  4. Install the four headlamp retainers (two per side).
  5. Install the two front bumper underside pin-type retainers.
  6. Install the four bumper cover retaining nuts (two per side) and tighten to 44 lbs-in.
  7. Install the two retainers in the wheel opening. (one per side)
  8. Position the radiator sight shield in place and install the two pin-type retainers.
  9. Adjust the fog light bean direction using the adjustment screw.
  10. Carefully remove the horse and corral from the stock grill.
    (NOTE:  I found it easier to do steps 10 and 11 in reverse order.  The horse blocks access to one of the screw holes required to mount the bracket.  I also used a dremel tool to slot the screw head on the existing screw since I did not have the required bit)|
  11. Install the horse and corral onto the supplied bracket using the four supplied tinnerman nuts.
  12. Install the horse/corral assembly and bracket onto the grille opening support with the two screws.

(installation complete)

(profile)


Its Done!

Great job on the install Audie! Car looks great!!

 

}}kev

 

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