Recently, StangTV had the opportunity to tour the ROUSH Mustang build facility. The Livonia Michigan based ROUSH production crew are busy cranking out 2010 ROUSH Stage 1 and 427R Mustangs. We spent some time on the line documenting the parts and processes of the top of the line 427R package. Thanks goes out to John Clark, Tom Lipinski and Mark Lindgren with ROUSH Performance for the tour.

For more information about ROUSH Mustangs visit the ROUSH Performance website.

ROUSH has been building their performance version of the Mustang since the mid 1990’s. The ROUSH package has a trademark look with unique ROUSH fascias, wheels, interior updates, suspension modifications and a supercharger option. Every Mustang ROUSH builds has already been pre-ordered by a ROUSH dealer. For 2010, a ROUSH dealer chooses their Stage 1, Stage 2 or 427R package with select options and then the factory builds each car to order.

Mustang GT’s from Flat Rock Assembly Plant arrive ready for the ROUSH transformation.

Station 1

This is where a your standard Mustang starts the ROUSH treatment. ROUSH starts with a premium package mustang GT manual or automatic. Most of what they were running during our visit was the manual ROUSH 427R Mustang upfit.

The build process begins with interior disassembly. The factory seats are removed and sent to the seat department for up-fit. On the interior, ROUSH pedal covers, illuminated sill plates, light harness for the fog lamps, and ROUSH logo push button for console is installed. The instrument cluster gets pulled for up-fit. On the exterior, the spoiler pilot holes are marked on the trunk lid and rear quarters. After holes are drilled the spoiler and spoiler end plates are installed.

Seats, instrument cluster and mustang sill plates are removed.

The trademark ROUSH rear wing is installed on the decklid.

Seat Upfit Station

ROUSH seat technicians remove the OE leather from the Mustang seats and install a ROUSH signature leather seat cover. In addition to the material update, they also reprogram the occupant classification sensor. The recalibration is set so that senses the 53 pounds for the airbag sensor. This update is done so that in the event a child seat or a light person is sitting in the front passenger seat the airbags will function properly.

The factory seat leather is removed and replaced with a Jack Roush signature leather seat cover.

ROUSH recalibrates the airbag sensor on this machine after the seat is recovered.

Station 2

The front fascia is removed as well as the stock Mustang GT wheels and tires. The ROUSH technicians completely update the suspension with ROUSH spec dampers, springs, and sway bars. The front struts with springs are assembled in the subassembly area and delivered to station 2 in large crates.

ROUSH dampers, sway bars and 20″ 427R wheels and tires are installed.

ROUSH sourced upper torque arm reduces wheel hop during hard acceleration.

Of interest is the installation of a ROUSH spec upper control arm (shown above). One of the first things Jack Roush wanted fixed on the factory S197 Mustang was the wheel hop he experienced during hard launches. ROUSH engineers came up with a new upper arm that slightly changes the geometry and has a performance bushing at the body and rear end mount.

Station 3

Is where they install the performance brake packages. Brake updates include slotted rotors front and rear. The performance brake package option gets a ROUSH four-piston front caliper or monster six-piston caliper and two-piece rotor.

ROUSH Mustangs get slotted rotors and the calipers are optional. They include a monster six piston caliper on the 427R models. This 427R had the four piston caliper installed.

Station 4

The OE mustang front fascia is removed, but they maintain the factory grill and driving lamps. The ROUSH front fascia is prepped with fog lamps and a front chin splitter. The rear fascia is removed and prepped for the ROUSH lower diffuser.

Front and rear fascias are removed and replaced with ROUSH fascias.

ROUSH lower fog lamps are installed in the front fascia. Rear fascia gets a lower diffuser installed.

Station 4 Intercooler Radiator and Pump Install

When the front fascia is off, all 427R’s feature a dedicated radiator for the ROUSHcharger intercooler. The unit is integrated in front of the factory radiator. A ROUSH tech installs mounting brackets, hoses, ducting and a pump to circulate coolant from the ROUSHcharger intercooler to the radiator. After the radiator is installed the ROUSH front fascia is bolted on. For the rear fascia, a ROUSH lower fascia with integrated diffuser is installed to the OE upper bumper cover. After the new diffuser is installed its bolted to the rear of the car. This station also installs the Roush short throw shifter as well as the off road exhaust pipes.

Radiator for the ROUSHcharger intercooler is installed in front of the engine radiator.

Coolant pump and hoses for the intercooler are installed before the fascia is attached.

Front fascia is installed using original front grill from the mustang.

Station 5

The stripe station is where the cars get their vinyl graphics. The 427R gets its unique hockey side stripe. The hood gets the ROUSHcharged graphic and hood stripe and the front windshield gets the ROUSH header decal . Any decals added to the door jams or the vehicle-altered sticker is done here. The serialized number and rear 427R badging is also installed. The ROUSH window sticker and addendum sticker, including 427R revised fuel economy rating, is installed in the passenger window.

ROUSH windshield header is installed along with all other stripes and emblems.

Vinyl 427R hockey side stripe is installed in the striping station.

Station 6

Here the engine is prepped for the ROUSHcharger installation. The coolant, battery, air intake and engine intake are removed. Engine valley coolant tubes are updated as well as the engine wiring harness for the updated ROUSHcharger.

Factory intake cover and intake are removed as well as coolant drained to prepare for ROUSHcharger.

Station 7

The ROUSHcharger is installed as well as the throttle body, air intake, alternator, and the wiring harness jumpers. A dedicated degas bottle is also installed for the ROUSHcharger intercooler system. The 427R also gets a new PCM calibration to work with the updated supercharged powertrain. A “key on” test is also performed and the engine is brought up to operating temperature to test for fit and function. Here the ROUSH Mustang also gets its ROUSH logoed white gauge face cluster installed.

ROUSHcharger with intercooler, air intake, alternator, belts and jumper harness installed. Now its a 427R.

Station 8

After the powertrain updates the 427R moves to the alignment rack, final assembly and final inspection. In the final inspection stage, a 65-point inspection is performed before the car is test driven on the ROUSH property.

The ROUSH 427R is given a new performance alignment since the dampers and swaybars are replaced.

A quality inspector checks over a 65-point inspection sheet before the car is test driven and ready to ship.

Once completed each ROUSH Mustang is prepped for shipment to the final dealer. The ROUSH floor mats and offroad exhaust pipes are shipped in the trunk for installation by the receiving dealer.

Once complete the cars are moved to the transport lot in preparation for shipping to the dealer and customer.

The ROUSH 427R is an impressive machine and to watch it through its transformation is very interesting to any enthusiast. ROUSH takes alot of pride in their quality and engineering of the parts before they are installed. Its not just a “make it fit” operation and they follow a system similar to Ford for engineering and quality control. We learned alot about the ROUSH build philosophy and their passion for the Mustang.

If you are in the market for a 2010 ROUSH Stage 1, 2 or 427R its worth a trip to your local ROUSH dealer for a test drive. The suspension updates, 430 horsepower and trademark ROUSH looks set it apart from your standard Mustang GT.

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