How to Upgrade your 1999-2004 ROUSH Mustang

How to upgrade your 1999-2004 ROUSH Mustang

Stage 3 Motorsports

ROUSH first began mass producing custom modified vehicles with the 1999 to 2004 "New Edge" Mustangs and offered nine different packages throughout that five-year time span from the appearance-only Sport version to the immensely powerful 440A that came standard with ROUSH's first generation of M90 superchargers, an exhaust kit and intake that gave that Mustang close to 400 horsepower. Though each ROUSH Mustang stands on the forefront of design, every ROUSH Mustang can benefit from power, suspension and styling upgrades that push the limits of performance and appearance. As these cars age, the parts available star to slowly thin out, but there's still time to turn some of the finest of Jack Roush's creations into something even more powerful and original.

All of the ROUSH designs for the SN-95 New Edge Mustangs incorporated the ROUSH body kit into the design in one form or another. Age has not been kind to the potential parts inventory of these cars, and the only real modification that can really alter the Mustang's look is a Cobra R 2000 hood from TruFiber that comes with a fully functional heat extraction system. TruFiber's hood helps to expel hot engine compartment air into the Mustang's slipstream for proper cooling. Sport versions didn't receive wheels as part of their package, Stage 1 Mustangs got 17" Argents while higher trim levels received 18" wheels standard. An excellent upgrade option for the lower trim vehicles are a set of 18" Chrome Bullitt wheels that have a similar five-spoke design to the original Argents. Stage 3 Motorsports has a wide variety of headlights and tailights that can add original styling to your ROUSH Mustang's front and rear ends. Sport, Stage 1 and Stage 2 owners can also upgrade their entire front frame with the ROUSH Stage 3 fascia that only came as a standard item on Stage 3, 380R and 440A Mustangs.

Even though the 1999 to 2004 model years weren't the most powerful generation of Mustangs, ROUSH did their best by adding the first M90 superchargers onto the Stage 3, 380R and 440A models that was capable of boosting the 4.6L V8's total power up to 360 horsepower with 375ft/lbs of torque. The 440A was able to generate 400hp flat with the additions of pulleys, intake and high-flow exhaust. For Stage 3 and 380R Mustangs, we offer a 75mm pulley capable of generating up to 8psi of boost. For fans of naturally aspirated Mustangs, a good first step is to add a BBK cold air intake to improve engine airflow. The addition of a BBK 75mm throttle body will allow the engine to generate an extra eight to ten horsepower. Both the CAI and throttle body are sold as part of a complete kit for greater convenience. If you're looking to swap out the smallish M90 for something more significant, take a look at the Procharger P-1SC supercharger that pushes the Mustang's V8 up to 400 to 425 horsepower with no additional modifications and a proper PCM calibration. The performance of both supercharged and naturally aspirated ROUSH Mustangs greatly benefit from major exhaust upgrades to boost horsepower and torque. BBK shorty headers are an excellent choice for boosting power while keeping your ROUSH Mustang street-legal. Greater performance can be gained by investing in a complete BBK long tube header and x-pipe package. This long tube header kit eliminates most of the back pressure caused by the stock system to create a massive V8 growl and huge power gains that easily push the engine to its maximum potential. BBK's long tube kit may not meet emissions requirements in your area. Check your local emissions guidelines or contact Stage 3 before ordering.

All of this power needs a suspension system that can handle it. Stage 2 ROUSH Mustangs and higher came with full ROUSH suspensions that included Bilstein shocks and struts, front and rear ROUSH lowering springs and ROUSH front and rear sway bars. Most of ROUSH's suspension items are discontinued, but Eibach offers a similar suspension kit while Steeda can provide a strut tower brace and subframe connectors to further stiffen the front chassis and reduce flex.

ROUSH's 1999 to 2004 Mustangs were the excellent beginnings of ROUSH's now legendary vehicle designs. Though they may not have aged well, and parts are becoming exceedingly difficult to find, these cars have a lot of life left in them and still go the distance on street or track. With the right amount of work, the lowly Sport models can be just as, or even more powerful than the mighty 440As. The right modifications can push these cars to their maximum performance envelopes and let ROUSH's premium design philosophies really sing.