1999-2004 Ford Lightning GT500 Swap Kit Installation Guide

By Garrett, GA Performance LLC

Installing a 2007-2014 Shelby GT500 engine in a 1999-2004 Ford SVT Lightning means planning the accessory drive as carefully as the engine itself. This guide follows GAPerformance Youtube video walkthrough of the GT500 Engine Swap Kit: power steering brackets, alternator relocation, pulleys, tensioners, belts, and the reservoir mount.

The engine in the demonstration is an iron-block setup. Use the video alongside this written guide to identify bracket orientation, hardware locations, and belt routing. 

Watch the GT500 swap kit installation video

Open the full installation video on YouTube.

Installation chapters

1. Prepare the engine and accessory components

Start with the GT500 engine stripped to the accessory configuration shown at the beginning of the video. GAP demonstrates reuse of a 90 mm pulley from the Lightning pulley bridge. A suitable billet pulley can also be used, but the demonstrated location has very little clearance: the 90 mm size is an important detail.

The demonstration also uses the Lightning A/C compressor with the donor-year GT500 10-rib clutch fitted to it, and the Lightning oil cooler mount. Confirm those components against your donor engine and compressor combination before assembly.

The current kit listing specifies power steering pump F85Z-3A674-ABRM. In the video, GAP points out that there are two pump styles and demonstrates the longer 2004-style pump. Identify the correct pump before installing its bracket; do not assume every Lightning pump has the same dimensions.

Check your kit configuration before starting

  • Confirm the alternator bracket option: the current listing offers Ford 4G and 6G configurations.
  • Match the power steering reservoir bracket to the OEM or Moroso tank you will use.
  • Select the correct 45-degree plenum adapter for your supercharger and inlet combination.
  • Check the pulley options and any separately selected fan, wiring, throttle, MAF, or fuel-system components.

The listing includes the supercharger belt tensioner without a pulley, alternator flip bracket, alternator 10-rib pulley, wide water pump pulley, power steering pump bracket, tensioner relocation insert, plenum elbow, throttle cable bracket, intake tube, air box, air filter, low-profile driver-side valve cover fitting, belts, gaskets, and hardware. Review the current kit contents and options for your order.

2. Install the power steering pump bracket and pump

Video chapter: 1:19. Locate the power steering pump bracket using the two mounting holes on the block. Start the block fasteners, then install the Allen fastener and high-collar lock washer at the timing-cover attachment shown in the video.

Fit the locating pins, position the pump, and install the retaining bracket. GAP identifies two bolt lengths in this assembly: the longer bolts go on the outside and the shorter bolts go on the inside. Two small bolts secure the retainer. Follow the video to distinguish the retainer hardware from the main pump mounting hardware.

The pump position is designed to clear the steering box in the demonstrated Lightning setup. Check that relationship on your own installation before completing the surrounding plumbing.

3. Mount the lower alternator bracket and water pump pulley

Video chapter: 4:09. Install the lower alternator bracket in the location shown, then fit the wide water pump pulley. This establishes the lower portion of the accessory arrangement before the upper bracket and alternator are assembled.

The current kit listing states that the water pump and alternator pulleys are supplied in anodized black. Check the supplied parts and hardware against your order before proceeding.

4. Assemble the upper alternator bracket and adjustable tensioner

Video chapter: 5:33. The upper alternator bracket also provides an adjustable tensioner function. Begin with the Allen fasteners and high-collar lock washers shown in the walkthrough.

GAP demonstrates reusing pulleys from the Lightning pulley bridge at the indicated locations. For the adjustable pulley assembly, pass the large bolt through the pulley and fit the nut behind the bracket. Leave that adjustment loose at this stage. It is locked down after the belt position and tensioner setting have been established.

5. Install the alternator and begin belt routing

Video chapter: 6:56. Fit the 10-rib alternator pulley before placing the alternator in its relocated position. GAP positions the belt while installing the alternator so it can be routed around the pulley, then secures the alternator.

Continue routing the belt and install the tensioner as demonstrated. Adjust the upper assembly and check that the pulleys and belt line up before locking the adjustment. Use the video for the actual belt path: the routing depends on seeing which side of each pulley the belt follows, rather than relying on a list of pulley names.

6. Fit the tensioner relocation insert and finish the belts

Video chapter: 10:31. GAP shows the locating pin on the back of the tensioner and explains how the relocation changes its clocking. In the demonstrated assembly, the locating pin is shaved down slightly and the supplied relocation insert provides the new engagement position.

This locating-pin preparation is part of the procedure shown in the video. Compare your tensioner and insert with the demonstration before modifying the pin; no fixed pin-trimming dimension is provided in the walkthrough. If the engagement or orientation is unclear, contact GAPerformance before proceeding.

Fit the insert at the back of the tensioner, position the assembly, and work the belt on slowly while watching its seating. GAP specifically emphasizes keeping an eye on the belt during this step. Once installed, check the power steering belt tension, main-drive belt tension, alignment, and seating across the pulleys.

7. Install the reservoir mount and review the assembly

Video chapter: 13:02. Install the power steering reservoir mount using the two M6 fasteners identified in the walkthrough. Confirm that the bracket matches the reservoir option selected with your kit.

In the completed demonstration, the power steering pump clears the steering box, the alternator is flipped into its relocated position, and the Lightning A/C compressor remains in its stock location. GAP explains that this arrangement retains the stock A/C line placement in the setup shown.

Final assembly checklist

  • Compare the bracket orientations and belt paths with the completed assembly in the video.
  • Confirm that the adjustment left loose earlier is now secured.
  • Check that all belt ribs are seated correctly and that the belt tracks in line with the pulleys.
  • Check the power steering pump, steering-box clearance, reservoir mounting, and nearby line routing.
  • Verify hardware installation and use the applicable component torque specifications. The video does not provide torque values.
  • Complete the separate wiring, fuel, cooling, and calibration checks required for the full engine swap before starting the engine.

Order the kit or discuss your build

Shop the GA Performance GT500 Engine Swap Kit or browse 1999-2004 Lightning GT500 swap parts. The kit is typically made to order; check the product listing and contact us for current production timing.

For help choosing the correct configuration, contact GA Performance with your truck year, GT500 donor year, block, alternator, supercharger, and power steering reservoir details. Our shop is located in Pompano Beach, Florida.