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Factory Five Racing GTM Supercar, Assembly Manual

The Factory Five Racing GTM Supercar is a high-performance vehicle that boasts sleek looks and impressive speed. For detailed instructions on assembling this powerful machine, download the free Assembly Manual from manualshive.com. This manual is essential for successfully building your dream car and getting it on the road.

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www.factoryfive.com

  508-291-3443 

 

 
 
Once all the universal joints and bearing retainer bolts are loosely installed, make sure the linkage does 
not bind and the steering system is functional. You can test the telescoping function of the column for any 
binding by hooking a test lead to the positive side of a battery (or a jumper box or battery charger) then to 
one pole on the motor plug, and a test lead to the negative side of the battery then to the other pole on the 
motor plug.  Switch the connections at the plug to move the column in the opposite direction.  Once you 
are sure the steering and telescoping ability are both free of any binding, tighten all the Hex set screws 
and then tighten the ½” nuts to lock the set screws in place on the universals. Tighten the Steering 
Column Bolts. 
 

Pedal Box and Master Cylinders 

 

Eye protection, drill, 

25

/

64

” drill bit, drill, ½”, 

7

/

16

” wrench, 

3

/

16

” Hex key, rivnut tool.  

 

Pedal box and hardware (FFR# 25225, 25375). 

 

 

Summary of Contents for GTM Supercar

Page 1: ...R E VI SI O N 2 D A PR I L 20 1 4...

Page 2: ...2014 Factory Five Racing Inc 9 Tow Rd Wareham MA 02571 Phone 508 291 3443 Fax 508 291 3883...

Page 3: ...ice Donor Car 11 Price Transaxle 12 Running Gear 12 Corvette Parts 13 Porsche Parts 14 Disassembly of a Corvette Donor for Parts 14 Doors 14 Hood 22 Radiator Coolant Reservoir 25 Horn Assembly 30 Wind...

Page 4: ...Belts 177 Wiring Harness Computer 182 Computer Bracket 199 Disassembly of the kit 202 Unpacking Your GTM Kit 203 Removal of Body 203 Aluminum Removal and Preparation 203 Chassis Assembly 208 Steering...

Page 5: ...rgency Brake and Cables 317 Cockpit Tunnel Aluminum 320 Axles and CV joints 323 Speedometer Gear 325 CV Axle Install 326 Chassis Wiring 328 Fuse Panel 328 Main Harness Routing 330 Steering column plug...

Page 6: ...nnel Cover Aluminum 437 Main Body mounting 440 Door area mounting 442 Rear body mount 443 Firewall mounting 444 Taillights 449 Fuel Filler Caps 451 Rear Quarter Windows 453 Rear Hatch Hinge 453 Rear H...

Page 7: ...r Window 589 Interior Engine Cover 593 Fuel Tank Cover Installation 596 Undercarriage Aluminum Installation 599 Engine Floor Engine Access Panel 599 Tunnel Floor 600 Rear Quarter Floor R L 602 Fuel Ta...

Page 8: ...x Cover Aluminum 700 Front Wheel Well Rear Splash Guard Aluminum 704 Body Close out Panels 707 Front 707 Rear 708 Door Sill Carpet 710 Aluminum Door Sill Covers 712 Cockpit Upper Side Walls and Rear H...

Page 9: ...viii www factoryfive com 508 291 3443 GTM A C Hose 746 Installation Instructions 746 Heat A C Hose kit Routing Diagram 754 Heat A C Servicing Procedure 755...

Page 10: ...idea of building your own car is NOT for everyone It is a serious endeavor that should be undertaken with care and consideration The desire to build your own custom car goes way back It is part of ou...

Page 11: ...ect you order a manual talk to car guys get all excited over glossy photos and perhaps order a kit from us With the whole pregnancy thing well for most folks that s even easier to get started When my...

Page 12: ...to test out how long an 8 8 rear diff can run on a track without gear oil answer about three laps before deciding to stop moving There will be highs and there will be lows but in the end there are fe...

Page 13: ...a project of this magnitude This kit is only a collection of parts designed for use primarily as a race car Factory Five Racing does not build completed or partially completed vehicles You are respons...

Page 14: ...or electrical systems and always keep a fire extinguisher handy Don t allow children in the work area Partially assembled cars attract a crowd Keep garage doors closed or mark off work areas Make sure...

Page 15: ...y complete interior and all trim down to the smallest details like correct fasteners brackets and badges We make it easy for you to use the engine of your choice with a list of available exhaust and m...

Page 16: ...at is full of pictures and diagrams Fasteners Over 1500 top quality zinc plated chrome and stainless steel fasteners numbered and packed individually by assembly What You Need Engine LS series engine...

Page 17: ...ful SAE Combination wrench set 3 8 15 16 Metric combination wrench set 10mm 18mm Full set of standard and Phillips head screwdrivers Standard Hex key set Long nose pliers 4 5 Snap ring pliers Pop rive...

Page 18: ...ssion fluid Mercon automatic Trans fluid 4 Qts Brake fluid DOT 3 1 Qt Oil filter Fuel filter Battery Spark plugs 5 minute epoxy glue Black permanent marker with pointed tip 2 ea 2 Masking Tape 1 roll...

Page 19: ...10 www factoryfive com 508 291 3443 Donor Parts and Parts needed Chapter 2...

Page 20: ...on Ebay There are companies that sell GTM Corvette parts Kits without engines for 5 000 Below is a list that contains salvage dealer websites we have found to be useful Many of the dealers listed ofte...

Page 21: ...ny different gear ratios with a Limited Slip Differential LSD or without an LSD all of which directly affect the price of the transmission As always mileage and use street or race plays a factor in ho...

Page 22: ...smission has for gears 5 or 6 speeds and what model Porsche it came out of Here are some tips to follow when checking out running gear Corvette Parts Examine the engine mounts Some small splits in the...

Page 23: ...lity to pivot clockwise and counter clockwise Also if you can obtain the correct pressure plate slave cylinder throw out bearing and clutch fork with the transmission this is a plus You will also need...

Page 24: ...10 13 mm socket T 30 Torx Window mechanism Mirrors Exterior Door Handle Lower the window Remove the access panel behind the pull handle and remove the screws behind the pull handle Pry up the window s...

Page 25: ...d lower clips free Remove the door panel start by prying the panel fastener at the rear of the panel near the part in the liner See picture Work your way forward watching for each fastener If you plan...

Page 26: ...ut breaking the fasteners is to pry between the male end and the female end The picture below shows what each part looks like Lift the panel off of the top clips and set aside Remove the Styrofoam ins...

Page 27: ...plug at the bottom of the door Remove the access plugs at the front and rear of the door to expose the mirror retaining nuts Some models have plugs while others have adhesive backed strips pictured I...

Page 28: ...91 3443 Unbolt the three mirror retaining nuts 10 mm It may help to have a magnet handy to prevent dropping the retaining nut once it is loose Disconnect the mirror electrical plugs Remove and save th...

Page 29: ...lamp bolts they will not clear the glass in the GTM Remove the glass Disconnect the window motor electrical plug Unbolt the lower track motor and upper track retaining nuts 10 mm Unclip the motor from...

Page 30: ...com 508 291 3443 Remove the door lock rod from the lock cylinder lever This works well using a pair of pliers to press on the bottom of the rod with one jaw of the pliers and the other pressing the l...

Page 31: ...or in order for the lock cylinder lever to clear the opening in the door Save the outside handle rods bolts linkage to interior handle Hood Two people are required to remove the hood 13 mm socket 10 m...

Page 32: ...not open the hood all the way This allows you to access the lower hinge bolts with the ratchet Disconnect the hood lamp electrical connection Remove the lower hinge bolts at the hood 13mm socket Hood...

Page 33: ...person holds the hood steady unbolt the upper hood bolts from the hinges 13 mm then carefully unclip the struts from the hood Lift the hood off the hinges one person per side Remove the struts hinges...

Page 34: ...spose of all coolant properly a local garage or parts store can do this for you 10 mm socket ratchet pliers 5 8 wrench Automatic and waste container bucket Coolant Reservoir hoses and clamps Radiator...

Page 35: ...26 www factoryfive com 508 291 3443 Remove the lower reservoir bolt using a 10mm socket...

Page 36: ...ine bay Drain any remaining coolant from the reservoir Save the reservoir Radiator If you have not done so already disconnect the inlet and outlet hoses from the radiator as well as the hoses from the...

Page 37: ...28 www factoryfive com 508 291 3443 If you plan to use the optional Heater and A C unit you will need to remove the Pressure Sensor from the refrigerant line...

Page 38: ...art info OEM Corvette Pressure Sensor with 3 wires to connect through C150 to PCM Part Number 22664328 square style harness connector or Part Number 22601619 Round style connector and O ring For Autom...

Page 39: ...ning slots on the radiator Save the condenser radiator and fan shroud assembly fans motors shroud A C Pressure Switch Horn Assembly 13 mm socket ratchet Horn Assembly Remove the passenger side front f...

Page 40: ...31 www factoryfive com 508 291 3443 Windshield Wiper 13 mm socket ratchet pry bar Wiper arm Remove the wiper shroud...

Page 41: ...ww factoryfive com 508 291 3443 Unbolt the wiper arm from the tapered shaft using a 13mm socket Pry the wiper arm off of the shaft Unbolt the wiper transmission Disconnect the wiper motor electrical p...

Page 42: ...handle by yourself having 2 people to remove the exhaust works best 15 mm socket 13 mm socket extension ratchet Before removing the exhaust pipes remove the blue electrical plug retainers from the Oxy...

Page 43: ...34 www factoryfive com 508 291 3443 Unbolt the H pipe from the muffler assembly flanges using a 15 mm socket Unbolt the H pipe from the exhaust manifold flanges using a 15 mm socket...

Page 44: ...35 www factoryfive com 508 291 3443 Unbolt the H pipe to Bell Housing flange bolts 15 mm socket Unbolt the H pipe bracket to Bell Housing bolts 15 mm...

Page 45: ...icient load capacity for the job Use extreme caution when moving the engine assembly Work on a clear and level surface When disconnecting electrical components remember to identify both ends of every...

Page 46: ...Front Rear Control Arms Brakes Spindles Outer CV Joints Engine Under Car Remove the torque tube pan bolts with a 5 16 socket If you own an air compressor and an impact gun or air ratchet you ll be tha...

Page 47: ...38 www factoryfive com 508 291 3443 Remove the fuel tank pans with a 13 mm socket Disconnect the Primary Oxygen sensors from the manifolds...

Page 48: ...the ground strap behind the exhaust manifold on the driver s side 15 mm If your donor car is an Automatic place a drain pan under the coolant lines then disconnect the coolant lines at the passenger s...

Page 49: ...t the line clamp nearest the bell housing 10 mm and move the line to access the bolts mounting the torque tube to the bell housing Also be sure to leave room to access the Engine Oil Level sensor Disc...

Page 50: ...e Engine Oil Level sensor it may be necessary to rotate the sensor housing 1 1 8 wrench to access the clip Once the plug clip is pointing down it may help to use a flathead screw driver to unclip the...

Page 51: ...42 www factoryfive com 508 291 3443 Engine Oil Level Sensor removal Unbolt the motor mounts with an 18mm socket Brace the torque tube before proceeding any further...

Page 52: ...43 www factoryfive com 508 291 3443 Remove the flywheel access plug from the bottom of the bell housing and loosen the drive shaft clamp bolt...

Page 53: ...3443 Unbolt the bell housing from the torque tube Carefully pry the torque tube away from the bell housing to break the seal this makes engine removal easier Unclip the wiring harness connection at th...

Page 54: ...disconnect the battery Before removing the electrical connections on the starter it may be easier to unbolt the starter lower it slightly and support it then remove the two connections with an 8 mm w...

Page 55: ...46 www factoryfive com 508 291 3443 Unbolt the ground wire next to the Crankshaft Position Sensor 15 mm Unclip the engine wiring harness clamp on the driver side behind the exhaust manifold...

Page 56: ...nclip the wiring harness clamp at the front of the engine s left bank driver side in between the cross member and the leaf spring If you do choose to unbolt the front clamp 13 mm save the bolt you wil...

Page 57: ...it to the frame rail so it s out of the way with zip ties a bungee cord etc Engine Above Car Disconnect the Intake Air Temperature and Mass Airflow sensors Reposition the air intake duct and cleaner i...

Page 58: ...www factoryfive com 508 291 3443 Unbolt the 4 EBTCM bracket bolts 13 mm Unbolt the steering gear nut 18 mm then remove the steering gear bolt Lift the EBTCM BPMV unit and bracket out of the engine ba...

Page 59: ...sing any fluid to leak However it may be helpful to disconnect the power steering reservoir line and move it out of the way Since the EBTCM has been removed you can place a drain pan under the car and...

Page 60: ...eering pump bolts To do this you will need a puller if you do not own one you can rent one from almost any auto parts store If you cannot prevent the outer wrench from turning while you turn the inner...

Page 61: ...52 www factoryfive com 508 291 3443 Using the engine cross member to brace the outer wrench Remove the power steering pump 13 mm...

Page 62: ...291 3443 Unbolt the power steering reservoir 15 mm wrench or socket Move the pump and reservoir out of the way Unbolt the intermediate steering shaft lower bolt 13 mm You will need a pry bar to remov...

Page 63: ...Disconnect the A C compressor electrical connection The A C compressor is fastened to the engine using 3 bolts and 1 stud Unbolt the top bolts 15mm socket Use a 7 mm wrench to advance the stud The bo...

Page 64: ...om 508 291 3443 just enough to remove the compressor from the engine Remove the belt 15 mm socket Move the compressor off to the side making sure to tie it securely out of the way Disconnect the brake...

Page 65: ...toryfive com 508 291 3443 Disconnect the throttle body motor electrical plug Disconnect the alternator connections 13 mm wiring clamp behind the alternator Disconnect the engine coolant temperature se...

Page 66: ...Alternator 15 mm Save the 2 Alternator Bolts Before relieving fuel pressure in the fuel rails have a rag ready to absorb the fuel To relieve the pressure unscrew the cap at the end of the rail then p...

Page 67: ...stic clips that you can find at just about any auto parts store i e NAPA These will also come in handy when removing the fuel tanks 1997 1998 Corvettes have two fuel lines running to the fuel rails In...

Page 68: ...59 www factoryfive com 508 291 3443 Disconnect fuel injector electrical plugs and coil main connections one on each side of the engine Disconnect the EVAP solenoid connection...

Page 69: ...60 www factoryfive com 508 291 3443 Disconnect the AIR Plug Disconnect the Throttle Position Sensor...

Page 70: ...w factoryfive com 508 291 3443 Remove the AIR manifolds from the exhaust manifolds 10 mm wrench or socket socket works best on the Right side Tie the AIR lines out of the way Remove the front wheels s...

Page 71: ...side access is easiest through the wheel well Unclip the harness from the harness clamp near the Driver Engine Mount If you choose to do so by unbolting the clamp be sure to save the bolt you will ne...

Page 72: ...ds from the spindle 18 mm wrench 6 mm Hex wrench To remove the rod end from the spindle hit the rod end through the spindle with a dead blow hammer If this does not work you may need to use a ball joi...

Page 73: ...structural component of the engine and NEVER come in contact with a jack jack stand Place something in between the jack stand and the pan that will not damage the oil pan while the engine is supported...

Page 74: ...65 www factoryfive com 508 291 3443 Place jack under Cross member and unbolt 21 mm Lower the jack and remove the Cross member Front Suspension Assembly out from under the car...

Page 75: ...e engine will not break anything such as the fuel lines coil packs etc Lift the engine up and out slightly to gain access to the electrical plugs grounds wire looms at the rear of the engine 2 passeng...

Page 76: ...67 www factoryfive com 508 291 3443 Harness Connection Passenger side Ground and harness Clamp at rear of Driver Side Unplug the knock sensor...

Page 77: ...68 www factoryfive com 508 291 3443 Unplug the Engine Oil Pressure Sensor EOP Unplug the Camshaft Position Sensor...

Page 78: ...69 www factoryfive com 508 291 3443 Unplug the Manifold Absolute Pressure Sensor MAP Route the harness away from the engine Slowly lift the engine OUT not up...

Page 79: ...You will need an 18 mm wrench and possibly a 6 mm Hex key to hold the rod end steady while you loosen the nut The ball joint may need some convincing to come out of the Control Arm If you plan to sell...

Page 80: ...71 www factoryfive com 508 291 3443 Disconnect the rear harness connection Passenger Side from the E brake line Move the rear harness connection out of the way Disconnect the ABS plug from the hub...

Page 81: ...up as you finish unbolting it Disconnect the brake line from the unions above the transmission Following the same procedure as in the front of the car disconnect the brake line then unbolt the line cl...

Page 82: ...73 www factoryfive com 508 291 3443 Rear Leaf Spring Lock Washer Rear Leaf Spring Bracket Cross Member bolt removal Disconnect the E brake clip from the spindle and unbolt the bracket 15 mm...

Page 83: ...74 www factoryfive com 508 291 3443 Disconnect the ground and line clamp on the driver side from the frame For Automatic Transmission donors Unbolt the shifter cable bracket 15 mm...

Page 84: ...ve com 508 291 3443 Unbolt the cable retaining bracket 13 mm Remove all electrical connections from the shifter box the Main Harness 20pt Plug and harness clips from the transmission and cross member...

Page 85: ...factoryfive com 508 291 3443 Transmission harness Clip Transmission Main Harness Connection Before unbolting the cross member bolts be sure the weight of the assembly is still supported by the jack s...

Page 86: ...it but do save the outer CV Joints and hardware Unbolt the shock from the control arm Unbolt the sway bar from the control arm T 40 Torx 18 mm wrench Unbolt the control arm Rear Bolt 15 mm head 18 mm...

Page 87: ...a flathead screw driver to loosen the clamps After removing the hose be sure to cover the opening in the tanks to keep dirt and debris out of the tanks Make note of the color codes on the fuel lines a...

Page 88: ...291 3443 Removing Fuel Line Unplug the fuel sender electrical connection already unplugged in previous pictures Disconnect the fuel tank vapor line Some Corvettes have a quick connect fitting others y...

Page 89: ...rked in black The fuel return line blue can be unsnapped with the 5 16 disconnect tool Be sure to take note of the colors used to distinguish the lines or make your own labels to hook up the lines pro...

Page 90: ...Seat Belt Buckle Convertible Donor Remove the folding top stowage compartment lid extension panel Open the folding top stowage compartment lid Remove the upper and lower screws from the extension pan...

Page 91: ...82 www factoryfive com 508 291 3443 Remove the caps covering the retaining nuts at the rear of the console and remove the nuts 10 mm Remove the retaining nuts at the front of the console...

Page 92: ...at the back and slide slightly rearward to expose the electrical connections Unplug the fuel door switch and accessory outlets Remove the push pins and covers from the Passenger seat front adjuster le...

Page 93: ...e rear bolts by performing the following steps Remove the recliner handle Flathead screwdriver Remove the seat trim panel screws 2 Phillips screwdriver Move the panel side to side to work the barrel p...

Page 94: ...43 Disconnect the seat belt harness clip Unbolt the track and remove Unbolt and save the Seat Belt Buckle Pull the carpet away from the E Brake handle Unbolt the E brake 3 Torx T 40 bolts Unbolt the E...

Page 95: ...the E brake bracket lifting the cable through the slot Drill out the rivets holding the bracket Picture below shows cables still attached it is easier to leave the bracket riveted in place to remove...

Page 96: ...m will help you to recognize what you need don t need when you get to the wiring stage of your GTM build Trim Plate IP Accessory Flathead Screwdriver T 15 Torx Shift into 2nd Automatic or 4th Manual f...

Page 97: ...to the lighter behind the grill plate and behind the ashtray T 15 Torx Pull the trim plate rearward Disconnect the electrical connection from the lighter You may need to lightly pry the plug clips pas...

Page 98: ...ven t done so already Remove the Fog lamp Trunk Release switch pry at the bottom to release Disconnect the electrical plug Unscrew the retaining bolt behind the switch and the two screws under the kne...

Page 99: ...g the airbags to accidentally deploy The airbags deploy quickly with a lot of force so you do not want to have your head or any body part near the airbag if it deploys without warning 7 11 mm socket 1...

Page 100: ...emove the bolster bracket screws by sliding a socket 7 mm with extension through access holes in the bottom of the bracket Remove the bracket Unbolt upper steering shaft coupling bolt 11 mm Remove upp...

Page 101: ...R Remove the positive connection clip from the yellow connector at the base of the column then unplug the connection Remove courtesy light Pry the Sound Insulator Panel front clips loose then with a s...

Page 102: ...com 508 291 3443 Remove panel Unplug the yellow plug behind the steering column brace Unplug the SDM fuse 16 in IP fuse block under passenger kick panel This is a safety feature to prevent the air ba...

Page 103: ...e hold the wheel or lower shaft to the break the two screws loose Or if you do not have an extra set of hands available you can hold the Torx screwdriver with a set of locking pliers and steady the wh...

Page 104: ...position assurance clip CPA unplug the module electrical connection Unscrew the ground connection T 25 Unscrew the horn connection Disconnect all electrical connections under the column attached to t...

Page 105: ...bolt the upper steering column nuts deep 13 mm Pull the column towards you rotating clockwise to allow the lower bracket and telescoping motor if equipped to clear the column brace Save the column inc...

Page 106: ...orange wires leading to the lock module on the column Strip a small section of insulation off the orange and purple wires the end of the wire leading to the column not the plug then simultaneously to...

Page 107: ...gnition to stereo bracket 10 mm Automatic donors Disconnect the park cable by inserting the key turn the ignition to ON and use a screw driver to release the lock tab at the underside Pull the cable c...

Page 108: ...m 508 291 3443 Shifter Automatic Flathead Screwdriver 10 mm socket ratchet Remove the four retaining nuts holding the shifter assembly to the tunnel Disconnect the park electrical connection from the...

Page 109: ...five com 508 291 3443 From under the car unclamp the shifter from the tunnel wall Press the clamp arms inward while pulling back Pull the cable out of the bracket by sliding the cable through the slot...

Page 110: ...oster grille by prying up with a screwdriver Unplug DRL and Sunload sensor if equipped by twisting it out of the grille Remove the pillar moldings Remove all screws holding the pad in place corners of...

Page 111: ...102 www factoryfive com 508 291 3443 Remove the dash Passenger Air Bag 10 mm socket Disconnect the electrical connection...

Page 112: ...lace Unclip the heater hose 2 locations Stereo and Heater Controls 10 mm socket Unbolt the 4 bolts holding the Aluminum center bracket in place 10 mm Slide the bracket out of place Disconnect the line...

Page 113: ...the pod away from the pedal bracket Unplug all electrical connections Pedal Bracket 7 10 13 mm socket extension Flathead screwdriver Throttle pedal Brake Light Switch wiring Remove the driver side win...

Page 114: ...1 3443 Lower the Bose Module Unbolt the throttle bolts 13 mm Remove the pedal and save Disconnect the Master Cylinder pushrod by removing the clip on the inside of the pedal then push the pin through...

Page 115: ...106 www factoryfive com 508 291 3443 Unplug the brake pedal sensor This plug is a little stubborn so it may take some effort Label and save the switch and wiring...

Page 116: ...bracket from the upper and lower Instrument Panel Braces Pull the Pedal Bracket out enough to expose the upper brake pedal pivot bolt This will take some shifting of the bracket to make it past the l...

Page 117: ...Latches Unscrew the 2 screws at the front of the handle Phillips screwdriver Unscrew the 1 screw behind the handle Pull handle to gain access T 15 Unbolt the hood latches Remove the cables from the la...

Page 118: ...bles out of the car by pulling the handle backwards drawing the cables through the firewall Save the Handle cable assembly and the latches Trim Panels Flathead Screwdriver T 50 Torx Seat Belts Door Si...

Page 119: ...110 www factoryfive com 508 291 3443 Unsnap the 3 clips holding the door sill panel to the doorsill Remove the panel Side Panel Coupe Pull the panel away from the sill by prying up with a screwdriver...

Page 120: ...Coupe Remove the retaining pins from the outside edge of the panel Starting at the center of the panel pry the clips free Remove the panel Rear Compartment Front Side Coupe Unbolt the seat belt upper...

Page 121: ...er working your way around the cover Remove the retaining pin HVAC Unit The procedure for removal of the HVAC Unit differs between Automatic and Manual Transmission cars deep 10 mm socket 7 32 socket...

Page 122: ...113 www factoryfive com 508 291 3443 Unbolt the heater pipe to core bolt 10 mm Snip factory zip tie and remove lines Remove the accumulator hose to evaporator bolt 13 mm...

Page 123: ...ts deep 10 mm socket Remove the A C Compressor Save the A C compressor and Accumulator canister if you plan to use the optional Heat AC option Remove the rubber drain tube protruding from the firewall...

Page 124: ...factoryfive com 508 291 3443 Remove the Left hand side window defroster duct if you haven t done so already the Inside Air Temperature duct and the Inside Air Temperature duct muffler twist off Unplug...

Page 125: ...116 www factoryfive com 508 291 3443 Remove Left hand floor heater duct bolts 7 32 Remove Duct Remove lower floor duct Passenger side twist turn clockwise...

Page 126: ...Remove Right hand side window defroster duct by prying the clips out Unclip sun load sensor from right hand side of defroster duct if equipped Remove temperature valve electric actuator connection Rem...

Page 127: ...on of the floor heater then unscrew the retaining screws Remove the duct Remove the carpet outlet duct twist turn counter clockwise Unclip the blower motor electrical connection reach under the dash s...

Page 128: ...119 www factoryfive com 508 291 3443 Unplug the vacuum electric solenoid connection Disconnect the blower motor control module plug...

Page 129: ...el vacuum source connection Purple hose connected to black elbow fitting hose Unbolt the 3 motor retaining bolts 7 32 Remove the motor with fan Unbolt the windshield defroster bolts Remove the windshi...

Page 130: ...121 www factoryfive com 508 291 3443 Unbolt the 2 retaining nuts on the firewall 10 mm Remove the HVAC Unit...

Page 131: ...if you haven t done so already Unbolt antenna module 7 mm grounds driver and passenger side 10 mm Remove all electrical connections and retaining clips along the floor board and grounds at the hinge...

Page 132: ...through the firewall into the cockpit Disconnect the 20 point plug with yellow tape vacuum line Throttle Actuator Control Module TAC plug and the brown under hood fuse panel plug the center plug in th...

Page 133: ...he outer computer bracket 7 mm Reposition the outer bracket Pull the computer out of the inner bracket Unscrew the 4 bracket screws 7 mm Remove the bracket and remaining harness from the car Save the...

Page 134: ...125 www factoryfive com 508 291 3443 Unbolt the Oil Temperature Sensor 10 mm Remove the gasket then clean and dry the machined surface of the engine block...

Page 135: ...291 3443 Apply some of the RTV to one side of the Oil Temperature Bypass Plate and place it on the engine block Apply some RTV to the outside face of the bypass plate then bolt down the Oil Temperatu...

Page 136: ...Flathead Screwdriver Intake Relocation Components FFR 25713 Clean the intake before removing to avoid any dirt getting in the engine through the heads particularly the area where the head meets the in...

Page 137: ...w factoryfive com 508 291 3443 Remove the PCV tube from the valve cover Depending on the year of your donor you will have to either unbolt or unclip shown the PCV lines from the intake on the passenge...

Page 138: ...91 3443 Remove the PCV line from the port on the passenger valve cover rear Remove the PCV line from the front of the intake just behind the throttle body Save the PCV Line you will re attach it after...

Page 139: ...130 www factoryfive com 508 291 3443 PCV Tube Removal from Front of Intake PCV Tube Removed from Engine Unclip the EVAP solenoid from the intake...

Page 140: ...d the throttle body by pushing down on the round section of the white clip the other side of the clip as three tabs that will spread allowing the tube to be pulled off and pull the line off of the por...

Page 141: ...132 www factoryfive com 508 291 3443 EVAP Line Removed Unclip the vapor vent hose from the throttle body Remove the second PCV hose from the top passenger side of throttle body Save the hose...

Page 142: ...s 8 mm leaving the fuel rail stop in place Turn the intake around and bolt in back on using either a clockwise or counter clockwise pattern The factory spec is to make one pass tightening the bolts to...

Page 143: ...1 3443 If you didn t remove the hose leading from the MAP sensor to the brake booster when you removed the engine remove it now Plug the port with the supplied cap FFR 25711 Remove the Vapor vent hose...

Page 144: ...135 www factoryfive com 508 291 3443 Cap off the Vapor port on the throttle body with the supplied cap FFR 25712...

Page 145: ...ving the Positive Assurance clip then the plug itself You may have to unbolt the driver rear and passenger front coil pack 97 98 the get the wiring out from between the coil pack PCV boss Leave the bo...

Page 146: ...37 www factoryfive com 508 291 3443 Unplugging Coil Pack Unbolt 97 98 Corvette 10 mm or unclip 99 Corvette the main harness plug from the valve cover Unclip the harness clamps from the coil pack bolts...

Page 147: ...138 www factoryfive com 508 291 3443 Remove the harness from the engine Be sure to label the harness Unplug the spark plug wires from the spark plugs...

Page 148: ...factoryfive com 508 291 3443 Unbolt the valve cover bolts 10 mm Repeat the steps for the Passenger side Bolt the driver valve cover onto the passenger side the PCV boss will now be at the front of the...

Page 149: ...3443 Bolt the passenger valve cover onto the driver side of the engine the Oil Filler Neck will now be at the back Reconnect the wiring harness the driver side harness should remain on the driver sid...

Page 150: ...Driver Side Make sure you retighten the coil pack that you left loose to get the coil pack wires out in step 3 Plug in the Spark Plug Wires Clip the harness back onto the valve cover bolts Reconnect...

Page 151: ...142 www factoryfive com 508 291 3443 Reconnect the PCV to the and front port on the driver side Re clip 97 98 Corvette or bolt 99 Corvette the PCV line onto the Intake Manifold...

Page 152: ...143 www factoryfive com 508 291 3443 Reconnect the hose to the lower port on the Intake Manifold Reconnect the second PCV hose to the Valve cover then to the upper port on the Throttle Body...

Page 153: ...144 www factoryfive com 508 291 3443 Reconnect the EVAP line to the passenger side lower Intake Manifold port just in front of the Throttle Body Clip the line back into the Intake Manifold...

Page 154: ...ront and rear Fuel Tanks 1997 2002 Fuel Tanks 7 mm socket Ratchet drill Drain the tanks Disconnect the quick connect fuel lines from the sender backing plate On the Corvette passenger side tank the GT...

Page 155: ...five com 508 291 3443 Remove the internals from the tank being careful not to bend the fuel level float this will affect the accuracy of your fuel level gauge if bent Remove the label next to the open...

Page 156: ...d the bulkhead fitting A good way to check is to place the nut from the bulkhead fitting against the inside of the tank to determine the best location and trace the inside diameter of the nut onto the...

Page 157: ...the tank and de burr the edges if necessary of the hole so the bulkhead fitting fits tightly in the opening Place one of the Teflon washers on the fitting then place a small amount of RTV on the fitt...

Page 158: ...pliers into the tank to hold the nut in place while you tighten the fitting Install the internals you removed previously and tighten the backing plate Repeat for the Corvette Driver side GTM passenger...

Page 159: ...291 3443 Cap off the port on the fuel tank that was previously used on the Corvette for the filler neck with FFR 25989 04 tank shown Clamp the cap in place using the supplied clamp FFR 10664 5 16 soc...

Page 160: ...7 98 tanks you will also have to cap off the small port on the tank previously used as a vent next to the filler port using the supplied cap FFR 25990 Clamp the cap in place using the supplied clamp F...

Page 161: ...er ring from the top of the tank by rotating it out of place Lift the internals out of the tank being careful not to bend the fuel level float this will affect the accuracy of your fuel level gauge if...

Page 162: ...ide wall of the tank once you ve installed the bulkhead fitting A good way to check is to place the nut from the bulkhead fitting against the inside of the tank to determine the best location and trac...

Page 163: ...head fitting into the hole Insert the bulkhead fitting into the hole Reach into the tank from the top opening and slide the washer onto the fitting then tighten the nut onto the fitting You may have t...

Page 164: ...se in a vise and trim off approximately 1 25 off of the 2 75 diameter collar You may have to cut a small section then rotate the hose until you cut all the way around the collar When cutting be carefu...

Page 165: ...156 www factoryfive com 508 291 3443 Repeat for the other end Place the hose in the vise again Using a hacksaw cut the corrugated hose about 4 ribs up from the section you just cut See photo...

Page 166: ...ww factoryfive com 508 291 3443 Repeat for the other end and de bur each end Press the tube collar assemblies into the tank and lock them in place by rotating the collar into the slots molded into the...

Page 167: ...158 www factoryfive com 508 291 3443 Press the black plastic clip into position This prevents the collars from rotating out of position...

Page 168: ...r ring back into place CAREFULLY shave away the flexible hose at the barbed elbow molded into the top of the sending unit on the Corvette driver side tank until it is just flexible enough to be remove...

Page 169: ...291 3443 Cap off the port on the fuel tank that was previously used on the Corvette for the filler neck with FFR 25989 04 tank shown Clamp the cap in place using the supplied clamp FFR 10664 5 16 soc...

Page 170: ...one If the airbags have not been deployed on your donor and you have not already removed them see the Steering Column section of Donor Teardown for safe removal procedure to avoid causing the airbags...

Page 171: ...e the lower cover is to tilt the front edge of the cover down so the slot for the tilt lever is vertical see photo Then slide the cover over the tilt lever Remove the upper cover Remove steering wheel...

Page 172: ...08 291 3443 Carefully remove the snap ring located in front of the plastic SIR coil assembly Clip the wire ties holding the column harness sections to the column Remove the coil assembly SIR snap ring...

Page 173: ...164 www factoryfive com 508 291 3443 Remove the thin washer behind the coil assembly SIR Washer Removal Remove the steering shaft seal discard...

Page 174: ...mbly this can be done by hand then the steering wheel position sensor if equipped discard Remove the plastic retaining clip holding the adapter and bearing assembly with a flathead screwdriver you wil...

Page 175: ...lt head assembly see photo Be careful not to cut the shaft inside the column jacket The column jacket will also need a groove cut along the passenger side 1 in height and end approximately 3 75 from t...

Page 176: ...race clips by tapping them out of the slots in the column brace See photo Remove the lower column by heating the lower portion with a torch until the injection molded plastic pours out then pull the l...

Page 177: ...168 www factoryfive com 508 291 3443 To fit under the dash in the full up position the top section of the cover will need to be trimmed roughly 17 16 in from the rear edge of the cover See photo...

Page 178: ...t a puller kit that has the necessary tools for a tilt column you will need them to remove the tilt pins from the column If the airbags have not been deployed on your donor and you have not already re...

Page 179: ...291 3443 Remove the four Torx head bolts holding the actuator to the column jacket If you do not have an inverted Torx you can use a 12 point socket Pull the actuator off of the drive ball Save the A...

Page 180: ...s of the motor mount bracket to about 45 degrees from the mounting face of the bracket Now you will need to shorten the steering column jacket Cut the jacket just after the telescope slider and remove...

Page 181: ...ing sleeve inside the column jacket Do not allow the blade cutting disc etc to go into the column much further than the thickness of the outside jacket Remove the Steering Column Brace Clips by tappin...

Page 182: ...s the room use a pair of vise grip pliers to hold the spring while you pry the spring out of position After the tilt pins are pressed in at the factory the tilt head is punched pressing a small amount...

Page 183: ...into the pin Then hand tighten the nut until the sleeve contacts the tilt head Using a wrench or socket on the end of the tool and a wrench for the nut continue tightening the nut until the pin is ou...

Page 184: ...ore removing the telescoping internally splined shaft you will have to pry the stop pressed into the shaft at the factory out of the way Once you have done this you can slide the shaft over the Teflon...

Page 185: ...te of where in relation to the internal splines the stop was made because you will have to re create this feature after you cut the shaft Measure 5 from the top of the shaft mark the location and cut...

Page 186: ...elescoping sleeve Install the tilt pins using the opposite procedure of when you removed them including pressing the material slightly over the face of the pin with a punch chisel Install the tilt spr...

Page 187: ...3 Inside of each belt retracting mechanism there is a plastic stopper See photo Remove these stoppers by squeezing the two plastic tabs external of the retracting mechanism or by pushing the plastic s...

Page 188: ...ck that a quick hard jerk on the belt will lock the seatbelt mechanisms Reattach the white plastic covers with the 3 Torx screws Remove the buckle and stalk from the seat track using an 18mm wrench It...

Page 189: ...in the GTM There is a large rivet just inside the plastic covering of the stalk Mark a line of the plastic approximately 1 to 2 from the bottom of the plastic Trim the plastic very carefully using a r...

Page 190: ...Be extremely careful removing the rivet taking care not to scratch or puncture the metal stalk To remove the rivet use a center drill or small diameter bit to drill a guide hole in the center of the...

Page 191: ...ormal Wiring Harness Computer Razor knife wire snips saw and or grinder Complete Donor wiring harness Transmission Tunnel Harness On a clear work surface or section of floor stretch out the harness th...

Page 192: ...183 www factoryfive com 508 291 3443 Strip the tape and sheathing off of the length of the harness...

Page 193: ...und wire from this plug runs through a junction before continuing to the loop connector Trim the extra wire off of the junction leaving enough wire for a splice On the round connector there is a thin...

Page 194: ...ll of these wires except one grey wire run into a large round plug Trace the solid grey wire that runs apart from the others back to the plug it runs into and trim it a couple inches from the end The...

Page 195: ...and should be kept attached See photo for detailed view of the vehicle speed sensor Front End Harness The front end harness needs 3 plugs clipped off of it It does not need to be stripped for this pr...

Page 196: ...e com 508 291 3443 Cut the two Fan plugs from the Harness about 4 inches into the harness Set the plugs aside Dash Harness Lay the Dash harness out on your work surface and spread it out with the fuse...

Page 197: ...e by wire Throttle control it is located near the orange brown fuse box plug and has a plastic red tab attached Follow this harness back into the main harness un wrapping it and separating it as you g...

Page 198: ...actoryfive com 508 291 3443 When you get to the other end there is an identical plug and the harness will separate cleanly from the main section without cutting any wires Pull this harness out and set...

Page 199: ...91 3443 Find the OBD II Engine Scan plug and cut it off leaving about 6 of wire Find the headlight switch turn signal plug You can plug in the stalk to ensure that you have the correct one Cut the plu...

Page 200: ...com 508 291 3443 Find the brake light switch it has two plugs and the smaller diameter threaded mount Unplug the rear connector and cut off the front plug toward the threaded section leaving 6 inches...

Page 201: ...192 www factoryfive com 508 291 3443 Cut the brown orange fuse box plug off of the harness leaving six of each wire and set it aside...

Page 202: ...m the main harness and has a firewall grommet near the plug Trace this harness back into the main harness about 2 feet to find the plug at the column Separate the harness from the main section by cutt...

Page 203: ...ors being relocated due to the intake and valve covers being flipped around to face backwards On this harness locate the plug for the throttle position sensor it is out at the end of one bank of injec...

Page 204: ...195 www factoryfive com 508 291 3443 Re tape the harness with the throttle position sensor wires in a separate loom so it can reach back to the new throttle location...

Page 205: ...om 508 291 3443 Strip the tape off of the other injector bank down past its first injector The throttle air temp sender and mass air meter wires get taped separately to allow them to reach backward to...

Page 206: ...1 3443 The evap solenoid plug needs to be taped separate to reach the opposite side of the intake manifold as before The alternator wires should also be taped separate from the coolant temp sensor wir...

Page 207: ...to install You now have all of the component plugs that you will need to complete your car it is a good idea to hold on to the leftover harness until you are finished because it can be a good source f...

Page 208: ...bosses begin in different planes Therefore if you trim all of the 1997 1998 computer bracket mounting bosses down to the main portion of the bracket the bracket will not mount flush to the steel brac...

Page 209: ...r upper boss until it is even with the front upper section of the bracket See Photo in Step 1 Trim the rear lower boss until it is level with the rear upper boss Trim the front lower boss until it is...

Page 210: ...201 www factoryfive com 508 291 3443 1999 and up Bracket Trim all of the bosses flush to the main section of the bracket...

Page 211: ...202 www factoryfive com 508 291 3443 Disassembly of the kit Chapter 3...

Page 212: ...box Removal of Body Marker 6 hex driver Three strong people can remove the body from the chassis One person on either side located where the door openings are and the additional person at the back of...

Page 213: ...inum from the chassis mark each panel and take pictures of how the panels fit together i e which is on top Remove any screws holding the panel to the frame and remove the aluminum panels Keep the 6 sc...

Page 214: ...pacing along the centerline of the pen outline that you made on the aluminum In most cases we use a 3 rivet spacing when mounting aluminum panels to the chassis and a 2 spacing when mounting panel to...

Page 215: ...l the marks with drill bit Position your frame in your workspace with plenty of room to move things around Use jack stands or 4 blocks to put the frame 4 above the ground This is close to ride height...

Page 216: ...1 3443 Having disassembled the donor or obtained the individual parts and prepared and modified them you are now ready to begin assembly of your car We will begin with the chassis and address each ass...

Page 217: ...208 www factoryfive com 508 291 3443 Chassis Assembly Chapter 4...

Page 218: ...ter tie rod end onto each of the inner tie rods Do not to fully tighten the jam nuts against the outer tie rod until the rolling chassis is completed and it is time to align the vehicle Install the as...

Page 219: ...gun Wheel well front inner FFR 25600 25480 25651 25655 Before you install the front suspension you need to position and install your left and right front inner wheel well aluminum Align the panel on t...

Page 220: ...91 3443 Using a 1 8 drill bit drill along the center line of where you outlined the frame on the backside of the aluminum panel Secure the panel in the original position as received from the factory u...

Page 221: ...led panel as a template attach it to the frame with the self tapping screws and drill the holes in the frame Remove the panel from the frame clean the surface and apply a bead of silicone to the frame...

Page 222: ...the 1 8 short rivets permanently rivet the panel in place Do not rivet the rearward few inches on the driver s side panel yet This will make installation of the pedal box easier right around the upper...

Page 223: ...291 3443 Using the same process mount the rear lower splash panels on both the driver and passenger side Do not drill or rivet the top edge flanged upper edge because the upper splash panel is later r...

Page 224: ...ls shown below Battery Tray and Front Center Undercarriage Aluminum Eye protection drill 3 16 drill bit rivet tool silicone caulk gun 3 16 rivets Battery tray Aluminum Panel Undercarriage Front Center...

Page 225: ...teering rack The holes on the side of the tray should be centered in between the X frame Some aftermarket batteries are larger than the stock Corvette battery so make sure the front edge of the batter...

Page 226: ...g the battery tray as a template and drill the holes on the frame with a 3 16 bit Remove the panel Tape the Front Center Undercarriage Panel in place Line up the front edge with the end of the 1 5 squ...

Page 227: ...rivets and drill out the panel You will not mount this panel until later in the build See photo from previous step Apply a bead of silicon to the frame rails the battery tray sits on and rivet the tr...

Page 228: ...5352 25755 It is helpful here to have someone help you with the installation of the front suspension since the assembly is heavy and requires aligning the control arms with the holes on the frame Whil...

Page 229: ...pper control arm hardware The smaller index faces the inside of the car The Corvette used a washer spacer in between the control arm and the frame This washer is now the nut side of the upper control...

Page 230: ...ve com 508 291 3443 Install the donor cam bolts on the lower control arms attaching them to the frame Torque to the specification listed in the Appendix 21mm bolt head same procedure used on driver an...

Page 231: ...Shock Assembly flat head screw driver The shocks are pre valved at the factory in compression The shocks are not adjustable The shocks are custom valved FSD Frequency Selective Dampening shock absorb...

Page 232: ...ings and coil over mounting hardware Insert the coil over assembly through the upper control arm the body of the shock down It is helpful at this time to jack up the lower control arm so the shock wil...

Page 233: ...h and ratchet Corvette rear suspension complete donor hardware for rear suspension lower shock bracket hardware It is helpful here to have someone help you with the installation of the rear suspension...

Page 234: ...in the Appendix 21mm same procedure used on driver and passenger side Install the donor cam bolts on the lower control arms front mount attaching them to the frame 21mm The supplied hardware is for t...

Page 235: ...coil over 450lb springs and coil over mounting hardware The lower shock brackets are side specific and mount the coil over to the front of the lower rear control arm Test fit the bracket on the lower...

Page 236: ...43 Place the large washer on the lower control arm in the circular recess Use the 5 8 flanged bolt and nut to attach the lower coil over mount to the lower control arm to the previously used lower sho...

Page 237: ...228 www factoryfive com 508 291 3443 The 2 25 flanged bolt and nut is used for the inboard rear mount wrench...

Page 238: ...of the shock down It is helpful at this time to jack up the lower control arm so the shock will slip in Attach the upper shock mount to the frame using the supplied hardware and shock spacers the upp...

Page 239: ...ure used on driver and passenger side Tighten the 5 8 bolt and nut that attach the lower coil over mount to the lower control arm 15 16 Rear Tie Rod The Corvette rear tie rod is installed using the do...

Page 240: ...231 www factoryfive com 508 291 3443 The inner tie rod is mounted to the frame using the Corvette nut 24mm wrench Torque to specification same procedure used on driver and passenger side...

Page 241: ...Using the aluminum installation techniques previously described aluminum removal and installation we will now build the driver s footbox The first pieces to be installed are the front wall FFR 25172 T...

Page 242: ...er upper wall FFR 25175 To get this piece in place start with it in the driver s footbox at an angle and lift into place The upper flange on this panel is flush horizontally with the 1 5 frame rail to...

Page 243: ...is shown below in picture FFR 25179 25180 Do not rivet the flange below the lower door hinge mount to the frame yet the body close out panels FFR 25443 25445 will have to slide behind the panel see p...

Page 244: ...235 www factoryfive com 508 291 3443...

Page 245: ...box is installed next FFR 24173 If you are planning on installing heat and air conditioning perform that installation now according to the instructions included with the Air Conditioning Kit Install t...

Page 246: ...237 www factoryfive com 508 291 3443 Install the passenger footbox upper wall panel FFR 25855 If air conditioning is not being installed install the passenger front foot box block off plate FFR 25853...

Page 247: ...oping Column 9 16 wrenches 5 32 5 16 Hex key Steering shaft components steering system hardware Slide the flange bearing and bearing retainers on the long upper steering shaft The Hex set screw on the...

Page 248: ...loosely fasten the bearing s mounting flange to the pedal box mounting plate Once all the universal joint and bearing retainer bolts are loosely installed make sure the linkage does not bind and the s...

Page 249: ...ring assembly must be installed next The Corvette shaft slides into the hollow long upper shaft previously installed The steering column is attached to the frame using the 3 8 supplied hardware FFR 10...

Page 250: ...ve any burs from cutting on both shafts as even a slight bur will make it very difficult to fit the shaft in the universal joint or hollow DD shaft Drill a 3 8 hole through the 17 8 long shaft 1 25 in...

Page 251: ...aft spacer and 17 8 long shaft then install the supplied lock nut FFR 25376 remove the tape and tighten 15 mm On the supplied steering shaft FFR 26022 measure up from the upper universal joint 8 and c...

Page 252: ...243 www factoryfive com 508 291 3443 Insert the 7 x DD shaft into FFR 25602 up to the 2 mark you made Measure 1 down from the end of FFR 26022 you just cut and drill a 1 8 hole through both shafts...

Page 253: ...s separately with a 3 16 drill bit Slide the 7 x DD tube FFR 25867 into the steering shaft FFR 26022 Put the assembly in a vise or against something solid that won t move when you drive the pin in Ins...

Page 254: ...shaft assembly in the chassis from the cockpit side carefully snaking the joints and shaft through the lowest hole on the 1 16 pedal box mounting plate Attach the lower universal joint to the steerin...

Page 255: ...d the mounting plate Attach the Corvette upper steering assembly to the frame using the 3 8 supplied hardware In order for the steering column to clear the bottom of the top 1 5 square dash bulkhead t...

Page 256: ...nd you have installed the brake light switch bracket you will be able to mount this bearing but for now leave just leave the bearing on the shaft Slide the 9 x DD shaft into the DD to DD universal joi...

Page 257: ...telescoping actuator frame bracket Bolt the telescoping actuator column bracket FFR 25870 to the actuator with the supplied hardware FFR 12336 10802 3 16 Hex 7 16 wrench socket Make sure the wires on...

Page 258: ...249 www factoryfive com 508 291 3443 Press the actuator arm onto the drive ball...

Page 259: ...com 508 291 3443 Using the 20 x 1 FFR 25461 bolts fasten the column actuator bracket to the frame 4mm Hex Mark a location on the frame for the motor bracket then drill and rivet the motor to the fram...

Page 260: ...on the motor plug and a test lead to the negative side of the battery then to the other pole on the motor plug Switch the connections at the plug to move the column in the opposite direction Once you...

Page 261: ...te Set the supplied pedal box on the frame mount bracket so that the outside flange is under the tube on the outside in order to check fitment Mark the underside of the tube where the pedalbox holes a...

Page 262: ...supplied rivnut tool FFR 33582 Install the pedal box to the frame using the 20 hardware FFR 25461 11088 into the 2 rivnuts installed onto the frame in the previous step do not fully tighten these bol...

Page 263: ...end of the threaded section and cut Even though the push rod is shortened there is more than enough pedal adjustment available All of the master cylinders are bore They are installed on the front side...

Page 264: ...508 291 3443 Fully tighten the 4 button heads mounting the pedal box to the chassis 7 16 wrench and 3 16 Hex key Once the pedal box is mounted you can thread the pushrods into the machined billet piec...

Page 265: ...256 www factoryfive com 508 291 3443 Remove the rubber covers and install the small reservoirs Gas Pedal Eye protection drill 25 64 drill bit 5 32 Hex tool rivnut tool...

Page 266: ...ight corner of the pedal box mounting panel and mark the location of the 2 holes DO NOT DRILL THESE HOLES YET Now set the Corvette gas pedal in place and make sure that you are satisfied with the gas...

Page 267: ...258 www factoryfive com 508 291 3443 Using the desired location from the steps above drill and install 2 20 rivnuts Using the supplied hardware FFR 25460 install the gas pedal...

Page 268: ...tall the fuel tank finish panels These panels must be installed before the engine The cutout on the passenger side houses the Corvette fuse panel These panels are riveted to the 1 frame members Make s...

Page 269: ...he hard aluminum coolant lines FFR 25534 25535 in the tunnel before the engine is installed Place the engine mount spacers on top of the mounts welded to the frame The rectangular slot will need to be...

Page 270: ...mm wrench as it aids in the installation The engine is installed with the engine mounts and rubber isolators mounted to the engine itself Engine Installation Attach the chain to the engine as low as p...

Page 271: ...owered enough you will have to rotate the motor back straight and continue to lower the engine making sure to line up the engine mount studs with the holes on the frame and lining up the boss on the e...

Page 272: ...secure the engine mounts to the chassis and torque to specification Alternator Installation 13 15 17 mm sockets 17 mm wrench 9 64 hex key 11 32 wrench or 9 mm wrench Ratchet Universal Joint Alternator...

Page 273: ...the flange bearing FFR 26084 to the Alternator Relocation Bracket FFR 25526 using the supplied fasteners FFR s 12774 12768 If you have trouble getting the bolts through the holes in the bracket you ma...

Page 274: ...ount Slide on the idler pulley Push on the washer and attach the locknut hand tight for now If you did not unbolt the engine harness clamp on the engine block just in front of the driver engine mount...

Page 275: ...f them until you have all of the bolts partially threaded into place shown with alternator already in place Upper left bracket bolt FFR 25831 17 mm Rear bolt the engine harness clamp bolt 13 mm Insert...

Page 276: ...rnator bolt into the engine block enough to keep the bolt in place Next slide the upper bolt through the hole in the bracket just enough to start the supplied mechanical lock nut FFR 25376 then push t...

Page 277: ...1 3443 Put in the upper bracket bolt FFR 25831 17 mm Now that you are sure all of the bolts are threaded in properly you can tighten all of the bolts down Remove the Corvette Idler Pulley from the Cor...

Page 278: ...by a washer FFR 13976 and nylon lock nut FFR 10834 Tighten the lock nut checking that the pulley moves freely Unbolt the Tensioner from the engine block 13 mm Save the Tensioner and bolts Mount the su...

Page 279: ...270 www factoryfive com 508 291 3443 Mount the Tensioner to the bracket with the supplied nuts bolts FFR s 25663 25662 17 mm Remove the Corvette Pulley wheel 15 mm...

Page 280: ...er and tighten 15 mm Now you are ready to mount the 6 rib serpentine belt FFR 25527 Wrap the belt around the Crankshaft Pulley over the Idler Pulley smooth side in contact with the pulley around the A...

Page 281: ...maining section of the belt past the bolt holding the Tensioner on Place a 15 mm socket on the Tensioner bolt and rotate the pulley wheel clockwise Put the belt on the pulley wheel and allow it to rot...

Page 282: ...ing the larger hole for the bearing misalignment beyond what the bearing is designed for will cause binding in the shifter linkage If using a Mendeola Transaxle skip this section and refer to Mendeola...

Page 283: ...274 www factoryfive com 508 291 3443 Use a center punch or marker to mark the 3 holes in the drill template...

Page 284: ...one of the flange bearings on the adapter plate using the holes just drilled The flat mounting side of the bearing is installed on the engine side of the adapter plate and fastened with the 10 32 hard...

Page 285: ...ve com 508 291 3443 Install the adapter plate on the engine Make sure the KEP logo is at the top facing rearwards in the car The adapter plate is attached to the motor using the eight M10 bolts Torque...

Page 286: ...277 www factoryfive com 508 291 3443 Throwout Bearing Assembly Place the two thin shims on the throwout bearing Place the toothed ring on the throwout bearing as shown in the pictures below...

Page 287: ...278 www factoryfive com 508 291 3443 Put the throwout bearing down on a table and place the pressure plate on top of it Place the thick ring on the throwout bearing...

Page 288: ...279 www factoryfive com 508 291 3443 Push the snap ring onto the throwout bearing locking it onto the pressure plate...

Page 289: ...aking it extremely hard for someone to do on their own Find assistance during this step Install the supplied studs on the adapter plate The longer stud should be installed on the lower right corner of...

Page 290: ...set of hands and or something to brace the transmission will be helpful here Before sliding the transmission all the way on install the top left nut then side the transmission the rest of the way on t...

Page 291: ...pply some lithium grease onto the clutch fork shaft then slide the shaft through the bearings in the transmission and the fork and push the cap on the shaft Install the retaining bracket 10 mm transmi...

Page 292: ...e Transmission Mount FFR 25311 into place The lower brackets may have pulled in slightly due to the heat from welding so you may have to increase the distance between them slightly to get the transmis...

Page 293: ...f the bolts are in Put the top bolts in so that the head of the bolt is on the inside of the frame once the wheel wells are in this will allow you to get the bolt out without having to access the bolt...

Page 294: ...443 Bolt the transmission to the Transmission Mount Tighten the Transmission Mount to frame bolts wrench socket Brake Line Routing Drill 7 16 wrenches Brake line components and Corvette flexible brake...

Page 295: ...and the other is used for rear brakes Insert the adapter fitting 3 8 24 THD to 3 16 tube inverted male flare found in the Wilwood cylinder kit into the front opening of the master cylinders Plumb the...

Page 296: ...wheel well aluminum Drill a 5 8 hole inline with the hole on the brake line bracket located above the upper surface of the brake line bracket After the hole is drilled insert the rubber grommets found...

Page 297: ...into the opening in the Corvette Brake line fitting same procedure used on driver and passenger side Plumb the driver side front brake line first using the 20 brake line FFR 13740 starting at the bra...

Page 298: ...The lines are longer than needed due to the inclusion of service loops Attach the long 60 brake line to the master cylinder for the rear brakes FFR 13738 Run this line down the driver side of the tunn...

Page 299: ...508 291 3443 At the end of the 60 line install the brake line union FFR 13743 On the other side of the brake line union install a 20 brake line FFR 13740 At the end of the 20 length install the brake...

Page 300: ...ket FFR 25762 With the rear brake line bracket fitted over the Corvette soft line hold the bracket and soft line up to the rear splash Drill and rivet the brake line bracket into place 2 of the rivets...

Page 301: ...determine a location for the bracket that will not stress the flexible brake line as the suspension travels It is also a good idea to put a wheel on to make sure the line does not contact the wheel T...

Page 302: ...senger and driver sides from the previously installed T fitting Install the metric adapter FFR 25502 in between the 3 16 brake line and the Corvette flexible line When all the lines are completed atta...

Page 303: ...cylinders to install the third clutch Master Cylinder Use the same procedure as the rear brake lines to plumb the hard line for the Clutch Slave Cylinder installed in the Transmission Installation se...

Page 304: ...ww factoryfive com 508 291 3443 Put a crush washer on either side of the line fitting then bolt the Stainless Steel Braided Flexible hose FFR 25817 to the Slave Cylinder using the provided banjo bolt...

Page 305: ...line you ran from the Clutch Master Cylinder Fill the master cylinder with brake fluid Holding the slave cylinder so the bleed screw points up open the bleed screw and gravity bleed the slave cylinder...

Page 306: ...olt the slave cylinder FFR 25501 to the transmission 13 mm Make sure the slave cylinder shaft engages the clutch fork Bleed the line at the slave cylinder 7 mm bleed screw until you no longer have air...

Page 307: ...ette battery battery hold down kit Insert the J hooks into the holes in the battery tray Place the battery on the battery tray and attach the J hooks on top of the battery with the supplied hardware F...

Page 308: ...uminum rear duct and under tray FFR 25495 25493 The radiator aluminum has to be installed before the radiator and coolant overflow container are installed The under tray aluminum piece is installed fi...

Page 309: ...300 www factoryfive com 508 291 3443 Install the rear duct aluminum next This piece is riveted on the bottom through the under tray and into the frame rail...

Page 310: ...e clipped onto the backside of the radiator If you are installing air conditioning in the car make sure the Corvette condenser is clipped onto the front of the radiator Insert the round insulator from...

Page 311: ...ryfive com 508 291 3443 Cut the nipple off the bottom of the Corvette driver side radiator bushing Set the Driver side Corvette bushing on the flange so that the radiator will sit on it as shown in th...

Page 312: ...303 www factoryfive com 508 291 3443 Set the radiator in place Drill and rivet the radiator to the three mounting tabs on the frame using the supplied 1 8 rivets...

Page 313: ...in the tunnel before the engine If this was not done you can slide them in by removing the steering rack The stainless corrugated lines connect the hard aluminum tubing to the motor radiator The corru...

Page 314: ...aller diameter aluminum tube extension FFR 25294 is the return to the radiator smaller connector The larger diameter hard line FFR 25293 goes from the radiator to the engine larger connectors Place th...

Page 315: ...larger diameter aluminum tube Then slide the 3 long adapter over the smaller ones it may help to spray Windex on the rubber to act as a lubricant Install the corrugated stainless line make sure to in...

Page 316: ...er hard line then to the radiator opening on the passenger side using the 3 long adapter and one of the 1 5 long thick adapters on the radiator opening Tighten the adapters with the supplied hose clam...

Page 317: ...ine to the upper port on the radiator The line is attached to the radiator using the modified elbow from the Corvette lower radiator hose Fasten with the supplied hose clamps Trim the upper port on th...

Page 318: ...s connected to the upper port on the water pump Use one of the thick 1 5 long adapters on the water pump and attach the corrugated line to the port with the 3 long adapter The corrugated line on the p...

Page 319: ...is still warm retighten the hose clamps used on the cooling system Surge Tank and Soft Coolant Line Routing 3 16 Hex key wrench flat screwdriver razor knife Corvette overflow tank radiator hose compo...

Page 320: ...nnel through the lower portion of the Dash bulkhead X member The heater ports on the water pump are different sizes Connect the larger heater hose to the larger port on the water pump front and the sm...

Page 321: ...o the cylinder head vent tube Attach these hoses onto the water pump with the large heater hose clamps FFR 10855 Route the heater hose in the tunnel as a bundle and fasten them to the aluminum hard he...

Page 322: ...291 3443 Route the bundle of heater hoses around the battery on the passenger side Install the small heater hose FFR 25536 onto the small fitting on the top of the passenger side of the radiator usin...

Page 323: ...The two larger lines from the water pump are attached to the base of the surge tank Install the larger diameter line on the front facing lower port and the smaller one on the rear facing lower port u...

Page 324: ...radiator Connect one end of the heater hose FFR 11202 to the upper rear facing port on the surge tank using the supplied hose clamp FFR 11206 Attach the other end of this hose to the larger port on th...

Page 325: ...rt the engine and let it idle for one minute Install the surge tank cap and bring the coolant up to temperature 210 F by revving the engine from idle to 3000 RPM in 30 second intervals then turn engin...

Page 326: ...then turn engine off Top off the coolant above the FULL COLD mark on the surge tank Emergency Brake and Cables 3 16 Hex key Corvette E brake handle cables connection bracket parking handle hardware FF...

Page 327: ...lied 5 16 button head hardware FFR 11024 Attach the single cable coming off of the e brake handle into the connection bracket Make this connection outside of the tunnel and then slide the cable and co...

Page 328: ...319 www factoryfive com 508 291 3443 If you removed the Corvette e brake cables from the rear hub assembly re install those now using the Corvette hardware...

Page 329: ...king gun 6 self tapping screws Rear cockpit lumbar aluminum FFR 25156 Using the previously described aluminum installation process install the rear driver FFR 25163 and passenger aluminum FFR 25164 pa...

Page 330: ...om 508 291 3443 Install the rear lumbar aluminum panels on the drivers FFR 25161 and passenger FFR 25162 side same procedure used on driver and passenger side Install the concave driver tunnel piece o...

Page 331: ...322 www factoryfive com 508 291 3443 Install the driver front tunnel wall FFR 25160 The driver side tunnel is now complete shown before panels were riveted in place...

Page 332: ...e brake handle in the up engaged position while installing this panel Axles and CV joints Vise dead blow hammer rubber mallet pliers 34mm socket ratchet Axle Shafts FFR 25290 Inner CV Joint Boot FFR 2...

Page 333: ...p on the inner race of the CV joint until it slides off of the old axle shaft Locate the new axle shafts provided in the kit and slide CV boots with the small clamps down over each end The Smaller Por...

Page 334: ...factoryfive com 508 291 3443 Attach the corvette CV joint to the new axle shaft and clamp the supplied boot FFR 25716 over the joint and axle Speedometer Gear If using a Mendeola Transaxle skip this...

Page 335: ...over one of the axle shafts Then on both shafts attach the inner CV joint and boot ring to the axle and clamp the boot FFR 25715 in place CV Axle Install Mount the axle assembly in the car by sliding...

Page 336: ...327 www factoryfive com 508 291 3443 Attach the inner CV joints back to the transmission using the original hardware The axle with the cog wheel mounts to the passenger side...

Page 337: ...arness 18 circuit Chassis Harness Zip Ties Flexible wiring loom Fuse Panel Remove the chassis harness from the box and find the mounting plate for the fuse panel Attach the fuse panel mounting plate t...

Page 338: ...n the driver s side of the Dash Cross member using 3 16 rivets Line the back corner of the mount panel up with the smaller side tube to support the back The fuse box mount panel has a fairly sharp edg...

Page 339: ...coming from the back of the fuse panel by separating the wires that stay in the cockpit behind the dash from the wires that exit the footbox into the tunnel The wires that stay behind the dash include...

Page 340: ...un to the front and back of the car from the fuse box out into the tunnel through the hole next to the driver s knee These wires must route under the tubes that support the pedal assembly They include...

Page 341: ...ss that was separated from the donor harness and pull the gray plastic section back from the plug to allow it to pass through the tunnel wiring hole Pass the drive by wire plug either end they are sym...

Page 342: ...1 3443 Separate the two grey fan control wires from the dash section of the chassis harness and route them through the pass through with the other wires These wires will be used for the fog lights as...

Page 343: ...ug are labeled A Z except that I O and Q are skipped Do not wire in the headlights or parking lights yet The letters correspond to the following circuit Pin letter Pin Wire Color Circuit Painless Harn...

Page 344: ...Park lamp switch output Z Orange Battery Positive Orange 959 The dark green and dark blue wires from the Painless harness need to be spliced into the dark green wire on the Corvette harness Pin B Sim...

Page 345: ...m 508 291 3443 1 Connect to Relay lead 86 2 12 volts from fuse panel 4 Ground 30 12V BRN 951 from Fuse panel 85 Ground 86 12V from switch 87 To Pin A Fog light wiring Wire crimper wire stripper Dash c...

Page 346: ...from fuse panel 4 Ground Headlight relays Misc electrical components Wire cutters 3 16 drill bit drill wire crimper wire stripper The headlights and parking lights require a relay so as not to overlo...

Page 347: ...le fifth wire from the relay plugs is not used and can be cut right at the socket Crimp on a ring terminal provided in the harness kit on each of the relay plugs blue ground wire circuit 85 on the rel...

Page 348: ...factoryfive com 508 291 3443 Ground the relays to the chassis using the 14 screw provided Constant power is wired into the relays from the same source that powers the light switch into the red wire r...

Page 349: ...e socket goes to the switch side and the white wire relay 30 attaches to the chassis harness It will be easier to trace any wiring later if you label the relay sockets as you hook them up Windshield W...

Page 350: ...3 4 foot section of pink wire from the remainder of the corvette harness This wire is spliced into the pink wire on the wiper harness and then run through the firewall plug Pull the free black ground...

Page 351: ...ed into either side door lock power from the chassis harness Cut the purple wire This wire is the high speed setting on the wipers which will cause the wiper arm to over extend past the windshield whe...

Page 352: ...tion in case you need to extend shorten the wires before crimping the ring terminals on Once you determine the location you want to mount the ignition you will have to drill a 1 hole with a hole saw t...

Page 353: ...Light Switch In the dash section of the chassis harness there is a brake light switch section Splice the switch that was removed from the donor into the harness matching the wire colors white and oran...

Page 354: ...3443 Unscrew the two hole retainer from the brake light switch and pop it into place on the brake switch bracket Thread the switch into the mounting bracket provided in the kit about half way to give...

Page 355: ...pedal is pushing the switch in about half way The bracket mounts to the bottom of the tubes holding the pedal assembly When the position is right mark for the holes on the bottom of the tube Drill the...

Page 356: ...www factoryfive com 508 291 3443 Attach the bracket top the chassis using two button head screws and plug the switch back in If the switch needs adjustment unplug the plug before threading it in or o...

Page 357: ...e harness fuse box It will have three heavy gauge wires an orange a purple and a pink Locate the engine section of the chassis harness it should be pulled through into the center tunnel and include th...

Page 358: ...tart wire hooks to the heavy gauge purple wire on the plug and the pink ignition harness wire splices into the two heavy pink and orange wires on the plug This section should be left as long as possib...

Page 359: ...black The fuel tank harness that was stripped earlier should have four loose wires two for the vehicle speed sensor a black ground and one small grey wire for the fuel pump feed The small grey wire sp...

Page 360: ...91 3443 Fan wires The fan wires need to be extended to reach to the fan plugs removed from the original Corvette harness These are the heavy gauge wires in grid positions B3 D10 E10 and F11 The 14ga w...

Page 361: ...508 291 3443 Wrap the fan harness in electrical tape from the plug down to the ground loop on the black fan wire Fuse panel mounting Sit the fuse box in place in the chassis with the terminal post tow...

Page 362: ...panel plug back through the tunnel and down low past the A C compressor Reach the plug up and plug it into the middle slot of the fuse panel Plug in the fan and fuel pump plug into the front slot of...

Page 363: ...t harness routes along this same path from the tunnel forward then over to a pass through space on the drivers side behind the radiator Drape the headlight wire over the radiator support for now and p...

Page 364: ...n the complete kits and the Hot Rod can be cut into multiple pieces if lighting is desired in each footbox and under the dash How to cut the LED light strip If you choose to cut and spread the lights...

Page 365: ...a carburetor Attach the ground wire to the headlight switch courtesy light ground wire Computer Bracket Mount Find the computer mounting bracket and hardware from the Corvette and computer bracket to...

Page 366: ...ed to the underside of this bracket using two of the three mounting holes with the plugs pointing toward the front of the car Hold it in this position clear of the bracket and trace the holes for dril...

Page 367: ...358 www factoryfive com 508 291 3443 Remove two of the screw clips from the top half of the computer bracket These clips are now attached to the throttle control module tabs...

Page 368: ...ve com 508 291 3443 Attach the throttle control module to the lower computer bracket using the original hardware and a 7mm socket or driver Bolt the bracket and module into the frame using the four bu...

Page 369: ...ww factoryfive com 508 291 3443 Computer Engine Harness Computer Rest the engine harness roughly into position over the top of the engine Route the fuse panel computer and plug in the large fuse panel...

Page 370: ...361 www factoryfive com 508 291 3443 Route the two computer plugs and the throttle module plugs up to the computer mounting bracket through the back corner of the fuel tank area...

Page 371: ...508 291 3443 Plug the computer plugs into the computer and mount it into the mount bracket using the original hardware The wires should come out of the plugs toward the inside of the car Plug the thr...

Page 372: ...ngine harness Both plugs are a few inches down the wiring harness from the fuse panel plugs Route the throttle control harness back through the tunnel along side of the other harnesses This harness is...

Page 373: ...508 291 3443 Starter Solenoid Locate the wires for the starter solenoid they include a heavy red alternator wire and a fusible link that attach to the large post and a small purple start wire that att...

Page 374: ...the same location of the harness that attaches to the engine block The conduit on the harness may need to be pulled back to get this and the rear sensor plugs to reach with the starter wires in place...

Page 375: ...366 www factoryfive com 508 291 3443 Crank Position Sensor Plug the crank position sensor into the side of the block...

Page 376: ...oil level sensor plug into the sensor in the bottom of the oil pan Wrap the harness for the driver side under the throttle body and across the back of the block Plug the injectors and coil plugs in o...

Page 377: ...gtail for the knock sensor Plug them both in making sure that the wire colors match on the knock sensor plug and pigtail it can be incorrectly switched with the oil level sensor plug Run the alternato...

Page 378: ...take tube On the 2001 2004 Corvettes the Intake Air Temperature sensor is integrated into the Mass Air meter so you can skip this step if you have a 2001 2004 Mass Air Meter If you are not sure which...

Page 379: ...the air temp sender into the air filter Attach the mass air meter to the air filter and then the entire assembly onto the throttle body You can now plug in the harness connections for the mass air ai...

Page 380: ...yfive com 508 291 3443 The manifold pressure sensor wires will not reach the front of the engine Extend these wires with some of the remaining harness so that this plug will reach around and plug into...

Page 381: ...372 www factoryfive com 508 291 3443 Connect any remaining ground loops on the harness to the block or cylinder heads The three wire plug pictured is the old oil pressure sensor and is not used...

Page 382: ...units Oil Pressure sending Unit Locate the oil pressure adapter fittings and remove from the oil pressure gauge package the sending unit Screw the base fitting into the block below the throttle body...

Page 383: ...e Teflon tape or paste Tighten the adapter until the opening faces the drivers side and just slightly forward Install the sending unit If it is tight to the intake vacuum nipple then it is ok to trim...

Page 384: ...375 www factoryfive com 508 291 3443 Water Temp Sending Unit Remove the coolant plug in front of the crank position sensor on the back passenger side of the engine block...

Page 385: ...e water temperature gauge and remove the sensor this sensor is threaded into the metric adapter provided in the kit using Teflon tape or paste Thread the sender and adapter back into the block making...

Page 386: ...ont of the A C compressor Route the water temperature sensor wire under the accessories and along the side of the block and connect it to the sensor with a loop connector Also in the chassis harness i...

Page 387: ...www factoryfive com 508 291 3443 Continue the pressure sensor wire along the intake manifold running it along side of the injector harness and attach it to the pressure sender with a small ring termi...

Page 388: ...ight harness has not yet been routed past the pass through into the tunnel Trace the fuel tank harness back to the round grey plug near the engine fuse panel Cut the two sending unit wires on this har...

Page 389: ...computer plug the Engine Speed Signal ESS wire The ESS wire is located in pin 35 in the Blue Computer Plug for 1997 1998 Corvettes and in pin 10 in the Red Computer Plug for 1999 2004 Corvettes The sa...

Page 390: ...e located in the engine section of the chassis harness needs to be spliced into the plug side of the yellow wire and the green black power antennae wire is spliced into the harness side of the yellow...

Page 391: ...peed Sender and the chassis ground Clean a spot on the chassis and ground the harness Vehicle Speed Sensor Porsche Transaxle 3 16 Hex key 7 16 wrench Intake relocation components The mounting bracket...

Page 392: ...small cover just above and behind the passenger side CV joint Remove the rear bolt from this cover Attach the bracket to the transmission by re installing the removed bolt through the slot in the bra...

Page 393: ...and wires from the area under the engine fuse panel along the engine harness and up to the transmission Install the sensor into the bracket using the provided hardware Adjust the sensor and bracket u...

Page 394: ...the Mendeola Transaxle the speed sensor mounts on the driver side at the 5 o clock position to a 5 16 threaded hole and reads the the toothed stub axle Attach the sensor to the bracket using a 5 32 H...

Page 395: ...actoryfive com 508 291 3443 OBD II Diagnostic Plug Locate the OBD II plug that was removed from the harness and attach a ground loop from the chassis harness kit to the black and black with white stri...

Page 396: ...fuse panel are three round grey plugs two of which are unplugged Find the plug that has four green wires in one row and cut the wire that is in the M position Install a male bullet connector from the...

Page 397: ...n of wire preferably purple so it matches the wire at the OBD II plug from the bundle roughly 6 7 feet will do Crimp a female bullet connector on one end Plug the bullet connector together and route t...

Page 398: ...ryfive com 508 291 3443 Splice the wire extension into the purple wire on the OBDII plug Find the side door lock power wire that wasn t used in the dash harness and splice it into the orange wire on t...

Page 399: ...291 3443 Rivet the OBDII plug to the chassis next to the steering column mount using 3 16 rivets Make sure that the wires to the plug run underneath the main chassis tube to allow for the aluminum pa...

Page 400: ...391 www factoryfive com 508 291 3443 Ground the plug to the chassis...

Page 401: ...ided with the kit a long cable that connects the battery to the engine fuse panel FFR 25996 and a short cable that connect the fuse panel to the starter FFR 25997 Hook the shorter wire onto the large...

Page 402: ...508 291 3443 Route the long cable through the tunnel along the same route as the heavy red wires from the chassis harness Hook both cables along with the two heavy red chassis power wires to the fuse...

Page 403: ...Cut the horn relay connector found on the backside of the driver s side air bag assembly approximately 5 from the end of the white plastic housing Install a female spade connector to this end arrow p...

Page 404: ...25459 on the Corvette column the square cutout on the boss is to allow the horn wire to pass through Use the Corvette steering wheel nut to attach the steering wheel adapter to the steering column Ins...

Page 405: ...teering slipped upside down insert the horn grounding ring into the backside of the wheel The white wire included with the steering wheel is used to connect the spade terminal on this grounding ring t...

Page 406: ...verhanging sections on the backside and install it onto the steering wheel adapter using the recessed Hex keyed fasteners After the wheel is installed connect the horn button relay wire to the other s...

Page 407: ...ill show the battery offset to the driver side If you are not using A C the battery as covered in the battery tray installation section will be centered on the floor cross member For the following sec...

Page 408: ...399 www factoryfive com 508 291 3443 Once the battery is in place make sure that the terminals are oriented towards the inside of the car...

Page 409: ...Conditioning system the hole on the passenger side of the battery tray sits on top of the 1 frame rail so you will have to drill it out If you are not installing A C skip to the next step Insert the...

Page 410: ...401 www factoryfive com 508 291 3443 Lay the battery crossbar hold down on top of the battery and fasten the J bolts into place using the supplied fasteners FFR 10802 11088...

Page 411: ...using the supplied button head bolt and washer 7 32 Hex FFR 25873 11005 The ground strap has to be attached to the frame Drill a 3 8 hole on the rearward passenger side steering rack mounting bracket...

Page 412: ...43 Attach the ground strap to the frame using the hardware provided FFR 11005 11024 13963 Attach the other side of the ground cable to the negative terminal on the battery using the supplied button he...

Page 413: ...h the shifter linkage you will have to grind the engine mount slightly to allow the linkage to clear the mount if this condition exists The shifter linkage is easier assembled outside of the car and t...

Page 414: ...hs of shifter shaft 2 long FFR 25897 25898 and 2 short FFR 25895 25896 Connect the two short and two long segments together with a universal joint FFR 25899 Attach a second universal joint to rear end...

Page 415: ...1 3443 Once the shifter assembly is assembled as seen above attach the pieces together using the short spring pins FFR 25901 Drive the pins into place using a small hammer unit they are flush with the...

Page 416: ...arm using the supplied long spring pin FFR 25894 Now that rear section of the shifter assembly is complete install it into the chassis With the rearward linkage arm oriented at the rear of the car in...

Page 417: ...t linkage arm onto the transaxle shift rod using the supplied bolt FFR 10601 You are advised to use Loc tite on the threads of this bolt Make sure that the transaxle is in neutral for the remainder of...

Page 418: ...r Slide one plastic flange bearing FFR 26084 onto the front portion of this shifter assembly with the flat mounting side towards the joint Next slide the shifter joint which is apart of the shifter ha...

Page 419: ...rearward end of this front shifter shaft assembly has to be attached to the rear shifter shaft assembly Insert the rod coming through the flange bearing mounted on the alternator bracket into the uni...

Page 420: ...ges are attached go back and tighten the front two flange bearings located on the front shifter linkage assembly Center the shifter handle joint in between the two flange bearings and tighten the bolt...

Page 421: ...aded into the shifter handle joint Make sure the shifter handle is threaded approximately half way into the shifter handle joint and tighten the jam nut this will act as the baseline setting Using whi...

Page 422: ...the rod end over the shifter handle shaft and insert it into the center hole on the frame mount FFR 25628 Using the supplied hardware FFR 12380 fasten the rod end into place Install the shifter knob...

Page 423: ...the car and shift through the gears You can adjust where the shifter is forward and backwards in the car by loosening the bolt holding the shifter handle assemble to the rest of the shifter mechanism...

Page 424: ...Exhaust Pipe Installation 15mm wrench GTM catalytic converter pipes FFR 25370 or 25876 and 25877 There were two versions of exhaust manifolds used on the C5 Corvette the first vintage was seen on cars...

Page 425: ...has specific driver FFR 25876 and passenger FFR 25877 pipes which are marked from the factory Make sure your cat pipes are the correct version in relation to the year of your exhaust manifolds The eas...

Page 426: ...orvette donor studs and nuts These studs are commonly damaged during disassembly and can be purchased from a GM dealership GM 12561310 Make sure all mounting studs are in place along with the donut ga...

Page 427: ...ed and will only attach to the Corvette manifolds in one orientation Go ahead and install the Corvette exhaust manifold nuts onto the studs holding the cat pipes in place Do not fully tighten these nu...

Page 428: ...r orientation and to see which tubes they are in contact with Mark the frame tubes which are in contact with the tanks same procedure used on driver and passenger side You will also want to cap off th...

Page 429: ...ing this panel make sure there is plenty of clearance between it and the engine belt pulley Also make sure its position does not affect the way the fuel tanks are installed into the frame Fuel tank Cr...

Page 430: ...421 www factoryfive com 508 291 3443 Thread the elbow onto the female fitting you just pressed onto the braided hose Thread one of the elbow fittings on the braided line onto the bulkhead fitting...

Page 431: ...line to the chassis yet Fuel line Routing Fuel filter to engine The Corvette fuel system and line routing changed a number of times over the span of the C5 The Corvette fuel lines utilize re usable qu...

Page 432: ...rails on the motor The first generation fuel line routing has 2 ports on the fuel rails one feed and one return The second generation has a single feed on the fuel rails and no return the fuel filter...

Page 433: ...the output of the filter facing the motor Connect the output on the fuel filter to the input on the motor large 10mm port on the fuel rail The fuel filter output requires a 10mm male fitting which is...

Page 434: ...the adapter piece and insert it into the output on the fuel filter Attach the other side of this line to large 10mm port on the fuel rail Fuel tank to fuel filter The Corvette fuel line with an inline...

Page 435: ...ve com 508 291 3443 Use caution and remove the rubber nylon line from this smaller port on the y fitting Also remove the straight 8mm fitting on the end of this section of hose that was just trimmed f...

Page 436: ...l line fittings to plumb the fuel system with On the driver side fuel tank has only 2 fittings and no internal pump make a short fuel line that simply loops from one fitting to the other fitting Using...

Page 437: ...ch it to the larger port on the passenger side tank Connect the other end of this line to the input on the fuel filter Return line Use 5 16 rubber fuel line along with 8mm connectors on both ends of t...

Page 438: ...508 291 3443 Refer to fuel filter to engine section to see which generation fuel system you are using Connect the other side of the 5 16 line to the return port on your system either the 8mm port on f...

Page 439: ...ts Connect the electrical plug into the back side of the tanks Same procedure for both the passenger and driver tank 2002 2004 Fuel Tanks Remove the tanks from the chassis and install the adhesive bac...

Page 440: ...While installing this panel make sure there is plenty of clearance between it and the engine belt pulley Also make sure its position does not affect the way the fuel tanks are installed into the frame...

Page 441: ...432 www factoryfive com 508 291 3443 Thread the elbow onto the female fitting you just pressed onto the braided hose Thread one of the elbow fittings on the braided line onto the bulkhead fitting...

Page 442: ...n the other tank Check for leaks before fastening the lines to the chassis Once you are sure the line isn t kinked and is safely out of the way of any moving parts and none of the fittings are leaking...

Page 443: ...434 www factoryfive com 508 291 3443...

Page 444: ...ion fluid rear axle gear oil engine oil coolant water Transmission Fill the transmission with fluid and install the shifter assembly Leave the shift handle and knob off for now Engine Fill the engine...

Page 445: ...the seat harnesses in and use them You will be very surprised at how quickly the car responds to small inputs and it is amplified by being extra light without the body in place Things to check for Any...

Page 446: ...Tunnel Cover Aluminum Eye protection drill w 6 hex nut driver drill bits drill rivet gun silicone caulking gun 6 self tapping screws GTM foot box aluminum FFR 25171 Install the front footbox wall FFR...

Page 447: ...o mark the rivet locations on the panel now Measure in from the sides of the panel and draw a line parallel to the edge of the aluminum Measure along the line every 2 approximately and mark the locati...

Page 448: ...me using the holes in the aluminum panel as a reference and rivet the panel to the frame Install the foot box top piece This piece is riveted around the outside to the frame as well as to the upper fl...

Page 449: ...dy Main FFR 25245 Rear Hatch Fasteners FFR 25429 Firewall Panel FFR 25497 Weatherstrip FFR 10761 Tail lights and Hardware FFR 25218 Fuel Filler Assembly FFR 25228 Rear Quarter Window Assembly FFR 2524...

Page 450: ...441 www factoryfive com 508 291 3443 Make sure that the body is sitting tight around the door openings Check that where the bottom of the body curls under is underneath the frame tubes...

Page 451: ...aking sure that the body is tight against the frame in these areas sink a few 1 8 rivets through the body into the door sill The front of the door opening will eventually be permanently mounted using...

Page 452: ...out 8 from the outside edges of the exhaust exit recess and draw a vertical line the material between these lines will not get cut This is where the license plate will mount Trim the body along the ou...

Page 453: ...ransmission mount then mark a line 2 25 to the right pass side of this This will be the location of the right side of the latch support Unpack the Hatch Fastener components FFR 26166 Locate the right...

Page 454: ...he panel into the chassis Pull the body up into position against the panel It is easiest to put some wooden blocks between the body and footbox tops to hold it in place With the body up tight against...

Page 455: ...ou leave enough room between the top edge of the panel and the body for the weather stripping You want the weather stripping to contact the body but not to be crushed Also make sure that the hood stru...

Page 456: ...his panel before setting it into place All of the mounting flanges should be pre drilled Picture below shows the panel with the flanges oriented upwards drilling the holes in this orientation makes is...

Page 457: ...448 www factoryfive com 508 291 3443 Once the bulb seal is installed fit the panel into place This piece of aluminum is mounted around the wiper cutout on the body and installed from the cockpit...

Page 458: ...perimeter of the panel on the foot box top Once the body is removed later in the build make sure to rivet this panel in place with the bulb seal installed on the panel Taillights Unpack the taillights...

Page 459: ...450 www factoryfive com 508 291 3443 Mount each taillight using the aluminum bracket and hardware the orientation is not important for initial fitment...

Page 460: ...Mount all four taillights to ensure a perfect fit it may be necessary to file or sand the body to get a perfect fit Fuel Filler Caps Unpack the fuel filler caps FFR 13490 and the hardware The hardware...

Page 461: ...body opening on the rear fender and if necessary sand or file until they will center in the recess Mark and drill 3 16 holes for the mounting hardware make sure that the cap orientation is the way yo...

Page 462: ...th his windshield adhesive Rear Hatch Hinge The panel has been trimmed oversize to allow for material to be removed until the desired seam is found Lower the hatch into the opening on the body to do i...

Page 463: ...454 www factoryfive com 508 291 3443 Unpack the hatch hinge brackets and hardware FFR 25236...

Page 464: ...factoryfive com 508 291 3443 Press the brass bushings FFR 13183 into the adjustment plates FFR 25404 and the long hinge arms FFR 25412 25413 driver passenger Press the bushings into the shorter arms F...

Page 465: ...456 www factoryfive com 508 291 3443 Press the bushings into the hatch attachment brackets FFR 25401 25402 driver passenger Attach the hinge arms to the adjustment brackets...

Page 466: ...ww factoryfive com 508 291 3443 Attach the tops of the hinge arms to the hatch attachment brackets Attach the hinge adjustment brackets to the chassis finger tight so the brackets can still slide to a...

Page 467: ...458 www factoryfive com 508 291 3443 Set the hatch back into position and line the hinges up With everything lined up mark the center of each mounting slot of the attachment bracket onto the hatch...

Page 468: ...com 508 291 3443 Remove the hatch and drill and install 20 rivnuts in the hatch The gas shock mounts are centered on the mounting pad on the hatch with the ball stud facing inward Drill and rivet both...

Page 469: ...Find and mark the centerline of the hatch striker mount area Mount the hatch to the hinges using the six small 20 button head screws Align the hatch paying close attention to the rear corners and the...

Page 470: ...ww factoryfive com 508 291 3443 Attach the gas shocks to the hatch Rear Hatch Latch 5 32 hex key socket ratchet 3 16 drill bit rivet tool rivnut tool 25 64 drill bit marker ruler Hatch fastener compon...

Page 471: ...462 www factoryfive com 508 291 3443 Close the hatch From the underside measure forward from the body latch mount area 15 16 and mark the hatch This is the front of the latch striker mount...

Page 472: ...ed Attach the striker mount to the hatch using the 20 x flanged button head screws Attach the shoulder bolt to the center of the striker mount hole Close the hatch so it is flush with the body From th...

Page 473: ...464 www factoryfive com 508 291 3443 Use the template to locate and drill latch mounting holes through the body latch area and the latch support bracket Insert the swivel wire stop in the latch hole...

Page 474: ...time tighten the release cable in the swivel wire stop Leaving the hatch open test the release cable If necessary either loosen and readjust the cable in the swivel fitting or loosen the latch screws...

Page 475: ...6 www factoryfive com 508 291 3443 Locate the wiper transmission from the kit and insert it upside down in the hole With the outer holes even mark through them on the body and drill out with a drill b...

Page 476: ...up to the chassis with a jack for fitment so that the Diffuser is sitting against the frame but can still be moved around The upward bend in the diffuser starts just behind the ends of the chassis tu...

Page 477: ...468 www factoryfive com 508 291 3443 Measure the height from the body down to the diffuser 3 75 is the length of the spacer provided but if a different look is desired these could be cut...

Page 478: ...ment again then put a little more pressure on the jack to hold the panel firmly in place Clamp the sides of the Diffuser near the bottom to hold it at the correct angle Trace the frame rails and body...

Page 479: ...ve but three could also be used Evenly position the spacers on the Diffuser so that the top is in the middle of the body mount flange A little masking tape between the diffuser and the body might be n...

Page 480: ...ive com 508 291 3443 Remove the diffuser and mark the panel for 3 16 rivets on both the bottom part and the sides Remember that the Diffuser sticks out past the body so do not mark for rivets in the a...

Page 481: ...472 www factoryfive com 508 291 3443 Drill 3 16 holes in the Diffuser for the rivets Drill 5 16 holes at the center of the marked spacer locations on both the body mount flange and the diffuser...

Page 482: ...the diffuser and using the diffuser rivet holes as a guide drill the bottom frame tubes Rivet the lower area For now you only need to put about every fourth rivet in place as the panel will be remove...

Page 483: ...474 www factoryfive com 508 291 3443 Use the Diffuser side holes as a guide and drill the side body holes for rivets...

Page 484: ...475 www factoryfive com 508 291 3443 Doors Position the doors in the openings and remove any excess material to allow the door sit flush with the body...

Page 485: ...cate the front door trim panels These panels locate the bolts that hold the door to the frame in the front Align the panels so there is a between the bottom outside corner and the bottom of the door s...

Page 486: ...and drill the two holes with a drill bit On the original power window tracks there is a stud at the top of each track hammer this stud out using a medium size steel hammer Resting the track on a sock...

Page 487: ...door hinge plate on the front of the door aligning the slots in the plate with previously drilled holes Mark the door to cut holes for the hinge pin sleeves and the door stop bracket Cut the marked t...

Page 488: ...479 www factoryfive com 508 291 3443 Position the door hinge plate in the door the plate is symmetrical and can be set in place with either side up...

Page 489: ...p stud FFR 26034 through hole in bracket and tighten lock nut FFR 13963 Depending on your door installation you may need to space off the door stop with washers if the door opens to far and contacts t...

Page 490: ...indow tracks in the door shells in rough position then set the door frames in above them Attach the latch to the latch adjuster bracket to the latch mechanism using the grade 8 screws The screws that...

Page 491: ...482 www factoryfive com 508 291 3443 Slide the latch assembly in behind the frame into position and loosely bolt the two together using 5 16 carriage bolts washers and lock nuts...

Page 492: ...nd insert the two carriage bolts from the bottom With the trim panel in position push two 5 16 carriage bolts through the door and the front of the door frame and finger tighten a lock nut on each Hol...

Page 493: ...the chassis for the vertical center of the slot then measure in 5 8 from the outside of the striker pad and drill an hole Walk the small drill around to make a larger hole that is centered with the sl...

Page 494: ...they are loose in the frame put a little grease around the outside to keep them from falling out while lining up the pins Position the door on the body lifting the hinge plate over the chassis hinge...

Page 495: ...lder bolts through both the hinge plate and chassis mount and finger tighten a lock nut on the bottom Remove the tape and align the door so that the surfaces are all flush and tighten the mounting nut...

Page 496: ...8 291 3443 The bottom edge of the body is still loose and can be moved in and out some to help line up the door surface Once you are happy with the door fit drill and rivet the body to the four ends o...

Page 497: ...five com 508 291 3443 Bolt the door latch pin to the chassis leaving it loose enough to adjust The washer on the door pin should be between the body and the chassis and is threaded to allow the pin to...

Page 498: ...d the door latch operational mark the center of the slots in the door latch mount where it meets the body and drill with a drill bit Bolt the rear of the door to the door frame using the stainless bol...

Page 499: ...file or sand until you have an even 3 16 gap around the door Open and close the door looking for interference between it and the body the main area that this will occur is the upper front corner The b...

Page 500: ...r lined up properly you can mark the location for a hole for the door latch on the supplied aluminum cover panel Drill the mounting holes in the panel and in the body but don t mount it permanently un...

Page 501: ...3443 Windows With the door frames installed and the doors adjusted set the window tracks in the door Using the Corvette window motor screws mount the window motor to the bracket on the door frame usin...

Page 502: ...m of the door so that the hole in the bracket is centered about the recess Using the track bracket as a template mark the position for the hole Drill a 6 mm approx if you don t have a 6 mm drill bit h...

Page 503: ...below shown already bolted in position Drill a 6 mm approx if you don t have a 6 mm drill bit hole in the door pocket Bolt the track to the door with the supplied hardware FFR 25798 but do not fully...

Page 504: ...as CLOSE TO PARALLEL AS POSSIBLE It is very critical that the tracks are parallel to prevent them from working against each other which will cause the tracks to bind and prevent smooth transition of t...

Page 505: ...t the diameter of a quarter and about 3 16 thick When applying the adhesive to the brackets if the location on the track that you will bond the bracket to has a hole place a piece of duct tape over th...

Page 506: ...497 www factoryfive com 508 291 3443 Starting at the back of the door push the felted bulb weatherstrip 26039 onto the flange going around the top of the door opening on the body to the front corner...

Page 507: ...498 www factoryfive com 508 291 3443...

Page 508: ...12750 around the lower door opening on the body Using the same adhesive back weatherstrip FFR 12750 install a strip along the rear door post so the bulb faces toward the front of the car This will al...

Page 509: ...Install the felted weather strip on the inner and outer edges of the window slot in the top of the door The weather strip with the wider edge is for the outside Also install a piece of the bulb weath...

Page 510: ...501 www factoryfive com 508 291 3443 Outside Weatherstrip Inside weatherstrip Slide the glass through the slot in the top of the door...

Page 511: ...502 www factoryfive com 508 291 3443 Set the bottom edge of the glass in the two guide clamps Do not tighten the clamps yet...

Page 512: ...eatherstripping Also make sure that the glass clears the door linkage and moves up and down smoothly Adjust as needed Depending on the position of the window track brackets you may have to bend the br...

Page 513: ...3443 Screw the window track brackets to the door frame using the supplied screws Side Mirrors The side view mirror gasket acts as the drilling template for the holes in the door slide the gasket down...

Page 514: ...er 2 back from the leading edge of the door and draw a mark The front stud of the mirror must be at least this far back to give clearance for the nut underneath Line the mirror up on the door the heig...

Page 515: ...506 www factoryfive com 508 291 3443 To set the height and angle of the mirror have someone hold the mirror while you stand from the front about 15 feet away and guide them...

Page 516: ...291 3443 With each mirror in the position you want them hold the gasket to the body and remove the mirror Mark the three holes through the gasket and drill with a drill bit Install the mirrors and gas...

Page 517: ...nts and Screens Locate and identify the mesh louvers for the body It is much easier to do any fitment on these panels prior to the body being painted Fit the rear hatch mesh panel to make sure that it...

Page 518: ...508 291 3443 Use the rear deck mesh as a template to mark the rear deck of the body with a marker Measure 1 in from the lane marked and remark the body Cut the rear deck for the mesh The rear exhaust...

Page 519: ...ece need to be bent at 90 in a vice Bend the end and the top for now Position each piece on the body and mark for the third flange to be bent for a tight fit Marking is easier on the outside of the bo...

Page 520: ...511 www factoryfive com 508 291 3443 The mesh for the side scoops need to be formed to fit the body...

Page 521: ...opening Hold it in place from the back and wrap the edges around the back side of the opening If the mesh does not sit flush sand the edge of the opening to fit Hood Preparation Drill 23 8 3 5 hole s...

Page 522: ...These cutouts allow air to escape from under the body after it passes through the radiator Wind tunnel tests suggests that these cutouts are cut using the factory shape Use a reciprocating saw cut 1 i...

Page 523: ...ive com 508 291 3443 Using a 3 5 hole saw drill out the 2 holes for the head light and high beams the turn signal indicator requires a 23 8 hole drilled Use the dimples found in the gel coal as center...

Page 524: ...a paint marker at this time the lights should not be installed in the buckets Using a 25 64 drill bit drill 3 8 into the headlight bucket from the backside You will drill through a layer of fiberglass...

Page 525: ...he bucket and high beam light on the inside hole of the bucket in the headlight bucket from the backside simply by pushing them into place Do not to push the retainer clips fully into the headlight bu...

Page 526: ...signal is installed using the self taping screws provided FFR 12780 Simply line up the turn signal in the head light bucket and screw them in from the backside Front wheel well panel Install bulb sea...

Page 527: ...ave one 90 bend along the length of the part as well as a 45 bend which is located at the bottom of the nose You will have to bend the upper flange of these nose support pieces to fit the contour of t...

Page 528: ...519 www factoryfive com 508 291 3443 Remove the front wheel well panel Drill and rivet the support onto the hood using 3 16 long rivets picture below shows the top flange on the hood liner...

Page 529: ...the headlight lenses to the nose headlight bucket Due to tolerances in the headlight lenses some filing of the edge is necessary to achieve a uniform gap around the outside After achieving the desire...

Page 530: ...ssembled The Corvette hinges are similar but there are differences side to side Look at the pictures below to see verify the correct side Driver Passenger The hood hinge bracket attaches the nose of t...

Page 531: ...nger Attach the hood hinge bracket to the Corvette hinge using the supplied carriage bolts and hardware The picture below is of the driver s side assembly Do not fully tighten the nuts during this ste...

Page 532: ...nstalled onto the car using the supplied carriage bolts and hardware Do not fully tighten the nuts during this step as they are adjusted after the nose is aligned Driver Passenger Install the rounded...

Page 533: ...e hood will support itself on top of the bulb seal while you position it into place Roughly position the nose on the car exactly lining of the hood is done later after the hinges are installed Once yo...

Page 534: ...hinge bracket attaches to the backside of the fog light recess in the nose Before drilling the fog light buckets to mount the nose check its alignment one last time Drill two 5 16 holes through the n...

Page 535: ...ctoryfive com 508 291 3443 Fasten the nose to the hood hinge bracket using the supplied hardware FFR 11024 11005 13963 Do not tighten the fasteners on the hinge assembly yet as they are tightened in a...

Page 536: ...tallation Attach the gas strut bracket onto the frame FFR 12207 using 3 16 rivets just forward of the upper control arm fastening it to the frame member Attach the gas strut ends FFR 13972 to both sid...

Page 537: ...ok at the picture below to locate the gas strut bracket Draw a line on the hood liner inline with the outermost ridge on the hood liner and a second line on the front face of the hood striker bracket...

Page 538: ...yfive com 508 291 3443 Using the location marked above place the gas strut bracket along the first line that was drawn above length wise of the vehicle Drill and attach this bracket to the nose using...

Page 539: ...ning The latches are different side to side the front edge is attached in 2 places and the rear is attached in just one on both driver and passenger side Picture below is of the passenger side of the...

Page 540: ...the latches are in place insert the Corvette striker brackets into the latches It is helpful to apply duct tape around the striker bracket holding it upright and in place Using a paint marker mark th...

Page 541: ...e the paint is still wet marking the perimeter of the striker bracket on the hood liner Remove the hatch striker bracket from the latch and open the hood Align the striker bracket to the underside of...

Page 542: ...om 508 291 3443 There is aluminum in the nose here Drill 3 16 holes in the hood liner and mount the striker brackets with 3 16 rivets Final Paint Prep Body Shop Tips Make sure all wheel wells are even...

Page 543: ...out for the body shop to do All Mesh openings need to be made flush and flat edges radiused The section of body where the dash rests should be painted flat black under the windshield we usually mark...

Page 544: ...flange behind the wheel well is visible with the hood open and should be trimmed to match the wheel well thickness Make sure that the front fender air exits are trimmed even and radiused we usually l...

Page 545: ...1 3443 The door openings should be trimmed flush with the chassis along the bottom and front to allow the aluminum trim to sit correctly if it overhangs in some area mark it to be ground when the body...

Page 546: ...537 www factoryfive com 508 291 3443 The side window openings and rear hatch opening should be sanded for an even thickness and flange width...

Page 547: ...um The underside of the body is not visible in most places however the area around the door pillars back to the rear quarter windows the outside area marked in the picture is visible past the headline...

Page 548: ...539 www factoryfive com 508 291 3443 Have the body mounting flange around the rear Diffuser painted black Send the body out to paint...

Page 549: ...nto the rear wall Cut two pieces of the rubber push on trim FFR 10761 9 long and push the trim onto the outside edges of the rear wall Cut a 41 section of the rubber push on trim and press the trim on...

Page 550: ...541 www factoryfive com 508 291 3443 Mark the locations where the rivnuts will be installed in the 1 square tubing Mark the location for the upper seat belt mount holes...

Page 551: ...owards the center of the car and the flange with the rounded edge points outward and will locate near the top of the door jam See Photo Passenger side shown Mark a trim line on the bulb seal as needed...

Page 552: ...08 291 3443 Set the fuel tank covers in place Mark the location of where the upper sets of holes need to be drilled in the rear wall for the rivnuts Mark the location of where the lower holes will be...

Page 553: ...dge of the fuel tank covers slightly to clear the door striker mounts Remove the fuel tank covers from the car and install the rivnuts in the floor pan Set the interior engine cover in place Make sure...

Page 554: ...type of application called 3M Super Trim Adhesive 3M I D 60 9800 4438 6 buyer s P N 08090 see photo below for what the can looks like When using the Super Trim Adhesive allow the adhesive to tack up b...

Page 555: ...ions of the material from when the cutting tool lifts for a second to readjust its position before cutting the rest of the radius Begin by performing a trial fit prior to applying the adhesive Startin...

Page 556: ...n near the top and towards the front The two tabs will wrap around the front bend of the side bar the top of the A pillar Work your way across the front cross bar to the passenger side taping the mate...

Page 557: ...e to the foam then wrap the material around the roll bar Make sure to spray the adhesive on the back of the material as you begin to overlap the material so it will stick to itself Taping along the ed...

Page 558: ...hesive designed for headliners Do not use 3M Super 77 it will not hold up However 3M does have a product available for this type of application called 3M Super Trim Adhesive Cut the Roll Bar Pad FFR 2...

Page 559: ...0 www factoryfive com 508 291 3443 Remove the padding from the roll bar Peel the backing off the adhesive strip on the roll bar padding Apply the padding to the roll bar just as you did in the trial f...

Page 560: ...ithout wrinkling the material Fit the roll bar cover over the padding starting at the junction of the top of the A pillar and the front cross bar Place the cover over the top of the corner of the side...

Page 561: ...the cover over the side bar taping the material down every few inches The material may tend to twist as you wrap it This is easily corrected by rotating the material until it faces an area that will b...

Page 562: ...pull the material away from the foam Instead peel the tape back so that the last bit of tape in contact with the material is at the cut edge of the material Again begin with the front upper bend of t...

Page 563: ...t around the roll bar you just sprayed until the adhesive dries Cut off any excess material at either end and repeat for the other side Vinyl Installation Fuel Tank Covers Super 77 Spray Adhesive mark...

Page 564: ...in the aluminum Lay the Driver side vinyl piece vinyl side down on a flat clean surface then lay the Driver side Fuel Tank Cover on top of the vinyl with the bent flange sticking up so that the alumi...

Page 565: ...the following picture Again leave about inch between the cut and the edge of the aluminum If the vinyl overlaps trim as necessary so that the vinyl only adheres to the aluminum Cut out the material a...

Page 566: ...and not be concerned with getting overspray on Spray the vinyl with the Super 77 covering the entire piece Spray the side of the aluminum that was in contact with the vinyl when you marked and cut th...

Page 567: ...rest on the bottom edge of the panel and smooth out the vinyl making sure that it sticks to the aluminum Spray the edges of the aluminum as well as the back so when you begin to wrap the vinyl around...

Page 568: ...kles Using the holes you already punched as a guide punch holes through the vinyl you just wrapped around the aluminum You will want to punch through each hole in a few different directions North to S...

Page 569: ...rtantly TAKE YOUR TIME You do not want to have wrinkles in the vinyl and you want to be sure that the vinyl is tightly adhered to the bends in the aluminum Remove the rear wall vinyl from the box and...

Page 570: ...he area to remove on each lower corner Sketch a line that follows the top arc of the aluminum panel about 1 off set from the edge of the aluminum An easy way to do this is to use a compass with a mark...

Page 571: ...p it over the top arc of the aluminum mark then cut evenly spaced sections out of the vinyl about every 8 See Photo Cut a slice in the vinyl at each side of the roll bar cutout on each side Once you a...

Page 572: ...d of the vinyl will be then mask off the aluminum that will be exposed to overspray Remove the aluminum and spray the vinyl with the Super 77 and the face of the aluminum panel that was just facing do...

Page 573: ...g the vinyl out onto the panel Be sure to get the vinyl into the bend line as tight as possible and spray the back of the lower flange Wrap the lower section of the vinyl over the rear wall Trace the...

Page 574: ...ndow outline with a razor blade slicing the outside edges into three or four sections to allow the vinyl to wrap around the aluminum properly Wrap the Vinyl around the aluminum panel Punch holes in th...

Page 575: ...nk covers and the engine cover Tunnel Driver and Passenger Side Masking tape Super 77 Spray Adhesive marker scissors Interior Vinyl parts For the vinyl installation work carefully and most importantly...

Page 576: ...nyl is situated in the right manner tape the top edges and the rear edge in place Tape the top edge of the vinyl at the front of the footbox in place Now you will need to identify the areas where you...

Page 577: ...ping the top edges to hold the vinyl in position When cutting the material do not cut too far The material may be higher or lower once glued in place and if you cut too far the slit may be visible so...

Page 578: ...he top of the dash bulkhead meeting at the front of the footbox to the right of the gas pedal Remove any excess in the corner between the inside footbox wall and the aluminum panel that the wiring pas...

Page 579: ...n at the beginning of the floor pan where the seat will mount Cut location for the area where the 1 5 steel tube begins to angle outward just in front of the inboard seat belt buckle bracket You may a...

Page 580: ...291 3443 Cut the material at the front and rear edges of the 1 5 square tube at the area where the dash and the interior engine cover meet Tape off the steel tube coming from the dash bulkhead going...

Page 581: ...ootbox Spray both the aluminum only the lower inside wall for now and the backing of the vinyl with Super 77 Wait a minute or two to allow the adhesive to tack up and then lower the vinyl onto the alu...

Page 582: ...don t accidentally spray in the wrong direction onto the black side of the vinyl when you get close to the edges Spray the aluminum and the backing of the vinyl Allow the adhesive to tack up Put the...

Page 583: ...ing section of the vinyl Allow the adhesive to tack up and apply the vinyl to the tunnel wall Try to keep the top edge of the material parallel with the 1 dash upright Smooth the material out starting...

Page 584: ...3443 Spray the rest of the front half of the tunnel up to the 1 5 square tube where the dash meets the interior engine cover Apply the vinyl smoothing it out from top to bottom Spray the rear half of...

Page 585: ...e of the vinyl to prevent overspray Mask off the ignition and any wiring that may get overspray on it as well Spray the upper edge of the vinyl and wrap it over the top of the 1 square tubes and the 1...

Page 586: ...wall trimming and slicing where necessary TAKE YOUR TIME Once you are sure the vinyl is trimmed properly spray the adhesive smooth the vinyl out in a similar fashion as with the driver side starting...

Page 587: ...cut a relief in the panel to allow it to bend slightly around the top of the door latch bracket Hold the panel in place and mark the location for the cut and trim a small section from the rear flange...

Page 588: ...Sides If you did not mark the location of the panel in relation to the frame and to the body when you received your kit make sure that the flange that sits on the aluminum floor pan sits flat the top...

Page 589: ...3 Make sure the front edge of the panel that sits in the recessed area of the floor pan is up to the edge of the raised aluminum floor pan Mark the location of the 1 5 square steel door sill tube and...

Page 590: ...l them out with a 1 8 drill bit Apply silicone to all edges of the panel that come in contact with steel or aluminum and set the panel back in place Drill the frame according to the holes you already...

Page 591: ...l fit before applying the adhesive to the carpet and to the floor aluminum panels Footbox Outside Wall Upper Tape off any wiring the fuse panel the exposed powder coated steel the steering column etc...

Page 592: ...inum panel and apply the carpet Repeat for the passenger side Footbox Outside Wall Lower Trial fit the carpet Make any necessary adjustments If you didn t already mask off the pedals particularly the...

Page 593: ...oryfive com 508 291 3443 Spray the back of the carpet and the aluminum then apply the carpet Make sure to keep the carpet tight in the corners and around any bends Repeat for the passenger side Footbo...

Page 594: ...ccelerator pedal to make installing the carpet easier and to avoid getting any glue on the pedal Spray the carpet and the aluminum then apply the carpet again keeping the carpet tight to the other sec...

Page 595: ...t the carpet in place making sure it fits snug against the lower bend in the front footbox aluminum piece Make sure the carpet sits flush against the raised edges front and rear of the floor pan and i...

Page 596: ...ary trim the carpet so that the back edge is about away from the rear lip of the floor pan this will allow the fuel tank covers to sit in place properly and allow you to bolt the panels in without cre...

Page 597: ...er portion will ensure there isn t any adhesive on the vinyl when you are done Spray both the floor and the underside of the carpet Lay the carpet in place starting with the front edge just like you d...

Page 598: ...ying to lock the self sealing gasket into place it helps to spray the gasket with some Window cleaner or apply some soap and water Press the window gasket onto the rear wall aluminum panel such that t...

Page 599: ...enly and there is no gap between them Leaving the contact paper on the rear window slide the window into the inner channel in the gasket An easy way to do this is to start on one side by hand and work...

Page 600: ...0 Below is a photo of what the gasket looks like when sealed off the car Use the probe of the closing tool to pry the grooved portion of the gasket open and the wheel to roll along the tongue sealing...

Page 601: ...592 www factoryfive com 508 291 3443 Trim the excess vinyl around the window gasket...

Page 602: ...install the bulb seal you cut previously to the top edges of the rear wall Install the rear wall using the supplied 20 x 1 button head screws 4 mm Interior Engine Cover 4mm Hex key 25 64 drill bits d...

Page 603: ...the engine cover is pressed onto the top of the steel it surrounds at the bottom end Then using the holes you already drilled in the engine cover drill holes in the frame A good way to prevent the eng...

Page 604: ...508 291 3443 Once you have drilled the six holes in the frame remove the engine cover and drill out the holes with a 25 64 drill bit Install the rivnuts Re install the engine cover bolting it to the...

Page 605: ...L Aluminum Panel Fuel Tank Cover Inside L R Set the fuel tank covers in place so that the side flange of the engine cover is in front of the fuel tank cover Slide the inside fuel tank cover aluminum p...

Page 606: ...num You may want to remove the 1 8 thick fuel tank covers first to avoid tearing the vinyl with the drill just make sure that you tape or clamp the inside panel in place first Bolt the fuel tank cover...

Page 607: ...598 www factoryfive com 508 291 3443...

Page 608: ...ne Floor Access Panel on the Engine Floor Make sure the Access Panel overlaps the cutout in the Engine Floor evenly Using the laser cut holes in the Access Panel drill and rivet the Access Panel to th...

Page 609: ...he panel to the frame Do not drill rivet near the front corners of the panel the Tunnel Floor Panel needs to overlap the front edge leave about 1 of the Engine Floor panel Once the Tunnel Floor is in...

Page 610: ...e edges with the edges of the Engine Floor Panel and making sure the panel lies about in from the outside edges of the 1 5 square steel tubes that run straight up the middle of the frame Drill and riv...

Page 611: ...l 1 square tube in front of the rear wheel The front edge of the panel should be in the middle of the 1 5 square tube that runs the width of the car under the crankshaft pulley Trace the outline of th...

Page 612: ...e side of the Engine Floor Measure in about from each edge of the panel and mark the rivet locations Remove the panel Apply a bead of silicone to the frame then reposition the panel and drill and rive...

Page 613: ...dge of the Lower Dash Bulkhead Tube and the inside edge of the panel touches the Tunnel Floor Panel you already installed Note where the panel overlaps the steel floor pan so you know where to apply t...

Page 614: ...e GTM and the Corvette Driver Side Seat belt reels will be mounted on the GTM Passenger side The donor seat belts assembly will be re mounted in the GTM chassis in their entirety Locate the belts and...

Page 615: ...1 3443 Bolt the upper seat belt guide through the firewall and to the chassis 3 4 wrench socket Bolt the seat belt receptacles to the chassis making sure that each release button is facing the inside...

Page 616: ...16 5 16 25 64 drill bits drill 4 mm Hex Key Seats Mark the bottom of the seats with masking tape so that you can locate the mounting surfaces with the seats in position The mounting surfaces are the...

Page 617: ...e com 508 291 3443 Position the seats in the chassis and sit in them to find a comfortable position Pay close attention to pedal position steering wheel position head clearance and visibility as well...

Page 618: ...touches the seat Removing the corner of the seat will allow the seat to move in more You will not feel anything when sitting in the seat This can also be done for the passenger side just cut the oppos...

Page 619: ...mark the side to side location for the rear bolts The front mounts will generally fall over the tubular section of chassis so it is important to measure from underneath where you can see the tubes to...

Page 620: ...n the chassis drill them out from the top with a 3 16 drill bit Re position the seat and very carefully drill through the chassis from the bottom into the seat In order to keep the seat in position wh...

Page 621: ...w factoryfive com 508 291 3443 Remove the seat and drill out the four holes and install 20 rivnuts in the base Drill the chassis holes out with a 5 16 drill and install the seat using 20 button head s...

Page 622: ...ape 11 16 drill bits hole saws drill Solder soldering iron marker masking tape GTM Gauge Assembly Door components Misc electrical components Use the following diagram as a guide for wiring the power w...

Page 623: ...s in their rough location and slide one of the small rubber grommets from the chassis harness box down each pair of red and black wires that will connect the motors to the switches The window wires ru...

Page 624: ...615 www factoryfive com 508 291 3443 Route the window motor wires through the chassis and push the grommet into the hole to protect the wires...

Page 625: ...through the pass through and splice and solder the red wire into both of the two yellow window power wires from the chassis harness The chassis harness is fused so the extra in line fuse can be remove...

Page 626: ...factoryfive com 508 291 3443 Gauge Installation Remove the gauges from the box and locate the retaining rings these will be used to help determine lay out Cover the front of the dash face with maskin...

Page 627: ...Trace the layout on the inside of each ring and cut with a hole saw jig saw or rotary cutter Remove the masking tape from the dash face Attach the gauges to the dash face Make sure that the gauge writ...

Page 628: ...l of the gauge face wires through a large plug One of the unused large round ones form the donor harness works well Run a ground circuit for all of the gauges and indicators The indicators are LED s a...

Page 629: ...iner Flip the body upside down and rest it on a protective surface Test fit the headliner to the body and trim to fit if needed Spray the front 12 of the liner with trim adhesive headliner glue and fi...

Page 630: ...621 www factoryfive com 508 291 3443 Finish the liner working in 12 increments until its sits smooth and is well attached in all corners and edges...

Page 631: ...ugs Install the fuel filler caps in the position you drilled before the body was painted and bolt in place using the hardware that came with the caps Phillips screwdriver 5 16 wrench socket Re install...

Page 632: ...com 508 291 3443 Taillights Wire in the tail lights to the chassis harness Use the third brake light feed for both brake lights and ground all lights to the chassis making sure the ground is clean and...

Page 633: ...ire to the switch on the transmission and attach it using the bullet connector from the chassis harness kit The remaining wire that was trimmed from this circuit attaches to the other side of the swit...

Page 634: ...of the following template to fit the fog lights to the nose and tape them in the light openings 2 Test fit the light in the opening aligning the holes with the slots on the light mount bracket Remove...

Page 635: ...mplate so the holes line up with the slot then mark the slot with the location of the hole With the bracket in a vise drill the location marked and the center of the sideways T for rivnuts Start with...

Page 636: ...627 www factoryfive com 508 291 3443 Use the rivnut tool to install 20 rivnuts in each bracket with the bracket ears pointed away from the tool as shown...

Page 637: ...628 www factoryfive com 508 291 3443 Reassemble the fog lights...

Page 638: ...emains of the template and push the wires through the center hole Mount the fog light using flange head screws Connect the Fog lights to the fog light wires Headlight wiring Wire the front lights into...

Page 639: ...five com 508 291 3443 Slide one of the supplied terminals onto the wire and crimp into place Slide the terminal into the headlight plug far enough so that the terminal will engage the male terminal on...

Page 640: ...3 Repeat for the other wire leading to the headlight Once both wires are installed in the plug press the blue plastic safety clip over the wires with a small screwdriver Press the plug onto the headli...

Page 641: ...sis harness and a small spade connector from the kit on either end of each wire Use these wires to ground the driving lights and headlights Headlight covers Silicone the headlight covers in place Alum...

Page 642: ...633 www factoryfive com 508 291 3443 Install the door latch cover plate Aluminum Firewall Aluminum Panel Firewall Rubber Push on Trim Aluminum Panel Rear Deck Trim Plate...

Page 643: ...e Firewall the body and then the L Flange of the Upper Wheel Well panel Install the cowl bracing side panels Press the weather stripping on the top edge of the panels At the ends of the Firewall where...

Page 644: ...635 www factoryfive com 508 291 3443 Fuel Filler Installation Fuel Filler Assembly The fuel filler hoses and clamps are provided with the kit use one small and one large clamp for each side...

Page 645: ...636 www factoryfive com 508 291 3443 1997 2002 Fuel tanks Slip the fuel filler over the tank inlet first then with both hose clamps over the hose slip it onto the filler cap...

Page 646: ...637 www factoryfive com 508 291 3443 Make sure the hoses are seated and tighten the hose clamps...

Page 647: ...the hose transitions from 2 25 diameter to 3 diameter Cut the large diameter end off of the hose making sure you leave enough room for the hose clamp to fit around the hose Install the other end of t...

Page 648: ...he cut end of the filler neck onto the filler cap Clamp tight Once you have the filler hose in position it isn t uncommon for it to be against the body Make sure there are no sharp rough edges that th...

Page 649: ...asher fluid tank FFR 25392 mounts to the chassis under the steering shaft Trial fit it into position it is easiest to pass it from the bottom through the middle of the lower control arm With the tank...

Page 650: ...a small piece of angle aluminum FFR 10648 Fit the tank into position so that there is clearance around the steering shaft and line up the mount bracket with the forward mounting boss on the tank Mark...

Page 651: ...com 508 291 3443 Remove the bracket and drill a hole to mount the tank and two 3 16 holes to rivet the bracket to the chassis Put the bracket back in position to mark the frame then drill and rivet t...

Page 652: ...643 www factoryfive com 508 291 3443 Bolt the tank into position using the two 20 button head screws and nuts provided...

Page 653: ...er support tube on the passenger side and the top of the footbox front wall aluminum Mark the location for the rivnuts 4 total Drill the Rivnut holes using a 25 64 drill bit You may want to begin by u...

Page 654: ...Install one of the rod ends FFR 25724 with the supplied jam nut FFR 25725 onto the wiper motor arm 9 16 wrenches You will have to trim some of the excess thread off of the rod end in order for it to h...

Page 655: ...tte screws that held the motor in place fasten the motor to the mount plate T 30 Torx Place a nylon spacer FFR 10960 between the frame and the mount plate at each of the rivnuts and bolt the plate int...

Page 656: ...e com 508 291 3443 For the bolt at the front corner of the plate you may have to use the supplied washers as well as the nylon spacer to prevent the bolt from bottoming out before the plate is firmly...

Page 657: ...off wheel As you did with the rod end on the wiper motor you will have to trim the threads on the rod end to clear the aluminum Place the aluminum tube over the threaded rod then screw the rod end FFR...

Page 658: ...www factoryfive com 508 291 3443 Install the wiper wheel box onto the body using the supplied 20 hardware Install the rod end on the wiper wheel box arm with the supplied jam nut FFR 25725 9 16 wrenc...

Page 659: ...FFR 25552 Clip the wiper arm onto the shaft of the wiper wheel box making sure that the tab on the arm clips into the channel on the wheel box shaft clip shown Using the supplied clear tubing with the...

Page 660: ...a hole in the cowl bracing aluminum and route the hose to the underside of the body Drill a hole in the body for the barbed elbow fitting for the windshield washer nozzle Insert the fitting and hook i...

Page 661: ...ade Fill the tank with fluid and spray the windshield Check the sweep by turning the wipers on start with the slowest setting to avoid damaging the linkage or running the wiper beyond the windshield M...

Page 662: ...s Hacksaw marker 1 8 25 64 drill bits drill Phillips head Screwdriver 3 8 wrench vise ruler tape measure Door liner L R FFR 25744 25745 Door handle and Fasteners FFR 25422 The inside door handles need...

Page 663: ...91 3443 Trim the four feet off of the handle flush with the screw hole Insert the door handle into the door liner so that the front prongs go over the edge of the plastic It may be necessary to grind...

Page 664: ...e of the door handle through the mounting bracket and attach with a nut Tighten the retaining nut with a Philips head screwdriver and 3 8 wrench Locate the donor car door handles and mark each one wit...

Page 665: ...1 3443 Fit the door handles into position on the door and measure 7 16 toward the front of the door from the end of the line you scribed and mark for the mounting holes taping the door handle in place...

Page 666: ...657 www factoryfive com 508 291 3443 Drill the holes with a drill bit...

Page 667: ...the original hardware The handle should have its original gasket around the outside and can be shimmed and adjusted for a good fit The door linkage from the donor car is re used for the inner and out...

Page 668: ...in the threaded linkage piece and cut with a hack saw On the remaining threaded piece measure in and 1 from the non threaded end and mark Bend the rod in a vice at the 1 mark in the same direction as...

Page 669: ...Bend the rod at the mark 45 back in the original direction Install the rod and clip into the door The bent end hooks through the outer door handle and the clip and threaded end snaps into the lower ho...

Page 670: ...ine the inner door liner up to the door so that there is an even gap around the outside Drill for the fasteners around the outside of the door with a drill You can use more of the screws on the bottom...

Page 671: ...es on the door with a larger 25 64 bit and install 20 rivnuts to hold the door panel in place Find the long linkage from the donor door that hooked up the original inside door handle use the longer of...

Page 672: ...door latch and install the door liner with the single bend end poking out of the door handle hole Line the inner handle up to the door and bend the linkage to fit the handle Once the linkage is the c...

Page 673: ...ling the rear splash guards is the same for both driver and passenger side all pictures below were taken from passenger side Make sure that the front lower splash guard is installed as previously inst...

Page 674: ...665 www factoryfive com 508 291 3443 Rear Front Upper...

Page 675: ...666 www factoryfive com 508 291 3443 Front Large Install the front large panel next Rivet the lower flange to the side of the front lower panel...

Page 676: ...667 www factoryfive com 508 291 3443 Install the front upper piece now This piece in riveted in place along the center front lower and front large panels...

Page 677: ...e com 508 291 3443 The rear splash guard is now installed This is a large panel and seals the rear section of the wheel wells Rivet this panel in place on the inner edge attaching it to the flange on...

Page 678: ...through the body using 5 16 rivets Exhaust Rear Mesh 5 16 Hex 9 16 wrenches tape measure 3 hole saw or jigsaw shears tin snips pliers silicone caulking gun Exhaust H Pipe Assembly Exhaust Mount Hardw...

Page 679: ...670 www factoryfive com 508 291 3443 Bolt the tailpipes in place you can leave the gaskets out for now as this will have to be removed for the mesh installation 5 16 Hex 9 16 wrench...

Page 680: ...ely assemble the H Pipe hangers with the supplied hardware Bolt the hanger to the tab welded to the H Pipe wrench Remove one of the transmission housing nuts and put the lower end of the H Pipe hanger...

Page 681: ...lytic converters center the exhaust tips in the rear of the body and tighten both the lower joint on the catalytic converter pipes and the sliders on the exhaust hangers Measure the distance from the...

Page 682: ...Transfer this measurement to the tailpipe mesh pieces and mark the center for a hole Drill or cut with a jig saw a 3 hole in the center of the mesh Using tin snips or shears cut slice around the outsi...

Page 683: ...674 www factoryfive com 508 291 3443 Using a pair of pliers carefully bend the tabs inward to form a radiused edge where the exhaust tip passes through...

Page 684: ...675 www factoryfive com 508 291 3443 Remove the tailpipe and slide both pieces of mesh over the ends Install the mesh using silicone and tape in place until dry...

Page 685: ...re strippers solder soldering gun License Plate Lights Center the license plate in the recess and mark the two upper holes Use a 5 16 drill bit and drill out the two holes Place the license plate into...

Page 686: ...ack wire into the ground circuit Cover any soldered joint with heat shrink or electrical tape and repeat for the other light Make sure the lights are aimed correctly and illuminate the whole plate the...

Page 687: ...king gun Low Tack Tape Rivnut tool clamps silver white marker 2 25 hole saw jig saw or similar razor knife 5 32 Hex key Stitched Interior components Shifter Handle Components dash components Dash Vent...

Page 688: ...t the retaining cup into the cutout in the dash There are small clips indexed in the retaining cup meant to put pressure against the back of the dash panel Make sure that these clips mount against the...

Page 689: ...www factoryfive com 508 291 3443 Insert the vent face into the retaining cup Check the rotation of the vent face it should be able to rotate 360 check to be sure the vent face opens and closes proper...

Page 690: ...at for the other side pod and the two vent locations in the center console Center Console Install the center console in the car so that the dash sits up on the body lip and the center area is sitting...

Page 691: ...91 3443 With the tranaxle in neutral mark around the shifter handle on the underside of the center console Remove the center console from the car and use a 2 25 hole saw to drill through the console a...

Page 692: ...down nice and tight on the frame Before doing the next steps make sure that you have oil in your transaxle and that it has been correctly broken in so that the shift forks do not stick Check the clea...

Page 693: ...m 508 291 3443 Use a white or light colored marker to mark the top of the console where it needs to be trimmed to allow for clearance around the handle Keep in mind when you shift hard the handle will...

Page 694: ...the area marked Re install the console and recheck the handle for clearance Trim again if necessary The center console can be attached to the frame a number of different ways Factory Five has provide...

Page 695: ...in the car position and clamp the right dash pod to the center console so that the top of the console in front of the pod is level with the top area of the pod and the point on the bottom inside of th...

Page 696: ...factoryfive com 508 291 3443 Install and clamp the left dash pod the same way On the inside of the left dash pod drill 4 3 16 holes through the mounting flange so that they are spread evenly around th...

Page 697: ...ve the center console assembly from the car One hole at a time drill a 3 16 hole and rivet using 3 16 long rivets around the mounting flange on the right dash pod Do this in four or more places around...

Page 698: ...689 www factoryfive com 508 291 3443...

Page 699: ...iver side pod and from the back of the dash trace the contour of the mounting flange onto the back of the dash face On the left side of the center console drill out the four mounting holes made previo...

Page 700: ...l out the mounting holes on the left dash pod using a drill bit Reinstall the center console assembly in the car for the last time with the front console flange on top of the body flange and the cente...

Page 701: ...692 www factoryfive com 508 291 3443 Install the left dash pod using the 20 x flange head screws Attach the bottom of the right dash pod to the 1 50 square tube using 3 16 rivets...

Page 702: ...u drill the first hole place a 3 16 rivet in the hole just place it in the hole do not set it with a rivet gun to hold the dash face in position This will keep the holes aligned as you drill the rest...

Page 703: ...or the instrument wiring Install the dash front face over the steering column and firmly against the mounting flange on the side pod Line up the holes in the dash face with the rivnuts on the mounting...

Page 704: ...d components Decide where you would like to locate the switches Drill holes in the center console Use a round file to open the holes up slightly so the switches will fit Insert the switches in the Cen...

Page 705: ...e Cut the hole for the switch retaining ring Press the window switch retainer into the console Connect the wiring to the window switches Install the FFR Ignition Switch unless you chose to mount it in...

Page 706: ...over Make sure to bolt it in place with the Torx head screw a 4mm socket will work if you don t have the Torx bit Install the lower steering column cover clipping it into the top cover and bolting it...

Page 707: ...698 www factoryfive com 508 291 3443 Emergency Brake Cover Plate drill bit drill marker Rivet Gun Aluminum Panel Emergency Brake Cover Plate Drill an hole in each corner of the aluminum panel...

Page 708: ...he emergency brake you may have to lift the handle to allow you to get the panel over the handle and down to the opening in the tunnel panel Using the holes in the panel as a reference mark the rivet...

Page 709: ...nd Pedal Box Cover Aluminum drill bit drill silicone caulking gun marker Aluminum Panels Wheel well Upper R L Aluminum Panel Pedal Box cover Plate R L Take the upper wheel well aluminum pieces out of...

Page 710: ...toryfive com 508 291 3443 Measure the rivet locations on the lower flange Drill the panel accordingly with a 1 8 drill bit Cut a section of the supplied rubber push on trim and apply to the top edge o...

Page 711: ...x wall where the Upper Wheel well panel will mount to Set the aluminum panel in place The L shaped flange on the panel goes behind the body Make sure the bulb seal has good contact with the body so th...

Page 712: ...703 www factoryfive com 508 291 3443 Rivet the lower flange in place Repeat for the other side Set the Pedal Box Cover Plate into position and mark the rivet locations on all three sides...

Page 713: ...r drill bits drill rivet gun silicone caulking gun 6 self tapping screws Driver passenger front wheel well rear splash guard aluminum FFR 26025 26026 aluminum body seal rubber push on trim FFR 26035 s...

Page 714: ...705 www factoryfive com 508 291 3443 2 Mark the rivet spacing and drill 1 8 holes along the bent flanges Cut and install the bulb seal on panel as shown...

Page 715: ...panel with the bent flanges against footbox and the bulb seal against the inner body The top outer corner should fit behind the hood latch mechanism Once properly fit secure panel with a few 6 self t...

Page 716: ...Body Close out Panels drill bit drill tin snips Aluminum Panel Body Close out Rear L R Aluminum Panel Body Close out Front L R Rubber Push on Trim Front Cut a section of the body seal and apply to th...

Page 717: ...frame Also make sure the top aluminum flange fits as tightly as possible to the underside of the body Seal any other gaps seams with silicone Repeat for the other side Rear Set the panel in place and...

Page 718: ...709 www factoryfive com 508 291 3443 Cut a section of bulb seal and apply to the top and outside edges of the aluminum...

Page 719: ...ontact with the body The flange on the close out panel should be on the outside of the door sill panel Rivet the panel to the lower door sill panel Repeat for the other side Door Sill Carpet Super 77...

Page 720: ...overlap between the carpet on the floor and the door sill carpet Check the fit around the seat belts you will have to make some slits in the carpet to get it to fit snug around the seat belts Mask of...

Page 721: ...driver side door sill in place so that the flange is on the inside of the car and the front edge of the aluminum is as close to the front edge of the door opening Notice where the panel contacts the...

Page 722: ...tch Release 5 32 Hex 3 32 drill bit drill Phillips screwdriver Cockpit Side Wall Brackets L R Aluminum Panel Cockpit Upper side Wall L R Rear Hatch Handle Rear Hatch Cable Rear Hatch Handle Screws Rei...

Page 723: ...the panel where it mounts to the frame and in the side wall bracket you just installed 3 32 drill bit Shown without body closeout installed without lower cockpit side wall carpeted Cut a section of t...

Page 724: ...508 291 3443 Mount the panel with the supplied screws Before installing the driver side panel install the hatch release cable to the handle Insert the rear hatch handle in the panel sliding the cable...

Page 725: ...716 www factoryfive com 508 291 3443 Drill two pilot holes 3 32 drill bit for the handle screws Screw the handle in place with the supplied Phillips head screws...

Page 726: ...cable along the frame using the supplied insulated clips to hold it in place Insert the cable through the hole on the driver side of the receiver Hood Release Cable 3 16 drill bit drill rivet gun Ins...

Page 727: ...wheel wells that will allow you to route the cable under the master cylinders on the driver side and under the square steel tube welded to the top of the shock tower that creates the top of the footbo...

Page 728: ...ww factoryfive com 508 291 3443 Connect the end of each cable to the latch mechanism making sure the cables are away from the wheels Mount the passenger cable in place with some of the insulated line...

Page 729: ...lass Windshield FFR 25000 Rear Hatch Window FFR 25001 The windshield rear hatch and rear quarter window glass are designed to be installed by a professional glass installer with the heated adhesive an...

Page 730: ...ariances in filament position can translate to large variances in beam pattern The following procedure does not require special aiming equipment and ensures proper aim Find a flat level surface next t...

Page 731: ...nterline mark at the distance of Measurement B from the vehicle centerline vertical line Turn the headlights on and adjust the vertical aim of the headlights so that the top horizontal cutoff of each...

Page 732: ...car to an alignment shop and have the car aligned properly before hitting the track A minor flaw in alignment can cause very twitchy handling Avoid temptation and never drive a car without proper ali...

Page 733: ...ntrol arm rear bolt 71 Rear upper control arm 65 Rear coil over to frame mount upper lower 75 Rear suspension tie rod nut frame side 44 Front lower coil over mount to lower control arm 21 Steering rac...

Page 734: ...ctoryfive com 508 291 3443 Thread SAE Metric Zinc Plated Ft Lb M8 18 M10 33 M12 61 M14 98 M16 120 ATTENTION Use the following specs in order to torque Stainless Bolts 3 16 11 ft lb 132 in lb 16 ft lb...

Page 735: ...350 350 360 A 350 375 M 350 360 A 350 375 M 350 360 A 350 375 M 350 360 A 350 375 M LS6 5 7 Corvette N A N A N A N A 385 385 405 400 405 400 405 400 LS1 5 7 Base F body N A 305 335 305 335 305 335 310...

Page 736: ...s M12 x 1 75mm x 55mm 10414261 8 each Bolts for upper control arm to chassis M10 x 1 5mm x 40mm 11515768 8 each Washers for upper control arm to chassis 10mm 10289125 4 each Cam bolts for lower contro...

Page 737: ...m 10414261 2 each Cam bolts for lower control arms to chassis forward most mount M14 x 2mm x 110mm 10254819 2 each Locknut for lower control arm bolts forward most mount M14 x 2mm 11516382 2 each Cam...

Page 738: ...2949 LH 1 each RH e brake cable to knuckle brackets 10262950 RH 4 each Bolts for e brake cable to knuckle brackets M10 x 1 5mm x 70mm 11516356 1 each RH E brake cable 10299165 RH 1 each LH E brake cab...

Page 739: ...ng screw kit contains 3 screws 22062547 2 each Fan motor connector w leads 12101917 1 each Radiator 52470606 1 each LH Radiator lower rubber isolator 10278679 LH 1 each RH Radiator lower rubber isolat...

Page 740: ...ctor w leads 3 way black 12101864 MISCELLANEOUS 1 each Ignition cylinder lock cylinder s and 2 key set 12458190 1 each LH Exterior door handle 10439373 LH 1 each RH Exterior door handle 10439374 RH 1...

Page 741: ...81 1 each Drive belt idler pulley 12564401 1 each Alternator 10353440 2 each Rubber motor mounts 11515744 nuts 4each 10284134 1 each LH Aluminum motor mount bracket 10260642 LH 1 each RH Aluminum moto...

Page 742: ...r unit see the instructions below We recommend using the Corvette Trinary switch to allow the Corvette computer to control the system See Hose Kit Installation Instructions However if you are running...

Page 743: ...five com 508 291 3443 Remove the 4 screws from the front bracket on the Evaporator Phillips screwdriver Begin the install by sliding the front end of the Evaporator to the front of the footbox and up...

Page 744: ...Turn the back end of the Evaporator into the center of the car making sure the bracket at the front of the Evaporator stays above the 1 tube at the front of the footbox and slide the front of the Eva...

Page 745: ...736 www factoryfive com 508 291 3443 You may have to trim the front of the mounting bracket to clear the front aluminum panel See below...

Page 746: ...oolant lines tubes you can mount the bracket under the 1 square tube if necessary Before drilling any holes for the Evaporator make sure the unit isn t resting on the coolant tubes and there is enough...

Page 747: ...lower Motor Extension to it is on the inside of the diagonal Make sure that the angled edge of the extension is parallel with the diagonal tube in the center of the chassis Before bolting the Evaporat...

Page 748: ...out of the way and drill two holes with a 25 64 drill bit and install two riv nuts Move the Evaporator unit back into place and bolt it in place using the supplied 20 bolts 7 16 socket Bolt the FFR su...

Page 749: ...740 www factoryfive com 508 291 3443 Drill two 3 16 holes in the bracket then through the 1 5 upright and rivet the bracket to the frame Screw the Extension onto the Evaporator...

Page 750: ...the port on the bottom of the Evaporator unit and route the hose to the bottom of the aluminum undercarriage panel If possible you can use one of the existing holes by opening it up with a 5 8 drill b...

Page 751: ...the body and under the wiper enclosure Routing the hoses with footbox roof panel already trimmed Install the 2 5 duct hose for the dash vents using the 4 plenums on top of the Evaporator unit The spa...

Page 752: ...correct length and allow you plenty of access Use the forward most plenum for the passenger side pod duct the rear two plenums for the center ducts and the plenum second from the front for the driver...

Page 753: ...it use a zip tie to hold each end in place and route the hose to the bottom of the driver side inner footbox wall Note the general location of the hose so you can locate the opening for the duct Using...

Page 754: ...to the plenums on the side of the Evaporator unit Set the dash in place and connect the hoses to the defroster ducts then to each of the 4 dash vents This will require you to lie on your back and rea...

Page 755: ...em Before installing any of the lines be sure that the supplied O rings are in place and will give the proper seal Perform an inventory of all the parts included with the kit using the Vintage Air pac...

Page 756: ...upper portion of the Evaporator unit See hose routing diagram will reach the Accumulator Shown with hoses already installed Install a 20 Rivnut in the 1 tube and mount the Accumulator to the chassis w...

Page 757: ...Air diagram Install the hard elbows onto the heater ports on the side of the Evaporator unit Now you will need to cut the 5 8 heater hose so that the end coming from the water pump can be connected t...

Page 758: ...the Orifice tube and A C line according to the Vintage Air diagram instructions Locate the Corvette AC Pressure Sensor and O ring Attach the O ring at the groove of the threaded NPT fitting of the sh...

Page 759: ...em to the back of the compressor If you haven t done so already it will help to remove the interior engine cover to access the hoses Once you have the hose routed through the tunnel the end with the L...

Page 760: ...751 www factoryfive com 508 291 3443 The other hose will connect to the upper port on the front side of the Condenser with the Corvette bolt...

Page 761: ...te If you are using a stand alone system screw the safety switch onto the inline fitting specified on the Vintage Air Diagram as Safety Switch See Appendix E and wire according to the instructions The...

Page 762: ...to the compressor The other is a black ground wire 1997 Model Years differ Re bolt the Evaporator unit back into place If your system had coolant in it already you will have to re burp the system acc...

Page 763: ...754 www factoryfive com 508 291 3443 Heat A C Hose kit Routing Diagram...

Page 764: ...755 www factoryfive com 508 291 3443 Heat A C Servicing Procedure...

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