Ferrari 355 Challenge Grill Installation

Transcription

Ferrari 355 Challenge Grill Installation
By:
Dave Lelonek
(Dave Rocks) on Ferrarichat.com
August 12, 2014
Created based on model year 1998 (355 F1 GTS), other model years may apply.
Disclaimer:
This document was created to assist others and has been created based on the procedure I
use and have proven successful. Others may use different procedures or variations to this
method.
Use at your own risk.
This document is not copyright protected, please feel free to use and share with others.
If you would like to add to or comment on this document, please email me at:
dave.lelonek@amtny.com
Ferrari_1998_355_Challenge-Grill_Installation_REV000.doc
Page 1 of 23
Dave Lelonek
1.0 Materials Needed:

Challenge Grill P/N: 65511400
OEM grill can be purchased thru Ricambi, Eurospares or any Ferrari Dealer:
http://www.ricambiamerica.com/product_info.php?products_id=252250
http://www.eurospares.co.uk/searchResult_one.asp?S=65511400&TM=1&TMo=512&TA=2&T
B=28714
Or you may purchase an aftermarket from Exotic Auto Recycling:
http://exoticautorecycling.com//index.php?main_page=product_info&cPath=10&products_id=1
1
I purchased the OEM grill thru Eurospares since the price was less than the aftermarket.
Ricambi could not get the OEM at the time of my purchase and the dealers price was higher.
Page 2 of 23
Dave Lelonek

Blind Rivets (pop): Quantity 2
P/N: 60677000
http://www.ricambiamerica.com/product_info.php?products_id=221800
These are aluminum pop rivets and can be found at many supply houses. I purchased mine
thru McMaster Carr:
http://www.mcmaster.com/#97517a015/=t8y7ms
1/8" Diameter, .063"-.125" Material Thickness Range, Domed Aluminum with Steel Mandrel.
Page 3 of 23
Dave Lelonek

Blue Painter's Tape:

Double Sided Tape:
Page 4 of 23
Dave Lelonek
2.0 Tools Required:

Drill Motor

1/8" (.125") Drill bit

Phillips head screw driver

1/4" Drive ratchet with extensions

1/4" Drive sockets: 7mm, 8mm (standard and deep well), 10mm

Rivet installation tool
http://www.mcmaster.com/#6659a21/=t8yco9

Wire cutters

Mallet / hammer

M5 x .8 thread die (see section 4.0)
Page 5 of 23
Dave Lelonek
4.0 Inspect New Challenge Grill:
My new OEM Challenge grill arrived with two of the threaded studs covered in paint. It would
have been time consuming to ship this back and wait for a replacement.
I was lucky to have a M5 x .8 thread die in my shop to chase the threads and clean off the
paint:
Page 6 of 23
Dave Lelonek
5.0 Turn Off Battery Switch:
While this is not totally required, I prefer to turn off the battery when working on the car,
especially if I will be doing anything with electrical connections. This is a preventative measure.
Turn off battery switch inside access panel under front bonnet:
Page 7 of 23
Dave Lelonek
6.0 Preparation:
Using Blue Painter's tape, mask off the boarders of the existing rear panel (bumper, quarter
panels, etc) as shown:
This is very cheap insurance to not scratch the pain when removing old grill and installing new.
Other masking tape can work but painter's tape won't leave a heavy residue and will reduce
any risk of peeling paint.
Page 8 of 23
Dave Lelonek
7.0 Remove Existing Rivets and Trim Piece:
Using a drill motor and 1/8" drill bit, carefully drill our the center of the two rivets (#37) that hold
on the trim piece P/N: 65083700 (number 31)
Trim
Rivet
Page 9 of 23
Dave Lelonek
Position drill on rivet center and run slow and gentle - do not push drill hard:
Only the very top (dome) of rivet will need to be drilled to free the connection:
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Dave Lelonek
Rivet Removed:
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Dave Lelonek
8.0 Remove Center Taillight Panel:
Using a Phillips screw driver, remove (4) screws that hold center tail light panel, P/N:
64526100 (#28)
Phillips Head Screws
Page 12 of 23
Dave Lelonek
Remove panel and unplug center taillight electrical connector, push tab on right side to unplug:
Tab
After removal, tape the wire and connector out of the way.
Page 13 of 23
Dave Lelonek
9.0 Remove Existing Grill:
The grill is attached with (9) nuts. The grill has (7) threaded studs and (2) holes. The inner
panel has (2) threaded studs to meet with the holes in the grill.
See below: (green circles are for the holes and red circles for the studs)
Using a 1/4" drive ratchet, extension and 8mm socket, remove (2) nuts at the top of the panel
from the exterior of the grill:
Page 14 of 23
Dave Lelonek
Using a 1/4" drive ratchet, 8mm socket, remove (7) nuts from the interior of the grill: All but the
(2) outer most corner are very easy to access. Note: These nuts also have washers behind
them.
Center
Left (right not
shown)
Left Upper
Page 15 of 23
Dave Lelonek
With care, Remove the grill:
Prior to installing new grill, clean inner panel area.
Page 16 of 23
Dave Lelonek
10.0 Remove The Cavallino (Prancing Horse):
Using a 1/4" drive ratchet and 7mm socket, remove (2) nuts from the inner side of the existing
grill that fasten the Cavallino. Install the Cavallino on the new Challenge Grill:
Page 17 of 23
Dave Lelonek
11.0 Remove Existing Rubber End Gaskets and Apply to New Grill:
Remove the rubber end gaskets P/N: 64420300 & 64420400 (#26) from the existing grill:
Apply double sided tape to one side of the gaskets and use a razor blade to cut profile:
Page 18 of 23
Dave Lelonek
Install gaskets to Challenge Grill:
Page 19 of 23
Dave Lelonek
12.0 Fit Challenge Grill to Car:
Carefully fit Challenge Grill to car and install nuts:
Note: I needed to use larger washers in the (2) lower most corners since the holes in the body
are too large for the factory (existing) washers.
Page 20 of 23
Dave Lelonek
Note: If needed, use a 1/4" drive ratchet and 10mm socket to loosen taillights to fit the grill
better. Re tighten after achieving proper fit.
Upper tail light nut
(lower not shown)
13.0 Re-Install Center Taillight Panel:
Plug in electrical connector and fasten (4) Phillips head screws (opposite of removal)
Page 21 of 23
Dave Lelonek
14.0 Re-Install Trim Piece:
Using (2) rivets, re-install the upper trim piece.
Slide trim piece on and align holes for rivets.
Insert rivet into hole, hold tool firmly against rivet and squeeze handle to compress rivet and
snap off mandrel.
If a tab is left after snapping rivet mandrel, use wire cutters to remove:
Page 22 of 23
Dave Lelonek
It's a good idea to remove the rivet mandrel by using a punch or the broken off shank of the
mandrel and a hammer / mallet to tap out the mandrel remains thru the center of the rivet.
15.0 Remove Painter's Tape, Clean up and Turn On Battery Switch:
Start to finish this project took just shy of 4 hours since I made 2 trips to my shop to get tools
and supplies. This job can comfortably be done is 2.5 hours if you have all that is needed from
the start.
Page 23 of 23
Dave Lelonek

Ferrari 355 Challenge Grill Installation

Transcription

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