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Factory Five Racing GTM Supercar Assembly Manual

Summary of GTM Supercar

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    R e v i s i o n 2 d , a p r i l 2 0 1 4.

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     2014 factory five racing inc. 9 tow rd wareham, ma 02571 phone 508.291.3443 • fax 508.291.3883.

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    Ii www.Factoryfive.Com 508-291-3443 table of contents table of contents................................................................................... Ii general information .................................................................... 1 foreword .............................................

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    Iii www.Factoryfive.Com 508-291-3443 stereo and heater controls ................................................................ 103 dash cluster ...................................................................................... 104 pedal bracket ....................................................

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    Iv www.Factoryfive.Com 508-291-3443 pre-engine preparation ............................................................... 260 engine installation ....................................................................... 261 alternator installation ........................................................

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    V www.Factoryfive.Com 508-291-3443 shifter linkage ............................................................................ 404 catalytic exhaust pipe installation .............................................. 415 fuel tank and fuel line routing ....................................................

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    Vi www.Factoryfive.Com 508-291-3443 roll bar padding ......................................................................... 545 front cross bar ................................................................................. 545 side bars ............................................................

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    Vii www.Factoryfive.Com 508-291-3443 windshield wipers and washer fluid tank ................................ 640 door handles/ liners .................................................................. 653 rear splash guards.................................................................... 664 exh...

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    Viii www.Factoryfive.Com 508-291-3443 gtm a/c hose ............................................................................ 746 installation instructions ....................................................................... 746 heat & a/c hose kit routing diagram .................................

  • Page 10: General Information

    1 www.Factoryfive.Com 508-291-3443 general information foreword f you are reading this, you are embarking on a mission to build your own car, or at least considering doing so. I wanted to share with you some of my experiences and lessons learned while working with literally thousands of people who h...

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    2 www.Factoryfive.Com 508-291-3443 very definition of always trying to go faster. The late carroll smith wrote something i really loved that speaks to this point. “there is no magic! The one basic truth of successful racecar preparation bears repeating. There is no magic. There is only logic, common...

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    3 www.Factoryfive.Com 508-291-3443 all the way thru the process, as you build your car, the seasoned guys at factory five in tech support will help you. The larger community of factory five customers will also be there for you, as the one thing that really sets us above the crowd of other companies ...

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    4 www.Factoryfive.Com 508-291-3443 safety notice while there are many things to love and be proud of in our country today there are a few things that we wish were different. With regret and a small amount of resentment we include the following warning and statement of non-liability at the advice of ...

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    5 www.Factoryfive.Com 508-291-3443 safety tips  read the manual. It is at least a good guide and place to start.  don’t take short cuts.  before starting work, make sure you have the proper tools, the required parts, and sufficient space for the job. If you damage any parts, it will probably be b...

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    6 www.Factoryfive.Com 508-291-3443 how to use this book this assembly manual is intended to help you build your factory five kit. This book will not explain such things as engine or transmission building. A secondary purpose of this book is to use it as reference for owners that want to do maintenan...

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    7 www.Factoryfive.Com 508-291-3443 engine/exhaust: complete exhaust system, 1990-1998 g50-ls1 transaxle adaptor kit, engine mount components, engine mount spacer, oil temp bypass, oil temp block-off, fasteners, air filter components, air filter, hose, hose clamps, and silicone reducer gauges and das...

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    8 www.Factoryfive.Com 508-291-3443 tools list the following lists detail the tools and supplies that are needed to build your kit. The “helpful” items are not crucial to the assembly but make life easier. Home depot husky®, sears craftsman®, and snap-on tools are all guaranteed for life and we’ve f...

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    9 www.Factoryfive.Com 508-291-3443 required supplies stick with name brand products like eastwood, 3m, and duplicolor. The eastwood brand coatings are great for bringing weathered and oxidized parts up to show quality. Ppg brand and dupont brand paints are excellent. Engine degreaser silicone doo...

  • Page 19: Chapter

    10 www.Factoryfive.Com 508-291-3443 donor parts and parts needed chapter 2.

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    11 www.Factoryfive.Com 508-291-3443 this chapter deals with the donor parts needed in addition to the parts that we included with our kit. Many people choose to use parts from a single corvette donor. If you are not going to use a donor car but choose to acquire parts separately, this section may st...

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    12 www.Factoryfive.Com 508-291-3443 of being able to pick the best of those that are available. There is a wide range in prices for donor packages depending on the type of car (coupe, convertible or z06) and mileage. Keep in mind that some cars may be wrecked, but considered “repairable”. A car that...

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    13 www.Factoryfive.Com 508-291-3443 have documentation on the origin and sale price. Check the numbers twice. The vin numbers are located on the back of the engine block, on a flat spot between the heads and at the apex where the bell housing meets the block. Some solvent or wd-40 can usually clean ...

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    14 www.Factoryfive.Com 508-291-3443 forward and backward. If you can’t drive it, let it run for a moment, and then re-start it. Look for main bearing oil leaks (behind the harmonic balancer) or oil pan leaks. Leaks aren’t common unless the car has high mileage. Although you will not be using the cor...

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    15 www.Factoryfive.Com 508-291-3443 flathead screwdriver, 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 switch from the back and unplug the ...

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    16 www.Factoryfive.Com 508-291-3443 remove the inside door handle bezel by pulling the handle, then prying the upper and 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 ...

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    17 www.Factoryfive.Com 508-291-3443 good way to remove the panel without 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 insert. Remove the speaker ass...

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    18 www.Factoryfive.Com 508-291-3443 remove the water deflector. Remove the front 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). If your donor ha...

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    19 www.Factoryfive.Com 508-291-3443 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 the mirrors and retaining nuts..

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    20 www.Factoryfive.Com 508-291-3443 reconnect the window switch. Move the window all the way up. You should now have access to the window clamp bolts. Remove the window clamp bolts (13 mm). You do not need to keep the clamp bolts (they will not clear the glass in the gtm). Remove the glass. Disconne...

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    21 www.Factoryfive.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 lock cylinder lever..

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    22 www.Factoryfive.Com 508-291-3443 unbolt the two outside door handle bolts (10 mm). You may have to use the key to unlock/lock the door 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...

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    23 www.Factoryfive.Com 508-291-3443 do 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 lamp connected. Hood lamp disconnected..

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    24 www.Factoryfive.Com 508-291-3443 while one 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, and ball studs (13 mm). Label and save the h...

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    25 www.Factoryfive.Com 508-291-3443 radiator/coolant reservoir drain the coolant from the system into a container or bucket before removing the reservoir and radiator. Avoid spilling any coolant. Dispose of all coolant properly – a local garage or parts store can do this for you. 10 mm socket, ratch...

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    26 www.Factoryfive.Com 508-291-3443 remove the lower reservoir bolt using a 10mm socket..

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    27 www.Factoryfive.Com 508-291-3443 remove the upper tank bolts using a 10mm socket. Disconnect the coolant level electrical connector. Lift the reservoir out of the engine bay. Drain any remaining coolant from the reservoir. Save the reservoir. Radiator if you have not done so already, disconnect t...

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    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..

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    29 www.Factoryfive.Com 508-291-3443 if the pressure sensor was damaged on your donor car see below for the replacement part 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 c...

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    30 www.Factoryfive.Com 508-291-3443 disconnect the fan motor electrical plugs and remove the wires/wire looms from the shroud assembly. Although the radiator and fan shroud assembly can be removed as one piece, if there is not enough room to do so, pull the fan shroud assembly out of the retaining s...

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    31 www.Factoryfive.Com 508-291-3443 windshield wiper 13 mm socket, ratchet, pry bar. Wiper arm remove the wiper shroud..

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    32 www.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 plug..

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    33 www.Factoryfive.Com 508-291-3443 save the wiper arm assembly. Exhaust the exhaust pipes can be heavy and difficult to 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 electrica...

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    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..

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    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)..

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    36 www.Factoryfive.Com 508-291-3443 unbolt the h-pipe hangers with a 13 mm socket. Remove the h-pipe. Remove both muffler assemblies. Engine removal/suspension/transmission when the corvette was assembled at the factory, the engine, suspension and transmission were installed from below as one assemb...

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    37 www.Factoryfive.Com 508-291-3443 engine, computer pcm and tac module, wiring harnesses, 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 than...

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    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..

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    39 www.Factoryfive.Com 508-291-3443 disconnect 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 side (below the starter) with and ¾” and 5/8” wre...

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    40 www.Factoryfive.Com 508-291-3443 unbolt 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. Disconnect the engine oil temperature sensor..

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    41 www.Factoryfive.Com 508-291-3443 disconnect the 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 plug (see photos). Engine oil level sensor ro...

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    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..

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    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..

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    44 www.Factoryfive.Com 508-291-3443 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 the upper left bell housing bolt..

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    45 www.Factoryfive.Com 508-291-3443 if you haven’t done so already, 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 wrench and a 13 mm wrench. Dis...

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    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..

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    47 www.Factoryfive.Com 508-291-3443 unclip 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 will need it to relocate the alternator..

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    48 www.Factoryfive.Com 508-291-3443 unbolt the air conditioning compressor bolts (15mm), and remove the compressor for added clearance when removing the engine. If you have trouble removing the compressor from the engine bay, you can tie it to the frame rail so it’s out of the way with zip ties, a b...

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    49 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 bay..

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    50 www.Factoryfive.Com 508-291-3443 the design of the power steering system allows you to disconnect the power steering system without causing 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, ...

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    51 www.Factoryfive.Com 508-291-3443 using a 15 mm socket, take the tension off of the accessory belt and remove. Remove the power steering pulley to gain access to the power steering 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 st...

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    52 www.Factoryfive.Com 508-291-3443 using the engine cross member to brace the outer wrench. Remove the power steering pump (13 mm)..

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    53 www.Factoryfive.Com 508-291-3443 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 remove the shaft from the joint..

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    54 www.Factoryfive.Com 508-291-3443 disconnect the power steering plug. 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 bolts will not come out o...

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    55 www.Factoryfive.Com 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 booster vacuum hose..

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    56 www.Factoryfive.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 sensor plug..

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    57 www.Factoryfive.Com 508-291-3443 unbolt and remove the 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 press the valve in with a punch or a...

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    58 www.Factoryfive.Com 508-291-3443 disconnect the fuel line(s) from the rail with a fuel fitting release tool (a pretty inexpensive set of plastic 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 ...

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    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..

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    60 www.Factoryfive.Com 508-291-3443 disconnect the “air” plug. Disconnect the throttle position sensor..

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    61 www.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 (¾” socket)..

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    62 www.Factoryfive.Com 508-291-3443 disconnect the brake fluid level sensor plug from the master cylinder, head light harness plugs, engine ground on driver frame rail. Disconnect the abs plugs and wiring clips from the cross member (passenger side access is easiest through the wheel well). Unclip t...

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    63 www.Factoryfive.Com 508-291-3443 unbolt the tie rod ends 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 joint fork. Unbolt the upper control ar...

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    64 www.Factoryfive.Com 508-291-3443 support the lower control arm with a jack. Unbolt the shock from the tower (15 mm wrench). Slowly lower the jack. To move the shock out of the way it may be necessary to pry the shock out of the tower the rest of the way. Brace the engine as far forward as possibl...

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    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..

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    66 www.Factoryfive.Com 508-291-3443 make sure the chain you are using to lift the 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 passenger looms, 1 driv...

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    67 www.Factoryfive.Com 508-291-3443 harness connection – passenger side. Ground and harness clamp at rear of driver side. Unplug the knock sensor..

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    68 www.Factoryfive.Com 508-291-3443 unplug the engine oil pressure sensor (eop). Unplug the camshaft position sensor..

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    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)..

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    70 www.Factoryfive.Com 508-291-3443 the engine must be out far enough so the drive shaft is all the way out of the bell housing before lifting the engine up and out of the engine bay. Move the a/c compressor off to the side if you haven’t done so already. Check for any fuel lines, evap lines, or ele...

  • 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..

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    72 www.Factoryfive.Com 508-291-3443 unbolt the shock (13 mm socket). The shock also uses a welded nut on the back, so all you need to do is loosen the bolt head with the 13 mm socket. The shock may pop up as you finish unbolting it. Disconnect the brake line from the unions above the transmission. F...

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    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)..

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    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)..

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    75 www.Factoryfive.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 before lowering..

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    76 www.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 stands..

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    77 www.Factoryfive.Com 508-291-3443 place a transmission jack or a floor jack with cup under the assembly. Unbolt the cross member (21 mm deep socket). Slowly lower the transmission/torque tube/cross member assembly checking that all brake lines and wiring have been disconnected. Unbolt the tie rod ...

  • Page 87

    78 www.Factoryfive.Com 508-291-3443 fuel tanks if there is still fuel in the tanks, use caution not to drop them as you lower them out of the car. Fuel line disconnect tool ( 5 / 16 ”, 3 / 8 ”), flathead screwdriver fuel tanks, lines, filter, cross-tube. Passenger disconnect tank cross over hose usi...

  • Page 88

    79 www.Factoryfive.Com 508-291-3443 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 you may have to cut the line..

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    80 www.Factoryfive.Com 508-291-3443 slowly lower the tank. This may take some effort as the tank is wedged tightly into place. You may have to pry (carefully!!) the neck away from the frame to get the tank out. Driver disconnect quick connect fittings at the tank. Use the 3 / 8 ” disconnect tool to ...

  • Page 90

    81 www.Factoryfive.Com 508-291-3443 unclip the fuel tank wiring harness from the frame. Emergency brake flathead screwdriver, 10, 13, 15 mm socket, 13 mm wrench emergency brake handle, cables, seat belt buckle. Convertible donor remove the folding top stowage compartment lid extension panel. Open th...

  • 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..

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    83 www.Factoryfive.Com 508-291-3443 lift the trim plate up 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 legs (slide them forward). Unbolt the fro...

  • Page 93

    84 www.Factoryfive.Com 508-291-3443 this is where moving the seat forward before disconnecting the battery will save you time. If you have the ability to put power to the seat motor, do so and move the seat forward to access the rear seat bolts. If you cannot move the seat forward, you can still gai...

  • Page 94

    85 www.Factoryfive.Com 508-291-3443 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-brake boot retaining nuts (10 mm)..

  • Page 95

    86 www.Factoryfive.Com 508-291-3443 unclip the electrical connection. Disconnect the rear cables from the retaining clip. Press in the clips on the front cable and slide the cable through the e-brake bracket, lifting the cable through the slot. Drill out the rivets holding the bracket (picture below...

  • Page 96

    87 www.Factoryfive.Com 508-291-3443 the following steps are required to remove the remaining wiring/components from the car. Labeling each connection as you disconnect them 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 accesso...

  • Page 97

    88 www.Factoryfive.Com 508-291-3443 unscrew retainer screws next 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 past the rib on the lighter to ...

  • Page 98

    89 www.Factoryfive.Com 508-291-3443 knee bolster flathead screwdriver, t-15 torx. Remove console and trim plate if you haven’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 t...

  • Page 99

    90 www.Factoryfive.Com 508-291-3443 remove the knee bolster. Steering column if the airbags have not been deployed on your donor, follow the disassembly instructions to avoid causing the airbags to accidentally deploy. The airbags deploy quickly with a lot of force so you do not want to have your he...

  • Page 100

    91 www.Factoryfive.Com 508-291-3443 remove 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 upper shaft. You will have to pry it off..

  • Page 101

    92 www.Factoryfive.Com 508-291-3443 disable sir – 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 short screwdriver pry the retaining washer off..

  • Page 102

    93 www.Factoryfive.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 bags from deploying..

  • Page 103

    94 www.Factoryfive.Com 508-291-3443 remove the airbag – unscrew the bolts holding the restraint module to the steering wheel (t-30). You may need to have someone 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 t...

  • Page 104

    95 www.Factoryfive.Com 508-291-3443 after removing the connection 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 the column brace. Unbolt th...

  • Page 105

    96 www.Factoryfive.Com 508-291-3443 unbolt 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, including all wiring, and the upper shaft..

  • Page 106

    97 www.Factoryfive.Com 508-291-3443 now you will need to disable the column lock pin to allow the wheel to rotate freely. The first step is to cut the purple and 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...

  • Page 107

    98 www.Factoryfive.Com 508-291-3443 ignition 7, 10 mm, flathead screwdriver. Ignition module, wiring, ignition key. Unbolt the screw to the left of the ignition (7 mm). Unbolt the 2 bolts connecting ignition to stereo bracket (10 mm). Automatic donors – disconnect the park cable by inserting the key...

  • Page 108

    99 www.Factoryfive.Com 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 front of the shifter..

  • Page 109

    100 www.Factoryfive.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 in the bracket..

  • Page 110

    101 www.Factoryfive.Com 508-291-3443 upper dash pad 7, 10 mm socket, flathead screwdriver remove the glove box: open box, reach behind it and push the plugs through the access lower bolts. (10 mm). Unbolt side and top screws. Slowly drop the box down enough to remove the light plug. Remove the glove...

  • Page 111

    102 www.Factoryfive.Com 508-291-3443 remove the dash. Passenger air bag 10 mm socket. Disconnect the electrical connection..

  • Page 112

    103 www.Factoryfive.Com 508-291-3443 unbolt the 4 retaining nuts (10 mm). Remove the air bag. To remove the bracket, unbolt the 9 bolts holding it in place. Unclip the heater hose (2 locations). Stereo and heater controls 10 mm socket. Unbolt the 4 bolts holding the aluminum center bracket in place ...

  • Page 113

    104 www.Factoryfive.Com 508-291-3443 disconnect the stereo and heater electrical connections. Lift the radio out of the car. Dash cluster 7 mm socket. Unscrew the 2 retaining bolts at the bottom of the gauge pod (7 mm). Lift the pod away from the pedal bracket. Unplug all electrical connections. Ped...

  • Page 114

    105 www.Factoryfive.Com 508-291-3443 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 (towards the outside of the car)..

  • 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

    107 www.Factoryfive.Com 508-291-3443 for manual transmission donors: remove the cruise control release switch bracket bolts. Move the switch and bracket out the way. Disconnect the clutch master cylinder push rod from the pedal. Unbolt the clutch pedal bracket retaining nuts. Remove the clutch pedal...

  • Page 117

    108 www.Factoryfive.Com 508-291-3443 hood release handle and cables phillips screwdriver, t-15 torx. Hood release handle and cables, screws, 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). Unb...

  • Page 118

    109 www.Factoryfive.Com 508-291-3443 pull the handle and cables 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 sill remove the door opening panel by ...

  • 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

    111 www.Factoryfive.Com 508-291-3443 slide the seat belt through the slot in the panel. Carefully pry the remaining clips and remove the panel. Upper roof bow panel (coupe) remove the retaining pins from the outside edge of the panel. Starting at the center of the panel, pry the clips free. Remove t...

  • Page 121

    112 www.Factoryfive.Com 508-291-3443 remove the upper retaining pin. Pry the panel away from the door sill lip. Remove the speaker cover by prying carefully at the top or bottom center, working your way around the cover. Remove the retaining pin. Hvac unit the procedure for removal of the hvac unit ...

  • 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

    114 www.Factoryfive.Com 508-291-3443 remove the canister retaining nuts (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. Remove the right hand lo...

  • Page 124

    115 www.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 the drl..

  • 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 ¼ turn clockwise)..

  • Page 126

    117 www.Factoryfive.Com 508-291-3443 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. Remove lower floor heater duct – passenger..

  • Page 127

    118 www.Factoryfive.Com 508-291-3443 remove lower portion of the floor heater, then unscrew the retaining screws. Remove the duct. Remove the carpet outlet duct (twist ¼ turn counter clockwise). Unclip the blower motor electrical connection (reach under the dash support beam just above the kick pane...

  • Page 128

    119 www.Factoryfive.Com 508-291-3443 unplug the vacuum electric solenoid connection. Disconnect the blower motor control module plug..

  • Page 129

    120 www.Factoryfive.Com 508-291-3443 remove the instrument panel 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 windshield defroster duct. Unbolt th...

  • 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

    122 www.Factoryfive.Com 508-291-3443 wiring, computer, fuse panel 7, 10 mm socket, 9 /32 ” socket and extension or deep 9 /32 ” socket. Computer, tac module, computer brackets, wiring, body control module, fuse panels. Remove the rear compartment wiring and grounds from all clips, speakers and the r...

  • Page 132

    123 www.Factoryfive.Com 508-291-3443 push the wiper motor plug 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 the bottom of the panel – 9/32”)...

  • Page 133

    124 www.Factoryfive.Com 508-291-3443 push the plug for the positive cable linking the two fuse panels through the firewall. Unclip the electrical connection next to the fuse panel (kick panel). Remove the harness from the car and save. Unscrew the vacuum canister (7 mm). Unscrew the outer computer b...

  • 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

    126 www.Factoryfive.Com 508-291-3443 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 temperature block-off plate (4mm hex)..

  • Page 136

    127 www.Factoryfive.Com 508-291-3443 intake pliers, 8 mm socket, ratchet, 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 intake. Disconnect the...

  • Page 137

    128 www.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 passenger side..

  • Page 138

    129 www.Factoryfive.Com 508-291-3443 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 you rotate the valve covers..

  • 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

    131 www.Factoryfive.Com 508-291-3443 unclip the evap line from the intake behind 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 port on the throttle b...

  • 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

    133 www.Factoryfive.Com 508-291-3443 unbolt the intake manifold bolts (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 44 in-lb (5 nm) then make ...

  • Page 143

    134 www.Factoryfive.Com 508-291-3443 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 from under the throttle body..

  • 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

    136 www.Factoryfive.Com 508-291-3443 valve covers 10 mm socket, ratchet. Unplug each coil pack by first removing 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...

  • Page 146

    137 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

    139 www.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 engine)..

  • Page 149

    140 www.Factoryfive.Com 508-291-3443 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 side and vice versa. Passenger side..

  • Page 150

    141 www.Factoryfive.Com 508-291-3443 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 the pcv to the front passenger port..

  • 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

    145 www.Factoryfive.Com 508-291-3443 reconnect the line to the evap modules front 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 gtm driver side ta...

  • Page 155

    146 www.Factoryfive.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 opening in the tank..

  • Page 156

    147 www.Factoryfive.Com 508-291-3443 before drilling the hole, make sure that the hole will allow enough room for the nut to rest flush against the inside 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...

  • Page 157

    148 www.Factoryfive.Com 508-291-3443 clean out any remaining debris from 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 fitting to help seal the hol...

  • Page 158

    149 www.Factoryfive.Com 508-291-3443 reach into the tank and slide the washer onto the fitting then tighten the nut onto the fitting. If your arms are too big, you may have to have someone else do this for you since the opening in the tank is only a few inches in diameter. Also, you can slide a set ...

  • Page 159

    150 www.Factoryfive.Com 508-291-3443 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 ” socket or flathead screwdriver)..

  • Page 160

    151 www.Factoryfive.Com 508-291-3443 for the ’97 – ’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, ffr# 11206 ( 5 / 16 ” socket or flat head sc...

  • Page 161

    152 www.Factoryfive.Com 508-291-3443 2003-2004 fuel tanks 7 mm socket, ratchet, drill. Drain the tanks. Remove the retainer 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 ...

  • Page 162

    153 www.Factoryfive.Com 508-291-3443 before drilling the hole, make sure that the hole will allow enough room for the nut to rest flush against the inside 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...

  • Page 163

    154 www.Factoryfive.Com 508-291-3443 mark the center of the circle you traced and drill a hole in the back of the tank. Clean out any remaining debris from 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 o...

  • Page 164

    155 www.Factoryfive.Com 508-291-3443 pull the hoses out of the corvette cross over tube. Place the corvette cross-over hose 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 coll...

  • 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

    157 www.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 tank..

  • 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

    159 www.Factoryfive.Com 508-291-3443 install the internals you removed previously and set the retainer 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 remo...

  • Page 169

    160 www.Factoryfive.Com 508-291-3443 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 ” socket or flathead screwdriver)..

  • Page 170

    161 www.Factoryfive.Com 508-291-3443 steering column (non-telescoping) blow torch, t-25 torx, 21 mm socket, ratchet, cut-off wheel/sawzall/hacksaw, flathead screwdriver, snap-ring pliers. Steering column, upper steering shaft, ffr# 25459 – steering wheel boss. You will need a steering wheel puller t...

  • Page 171

    162 www.Factoryfive.Com 508-291-3443 slide the lower cover over the tilt lever. The easiest way to remove 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 steer...

  • Page 172

    163 www.Factoryfive.Com 508-291-3443 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 removal. Sir coil removed..

  • 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

    165 www.Factoryfive.Com 508-291-3443 remove the sensor retainer (unclip it from the bearing assembly – 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 (y...

  • Page 175

    166 www.Factoryfive.Com 508-291-3443 now you will need to shorten the steering column jacket. Cut the jacket, leaving 5.25” (measured from the junction of the column jacket and the tilt head assembly - see photo). Be careful not to cut the shaft inside the column jacket. The column jacket will also ...

  • Page 176

    167 www.Factoryfive.Com 508-291-3443 remove the steering column brace 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 lower shaft off of the upper sha...

  • 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 1 7 / 16 ” in from the rear edge of the cover (see photo)..

  • Page 178

    169 www.Factoryfive.Com 508-291-3443 steering column (telescoping) t-25, t-40 torx, ¼”-12 point socket, 15mm wrench/socket, 21 mm socket, ratchet, cut-off wheel/sawzall/hacksaw, flathead screwdriver, snap-ring pliers, 3 / 8 ” drill bit, drill, punch, vise grip pliers. Steering column, upper steering...

  • Page 179

    170 www.Factoryfive.Com 508-291-3443 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 ¼”-12 point socket. Pull the actuator off of the drive ball. Save the actuator and motor assembly..

  • Page 180

    171 www.Factoryfive.Com 508-291-3443 bend the side tabs 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 the lower portion of the jacket – you will ...

  • Page 181

    172 www.Factoryfive.Com 508-291-3443 be careful not to cut the shaft or the telescoping 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 tapping them out of...

  • Page 182

    173 www.Factoryfive.Com 508-291-3443 remove the tilt spring. To avoid shooting the spring across 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

    174 www.Factoryfive.Com 508-291-3443 thread the tilt pin removal tool supplied in the puller kit 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 out...

  • Page 184

    175 www.Factoryfive.Com 508-291-3443 before 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 coated lower portion of the upper shaft..

  • Page 185

    176 www.Factoryfive.Com 508-291-3443 now you will need to shorten the lower shaft. However, before doing so be sure to take note 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 5½” from the top of the sha...

  • Page 186

    177 www.Factoryfive.Com 508-291-3443 drill a 3 / 8 ” hole through the flat faces of the shaft ½” in from the end of the shaft. Slide the lower shaft back over the upper shaft and re-create the factory stop. If you are preparing the donor parts before receiving your kit, the following steps can be do...

  • Page 187

    178 www.Factoryfive.Com 508-291-3443 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 stoppers towards the large bolt hole..

  • Page 188

    179 www.Factoryfive.Com 508-291-3443 now check 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 may be difficult to loosen, which is normal..

  • Page 189

    180 www.Factoryfive.Com 508-291-3443 the stalk must be shortened to operate in the gtm. There is a large rivet just inside the plastic covering of the stalk. Mark a line of the plastic approximately 1½” to 2” from the bottom of the plastic. Trim the plastic very carefully using a razor or tin snips....

  • Page 190

    181 www.Factoryfive.Com 508-291-3443 now that the rivet is exposed it must be removed. 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 rivet. Then...

  • Page 191

    182 www.Factoryfive.Com 508-291-3443 once the rivet is sheared off, do not be alarmed if the hole in the metal stalk appears elliptical, this is normal. Wiring harness/computer razor knife, wire snips, saw and/or grinder. Complete donor wiring harness. Transmission tunnel harness on a clear work sur...

  • Page 192

    183 www.Factoryfive.Com 508-291-3443 strip the tape and sheathing off of the length of the harness..

  • Page 193

    184 www.Factoryfive.Com 508-291-3443 starting at the plug that connects to the fuel tank harness separate the harness that connects the fuel tank to the main engine harness. The ground wire from this plug runs through a junction before continuing to the loop connector. Trim the extra wire off of the...

  • Page 194

    185 www.Factoryfive.Com 508-291-3443 all 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 remaining harness is what will be used..

  • Page 195

    186 www.Factoryfive.Com 508-291-3443 the wires for the vehicle speed sensor (which plugs into the differential) also run into this plug 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 d...

  • Page 196

    187 www.Factoryfive.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 box in the middle..

  • Page 197

    188 www.Factoryfive.Com 508-291-3443 find the plug for the drive 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 go. You will have to cut the firewa...

  • Page 198

    189 www.Factoryfive.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 it aside..

  • Page 199

    190 www.Factoryfive.Com 508-291-3443 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 plug off, again leaving 6” of wire..

  • Page 200

    191 www.Factoryfive.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 of wire. Set it aside..

  • 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

    193 www.Factoryfive.Com 508-291-3443 locate the windshield wiper motor plug. It sticks out separately from 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 ...

  • Page 203

    194 www.Factoryfive.Com 508-291-3443 engine harness the engine harness must be stripped down to allow for some of the sensors 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 ...

  • 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

    196 www.Factoryfive.Com 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 the air intake area..

  • Page 206

    197 www.Factoryfive.Com 508-291-3443 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 wires back past the last injector..

  • Page 207

    198 www.Factoryfive.Com 508-291-3443 tape off the rest of the harness and it is ready 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 for extra wir...

  • Page 208

    199 www.Factoryfive.Com 508-291-3443 computer bracket the computer bracket is different for 1997-1998 and 1999 and up donors. Unlike the 1999 and up computer bracket, the 1997-1998 computer bracket mounting bosses begin in different planes. Therefore, if you trim all of the 1997-1998 computer bracke...

  • Page 209

    200 www.Factoryfive.Com 508-291-3443 trim the rear 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 level with the front upper section of the brack...

  • 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: Disassembly Of The Kit

    202 www.Factoryfive.Com 508-291-3443 disassembly of the kit chapter 3.

  • Page 212

    203 www.Factoryfive.Com 508-291-3443 unpacking your gtm kit please note that your boxes are numbered, when you read your packing list you will see that next to each assembly there is a number circled. This is the box number that the assembly was packaged into. After everything is safely in your gara...

  • Page 213

    204 www.Factoryfive.Com 508-291-3443 before removing the aluminum 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 screws to help with aluminum posit...

  • Page 214

    205 www.Factoryfive.Com 508-291-3443 using a ruler and marker, mark the rivet spacing 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 panel. Use the ⅛” ...

  • Page 215

    206 www.Factoryfive.Com 508-291-3443 drill the marks with ⅛” 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, making the suspension easier to position..

  • Page 216

    207 www.Factoryfive.Com 508-291-3443 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 assembly in a sequential fashion..

  • Page 217: Chassis Assembly

    208 www.Factoryfive.Com 508-291-3443 chassis assembly chapter 4.

  • Page 218

    209 www.Factoryfive.Com 508-291-3443 steering rack installation ¾” socket, ratchet, ¾” wrench. Steering system hardware (ffr# 25545, 25524). Install the bushings and sleeves in the steering rack. Thread a jam nut and outer tie rod end onto each of the inner tie rods (do not to fully tighten the jam ...

  • Page 219

    210 www.Factoryfive.Com 508-291-3443 inner wheel wells eye protection, drill w/#6 hex nut driver, ⅛” drill bits, drill, rivet gun, silicone, caulking 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...

  • Page 220

    211 www.Factoryfive.Com 508-291-3443 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 using the self tapping screws..

  • Page 221

    212 www.Factoryfive.Com 508-291-3443 using the drilled panel as a template, attach it to the frame (with the self tapping screws) and drill the ⅛” holes in the frame. Remove the panel from the frame, clean the surface and apply a bead of silicone to the frame where the panel is in contact with the f...

  • Page 222

    213 www.Factoryfive.Com 508-291-3443 using 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 square cutout in the pane – see photo below)..

  • Page 223

    214 www.Factoryfive.Com 508-291-3443 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 riveted in the same location..

  • Page 224

    215 www.Factoryfive.Com 508-291-3443 install the center splash panel. These have to be installed before the rear suspension because the upper control arm mounts protrude through this panel. Rivet this panel into place using the above procedure along the frame rails shown below. Battery tray and fron...

  • Page 225

    216 www.Factoryfive.Com 508-291-3443 orient the battery tray on the horizontal “x” frame member just behind the steering 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 ...

  • Page 226

    217 www.Factoryfive.Com 508-291-3443 space out 8 holes and drill the battery tray out where it intersects with the frame using a 3/16” bit. Lay the battery tray back on the frame using the battery tray as a template, and drill the holes on the frame with a 3 / 16 ” bit. Remove the panel. Tape the fr...

  • Page 227

    218 www.Factoryfive.Com 508-291-3443 trace the outline of the 1” and 1.5” square steel tubes. Remove the panel. Following the same procedure as in the aluminum panel prep section, measure the locations for the rivets and drill out the panel. You will not mount this panel until later in the build (se...

  • Page 228

    219 www.Factoryfive.Com 508-291-3443 corvette front suspension (complete) and donor hardware for front suspension, lower shock bracket hardware (ffr# 25376, 25352, 25755). It is helpful here to have someone help you with the installation of the front suspension, since the assembly is heavy and requi...

  • Page 229

    220 www.Factoryfive.Com 508-291-3443 the front brake line bracket is installed below the rear upper control arms (on the rear leg of the control arm) and fastened with upper control arm hardware. The smaller index faces the inside of the car. The corvette used a washer/spacer in between the control ...

  • Page 230

    221 www.Factoryfive.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 and passenger side)..

  • Page 231

    222 www.Factoryfive.Com 508-291-3443 install the lower coil-over mount on the upper surface of the lower control arm. This bracket is installed (ffr# 25714) using the corvette 7mm shock mount hardware (this bracket is pitched inward). (same procedure used on driver and passenger side) coil-over shoc...

  • Page 232

    223 www.Factoryfive.Com 508-291-3443 slide the spring over the damper, and then install the spring hat at the other end of the coil-over assembly. You may have to slide the rubber bumper down on the shaft to install the top hat. Rotate the shock collar to preload the spring. Re-install the “c” clip ...

  • Page 233

    224 www.Factoryfive.Com 508-291-3443 rear suspension mounting to chassis 19mm, 21mm socket, wrench 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 suspensio...

  • Page 234

    225 www.Factoryfive.Com 508-291-3443 install the rear upper control arm to the frame using the supplied hardware . Torque to the specification 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...

  • Page 235

    226 www.Factoryfive.Com 508-291-3443 rear coil-over shock and mount ¾”, 15 / 16 ”, 18mm, 24mm socket and wrench, ratchet, jack, grinder. Assembled 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 ...

  • Page 236

    227 www.Factoryfive.Com 508-291-3443 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 shock mount (leave bolt loose for now)..

  • Page 237

    228 www.Factoryfive.Com 508-291-3443 the ½-2.25” flanged bolt and nut is used for the inboard rear mount (¾” wrench)..

  • Page 238

    229 www.Factoryfive.Com 508-291-3443 rear coil-over shock mounting lower 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 will slip in. Attach the upper shock mount to the frame using the suppl...

  • Page 239

    230 www.Factoryfive.Com 508-291-3443 the 3½” bolts are used in combination with the longer spacers on the upper rear coil-overs. Torque all coil-over hardware to specifications (¾” wrench) (same procedure used on driver and passenger side). Tighten the 5 / 8 ” bolt and nut that attach the lower coil...

  • 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

    232 www.Factoryfive.Com 508-291-3443 footbox aluminum eye protection, drill w/#6 hex nut driver, ⅛” drill bits, drill, rivet gun, silicone, caulking gun, #6 self tapping screws. Driver/passenger footbox aluminum (ffr# 25172, 25174, 25175, 25176, 25173). Using the aluminum installation techniques pre...

  • Page 242

    233 www.Factoryfive.Com 508-291-3443 we now have to install the inner 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 towards the rear of the ca...

  • Page 243

    234 www.Factoryfive.Com 508-291-3443 the last piece to be installed is the upper x panel (ffr# 25176). Install the foot box outer wall on both the driver and passenger side; passenger side is shown below in picture (ffr# 25179, 25180). Do not rivet the flange below the lower door hinge mount to the ...

  • Page 244

    235 www.Factoryfive.Com 508-291-3443.

  • Page 245

    236 www.Factoryfive.Com 508-291-3443 install the outside drop floor piece next on both the driver and passenger side (ffr# 25191, 25192). The front wall on the passenger footbox is installed next (ffr# 24173). If you are planning on installing heat and air conditioning, perform that installation now...

  • 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

    238 www.Factoryfive.Com 508-291-3443 steering column/shafts non-telescoping column ½”, 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 bearing...

  • Page 248

    239 www.Factoryfive.Com 508-291-3443 the assembly is installed from the cockpit side, carefully snaking the joints and shaft through the lowest hole on the pedal box mounting plate. The lower universal joint now gets attached to the steering rack. This joint is splined and the hex set screw has to b...

  • Page 249

    240 www.Factoryfive.Com 508-291-3443 the donor corvette upper steering 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# 1040, 11005, 13964). Fully t...

  • Page 250

    241 www.Factoryfive.Com 508-291-3443 (optional) telescoping column 7 / 16 ”, ½”, 9 / 16 ” wrench, 5 / 32 ”, 3 / 16 ”, 5 / 16 ”, 4mm hex keys, ⅛”, 3 / 16 ” drill bits, drill, 5 / 32 ” punch, hammer. Steering shaft, steering system hardware, telescoping steering column adapter assembly (ffr# 25545, 26...

  • Page 251

    242 www.Factoryfive.Com 508-291-3443 insert the 10 mm bolt (ffr# 25662) through the corvette shaft, spacer and 1 7 / 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 joi...

  • Page 252

    243 www.Factoryfive.Com 508-291-3443 insert the 7”x ¾” 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

    244 www.Factoryfive.Com 508-291-3443 remove the ¾” dd tube (ffr# 25867). Drill through the 1 / 8 ” pilot holes you just drilled in both the 1”dd and the ¾” dd tubes separately with a 3 / 16 ” drill bit. Slide the 7”x ¾” dd tube (ffr# 25867) into the steering shaft (ffr# 26022). Put the assembly in a...

  • Page 254

    245 www.Factoryfive.Com 508-291-3443 slide the flange bearing and bearing retainers (ffr# 12640) on the long/upper steering shaft. The hex set screw on the bearing should be on the shaft side of the bearing, not the joint side. Install the shaft assembly in the chassis from the cockpit side, careful...

  • Page 255

    246 www.Factoryfive.Com 508-291-3443 place the steering column adapter plate on the corvette steering column in between the steering shaft housing and 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...

  • Page 256

    247 www.Factoryfive.Com 508-291-3443 install the ¾” pillow block bearing on the 9”x ¾”dd shaft. Once the pedal box is mounted and 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 ¾” dd shaf...

  • Page 257

    248 www.Factoryfive.Com 508-291-3443 drill out the bracket to 25 / 64 ” and install two rivnuts in the 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)....

  • Page 258

    249 www.Factoryfive.Com 508-291-3443 press the actuator arm onto the drive ball..

  • Page 259

    250 www.Factoryfive.Com 508-291-3443 using the ¼”-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 frame with a 3 / 16 ” rivet..

  • Page 260

    251 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 s...

  • Page 261

    252 www.Factoryfive.Com 508-291-3443 install rivnuts on the top side of the inside pedal box mounting plate. Set the supplied pedal box on the frame mount bracket so that the outside flange is under the ¾” tube on the outside in order to check fitment. Mark the underside of the ¾” tube where the ped...

  • Page 262

    253 www.Factoryfive.Com 508-291-3443 install ¼-20” rivnuts (ffr# 25530) in the holes which were just drilled from the underside using the supplied rivnut tool (ffr# 33582). Install the pedal box to the frame using the ¼-20 hardware (ffr# 25461, 11088) into the 2 rivnuts installed onto the frame in t...

  • Page 263

    254 www.Factoryfive.Com 508-291-3443 the push rods on the master cylinders must now be shortened. As seen in the picture below, mark ¾” from the 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 cylinde...

  • Page 264

    255 www.Factoryfive.Com 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 pieces mounted on the pedals..

  • 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

    257 www.Factoryfive.Com 508-291-3443 ¼-20” rivnuts, ¼-20” short flanged button heads, washers (ffr# 25460, 11088, 25375). Place the “l” shaped template (ffr# 25763) over the lower right corner of the pedal box mounting panel and mark the location of the 2 holes. Do not drill these holes yet. Now set...

  • Page 267

    258 www.Factoryfive.Com 508-291-3443 using the desired location from the steps above, drill and install (2) ¼-20” rivnuts. Using the supplied hardware (ffr# 25460), install the gas pedal..

  • Page 268

    259 www.Factoryfive.Com 508-291-3443 fuel tank finish panels eye protection, drill, #6 hex nut driver, ⅛” drill bits, drill, rivet tool, silicone, caulk gun, #6 self tapping screws. Fuel tank finish panels (ffr# 25641, 25643). Using the previously described aluminum installation process, it is now t...

  • Page 269

    260 www.Factoryfive.Com 508-291-3443 pre-engine preparation 10mm, 17mm socket, ratchet, 2x4 steel bar or something to support rear of engine. Engine mount spacers (ffr# 25756), radiator tubes – 1.5/1.25od (ffr# 25534, 25535) you must place the hard aluminum coolant lines (ffr# 25534, 25535) in the t...

  • Page 270

    261 www.Factoryfive.Com 508-291-3443 when installing the engine it is a good idea to have at least one person assisting you, two is preferred. Before the engine is installed, remove the thermostat housing (10mm wrench) as it aids in the installation. The engine is installed with the engine mounts an...

  • Page 271

    262 www.Factoryfive.Com 508-291-3443 once the motor has been lowered 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 engine mount with the rectangular cuto...

  • Page 272

    263 www.Factoryfive.Com 508-291-3443 use the flanged corvette engine mount nut to 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. Alternato...

  • Page 273

    264 www.Factoryfive.Com 508-291-3443 mount 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 may need to chase the holes with a drill bit)..

  • Page 274

    265 www.Factoryfive.Com 508-291-3443 install the pulley spacer. Install the alternator support bracket. Install idler pulley mount. 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 fron...

  • Page 275

    266 www.Factoryfive.Com 508-291-3443 put the following bolts in, but do not tighten any of 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). Inse...

  • Page 276

    267 www.Factoryfive.Com 508-291-3443 thread the lower alternator 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 the bolt the rest of the way through ...

  • Page 277

    268 www.Factoryfive.Com 508-291-3443 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 corvette alternator bracket (13 mm)..

  • Page 278

    269 www.Factoryfive.Com 508-291-3443 put the corvette idler pulley on the sleeve followed by a ½” 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...

  • 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

    271 www.Factoryfive.Com 508-291-3443 mount the supplied pulley wheel (ffr# 10775) onto the tensioner 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), aro...

  • Page 281

    272 www.Factoryfive.Com 508-291-3443 loop the remaining 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 rotate counter-clockwise until the tensioner stops..

  • Page 282

    273 www.Factoryfive.Com 508-291-3443 transaxle adapter plate preparation and installation drill, ⅞”, 3 / 16 ” bit, 9 / 64 ” hex key, 11 / 32 ” wrench. Transaxle adapter plate, hardware and drill template. When drilling the template do not allow the drill to walk, particularly when drilling the large...

  • 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

    275 www.Factoryfive.Com 508-291-3443 remove the drill template from the adapter plate. Using a 3 / 16 ” bit, drill all 3 holes completely through the adapter plate. Then use a ⅞” drill bit to drill out the center hole. A drill press is best, but a hand held drill can be used. Install one of the flan...

  • Page 285

    276 www.Factoryfive.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 to specification..

  • 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

    280 www.Factoryfive.Com 508-291-3443 transaxle install 1990 and later g50 17 mm wrench, 10, 13, 17 mm socket, ¾” socket/wrench, ratchet, pick and/or screwdriver. Transmission, clutch, pressure plate, transmission mount, 90-98 g50 transaxle adapter kit. The transaxle is a heavy and has to get aligned...

  • Page 290

    281 www.Factoryfive.Com 508-291-3443 slide the fork onto the throw-out bearing and tape in place. Make sure the socket on the bottom arm of the fork faces rearward. Slide the transmission onto the studs. Another set of hands and/or something to brace the transmission will be helpful here. Before sli...

  • Page 291

    282 www.Factoryfive.Com 508-291-3443 apply 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 – transmission housing, 13 mm – clutch fork shaft)..

  • Page 292

    283 www.Factoryfive.Com 508-291-3443 remove the tape from the clutch fork by inserting a pick or a screwdriver through the access holes in the transmission. Slide the transmission mount (ffr# 25311) into place. The lower brackets may have pulled in slightly due to the heat from welding, so you may h...

  • Page 293

    284 www.Factoryfive.Com 508-291-3443 put the top bolts in, but do not fully tighten them until all of 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 ...

  • Page 294

    285 www.Factoryfive.Com 508-291-3443 bolt the transmission to the transmission mount. Tighten the transmission mount to frame bolts (¾” wrench/socket). Brake line routing drill, ⅜”, 7 / 16 ”, ½” wrenches. Brake line components and corvette flexible brake line (ffr# 25567, 13738, 13739, 13740)..

  • Page 295

    286 www.Factoryfive.Com 508-291-3443 the master cylinders have 2 openings; the upper outlet is used as a bleeder to bleed the master cylinders themselves. The front facing opening is used to plumb brake lines. One of the cylinders is used for the front brakes and the other is used for rear brakes. I...

  • Page 296

    287 www.Factoryfive.Com 508-291-3443 the front brake lines pass through the front inner wheel well aluminum. Drill a 5 / 8 ” hole inline with the hole on the brake line bracket located, ½” above the upper surface of the brake line bracket. After the hole is drilled, insert the rubber grommets found ...

  • Page 297

    288 www.Factoryfive.Com 508-291-3443 insert the corvette soft brake line into the brake line bracket from the bottom and hold it in place using the clip found on the corvette. The brake line metric adapter (ffr# 25502) is then inserted into the opening in the corvette brake line fitting. (same proce...

  • Page 298

    289 www.Factoryfive.Com 508-291-3443 the front passenger side line is installed in a similar process using the 51” brake line (ffr# 13739). Run the passenger line along the 1” frame rail. The lines are longer than needed due to the inclusion of service loops. Attach the long 60” brake line to the ma...

  • Page 299

    290 www.Factoryfive.Com 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 line t fitting (ffr# 25556)..

  • Page 300

    291 www.Factoryfive.Com 508-291-3443 the soft corvette brake lines are attached to the car using the rear brake line bracket (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 ...

  • Page 301

    292 www.Factoryfive.Com 508-291-3443 frame/aluminum, run the suspension through its full range of motion to 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...

  • Page 302

    293 www.Factoryfive.Com 508-291-3443 use the 60” to plumb the passenger 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, attach them to the frame usin...

  • Page 303

    294 www.Factoryfive.Com 508-291-3443 clutch line routing drill, 3 / 8 ”, 7 / 16 ”, ½” wrenchs, 7 mm wrench, 14 mm wrench. Clutch slave cylinder kit (ffr# 25564), wilwood master cylinder (ffr# 25227). Use the same procedure as the brake master cylinders to install the third clutch master cylinder. Us...

  • Page 304

    295 www.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 (14 mm)..

  • Page 305

    296 www.Factoryfive.Com 508-291-3443 using the supplied fittings, mate the flexible line to the hard 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 cyli...

  • Page 306

    297 www.Factoryfive.Com 508-291-3443 bolt 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 in the lines and have good pedal feel..

  • Page 307

    298 www.Factoryfive.Com 508-291-3443 battery install 7 / 16 ” wrench. Corvette 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 ¼” hardware (ffr# 10802). The ter...

  • Page 308

    299 www.Factoryfive.Com 508-291-3443 radiator aluminum and radiator install eye protection, drill w/#6 hex nut driver, ⅛” drill bits, drill, rivet gun, silicone, caulking gun, #6 self tapping screws. Radiator aluminum rear duct and under tray (ffr# 25495, 25493). The radiator aluminum has to be inst...

  • 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 ¾” frame rail..

  • Page 310

    301 www.Factoryfive.Com 508-291-3443 the radiator assembly is installed next. The fan shroud must be 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 fr...

  • Page 311

    302 www.Factoryfive.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 the photo below..

  • 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

    304 www.Factoryfive.Com 508-291-3443 cooling system drill (a right angle drill is extremely helpful in this section), 3/16” drill bit, flat screw driver, hack saw, tape measure. Stainless radiator hose kit, loop strap, (ffr# 13883, 25767, 25768, 10984). The hard aluminum tubes should have been insta...

  • Page 314

    305 www.Factoryfive.Com 508-291-3443 the smaller 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 the tubes on the passenger side of the tunnel..

  • Page 315

    306 www.Factoryfive.Com 508-291-3443 install the 1.5” long rubber adapters over the hard aluminum line, thicker adapters are for the smaller diameter hard lines and the thinner ones are for the larger diameter aluminum tube. Then slide the 3” long adapter over the smaller ones. (it may help to spray...

  • Page 316

    307 www.Factoryfive.Com 508-291-3443 start plumbing the lines at the front of the car first; these are routed under the steering rack and around the battery. Connect the corrugated line to the 1.25” diameter hard line then to the radiator opening on the passenger side using the 3” long adapter and o...

  • Page 317

    308 www.Factoryfive.Com 508-291-3443 attach the corrugated line to the 1.5” diameter hard line 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 the wate...

  • Page 318

    309 www.Factoryfive.Com 508-291-3443 connect the rear lines next. The driver side corrugated line is 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 th...

  • Page 319

    310 www.Factoryfive.Com 508-291-3443 after running the car for the first time once coolant is added and while the system is still warm, retighten the hose clamps used on the cooling system. Surge tank and soft coolant line routing 3 / 16 ” hex key, ½” wrench, flat screwdriver, razor knife. Corvette ...

  • Page 320

    311 www.Factoryfive.Com 508-291-3443 the heater hoses are installed next. Snake the long ⅝” (ffr# 25537), ¾” (ffr# 11205) and ¼” (ffr# 25536) radiator hose down the tunnel through the lower portion of the dash bulkhead x member. The heater ports on the water pump are different sizes. Connect the lar...

  • Page 321

    312 www.Factoryfive.Com 508-291-3443 the small heater hose is connected to 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 heater line on the passe...

  • Page 322

    313 www.Factoryfive.Com 508-291-3443 route the bundle of heater hoses around the battery on the passenger side. Install the small ¼” heater hose (ffr# 25536) onto the small fitting on the top of the passenger side of the radiator using the ¼” hose clamp (ffr# 10855)..

  • Page 323

    314 www.Factoryfive.Com 508-291-3443 the two larger lines from the water pump are attached to the base of the surge tank. Install the larger diameter line (¾”) on the front facing lower port and the smaller one (⅝”) on the rear facing lower port using the large hose clamps (ffr# 25601)..

  • Page 324

    315 www.Factoryfive.Com 508-291-3443 the surge tank now has to be connected to the radiator. Connect one end of the ½” 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 ½” hose to the larger port on the t...

  • Page 325

    316 www.Factoryfive.Com 508-291-3443 the filling process is taken from the gm corvette service manual. Make sure to use a 50-60% mixture of distilled water and dex-cool® coolant. Fill the system through the surge tank opening until the fluid level is ½” below opening. With the cap removed from the s...

  • Page 326

    317 www.Factoryfive.Com 508-291-3443 once again, bring the coolant up to temperature (210°f) by revving the engine from idle to 3,000 rpm in 30 second intervals; then turn engine off. Top off the coolant ½” above the full cold mark on the surge tank. Emergency brake and cables 3 / 16 ” hex key. Corv...

  • Page 327

    318 www.Factoryfive.Com 508-291-3443 install the corvette e-brake to the frame using the supplied 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 ...

  • 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

    320 www.Factoryfive.Com 508-291-3443 loop the cables forward and attach the ends into the emergency brake connection bracket. Cockpit/tunnel aluminum eye protection, drill w/#6 hex nut driver, ⅛” drill bits, drill, rivet gun, silicone, caulking gun, #6 self tapping screws. Rear cockpit lumbar alumin...

  • Page 330

    321 www.Factoryfive.Com 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 of aluminum (ffr# 25158)..

  • 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

    323 www.Factoryfive.Com 508-291-3443 the last piece that has to be installed is the passenger tunnel wall (ffr# 25157). The hole in this panel is for the e-brake handle to pass through. Position the e-brake handle in the “up/engaged” position while installing this panel. Axles and cv joints vise, de...

  • Page 333

    324 www.Factoryfive.Com 508-291-3443 using a hammer or soft mallet tap 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 porsche cv boot fits over the en...

  • Page 334

    325 www.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 section..

  • Page 335

    326 www.Factoryfive.Com 508-291-3443 slide the speedometer gear (ffr# 25149) 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 the outer cv thro...

  • 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

    328 www.Factoryfive.Com 508-291-3443 chassis wiring electrical tape, wire strippers, wire crimpers. Prepared donor wiring harness, 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...

  • Page 338

    329 www.Factoryfive.Com 508-291-3443 mount the fuse panel to the chassis on 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 edge and should be prot...

  • Page 339

    330 www.Factoryfive.Com 508-291-3443 main harness routing begin routing the wires 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: gauges, stalk s...

  • Page 340

    331 www.Factoryfive.Com 508-291-3443 route the sections of harness that run 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 the headlights, tailligh...

  • Page 341

    332 www.Factoryfive.Com 508-291-3443 locate the drive by wire harness 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 symmetrical) through the pass thr...

  • Page 342

    333 www.Factoryfive.Com 508-291-3443 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 the fan is computer controlled..

  • Page 343

    334 www.Factoryfive.Com 508-291-3443 steering column plug find the plug that was removed from the harness that attaches to the turn signal stalk/ headlight switch. The wires from the turn signal section of the chassis harness need to be spliced into this plug to operate the turn signals and horn and...

  • Page 344

    335 www.Factoryfive.Com 508-291-3443 l tan headlight low beams black (relay #86) from low beam relay (white wire (relay #30) input is #909) m ---- not used n black ground ground p ---- not used r brown parking/dash lights black (relay #86) from parking relay (white wire (relay #30) input are 927 and...

  • Page 345

    336 www.Factoryfive.Com 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 components 85 87 86 30

  • Page 346

    337 www.Factoryfive.Com 508-291-3443 strip and connect the wires to the switch connectors. Connect the switch wires. 1 – connect to fog lights. 2 - +12 volts from fuse panel 4 – ground headlight relays misc. Electrical components wire cutters, 3 / 16 ” drill bit, drill, wire crimper, wire stripper t...

  • Page 347

    338 www.Factoryfive.Com 508-291-3443 if on the plug, the middle (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 relay). Attach the relays to the cha...

  • Page 348

    339 www.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. (relay #87).

  • Page 349

    340 www.Factoryfive.Com 508-291-3443 hook the high beam, low beam, and parking lights up one through each relay, the black wire (relay #86) on the 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 t...

  • Page 350

    341 www.Factoryfive.Com 508-291-3443 remove a 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 wire back through the plug at the same time..

  • Page 351

    342 www.Factoryfive.Com 508-291-3443 plug the wiper harness into the column and stretch it out forward toward the radiator. The yellow wire that is hanging free is spliced into either side door lock power from the chassis harness. Cut the purple wire. This wire is the high speed setting on the wiper...

  • Page 352

    343 www.Factoryfive.Com 508-291-3443 ignition switch locate the bundle of heavy gauge wires that attach to the ignition switch in the chassis harness. You can mount the ignition switch on the gauge face, on the center section of the dash etc. Although you won’t be permanently mounting the switch now...

  • Page 353

    344 www.Factoryfive.Com 508-291-3443 brake 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 orange, the third wire on the switch is not used..

  • Page 354

    345 www.Factoryfive.Com 508-291-3443 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 adjustment in either direction..

  • Page 355

    346 www.Factoryfive.Com 508-291-3443 line the bracket up in the car so that the 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 mounting holes o...

  • Page 356

    347 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 out..

  • Page 357

    348 www.Factoryfive.Com 508-291-3443 engine harness fuse panel connection locate the large center plug that attaches to the corvette engine 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 t...

  • Page 358

    349 www.Factoryfive.Com 508-291-3443 the fuse panel power wires attach from the large plug to the end of this section of harness. The purple start 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. Th...

  • Page 359

    350 www.Factoryfive.Com 508-291-3443 the final large plug on the underside of the corvette fuse panel contains the circuit for the cooling fans as well as the fuel pump. It is recognizable by four heavy gauge wires, blue, white, grey, and black. The fuel tank harness that was stripped earlier should...

  • Page 360

    351 www.Factoryfive.Com 508-291-3443 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. Wires are provided in the kit..

  • Page 361

    352 www.Factoryfive.Com 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 toward the rear of the car..

  • Page 362

    353 www.Factoryfive.Com 508-291-3443 route the engine section of the chassis harness and spliced in fuse 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 sl...

  • Page 363

    354 www.Factoryfive.Com 508-291-3443 continue routing the fan harness toward the front of the car. The headlight 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 f...

  • Page 364

    355 www.Factoryfive.Com 508-291-3443 underdash light the dash light provided in 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 around, wires will ne...

  • Page 365

    356 www.Factoryfive.Com 508-291-3443 wiring connect the power to a 12v source such as the electric choke if not using 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 ...

  • Page 366

    357 www.Factoryfive.Com 508-291-3443 the tach module will be mounted 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 drilling. Remove the bracket and 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

    359 www.Factoryfive.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 button head screws..

  • Page 369

    360 www.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 plug..

  • 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

    362 www.Factoryfive.Com 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 throttle control module in..

  • Page 372

    363 www.Factoryfive.Com 508-291-3443 plug the round connector from the fan/fuel pump harness into the round connector on the engine 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 oth...

  • Page 373

    364 www.Factoryfive.Com 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 attaches to the small post..

  • Page 374

    365 www.Factoryfive.Com 508-291-3443 there is a black ground wire that comes out of 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. Ground this wi...

  • 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

    367 www.Factoryfive.Com 508-291-3443 oil level sensor plug the 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 on both sides of the engine along wit...

  • Page 377

    368 www.Factoryfive.Com 508-291-3443 under the throttle body is the cam position sensor and pigtail 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 alternator w...

  • Page 378

    369 www.Factoryfive.Com 508-291-3443 air temperature sensor for 1997-2000 corvettes, the air filter needs to be drilled to accept the air temperature sending unit that was removed from the corvette intake tube. On the 2001-2004 corvettes, the intake air temperature sensor is integrated into the mass...

  • Page 379

    370 www.Factoryfive.Com 508-291-3443 insert 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, air temperature, and throttle position sensor..

  • Page 380

    371 www.Factoryfive.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 to the sensor..

  • 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

    373 www.Factoryfive.Com 508-291-3443 instrument sending 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. An open end wrench will fit in through from...

  • Page 383

    374 www.Factoryfive.Com 508-291-3443 thread in the 45° adapter using some 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 the nipple down to about ...

  • 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

    376 www.Factoryfive.Com 508-291-3443 open the 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 sure that the copper ring gasket is in place..

  • Page 386

    377 www.Factoryfive.Com 508-291-3443 attaching senders to chassis harness separate the coolant temperature wire from the chassis harness back to just in front 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 se...

  • Page 387

    378 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 terminal..

  • Page 388

    379 www.Factoryfive.Com 508-291-3443 fuel level wires separate the fuel level send wire and the power antennae wire from the taillight harness and re-route them in with the engine section of the chassis harness. The tail light harness has not yet been routed past the pass through into the tunnel. Tr...

  • Page 389

    380 www.Factoryfive.Com 508-291-3443 the tachometer signal wire is located in the engine section of the chassis harness. This wire is spliced into the white wire leading into the computer plug (the engine speed signal – ess – wire). The ess wire is located in pin #35 in the blue computer plug for 19...

  • Page 390

    381 www.Factoryfive.Com 508-291-3443 the white “alternator regulator” wire 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 wire. This circuit will b...

  • Page 391

    382 www.Factoryfive.Com 508-291-3443 out further on the fuel tank harness is the plug from the vehicle speed 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 mo...

  • Page 392

    383 www.Factoryfive.Com 508-291-3443 on the transmission there is a 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 bracket and back into the transmis...

  • Page 393

    384 www.Factoryfive.Com 508-291-3443 route the vehicle speed sender 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 until there is an even 3 / 16 ” ...

  • Page 394

    385 www.Factoryfive.Com 508-291-3443 mendeola transaxle thread lock, 5 / 32 ”, 3 / 16 ” hex key, 7 / 16 ” wrench intake relocation components, mendeola installation parts on the mendeola transaxle, the speed sensor mounts on the driver side at the 5 o’clock position to a 5 / 16 ” threaded hole and r...

  • Page 395

    386 www.Factoryfive.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 stripe wires..

  • Page 396

    387 www.Factoryfive.Com 508-291-3443 underneath the engine 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 chassis harness kit on the harness end ...

  • Page 397

    388 www.Factoryfive.Com 508-291-3443 in the remaining donor harness pull a long section 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 the remain...

  • Page 398

    389 www.Factoryfive.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 the obdii plug..

  • Page 399

    390 www.Factoryfive.Com 508-291-3443 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 panel that covers the footbox..

  • Page 400

    391 www.Factoryfive.Com 508-291-3443 ground the plug to the chassis..

  • Page 401

    392 www.Factoryfive.Com 508-291-3443 battery cables two positive battery cables are provided 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 term...

  • Page 402

    393 www.Factoryfive.Com 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 panel outside terminal..

  • Page 403

    394 www.Factoryfive.Com 508-291-3443 steering wheel and horn wire stripers and crimpers, 21mm socket and ratchet steering wheel and fasteners ffr# 25268 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...

  • Page 404

    395 www.Factoryfive.Com 508-291-3443 install the steering wheel boss (ffr# 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. Install the steering whe...

  • Page 405

    396 www.Factoryfive.Com 508-291-3443 with the steering 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 to one of the spade terminals on the horn button..

  • Page 406

    397 www.Factoryfive.Com 508-291-3443 remove the center section of the wheel by peeling back the overhanging 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 sp...

  • Page 407

    398 www.Factoryfive.Com 508-291-3443 battery install 7 / 16 ” wrench, 3 / 16 ” hex key, dill, 5 / 16 ”, ⅜” drill bit corvette donor battery and battery hold down kit (ffr# 25546). The instructions for this section were written during a build-up of a car to be fit with the optional air conditioning s...

  • 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

    400 www.Factoryfive.Com 508-291-3443 if you are installing the optional air 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 battery hold down “j”...

  • 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

    402 www.Factoryfive.Com 508-291-3443 attach the positive cable to the positive terminal on the battery 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 r...

  • Page 412

    403 www.Factoryfive.Com 508-291-3443 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 head bolt and washer (ffr# 25873, 11005)..

  • Page 413

    404 www.Factoryfive.Com 508-291-3443 shifter linkage hammer, hacksaw, 13mm, 9mm wrench, 3.5mm hex key. Shifter linkage and hardware, shifter handle assembly (ffr# 25832, 26085). On some engines, the engine mount may interfere with the shifter linkage – you will have to grind the engine mount slightl...

  • Page 414

    405 www.Factoryfive.Com 508-291-3443 the shifter linkage must now be assembled. There are 4 lengths 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 ...

  • Page 415

    406 www.Factoryfive.Com 508-291-3443 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 casing on the universal joint..

  • Page 416

    407 www.Factoryfive.Com 508-291-3443 install the rear shifter linkage (ffr# 25436) into the joint previously installed into the rearward linkage 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 rearw...

  • Page 417

    408 www.Factoryfive.Com 508-291-3443 install the rearward most 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 this procedure. (picture below is...

  • Page 418

    409 www.Factoryfive.Com 508-291-3443 the front portion of the shifter assembly has one end with a universal joint attached to (rearward section) and the other end just has the shifter rod itself (front). You are going to have to assemble this in the car. Slide one plastic flange bearing (ffr# 26084)...

  • Page 419

    410 www.Factoryfive.Com 508-291-3443 loosely attach these flange bearings to the frame using the supplied hardware. (ffr# 12775, 12768) the 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 mounte...

  • Page 420

    411 www.Factoryfive.Com 508-291-3443 once the shifter linkages 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 holding it in place. (this will act as...

  • Page 421

    412 www.Factoryfive.Com 508-291-3443 the bottom of the shifter handle shaft is threaded 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 white lithium gr...

  • Page 422

    413 www.Factoryfive.Com 508-291-3443 slide the ¾” 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 (ffr# 25374) onto the shifter handle assembly..

  • Page 423

    414 www.Factoryfive.Com 508-291-3443 place the seat temporarily into 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. Loosen this bolt and adjust...

  • Page 424

    415 www.Factoryfive.Com 508-291-3443 you can also slightly adjust the height (motion ratio) of the shifter mechanism by loosening the jam nut at the base of the threaded shifter handle. Slight adjustments here result is significant changes in the overall “feel” of the shifter mechanism. Catalytic ex...

  • Page 425

    416 www.Factoryfive.Com 508-291-3443 1997-2000 2001-2004 due to the corvette having two different styles of exhaust manifolds, there are two different versions of the catalytic converter pipes. The earlier vintage (1997-2000) cat pipes (ffr# 25370) use the same pipe on the driver and passenger side....

  • Page 426

    417 www.Factoryfive.Com 508-291-3443 the ffr cat pipes attach to the corvette manifolds using the corvette 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...

  • Page 427

    418 www.Factoryfive.Com 508-291-3443 the flanges are indexed 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 nuts as you will do that later when the h-...

  • Page 428

    419 www.Factoryfive.Com 508-291-3443 fuel tank and fuel line routing 1997–2002 fuel tanks 3 / 16 ” hex key, ½” wrench, flat screwdriver, razor knife. Corvette gas tanks/fuel lines, fuel filter/regulator, ac compressor cover plate, pre-bent barbed fuel line (ffr# 25753, 25888, 25889). The corvette fu...

  • Page 429

    420 www.Factoryfive.Com 508-291-3443 install the ac compressor cover plate using the 3 / 16 ” short rivets. 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 int...

  • 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

    422 www.Factoryfive.Com 508-291-3443 route the braided line along the 1.5” square tube between the engine mount brackets, making sure that it is low and away from the exhaust, crank pulley, a/c compressor etc. Check for kinks in the line. Install the other elbow onto the braided hose. Thread the hos...

  • Page 432

    423 www.Factoryfive.Com 508-291-3443 the next way to verify the year of fuel system is to look at the fuel 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 f...

  • Page 433

    424 www.Factoryfive.Com 508-291-3443 the fuel filter is installed under the pcm on top of the fuel tank finish panel (just forward of the engine fuse box). Install a ¼-20” rivnut into the frame then attach the fuel filter to the frame using the flanged button head fastener (ffr# 25460). The filter s...

  • Page 434

    425 www.Factoryfive.Com 508-291-3443 attach the 3 / 8 ” fuel line to 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 y-fitting needs to be modif...

  • Page 435

    426 www.Factoryfive.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 from the y-fitting..

  • Page 436

    427 www.Factoryfive.Com 508-291-3443 use the same process and remove the other 10mm and 8mm quick connect fuel 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 ...

  • Page 437

    428 www.Factoryfive.Com 508-291-3443 use the quick connect fuel lines removed from the “y” fuel line and connect the larger 10mm fitting to the ⅜” rubber line and attach 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 ...

  • Page 438

    429 www.Factoryfive.Com 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 fuel filter or fuel rail..

  • Page 439

    430 www.Factoryfive.Com 508-291-3443 check for leaks before fastening the braided line to the chassis. Once you are sure the braided line isn’t kinked and is safely out of the way of any moving parts and none of the fittings are leaking, secure the line to the chassis using the supplied insulated ho...

  • Page 440

    431 www.Factoryfive.Com 508-291-3443 install the ac compressor cover plate using the 3 / 16 ” short rivets. 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 int...

  • 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

    433 www.Factoryfive.Com 508-291-3443 route the braided line along the 1.5” square tube between the engine mount brackets, making sure that it is low and away from the exhaust, crank pulley, a/c compressor etc. Check for kinks in the line. Install the other elbow onto the braided hose. Thread the hos...

  • Page 443

    434 www.Factoryfive.Com 508-291-3443.

  • Page 444

    435 www.Factoryfive.Com 508-291-3443 drive/test chassis (go-cart) front suspension now is a good time to double check all your hardware, make sure your wiring and hoses are away from extreme heat and moving parts, make sure the steering turns freely lock to lock, and make sure your brake flex lines ...

  • Page 445

    436 www.Factoryfive.Com 508-291-3443 wheels install and torque your wheels. Make sure they rotate freely and do not interfere with the brake calipers, lines, or any suspension components. Rattle patrol get the engine up to temperature and check for leaks and make sure the fan is working. After runni...

  • Page 446

    437 www.Factoryfive.Com 508-291-3443 foot box front wall, top panel, and tunnel cover aluminum eye protection, drill w/#6 hex nut driver, ⅛” drill bits, drill, rivet gun, silicone, caulking gun, #6 self tapping screws. Gtm foot box aluminum (ffr# 25171). Install the front footbox wall (ffr# 25190). ...

  • Page 447

    438 www.Factoryfive.Com 508-291-3443 if you did not do so when you removed the tunnel cover aluminum panel (ffr# 25802) from the frame, you will need to mark the rivet locations on the panel now. Measure in from the sides of the panel ½” and draw a line parallel to the edge of the aluminum. Measure ...

  • Page 448

    439 www.Factoryfive.Com 508-291-3443 apply a bead of silicone to just the top edge of the dash bulkhead tube. Set the panel in place. Drill the frame 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 th...

  • Page 449

    440 www.Factoryfive.Com 508-291-3443 main body mounting ⅛”, 3 / 16 ”, ¼”, ⅜”, 25 / 64 ” drill bits, drill, rivnut tool, ½” wrench/socket, ratchet, 3 / 16 ” hex key, 1” hole saw body – main (ffr# 25245), rear hatch fasteners (ffr# 25429), firewall panel (ffr# 25497), weatherstrip (ffr# 10761), tail l...

  • 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

    442 www.Factoryfive.Com 508-291-3443 door area mounting the body is located by the door openings underneath the door sills and front to back by the chassis in front of the door opening. Making sure that the body is tight against the frame in these areas sink a few 1 / 8 ” rivets through the body int...

  • Page 452

    443 www.Factoryfive.Com 508-291-3443 rear body mount measure in about 8½” 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 outline of the exhaust recess ...

  • Page 453

    444 www.Factoryfive.Com 508-291-3443 raise the back of the body with a jack or blocks until the bottom corner of the license plate recess and the top corner of the transmission mount are lined up. The rear section of the body needs to be leveled and centered side to side by measuring from the wheel ...

  • Page 454

    445 www.Factoryfive.Com 508-291-3443 rivet the bottom corners of the 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 the panel put a rivet on each e...

  • Page 455

    446 www.Factoryfive.Com 508-291-3443 set the side cowl bracing panels in place, lining up the top edge of the panel with the top edge of the center firewall panel you just installed. Make sure you leave enough room between the top edge of the panel and the body for the weather stripping. You want th...

  • Page 456

    447 www.Factoryfive.Com 508-291-3443 with the body in place the wiper enclosure panel (ffr# 25500) has to be fit to the body/chassis. Pre-drill the holes (⅛”) in this panel before setting it into place. All of the mounting flanges should be pre-drilled. Picture below shows the panel with the flanges...

  • 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

    449 www.Factoryfive.Com 508-291-3443 use a marker and mark the location of location of this panel. (mark the 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 th...

  • 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

    451 www.Factoryfive.Com 508-291-3443 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 is in the small boxes with the caps..

  • Page 461

    452 www.Factoryfive.Com 508-291-3443 lower each cap into the 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 you want it. We prefer the flip up t...

  • Page 462

    453 www.Factoryfive.Com 508-291-3443 rear quarter windows fit each window up to the opening lining the front edge up flush with the body. Use black silicone or have the windshield guy attach the windows with his windshield adhesive. Rear hatch hinge the panel has been trimmed oversize to allow for m...

  • Page 463

    454 www.Factoryfive.Com 508-291-3443 unpack the hatch hinge brackets and hardware (ffr# 25236)..

  • Page 464

    455 www.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 (ffr# 25410)..

  • 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

    457 www.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 adjust..

  • 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

    459 www.Factoryfive.Com 508-291-3443 remove the hatch and drill and install ¼-20 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 mounts to the hatch..

  • Page 469

    460 www.Factoryfive.Com 508-291-3443 find and mark the centerline of the hatch striker mount area. Mount the hatch to the hinges using the six small ¼”-20 button head screws. Align the hatch paying close attention to the rear corners and the bottom corners of the window openings..

  • Page 470

    461 www.Factoryfive.Com 508-291-3443 attach the gas shocks to the hatch. Rear hatch latch 5 / 32 ” hex key, ½” socket, ratchet, 3 / 16 ” drill bit, rivet tool, rivnut tool, 25 / 64 ” drill bit, marker, ruler hatch fastener components.

  • 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

    463 www.Factoryfive.Com 508-291-3443 open the hatch. Center and locate the striker mount bracket on the hatch and mark the mounting holes. Drill and install rivnuts at the locations marked. Attach the striker mount to the hatch using the ¼”-20 x ¾” flanged button head screws. Attach the shoulder bol...

  • Page 473

    464 www.Factoryfive.Com 508-291-3443 use the template to locate and drill ¼” latch mounting holes through the body latch area and the latch support bracket. Insert the swivel wire stop in the latch hole..

  • Page 474

    465 www.Factoryfive.Com 508-291-3443 from the latch support side insert the ¼”-20 x 1.00” flange head screws through the latch support, body, latch spacer and into the latch. Tighten the screws. Insert the hatch release cable end fitting into the latch spacer. Insert the cable into the swivel wire s...

  • Page 475

    466 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 ¼” drill bit..

  • Page 476

    467 www.Factoryfive.Com 508-291-3443 diffuser drill, 3 / 16 ”, 5 / 16 ” drill bit, rivet tool, clamps, measuring tape, marker. Secondary body fasteners, rear diffuser. Raise the diffuser up to the chassis with a jack for fitment so that the diffuser is sitting against the frame but can still be move...

  • 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

    469 www.Factoryfive.Com 508-291-3443 double check the in/out measurement 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 flanges onto the diffuser from...

  • Page 479

    470 www.Factoryfive.Com 508-291-3443 decide how many spacers you would like to use to hold the diffuser. We provide five 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...

  • Page 480

    471 www.Factoryfive.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 area sticking out..

  • 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

    473 www.Factoryfive.Com 508-291-3443 re-position 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 removed prior to paint. Bolt the spacers onto the body...

  • 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

    476 www.Factoryfive.Com 508-291-3443 door hinge locate 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 ½” between the bottom outside corner and the bottom of the door (see arrow) and mark the two square holes on t...

  • Page 486

    477 www.Factoryfive.Com 508-291-3443 remove the panel and drill the two holes with a ⅜” 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 socket will keep it from deforming when remov...

  • Page 487

    478 www.Factoryfive.Com 508-291-3443 position the 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 through holes, be sure to leave room for adjustmen...

  • 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

    480 www.Factoryfive.Com 508-291-3443 insert rubber door stop 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 the body. This can be done after ...

  • Page 490

    481 www.Factoryfive.Com 508-291-3443 power window track set the window 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 ¼” screws. The screws that come in the package with the ...

  • 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

    483 www.Factoryfive.Com 508-291-3443 lift the frame and hinge plate in the front of the door as high as you can get it and insert the two ½” 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 t...

  • Page 493

    484 www.Factoryfive.Com 508-291-3443 drill out the body slots for the door striker. Mark the chassis for the vertical center of the slot then measure in 5 / 8 ” from the outside of the striker pad and drill an ⅛” hole. Walk the small drill around to make a larger hole that is centered with the slot ...

  • Page 494

    485 www.Factoryfive.Com 508-291-3443 push the brass bushings from the door hardware into the chassis and door frame, if 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 ove...

  • Page 495

    486 www.Factoryfive.Com 508-291-3443 slide the shoulder 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 nuts from the hinge to the frame and frame to the d...

  • Page 496

    487 www.Factoryfive.Com 508-291-3443 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 of the chassis cross- tubes..

  • Page 497

    488 www.Factoryfive.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 adjust outward..

  • Page 498

    489 www.Factoryfive.Com 508-291-3443 with the door in position and the door latch operational mark the center of the slots in the door latch mount where it meets the body and drill with a ¼” drill bit. Bolt the rear of the door to the door frame using the ¼” stainless bolts provided and tighten them...

  • Page 499

    490 www.Factoryfive.Com 508-291-3443 mark the seams for an even gap and 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 body will be just and ...

  • Page 500

    491 www.Factoryfive.Com 508-291-3443 once you have the door 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 until the body has been painted (shown af...

  • Page 501

    492 www.Factoryfive.Com 508-291-3443 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 using the three holes in the bracket..

  • Page 502

    493 www.Factoryfive.Com 508-291-3443 splice the corvette window motor plug into the wires that you ran earlier in the build from the window switches. Position the front lower track mount tab to the recess in the bottom of the door so that the hole in the bracket is centered about the recess. Using t...

  • Page 503

    494 www.Factoryfive.Com 508-291-3443 place the lower portion of the rear track into the molded recess on the inside of the door near the back of the door. Position the track so that the mounting hole in the track is in the approximate location shown in the picture below (shown already bolted in posi...

  • Page 504

    495 www.Factoryfive.Com 508-291-3443 the actual measurement from the edge of the door may vary car to car, but the important things to be sure of are that both tracks are below the opening in the door and they are as close to parallel as possible! It is very critical that the tracks are parallel to ...

  • Page 505

    496 www.Factoryfive.Com 508-291-3443 squeeze a small amount of the supplied adhesive (ffr# 25865) onto a flat surface like a piece of cardboard (something you are willing to discard). The epoxy is a two part epoxy, so be sure that both parts a and b are coming out of the tube. Mix part a and b toget...

  • 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

    499 www.Factoryfive.Com 508-291-3443 attach the adhesive-back weatherstrip (ffr# 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 allow the rear ...

  • Page 509

    500 www.Factoryfive.Com 508-291-3443 window down window up 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 weather strip on the flange at the edge of th...

  • 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

    503 www.Factoryfive.Com 508-291-3443 using the switch, move the window up and check its position in the window opening around the door and also along the body. Make sure it is contacting the weatherstripping. Also, make sure that the glass clears the door linkage and moves up and down smoothly. Adju...

  • Page 513

    504 www.Factoryfive.Com 508-291-3443 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 to the end of the mirror studs..

  • Page 514

    505 www.Factoryfive.Com 508-291-3443 measure on the door upper corner 2¼” 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 height is set by keeping the gas...

  • 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

    507 www.Factoryfive.Com 508-291-3443 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 ¼” drill bit. Install the mirrors and gasket using the original nuts..

  • Page 517

    508 www.Factoryfive.Com 508-291-3443 vents 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 fits in the recess and trim if needed..

  • Page 518

    509 www.Factoryfive.Com 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 passes through the mesh..

  • Page 519

    510 www.Factoryfive.Com 508-291-3443 the flanges that stick out from the piece 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 body then bend 1 / 8 ” ...

  • 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

    512 www.Factoryfive.Com 508-291-3443 the front radiator opening mesh and can be fit by hand to the 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, 2 3 / 8 ”, 3...

  • Page 522

    513 www.Factoryfive.Com 508-291-3443 nose assembly, fog light components, headlight bucket assembly, headlights and hardware, front turn signals and hardware, gtm nose aluminum (ffr# 25243, 25216, 2553, 25209, 25214, 25686, 25533 ) if you are going to make up your own pattern, do so out of paper/car...

  • Page 523

    514 www.Factoryfive.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 2 3 / 8 ” hole drilled. Use the dimples found in the gel-coal as center points to drill..

  • Page 524

    515 www.Factoryfive.Com 508-291-3443 drill 4 holes in the headlight bucket. From the backside of the headlight bucket, use the headlight cutout template (ffr# 25484) and mark the 4 locations using a paint marker. (at this time the lights should not be installed in the buckets) using a 25 / 64 ” dril...

  • Page 525

    516 www.Factoryfive.Com 508-291-3443 install the low beam (on the outside hole in the 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 bucket during i...

  • Page 526

    517 www.Factoryfive.Com 508-291-3443 the turn 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 seal (ffr# 10761) on the outside edge of this panel..

  • Page 527

    518 www.Factoryfive.Com 508-291-3443 this panel is located behind the headlights in front of the front wheels. The hole in the center is used as an access panel for the backside of the headlights. The hood support for both the driver and passenger are installed next. These hood support brackets have...

  • 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

    520 www.Factoryfive.Com 508-291-3443 headlight lenses fit 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 desired shape, use 600-1200 grit sandpaper to ...

  • Page 530

    521 www.Factoryfive.Com 508-291-3443 hood hinge/hood mounting before the nose is set on the body, the hinges have to be assembled. 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 brack...

  • Page 531

    522 www.Factoryfive.Com 508-291-3443 driver passenger 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 step, as they are adjusted after the nose is aligned...

  • Page 532

    523 www.Factoryfive.Com 508-291-3443 the hinge assembly is now installed 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 push on bulb seal (ffr# 10761) to...

  • Page 533

    524 www.Factoryfive.Com 508-291-3443 with the help of a friend, position the nose on the car. The 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

    525 www.Factoryfive.Com 508-291-3443 the hood 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 nose centered in the slot on the hinge bracket..

  • Page 535

    526 www.Factoryfive.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 few steps..

  • Page 536

    527 www.Factoryfive.Com 508-291-3443 align the nose to the main body section with the hood in the closed position. Gas strut installation 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 ¾” frame member. Attach t...

  • Page 537

    528 www.Factoryfive.Com 508-291-3443 there is aluminum glassed into the nose to provide an attachment point for the gas strut bracket. Look 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 f...

  • Page 538

    529 www.Factoryfive.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 (3) 3 / 16 ” rivets..

  • Page 539

    530 www.Factoryfive.Com 508-291-3443 hood latches the corvette hood latches are mounted to the sides of the body towards the rear of the nose opening. 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 sid...

  • Page 540

    531 www.Factoryfive.Com 508-291-3443 once 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 the perimeter of the hatch striker bracket..

  • Page 541

    532 www.Factoryfive.Com 508-291-3443 close the nose (while 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 the hood and mark the location for the ...

  • Page 542

    533 www.Factoryfive.Com 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 thickness and radius.

  • Page 543

    534 www.Factoryfive.Com 508-291-3443 all trimmed panel edges should be radiused and should be either done or pointed 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 windshiel...

  • Page 544

    535 www.Factoryfive.Com 508-291-3443 the body 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 leave ¼” of a flange for strength and appearance..

  • Page 545

    536 www.Factoryfive.Com 508-291-3443 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 is removed prior to painting..

  • 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

    538 www.Factoryfive.Com 508-291-3443 radius the body edge above the front tires from the wheel well in to the vertical aluminum. 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) ...

  • 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

    540 www.Factoryfive.Com 508-291-3443 interior - rear wall ¼”, 25 / 64 ”, ½” drill bits, drill, clamps, marker, tape measure. Secondary body fasteners, aluminum rear wall (ffr# 25271), upper cockpit sidewall brackets (25741, 25742), fuel tank covers (ffr# 25195, 25196). Slightly rounding off the edge...

  • 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

    542 www.Factoryfive.Com 508-291-3443 set the upper cockpit side wall brackets (ffr# 25741, 25742) in place and mark the holes you will need to drill in the body and the rear wall. The square flange of the bracket goes behind the rear wall (pointing in towards the center of the car) and the flange wi...

  • Page 552

    543 www.Factoryfive.Com 508-291-3443 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 drilled in the floor pan..

  • Page 553

    544 www.Factoryfive.Com 508-291-3443 you may have to trim/grind the outside edge 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 that the engine cov...

  • Page 554

    545 www.Factoryfive.Com 508-291-3443 set the fuel tank covers in place. Roll bar padding front cross bar masking tape, headliner spray adhesive. Roll bar cover- front cross bar (ffr# 25773). The adhesive you should use needs be a high temperature, high strength adhesive designed for headliners. Do n...

  • Page 555

    546 www.Factoryfive.Com 508-291-3443 you may have to trim the small bit of material left on the round sections 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....

  • Page 556

    547 www.Factoryfive.Com 508-291-3443 wrap the cover around the roll bar starting with the top edge, then wrap the other end around the bar in a clockwise motion. The cut edge should be in an area that will be hidden once the body is on (near the top and towards the front). The two tabs will wrap aro...

  • Page 557

    548 www.Factoryfive.Com 508-291-3443 once you have determined that you can wrap the material around the roll bar without wrinkling the material, placing the exposed edge in a place that will be covered by the body and the material reaches all the way across, begin applying the adhesive to the foam t...

  • Page 558

    549 www.Factoryfive.Com 508-291-3443 side bars hacksaw, masking tape, headliner spray adhesive, knife/razor. Closed-cell roll bar padding (ffr# 25772), roll bar covers. Mask off any area that could get overspray on it, including the engine bay, wiring etc. When spraying the adhesive, work in small s...

  • Page 559

    550 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 fit..

  • Page 560

    551 www.Factoryfive.Com 508-291-3443 before gluing the cover material to the roll bar, test fit it so you can practice covering the roll bar without 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...

  • Page 561

    552 www.Factoryfive.Com 508-291-3443 continue wrapping 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 be covered by the body (facing up and towar...

  • Page 562

    553 www.Factoryfive.Com 508-291-3443 remember to work carefully! After spraying the adhesive and wrapping the material around the roll bar and overlapping it at the top of the roll bar, tape the cover in place with masking tape until the adhesive dries. When removing the tape, do not begin pulling t...

  • Page 563

    554 www.Factoryfive.Com 508-291-3443 tape over the section (along the edge of the material, not 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, marke...

  • Page 564

    555 www.Factoryfive.Com 508-291-3443 for the vinyl installation, work carefully and most importantly take your time! You do not want to have wrinkles in the vinyl, you don’t want to get any adhesive on the vinyl that will show, and you want to be sure that the vinyl is tightly adhered to the bends i...

  • Page 565

    556 www.Factoryfive.Com 508-291-3443 mark the inside edges according to the following picture. Again, leave about ¼ 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 at the upper bend line ...

  • Page 566

    557 www.Factoryfive.Com 508-291-3443 remove the aluminum panel from the vinyl. If you have been working on a surface that you don’t want overspray on, use a box or something similar that you can set the vinyl on and not be concerned with getting overspray on. Spray the vinyl with the super 77, cover...

  • Page 567

    558 www.Factoryfive.Com 508-291-3443 tilt the panel up, allowing it to 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 it, the vinyl will stick t...

  • Page 568

    559 www.Factoryfive.Com 508-291-3443 begin to wrap the vinyl around the aluminum, pressing first along the sides of the aluminum. Then press the vinyl over the back of the aluminum until each section of vinyl sticks to the panel with no wrinkles. Using the holes you already punched as a guide, punch...

  • Page 569

    560 www.Factoryfive.Com 508-291-3443 repeat for the passenger side. Rear wall masking tape, super 77 spray adhesive, marker, scissors, rivnut kit, rivnuts, ¼”, 25/64” drill bits, drill, razor knife/razor blade. Interior vinyl parts, aluminum panel – rear wall (ffr# 25194). For the vinyl installation...

  • Page 570

    561 www.Factoryfive.Com 508-291-3443 mark the sections to slice and the 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 marker on it (see photo). Trim t...

  • Page 571

    562 www.Factoryfive.Com 508-291-3443 to prevent the material from wrinkling as you wrap 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 are ready...

  • Page 572

    563 www.Factoryfive.Com 508-291-3443 if you don’t plan on painting the rear wall or you have already had it powder coated/anodized etc, before spraying the wall with the adhesive, you may want to wrap the vinyl around the wall to determine where the end of the vinyl will be, then mask off the alumin...

  • Page 573

    564 www.Factoryfive.Com 508-291-3443 work your way down the panel from the top, smoothing 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 outline o...

  • Page 574

    565 www.Factoryfive.Com 508-291-3443 spray the area with the adhesive. Cut the window 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 the vinyl for the ...

  • Page 575

    566 www.Factoryfive.Com 508-291-3443 cut out the holes for the lower rivnuts with a razor knife or razor blade. Install the rivnuts for the fuel tank covers and the engine cover. Tunnel – driver and passenger side masking tape, super 77 spray adhesive, marker, scissors. Interior vinyl parts. For the...

  • Page 576

    567 www.Factoryfive.Com 508-291-3443 remove the driver side tunnel vinyl and set in place on the tunnel. Make sure you have enough material to wrap around the 1” square steel dash upright and onto the floor (the carpet will overlap the excess vinyl). Once the vinyl is situated in the right manner, t...

  • Page 577

    568 www.Factoryfive.Com 508-291-3443 steel/aluminum and trace downward until the panel meets up with the lower portion of the footbox aluminum. Remove the vinyl and cut along the line you just made. Put the vinyl back on the tunnel, taping the top edges to hold the vinyl in position. When cutting th...

  • Page 578

    569 www.Factoryfive.Com 508-291-3443 cut around the ¾” steel tube coming from the 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 passes through. You ...

  • Page 579

    570 www.Factoryfive.Com 508-291-3443 mark and cut the location 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 also have to trim around the inboar...

  • Page 580

    571 www.Factoryfive.Com 508-291-3443 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 ¾” steel tube coming from the dash bulkhead going to the front of the footbox..

  • Page 581

    572 www.Factoryfive.Com 508-291-3443 tape off or conceal any wiring that could possibly get the spray adhesive on it. Lift up the bottom edge of the vinyl in the footbox. 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 ...

  • Page 582

    573 www.Factoryfive.Com 508-291-3443 remove the tape from the top edge of the footbox section and lower the vinyl down. Mask off any area that could get overspray on it. Before spraying, pay close attention to how the super 77 sprays so you don’t accidentally spray in the wrong direction onto the bl...

  • Page 583

    574 www.Factoryfive.Com 508-291-3443 remove the tape from the upper edge of the dash upright and from the back edge of the material. Pull the vinyl away from the tunnel wall. Spray the upper half of the recessed section of the tunnel wall and the corresponding section of the vinyl. Allow the adhesiv...

  • Page 584

    575 www.Factoryfive.Com 508-291-3443 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 the tunnel and apply the vinyl..

  • Page 585

    576 www.Factoryfive.Com 508-291-3443 mask off the top edge 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 1.5” square tube section at that dash/eng...

  • Page 586

    577 www.Factoryfive.Com 508-291-3443 remove the passenger side tunnel vinyl from the box and as with the driver side, fit the vinyl to the tunnel 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 ...

  • Page 587

    578 www.Factoryfive.Com 508-291-3443 cockpit side wall (upper) super 77 spray adhesive, scissors. Interior vinyl parts work carefully and most importantly take your time! You do not want to have wrinkles in the vinyl and you want to be sure that the vinyl adheres tightly to the bends in the aluminum...

  • Page 588

    579 www.Factoryfive.Com 508-291-3443 cockpit – door sill inside panel installation 1 / 8 ” drill bit, drill, marker, silicone, caulking gun. Aluminum panel – door sill, inside, driver and passenger sides. If you did not mark the location of the panel in relation to the frame and to the body when you...

  • Page 589

    580 www.Factoryfive.Com 508-291-3443 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 1.5” square steel dash upright tube..

  • Page 590

    581 www.Factoryfive.Com 508-291-3443 mark the locations for the rivets and drill 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 drilled in the ...

  • Page 591

    582 www.Factoryfive.Com 508-291-3443 carpet installation razor, scissors, low-tack tape, silicone, caulking gun. Carpet perform a trial 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...

  • Page 592

    583 www.Factoryfive.Com 508-291-3443 after trial fitting the carpet and making any necessary adjustments, spray the carpet and the aluminum 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 alrea...

  • Page 593

    584 www.Factoryfive.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. Footbox front wall.

  • Page 594

    585 www.Factoryfive.Com 508-291-3443 trial fit the carpet to be sure it fits snugly against the vinyl and the other sections of carpet on the outside wall. Make any necessary adjustments. Mask off the carpet you just applied and the vinyl if you haven’t done so already. Remove the accelerator pedal ...

  • Page 595

    586 www.Factoryfive.Com 508-291-3443 set 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 is tight in the corners (front edge shown)..

  • Page 596

    587 www.Factoryfive.Com 508-291-3443 trim the area around the inside seat belt bracket. If necessary, trim the carpet so that the back edge is about ¼” 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 ...

  • Page 597

    588 www.Factoryfive.Com 508-291-3443 mask off any area that could get overspray on it, especially the vinyl you applied to the tunnel wall. A box, some brown paper, or newspaper will work well. The super 77 is a “misting adhesive” which means that it does have a fair amount of overspray associated w...

  • Page 598

    589 www.Factoryfive.Com 508-291-3443 repeat for the other side. Cockpit rear window small flathead screwdriver, razor blade, weather strip closing tool. Interior rear window, gasket. Once the window is in place (before trying to lock the self-sealing gasket into place) it helps to spray the gasket w...

  • Page 599

    590 www.Factoryfive.Com 508-291-3443 trim the excess gasket material – be sure that the ends of the gasket will contact each other evenly 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 t...

  • Page 600

    591 www.Factoryfive.Com 508-291-3443 again, spray the gasket with some window cleaner or something similar and begin to lock the weather strip into place with the supplied weather strip closing tool (ffr# 25890). Below is a photo of what the gasket looks like when sealed (off the car). Use the probe...

  • Page 601

    592 www.Factoryfive.Com 508-291-3443 trim the excess vinyl around the window gasket..

  • Page 602

    593 www.Factoryfive.Com 508-291-3443 re-install the bulb seal you cut previously to the top edges of the rear wall. Install the rear wall using the supplied ¼”-20 x 1” button head screws (4 mm). Interior engine cover 4mm hex key, ¼”, 25 / 64 ” drill bits, drill, rivnut tool. Interior engine cover..

  • Page 603

    594 www.Factoryfive.Com 508-291-3443 set the engine cover in place, and fasten it to the rear wall with the supplied ¼”-20 bolts (4 mm hex). Before drilling, make sure 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 t...

  • Page 604

    595 www.Factoryfive.Com 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 rear wall and the frame..

  • Page 605

    596 www.Factoryfive.Com 508-291-3443 fuel tank cover installation 4mm hex key, 1 / 8 ” drill bit, drill. Aluminum panel- fuel tank cover (r, 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...

  • Page 606

    597 www.Factoryfive.Com 508-291-3443 drill and rivet the flanges of the inside panel to the tunnel aluminum. 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...

  • Page 607

    598 www.Factoryfive.Com 508-291-3443.

  • Page 608

    599 www.Factoryfive.Com 508-291-3443 undercarriage aluminum installation 1 / 8 ” drill bit, drill, marker, silicone, caulking gun, tape measure/ruler. Tunnel floor (ffr# 25185), undercarriage panel – front/center (ffr# 25187), engine floor (ffr# 25186), engine floor access panel (ffr# 25419), rear q...

  • Page 609

    600 www.Factoryfive.Com 508-291-3443 from the inside the tunnel, trace the outline of the 1.5” square tubes onto the panel with a marker. Remove the tape and the panel. Using the procedure described in the aluminum preparation section, drill the panel, apply a bead of silicone to the frame and re-ta...

  • Page 610

    601 www.Factoryfive.Com 508-291-3443 from inside the tunnel, trace the outline of the 1.5” square and ¾” square steel tubes. Remove the panel. Mark the rivet locations on the panel and drill them out. Apply a bead of silicone to the frame/front edge of the engine floor, then re-install the panel to ...

  • Page 611

    602 www.Factoryfive.Com 508-291-3443 rear quarter floor (r, l) tape the one of the rear quarter floor panels into place, lining it up with the 1.5” square tube that runs along side the engine, and the diagonal 1” square tube in front of the rear wheel. The front edge of the panel should be in the mi...

  • Page 612

    603 www.Factoryfive.Com 508-291-3443 fuel tank floor (r, l) place one of the fuel tank floor panels onto the frame. It should contact the front edge of the rear quarter floor and the side of the engine floor. Measure in about ¼” from each edge of the panel and mark the rivet locations. Remove the pa...

  • Page 613

    604 www.Factoryfive.Com 508-291-3443 set the panel in place on the frame so the front edge of the panel meets up with the front edge 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 pa...

  • Page 614

    605 www.Factoryfive.Com 508-291-3443 seat belts ¾” wrench, ¾” socket, ratchet, 19 mm wrench/socket. Seat belt hardware the corvette passenger side seat belt reels will be mounted on the driver side of the gtm, and the corvette driver side seat belt reels will be mounted on the gtm passenger side. Th...

  • Page 615

    606 www.Factoryfive.Com 508-291-3443 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 of the car (19mm wrench/socket)..

  • Page 616

    607 www.Factoryfive.Com 508-291-3443 seats masking tape, measuring tape/ruler, 3 / 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 t...

  • Page 617

    608 www.Factoryfive.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 as general comfort..

  • Page 618

    609 www.Factoryfive.Com 508-291-3443 if you find that your head is close to the rollcage and you could use a bit more room, look at the inside seat belt mount and where it touches the seat. Removing the corner of the seat will allow the seat to move in more. You will not feel anything when sitting i...

  • Page 619

    610 www.Factoryfive.Com 508-291-3443 measure in 2” from the flat pads on the front and 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 make sure th...

  • Page 620

    611 www.Factoryfive.Com 508-291-3443 once you have the locations marked on 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 while you drill you can us...

  • Page 621

    612 www.Factoryfive.Com 508-291-3443 remove the seat and drill out the four holes and install ¼”-20 rivnuts in the base. Drill the chassis holes out with a 5 / 16 ” drill and install the seat using ¼”-20 button head screws..

  • Page 622

    613 www.Factoryfive.Com 508-291-3443 dash wiring and gauge installation wire strippers, wire snips, electrical tape, ⅝”, 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...

  • Page 623

    614 www.Factoryfive.Com 508-291-3443 power window wiring locate the power window switches and wiring provided with the kit. Lay the window switches 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 ...

  • 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

    616 www.Factoryfive.Com 508-291-3443 run the two remaining power and ground wires back into the driver footbox 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 c...

  • Page 626

    617 www.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 masking tape..

  • Page 627

    618 www.Factoryfive.Com 508-291-3443 draw a line around the outside of the dash face ½” in from the edge. This area is used to attach the dash face to the dash pod. Arrange the rings on the dash face until you have a lay-out that you like. Leave 3 / 8 ” between gauges to account for the bezel thickn...

  • Page 628

    619 www.Factoryfive.Com 508-291-3443 wire the gauges up to the pre-labeled chassis harness. It will be easier to work on the car later if you run all 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 th...

  • Page 629

    620 www.Factoryfive.Com 508-291-3443 headliner headliner adhesive. Headliner. The headliner is now black. These instructions show the old headliner 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 ...

  • 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

    622 www.Factoryfive.Com 508-291-3443 body final installation 1 / 8 ” drill bit, drill, silicone, caulking gun, flathead screwdriver, 5 / 16 ” socket, ratchet, low-tack tape, phillips head screwdriver, wire strippers. Aluminum panel – firewall, fuel filler assembly, rubber push on trim, aluminum pane...

  • Page 632

    623 www.Factoryfive.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 free of powder coat..

  • Page 633

    624 www.Factoryfive.Com 508-291-3443 run the reverse light wire 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 switch and then runs to the two white secti...

  • Page 634

    625 www.Factoryfive.Com 508-291-3443 fog lights make two copies 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 the lights from the nose and remo...

  • Page 635

    626 www.Factoryfive.Com 508-291-3443 set the bracket on the template 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 a small hole and work your way up...

  • Page 636

    627 www.Factoryfive.Com 508-291-3443 use the rivnut tool to install ¼”-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

    629 www.Factoryfive.Com 508-291-3443 on the nose, drill a ¼” hole in the center of the light template for the fog light wires to go through. Drill the two mounting holes using a ¼” drill bit. Remove the remains of the template and push the wires through the center hole. Mount the fog light using ¼” ...

  • Page 639

    630 www.Factoryfive.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 the headlight..

  • Page 640

    631 www.Factoryfive.Com 508-291-3443 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 headlight until the clips snap into place..

  • Page 641

    632 www.Factoryfive.Com 508-291-3443 repeat for the other three headlights. Cut 6 twenty inch long section from the black ground wire provided with the kit. Crimp a small loop connector from the chassis harness and a small spade connector from the kit on either end of each wire. Use these wires to g...

  • 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

    634 www.Factoryfive.Com 508-291-3443 set the firewall in place as you did during the trial fit of the body. Drill and rivet through the 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 ...

  • 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

    638 www.Factoryfive.Com 508-291-3443 2003-2004 fuel tanks you will have to trim the large end off of the supplied filler necks in order to fasten them to the filler caps. Draw a line at the beginning of the point where the hose transitions from 2.25” diameter to 3” diameter. Cut the large diameter e...

  • Page 648

    639 www.Factoryfive.Com 508-291-3443 install the 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 the hose could rub on, possibly cutting the hose..

  • Page 649

    640 www.Factoryfive.Com 508-291-3443 windshield wipers and washer fluid tank 3 / 16 ”, ¼” drill bits, drill, marker, rivet gun, 4mm hex key. Windshield wiper hardware (ffr# 25529). The windshield washer fluid tank (ffr# 25392) mounts to the chassis under the steering shaft. Trial fit it into positio...

  • Page 650

    641 www.Factoryfive.Com 508-291-3443 the mounting bracket for the top mount is 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 the bracket at t...

  • Page 651

    642 www.Factoryfive.Com 508-291-3443 remove the bracket and drill a ¼” 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 the bracket in place..

  • Page 652

    643 www.Factoryfive.Com 508-291-3443 bolt the tank into position using the two ¼”-20 button head screws and nuts provided..

  • Page 653

    644 www.Factoryfive.Com 508-291-3443 place the wiper motor mount plate (ffr# 25391) along the edge of the ¾” shock tower 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....

  • Page 654

    645 www.Factoryfive.Com 508-291-3443 grind down both sides of the knob at the end of the wiper motor arm until it’s flush with the arm. Drill out the remaining material, starting with a small drill bit, and work your way up to a 3/8” bit – this hole will be used for the linkage rod end. Install one ...

  • Page 655

    646 www.Factoryfive.Com 508-291-3443 using the three corvette 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 into position using the supplied ¼”-20...

  • Page 656

    647 www.Factoryfive.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 in place (see photo)..

  • Page 657

    648 www.Factoryfive.Com 508-291-3443 screw the supplied section of threaded rod (ffr# 25723) into the rod end on the wiper motor. Slide the aluminum tube (ffr# 25934) over the threaded rod and measure how much of the aluminum tube will need to be trimmed once the rod end is screwed on. Trim the tubi...

  • Page 658

    649 www.Factoryfive.Com 508-291-3443 install the wiper wheel box onto the body using the supplied ¼-20 hardware. Install the rod end on the wiper wheel box arm with the supplied jam nut (ffr# 25725) (½”, 9 / 16 ” wrenches)..

  • Page 659

    650 www.Factoryfive.Com 508-291-3443 install the wiper blade (ffr# 25629) onto the wiper arm (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 th...

  • Page 660

    651 www.Factoryfive.Com 508-291-3443 route the hose through the recess in the tank, up to the top of the tank. Drill 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...

  • Page 661

    652 www.Factoryfive.Com 508-291-3443 clip the nozzle onto the wiper blade. 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. Make any necessary adjust...

  • Page 662

    653 www.Factoryfive.Com 508-291-3443 door handles/ liners hacksaw, marker, 1 / 8 ”, ¼”, 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 to be ...

  • Page 663

    654 www.Factoryfive.Com 508-291-3443 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 the door liner to allow this..

  • Page 664

    655 www.Factoryfive.Com 508-291-3443 insert the screw from the inside 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 with a line next to each moun...

  • Page 665

    656 www.Factoryfive.Com 508-291-3443 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 from the front may be helpful).

  • Page 666

    657 www.Factoryfive.Com 508-291-3443 drill the holes with a ¼” drill bit..

  • Page 667

    658 www.Factoryfive.Com 508-291-3443 bolt the exterior door handles into position on the doors using 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 o...

  • Page 668

    659 www.Factoryfive.Com 508-291-3443 measure 3” from the bend in the threaded linkage piece and cut with a hack saw. On the remaining threaded piece measure in ½” and 1” from the non-threaded end and mark. Bend the rod in a vice at the 1” mark in the same direction as the kink until it is perpendicu...

  • Page 669

    660 www.Factoryfive.Com 508-291-3443 bend the rod at the ½” 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 hole on the door latch from the outside..

  • Page 670

    661 www.Factoryfive.Com 508-291-3443 line 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 ¼” drill. You can use more of the screws on the bottom as they will be hidden by the armrest..

  • Page 671

    662 www.Factoryfive.Com 508-291-3443 drill the holes on the door with a larger 25 / 64 ” bit and install ¼”-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 the two pieces with the u-shaped bend at...

  • Page 672

    663 www.Factoryfive.Com 508-291-3443 hook the u-bend end into the 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 correct length and functioning pro...

  • Page 673

    664 www.Factoryfive.Com 508-291-3443 rear splash guards eye protection, drill w/#6 hex nut driver, ⅛”, 3 / 16 ” drill bits, drill, rivet gun, silicone, caulking gun, #6 self tapping screws. Rear splash guard assembly (ffr# 25688). The process for installing the rear splash guards is the same for bot...

  • 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

    668 www.Factoryfive.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 the center splash..

  • Page 678

    669 www.Factoryfive.Com 508-291-3443 drill and rivet the bottom of this panel through the body using 5 / 16 ” rivets. Exhaust/ rear mesh 5 / 16 ” hex, ½”, 9 / 16 ” wrenches, tape measure, 3½” hole saw or jigsaw, shears/tin snips, pliers, silicone, caulking gun. Exhaust – h pipe assembly, exhaust mou...

  • 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

    671 www.Factoryfive.Com 508-291-3443 loosely assemble the h-pipe hangers with the supplied hardware. Bolt the hanger to the tab welded to the h-pipe (½” wrench). Remove one of the transmission housing nuts and put the lower end of the h-pipe hanger on the stud. Tighten the hanger in place..

  • Page 681

    672 www.Factoryfive.Com 508-291-3443 with the lower joint slightly loose on the catalytic 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 outside flange ...

  • Page 682

    673 www.Factoryfive.Com 508-291-3443 transfer this measurement to the tailpipe mesh pieces and mark the center for a hole. Drill or cut with a jig saw a 3½” hole in the center of the mesh. Using tin snips or shears cut ½” slice around the outside perimeter of the holes about ½” apart..

  • 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

    676 www.Factoryfive.Com 508-291-3443 license plate lights 3 / 16 ”, 5 / 16 ” drill bits, drill, rivet gun, ½” wrench, 3 / 16 ” hex key, wire 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 ...

  • Page 686

    677 www.Factoryfive.Com 508-291-3443 tighten the light down using a ½” wrench and a 3 / 16 ” hex key. Solder the red wire into the positive wire for the tail light circuit. Solder the black wire into the ground circuit. Cover any soldered joint with heat shrink, or electrical tape and repeat for the...

  • Page 687

    678 www.Factoryfive.Com 508-291-3443 dash 3 / 16 ”, ¼”, 25 / 64 ” drill bits, drill, silicone, caulking 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 compo...

  • Page 688

    679 www.Factoryfive.Com 508-291-3443 insert 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 small tabs in the dash cutout (see photos)..

  • Page 689

    680 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 properly..

  • Page 690

    681 www.Factoryfive.Com 508-291-3443 repeat 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 up on the shifter handle. Dash on body lip.

  • Page 691

    682 www.Factoryfive.Com 508-291-3443 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 at the shifter location marked..

  • Page 692

    683 www.Factoryfive.Com 508-291-3443 reinstall the console in the car so that it sits 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 clearance of the...

  • Page 693

    684 www.Factoryfive.Com 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 ⅛”- ¼” clearance around the handle. Keep in mind, when you shift hard, the handle will go just a bit further..

  • Page 694

    685 www.Factoryfive.Com 508-291-3443 remove the console again! Cut the cover material on the line you marked so that it will not get messed up by a saw blade. Use a jig saw or similar to trim the area marked. Re install the console and recheck the handle for clearance. Trim again if necessary. The c...

  • Page 695

    686 www.Factoryfive.Com 508-291-3443 attach the center console to the frame. Dash pods with the center console 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 ...

  • Page 696

    687 www.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 the flange..

  • Page 697

    688 www.Factoryfive.Com 508-291-3443 unclamp and remove the left dash pod only. With the right dash pod still clamped, carefully remove 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...

  • Page 698

    689 www.Factoryfive.Com 508-291-3443.

  • Page 699

    690 www.Factoryfive.Com 508-291-3443 place the dash face in the driver 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 previously using a 25 / 64 ” drill bi...

  • Page 700

    691 www.Factoryfive.Com 508-291-3443 drill out the mounting holes on the left dash pod using a ¼” 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 center section sitting down on the frame tubes..

  • Page 701

    692 www.Factoryfive.Com 508-291-3443 install the left dash pod using the ¼”-20 x ¾” flange head screws. Attach the bottom of the right dash pod to the 1.50” square tube using 3 / 16 ” rivets..

  • Page 702

    693 www.Factoryfive.Com 508-291-3443 gauge panel apply some masking tape to the edges of the gauge panel and drill four 3 / 16 ” holes in the gauge panel, 2 at the top of the dash face and 1 on either side of the dash face near the bottom just before the panel begins to wrap under the dash. After yo...

  • Page 703

    694 www.Factoryfive.Com 508-291-3443 reconnect the plugs you used for 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 flange. Bolt the face to the f...

  • Page 704

    695 www.Factoryfive.Com 508-291-3443 fog light switch ¾” hole saw, round file dash and components decide where you would like to locate the switches. Drill ¾” 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 center conso...

  • Page 705

    696 www.Factoryfive.Com 508-291-3443 hazard switch ¾” hole saw, round file dash and components decide where you would like to locate the switches. Drill ¾” 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 center console....

  • Page 706

    697 www.Factoryfive.Com 508-291-3443 column cover installation install the top column cover. 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 in place...

  • Page 707

    698 www.Factoryfive.Com 508-291-3443 emergency brake cover plate ⅛” drill bit, drill, marker, rivet gun aluminum panel – emergency brake cover plate. Drill an ⅛” hole in each corner of the aluminum panel..

  • Page 708

    699 www.Factoryfive.Com 508-291-3443 slide the panel over the 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 locations on the tunnel panel and riv...

  • Page 709

    700 www.Factoryfive.Com 508-291-3443 front upper wheel well and pedal box cover aluminum ⅛” 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 the box. The driver...

  • Page 710

    701 www.Factoryfive.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 of the panel..

  • Page 711

    702 www.Factoryfive.Com 508-291-3443 apply a bead of silicone to the top of the outside footbox 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 the...

  • 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

    704 www.Factoryfive.Com 508-291-3443 drill the panel according to the marks you made, apply silicone to the frame/mounted aluminum, and rivet the panel in place. Front wheel well rear splash guard aluminum eye protection, drill w/#6 hex nut driver, ⅛” drill bits, drill, rivet gun, silicone, caulking...

  • 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

    706 www.Factoryfive.Com 508-291-3443 fit 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 tapping screws. Drill and rivet into place..

  • Page 716

    707 www.Factoryfive.Com 508-291-3443 body close-out panels ⅛” 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 the outside edge of the aluminum panel..

  • Page 717

    708 www.Factoryfive.Com 508-291-3443 place the panel on the frame, making sure that the rubber seal has good contact with the body and rivet it to the 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. Repe...

  • 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

    710 www.Factoryfive.Com 508-291-3443 set the panel in place, making sure the bulb seal has good contact 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

    711 www.Factoryfive.Com 508-291-3443 set the carpet in place. Make sure that it doesn’t protrude past the edge of the body. Make any adjustments needed to make sure all of the seams fit tightly and there is no overlap between the carpet on the floor and the door sill carpet. Check the fit around the...

  • Page 721

    712 www.Factoryfive.Com 508-291-3443 apply the carpet. Reinstall the seat belts. Repeat for the passenger side. Aluminum door sill covers ⅛” drill bit, drill, silicone, caulking gun. Aluminum panel – door sill cover (l, r). Set the driver side door sill in place so that the flange is on the inside o...

  • Page 722

    713 www.Factoryfive.Com 508-291-3443 cockpit upper side walls and rear hatch 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. Reins...

  • Page 723

    714 www.Factoryfive.Com 508-291-3443 set the passenger side wall in place and drill pilot holes in the lower section of 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 wa...

  • Page 724

    715 www.Factoryfive.Com 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 through the hole first..

  • 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

    717 www.Factoryfive.Com 508-291-3443 rear hatch release cable 5 / 32 ” hex, 3 / 32 ” drill bit, drill, phillips screwdriver, regular screwdriver. Rear hatch cable, insulated line clips. Route the cable along the frame, using the supplied ¼” insulated clips to hold it in place. Insert the cable throu...

  • Page 727

    718 www.Factoryfive.Com 508-291-3443 drill a 5 / 16 ” hole in the upper wheel wells that will allow you to route the cable under the master cylinders on the driver side and under the ¾” square steel tube welded to the top of the shock tower that creates the top of the footbox (shown without upper wh...

  • Page 728

    719 www.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 ¼” insulated line clips..

  • Page 729

    720 www.Factoryfive.Com 508-291-3443 mount the corvette handle to the supplied bracket and mount the bracket/release handle somewhere you can reach it easily. A good spot is near the outside of the footbox wall next to the fuse panel. Windshield, rear hatch and side window glass windshield (ffr# 250...

  • Page 730

    721 www.Factoryfive.Com 508-291-3443 finishing touches headlight alignment masking tape, marker, tape measure make sure that the car is at the correct ride height before the alignment procedure is done. Ride height should be 4½” at the front and 4½” at the back measured to the bottom of the 4” round...

  • Page 731

    722 www.Factoryfive.Com 508-291-3443 on a piece of masking tape, draw one horizontal line on the wall at a height exactly 2 inches lower than measurement a. On the line, make vertical marks both to the right and left of the vehicle centerline mark at the distance of measurement b from the vehicle ce...

  • Page 732

    723 www.Factoryfive.Com 508-291-3443 alignment specifications take your new 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 alignment. Toe in (inche...

  • Page 733

    724 www.Factoryfive.Com 508-291-3443 appendix a - torque specifications suspension bolts location ft-lb front lower control arm cam bolt 125 front upper control arm bolts 48 front coil over to frame mount (upper/lower) 75 rear lower control arm front bolt 107 rear lower control arm rear bolt 71 rear...

  • Page 734

    725 www.Factoryfive.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) ⅜” 16 ft-lb (192 in-lb).

  • Page 735

    726 www.Factoryfive.Com 508-291-3443 appendix b – donor specs by year gen. Iii horsepower/torque by model year model year engine/application 1997 1998 1999 2000 2001 * 2002 2003 2004 ls1 5.7 corvette 345/350 345/350 345/350 345/350 350/360 a 350/375 m 350/360 a 350/375 m 350/360 a 350/375 m 350/360 ...

  • Page 736

    727 www.Factoryfive.Com 508-291-3443 appendix c – donor parts required front suspension 1 each lh front lower control arm (rubber bushings installed and ball-joints pressed in) 10326693-lh 1 each rh front lower control arm (rubber bushings installed and ball-joints pressed in) 10326694-rh 1 each lh ...

  • Page 737

    728 www.Factoryfive.Com 508-291-3443 1.0mm)('01-'04) 4 each 4 crush washers 21012386 1 pair front brake pads 12530681 10 each lug-nuts for front suspension (m12 x 1.5mm)(stainless steel capped) 9595165 rear suspension 1 each lh rear lower control arms (rubber bushings installed and ball-joints press...

  • Page 738

    729 www.Factoryfive.Com 508-291-3443 4 each 4 crush washers 21012386 1 pair rear brake pads 12530688 10 each lug-nuts for rear suspension (m12 x 1.5mm)stainless steel capped) 9595165 2 each outer cv-joints 12532153 2 each locknuts for outer cv-joints (m27 x 2mm) 10257766 2 each rear toe link, 784442...

  • Page 739

    730 www.Factoryfive.Com 508-291-3443 1 each fuel sender feed hose rear ('97-'98) 10404931 1 each fuel feed hose rear w/check valve ('97-'98) 10413424 1 each fuel return hose rear ('97-'98) 10404927 1 each fuel feed hose rear w/check valve ('99-'02) ('03 first design) 10448899 1 each fuel press. Reg....

  • Page 740

    731 www.Factoryfive.Com 508-291-3443 2 each long 4 wire oxygen sensors 25312202 1 each vehicle speed sensor (vss) with mounting bracket 12369458 1 each vss connector w/leads (black) ('97-'04) 88987993 1 each vss connector w/leads (gray) ('01-'04) 15306302 1 each engine harness 12189523 1 each brown ...

  • Page 741

    732 www.Factoryfive.Com 508-291-3443 1 each lh power window mechanism w/motor 10344131-lh 1 each rh power window mechanism w/motor 10344132-rh 2 each window motor connector w/leads 15305982 1 each lh seat belt 88893517-lh 1 each rh seat belt 88893521-rh 2 each seat belt upper bolt plastic covers 102...

  • Page 742

    733 www.Factoryfive.Com 508-291-3443 appendix d – heat & a/c installation gtm a/c evaporator kit heater & a/c evaporator kit ratchet, 7 / 16 ” socket, hose crimping tool (some parts stores can do this for you), wire cutters, wire crimpers, philips head screwdriver, 3 / 16 ”, 1 / 8 ”, 5 / 8 ” drill b...

  • Page 743

    734 www.Factoryfive.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 towards the top..

  • Page 744

    735 www.Factoryfive.Com 508-291-3443 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 evaporator toward the center of the car..

  • 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

    737 www.Factoryfive.Com 508-291-3443 once in place, the plenums at the back of the unit should be between the dash bulkhead “x” and the 1.5” dash bulkhead upright tube. If you need clearance fitting the evaporator unit into the chassis due to the routing of your coolant lines/tubes you can mount the...

  • Page 747

    738 www.Factoryfive.Com 508-291-3443 unscrew the blower motor extension from the blower motor (phillips screwdriver). If necessary, lift up the evaporator so that the lower screw fastening the blower motor extension to it is on the inside of the ¾” diagonal. Make sure that the angled edge of the ext...

  • Page 748

    739 www.Factoryfive.Com 508-291-3443 move the evaporator out of the way and drill two holes with a 25/64” drill bit and install two ¼” riv-nuts. Move the evaporator unit back into place and bolt it in place using the supplied ¼”-20 bolts ( 7 / 16 ” socket). Bolt the ffr supplied bracket to the back ...

  • 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

    741 www.Factoryfive.Com 508-291-3443 screw the blower motor onto the extension using the 6 supplied screws. Install the supplied drain hose onto 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 exi...

  • Page 751

    742 www.Factoryfive.Com 508-291-3443 trim the footbox center roof panel (ffr# 25181) to allow space for the dash vent and defroster duct hoses. Leave enough of the panel intact to cover the top of the footbox on the outside of the body and under the wiper enclosure. Routing the hoses with footbox ro...

  • Page 752

    743 www.Factoryfive.Com 508-291-3443 setting the dash in place temporarily as you route each hose will help to allow for the 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 fro...

  • Page 753

    744 www.Factoryfive.Com 508-291-3443 cut a small section of the 2.5” hose (about 4”) and fasten one end to the supplied hose adapter. Install the other end to the top plenum on the back of the evaporator unit (use a zip tie to hold each end in place) and route the hose to the bottom of the driver si...

  • Page 754

    745 www.Factoryfive.Com 508-291-3443 to locate the opening in the dash for the defroster ducts, using the duct opening as a template, place the duct on the underside of the dash such that the center of the opening is approximately in line with the side flange of the dash. Make sure you account for t...

  • Page 755

    746 www.Factoryfive.Com 508-291-3443 gtm a/c hose heater & a/c hose kit rivnut tool, wire cutters, wire crimpers, 4 mm hex key, 25 / 64 ” drill bit, drill, 134a charge and oil kit installation instructions refer to the manufacturers directions (see appendices e, f) on routing the hoses for the a/c s...

  • Page 756

    747 www.Factoryfive.Com 508-291-3443 locate the corvette accumulator on the chassis according to the picture below. Make sure that the line supplied by vintage air for the outside, larger line coming from the upper portion of the evaporator unit (see hose routing diagram) will reach the accumulator ...

  • Page 757

    748 www.Factoryfive.Com 508-291-3443 install the line connecting the lower port on the condenser and the evaporator port per the vintage 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 com...

  • Page 758

    749 www.Factoryfive.Com 508-291-3443 install the heater control valve in the 5 / 8 ” heater hose between the section you just installed onto the heater inlet elbow on the evaporator and the coolant reservoir. Follow the supplied diagrams for instructions on how to wire the control valve. Install the...

  • Page 759

    750 www.Factoryfive.Com 508-291-3443 route the compressor lines through the tunnel and connect them 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 ...

  • 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

    752 www.Factoryfive.Com 508-291-3443 next locate the “ac request signal wire” that the oem hvac used to tell the pcm to enable ac. This signal wire runs through connector c150 (the same connector used for obdii signal and vss signals), and is dark green and white. If you are using a stand alone syst...

  • Page 762

    753 www.Factoryfive.Com 508-291-3443 supply power to the a/c request signal wire by connecting the blue 12v source wire from the vintage air unit to the a/c signal wire (the vintage air power wire is blue). You will need to keep the oem compressor control wiring which are two wires. One is dark gree...

  • 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.