Ferrari 355 Challenge Grill Installation

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1 Ferrari 355 Challenge Grill Installation By: Dave Lelonek (Dave Rocks) August 12, 2014 Created based on model year 1998 (355 F1 GTS), other model years may apply. Disclaimer: This document was created to assist others and has been created based on the procedure I use and have proven successful. Others may use different procedures or variations to this method. Use at your own risk. This document is not copyright protected, please feel free to use and share with others. If you would like to add to or comment on this document, please me at: dave.lelonek@stickyrxrs.com Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 1 of 23 Dave Lelonek

2 1.0 Materials Needed: Challenge Grill P/N: OEM grill can be purchased thru Sticky RX Refinishing Solutions Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 2 of 23 Dave Lelonek

3 Blind Rivets (pop): Quantity 2 P/N: These are aluminum pop rivets and can be found at many supply houses. I purchased mine thru McMaster Carr: 1/8" Diameter,.063"-.125" Material Thickness Range, Domed Aluminum with Steel Mandrel. Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 3 of 23 Dave Lelonek

4 Blue Painter's Tape: Double Sided Tape: Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 4 of 23 Dave Lelonek

5 2.0 Tools Required: Drill Motor 1/8" (.125") Drill bit Phillips head screw driver 1/4" Drive ratchet with extensions 1/4" Drive sockets: 7mm, 8mm (standard and deep well), 10mm Rivet installation tool Wire cutters Mallet / hammer M5 x.8 thread die (see section 4.0) Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 5 of 23 Dave Lelonek

6 4.0 Inspect New Challenge Grill: My new OEM Challenge grill arrived with two of the threaded studs covered in paint. It would have been time consuming to ship this back and wait for a replacement. I was lucky to have a M5 x.8 thread die in my shop to chase the threads and clean off the paint: Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 6 of 23 Dave Lelonek

7 5.0 Turn Off Battery Switch: While this is not totally required, I prefer to turn off the battery when working on the car, especially if I will be doing anything with electrical connections. This is a preventative measure. Turn off battery switch inside access panel under front bonnet: Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 7 of 23 Dave Lelonek

8 6.0 Preparation: Using Blue Painter's tape, mask off the boarders of the existing rear panel (bumper, quarter panels, etc) as shown: This is very cheap insurance to not scratch the pain when removing old grill and installing new. Other masking tape can work but painter's tape won't leave a heavy residue and will reduce any risk of peeling paint. Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 8 of 23 Dave Lelonek

9 7.0 Remove Existing Rivets and Trim Piece: Using a drill motor and 1/8" drill bit, carefully drill our the center of the two rivets (#37) that hold on the trim piece P/N: (number 31) Trim Rivet Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 9 of 23 Dave Lelonek

need to be drilled to free the connection:

10 Position drill on rivet center and run slow and gentle - do not push drill hard: Only the very top (dome) of rivet will need to be drilled to free the connection: Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 10 of 23 Dave Lelonek

11 Rivet Removed: Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 11 of 23 Dave Lelonek

12 8.0 Remove Center Taillight Panel: Using a Phillips screw driver, remove (4) screws that hold center tail light panel, P/N: (#28) Phillips Head Screws Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 12 of 23 Dave Lelonek

13 Remove panel and unplug center taillight electrical connector, push tab on right side to unplug: Tab After removal, tape the wire and connector out of the way. Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 13 of 23 Dave Lelonek

14 9.0 Remove Existing Grill: The grill is attached with (9) nuts. The grill has (7) threaded studs and (2) holes. The inner panel has (2) threaded studs to meet with the holes in the grill. See below: (green circles are for the holes and red circles for the studs) Using a 1/4" drive ratchet, extension and 8mm socket, remove (2) nuts at the top of the panel from the exterior of the grill: Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 14 of 23 Dave Lelonek

15 Using a 1/4" drive ratchet, 8mm socket, remove (7) nuts from the interior of the grill: All but the (2) outer most corner are very easy to access. Note: These nuts also have washers behind them. Center Left (right not shown) Left Upper Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 15 of 23 Dave Lelonek

16 With care, Remove the grill: Prior to installing new grill, clean inner panel area. Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 16 of 23 Dave Lelonek

17 10.0 Remove The Cavallino (Prancing Horse): Using a 1/4" drive ratchet and 7mm socket, remove (2) nuts from the inner side of the existing grill that fasten the Cavallino. Install the Cavallino on the new Challenge Grill: Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 17 of 23 Dave Lelonek

18 11.0 Remove Existing Rubber End Gaskets and Apply to New Grill: Remove the rubber end gaskets P/N: & (#26) from the existing grill: Apply double sided tape to one side of the gaskets and use a razor blade to cut profile: Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 18 of 23 Dave Lelonek

19 Install gaskets to Challenge Grill: Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 19 of 23 Dave Lelonek

corners since the holes in the body are too large for the factory (existing)

20 12.0 Fit Challenge Grill to Car: Carefully fit Challenge Grill to car and install nuts: Note: I needed to use larger washers in the (2) lower most corners since the holes in the body are too large for the factory (existing) washers. Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 20 of 23 Dave Lelonek

21 Note: If needed, use a 1/4" drive ratchet and 10mm socket to loosen taillights to fit the grill better. Re tighten after achieving proper fit. Upper tail light nut (lower not shown) 13.0 Re-Install Center Taillight Panel: Plug in electrical connector and fasten (4) Phillips head screws (opposite of removal) Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 21 of 23 Dave Lelonek

22 14.0 Re-Install Trim Piece: Using (2) rivets, re-install the upper trim piece. Slide trim piece on and align holes for rivets. Insert rivet into hole, hold tool firmly against rivet and squeeze handle to compress rivet and snap off mandrel. If a tab is left after snapping rivet mandrel, use wire cutters to remove: Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 22 of 23 Dave Lelonek

23 It's a good idea to remove the rivet mandrel by using a punch or the broken off shank of the mandrel and a hammer / mallet to tap out the mandrel remains thru the center of the rivet Remove Painter's Tape, Clean up and Turn On Battery Switch: Start to finish this project took just shy of 4 hours since I made 2 trips to my shop to get tools and supplies. This job can comfortably be done is 2.5 hours if you have all that is needed from the start. Ferrari_1998_355_Challenge-Grill_Installation_REV001.doc Page 23 of 23 Dave Lelonek

Ferrari 355 Oil Change Procedure

Ferrari 355 Oil Change Procedure By: Dave Lelonek (Dave Rocks) on Ferrarichat.com July 21, 2014 Created based on model year 1998 (355 F1 GTS), other model years may apply. Disclaimer: This document was