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If using a 4.6L engine or donor parts newer than 1995 call and ask for the 4.6L Assembly Manual
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 in. The kit is
packaged in the order that you will be using the parts.
After everything is safely in your garage, take the time to open each box and do a physical inventory of
all the parts. It is a good idea to work one box at a time and replace all the contents before going on to the
next box.
ATTENTION: Mark all aluminum panels with a marker for easier installation. Acetone will remove
even permanent markers as well as any ink that is on the aluminum.
TOOLS: ½",
/
", ⅝" sockets, "vise-grip" pliers or slip joint pliers, hex key set, ½", ⅝" wrenches,
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marker, 2"x 4"x 34.25" brace, 2"x 4"x 24" (for body support), duct tape, #8 hex driver.
1. Four strong people can lift and move the body/frame assembly into the work area. Lift by the quick
jacks in the back and the radiator/nose hole and wheel wells in the front.
2. Remove the doors by either unbolting them from the hinges with a
from the frame.
3. The body is shipped bolted to the frame in six places. The inner side of the front nose (use a hex
wrench and ½" socket), one bolt on each side (use a hex wrench and ½" wrench), and the rear quick
jack bumpers (⅝" wrench and socket).
4. The best way to remove the body is with four people, one per wheel well. Each person should watch
to not stress the narrow body section under the door area. If you only have two people you can
remove the body like we do here with one person at each end lifting in the nose and under the back.
Remove the body by lifting the rear end up over the trunk aluminum first and then sliding the nose
slightly forward past the quick jack supports, then up and away. Notice the dash hoop support to
clear is tapered so as you go up it gets wider. Removing the body should be done very carefully.
Unpacking Your Replica Kit
Removal of Body & Aluminum
When lifting the composite body shell use a cockpit brace as shown
www.factoryfive.com
39
508-291-3443
/
" socket or unbolting the hinge
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.
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