Problem:

One of the major design changes in the above models in early Fall 2004 included a grille and baffle type and size modification. When one of the above models is installed, the clearance between the baffle and the grille does not allow the grille to be installed easily. This lack of clearance is due to the grille being slightly oversized to prevent slippage from the baffle in high volume situations.

Solution:

Cut one notch at least 1/16" (1.5 mm) wide into the side of the grille (see images below) with a pair of metal shears or cutters. This will allow the grille material around the edge of the grille to 'give' slightly, therefore allowing the grille to be installed much easier. (click for larger image) (click for larger image) (click for larger image)