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• 1955 Chevrolet Vehicles
• 1956 Chevrolet Vehicles
• 1957 Chevrolet Vehicles

SECTION 1

BODY

CONTENTS OF THIS SECTION

The 1955 Chevrolet body has been completely redesigned to give greater strength and rigidity to the body. Fabrication and manufacturing processes have undergone radical changes to insure body shell alignment and dimensional control.

The cowl and dash now includes a shroud-length panel forming an enclosure, called a plenum chamber, which is utilized for the cowl intake ventilation system. In addition, this panel gives double wall strength to the cowl upper and side panels. The framework for the plenum chamber and the windshield pillars is formed by a heavy gauge one piece pillar facing. This facing wraps around the door opening section of the windshield and hinge pillar. A flared section at the upper and lower pillar joint is reinforced by a heavy gauge angle brace from the plenum chamber.

The column framed by the cowl side panels and the pillar facing is solidly supported by a heavy gauge reinforcement welded to base of the pillar and floor. Another heavy gauge brace is welded under the floor between the frame side members. Outrigger brackets, formed from "U" channels, are attached to the base of this box structure to form a body frame cross member eliminating the need for chassis frame second cross member.

The rear quarter inner panel from the door opening to the deck lid opening, including the deep drawn wheelhouse, is of one piece construction. The inner wall of the panel is ribbed at the rear and welded to the outer panel at the rear compartment opening. There is no welding seam at the formed wheel opening and by bringing the side walls of the rear end in line with the frame, resistance has been added to stresses on the body shell.

The gravel shield is integral with the lower end panel and the package shelf is integral with the upper end panel to provide additional resistance to torsional stress. Torque rod hinges which give full-travel counter balancing of the rear compartment lid, rotary door locks and rubber cushioned body mountings are a few of the many design changes in the 1955 Chevrolet body.

Body Lubrication

Movable parts of the body are lubricated at the factory insuring proper operation. Those body parts which have frequent use, such as door locks etc., should be lubricated twice a year. Other body parts should be lubricated when access is available.

The following parts should be lubricated twice a year.

Wipe off all lubrication points before applying new lubricant. Remove all excess lubricant to prevent staining of trim parts.

Lubrication Points                                Lubricant

Instrument Compartment Door Hinge                 Dripless Oil
Front Door Hold Open Clips                        Lubriplate or Equivalent
Door Jamb Light Switch                            Lubriplate or Equivalent
Door Lock Bolt Housing                            Stick Type Lubricant
Door Lock Striker Teeth                           Stick Type Lubricant
Rear Door Hinge and Hold Open                     Lubriplate or Equivalent
Deck Lid Hinge and Torque Rod Ends                Lubriplate or Equivalent
Deck Lid Lock Bolt                                Lubriplate or Equivalent
Gas Filler Door Hinge                             Dripless Oil
Folding Top Linkage Bearing Points                No. 10 Engine Oil
Side Roof Rail Mechanical Sealing Strip Gasket    Silicone Emulsion
Parts to be lubricated when access to parts can
be obtained.
Windshield Wiper Motor and Transmission Spools    Lubriplate or equivalent
Door Lock Parts                                   Lubriplate or equivalent
Window Regulator Rack and Cam Channels            Lubriplate or equivalent

Front End Assembly

Windshield Wiper Assembly

The windshield wiper assembly consists of a motor, auxiliary drive and two transmissions. The standard motor is vacuum operated and the optional motor is electrically powered. Both motors are interchangeable. The transmission incorporates spring loaded pulleys which provide for adjustment of the wiper cable tension. The wiper motor auxiliary drive incorporates two drums to which transmission drive cables are attached. The wiper motor and auxiliary drive assembly is installed to engine side of the dash panel. The motor and auxiliary assembly may be removed as a unit or the motor may be removed separately.

Transmission Cable Adjustment

The windshield wiper transmission drive cables are tensioned by spring loaded pulleys. The end of the transmission shaft is pushed in to unlock the pulleys. To tension cables push in on transmission shaft end if blade has been removed or on the base of the wiper arm if the blade is installed (fig. 1).

To release cable tension for removal of components push in on transmission shaft end and have helper on the inside, pull on cables to obtain desired slack then release pressure on transmission shaft. NOTE: Wiper blade snap or over-travel is indicative of loose transmission drive cables.

Windshield Wiper Motor

Removal and Installation

1. Loosen screw indicated at "A" and remove control cable (fig. 2).
2. On vacuum operated motors disconnect vacuum line at "B". On electric wiper motors disconnect feed wire under the instrument panel.
3. Remove screws "C" and remove motor. NOTE: Ground wire is attached under one of the attaching screws on electric motor installations.
4. To install, reverse this procedure.

Windshield Wiper Motor and Auxiliary Drive Removal

1. Remove instrument panel compartment box and heater defroster duct.
2. Adjust drive cables to slack position and remove. NOTE: Inspect attachment of transmission cables to each drum and note the right cable cross for installation purpose. On electric wiper motor installations, disconnect feed wire under instrument panel.
3. At the front of the dash, remove control cable at "A", vacuum line at "B" and electric motor ground wire where necessary (fig. 2). Remove attaching screws "D" and remove motor and auxiliary drive assembly from dash panel.

Installation

1. Lubricate outside surface of auxiliary drive drums with Lubriplate or its equivalent.
2. Secure wiper motor and auxiliary drive to dash with screws "D" (fig. 2).
3. Inside the body, attach transmission cables to drive drums. Adjust cable tension, see Adjustment. NOTE: Right drive cable is crossed and attaches to drive drum "A," left transmission cable (not crossed) attaches to drive drum "B" (fig. 3).
4. Attach control cable, vacuum line or electric motor feed line and ground. Check operation of wiper assembly and install compartment box and heater defroster duct.

Windshield Wiper Transmission Removal

1. Remove wiper blade and arm assembly.
2. Remove instrument panel compartment box and heater defroster duct.
3. Adjust drive cables to slack position and remove cables from drive drums. NOTE: Inspect attachment of drive cables to their respective drive drums and note crossed drive cable from right transmission.
4. At the outside of the body remove the escutcheon nut with tool J-5449 then disconnect washer hose, if so equipped, and remove escutcheon.
5. Remove spacer nut with tool J-5449 and remove spacer.
6. From the inside of the body, remove transmission assembly from under the instrument panel. Figure 4 shows an exploded view of the right transmission.

Installation

1. Lubricate pulley grooves in transmission assembly with Lubriplate or equivalent.
2. Install gasket to transmission, position transmission in body and install spacer and spacer nut with tool J-5449.
3. Attach transmission drive cables to auxiliary drive drums and adjust cable tension. CAUTION: Cross right transmission drive cables and install to drum "A," install left transmission drive cables (not crossed) to drum "B" fig. 3).NOTE: If new transmission is installed it is necessary to remove the plastic collar before adjusting cable tension (fig. 4).
4. Connect washer hose to escutcheon, if so equipped, secure escutcheon nut using tool J-5449.
5. Install wiper blade and arm assembly and check operation of wiper blades.
6. Install instrument panel compartment box and heater defroster duct.

Windshield Wiper Control

Removal and Installation

1. Remove control cable from motor assembly by loosening screw "A" at motor (fig. 2).
2. Loosen set screw in control knob at instrument panel and remove knob.
3. Remove spanner nut with tool J-5449, on Bel-Air models remove control escutcheon.
4. Remove control assembly from instrument panel and remove wiper hose after tagging for proper installation.
5. To install reverse this procedure.

Cowl Side Drain Gutter

Removal and Installation

1. On all models, remove wiper blade and arm assembly, transmission, spanner nuts and escutcheons. On models equipped with reveal moldings remove lower reveal moldings and clips.
2. Lift up hood and remove screws and drain gutter (fig. 5).
3. To install, apply a continuous bead of body caulking compound between gutter and windshield frame and install gutter.

Cowl Ventilating System Description

Air intake for the body is through the air intake louvre panel located on top of the cowl. Air enters the inlet panel through a duct which directs the air into the body through an opening at each cowl side panel. The flow of air into the body is regulated by a valve in each cowl side opening. The valves are controlled by separate cables and knobs. Water entering the intake into the air duct flows down the cowl side duct panel into a gutter and out of the body.

Air Intake Louvre Panel

Removal and Installation

1. Remove windshield lower reveal molding.
2. Remove lower reveal molding retaining clips located in the louvre panel.
3. Lift up hood and remove screws attaching louvre panel and remove panel (fig. 6).
4. To install, reverse this procedure.

A new large, one piece wrap-around windshield is retained in the body windshield opening by a one piece rubber channel. A windshield drain gutter is provided on all models.

Windshield Garnish Moldings

Removal and Installation

1. Remove screws attaching the garnish moldings and carefully remove the moldings in the following sequence.

Convertible Bodies:
1. Upper Moldings
2. Side Moldings
3. Escutcheon
4. Lower Moldings

All Other Bodies:
1. Side Moldings
2. Escutcheon
3. Upper Moldings
4. Lower Moldings

Figure 7 identifies the windshield garnish moldings.

2. To install, reverse this procedure.

Rear View Mirror Support Removal and Installation

1. Remove side and upper windshield garnish moldings on all models except convertible. On convertibles, remove the upper garnish moldings.
2. Remove three screws securing mirror support and remove support.
3. To install, reverse this procedure.

Windshield Reveal Moldings

2100 and 2400 Series

The reveal moldings used on the sedan and sport coupe models are of the same design. The Bel-Air sedans and sport coupes have, in addition, windshield side pillar finishing moldings. Figure 8 shows the location of these moldings and the location of the retaining clips and screws. The convertible model has a different windshield upper and side reveal molding, these moldings and the location of the retaining clips and screws are shown in figure 9.

Removal and Installation

1. Apply protective covering to area adjacent to the reveal moldings.
2. Remove windshield wiper blade and arm assemblies. Remove wiper transmission escutcheon spanner nut with tool J-5449, then remove escutcheon.
3. Carefully slide the escutcheon back on the lower reveal molding. Remove screw securing retaining clip (located under escutcheon) and slide clip into either molding.
4. Slide either lower reveal molding approximately 1-1/2" toward center line of body to align cutouts in molding with clips.
5. Carefully pry lower edge of molding upward to disengage retaining clips. Lift entire molding up to disengage molding upper flange from clips and remove molding. Repeat removal operations on opposite molding.
6. On sedan and sport coupe models remove screw securing lower corner reveal molding, pull molding out slightly and slide corner reveal molding down and remove (fig. 8). On convertible models, remove screw from lower corner of side reveal molding, then open door and remove three screws securing molding to windshield side pillar and remove molding ( fig. 9). Repeat operation at opposite side. NOTE: Upper reveal moldings can only be removed from the windshield rubber channel after the windshield assembly is removed from the body. If the windshield is to be removed, remove screw retaining upper reveal molding exposed by the removal of the corner reveal molding or the side reveal molding.
7. To install apply medium bodied sealer to all screw and clip holes, then reverse the removal procedure.

Windshield Side Pillar Finishing Molding

Sport Coupe and Bel-Air Models

Removal and Installation

1. Remove windshield lower reveal and lower corner molding.
2. Remove screw securing end of upper reveal, open door and remove three screws (fig. 8) from face of windshield side pillar and carefully pry off molding.
3. To install, seal all attaching screw holes with a medium body sealer, then reverse the removal procedure.

Windshield Side Pillar Finishing Molding

Convertible Styles

Removal and Installation

Remove the windshield side garnish and side reveal moldings, the finishing molding is retained by its flanges which fit under the garnish and reveal moldings. To install, reverse the removal procedure.

Windshield Header Molding

Convertible Styles

1. Removal and Installation
2. Remove windshield side reveal moldings and remove screw securing end of upper reveal.
3. Raise the top and on the inside of the body remove the header molding escutcheon. Also remove windshield upper and side garnish moldings, sunshade rod retainers, sunshade supports and front roof rail lock strikers.
4. Disengage front edge of header molding from under windshield upper reveal molding and remove.
5. To install, reverse this procedure.

Windshield

When a cracked windshield glass is to be removed and there is an indication of a strain break, mark the location of the break on the windshield rubber channel and the body.

Removal

1. Place protective covering over the hood, front fenders, instrument panel and front seat assembly. On convertible models, lower the top.
2. Remove the windshield garnish moldings and rear view mirror support.
3. On sedans and sport coupes, remove the windshield lower and lower corner reveals. Carefully pry off escutcheon at junction of upper reveal. On convertibles, remove lower and side reveals.
4. Remove screws attaching ends of upper reveals. Also remove lower reveal attaching clips from body (fig. 10).
5. On the inside of the body, loosen the lip of the windshield rubber channel from the pinch-weld flange along the top and at the sides by applying pressure with the palm of the hand to the edge of the glass. At the same time assist the lip of the rubber channel over the pinchweld flange with a flat bladed tool (fig. 11).
6. After freeing the rubber channel, with the aid of a helper, lift the windshield from the body and place it on a covered bench.
7. Disengage the "T" flange of the upper reveals from the rubber channel and remove moldings. NOTE: On convertible bodies a notch is cut at each end of the upper reveal molding in the windshield rubber channels.
8. Remove rubber channel from glass.

Body Windshield Opening Check

Due to the expanse and contour of the windshield it is imperative in the event of a strain break that the windshield opening be thoroughly checked before installing a replacement windshield. The replacement glass is used as a template for checking the windshield opening.

1. Check for the following conditions at the previous marked point of fracture.
   • Chipped edges on glass.
   • Irregularities in body opening.
   • Irregularities in rubber channel.
2. Remove all sealer from flange and body around windshield opening.
3. Check flange area for solder, weld high spots, or hardened spot-weld sealer. Remove all high spots.
4. Check windshield glass to opening, by supporting glass with six wooden spacers J-5742 (fig. 12). CAUTION: Do not strike glass against body metal. Chipped edges on the glass can lead to future breaks.
5. With the windshield supported and centered in its opening, check the relationship of the glass to the body opening flange around the entire perimeter of the glass.
6. Figure 13 is a cross section taken through the glass channel and body opening. Check the relationship of glass to opening as follows:
   • Inside edge of glass to body flange, at any point, dimension 3/16" to 1/4".
   • Outer edge of glass to parallel body metal at any point, dimension 5/16" to 7/16".
7. Mark areas of body metal or flange to be reformed, remove glass and correct as necessary.
8. Recheck windshield in its opening and if satisfactory, mark the glass and body so the glass may be accurately centered upon installation.

Installation

1. Check the windshield drain gutter and drain hoses for obstruction. Clean if necessary. Reseal each drain hose with medium bodied sealer (fig. 14).
2. Assemble rubber channel to glass and install upper reveal. To facilitate installation of reveal molding to channel apply a mild soap solution to rubber channel molding cavity and "T" flange of molding.
3. On convertibles, carefully center upper reveal molding in channel, and where a new rubber channel is being used, at each end of the molding cut a notch in rubber channel at the molding attaching screw locations (fig. 15).
4. Insert cord into pinchweld cavity of channel around the entire windshield. Tie cord loosely and tape ends to inside surface of glass (fig. 16).
5. Apply a heavy ribbon of medium bodied sealer at the base of the pinchweld flange around the entire perimeter of the opening.
6. Carefully place and center the windshield in the body opening with the aid of a helper.
7. Press firmly on the outside surface of the glass and have the helper, inside the body, slowly pull the cord outward from the lower center toward each lower corner to seat the lip of the rubber channel over the flange. (fig. 17).
8. Seal the outside lip of the rubber channel to the glass with weatherstrip adhesive.
9. Remove all excess sealer and adhesive with mineral spirits.
10. Reinstall moldings, sunshade supports, etc.

Instrument Panel Compartment Door

Removal and Installation

1. Scribe location of door hinge on door panel.
2. Remove door hinge attaching screws at door inner panel or at instrument panel flange.
3. Remove stop attaching screws from right side of door inner panel and remove door (fig. 18).
4. To install, position hinge within scribe lines and install attaching screws.

Adjustment

To reposition compartment door up or down in its opening, loosen hinge attaching screws at the door inner panel and shift in the desired direction.

To reposition the door laterally, loosen hinge attaching screws at instrument panel flange and shift door in the desired direction. The door lock striker may be adjusted by loosening the attaching screws and moving the striker either in or out.

Door lock

Removal and Installation

1. The lock is released by removing screw and washer on lock retainer cap.
2. To install, reverse this procedure.

Compartment Box

Removal and Installation

1. Remove compartment box door at the instrument panel.
2. Remove screws from the interior of the box at the upper and side edges.
3. Move box forward and downward to remove.
4. To install, reverse this procedure.

SEDAN FRONT DOOR

Figures fig. 19 and fig. 20 are the sedan front door Inside Handles assemblies with trim pads removed, showing various door component attaching and adjusting points.

1. Glass Run Channel
2. Window Garnish Molding Spacing Clip
3. Ventilator Regulator
4. Upper Hinge
5. Window Manual Regulator Attaching Screws
6. Lock Remote Control
7. Lock Remote Control Connecting Rod
8. Inside Lock Rod
9. Lock
10. Ventilator Division Channel Adjusting Stud
11. Wind Regulator Stationary Cam Attaching Screws
12. Inner Panel Access Hole Covers
13. Trim Pad Retainer
14. Window Control Switch Terminal Block
15. Window Electric Regulator Attaching Screws
16. Window Regulator Motor Electric Connectors
17. Plastic Type Door Arm Rest Attaching Holes
18. Hanger Plate for Built-in Type Door Arm Rest

Inside Handles

Removal and Installation

1. Depress door trim and insert door handle plier J-4614-A between the bearing plate and the handle and remove the horseshoe clip retaining the handle to the shaft. To install, place clip in handle and press handle to place on shaft.

Garnish Molding

Removal and Installation

1. Remove inside locking rod knob and screws securing garnish molding.
2. Disengage molding from window opening and lift to clear spacing clips and remove.
3. To install, reverse this procedure, apply a small amount of weatherstrip adhesive to locking rod knob hole before installing knob to rod.

Arm Rest-Plastic Type

Removal and Installation

1. Remove screws from underside of arm rest and remove arm rest.
2. To install, reverse this operation.

Arm Rest - Built in Type

Removal and Installation

1. Remove trim pad and carefully remove staples securing arm rest trim to front edge of trim pad foundation.
2. Carefully bend out arm rest clinch tabs and remove arm rest from trim pad.
3. To install, reverse this procedure.

Trim Pad

Removal and Installation

1. Remove garnish molding, inside hardware and arm rest. On doors with built in arm rest, remove screws from arm rest recess.
2. Remove screw from lower corners of trim pad, then tap front and rear edge of trim pad with a clean rubber mallet.
3. Use a flat bladed tool to pry front and rear edges of trim pad from nail slots in door inner panel. NOTE: On electric window lifts, disconnect switch from terminal block.
4. Lift trim pad up, freeing it from retaining tabs and retainer.
5. To install, reverse this procedure. Broken retaining nails may be replaced with repair tabs.

Window Control Switch

Removal and Installation

1. Remove door window garnish molding and ventilator regulator handle. Loosen trim pad at top to gain access to switch terminal and disconnect block from switch.
2. Carefully push switch assembly from trim pad. In some instances it may be necessary to pry open tabs "A" (fig. 21).
3. Remove switch from escutcheon by depressing clips with an awl at "B" and remove clips.
4. To install, reverse this procedure. NOTE: Feed stud of master control switch should point toward front of car when installed. Check switch operation before completing installation.

Front Door Window

Front door window is removed and installed in a similar manner for both manually and electrically operated windows.

Removal and Installation

1. Lower door glass window and remove trim pad. NOTE: On electric window lift installations, disconnect positive or negative battery cable.
2. Remove door ventilator assembly, then, remove large access hole cover and tape covering small circular hole between the two access holes.
3. Remove screws indicated at "A" attaching sash channel cam to glass channel (fig. 22). NOTE: On electric lift installations, remove conduit, disconnect motor leads and wire harness from door.
4. Disengage window from sash channel. cam, raise glass almost to a fully closed position, tilt glass inward and remove from door. NOTE: Do not operate electric window regulator with glass removed.
5. To install, reverse the removal procedure, then seal door inner panel as specified under Door Inner Panel Sealing

Adjustment

1. To correct a glass slanted in the run channels, loosen the stationary cam screws "A", then adjust rear of cam up or down and retighten screws (fig. 23).
2. Loosen ventilator division channel adjusting stud lock nut "B" and turn stud in or out or position stud fore or aft, as required.
3. Between the inner and outer door panel, indicated at "C" loosen run channel attaching nut at the lock pillar and position channel in or out as required.

Glass Run Channel

Removal and Installation

1. Lower door window, remove trim pad and large access hole cover.
2. Between the inner and outer door panels, working through the access hole, loosen the nut securing the lower end of the run channel to the lock pillar.
3. Carefully disengage channel and retaining clips from door. At the reveal line, disengage rosebud fastener and remove run channel.
4. To install, reverse this procedure, reseal door inner panel.

Window Regulator

Removal and Installation

1. Lower door glass, remove trim pad, both access hole covers and tape from small circular access hole located at "A" (fig. 24). NOTE: On electric window lifts disconnect motor leads "C".
2. Remove screws at "A" and "B", disengage window from cam and prop glass in the up position. NOTE: Do not operate electric regulator in or out of body after window has been disengaged.
3. Remove division channel adjusting stud and nut "D" and stationary cam attaching screws E", then disengage cam from regulator arm and remove stationary cam.
4. Disengage window sash channel cam from regulator arms and remove.
5. Remove regulator attaching screws "F" and remove regulator through large access hole.
6. To install, reverse this procedure, reseal or inner panel.

Weatherstrips

The door weatherstrip is a one piece mechanically retained type. The weatherstrip is also cemented across the bottom and up a short distance on each pillar. An auxiliary weatherstrip is provided on front doors at the hinge pillar to direct water from the offset area of the hinge pillar through drainage hole in the door pillar. This weatherstrip is cemented to the door hinge pillar and has two snap clips at the lower portion. At the bottom of the door, the drain holes are covered by rubber sealing strips. Service procedures for front and rear door weatherstrips are similar and both weatherstrips are covered herein.

NOTE: Some door weatherstrips are retained entirely by weatherstrip adhesive and a metal retainer at the lower edge of the door. The installation and removal procedures for this type of weatherstrip is the same as used in previous years.

Removal

1. Insert tip of tool J-5757 under weatherstrip at the clips and carefully snap clips from retaining hole ( fig. 25). Break cement seal arid remove weatherstrip from door.

Installation

1. Service replacement weatherstrips are longer than necessary to insure a satisfactory joint. Do not cut weatherstrip until all clips are installed into retaining holes. Install weatherstrip clips into clip holes along sides and top of doors after positioning weatherstrip as follows:
2. On front doors, formed bend in weatherstrip should be located in the cove area of door (fig. 26).
3. Color mark on weatherstrip should be located between the third and fourth clip holes on front doors and the fourth and fifth holes on rear doors (fig. 27).
4. Butt joint should be located at the bottom center of the door between two clips.
5. Across bottom of door and up each side, indicated at five in figure 26 or six in figure 27, apply a full coat of weatherstrip adhesive to surface of door which will retain weatherstrip.
6. Install clips to door by placing notched end of tool J-5757 in loop of clip and pushing clip into retaining hole. Repeat operation along both sides and top of door. NOTE: Do not distort clips or unsatisfactory weatherstrip retention will result.
7. Carefully trim ends of weatherstrip to form butt joint, and install balance of clips. Make sure a complete bond is made at cemented area.
8. Coat ends of weatherstrip with weatherstrip adhesive and form butt joint.

Front Hinge Pillar Auxiliary Weatherstrip

Removal

1. Remove two snap fasteners "A" with flat bladed tool, break cement seal and remove weatherstrip (fig. 28).

Install

1. Apply weatherstrip adhesive to door retaining surface and to weatherstrip.
2. Install clips "A" to weatherstrip, then install lower portion of weatherstrip to door pillar. Align weatherstrip with drain hole "B". Weatherstrip must not cover any part of drain hole.
3. Install remainder of weatherstrip into place and firmly press weatherstrip to establish a complete bond.
4. Remove excess adhesive.

Door Lock

These service operations may be used for door locks on all models. However, in addition to the following operations, it is necessary to remove the door window and glass run channel, to remove the door lock from sport coupes and convertibles.

Operation

A rotary bolt type door lock is used on all models. Figures fig. 29 and fig. 30 show the door lock construction and striker with the names of component parts. When the door is being closed, the lock bolt rotates as it comes in contact with the striker, until it becomes firmly engaged with the teeth at the lower end of the striker. When the door is completely closed, the locking cam, shown in the illustration, is firmly locked by the detent lever (fig. 29).

To open the door, the locking cam is released so that the bolt can rotate. This action is obtained by the operation of the push button or remote control handle.

1. When the push button on the door outside handle is depressed: the push button lever operates the intermittent lever contacting the multiplier lever and in turn lifts the detent lever free of the locking cam (fig. 30).
2. When the inside remote control handle is operated, the connecting rod from the remote control operates the remote lever on the lock contacting the detent lever and lifting it free of the locking cam.

Locking of the door by key or by the lock rod is accomplished in the lock in the following manner.

1. When the door is locked with the key, the action of the cylinder pawl on the locking lever operates the connecting link and trip lever downward. The trip lever contacts the intermittent lever and lowers it under the engaging lug of the multiplier lever.
2. When the door inside locking rod, which is connected to the bellcrank is operated to the down position, the action of the bellcrank operates the trip lever which contacts the intermittent lever and lowers it under the engaging lug of the multiplier lever.

Door Lock Remote Control

Removal and Installation

1. Remove door trim pad and remove remote control attaching screws "A" (fig. 31).
2. Detach connecting rod from clip "B" and disengage remote control from connecting rod and remove.
3. To install, reverse removal procedure.

Door Lock

Removal and Installation

1. Remove trim pad and access hole cover.
2. Remove remote control and connecting rod (fig. 31).
3. Working through access hole remove nut securing lower end of glass run channel at lock pillar.
4. Remove screws "C" and remove lock and locking rod through access hole.
5. To install, reverse removal procedure. NOTE: Before installing door lock, apply a ribbon of caulking compound on the door lock facing at the top and side joints of the lock bolt cover as indicated at "l" (See inset figure 31.) Check operation of door lock before installing trim and hardware parts.

Door Lock Striker

The door lock striker is secured to the body pillar with three screws. Serrations on the back surface of the striker plate and the upper and lower striker adjusting plates "A", which are inserted between the striker and pillar, help secure the striker in position. (fig. 32).

The teeth at the lower end of the striker engage with the door lock rotary bolt. As the door closes, the teeth on the striker indicated at "B" causes the lock bolt to rotate until it becomes firmly engaged and the door is completely closed. The sliding shoe "C," at the upper end of the striker opening, prevents excessive up and down movement of the lock bolt within the striker when the door is closed.

Removal and Installation

1. Scribe position of striker on body pillar and remove attaching screws, striker and upper and lower adjusting plates.
2. To install, place striker and adjusting plates within scribe marks and install attaching screws.

Adjustment

1. Up or down or in or out-loosen striker plate attaching screws and shift striker and adjusting plates to desired position.
2. Door lock rotary bolt should overlap the striker a minimum of 1/4" to a maximum of 3/8". If overlap is less than 1/4", an emergency spacer should be installed between the striker and adjusting plates to obtain the required overlap ( fig. 33). NOTE: The amount of lock bolt overlap on the striker can be determined by applying modeling clay on the striker teeth, then closing the door to form a measurable impression in the clay.

NOTE: The door lock and striker should be lubricated periodically to obtain maximum operating efficiency.

The front door may be removed with or without the hinges attached.

Removal

1. Place suitable protective covering over front fender at door opening to protect finish, then remove door trim pad. NOTE: On bodies with manual window lifts, the trim pad does not have to be removed, if the door is to be removed with the hinges attached.
2. Scribe location of hinge box on front body pillar or location of hinge strap on door inner panel, depending on method of door removal.
3. On door with electric window lifts with the trim pad removed:
   • Remove screws securing electric conduit and carefully slide conduit toward front pillar exposing wire harness.
   • Detach wire harness from clips and disconnect motor leads. Disengage wiring from retaining clips and carefully pull harness from cutout in door hinge pillar.
4. Support door and remove bolts "A" or "B" (fig. 34). Two bolts "A" at upper hinge and one bolt "A" at lower hinge are located inside the hinge box. With the aid of a helper remove door from body.

Installation

1. Coat all hinge attaching surfaces, as indicated in figure 35, with a medium bodied sealer. Apply enough sealer at area "A" to insure a water tight seal.
2. Reinstall door to body with the aid of a helper. Align hinges within scribe marks and tighten bolts. Check door alignment.
3. On doors with electric window lifts, install wire harness to door and connect motor leads. Tighten wire harness clips, make sure spacers are properly installed and attach conduit to door hinge pillar.
4. Reseal and lubricate door as required.

Door Inner Panel Sealing

Whenever work is performed on a door and the inner panel sealing is disturbed, the area must be resealed to insure a water tight door. Figures fig. 36 and fig. 37 show the sealing areas of four and two door sedans respectively.

            Location                      Key Sealer        
1. Access door opening flange       Medium bodied sealer
2. Access door side flange          Medium bodied sealer
3. Access door corner,              Medium bodied sealer
4. Window regulator holes           Body caulking compound
5. Wind cam holes                   Body caulking compound
6. Division channel adjusting screw Body caulking compound
7. Arm rest holes                   Waterproof tape
8. Trim pad nail slots              Waterproof tape
9. Access hole (two door only)      Waterproof tape

Front Door Adjustment

Door adjustment is provided at the hinges through the use of cage nuts and anchor plates. When checking a door for misalignment, remove the door lock striker and allow the door to hang free on its hinges, then check the spacing at the sides and top of the door. After determining the type of correction needed, correct in the following manner:

Up or Down and In or Out

1. Scribe location of hinge box on pillar.
2. Loosen bolts attaching hinge box to pillar.
3. Shift door to desired position and retighten bolts.

Up or Down and Fore or Aft

1. Remove trim pad.
2. Scribe location of hinge strap on door.
3. Loosen bolts attaching strap to inner panel, shift door to desired position and retighten bolts.
4. Install trim pad and lubricate door hold opens and hinge pins with Lubriplate or its equivalent.

Should the door clearance at the body hinge and windshield pillars be parallel and fall within 1/16" to 3/16" clearances and the door at the center or lock pillar be tilted (close at the top, wide at the bottom or vice-versa) it is indicative of another type of correction, namely body shimming. In most cases, where adjustment of the doors cannot correct a door alignment problem, body shimming will be the answer. Figure 38 shows the location of all body mounting points and where shims may be added or removed to correct body alignment faults. In addition figure 39 gives the dimensional clearances of the doors at the pillars.

Door Lock Striker

The door lock striker provides an additional adjusting point, where the lock pillar side of the door may be moved in or out to conform to the general body contour.

Adjustment

Adjustment of the door lock striker plate is provided by floating anchor plates in retaining cages behind the body lock pillar or the center pillar facings. Serrations of the striker plates and anchor plates provide retention to hold the striker plates in the desired position.

To adjust the striker plate, the attaching screws should be loosened sufficiently to allow the striker plate to be moved by hand to the desired location. Scribing the position of the striker plate on the pillar, prior to loosening the attaching screws, will clearly indicate the amount the striker plate has been moved. Hammering or blocking the striker plate should never be attempted as damage to the serrations may result in the loss of proper tension. Hammering or blocking of the striker plate may also result in closing the lock bolt groove which will affect the lock operation because of a bind condition which develops at the lock bolt roller.

Ventilator Regulator

Removal and Installation

1. Remove door garnish molding, trim pad and small access hole cover.
2. Remove screws "A" and "B" (fig. 40), disengage regulator from "Tee" shaft and lower it between door panels out through small access opening.
3. To install, seal as specified under Door Sealing, reverse removal procedure.

Adjustment

Ventilator flutter, when the ventilator is open, may be eliminated by tightening "Tee" shaft screw "A." Tighten screw carefully to avoid stripping threads (fig. 41). Opening and closing effort may be increased or decreased by an adjusting friction clamp screw "B."

Ventilator and Division Channel

Removal and Installation

1. Lower door glass window, remove trim pad, small access hole cover and ventilator regulator.
2. Loosen upper section of glass run channel "A," remove attaching screws "B" and adjusting stud and nut"C" (fig. 42).
3. Work ventilator inward, then lift ventilator assembly from door.
4. To install, seal as specified under Door Sealing and reverse the removal operation.

Adjustment

In addition to the regulator adjustment, the ventilator assembly may be adjusted in or out, fore or aft to align the ventilator with the door glass. To adjust, loosen stud lock nut "C" and turn adjusting stud in or out as desired. Shift position of stud in opening for fore or aft adjustment and retighten lock nut. Seal stud with caulking compound.

Outside Handle

Removal and Installation

1. With the door glass in the closed position remove the trim pad.
2. Through access holes indicated at "A" and "B" (fig. 43) remove two screws securing handle to door outer panel.
3. Remove handle and gaskets.
4. To install, reverse this procedure.

Lock Handle Push Button

Removal and Installation

1. Remove door handle from door.
2. Depress stop wash slightly and make quarter turn and remove stop washer, retainer, spring and push button and shaft (fig. 44).
3. To install, reverse this procedure.

Lock Cylinder

Removal and Installation

1. Pry retainer "C" out sufficiently to release cylinder (fig. 43).
2. Remove cylinder and gasket.
3. Remove retaining clip "A" and pawl (fig. 45).
4. Carefully bend open four cylinder housing: scalp tabs "B" and remove scalp
5. Remove cylinder from housing. Figure 46 shows an exploded view of the door lock. CAUTION: When removing scalp, hold spring loaded cylinder cap depressed with finger. Note position of springs and cap for reassembly purposes.
6. To install, reverse this procedure, insert cylinder with curved edge toward lock pillar "B" ( figure 43) remove two screws securing and check operation of lock cylinder.

Figures fig. 47 and fig. 48 indicate the various door parts.

The following assemblies are removed from and installed to sport coupe and convertible bodies in the same manner as on sedan bodies. Service procedure for these installations and removals are found under Sedan Door in this section.

• Inside Handles
• Arm Rest
• Trim Pad
• Window Control Switch
• Door Removal
• Hinge Sealing
• Outside Handle
• Handle Push Button Shaft
• Lock Cylinder
• Lock Remote Control
• Lock Striker
• Hinge Pillar Auxiliary Weatherstrip

Ventilator Garnish Molding

Removal and Installation

1. Remove belt finishing molding, weatherstrip retainer at top of ventilator and screw securing weatherstrip tab at upper portion of hinge pillar.
2. Remove two attaching screws at face of pillar and screw at top of ventilator.
3. Pull molding inward to remove.
4. To install, reverse this procedure.

Weatherstrips

Two methods of weatherstrip retention are used; namely, by clips and weatherstrip adhesive or weatherstrip adhesive alone. Where an adhesive retained weatherstrip is removed or installed, the same procedures used in previous years are recommended. The clip retained weatherstrips are covered in the following text.

Removal

1. Remove ventilator garnish molding and screw securing rear end of belt finishing molding and weatherstrip.
2. Remove two screws securing upper portion of weatherstrip to ventilator frame and door hinge pillar extension.
3. Remove weatherstrip retaining clips from door by inserting notched end of tool J-5757 under clip and snapping clip from place. Complete clip removal and remove weatherstrip from door.

Installation

1. Install weatherstrip to top of ventilator frame and hinge pillar extension with two screws.
2. Install weatherstrip clips into holes at hinge pillar and extension by placing notched end of tool J-5757 around clip loop and snapping clips into retaining holes.
3. Apply a coat of weatherstrip adhesive to the weatherstrip bonding area on the door, as indicated at "A", to a point just below the lower attaching clip holes (fig. 49).
4. Install remaining clip and seal weatherstrip to door at cemented area.
5. Install ventilator garnish molding and two screws retaining rear end of belt finishing molding and weatherstrip.

Door Ventilator

Removal and Installation

1. Lower door glass, remove trim pad, ventilator garnish molding and small access hole cover.
2. Remove division channel adjusting stud and nut "A" and "Tee" shaft screw "B" (fig. 50).
3. Remove screws "C" retaining ventilator to pillar and door flange and ventilator to regulator attaching screws.
4. Disengage "Tee" shaft from regulator and remove ventilator.
5. To install, reverse this procedure and reseal door inner panel.

Adjustment

To adjust lower end of division channel loosen stud nut at "A" (fig. 50) and turn adjusting stud in or out, fore or aft adjustment may be made by shifting the stud position in the elongated hole.

Ventilator Regulator

Removal and Installation

1. Remove trim pad, small access hole cover and screw "A" and screws "B" (fig. 51).
2. Lower regulator to disengage from "Tee" shaft and remove through access hole.
3. To install, reverse this procedure, then reseal inner door panel.

Adjustment

Flutter of ventilator in the open position may be corrected by tightening screw "A". Opening or closing effort of the ventilator is controlled by screw "C" (fig- 51).

Door Window

Removal and Installation

1. Lower door glass, remove belt finishing molding clips and trim pad. NOTE: On electric window lift, disconnect positive or negative battery cable.
2. Remove window stops "A" and bumper "B", then remove large access hole cover and tape from circular cutout "H", (fig. 52).
3. Remove screws at "C" and "H" from each end of sash channel cam and disengage window from sash channel cam.
4. Lift glass up and tilt to the rear to clear ventilator frame and remove. NOTE: Do not operate electric lift with window removed.
5. To install, reverse this removal operation and reseal door inner panel.

Adjustment

1. A cocked glass in run channel, may be corrected by loosening the stationary cam rear screw at "D" and adjust cam up or down as required, then tighten screw (fig. 52).
2. Compensating adjustments may be made by adjusting the division channel adjusting stud "E" in or out and moving the division channel fore or aft as desired.
3. Additional adjustment is provided by screws "F" which may be loosened to reposition the rear glass rear channel.

Glass Run Channel

Removal and Installation

1. Remove door window glass, then remove glass run attaching screws "F" and run channel.
2. To install, reverse this procedure.

Window Regulator

Removal and Installation

1. Remove trim pad, both access hole covers and window glass. CAUTION: Do not operate electric lifts with window removed.
2. Remove stationary cam screws "D", and disengage cam from regulator arm and remove. Disconnect motor leads on electric lift bodies through small access hole (fig. 52).
3. Disengage window sash channel cam from regulator arms and remove.
4. Remove division stud and nut "E" and regulator attaching screws "G", carefully remove regulator through large access hole.
5. To install, reverse this procedure, reseal and lubricate as specified.

Side Roof Rail Mechanical Sealing Strip

Special Coupe

Removal

1. Remove screws "A" and "B" and remove front and rear outer weatherstrip (fig. 53).
2. Remove screws "C" and remove sealing strip and attached gasket.

Installation

1. Clean old sealer from side roof rail and gasket. If gasket was removed, discard double coated tape from sealing strip.
2. Tape sealing assembly with flipper section held in the closed position.
3. Cement rubber gasket to sealing strip with a good weatherstrip adhesive by applying a film of adhesive to the sealing strip. NOTE: Do not apply cement to lip or awning of gasket nor to hinge portion of gasket so it lies flat and the awning of lip is over the radius of the sealing strip hinge.
4. Apply bead of caulking compound along outside edge of gasket (fig. 54).
5. Position sealing strip assembly to side roof rail and install retaining screws snugly.
6. Apply weatherstrip adhesive to attaching surfaces of front and rear outer weatherstrips and install to body.
7. Align sealing strip with top of door window and ventilator, then uniformly tighten all attaching screws.
8. Lubricate inner side of awning with rubber lubricant.

Inner Panel Sealing

Special Coupe and Convertible

Whenever the sealing of the inner panel is disturbed, the inner panel should be resealed as out lined below (fig. 55).

     Location Key                          Sealer

1. Access door opening flange       Medium bodied sealer
2. Access door flange               Medium bodied sealer
3. access door corners              Medium bodied sealer
4. Arm rest attaching holes         Waterproof tape
5. Access hole                      Waterproof tape
6. Trim pad nail slots              Waterproof tape
7. Window cam attaching holes       Body caulking compound
8. Regulator attaching holes        Body caulking compound
9. Ventilator lower attaching hole  Body caulking compound

The manual regulator type rear door inner panel and the electric regulator type rear door inner panels are shown in figures fig. 56 and fig. 57 respectively. The illustrations show the location of hardware parts and their attaching points.

1. Glass Run Channel
2. Upper and Low Hinge Cover Plates and Hinges
3. Locking Rod and lever
4. Lock Remote Control
5. Lock Remote Control Connecting Rod
6. Lock
7. Window Regulator
8. Window Regulator Stationary Cam Adjusting Screws
9. Access Hole Cover Plate
10. Trim Pad Retainers
11. Glass run Channel Adjusting Screw
12. Window Control Switch Terminal Block
13. Window Electric Regulator
14. Electrical Conduit Opening
15. Electric Connectors for Door Window Regulator Motor
16. Attaching Holes for plastic Type Door Arm Rest
17. Hanger Plate for Built-in Type Door Arm Rest

Rear door inside hardware parts are installed and removed in the same manner as front door inside hardware parts and are covered under the front door in this section.

Door Hinge

The rear door is attached to the center pillar with two butt-type hinges. The door may be removed with or without the hinge attached.

Removal

1. Remove hinge cover plates from center pillar, clean sealer from around hinge straps and scribe location of straps on center pillar.
2. On electric window lift installations, remove trim pad and access hole cover. Remove two screws securing wire harness conduit to center pillar, bend out conduit tabs and remove from harness. Loosen harness from clip and disconnect motor leads and remove harness from door.
3. Support door and remove three upper and lower attaching bolts from hinge strap and remove door.

Installation

1. Clean all old sealing compound from hinge areas. Do not soil adjacent trim.
2. Apply a full coat of heavy bodied sealer to attaching surface of hinge strap, this sealer acts as a weatherseal and anti-squeak (fig. 58).
3. Place door in body opening and install attaching bolts loosely. Align straps within scribe marks and tighten bolts. NOTE: On electric lift installation, install wire harness to conduit, conduit to hinge pillar and connect motor leads. Install access door, trim pad and inside hardware.
4. Apply medium bodied sealer to upper and lower hinge as indicated at "A" and "B" in figure 59.
5. Install hinge cover plates and remove excess sealer.

Adjustment

To check the rear door alignment in the body opening, remove the lock striker from the body lock pillar and allow the door to hang free. Then check spacing (fig. 39) between the door and body opening edges. Clearance between the door header and side roof rail and the door pillar and body pillar should be 1/16" - 3/16" Clearance between the bottom of the door and rocker panel should be 1/8" - 1/4".

In or Out- Remove hinge cover plates at center pillar and loosen center pillar strap attaching bolts, shift door in or out as desired and retighten bolts.

Up or Down- Remove trim pad and loosen hinge strap attaching bolts at inner panel, shift door to desired position and retighten bolts.

Rearward- Support door, then remove upper center pillar hinge attaching bolts, and cement a full weatherproof shim to hinge strap and reinstall strap to center pillar. Perform same operation on lower hinge strap.

Forward- Support door, remove hinge cover plates and loosen hinge strap to center pillar attaching bolts. Insert a partial waterproof shim at the inner edge of the hinge straps and retighten bolts.

Reseal hinges and hinge cover plates as described under Rear Door removal

Rear Door Remote Control

Removal and Installation

1. Remove trim pad and remote control attaching screws "A" (fig. 60).
2. Remove remote control after disengaging connecting rod.
3. To install, reverse this procedure.

Rear Door Lock

Removal and Installation

1. Remove trim pad, access hole cover and remote control.
2. Remove inside locking rod lever attaching screw "B" and washer, disengage lever connecting rod from clip "C" and door lock (fig. 60).
3. Remove glass run channel screw "D" and four lock attaching screws "E".
4. Remove lock through access hole.
5. To install, reverse this procedure. Check operation of lock components and reseal as specified under Rear Door Inner Panel Sealing.

Free Wheeling Adjustment

Free wheeling is a safety feature of rear door locks in all passenger models. The rear door lock may be placed in or out of free wheeling depending on the owner's preference. When a rear door lock is in the free wheeling position, with the locking rod knob in the down or locked position, the door cannot be opened by operation of the inside door handle. All passenger cars as shipped from production have rear door locks set in free wheeling. To place the rear door lock in free wheeling proceed as follows:

1. Pull inside locking rod knob to the "up" position and remove rear door lock upper attaching screw.
2. Insert adjusting tool through screw hole as shown in illustration, (fig. 61).
3. Engage hooked end of rod in loop of remote control connecting link as shown in the illustration. Push rod forward to set lock "out" of free wheeling and pull rod rearward to set lock "in" free wheeling, (fig. 62).

NOTE: Adjusting tool may be made from a 7" x 1/8" rod bent to form a right angle 3/8" from one end.

Glass Run Upper Channel

Removal and Installation

1. Lower door window and remove trim pad and access hole cover (fig. 63).
2. Remove screw "E" at lower end of channel and carefully pry channel rose-bud fasteners from retaining holes at door header.
3. Carefully pull channel from door.
4. To install, reverse the removal procedure. Upper channel must fit properly into end of lower channel at "G". Align channel for free glass travel and reseal inner panel.

Glass Run Lower Channel

Removal and Installation

1. Lower door window, remove trim pad, access hole cover and screw "D" from end of glass run channel (fig. 63).
2. Detach upper channel from door lock pillar, then remove rose-bud fastener from retainer at "G."
3. Carefully pull lower glass run channel up through window opening.
4. To install, reverse this procedure making sure upper and lower run channels are properly aligned. Align channels for free glass travel and reseal inner panel.

Rear Door Window

Removal and Installation

1. Lower door glass, remove trim pad, access hole cover and tape covering small access hole "A" ( fig. 63). NOTE: On electric lift installation, disconnect positive or negative battery cable.
2. Remove upper glass run channel and through access holes "A" and "B" remove window to sash channel cam screws.
3. Disengage window from sash channel cam, lift window upward, carefully tilting it inward as it is lifted until window can be removed from door. CAUTION: Do not operate electric lifts with window removed.
4. To install, reverse this procedure and reseal inner panel.

Adjustment

1. To correct a glass tilted in the run channels, loosen stationary cam screw "C" and move stationary cam as desired (fig. 63).
2. To correct glass bind, due to glass run channel misalignment, loosen screws "D" and "E" and adjust channels in or out as desired.

Rear Door Window Regulator

Removal and Installation

1. Lower door glass, remove trim pad access hole cover and tape from small access hole (fig. 63). NOTE: Disconnect motor leads on electric lift installations.
2. Through access holes at "A" and "B" remove window to sash channel cam screws and prop window in closed position.
3. Remove stationary cam screws "C" and cam, disengage sash channel cam from regulator and remove sash channel cam.
4. Remove screws "F" and carefully remove regulator.
5. To install, reverse this procedure. Reseal door inner panel as specified in this section.

Rear Door Weatherstrip

The removal and installation of rear door weatherstrips is similar to the weatherstrip operation on front doors. The service operation is covered in the Front Door section.

Rear Door Outside Handle

The rear door outside handle is removed and installed in the same manner as the front door outside handle. Removal and installation procedure is covered under Front Doors in this section.

Door Inner Panel Sealing

Whenever it is necessary to disturb the seal on the rear door inner panel, the inner panel must be resealed to insure a weatherproof door. The illustration keys the door inner sealing points with the sealing material required (fig. 64).

 
    Location Key                        Sealer

1. Access Door Opening            Flange Medium Bodied Sealer
2. Access Door Flange               Medium Bodied Sealer
3. Access Door Corners            Medium Bodied Sealer
4. Window Regulator Holes      Body Caulking Compound
5. Window Cam Attaching         Holes Body Caulking Compound
6. Welding Access Holes           Waterproof Tape
7. Arm Rest Attaching Holes    Waterproof Tape
8. Trim Pad Nail Slots                Waterproof Tape

BACK WINDOW ASSEMBLY

Back Window Garnish Moldings

The removal of the back window garnish molding on all two and four door sedans requires only the removal of the retaining screws and moldings. The removal of the garnish molding from sport coupes is as follows:

Removal and Installation

1. Remove rear seat cushion, back and rear quarter belt finishing molding.
2. Remove back window side garnish moldings by removing three screws from each molding.
3. Remove back window upper garnish molding screws and molding.
4. To install, reverse the above procedure.

Back Window Upper Reveal Molding

The back window upper reveal and upper corner escutcheons may be removed with the back window in the body. However, to remove the back window lower reveal it is necessary to remove the back window from the body.

Removal

1. Apply protective covering to painted surfaces at the molding area.
2. Remove back window garnish molding from interior of body.
3. Remove both reveal molding upper escutcheons by folding headlining trim back and removing retaining nuts.
4. Carefully pry upper reveal molding free of retaining clips and remove. Figure 65 shows the cross section of the back window with the upper and lower moldings.

Installation

1. Position reveal molding and at each clip location press the molding until the leg of the molding is held by the retaining clip.
2. Apply medium bodied sealer around upper corner escutcheon bolts holes, then install moldings.
3. Install back window garnish moldings.

Back Window

Removal

1. Place protective coverings on painted surfaces surrounding the back window. Inside the body, protect the parcel shelf and rear seat with a suitable covering.
2. Remove back window garnish moldings, upper corner escutcheons and upper reveal molding.
3. Break the seal between the rubber channel and the pinch weld flange on the inside of the body with a putty knife.
4. From the inside of the body carefully push the top of glass and channel outward with the palm of the hand, then with the aid of a helper remove the complete assembly from the body opening.
5. Place assembly on covered bench and remove lower reveal moldings, clips and rubber channel from glass. Also remove upper reveal molding clips from pinchweld flange.

Installation

Clean old sealer from window opening and rubber channel, check the body pinchweld flange for irregularities, use the glass as a template. Install upper reveal molding clips to pinchweld, make sure they are secure. Examine back window drain gutter and both drain hoses for obstructions, clean if necessary. The back window drain is located under the parcel shelf trim.

1. Assemble rubber channel to glass.
2. With lower reveal molding clips secured to the moldings, apply a medium bodied sealer to the molding clips as shown at 1 in figure 66. Install lower reveal moldings in rubber channel.
3. Insert cord into pinchweld cavity of rubber channel and tie cord loosely at bottom center of glass. Tape ends to inside surface of glass.
4. Apply a heavy bead of medium bodied sealer at the rabbet (cross section 2) of the pinch weld flange around the entire perimeter of the window opening.
5. Bridge the upper reveal molding clips at the pinchweld with medium bodied sealer.
6. Place the back window assembly into the body opening, this is a two-man operation.
7. While pressing firmly on the outside surface of the glass, have the helper carefully pull the cord from the pinchweld cavity of the channel seating the lip of the rubber channel over the pinchweld flange.
8. Outside the body, seal lip of rubber channel to surface of glass with weatherstrip adhesive.
9. Install upper reveal, corner escutcheon and garnish moldings. Remove excess sealer and protective covering.

NOTE: If parcel shelf trim has been disturbed re-cement to place with trim cement before installing garnish molding.

Rear Compartment Assembly

Rear Compartment Lid

The rear compartment lid employs two torsion rods between the hinge assemblies as a counterbalance and a hold-open. Notches are provided at the hinge assemblies for rod adjustment. The rear compartment weatherstrip is retained to compartment lid inner panel by integral clips or by weatherstrip cement.

Removal and Installation

1. Open lid and place protective covering over adjacent finish areas.
2. Disconnect light wire at connector and remove wire from lid. Scribe position of hinge straps on lid inner panel.
3. With a helper-assisting, remove bolts attaching hinge strap to lid inner panel and remove compartment lid.
4. To install reverse this procedure, make sure hinge straps are aligned within scribe marks.

Rear Compartment Lid Hinge

Removal

1. Place protective covering over paint finish at working area and place a suitable support under lid near the hinge being removed.
2. Scribe location of hinge strap on lid inner panel, then remove strap to lid retaining bolts.
3. Remove screws for the torsion rod cover at the left hinge (see inset fig. 67) and remove cover.
4. Mark notch engaging torsion rod, then install a suitable length of pipe over end of torsion rod and disengage torsion rod from retaining notches at inboard face of the opposite hinge box (fig. 68).
5. Disengage torsion rod from movable portion of hinge strap and remove rod.
6. Bend up hinge pin retaining tab "A" and remove pin, then remove hinge from hinge box. Figure 69 shows the various positions for adjusting the torsion rod.

Installation

1. Place hinge in hinge box and install pin, bend down pin retaining tab.
2. Install hinge strap to lid within scribe marks on lid inner panel.
3. Install "U" shaped end of torsion rod to hinge box, making certain outer end of rod is engaged in hole in outboard face of hinge box.
4. Engage torsion rod in movable portion of hinge strap and engage other end of rod to previously marked position on inboard side of opposite hinge box.
5. Center rubber silencer at the crossover point of the torsion rods, then install rod cover to left hand hinge box.
6. Check lid alignment in compartment opening and remove protective covering.

Lid Lock Cylinder

Removal and Installation

1. Insert suitable hooked tool through inner panel of lid and pull lock cylinder retainer away from cylinder. See inset in figure 70.
2. Remove lock cylinder and gasket from lid outer panel.
3. To install, reverse this procedure, after sealing at cylinder opening in outer panel.

Lid Lock

Removal and Installation

1. Remove lock cylinder from compartment lid.
2. Remove lid lock and cover plate screws "B" and "C" and remove lock and cover plate assembly ( fig. 70).
3. To install, reverse this procedure.

Rear Compartment Lid Weatherstrip

The weatherstrip for the rear compartment lid is retained either mechanical (integral clips) or by weatherstrip adhesive. The clip retained weatherstrip removal and installation procedure is outlined as follows. The service procedures for the cemented weatherstrip are the same as used in previous years.

Removal

1. Use tool J-5757 by slipping notched end of tool under the weatherstrip retaining clips and carefully snapping the clips out the holes in the inner panel.

Installation

1. Service replacement weatherstrips are longer than required, but should not be cut until weatherstrip is installed.
2. Locate two clip holes indicated at. "A" in figure 71 near the lid lock bolt. These holes are closer together than the others.
3. Insert second clip on weatherstrip into clip hole "B" by placing notch of tool J-5757 on loop of clip and snapping clip to place. Do not use excessive force or clip may be distorted resulting in improper weatherstrip retention. This places the butt joint of the weatherstrip between clip holes "A".
4. Install all clips except those to be inserted into clip holes at "A".
5. Accurately cut and trim weatherstrip to proper length and apply weatherstrip adhesive to the surface of the compartment lid, a distance of 21/2 inches on each side of the butt joint.
6. Apply weatherstrip adhesive to the butt ends of the weatherstrip and install last two clips. NOTE: Ends should match evenly to provide a continuous seal.

Compartment Lid

Rear compartment lid may be adjusted forward, rearward or to either side by loosening hinge strap attaching bolts and shifting the lid in the desired direction and retighten bolts.

To raise or lower the lid at the hinge area, place shim under strap at "A" to raise the lid and at "B" to lower the lid (fig. 72). A combination of shims may be used under the lid hinge strap to tilt the lid in its opening. Lid Lock Bolt and Striker Engagement Check may be made by insert modeling clay, as shown in figure 73. Close the lid with moderate force, open the lid and check the engagement by measuring the distance between "U" in the clay and the base of lock. This dimension should be 1/8" to 5/32"- If necessary, adjust striker as follows:

Lid Lock engagement may be adjusted at the lid lock striker by loosening attaching bolts and shifting the striker plate on its beveled anchor plate. In extreme cases to obtain proper engagement a spacer or shim may be placed between the striker plate and beveled anchor plate.

Compartment Lid Torsion Rod

The position of the torsion rods in the notches on the inboard side of the hinge boxes determines the amount of effort required to open and close the rear compartment lid.

By placing the torsion rod in position three (fig. 69) the amount of effort required to open the lid is the least and conversely the amount of effort to close the lid the greatest. It is not necessary to adjust right and left rods at the same time, nor is it necessary to have the same final position of adjustment on both rods. If adjustment is required at the left hinge box it is necessary to remove the torsion rod cover.

Rear Compartment Lid Bumpers

Raise compartment lid and loosen weatherstrip enough to gain access to bumper attaching screws.

Loosen bumper screws and adjust bumper by moving anchor plate so clearance between bumper and rear end panel is 1/16". The guide pin alignment adjustment is provided through oversize attaching screw holes. figure 74 for clearances at the rear compartment lid.

Back Window Gutter Drain Hose

A drain gutter is provided on all sedan styles to collect any moisture in the back window area. The drain gutter has outlets at each end connected to drain hoses which direct water to the outside of the body between the rear quarter inner and wheelhouse panel.

Removal

1. From inside rear compartment, remove drain hose from rear quarter inner panel (fig. 75).
2. Remove rear seat cushion, back and back window garnish moldings.
3. With a wide blade putty knife or some other suitable tool, carefully separate cemented parcel shelf trim from metal.
4. Loosen the cemented upper end of drain hose at "A" and carefully remove hose from outlet (fig. 75).

Installation

1. Apply weatherstrip adhesive to sealing edges "A" of drain hose and place hose in outlet opening.
2. From inside rear compartment draw hose down into position and insert other end of hose into opening in rear quarter panel.
3. Remove all excess sealer and reinstall parcel shelf covering, garnish molding, rear seat back and cushion.

Rear Quarter Trim Panel

Two Door Sedan

1. Remove rear seat cushion, back and quarter window garnish molding.
2. Remove rear quarter window handles and on models so equipped remove quarter arm rest screws and rests. On electric quarter window lifts remove switch by prying it from its retainer.
3. Remove two screws attaching the rear upper and lower corners of trim panel.
4. Swing rear of trim panel forward exposing hidden tacks at body lock pillar and remove tacks and trim panel.
5. To install, reverse this procedure.

Rear Quarter Trim

Four Door Sedan

Removal and Installation

1. Remove rear seat cushion and back assemblies.
2. Remove rear quarter garnish molding.
3. Remove screws from upper and lower rear corner of trim panel, regulator handles and on models so equipped, remove arm rests and disconnect switch block.
4. Rotate the rear edge of the trim panel forward exposing the trim panel to lock pillar attaching tabs at front edge of trim panel.
5. Remove attaching tabs and trim panel.
6. To install, reverse this procedure.

Rear Quarter Window

Two Door Sedan

Removal and Installation

1. Remove the rear seat cushion, back, quarter window garnish molding, window regulator handle or window electric switch. NOTE: Disconnect positive or negative battery cable on electric window lifts.
2. Remove rear quarter arm rest from bodies so equipped and remove rear quarter trim panel.
3. Remove access hole cover from inner panel.
4. With quarter window in the up position, remove quarter window guide attaching screws "A" and guide from body (fig. 76).
5. On electric installations, temporarily connect power supply and lower window to expose sash channel screws, remove screws and disengage channel from cam. On manual operated windows temporarily install handle to lower window.
6. Remove quarter window lower stop from the end of window front guide by working through the access hole. This will permit the front roller of the glass assembly to fall free of the front guide.
7. Rotate the forward edge of the glass until the rear roller is disengaged from the rear guide "B" and remove window.
8. To install, reverse this procedure.

Adjustment

By raising or lowering the rear quarter window lower stop the window may be properly positioned in the body opening.

Rear Quarter Stationary Window

Four Door Sedan

Removal

1. Remove rear quarter garnish molding.
2. Carefully loosen rubber weatherstrip from sealer around window opening, then push glass from body opening with the palm of hand.

Installation

1. Clean old sealer from rabbet and rubber weatherstrip.
2. Install glass into rubber weatherstrip and insert a cord into the pinchweld cavity of the weatherstrip around the entire window.
3. Apply a bead of weatherstrip adhesive around the window opening at the weatherstrip contacting surface on both sides of flange.
4. Insert window and weatherstrip assembly into its opening and pull string, lifting the lip of the rubber weatherstrip over the flange.
5. Apply a bead of weatherstrip adhesive between the outer lip of the weatherstrip and the glass. Remove all excess adhesive and install garnish molding.

Rear Quarter Window Regulator

Two Door Sedan

Removal and Installation

1. Lower rear quarter window approximately two inches. NOTE: On electrically operated styles disconnect positive or negative battery cable.
2. Remove rear seat cushion and back, quarter window garnish molding, arm rest and quarter trim panel.
3. Remove access hole cover and remove rear quarter windows.
4. Remove four screws attaching regulator to inner panel. NOTE: On electrically operated windows disconnect motor leads. Lift regulator out through access hole.
5. To install reverse this procedure. Seal access cover perimeter with weatherstrip adhesive and all attaching screws with sealing compound.

Rear Quarter Glass Run Channel

Two Door Sedan

Removal and Installation

1. Remove quarter window garnish molding and lower glass to the full down position.
2. Disengage glass run channel clips from window header and door lock pillar by carefully pulling channel inward. Then, pull the, glass channel upward to free channel from retainers at each end and remove from body.
3. To install, reverse this procedure.

Belt Finish Molding

Removal and Installation

1. Remove rear seat cushion and back, then remove retaining screws and molding.
2. To install, reverse this procedure.

Quarter Arm Rest

Removal and Installation

1. Remove rear seat cushion and back, disconnect courtesy lamp switch at left side only.
2. Remove attaching screws and rear quarter arm rest. Lift arm rest up to clear retaining tabs.
3. To install, reverse this procedure.

Quarter Trim Panel

Removal and Installation

1. Remove quarter arm rest, belt finish molding and window regulator. On electric lift installations, disconnect switch.
2. Remove nail from rear corner of trim panel and swing trim panel forward exposing tacks at lock pillar edge of trim.
3. Remove tacks and trim.
4. To install, reverse this procedure.

Quarter Window

Removal and Installation

1. Remove rear seat cushion, back, quarter hardware, arm rest, trim panel and access hole cover. NOTE: On electric quarter window lifts disconnect switch terminal and positive or negative cable of battery.
2. With window in up position remove window rear guide screws "A" and remove guide(fig. 77).
3. Lower window so the regulator roller cam can be disengaged from window channel. NOTE: Temporarily hook up power supply on electric lifts to lower window or install regulator handle on manual lifts.
4. Disengage front roller from guide channel and remove quarter window.
5. To install, reverse the removal operation.

Adjustments

Fore and Aft-Loosen rear guide channel screws "A" and "B" and front guide channel screws "C" and "D." Move window fore or aft as desired (fig. 78).

In and Out - To move window in or out at the lock pillar, loosen upper front guide stud nut "C" and turn adjusting stud in or out, then tighten lock nut. To move window in or out at the rear area, loosen stud nut "A" and turn adjusting stud in or out, then tighten lock nut.

Down Travel-May be adjusted by removing the access door, loosening the nut retaining the stop to the front guide channel and moving the stop.

Up Travel- May be adjusted by loosening screw "E" and moving stop.

Electric Window Regulator

Removal and Installation

1. Remove quarter window.
2. Remove access hole cover and disconnect motor wire.
3. Remove regulator attaching screws "A" and remove regulator (fig. 79).
4. To install, reverse this procedure, then reseal access hole cover and regulator attaching screws.

Window Guide-Rear

Removal and Installation

1. Remove rear seat hardware and trim.
2. Remove access hole cover and with the window in the up position, remove attaching screws "A" ( fig. 80).
3. Disengage rear guide from window roller and remove guide from body.
4. To install, reverse this procedure.

Window Guide-Front

Removal and Installation

1. Remove quarter window and regulator.
2. Remove front guide screws "B" and remove guide from body through access hole (fig. 80).
3. To install, reverse this procedure.

Window Sealing Strip

Removal and Installation

1. With the window in the down position remove the side roof rail mechanical sealing strip.
2. Remove rear seat cushion, back, quarter belt finishing molding and side roof rail finishing molding.
3. Remove screws attaching inner extension and outer extension (fig. 81).
4. Remove screws attaching sealing strip, pull sealing strip forward to disengage from outer molding and remove.
5. To install, remove old sealer, then apply a bead of caulking compound along the entire length of the sealing strip as shown in the inset. Reverse the removal procedure.

Adjustment

Attaching screw holes are slotted to provide adjustment of the sealing strip.

Convertible Rear Quarter

Folding Top Compartment Side Trim Panel

Removal and Installation

1. Remove rear seat cushion and back, on left side of body, disconnect courtesy lamp switch.
2. Remove attaching screws and top compartment side trim panel.
3. To install, reverse this procedure.

Trim Panel

Removal and Installation

1. Remove folding top side compartment trim panel, quarter belt finishing molding and window regulator handle. NOTE: On electric window lift styles, disconnect switch terminal block.
2. Remove nail from rear of trim panel and swing panel out to expose tacks attaching panel to lock pillar. Remove tacks and panel.
3. To install, reverse the removal procedure.

Quarter Window-Electric and Manual

Removal and Installation

1. Remove rear seat cushion and back, then lower the folding top.
2. Place window in the half way position, on electric models disconnect positive battery cable.
3. Remove top compartment side trim panel and belt finishing molding. Break window switch circuit at terminal block and pivot quarter trim away from quarter inner panel.
4. Remove pivot bolt "A" and disengage male hinge from female hinge (fig. 82).
5. Temporarily connect lift power supply or reinstall quarter window handle and carefully operate window until regulator arm can be removed from the cam channel.
6. Remove window from body, exercise caution to prevent scratching of glass on window stop. Disconnect power supply from electric lift.
7. To install, reverse this procedure.

Adjustment

In or Out- Loosen pivot bolt "A" and adjust stud nuts "B" in or out. Retighten lock nuts and pivot bolt (fig. 82).

Up or Down- Fore or Aft-Loosen pivot bolt "A" and stud nuts "B" and shift assembly as desired, then retighten bolt and studs.

UP Travel- Loosen stop attaching nut "C" and move stop.

Guide Channel Alignment -To compensate for various adjustments it may be necessary to reposition the quarter window guides. To adjust guide channel loosen screw "E" and move channel.

Window Regulator

Removal and Installation

1. Remove rear quarter window, access hole cover and regulator attaching screws "A." On electric equipped lifts, disconnect switch (fig. 83).
2. Remove regulator from body through access hole.
3. To install, reverse this procedure, reseal access door and regulator holes.

Window Guide

Removal and Installation

1. Remove quarter window.
2. Remove guide screw "B" at quarter lock pillar, two upper attaching screws at "C" and center stud nut and washer at "D" (fig. 83).
3. Remove guide assembly from window opening.
4. To install, reverse this removal procedure.

FRONT SEATS

Construction of a typical seat is shown in figure 84. The springs are of a zig-zag construction set in a box type frame. Covering the spring is 1/2" insulated jute pad which in turn is covered With a 1 1/4" foam rubber pad. On 1500 series models the foam rubber pad is replaced with a cotton pad. Finish trim is a combination cover of cloth and imitation leather on the 2100 and 2400 series, on the 1500 series it is all cloth.

Seat Side Panels-Divided Back

Removal and Installation

1. On the left side remove adjuster knob "A" by loosening set screw (fig. 85). NOTE: On electrically operated seat adjusters detach switch block from switch.
2. Remove three screws "B" at front and rear of lower side panel and remove panel.
3. Remove screws "C" from upper side panel and rotate panel out of position.
4. To install, reverse this procedure.

Side Panels-Solid Back

Removal and Installation

1. On left side, remove adjuster knob by loosening set screw. NOTE: On electrically operated seat remove switch terminal block from switch.
2. Remove two screws at front of seat side panel and two screws from upper section of side panel.
3. Pull panel out at the front to clear retaining brackets and remove seat.
4. Remove front seat side panel extension located at the rear corner of the seat cushion, by removing three screws.
5. To install, reverse the above procedure.

Seat Regulator Switch

Removal and Installation

1. Remove screws from retaining escutcheon and pull escutcheon and switch assembly from side panel.
2. Detach terminal block from switch and through hole "A" depress clip tab and remove clip "B". Remove three remaining clips in the same manner, then remove switch from escutcheon (fig. 86).
3. To install, place switch in escutcheon and push retaining clips to place. Attach terminal block to switch and install assembly to side panel.

Horizontal Regulator Assembly

Removal and Installation

1. Move seat to extreme rearward position and disconnect regulator motor wires from wiring harness and remove motor ground wire from floor pan.
2. Remove retainers "A" from front and rear support pins, remove support pins and regulator from support (fig. 87). NOTE: This operation may be performed with the seat installed in the body. The seat in figure 87 has been removed for illustrative purpose only.
3. To install, reverse this procedure.

Seat Assembly

Removal and Installation

1. Place seat in the extreme forward position, loosen sill plates and turn floor carpet back exposing seat attachment. NOTE: On electric seat adjuster models, disconnect regulator wiring harness from seat frame bottom, move seat to extreme rearward position and at the front of the seat remove the horizontal regulator front support pin.
2. Remove two bolts from rear leg of each adjuster. Then pull the entire seat assembly rearward, lifting slightly to clear front legs from retaining brackets. Remove seat from body.
3. To install, reverse this operation.

Adjustment

1. In the event an additional rearward adjustment of the front seat is desired, provisions are made to relocate the seat assembly one inch back.
2. Remove the seat assembly from the body.
3. Remove front leg brackets from floor pan and drill 5/16" holes in the floor pan. These holes must be one inch to the rear of original attaching holes and on the same center line.
4. Drill out to 5/16" diameter, the forward two 1/4" pierced holes in each of the seat rear adjuster legs.
5. Seal the original attaching holes with body caulking compound.
6. Install front leg brackets, then install seat assembly. Use longer bolts to attach the rear legs to floor pan.

NOTE: It is imperative, when the seat assembly is moved to the rear, that all attaching points are moved to the rear to insure adequate seat to floor pan retention.

Seat Adjuster

Removal and Installation

1. Remove seat assembly from body and place seat upside down on a covered bench.
2. Remove seat side panels. NOTE: On electric seat adjuster installations, remove tensioner spring "A" from right seat adjuster (fig. 88).
3. Move adjuster to extreme rearward position and remove bolt "B" from channel, move adjuster to full forward position and remove bolt indicated at "C".
4. Detach seat adjuster from frame, disengage locking rod and remove seat adjuster.
5. To install reverse this procedure. Seat adjuster attachment to frame must be made with the sliding mechanism in the same relative position.

Seat Back

Tilting Style

Removal and Installation

1. Remove seat lower side panel, then remove "C" clip from hinge pin (fig. 89).
2. Remove the center hinge post cover plate.
3. Tilt opposite seat back half forward, then pull seat back toward outside of body disengaging outer support arm from hinge pin.
4. Rotate the seat back forward, disengaging the hooked end of center hinge pin from its retainer and remove back.
5. To install, reverse this procedure.

Solid Back

Removal and Installation

1. Remove seat side panel and side panel extension.
2. Remove four seat back to frame bolts "A" at each lower corner of the seat back (fig. 90). NOTE: It is not necessary to remove seat from body to perform this operation.
3. To install, reverse this procedure.

Seat Back of Back Trim

Tilting Back Style

Removal and Installation

1. Remove upper side panel and at the center remove finishing trim strip (fig. 91).
2. Remove stops at each lower corner.
3. Remove hog rings attaching trim to frame along each side and at the bottom. Seat back of back trim is sewn to the bolster at the top edge and can only be completely removed when the front portion of the seat back trim is removed.
4. Seat back springs maybe made accessible by removing hog rings attaching jute pad to springs.
5. To install, reverse the removal operation.

Solid Back

Removal and Installation

1. Remove seat back assembly, remove ash tray assembly from bodies so equipped by removing screws retaining escutcheon to seat back frame.
2. Remove hog rings retaining back of back trim to frame at sides and along bottom edge of frame. Back of back trim is sewn to top of the seat back trim and is not removable unless front portion of seat back trim is removed.
3. Access to the spring may be obtained by removing hog rings attaching jute pad to springs.
4. To install, reverse this procedure.

Rear Seat Cushion

Removal and Installation

1. Lift front edge of cushion upward disengaging locating tabs from retaining holes in floor pan.
2. Pull cushion from under seat back and remove from body.
3. To install, reverse this procedure.

Rear Seat Back

Sedan and Sport Coupe

Removal and Installation

1. Remove rear seat cushion.
2. Bend down body to seat back retaining tabs at floor pan and along wheelhouse.
3. Pull seat back out at the bottom and lift upward to disengage top of seat back from hangers located at parcel shelf and remove.
4. To install, make sure hangers and tabs are covered with tape which acts as an anti-squeak, then reverse this procedure.

Convertible

Removal and Installation

1. Remove rear seat cushion.
2. Remove attaching screws and washer along inner bottom edge of seat back. Remove the screws attaching fold top compartment side panels to each corner of seat back.
3. Elevate seat back to clear retaining hangers at upper edge of seat back and remove.
4. After making certain all retaining tabs are taped, reverse this procedure to install seat back.

The headlining removal and installation service operation is similar for all models. Variation such as exposed roof bows on the sport coupe and various interior molding arrangement present no problem. The procedure as presented for sedan models, therefore, can be followed with minor deviations on any body model.

Sedan Styles

Removal

1. Remove the following hardware and trim assemblies; rear seat cushion and back, rear view mirror, sunshades, dome lamp cover, coat hooks and all garnish moldings except the door garnish moldings.
2. Remove tacks or staples at windshield opening and carefully loosen cemented edge of headlining. NOTE: Clean hands are essential when working on trim assemblies.
3. Loosen edge of parcel shelf trim to gain access to headlining, then remove tacks or staples from headlining around quarter window and back window. Loosen cemented edge of headlining.
4. Carefully disengage headlining from metal retainer tabs along side roof rails (fig. 92).
5. Starting at the front, disconnect headlining support wires from side roof rails. Then bend down metal tabs retaining listing wire at center bow, roll headlining up with listing wires on outside to keep headlining clean.

Installation

1. Attach listing wires to side roof rails by starting at the rear of the body and work toward the front. NOTE: Center and align headlining in relation to back window, door openings and dome lamp opening. Hook number 3 listing wire to retainers at center roof bow (fig. 92).
2. Cement.(trim cement) and stay-tack headlining at tacking areas of back window, rear quarter windows and windshield. Check alignment of sunshade opening in headlining with attaching screw holes.
3. Working from the front to rear remove all fullness and draws from headlining. Then permanently tack in place.
4. Carefully insert headlining under retainers at side roof rails with tool J-2772.
5. Cement parcel shelf trim in place with trim cement, then install hardware and trim assemblies.

Illustrationsfig. 93, fig. 94, fig. 95 and fig. 96 may be used for reference purposes of exterior body moldings. The moldings are all keyed numerically to their respective removal and installation procedures.

SEDAN FRONT AND REAR DOOR EXTERIOR MOLDINGS

The door exterior moldings are secured to the door by a combination of self-tapping metal screws, snap-on clips, tee bolt clips and clips retained by screws. Before removing a molding which has to be pried from a body panel, apply a strip of masking tape to the surface adjacent to the molding to prevent possible damage to, the finish. When installing exterior moldings using retainers with self-tapping metal screws, snap-on clips, or bolt and clip assemblies, apply medium bodied sealer around the attaching holes in the body panels to provide a watertight seal. Whenever it is necessary to disturb the door inner panel sealing, reseal panel as specified in Door Inner Panel Sealing procedures in this section.

1. Front and Rear Door Window Upper Reveal Molding-2400 Series.

These moldings are secured to the door by clips attached to the upper flange of the molding and retained by screws through the door hemming flange. Two screws, located under the glass run channel, secure the molding to the window frame. To remove molding, detach upper portion of glass run channel and remove molding attaching screws. Remove attaching screws along door hemming flange and remove molding. To install, reverse removal procedure.

2. Front and Rear Door Window Lower Reveal Molding-2400 Series.

These moldings are secured to the return flange of the door outer panel with self-tapping metal screws. Each end of the molding is retained by a screw clip to the door hemming flange. To remove molding, remove door trim pad and access hole cover : On front doors, remove ventilator assembly, disengage window regulator cam from glass and lower glass sufficiently to remove reveal molding attaching screws from door outer panel flange. To install, reverse removal procedure.

2. Front and Rear Door Window Lower Reveal Molding-2100 Series.

The moldings are secured to the door outer panel with snap-on clips and one screw clip at each end of the molding. To remove molding, remove screw securing ends of molding to door hemming flange and with a flat-bladed tool, molding, with attached clips, from the door. To install, apply sealer around clip holes, replace clips where required and reverse removal procedure.

3. Front Door Lower Molding-2400 Series

The molding is secured to the door with snap-on clips and one screw clip at the front end of the molding. To remove molding, remove screw securing front end of molding to door hemming flange and with a flat-bladed tool, pry molding with attached clips from the door. To install, apply sealer around clip holes, replace clips where required and reverse removal procedure.

4. Rear Door Molding-2100 and 2400 Series

The molding is secured to the door outer panel by bolt and clip assemblies, and a screw clip at the door hemming flange. To remove molding, remove door trim pad and access hole cover. Remove screw at door hemming flange; then, through access hole remove nuts securing bolt and clip assemblies and remove molding. To install, apply sealer around bolt holes and reverse removal procedure.

5. Rear Door Diagonal Molding-2100 and 2400 Series

The molding is secured to the door outer panel by three bolt and clip assemblies. To remove molding, remove door trim pad and access hole cover; then, through access hole remove nuts securing bolt and clip assemblies and remove molding. To install, apply sealer around bolt holes and reverse removal procedure.

6. Rear Fender Diagonal Molding - 2100 and 2400 Series

The molding is attached to the rear fender with tee bolt and clip assemblies. Access to the bolts and nuts is gained by removing rear quarter trim panel and access hole cover. To install, reverse the removal procedure.

7. Rear Fender Lower Molding-2100 and 2400 Series

The molding is installed to the rear fender with tee bolt and clip assemblies. To remove molding, remove rear quarter trim panel and access hole cover to gain access to the molding attaching nuts. The remainder of the molding attaching nuts may be removed by reaching up under the rear fender. To install, reverse the removal procedure.

8. Door Lower Rear Molding-2100 and 2400 Series

The molding is secured to the door with a tee bolt clip at the front of the molding and a screw clip at the rear end of the molding. To remove molding, remove door trim pad and large access hole cover; then, from between door panels remove tee bolt clip attaching nut and sealing washer. Remove screw securing rear end of molding to door hemming flange and remove molding. To install, reverse removal procedure.

9. Rear Door Emblem and Ornament-2400 Series

The rear door emblem and ornament are secured to the door outer panel by lock nuts. To remove emblem and ornament, remove door trim pad and access hole cover; then, through access hole remove lock nuts. To install, reverse removal procedure.

10. Center Pillar Upper Reveal Molding-2400 Series

The molding, together with a filler and sealing washer, is secured to the center pillar by a bolt and clip with an attaching nut on the inside of the body under the center pillar trim. To remove molding, loosen headlining and upper portion of center pillar trim sufficiently to remove the attaching nut. To install, assemble center pillar filler and sealing washer to molding tee bolt and reverse removal procedure.

10. Center Pillar Upper Filler Cap-1500 and 2100 Series

A painted center pillar upper filler cap is secured to the center pillar by a bolt and clip with an attaching nut on the inside of the body under the center pillar trim. The filler cap is removed and installed in the same manner as the center pillar upper reveal molding on the 2400 Series.

11. Center Pillar Lower Reveal Molding - All Series

The molding is secured by one screw through the side face of the center pillar.

Sedan Rear Quarter and Rear Fender Molding

12. Rear Quarter Window Lower Reveal Molding-2100 Series-4 Door Sedan

This molding is attached to the rear quarter outer panel by snap-on clips. To remove molding, pry off with suitable tool. Seal snap-on clips when installing.

12a. Rear Quarter Lower Reveal Molding-2400 Series-4 Door Sedan

This molding is installed to the rear quarter outer panel by self-tapping screws. To remove molding, remove rear quarter window. To install, reverse procedure.

13. Rear Quarter Window Upper Reveal Molding-2400 Series-4 Door Sedan

This molding is installed to the rear quarter window header by snap-on clips, self-tapping screws and to the rear quarter outer panel by a bolt and clip assembly. To remove molding, remove washer and nut which are accessible through rear compartment, rear quarter window and rear quarter lower reveal molding. Then, pry molding from snap-on clips. Apply sealer to clips and bolt hole before installation.

14. Rear Fender Molding-2100 and 2400 Series 4 Door Sedan

The molding is installed to the rear fender using tee bolt and clip assemblies. Access to the molding attaching nuts is gained by reaching up under the rear fender panel. To install, reverse the removal procedure.

15. Rear Quarter Window Lower Reveal Moldings-2100 Series-2 Door Sedan

The molding is attached to the rear quarter outer panel by snap-on clips and bolt and clip assemblies at the front and rear of molding. To remove molding, remove rear seat, garnish molding, trim panel and access hole cover. Nuts securing bolt and clip assemblies are then accessible for removal. Pry molding from snap-on clips. To install, reverse procedure. Seal around clips and bolts holes with medium-bodied sealer.

15. Rear Quarter Window Lower Reveal Molding-2400 Series-2 Door Sedan

The molding is attached to the return flange of the rear quarter outer panel with self-tapping screws and tee bolt and clip assembly at the front end of the molding. Access to screws and bolts is gained by removing the rear quarter window. To install, reverse the procedure.

16. Rear Quarter Window Upper Reveal Molding-2400 Series-2 Door Sedan

The molding is secured to the body with snap-on clips and self-tapping screws. To remove molding, loosen the glass run channel at upper window opening to gain access to screws and forward section of rear quarter window upper rear reveal molding. Apply masking tape above molding to protect body finish. Pry molding with attaching clips from panel. To install, apply a medium bodied sealer around clip holes, and reverse procedure.

17. Rear Quarter Window Upper Rear Reveal Molding-2400 Series-2 Door Sedan

The molding is installed to the rear quarter window header by snap-on clips, self-tapping screws and to the rear quarter outer panel by a bolt and clip assembly. To remove molding, remove washer and nut which are accessible through rear compartment. Remove rear quarter window reveal molding lower. Loosen the glass run channel at window opening to gain access to screws and rear section of quarter window upper reveal molding. Apply masking tape above molding to protect body finish. Pry molding with attached clips from panel. To install, apply medium-bodied sealer around clip holes, reverse the procedure.

18. Rear Fender Crest Emblem and Ornament 2400 Series-2 Door Sedan

The emblem and ornament are installed to the rear fender using locking nuts. Access to the locking nuts is gained by removing rear quarter arm rest and access hole cover. To install, reverse the removal procedure.

Convertible and Sport Coupe Door Exterior Moldings

19. Door Window Front Reveal Molding

The molding is located at the bottom of the door ventilator and is secured to the return flange of the door outer panel by two self tapping metal screws between the ventilator frame and outer panel. Remove door trim pad and door ventilator. Remove attaching screws and molding. To install, reverse removal procedure.

20. Door Window Rear Reveal Molding

The molding is secured to the return flange of the door outer panel with self-tapping metal screws. Remove door trim pad and large access hole cover. Disengage regulator cam from glass and lower glass sufficiently to remove reveal molding attaching screws. Loosen rear screw of front reveal molding and remove rear molding. To install, reverse removal procedure.

21. Door Ventilator Reveal Molding

The molding is secured to the door pillar by self-tapping metal screws. Remove door ventilator assembly, molding attaching screws and lift molding upward to detach from door pillar. To install, reverse removal procedure.

22. Door Lower Front Molding

The molding is secured to the door with snap-on clips and one screw clip at the front end of the molding. Remove screw securing front end of molding to door flange and pry molding with attached clips from the door. To install, apply sealer around clip holes, replace clips where required and reverse removal procedure.

23. Door Lower Rear Molding

The molding is secured to the door with a tee bolt clip at the front and a screw clip at the rear. Remove door trim pad, large access hole cover and from between door panels remove tee bolt clip attaching nut and sealing washer. Remove screw securing rear end of molding to door flange and remove molding. To install, reverse removal procedure.

Convertible and Sport Coupe Rear Quarter and Rear Fender Moldings

24. Rear Quarter Lower Front Reveal Molding Sport Coupe

The molding is secured to the return flange of the rear quarter outer panel with screws. Remove rear quarter window to gain access to screws. To install, reverse removal procedure.

25. Rear Quarter Reveal Molding-Sport Coupe

The molding is secured to the body by screws. Remove quarter lower front reveal molding and rear quarter sealing strip. Then remove molding attaching screws. To install, reverse the removal procedure.

26. Rear Quarter Reveal Molding-Convertible

The molding is secured to the return flange of the quarter outer panel with screws. Remove rear quarter window and reveal molding attaching screws. To install, reverse removal procedure.

27. Rear Quarter Pinchweld Finishing Molding Convertible

The two moldings are snapped over the pinchweld flange and retaining clips along the folding top compartment. The right rear quarter molding overlaps the left rear quarter molding and is secured at the front and rear by a screw. The left molding is secured at the front by a screw. Remove rear quarter reveal molding. On inside of body, detach front edge of folding top compartment bag from rear seat back panel and detach trim stick to gain access to screw at end of rear quarter molding. To install, replace waterproof tape covering pinchweld flange and apply a bead of medium-bodied sealer in crown of molding. Replace retaining clips where required and reverse removal procedure.

28. Rear Fender Molding

The molding is installed to the fender with the tee bolt and clip assemblies. Remove quarter trim panel and access hole cover to remove attaching nuts. The remainder of the attaching nuts are removed from under the fender. To install, reverse the removal procedure.

29. Rear Fender Diagonal Molding

The molding is installed to the rear fender with tee bolts and clip assemblies. Access to the molding attaching nuts is gained by removing rear quarter arm rest and access hole cover. On convertible electrically operated windows, disconnect rear quarter window regulator and prop window in the up position. To install, reverse the removal procedure.

30. Rear Fender Crest Emblem and Ornament

The emblem and ornament are installed to the rear fender with locking nuts. Access to the locking nuts is gained by removing quarter arm rest and access hole cover. To install, reverse the removal procedure.

31. Rear Fender Rear Ornament

The molding is secured to the rear fender panel with tee bolt and clip assemblies. To remove molding, reach up under the rear fender panel. To install, reverse the removal procedure.

Electric Window Regulator and Seat Adjuster

Description

The windows and front seat adjuster are operated by individual 12-volt reversible motors. Each motor incorporates an internal thermal circuit breaker to prevent overloading. All other components of the window and seat adjuster circuit are protected by an additional circuit breaker which is in the power feed circuit.

Operation

The operation of the reversible motor is controlled by two motor feeds running from the control switch to the motor. The motor is grounded through its attachment to the body. By actuating the toggle control switch in one direction a clockwise motor shaft rotation is obtained, by moving the switch control in the opposite direction a counterclockwise shaft rotation is obtained. On window installations the motor drives the pinion gear which is meshed to rack portion of the regulator sector providing an up and down movement of the regulator lift arm. On seat installations, the armature shaft of the motor has a worm cut in it. This worm drives another worm to provide the adjuster movement.

Window Regulator

Disassembly

1. Remove electric window regulator assembly from door or rear quarter.
2. Place regulator assembly in vise and drill a 1/4" hole through the back plate and regulator sector at either "A," "B," or "C" locations, at least 3/4" away from the edge of the back plate or sector, depending on the position of the lift arm (fig. 97). NOTE: Do not drill into the motor housing, which is indicated by dotted line.
3. Insert bolt through holes and install nut loosely. NOTE: The regulator lift is under spring tension and must be locked in place to prevent possible injury when the motor assembly is removed.
4. Remove attaching bolts "D" and remove motor assembly from regulator. Clean drill chips from sector and pinion gear.

Assembly

1. Install motor to regulator. If trouble is encountered in aligning the attaching holes, the regulator arm may be moved up or down manually to permit meshing of sector teeth and pinion gear.
2. Remove temporary bolt and nut from back plate and sector.
3. Install regulator to door or quarter.

Quarter Window Switch

Removal and Installation

1. Remove rear quarter window garnish molding.
2. Pull quarter trim panel out slightly, reach down behind panel and disconnect terminal block from switch.
3. Carefully pry retaining tabs open at each side of switch and remove switch.
4. To install, press switch into trim panel, then reverse the removal procedure.

A light tester can be used to locate open or short circuits in the electrical circuit. Figure 98 is a schematic with wire codings of the wiring circuit for power windows and seat.

Checking Door Switch

1. Ground test light wire to body metal and insert test light prod into switch center feed terminal (fig. 99).
2. If test light fails to light, current is failing to reach switch. Back check over feed circuit to locate fault.
3. If test light operates, place a No. 12 jumper wire between the center terminal and either of the two switch motor terminals (fig. 100). If motor operates the switch is faulty. (Test each switch motor terminal). Check terminal block to make sure wires are secure in terminal block.
4. Place a No. 12 jumper wire between the switch center terminal and switch motor lead terminal being tested. Disconnect motor lead at motor and install light tester and check switch to motor wire (fig. 101). Test opposite motor lead wire in the same manner.
5. Check the ground of the motor at its attachment to the door inner panel. Scrape any paint away from under the attaching bolt which may be insulating the motor.
6. Check operation of the motor, by breaking the motor leads at the plastic connectors through the loading hole in the inner door panel and connecting a No. 12 jumper wire between the battery positive post and the motor lead (fig. 102). If the motor fails to operate, motor is defective or a mechanical stoppage exists. Check the other motor lead in the same manner.

Trouble Diagnosis

1. Window will not operate from immediate control switch but will operate from master control switch.
   • Check feed wire to immediate switch.
   • Check immediate control switch.
   • Check motor leads from immediate control switch to motor.
2. Window will not operate from master switch but will operate from immediate switch.
   • Check operation of master switch.
   • Check two motor leads from master switch to motor.
3. Window will not operate from either immediate nor master switch. Operation of other windows is satisfactory.
   • Check for mechanical stoppage.
   • Check operation of immediate and master switches.
   • Check motor leads from each switch to motor for shorts or open circuit.
   • Check operation of motor.
4. Windows will not operate from master switch but will operate from immediate switches.
   • Check feed wire from circuit breaker to master switch.
   • Check operation of master switch.
5. Seat regulator will not operate, windows do operate.
   • Check for mechanical stoppage of seat adjuster.
   • Check feed wire from circuit breaker to seat adjuster switch.
   • Check operation of seat adjuster switch.
   • Check motor leads to motor from switch.
   • Check seat adjuster motor.
6. Neither windows or seat adjuster will operate.
   • Check battery.
   • Check circuit from battery to circuit breaker.
   • Check circuit breaker.
   • Check feed wire from circuit breaker to switches.
   • Check operation of all switches.

Quick Checks

1. Turn dome lamp on and actuate the switch, if dome light dims and there is no operation of the unit being tested, look for a mechanical stoppage.
2. Actuate switch of unit being tested, if there is no operation continue to hold the switch in operating position. At the same time listen for circuit breaker in the motor. If you hear the circuit breaker, look for a mechanical stoppage.

Mechanical stoppage is not the only cause of failure in the two aforementioned quick checks. The failure could be in the motor but in most cases mechanical stoppage will be the cause.

Side Roof Rail Weatherstrip

Description

The convertible top is sealed at the door and quarter windows by a three sectioned side roof rail weatherstrip. The weatherstrip sections with integral studs are attached to the side roof rails with nuts, in addition, the weatherstrip ends are secured with screws.

Removal

1. Lower top halfway and remove weatherstrip attaching screws "A" (fig. 103).
2. Remove weatherstrip attaching nuts and washer "B" from inside the channel section of the side roof rail (fig. 103). NOTE: To remove the front section of the sideroof rail weatherstrip it is necessary to loosen the front roof rail weatherstrip retainer.

Installation

To install, apply a ribbon of body caulking compound to the attaching surface of the front and center sections of the side roof rail weatherstrip as indicated at "1" (fig. 103), then reverse the removal operation.

Adjustment

1. The side roof rail weatherstrips may be adjusted laterally by removing the attaching screws and loosening the attaching nuts and positioning the weatherstrips as desired. Retighten nuts and install screws. The front section of the weatherstrip may be adjusted fore and aft in the same manner.
2. To move the weatherstrips down to give a better seal at the windows, loosen weatherstrip attaching screws and nuts and install waterproof shims between the weatherstrips and side roof rail. Retighten attaching screws and nuts.

Front Roof Rail Weatherstrips

Two weatherstrips, front and rear, are utilized to seal the front roof rail to the windshield header. These weatherstrips are secured to the front roof rail with weatherstrip adhesive and a two piece metal retainer. Remove the two piece metal retainer and loosen weatherstrip from front roof rail and remove weatherstrip. To install, clean old adhesive from rail with oleum sprits, re-cement attaching surfaces of weatherstrip and rail with weatherstrip adhesive. Firmly install weatherstrip to rail, then install two piece metal retainer.

Folding Top

Description

The folding top linkage consists of three sections of right and left side roof rails and a front roof rail connected together by bolts, hinges, and a series of connecting links and bows. The top linkage is attached to the body at the rear quarter area by a male hinge bolted to an adjustable support. The front roof rail is locked in place at the windshield header by two cam locks which are an integral part of the locking handles. To correct some top variations, only a single adjustment is required; other top variations require a combination of several adjustments. In addition to adjustment of the folding top, it may be necessary to adjust the door glass, rear quarter glass, or the side roof rail weatherstrips. Adjustment of the door glass, rear quarter window and side roof rail are covered in this body section.

ADJUSTMENTS

Front Roof Rail Corner Brace

Condition: Front roof rail too far forward or too far to the rear for proper engagement of the guide studs in the front roof rail with the holes in the sun shade support.

Correction:

1. Raise top slightly above windshield header and remove screw from groove of side roof weatherstrip at front corner.
2. Loosen corner brace attaching screw "A" and bolt "B" and,- adjust front roof rail fore or aft as required (fig. 104). Repeat on opposite side if necessary. NOTE: This adjustment is limited, should additional adjustment be required, it can be made at folding top male hinge. Sunshade Supports and Lock Handle Strikers

Condition: Difficult to lock top in raise position or loose fit between top front roof rail and windshield header.

Correction:

1. Raise top slightly above windshield header and loosen screws "A" and adjust the strikers up or down or from side to side as required (fig. 105).
2. If an additional downward adjustment is desired, install an emergency striker.
3. Align the sunshade supports with the front roof rail guide studs and tighten attaching screws.

Male Hinge

Condition: Excessive opening between side roof rail rear weatherstrip and rear quarter window or front roof rail too far forward or rearward.

Correction:

1. Loosen the four male hinges attaching bolts "A" and move hinge fore or aft, as required; then, tighten bolts (fig. 106).
2. Check side roof rail alignment and stacked position of top, and readjust if necessary.

Control Link Adjusting Plate

Condition 1: Side roof rail too high or too low at top of the door glass.

Correction:

1. Place top midway in the operational cycle and loosen two nuts indicated at "B" (fig. 106).
2. Without changing the fore or aft location of the adjusting plate "C," move adjusting plate up or down as required. To lower side roof rail, move adjusting plate up, to raise side roof rail, move adjusting plate down.

Condition II: Top will not stack properly in the folding top compartment.

Correction:

1. Lower top to stacked position and loosen nuts "B" (fig. 106) and move adjusting plate "C" forward or rearward as required. To lower the stacked position, move the adjusting plate rearward. To raise the stacked position, move the adjusting plate forward. NOTE: Do not change the vertical position of the adjusting plate.

Male Hinge Support

Condition.- Side roof rail too high or too low at the rear quarter windows.

Correction:

1. Loosen attaching bolts "D" (fig. 106). The support is secured firmly in place by serrations on the contacting surfaces of support and brace.
2. Adjust support up or down as required; then tighten bolts.
3. Check side roof rail alignment and readjust if necessary.

Description

The convertible folding top is operated by a "sealed-in" electric-hydraulic unit which is comprised of a motor and pump assembly, two hydraulic lift cylinders, upper and lower hose assembly and a wiring circuit (fig. 107).

The pump is operated by a 12 volt reversible direction motor and is installed in a horizontal position in the rear compartment behind the rear seat back. The pump is provided with an adjustable pressure relief valve which is set to deliver a pressure ranging from 240 psi to 280 psi. The top operation is controlled by a self-centering switch, which is connected directly to the motor.

Operation

To raise the top, the control knob is pushed in toward the instrument panel; completing an electrical circuit through the switch to the motor via the red motor lead. The motor and pump operates, forcing fluid through the hose to the lower end of the double acting lift cylinders. Fluid pressure exerted against the piston forces the piston rod, which is connected to the top linkage, upward raising the top. Fluid in the top of the cylinder is forced out of the cylinder by the reaction force of the piston and returns to the pump reservoir for recirculation.

To lower the top, the control knob is pulled out from the instrument panel completing the electrical circuit through the switch via the green motor lead to the motor. This reverses the action of the motor and pump. Hydraulic fluid is then directed under pressure to the top of the lift cylinders forcing the piston down and lowering the top. Fluid in the bottom of the cylinder, which is displaced by the reaction force of the piston, is directed back to the reservoir for circulation.

Reservoir Fluid Level Check

1. With top in raised position, disconnect positive or negative battery cable.
2. Remove pump and motor shield in rear compartment and place absorbent material below reservoir.
3. Remove filler cap "A," fluid should be at lower edge of filler cap hole as indicated by dotted line (fig. 108).
4. Bring fluid to specified lever, by adding Delco Super No. 11 to reservoir.
5. Install filler cap, shield and connect battery cable.

Motor and Pump Assembly

Removal and Installation

1. With the top in the up position, disconnect the positive or negative battery cable.
2. Inside the rear compartment, remove the pump and motor shield and remove the clip securing the wire harness and ground wire, then disconnect motor leads fig. 109). NOTE: Place absorbent material below reservoir and hose connection to prevent damage to body parts from hydraulic fluid.
3. Vent the system by removing filler cap "A" then replace cap. NOTE: Since the hydraulic system is under pressure, venting of the system is necessary to prevent fluid being forced from disconnected hydraulic line.
4. Disconnect hydraulic lines at reservoir and cap hydraulic fittings immediately to prevent loss of fluid and damage to body parts.
5. Release four attaching grommets and lift motor and pump assembly from body.
6. To install, reverse this procedure. Check fluid level in reservoir.

Top Lift Cylinder

Removal and Installation

1. With the top in the raised position, disconnect the positive or negative battery cable.
2. Remove motor and pump shield in rear compartment and vent system to remove pressure in system by removing filler cap, catch any fluid leakage in rags then replace filler cap.
3. Inside the body, remove rear seat cushion, back and folding top compartment side panel.
4. Remove nut and bolt at "A" retaining piston rod to top linkage (fig. 110).
5. Remove hydraulic hose retainer "B" at top compartment brace. Back under the door lock pillar brace, remove cotter key and pin at "C" from lift cylinder support bracket. Observe location of washers.
6. Disconnect hydraulic lines from cylinder and cap fittings. Immediately wipe up any fluid leakage.
7. Through opening in face of top compartment brace remove cylinder from body.
8. To install, reverse this procedure. Apply a good grade of high pressure sealing compound to all male fittings before connecting lines. Check fluid level.

Failure of the Hydro-Lectric system where the cause is not readily evident, should be checked in the following sequence: Mechanical, Electrical and Hydraulic systems.

Mechanical Check

If top action is slow, check for mechanical bind.

1. Disconnect piston rods at top linkage attachment and raise and lower the top by hand through the cycle, noting any binding action of the top linkage.
2. While locking top at header, if binding action is noted, check alignment of door windows, ventilators and rear quarter windows in relation to the side roof rail weatherstrips. Make necessary adjustment to correct.

Electrical Check

Battery

1. Check battery condition, a partially discharged battery will result in a sluggish operating pump.

Folding Top Switch

1. Connect one lead of test light to feed wire terminal of control switch and ground the opposite lead. If tester does not light, there is an open or shorted circuit between battery and switch.
2. Disconnect leads to motor at switch terminal and place one lead of tester to up cycle terminal and other lead of tester to ground (fig. 111). Push control knob forward, if tester fails to light switch is defective. Check down cycle side of switch, by hooking tester to down cycle terminal and ground and pulling control knob out. Failure of tester to light indicates a faulty switch. Replace switch.

Switch to Motor Lead Wires

1. Disconnect switch to motor leads at motor in rear compartment. Connect tester to green motor wire (down cycle) and ground, pull control knob out to check (fig. 112). Connect tester to red motor wire lead and ground, push control knob in to check. If tester fails to light in either case, the circuit from the switch to motor is either open or shorted.

Motor Unit

Check the operation of the motor by connecting first one lead of motor via a jumper wire directly to the positive post of the battery; if the motor operates check the other motor lead in the same manner. If motor operates, but will not operate when hooked into the wiring harness, check back over the wiring harness for shorts. A sluggish operating motor when hooked into wiring harness could be indicative of low voltage at the motor resulting from poor connection, poor motor ground or a short.

Hydraulic Checks

Hydraulic system failure can be caused by lack of fluid in the system, leaks, obstruction or kinks in lines, faulty lift cylinders or pump. Troubles in the hydraulic system can be readily located with a pressure gauge. Pressure should read between 240 psi and 280 psi when pressure relief valve opens.

Pump

1. Install pressure gauge into lines leading to bottom of lift cylinders. Hydraulic lines have been shortened for illustrative purposes (fig. 113).
2. Kink lines "A" and "B" to shut off fluid flow to bottom of cylinders. Push control knob in and hold it several seconds. Pressure should be between 240 psi to 280 psi.
3. Install pressure gauge in lines leading to top of lift cylinders, kink lines "C" and "D," pull control knob out and hold for several seconds and take reading. This reading should be between 240 psi and 280 psi. NOTE: A variation between the pressure reading at pump feed to top and bottom of cylinders is satisfactory, providing both pressures fall between 240 psi and 280 psi.

Adjustment of Pump Pressure

1. Remove pump and motor assembly and place assembly upright in a bench vise. Hook motor up to a battery through a switch.
2. Install plug in one port and pressure gauge in other port.
3. Remove cap nearest to reservoir attaching bracket from top of reservoir.
4. Insert screwdriver through opening ( fig. 114) and start motor and adjust pressure by turning adjusting screw until satisfactory reading of 240 psi to 280 psi is obtained. Repeat adjustment with gauge installed in other port. NOTE: Turning adjusting screw clockwise, increases pressure, counterclockwise, decreases pressure. Satisfactory adjustment should be obtained within two turns in either direction.
5. If it is impossible to obtain proper pressure adjustment, trouble is in the pump unit and it should be repaired or replaced.

Lift Cylinders

1. Remove rear seat cushion, back and folding top compartment side panel assembly.
2. Operate the folding top, while watching action of the lift cylinders. If operation is sluggish or a binding is evident, check for a kinked hydraulic line. Remove the lines and inspect for obstruction within the lines.
3. Vent the system by removing the filler plug, then install pressure gauge between line and fitting at bottom of cylinder. With the top in the up position, push the control knob in and hold for several seconds. Note reading on pressure gauge, if not up to standard (240 psi to 280 psi) fluid is leaking past the cylinder piston and the cylinder must be replaced. This check is based on the assumption that pump pressure and lines have been checked and found satisfactory. Repeat this test at each cylinder port. When the down cycle is being checked, have the top locked at header and pull the control knob out.

Lock cylinders are furnished for service uncoded, this necessitates the coding of all replacement lock cylinders.

The side bar type lock (fig. 115) is used for the ignition, door and trunk lid on passenger cars. Glove compartment locks are wafer tumbler single bitted type having 4 tumblers on passenger cars. These locks are all coded the same allowing a usage of one key for all locks on the vehicle. To protect owners, automobile lock manufacturers stamp the lock number on the lock core, shaft, etc., where they will not show until the lock is removed.

To obtain the code number remove the door lock, the key number may be obtained from the lock core, shaft, etc., which will be the same on all of the other locks.

In addition, when a lock cylinder requires replacement the lock code number may be obtained either from the key, if available, or from the old lock cylinder which is being replaced.

Once the code number of the lock is obtained, look up this number in a key cutting book. There are two types of code booklets in general use, one which lists the cutting code by letter C, N, B and Y. Numbers or letters are always recorded from the head of the key to the end. Numbers may be transposed to letters to numbers as follows:

Code Book-Numbers                                Code Book-Letters
        1                                                C
        2                                                N
        3                                                B
        4                                                Y

All side bar locks furnished to the field by the Parts Department are uncoded, that is, they are furnished without tumblers, springs or spring retainers; these parts are serviced separately. The tumblers come in four different depths indicated by colors "C" for copper, "N" for nickel, "B" for black and "Y" for yellow. The side bar locks have six tumbler positions, and in looking up the cutting code, the following may be used as an example. After key code number is determined, either from key or from number stamped on lock cylinder refer to your code book and record the key cutting information as follows.

    Key of                     Keycutting         Key cutting
   lock code                      code                code
    Number                     Numerical          Alphabetical
     8109                      2-3-2-1-2-4         N-B-N-C-N-Y
Cutting or Tumbler             1-2-3-4-5-6         1-2-3-4-5-6
position from head
of lock

The numbers or letters (depending on code book) which are written above the cutting or tumbler position indicate the different color tumblers which are to be dropped into each tumbler slot of the lock: "C"-copper, "N"-nickel, "B"- black, "Y"-yellow.

NOTE: If code book used lists the key cutting code numerically, the numbers must be transposed to letters as previously stated in order to select proper color tumblers for installation into the lock.

In cases where a code book is not available, the diagram as shown in figure 116 may be used to determine the tumblers required to assemble an uncoded lock cylinder.

1. Lay the key on the diagram (fig. 116) with the bottom of the key flush with the edge of the drawing, head and point carefully lined up.
2. Read the code in letters C-N-B-Y from the head of key to the end from positions 1 to 6 inclusive. As each depth is determined write that letter in the blank space provided above the position numbers (1-2-3-4-5-6).
3. With the key properly lined up on the diagram, all cuts that show in the first section are to be marked "C."
4. Cuts that fall in the first black section, mark "N."
5. Cuts that fall in the White section, mark "B."
6. Cuts that fall in the second black section, mark "Y."

After the letters (C-N-B-Y) have been determined and written above the cutting positions the lock cylinder should be assembled as follows:

Lock Cylinder Assembly

1. Hold cylinder with head of cylinder away and starting at the head of the cylinder, insert the tumblers in their proper slots in the order called for by the code, ribbed side toward you and long point down (fig. 117).
2. After all tumblers are in place, check for correctness with the code. Then press tumblers down with one finger (fig. 118).
3. Insert one tumbler spring in the space provided above each tumbler (fig. 119). CAUTION: If the springs are tangled, do not pull them apart-unscrew them.
4. Reverse the lock cylinders so that the head of the cylinder is now toward you. Insert the spring retainer so that one of its six prongs enters into each of the springs and the two large end prongs slide into the slots at either end of the cylinder ( fig. 120). Press the retainer down with one finger.
5. To check, insert proper key and if tumblers are installed properly the side bar will be allowed to drop down. If bar does not drop down, remove the key, spring retainer, springs and tumblers and reassemble correctly. NOTE: If the tumblers have not been assembled correctly and not according to the code, the tumblers can be removed from the cylinder by holding it with the tumbler slots down, pulling the side bar out with the fingers and jarring the cylinder to shake the tumblers out. This procedure is necessary because after the tumblers have been pressed down into the cylinder they are held in their slots by the cross bar.
6. If after checking it is found that the lock is assembled properly, remove key and place cylinder in a vise using leather or wood on each side to prevent damage to the cylinder.
7. Stake the retainer securely in place by staking the cylinder metal over both edges of the retainer ends using a suitable staking tool at right angles to the top of the retainer and from the cast metal of the cylinder over the retainer at each corner.

This section contains general directions for the proper care of the interior trim of the car and the convertible top. Several types of cloth material are or have been used in the Chevrolet; Nylons, Gabardines, Broadcloths, Pile fabrics. They are distinguished in part by flat woven yarns as in the broadcloths and pile surfaces, upright fibers densely woven at right angles to the base of the fabric.

General Instructions

Dirt and dust particles should be removed every few weeks, or more often if car upholstery is subject to constant hard driving. This can be done with a whisk broom, carpet beater or vacuum cleaner.

It is essential that stains be removed from upholstery as soon as possible. If they are allowed to remain on the fabric for some time, they often become oxidized and removal is difficult, if not impossible.

There are two basic types of popular cleaners available to car owners: (1) Volatile Cleaners, colorless liquids, generally having carbon-tetra-chloride or naphtha as a base. (2) Alkaline Cleaners which have a soap base.

The Volatile Cleaners are recommended since they have great solvent powers for grease, oil and road grime. Alkaline Cleaners generally remove stains satisfactorily but at possible risk to the removal of the color from the fabric.

Cleaning Pile Fabric

Soap and water may be used in cleaning pile fabrics, providing the instructions which follow are adhered to closely. A neutral non-alkaline soap should be used with lukewarm water. The suds should be frothy, not watery. They should be applied in moderate quantities with a damp cloth, sponge, or soft brush. Rub with the pile, not against it. Soapsuds should be removed with a clean, damp cloth or sponge. Then wipe the surface several times with a dry cloth. While still damp, brush lightly with a whisk broom or brush of medium stiffness. Permit air to circulate freely over the wet upholstery. When dry, brush again, against the pile.

The surface of pile fabrics can also be freshened by steaming. Spread a damp cloth over the surface and touch a hot flatiron to it lightly. While still damp, the upholstery should be brushed lightly with a whisk broom or brush of medium stiffness. When thoroughly dry, the material should again be brushed. Brush against the pile.

Cleaning Broadcloths, Nylons and Gabardines

Soap and water, regardless of the basic type of soap, is not recommended for cleaning flat cloths, particularly broadcloths.

1. Carefully brush all loose particles of dirt and soil.
2. Immerse small cloth in volatile type cleaning solution, wring out thoroughly, open cloth and allow medium evaporation.
3. Place cloth on soiled spot, do not rub, apply slight tapping pressure, several times. This will pick up particles which are too embedded to be removed in the brushing operation. This operation should be repeated several times- in each instance using a clean area of the cloth.
4. Immerse a new cloth in cleaner, wring out thoroughly, open and allow to evaporate until barely damp. Apply increased pressure and rub soiled area in a backward and forward motion. The cleaning cloth should be reversed several times in this operation.
5. Immerse third cloth, wring out, allow evaporation and apply to both the soiled and the area surrounding same, using a light, brisk motion.
6. Repeat brushing operation.
7. If a cleaning ring should form, the entire area of the assembly which is being cleaned should be thoroughly brushed and gone over lightly with the solvent.

Safety Precautions for Cleaning Fabrics

1. Do not use as a cleaning solvent any gasoline which is colored or contains tetraethyl lead.
2. Do not use any of the following bleaches or reducing agents, as their use tends to weaken the fabric and change or bleach the color of the goods: Chloride of lime, Javelle water, Hydrogen peroxide, Sodium Hydrosulphite, Potassium permanganate, Chlorine or chlorine water, Sulphurous acid (sulphur dioxide), Sodium thiosulphate (Photographers' hypo).
3. Carbon tetrachloride is non-inflammable, but it is considered toxic and should be used with care. Most other types of cleaning solvents are inflammable; and every precaution and care must be exercised in handling them.
4. Do not permit cleaning solvents to come in contact with the skin on the upper arms or the body. Such contacts sometimes produce local irritation, which is unpleasant, if not serious.
5. Do not breathe the fumes of cleaning solvents, since they are usually toxic in large quantities.
6. Keep oxalic acid out of reach of children and away from the mouth. It is a deadly poison.
7. There are on the market a great number of inexpensive, slow-drying cleaners of the clear type which are not recommended. Care should be taken, in the selection of a cleaner for the upholstery in your car, to select a product of proven reputation and quality.
8. Do not use too much cleaning fluid; some interior trim assemblies are padded with rubber, and volatile cleaners are generally solvents for rubber. The application of too much cleaner may destroy these rubber pads or cause the rubber itself to penetrate the upholstery fabric and soil it.

Cleaning Genuine Leathers and Imitation Leather

Care of genuine leather and imitation leather is a relatively simple but important matter. If dirt accumulates on the surface, this generates into a hard grit which under pressure will cut the finish and cause the leather to crock or bleed color. The surface should be gone over occasionally with a dry cloth and if dirt should accumulate, the following cleaning instructions should be used:

Lukewarm water and a neutral soap should be used and a thick suds worked up on a piece of cheesecloth and applied to the surface.

The operation should be repeated, using only a damp cloth and no soap.

The leather should then be wiped dry with a soft cloth. Polishes and cleaners used for body finishes, volatile and other clear cleaners, naphtha, furniture polishes, oils, varnishes or household cleansing and bleaching agents should never be used.

Cleaning Convertible Top Materials

The top materials are easily cleaned and kept attractive if the proper methods of cleaning and care, are exercised. Generally, soilage can be removed with art gum or crude rubber. If dirt is embedded in the fabric, the top should be thoroughly brushed with a whisk broom. In this brushing a minimum of pressure should be applied to those areas of the assembly which cover the metal bows of the top structure, since heavy abrasion will disturb the surface of the material appreciably, causing an unsightly appearance.

After brushing, the top should be washed thoroughly with a neutral soap suds and lukewarm water. A cloth or brush with soft bristles should be used. Generous quantities of clear water should then be applied over the surface to remove any soap which might remain. Volatile and other clear cleaners, naphtha, gasoline or household cleaning and bleaching agents should never be used.

After cleaning, always be sure that the top is thoroughly dry before folding it down. Folding the top while still wet or damp may cause mildew and unsightly wrinkles.

This precaution should also be taken by the owner in service. After rainfall, the top should be allowed to dry out thoroughly before being collapsed because, in addition to causing mildew and wrinkles, the top material will possibly shrink, after such abuse, to a degree that it may be impossible to return the top structure to its normal upright position.

Cleaning Carpet Floor Coverings

To clean carpet floor coverings, they should first be brushed thoroughly. If soil remains, a volatile type cleaner is recommended. The cleaning operation should be repeated for heavily embedded stains.

Extreme care should be taken by the owner to make certain that the carpets are not "soaked" with the cleaner. This may cause deterioration of the rubber compound backing construction of some carpets.

Neutral soap and water may also be used, at the risk of color removal, but the owner is cautioned to make certain that the carpets are thoroughly dry before closing all window and door openings to prevent possible mildew of the carpet.

Cleaning Convertible Plastic Back Window

1. To remove road dust use a soft cloth moistened with water and wipe crosswise of the window to remove superficial dust. NOTE: Do not use a dry cloth or paper cleaning tissue.
2. To clean the back window use cold or warm water and a mild neutral soap suds. After washing, rinse with clear water and wipe with a damp cloth. CAUTION: Never use cleaners of alcoholic or chemical content as they may have a deteriorating effect on the plastic or may spot the Duco finish below the window.
3. Do not use a scraper to remove frost, ice or snow from the plastic back window. Warm water may be used in an emergency.