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ALPHABETICAL INDEX

All Passenger Cars

Step 1 tape template to fender and drill holes Fig. 181.

Step 2 insert screw driver or rod in 1 inch dia. hole and knock out rubber plug from hinge pillar.

Step 3 remove the right cowl kick panel.

Step 4 install radio antenna Fig. 181.

Step 5 insert the jack end of antenna lead-in cable into the radio and screw the antenna lead-in coupling onto the antenna firmly.

Step 6 replace the right cowl kick panel.

Radio Antenna (Manually Operated)

All Passenger Cars

Step 1 locate templates on left rear fender and drill three holes.

Step 2 attach clip and bracket Fig. 182 and insert antenna assembly through holes.

Step 3 place gasket and bezel on antenna rod and secure with cap tightly.

Step 4 attach bracket to inner panel Fig. 182 and tighten clip nut.

Step 5 remove kick panel, clamp cable Fig. 182 and route toward front of car.

Step 6 replace kick panel.

Step 7 adjust antenna trimmer located on the bottom of radio.

Radio Antenna (Electrically Operated) Installation Instructions

PASSENGER CARS

Step 1 - locate templates on right rear fender and drill three holes.

Step 2 - attach clip and bracket Fig. 183 and insert antenna assy up through drilled holes.

Step 3 - place gasket and bezel on antenna rod and secure with cap tightly.

Step 4 - attach bracket to inner panel Fig. 183 and tighten clip nut.

Step 5 -remove r. h. kick panel, route wire and cable (after cable is clamped Fig. 184) together toward front of car.

Step 6 install switch and complete cable and wire routing through main wire harness clips.

Step 7 connect all terminals, insert antenna lead-in cable jack into radio receiver and fuse into terminal block.

Step 8 adjust antenna trimmer located on bottom of radio.

Step 9 replace the kick panel.

Radio Installation Instructions

ALL PASSENGER CARS

PRELIMINARY:

Check all items against the packing slip. If any items are missing, mark them on the packing slip, fill in the dealers' name, and forward it to the zone office. Attention of the zone parts and accessories manager. After checking the tubes and vibrator to be sure they are pushed tight into the sockets. Hook the radio receiver to a 12 volt power supply and play the radio while installing the supression equipment. (A new radio that plays properly for the first 15 minutes can be assumed to be an acceptable product which should operate in a normal manner without interruption.)

Step 1 install ground straps, capacitors, and static collectors. See illustrations no. Fig. 185 Fig. 186, Fig. 187 Fig. 188, AND STEP 12.

Step 2 remove radio grille, glove box, and radio control cover from instrument panel.

Step 3 install radio speaker. Fig. 189.

Step 4 replace grille with the nuts and washers previously removed. one of these nuts is used to install the radio support brace.

Step 5 install antenna lead-in clip. (Manual Radio Only) Fig. 189.

Step 6 install radio receiver.

Step 7 install control knobs and escutcheons.

Step 8 route and connect all leads and wires as illustrated. see Fig. 190 For manual wiring or Fig. 191Fig. 192 for signal seeking wiring.

Step 9 install fuse on terminals designated "radio power" on fuse junction block under instrument panel on left hand side of dash panel. see view c.

Step 10 extend antenna full height and tune for a weak station between 800 and 1000 kc. Adjust the antenna trimmer on the bottom of the radio for maximum volume.

Step 11 replace glove compartment box.

Step 12 see sheet 4 for v-8 engine special ground straps.

Fig. 193.

Radio Antenna

All Trucks

1. Place the template on the right hand front fender as indicated in Fig. 194. CAUTION: Follow the directions given on the template. Secure the template with masking tape.
2. Select the proper hole for drilling. This is indicated on the template. See Fig. 194. Centerpunch.
3. Remove template and drill a 13/16 inch diameter hole perpendicular to the fender surface.
4. Drop the inner spacer on the antenna. See Fig. 195.
5. From under the fender, pass the antenna up through the hole just drilled. Add the gasket and the outer spacer. Install the special hex head nut and tighten to finger tightness only. CAUTION: Make sure the extension arm at the bottom of the antenna faces inboard. See Fig. 196.
6. Attach the bracket loosely to the antenna extension arm with the hex head machine screw, internal-external tooth lockwasher and hex head nut. IMPORTANT: For Series 3000 trucks, shorten the bracket before attaching as shown in Fig. 196.
7. Align the bracket flush with the baffle, as shown in Fig. 198. then tighten the screw and nut assembly securely.
8. Using the holes in the bracket as a template, (See Fig. 196) centerpunch and drill two holes with a number 28 drill through the baffle. Secure the bracket to the baffle with two tapping screws.
9. Tighten the special hex head nut on the antenna assembly securely against the outer spacer. Add the special felt washer and antenna cap nut. The assembly should now be complete as shown in Fig. 195.
10. Locate on the cowl under the front fender, the dash mat clip. Measure outboard 1-3/4 inches from dash mat clip, centerpunch, and drill a 7/16 inch hole, as shown in Fig. 197. Remove any burrs resulting from the drilling and install the rubber grommet provided.
11. Attach the antenna cable to the antenna connector and pass the cable through the grommet. Route the cable under the instrument panel, connect the cable to the radio by means of the cable plug-in jack. This is shown in Fig. 198.
12. Attach the antenna cable to the inside bottom lip of the instrument panel with the clip provided, as shown in Fig. 198.

5000 SERIES

1. Place the template on the right hand front fender, as indicated in the upper portion of Fig. 199.CAUTION: Follow the directions given on the template. Secure the template with masking tape.
2. Select the proper hole for drilling. This is indicated on the template. See upper portion of Fig. 199. Centerpunch.
3. Proceed as directed in steps 3, 4, and 5 of the 3000, 4000, and 6000 Series instructions. CAUTION: Make sure the extension arm at the bottom of the antenna faces outboard during step 5.
4. Proceed as directed in step 6 of the 3000, 4000 and 6000 Series instructions. IMPORTANT: For Series 5000 trucks, shorten the bracket before attacking as shown in Fig. 199.
5. The bracket should now rest on the inside lip of the wheel opening flange. Using the remaining hole centerpunch and drill through the flange with a No. 33 drill.
6. Use a 1/4 inch standard hex nut (this is not included in the package) as a spacer between the bracket and the wheel opening flange, and from the bottom introduce the tapping screw provided making sure that it passes through the nut and bracket. Tighten securely. See Fig. 199.
7. Tighten the hex head machine screw, internal-external tooth lockwasher and hex head nut.
8. Repeat step 9 of the 3000, 4000 and 6000 Series instructions.
9. From inside the cab locate the perforated hole on the dash mat 3-1/4 inches up from the bottom of the mat and 1-1/2 inches in from the kick panel. Remove the material along the perforations, centerpunch and drill a 1/2 inch diameter hole through the cowl. Remove any burrs resulting from the drilling.
10. From under the right hand front fender, install the grommet in the hole just drilled and route the cable through the grommet to the inside of the dash panel. Connect it to the radio by means of the radio plug-in jack.

TRUCKS

Unpack the radio receiver and check all the parts with the packing slip. If any items are missing, indicate this on the packing slip and together with the dealer name and address send the packing slip to the Zone Office to the attention of the Zone Parts and Accessories Manager.

While bench convenience is available, check the tubes and vibrator to make sure they are secured tightly in their sockets. Connect the radio to a 12-volt power supply and allow the radio to play while installing the noise suppression equipment. Radios that play for 15 minutes should give many months of uninterrupted service.

1. Remove the high tension coil wire from the distributor cap. Install the distributor suppressor and nipple in the distributor cap and connect the high tension wire to the suppressor. See Fig. 201.
2. Mount the generator capacitor (No. 1911095) on the generator with the existing screw in the generator housing and connect the lead wire to the generator armature terminal. See Fig. 201. NOTE: Do not connect the lead wire to the generator field terminal.
3. Install the ignition coil capacitor (No. 1929070) to the coil mounting bracket with the screw and lockwasher provided and attach the lead wire to the positive terminal of the coil. See Fig. 201.
4. Mount the voltage regulator capacitor (No. 1917580) under the voltage regulator mounting screw and attach the lead wire to the battery terminal on the voltage regulator. See Fig. 201.
5. Remove both front wheel hub caps. Prepare to install the front wheel static collectors by removing both grease retainers and cleaning them of any grease. Remove the grease from the center holes in the front wheel spindles and clean the holes with sand paper to assure a good electrical contact for the static collector buttons. Bend the cotter pins to give adequate clearance for the static collector buttons so they may contact properly with the wheel spindle holes.
6. Press the static collectors into the grease retainers with the collector buttons up and the planes of the buttons parallel with the open sides of the retainers. See Fig. 202. NOTE: For 5000 and 6000 Series trucks only, it will be necessary to attach the static collectors to the adapters provided. See Fig. 202.
7. Replace grease retainers and hub caps.
8. Remove the radio hole cover plate and the two button plugs from the instrument panel.
9. Attach the radio mounting brace loosely to the bracket on the plenum panel with the bolt and spring lockwasher provided. See Fig. 203.
10. Lift the radio up behind the instrument panel with the control studs pointing up, then tip the set to bring the control studs and dial through the holes in the instrument panel.
11. Attach the radio to the instrument panel at the control studs with the two special nuts provided. Fasten to finger tightness.
12. Attach the mounting brace loosely to the radio at the mounting pad with the bolt and spring lockwasher provided. See Fig. 203.
13. Level the radio with the instrument panel so that it positions with a minimum of stress at the control studs. Tighten securely the tow bolts in the mounting brace and the two special nuts on the radio control studs.
14. Place the radio control knob assemblies and felt washers on the control studs. See Fig. 203. NOTE: The control knob assembly for the left hand control stud is keyed.
15. Route the power and dial lamp lead wires from the radio through the clip on the back of the instrument cluster and through the clip on the plenum panel and down to the accessory junction block. See Fig. 200.
16. Connect the terminal on the black power lead wire to the terminal on the accessory junction block marked "RADIO". Install the fuse in the clips directly underneath. See Fig. 204.
17. Connect the terminal on the gray dial lamp lead wire to one of the terminals on the upper left hand corner of the accessory junction block. See Fig. 204.
18. Connect the capacitor (No. 7263920) to the accessory junction block with the existing screws, one wire to the bracket and the other wire to the connection in the lower left hand corner. See Fig. 204.
19. Attach the antenna lead wire clip (provided in the antenna package) to the reinforcement flange of the instrument panel placing it near the lower left hand corner of the dispatch box opening. See Fig. 200.
20. Route the antenna lead wire through the clip on the instrument panel and plug it into the connector on the right side of the radio.
21. Tape the template to the header panel keeping it flush with the edge of the header panel and centered with the dimple on the underside of the header panel. See Fig. 205. NOTE: If a rear view mirror is installed, keep the template centered with the centerline of the rear view mirror bracket.
22. Centerpunch the seven hole locations indicated on the template; that is, two center holes, four corner holes and one hole for the speaker ground wire.
23. Remove the template and drill the four corner holes and the hole for the speaker ground wire with a 1/8 inch diameter drill. See Fig. 205.
24. Cut out the two center holes with a 3-1/2 inch diameter hole saw.
25. Cut out the two triangles of metal between the two center holes.
26. Place the rubber grommet in the cut-out on the speaker shroud. See Fig. 205. NOTE: When a rear view mirror is installed, discard the grommet.
27. Feed a stiff wire up through the right hand windshield pillar and out through the speaker opening in the header panel. Attach the speaker lead wire to this wire and pull it back down through the windshield pillar. Detach the speaker lead wire from the stiff wire and plug this end of the speaker lead wire into the connector on the underside of the radio case.
28. Attach the speaker ground wire to the header panel with the screw provided.
29. Plug the speaker lead wire and the ground wire into the connectors on the speaker.
30. Attach the speaker assembly to the header panel with the four self-tapping screws provided. See Fig. 205.
31. Position the slack of the speaker lead wire along the inside of the instrument panel reinforcement flange and attach it to the antenna clip. See Fig. 200.
32. Extend the antenna to full height. Turn on the radio receiver and tune in a weak station near 800 on the dial with the volume control turned to maximum position. With a small screwdriver adjust the antenna trimmer condenser for clearest and maximum volume. NOTE: The antenna trimmer is located on the bottom of the radio receiver and is indicated by a red sticker.
33. Hang the radio operation instruction tag on one of the radio control knobs.

PASSENGER CARS

Step 1 drill a 17/32 inch dia. hole in instrument panel. Install auxiliary speaker switch. see view "a".

Step 2 disconnect speaker from transformer jack and join it to auxiliary switch wire having the connector. See Fig. 253 For manual and push button receivers or Fig. 254 For signal seeking receiver.

Step 3 attach center wire of auxiliary switch to transformer jack at point where wire was removed in step no. 2.

Step 4 route auxiliary speaker switch to auxillary speaker wire as shown. See illustration no. Fig. 253 and no. Fig. 254.

Step 5 install the auxiliary speaker as shown. See Fig. 255.

Step 6 turn radio on and put auxiliary speaker control knob in its extreme counter clock-wise position. To test, turn control in a clock-wise rotation to have the sound transfer from entirely on the front speaker to entirely on the auxiliary speaker.

Air Conditioning and Heating

8 CYLINDER PASSENGER CARS

Body front end and engine modification disconnect battery. Remove hood from hood hinges. Remove the front fender baffle to radiator support bolts. remove the horns and allow them to hang.

STEP 1 - Mount compressor support and compressor fig. 1.

STEP 2 - 35 AMP generator, part no. 1102083 and 1119002 regulator, are recommended but not in package. See Fig. 1.

STEP 3 - Replace harmonic balancer with special harmonic balancer.

STEP 4 - Replace production pulley with new pulley at the same time assembling special fan.

STEP 5 - Replace fuel line from carburetor to fuel pump. See Fig. 2.

STEP 6 - From passenger compartment remove two perforated areas from dash mat. From engine side of dash, remove the two hole covers. Retain screws and special clamps for future use. CAUTION: When Extending capillary tube make sure valve lever is in locked open Position and secured by disposable wire clip Fig. 2.

STEP 7 - Install transition piece, gasket, core and core housing Fig. 2.

STEP 8 - Install water valve Fig. 2. NOTE: Apply adhesive cement to this surface of gasket and adhere to inside surface of transition piece.

STEP 9 - Install defroster duct and distribution duct assemblies Fig. 3. NOTE: Locking clip must not be removed until capillary is clipped into position. Slide special grommet over capillary tube from water control. Slide grommet into slot on top of distribution duct and extend coil. Clip capillary tube to deflector Fig. 3.

STEP 10 - Mount condenser and horns to baffle Fig. 4. Horn brackets slide into slots on condenser mounting bracket. CAUTION: Two brown leads and one black lead are connected to "a" terminal. Dark blue lead is connected to "f" terminal.

STEP 11 - Assemble special sleeve onto transition piece, folding It back on itself half way, until evaporator is in place, then unfold Over mouth of blower Fig. 5.

STEP 12 - For mounting air outlets to instrument panel, follow instructions on templates in locating and cutting 4 inch diameter hole. Place bezel in hole and mark instrument panel for screw holes to be drilled.

STEP 13 - Install control in instrument panel and attach cables Fig. 6. NOTE: Heavier front springs for air conditioner installation recommended but not in package. For dealer installation, order under part no. 3722423. For air conditioner only. Replace 10 amp fuse in fuse junction block Fig. 7.

STEP 14 - Bolt the shut-off valves together Fig. 8 in view "a".

STEP 15 - Remove cover plate from head of compressor and install valve assembly.

STEP 16 - Loosed gage connection cap at "a" and acorn nuts "d" and "e".

STEP 17 - Run compressor at approximately 1.000 r.p.m. for two minutes and then tighten cap at "a".

STEP 18 - Stop compressor. Tightly back seat valves "d" and "e" as shown.

STEP 19 - Install acorn nuts at "d" and "e".

STEP 20 - Blow out the area with compressed air and halogen leak test shut off valves at compressor head.

It must be noted that at no time must the plate or shut off valves be removed from the compressor for a period of time to exceed 2 minutes. Failure to adhere to this condition would result in contamination of the system and lead to early failure. (The time required to perform steps one and two is less than a minute by an inexperienced operator; therefore, there should be no cause for leaving the system open for any longer period.) At no time should the compressor be operated with the valves removed.

STEP 21 - Locate, scribe and drill all holes using dimensions Fig. 9.

STEP 22 - If the car is equipped with powerglide transmission, drain and retain the transmission fluid. Remove the filler tube and transmission housing side cover. Retain the filler tube and all attaching bolts and washers. Install the new side cover, using the attaching bolts retained. Place the "o" ring in the filler tube cover opening, and install the filler tube. (Henceforth, the filler tube will act only as a vent.) Refill the transmission through the plug hole in the cover. Install the plug and gasket. Check the fluid level with the engine idling, parking brake set, transmission oil hot and control lever in "n" position. (The transmission is properly filled when the transmission oil is level with the plug opening in the cover.)

Air Conditioning Conversion

8 CYLINDER PASSENGER CARS

Body front end and engine modification disconnect battery. Remove hood from hood hinges. Remove the front fender baffle to radiator support bolts. remove the horns and allow them to hang.

STEP 1- Mount compressor support and compressor Fig. 10.

STEP 2 - 35 AMP generator, part no. 1102083 and 1119002 regulator, are recommended but not in package. See Fig. 10.

STEP 3 - Replace harmonic balancer with special harmonic balancer.

STEP 4 - Replace production pulley with new pulley at the same time assembling special fan.

STEP 5 - Replace fuel line from carburetor to fuel pump. See Fig. 10.

STEP 6 - Install transition piece, gasket, core and core housing Fig. 11.

STEP 7 - Mount condenser and horns to baffle Fig. 12. Horn brackets slide into slots on condenser mounting bracket. CAUTION: Two brown leads and one black lead are connected to "a" terminal. Dark blue lead is connected to "f" terminal.

STEP 8 - Assemble special sleeve onto transition piece, folding it back on itself half way, until evaporator is in place, then unfold over mouth of blower Fig. 13.

STEP 9 - For mounting air outlets to instrument panel, follow instructions on template in locating and cutting 4 inch diameter hole. Place bezel in hole and mark instrument panel for screw holes to be drilled.

STEP 10 - Install control in instrument panel and attach cables Fig. 14.

STEP 11- Bolt the shut-off valves together Fig. 15 in view "a".

STEP 12 - Remove cover plate from head of compressor and install Valve assembly.

STEP 13 - Loosen gage connection cap at "A" and acorn nuts "D" and "E".

STEP 14 - Run compressor at approximately 1. 000 r. p.m. for two minutes and then tighten cap at "a".

STEP15 - Stop compressor. Tightly back-seat valves d & e Fig. 15.

STEP 16 - Install acorn nuts at "d" and "e".

STEP 17 - Blow out the area with compressed air and halogen leak test shut off valves at compressor head. It must be noted that at no time must the plate or shut off valves be removed from the compressor for a period of time to exceed 2 minutes. Failure to adhere to this condition would result in contamination of the system and lead to early failure. (The time required to perform steps one and two is less than a minute by an inexperienced operator; therefore, there should be no cause for leaving the system open for any longer period.) At no time should the compressor be operated with the valves removed.

STEP 18 - Locate, scribe and drill all holes using dimensions Fig. 16. Assemble all parts Fig. 16.

STEP 19 - If the car is equipped with powerglide transmission, drain and retain the transmission fluid. Remove the filler tube and transmission housing side cover. Retain the filler tube and all attaching bolts and washers. Install the new side cover, using the attaching bolts retained. Place the "o" ring in the filler tube cover opening, and install the filler tube. (Henceforth, the filler tube will act only as a vent.) Refill the transmission through the plug hole in the cover. Install the plug and gasket. Check the fluid level with the engine idling, parking brake set, transmission oil hot and control lever in "n" position. (The transmission is properly filled when the transmission oil is level with the plug opening in the cover.)

Air Conditioning

6 CYLINDER PASSENGER CARS

Body front end and engine modification disconnect battery. Remove hood from hood hinges. Remove the front fender baffle to radiator support bolts. Remove the horns and allow them to hang.

STEP 1 - Mount support and compressor Fig. 17.

STEP 2 - 35 AMP generator, part no. 1102083 and 1119002 regulator, recommended but not in package. See Fig. 17.

STEP 3 - Replace harmonic balancer with special harmonic balancer.

STEP 4 - Couple new fan pulley to production pulley at the same time assembling special fan Fig. 17. NOTE: Remove thermostat housing, and replace heater plug with elbow and special nipple in position Fig. 17. Replace thermostat housing.

STEP 5 - From passenger compartment remove two perforated areas from dash mat. From engine side of dash, remove the two hole covers. Retain screws and special clamps for future use.

STEP 6 - Install transition piece, gasket, core and core housing Fig. 18.

STEP 7 - Install water valve Fig 18. NOTE: Apply adhesive cement to this surface of gasket and adhere to inside surface of transition piece.

STEP 8 - Install defroster duct and distribution duct assemblies Fig. 19. NOTE: Locking clip must not be removed until capillary is clipped into position. Slide special grommet over capillary tube from water control. Slide grommet into slot on top of distribution duct and extend coil. Clip capillary tube to deflector Fig. 19.

STEP 9 - Mount adapters and condenser to radiator Fig. 20. Remount horns to baffle. CAUTION: Two brown leads and one black lead are connected to "a" terminal. Dark blue lead is connected to "f" terminal.

STEP 10 - Assemble special sleeve onto transition piece, folding it back on itself half way, until evaporator is in place, then unfold over mouth of blower Fig. 21.

STEP 11 - For mounting air outlets to instrument panel, follow instructions on template in locating and cutting 4 inch diameter hole. Place bezel in hole and mark instrument panel for screw holes to be drilled.

STEP 12 - Install control in instrument panel and attach cables Fig. 22.

STEP 13 - Bolt the shut-off valves together Fig. 24 in view "a".

STEP 14 - Remove cover plate from head of compressor and install Valve assembly.

STEP 15 - Loosed gage connection cap "a" and acorn nuts "d" and "e".

STEP 16 - Run compressor at approximately 1.000 r.p.m. for two minutes and then tighten cap at "a".

STEP 17 - Stop compressor. tightly back - seat valves "d" and "e" Fig. 24.

STEP 18 - Install acorn nuts at "d" and "e".

STEP 19 - Blow out area with compressed air and halogen leak test shut off valves at compressor head. It must be noted that at no time must the plate or shut off valve be removed from the compressor for a period of time to exceed 2 minutes. Failure to adhere to this condition would result in contamination of the system and lead to early failure. (The time required to perform steps one and two is less than a minute by an inexperienced operator; therefore, there should be no cause for leaving the system open for any longer period.) At no time should the compressor be operated with the valves removed.

STEP 20 - Locate, scribe and drill all holes using dimensions Fig. 25.Assemble all parts Fig. 25.

STEP 21 - If the car is equipped with powerglide transmission, drain and retain the transmission fluid. remove the filler tube and transmission housing side cover. Retain the filler tube and all attaching bolts and washers. Install the new side cover, using the attaching bolts retained. Place the "o" ring in the filler tube cover opening, and install the filler tube. (Henceforth, the filler tube will act only as a vent.) Refill the transmission through the plug hole in the cover. Detail the plug and gasket. Check the fluid level with the engine idling, parking brake set, transmission oil hot and control lever in "n" position. (The transmission is properly filled when the transmission oil is level with the plug opening in the cover.)

Air Conditioning Conversion Installation Instructions

6 CYLINDER PASSENGER CARS

Body front end and engine modification disconnect battery. Remove hood from hood hinges. Remove the front fender raffle to radiator support bolts. Remove horns and allow them to hang.

STEP 1 - Mount support and compressor Fig. 26.

STEP 2 - 35 AMP generator part no. 1102083 and 1119002 regulator recommended but not in package. See Fig. 26.

STEP 3 - Replace harmonic balancer with special harmonic balancer.

STEP 4 - Couple new fan pulley to production pulley, at the same time assembling special fan Fig. 26. NOTE: Remove thermostat housing, and replace heater plug with elbow and special nipple in position Fig. 26. Replace thermostat housing.

STEP 5 - Install transition piece, gasket, core and core housing Fig. 27. NOTE: Apply adhesive cement to this surface of gasket and adhere to inside surface of transition piece.

STEP 6 - Mount adapters and condenser to radiator Fig. 28. Remount horns to baffle. CAUTION: Two brown leads ad one black lead are connected to "a" terminal, dark blue lead is connected to "f" terminal.

STEP 7 - Assemble special sleeve onto transition piece, folding it back on itself half way, until evaporator is in place, then unfold over mouth of blower Fig. 29.

STEP 8 - For mounting air outlets to instrument panel, follow instructions on template in bezel in hole and mark instrument panel for screw holes to be drilled.

STEP 9 - Install control in instrument panel and attach cables Fig. 30.NOTE: Heavier front springs for air conditioner Installation recommended but not on package. For dealer installation Order under part No. 3722423.

STEP 10 - Bolt the shut-off valves together Fig. 31 in view "a".

STEP 11 - Remove cover plate from head of compressor and install valve assembly.

STEP 12 - Loosen gage connection cap at "a" and acorn nuts at "d" and "e".

STEP 13 - Run compressor at approximately 1. 000 r. p. m. for two minutes and then tighten cap at "a".

STEP 14 - Stop compressor. tightly back -seat valves "d" and "e" Fig. 31.

STEP 15 - Install acorn nuts at "d" and "e".

STEP 16 - Blow out the area with compressed air and halogen leak test shut -off valves at compressor head. It must be noted that at no time must the plate or shut off valves be removed from the compressor for a period of time to exceed 2 minutes. Failure to adhere to this condition would result in contamination of the system and lead to early failure. (The time required to perform steps one and two is less than a minute by an inexperienced operator; therefore, there should be no cause for leaving the system open for any longer period.) At no time should the compressor be operated with the valves removed.

STEP 17 - Locate, scribe and drill all holes using dimensions Fig. 32. Assemble all parts Fig. 32.

STEP 18 - If the car is equipped with powerglide transmission, drain and retain the transmission fluid. Remove the filler tube and transmission housing side cover. Retain the filler tube and all attaching bolts and washers. Install the new side cover using the attaching bolts retained. Place the "o" ring in the filler tube cover opening, and install the filler tube. (Henceforth, the filler tube will act only as a vent.) Refill the transmission through the plug hole in the cover. Install the plug and gasket. Check the fluid level with the engine idling, parking brake set, transmission oil hot and control lever in "n" position. (The transmission is properly filled when the transmission oil is level with the plug opening in the cover.)

Car Heater and Defroster (Deluxe) Installation Instructions

Step 1 remove perforated portions of dash mat.

Step 2 fit distributor ends of defroster in slots provided in cowl. Attach defroster to cowl.

Step 3 install the core housing and distributor duct, securing the core housing and distributor duct together.

Step 4 assemble seal to base of water control valve. Secure cable to valve and seat the valve base on the dash and secure in place.

Step 5 slide special grommet over capillary tube from valve control. Slide grommet into slot on top of distiubutor. Clip capillary tube to deflector. (Caution: When extending capillary make sure valve lever is in locked open position and secured by disposable wire clip Fig. 114 in step 4.)

Step 6 from engine side install the core and transition assembles.

Step 7 assemble blower mounting bracket to fender and skirt. Assemble blower motor and gasket to bracket. Install sleeve between blower and transition assembly. Install air hose from takeoff tube to blower.

Step 8 drain radiator.

Step 9 remove plugs from thermostat housing and water pump and install nipples and hoses.

NOTE: Cut hose to requieted length Fig. 115.

Step 10 install control assembly in instrument panel and attach cables Fig. 116.

Step 11 install 10 amp fuse in fuse and terminal block.

Step 12 refill radiator.

Car Heater and Defroster (Recirculating) Installation Instruction

Step 1 remove perforated portions of dash mat.

Step 2 install defroster duct.

Step 3 install distributor duct.

Step 4 install heater hole cover plate to dash and attach blower motor assembly and secure to distributor duct.

Step 5 drain radiator. install nipples and hoses.

Step 6 install heater control switch.

Step 7 install 10 amp fuse in terminal and fuse block.

Step 8 refill radiator.

Fig. 117.

Heater and Defroster Installation Instructions

ALL TRUCKS

Step 1 drain radiator.

Step 2 punch holes through dash mat for insertion of studs and core pipes into dash panel. Remove glove box.

Step 3 install defroster inlets.

Step 4 remove cover plate from inlet opening. assemble blower housing unit. Apply sealer Fig. 118 In view A.

Step 5 install and adjust cable Fig. 118 In view B. ( have air inlet door in outside air position.)

Step 6 install complete unit into dash panel Fig. 118. Secure in place.

Step 7 install right and left hand defroster hoses Fig. 118.

Step 8 remove control panel dummy plate.

Step 9 install control unit (view c)

Step 10 route air inlet cable (No. 1) into location on control unit Fig. 119. Pull cable out to close inlet door. Move lever approx. 1/8 inch toward inside air position. Tighten screw holding cable wire to control lever. Move lever to inside air position without moving door crank.

Step 11 attach temperature cable (No. 2) to control unit Fig. 119. Adjust for clearance. move lever on control panel toward bottom Fig. 119 In view D. Partially tighten clamp. Return lever to 1/16 inch from top of slot and secure.

Step 12 attach and clearance adjust the defroster cable (No. 3) Fig. 119 In view F. Control panel adjustment is the same as No. 2 cable.

Step 13 plug connectors together and install in clip on heater housing Fig. 119 In view H.

Step 14 route red and gray wires through the 3 clips Fig. 119 And plug connector ends into junction lock Fig. 119 In view G. Install fuse.

FENDER SKIRT MOUNTING RACKET NOT REQUIRED 5000 SERIES

Step 1 remove plugs in thermostat and water pump housings.

Step 2 installthe long and short nipples Fig. 120.

Step 3 install hoses and secure to fender skirt Fig. 120.

7000 AND 8000 SERIES WITH AIR OVER HYDRAULIC BRAKES

Step 1 remove plugs, cut hoses, and drill for 8000 series.

Step 2 install parts Fig. 121.

9000, 10000 SERIES

Step 1 drill and install parts Fig. 122.

Step 2 fill radiator and set temperature lever for "on" position.

Heater and Defroster Installation Instructions (Recirculating)

All Trucks

Step 1 drain radiator.

Step 2 punch holes through dash mat for insertion of studs and core pipes into dash panel.

STEP 3 Install rh & lh defroster inlets Fig. 123.

Step 4 install heater housing into place in dash panel and secureFig. 123.

Step 5 install defroster hoses Fig.123.

Step 6 remove instrument panel control dummy plate.

Step 7 locate and drill hole in plate (View B).

Step 8 replace plate and assemble switch parts Fig. 124 In view B.

Step 9 install wiring hook-up as indicated in above wiring instructions.

7000 & 8000 SERIES (AIR OVER HYDRAULIC BRAKES)

Step 1 remove pipe plugs, cut hoses, and drill for 8000 series.

Step 2 install parts Fig. 125.

9000 & 10,000 SERIES

Step 1 drill and install parts Fig. 126.

Step 2 fill radiator and set temperature lever for "on" position,

3000, 4000, 5000, 6000, 7000, 8000 SERIES

Step 1 remove plugs in thermostat and water pump housing.

Step 2 install the long and short nipples Fig.127.

Step 3 install hoses and secure to fender Fig. 127.

Electrical

Pull back floor mat remove foot switch and switch plate noting orientation of terminals. File notch in plate Fig. 33, Install new foot switch using existing mounting parts. Bring amplifier harness through speedometer cable grommet in firewall assemble triple connector over three female terminals

(See Fig. 3) And attach to switch, remount switch plate and switch on toe pan. Connect red wire from switch to red wire from amplifier using connector provided. Connect extension wire assembly provided to harness removed from foot switch and route out thrugh speedometer cable grommet to connect to power relay Fig. 33 In Fig. 3. replace floor mat to cover all foot switch wiring.

TO INSTALL POWER RELAY;

Select convenient location in engine, compartment within reach of extension wire harness from harness removed from foot switch, using relay as a template, center punch and drill two 1/8 dia. holes. Attach relay with # 10 x 1/2 tapping screws provided.

TO INSTALL AMPLIFIER;

Locate hole "A" Fig. 34 and drill 3/16 dia. hole. Using amplifier as a template, locate and drill other three holes. 1/4-14 x 3/4 screws from packarge are to be used for attaching amplifier. ("dim and "hold" on amplifier cover should be toward front of car.) Locate and drill 1" dia. hole "b" as shown. Route amplifier harness back through this hole, using split grommet provided in package.

Fig. 35.

Fig. 36.

The centerline of the photo tube unit must be aimed parallel to the centerline of the car afterinstallation is made. Horizontal aim must be checked as follows: place two pieces of tape on a wall or screen at hood height Fig. 37, Place the car 25 feet back from the wall, with the centerline of the hood aimed at the right hand tape. Remove cover and replace with level from autronic eye tester. Aim over sights to left hand tape. If unit is aimed more than 4" left or right of tape, elongate one side of mounting stud hole in the instrument panel sufficiently to rotate unitfor correct aim.

Wiring Junction Block

All Passenger Cars

STEP 1 - Place wiring junction block on cowl side panel, and secure in place with the two screws furnished. Attach the wiring harness assembly connectors, and main wiring harness connectors on the junction block as directed.

STEP 2 - Attach the pink wire to the terminal on the ignition switch marked "acc. ". Fig. 51.

Block Wiring Junction Truck

ALL TRUCKS

STEP 1 - Locate and remove rectangular section (knock-out) Fig. 52 in illustration.

STEP 2 - Connect the harness wires to the junction block Fig. 52.

STEP 3 - Position the block in the cut-out Fig. 52. Coat tapping screws with windshield sealer. Secure the Junction block firmly into the dash.

STEP 4 - Route the junction block harness with the main wiring harness through clip Fig. 52.

STEP 5 - Plug the red and gray wires into the light switch Fig. 52 in the illustration and View A.

STEP 6 - If accessory terminal on the ignition switch is occupied, disconnect that connection and connect to the male connector (pig tail) on the pink wire.

STEP 7 - Connect the female terminal on the pink wire to the accessory terminal on the ignition switch.

Vibrator Horn Installation Instructions

PASSENGER CARS

Fig. 128.

Vibrator Horn

Trucks

Step 1 mount r.h. horn assembly with existing bolt for series 3000, 4000, 6000, 8000, and 10,000. See view A. for series 5000, 7000, and 9000 mount with attaching parts supplied as in view B.

Step 2 route R.H. horn wire assembly with main wiring harness extension assembly for all models.

Step 3 test installation.

Fig. 129.

Backing Lamp Installation Instructions

PASSENGER CARS, STATION WAGONS, AND SEDAN DELIVERY

PASSENGER CARS ONLY

Step 1 locate area in steering column (Fig. 130R switch mounting (manual shift only) or location of exisitng production switch. ( Atomatic Transmission)

Step 2 in manual shift cars, opening is taped. (View C) remove tape and place gear shift lever in neutral.

Step 3 locate the two holes at sides of opening. (View C)

Fig. 131.

Step 4 position the switch and install with the two wide-pitch tapping screws provided.

Step 5 plug the "V" connector of the wire assembly on the two terminals of the installed switch (view c ), Fig. 130.

NOTE: If the car is equipped with automatic transmission, simply plug the "v" connector (View D , Fig. 132) on the unused terminals of the existing combination switch Fig. 132.

Step 6 snap clip provided and Fig. 132 in view "a" near the dash end of the steering support housing. (Fig. 131)

Step 7 for either switch, run the harness upward into the clip Fig. 132 and directly to the left along the face of the dash mat to the accessory junction block (SEE Fig. 131 View B).

Step 8 position the clip provided on the top edge of kick pad near the forward end of junction block and close to the dash mat.

Step 9 place the harness into clip taking up slack.

Step 10 allow short terminal wire to hang loose for future installation and feed long wire down corner of cowl between dash mat and kick pad and under floor mat on toe pan to the floor. (Fig. 131)

Step 11 remove the door scuff plate, carpet, and wiring harness cover and route wire with body harness to rear. Locate loom so that front end extends 4 inches under the cover. (See View E, Fig. 132)

Step 12 re-assemble and route wire to deck floor pan. (Fig. 132)

Step 13 remove L. H. and R. H. existing covers in backing lamp openings.

Step 14 insert bracket through mounting hole. hook one leg in place in notch at side. pull opposite leg toward center of lamp and hook at remaining notch.

Step 15 disassemble backing lamp assembly, L. H. & R. H. Fig. 133 IN Fig. 133.

Step 16 insert wire through hole in opening of bracket and over top of reinforcement to brace Fig. 134. Secure housing to mounting bracket with the two 8-32 x 3/4 flat hd. screws provided. Complete assembly with the lens and gasket. (follow view h & i for all screw locations.)

Step 17 locate hole in left and right hand bumper brace. (Fig. 133) snap clips provided into each hole. (View G )

Step 18 locate existing plugs in floor pan. (L. H. & R. H.) Remove and install the two grommets provided.

Step 19 route L. H. & R. H. lamp wire through clips and grommets and bring out on floor pan. (Fig. 133) Remove any slack to insure clearance at exhaust pipe.

Step 20 join L. H. & R. H. wires and switch wire with "Y" connector according to View G.

Step 21 attach short terminal wire (leading off installed harness at cowl) to junction block Fig. 131 In view B, Fig. 131.

Step 22 install fuse provided and check for operation. Station wagon and sedan delivery

NOTE: Passenger car switch installation and front wiring will be identical for station wagons and sedan delivery excepting additional removal of rear floor edge mouldings.

NOTE: The following steps are for station wagon and sedan delivery only.

Step 18 after step 17 has been completed, locate and drill hole for L. H. grommet. (View K, Fig. 134) pass switch wire down through hole.

Step 19 install the small grommet. (Small Hole)

Step 20 install large clip on body anchor plate Fig. 134 in Fig. 134.

Step 21 place L. H. lamp wire into clip at bumper brace and route into body anchor plate clip Fig. 135. Route switch wire into clip. (Fig. 134) Plug both wires into "y" connector.

Step 22 install the three clips provided at equal distances along rear cross member. (Fig. 135)

Step 23 route R. H. lamp wiring in same manner as L. H. except to lead lamp wire through the three clips and plug into connector Fig. 135.

Step 24 attach short terminal wire (leading off installed harness at cowl) to junction block Fig. 131 in view B, Fig. 131.

Step 25 install fuse provided and check for operation.

Backing Lamp Installation Instructions

SUBURBAN CARRYALL, PANEL AND PICKUP TRUCKS

FOR 3-SPEED TRANSMISSIONS:

1. Attach the switch lever loosely to the gearshift lever, as shown in Fig. 136.
2. Place the template provided over the gearshift rod and on the steering gear cowl upper bracket, Fig. 136 In Fig. 136. Centerpunch and drill two 13/64 holes on the LEFT HAND side of the steering column. Attach the switch to the bracket and tighten securely. Attach the switch and bracket assembly to the steering gear cowl upper bracket by means of two 8-32 x 1/2 screws, Fig. 136 in Fig. 136.
3. Place the gearshift lever in reverse, and position the switch lever working surface directly over the switch plunger. Tighten only the switch bracket. See Fig. 136. With the gearshift lever in the REVERSE position, rotate the switch lever so that the switch plunger is depressed to 3/16-inch from the end of the switch.
4. Tighten securely in this position. Return the gear. shift lever to the NEUTRAL position. See view B, Fig. 136.
5. Select the long wire with the two connectors. Enlarge the hole in the main wiring harness grommet. From the engine compartment, route the male terminal end of this wire through the hole in the grommet into the driver's compartment. Connect this wire to the switch. Clip in place. See Fig. 136.
6. Connect the male terminal of the remaining wire to the switch, and connect the female terminal to the junction block terminal marked BACK-UP LP. Clip the wire in place. See Fig. 136.

FOR HYDRA-MATIC TRANSMISSION:

Same as 3-speed transmission installation, except the switch lever and the switch bracket are mounted on the RIGHT HAND side of the steering column. Final assembly should be Fig. 136 in view C Fig. 136.

FOR 4-SPEED TRANSMISSION:

1. Remove and retain the gearshift lever knob.
2. Remove and discard the existing gearshift levercap.
3. Attach the switch to the new cap, and install this assembly on the transmission, locking it in place. See Fig. 137.
4. Place the gearshift lever in the REVERSE position. Install the switch lever on the gearshift lever, depressing the switch plunger to 3/16 inch from end of switch. Hold in this position by tightening the set screw. Replace the gearshift lever knob. Place the gearshift lever in the neutral position. See Fig. 137.
5. Attach the two clips provided to the support bracket under the dash.
6. Repeat steps 5 and 6 of the 3-speed transmission back-up switch installation, but route the wires UNDER the floor mat. Refer to Fig. 137.

FOR ALL TRANSMISSIONS:

1. From the engine compartment, take up any slack in the switch wire. Route this wire to the rear, clipping it in place on the dash and on the frame side member along with the main wiring harness.
2. Locate the holes to be drilled in the left rear fender for attaching the backing lamp. See Fig. 138 for pickups, Fig. 139 for panels and suburban carryalls. At these locations, centerpunch and drill a 1-1/2 inch diameter hole and two 5/16 inch diameter holes. Repeat process for right rear fender.
3. Install the spring nuts over the 5/16 inch diameter holes.
4. Remove the doors, lenses and gaskets from the lamp assemblies. Pass the lamp lead wires through the 1-1/2 inch diameter holes. FOR PANELS ONLY, attach a stiff wire to the lamp lead wires, then work the wires through the grommets in the filler panels. Remove the stiff wire and pull the lamp wires through the grommets. FOR SUBURBAN CARRYALLS ONLY, repeat process; but first remove the plugs in the filler panel. Rework the left hand plug as a grommet, then re-install this reworked plug and the grommet from the kit in the filler panels.
5. Attach the pods and lamp bodies to the fenders with the topping screws provided, fitting the pods to the fender contour. Refer to Fig. 138 for pickups, Fig. 139 for panels and suburban carryalls.
6. Attach clips to the panel flanges and side members. Route the lamp lead wires through the clips and through the grommets in the rear cross member. Refer to Fig. 140 for pickups, Fig. 141 for panels and suburban carryalls.
7. Attach clips to the rear cross member. Connect the lamp lead wires to the wires loading from the dash. Take up any slack by folding and taping (or cut, splice, solder and tape the wires). Clip the wires leading from the dash in place along the side member and rear cross member. Refer to Fig. 140 for pickups, Fig. 140 for panels and suburban carryalls.
8. Install fuse in fuse block. See Fig. 136 or Fig. 136.

Passenger Cars

Step 1 locate outermost existing holes at each end of instrument panel. (main view.)

Step 2 position bracket assemblies Fig. 142 in view a and secure each with tapping screws furnished.

Step 3 install 4 clips on instrument panel reinforcement Fig. 142 in view c and route wire through clips.

Step 4 remove production wires from switches and attach to courtesy lamp connectors (View D).

Step 5 plug courtesy lamp wires into switches (View D).

Step 6 plug connector with double wires into terminal Fig. 142 on junction block (View B)

Fog Lamp Installation Instructions

ALL TRUCKS

1. Refer to Fig. 143 for the location of the two holes to be drilled in bumper for the fog lamp installation on the various models. At these points, 11/16-inch forward of the bumper rear edge, centerpunch and drill two 11/16-inch diameter holes. NOTE: On models with a radiator grille guard, locate the holes to be drilled by using the centerlines of the two existing holes in the base of the grille guard. Centerpunch at these points. Remove the grille guard and drill two 11/16-inch diameter holes. Remount the grille guard. On 8000 and 10,000 Series mount in the hole on the base of the grille guard only.
2. Attach the fog lamps loosely to the bumper in the sequence shown in Fig. 144. NOTE: Use the thick upper bracket for 3000 Series models only. Use the thin upper bracket for all other models. On all models, the lamp with the longest wire is used on the right side.
3. Route the fog lamp wires under the front edges of the fenders and through the parking lamp grommets and clips on the fender skirts and in the engine compartment. Clip the wires to the front fender flanges. Route the right hand wire through the main wiring harness clips on the radiator support. See Fig. 143
4. Connect the fog lamp wires to the double terminal wire (from the package). Route wire through the main wiring harness clips on the left hand fender skirt and through the main wiring grommet on the dash panel and into the cab interior. See Fig. 143.
5. Locate a point at the center of the horizontal centerline running through the choke and light switch. Two inches up from this point, centerpunch and drill a 13/32 inch diameter hole through the instrument panel. See Fig. 145.
6. Remove the face nut from the fog lamp switch, and from behind the instrument panel, insert the knob through the 13/32 inch diameter hole just drilled. Replace the face nut, and tighten securely.
7. Continue the routing of the wire in step 4 through the main wiring harness clip on the plenum chamber and up to the fog lamp switch. See Fig. 145.
8. Connect this wire to the terminal on the fog lamp switch marked ROAD.
9. Remove the black tail lamp wire from the main light switch. Connect it to the jumper wire on the short wire assembly from the package, making sure that the rubber sleeve covering the jumper wire terminal is in place. See Fig. 145.
10. Connect the terminal on the jumper wire to the terminal of the main light switch from which the tail lamp wire was removed. See Fig. 145.
11. Connect the eyelet terminal of the short wire assembly to the terminal on the fog lamp switch marked TAIL. See Fig. 145.
12. Connect the eyelet terminal of the remaining wire from the package to the terminal on the fog lamp switch marked BAT. Route it through the main wiring harness clip and attach it to the terminal on the junction block marked FOG LP. Install the 14 ampere fuse provided. See Fig. 145.

LAMP ALIGNING PROCEDURE

Place the truck on a level surface with a light-colored wall (or aiming screen) 25 feet ahead. Draw a horizontal line an the wall 4 inches below the level of the fog lamp centers. From inside the cab, sight through the windshield and down the center of the hood to determine the vertical center of the truck. At this point, draw a vertical line on the wall. To the right and to the left of this vertical centerline, draw another vertical line the same distance from the centerline of the truck as shown in Fig. 143. Turn on the fog lamps. Aim each lamp so the top of the beam is at the horizontal line on the wall and centered on the appropriate vertical line, as shown in Fig. 146. When the lamps have been properly aimed, tighten them in position.

Glove Compartment Light Switch Installation Instructions

1500 PASSENGER CARS AND TRUCKS

Step 1 install the light assembly in hole provided in outer edge of glove compartment opening.

Step 2 crush and remove insulator from terminal on red wire. Make sure not to distort terminal. insert terminal in switch and install bulb.

NOTE: Discard the three clips and the wire assembly in the kit. They are provided for truck installation only.

Fig. 147.

TRUCK INSTALLATION

Step 1 install the light switch assembly Fig. 148. Insert wire terminal and install bulb.

Step 2 remove existing screw, slit hole in glove compartment partition and route wire Fig. 148.

Step 3 remove the orange dome light wire from the main light switch and attach it to the male terminal of the wire assembly furnished in the kit.

Step 4 connect the female terminal of the wire assembly to the main light switch terminal from which the orange dome lamp wire was removed.

Step 5 install the three cups on the instrument panel reinforcement and route wire assembly through Fig. 148 AND VIEW "A".

Step 6 check the installation for proper operation.

Luggage Compartment Lamp Installation Instructions

PASSENGER CARS

Step 1 locate the recessed opening in the inner panel of the deck lid shown in Fig. 149 and View B.

Step 2 pass the wire assembly only, through the opening, down between the outer and inner panels and bring out through smallest opening near left hinge Fig. 149.

Step 3 mount the lamp inside the inner panel Fig. 149 in View B and attach the bracket to existing hole with the tapping screw provided.

Step 4 locate and attach the 4 cups provided, Fig. 150.

Step 5 route the wire through the clips and behind the hinge pillars.

Step 6 open the license lamp connectors and install the luggage wire connectors in their correct position Fig. 151 in View C.

Step 7 when light switch is in an "on" position, the luggage lamp light will light when deck lid is raised and go off automatically when lid is lowered.

Tail and Stop Lamp Installation Instructions

TRUCKS

Procedure for installation of a right hand tail and stop lamp on all trucks and commercials.

First, determine the model of the truck and follow the instructions for that particular model installation.

PICKUP INSTALLATION

1. Remove the two bolts, nuts and lockwashers from the front side of the right rear stake pocket.
2. Place a wiring clip on one of these bolts and attach the tail lamp bracket to the stake pocket with the lockwasher and nut in their former location. Make sure the cut-out section in the bracket is down and the bolt is in the outer hole of the stake pocket. Install the second bolt in the inner hole and with its lockwasher and nut in place, tighten both bolts securely as shown in Fig. 152.
3. Mount the tail lamp to the bracket support with the two nuts and lockwashers keeping the tail lamp drain hole at the bottom.
4. Drill an 11/32 inch hole in the right frame side rail, 1-1/2 inches down and 3/4 of an inch from the end. This hole is marked "Drill only rear hole for all pickups and platforms", as shown in Fig. 153.
5. At this hole, attach another clip for the tail lamp extension wire using the bolt, nut and lockwasher provided.
6. Install the rubber grommet in the hole in the right end of the rear cross member.
7. Route the tail lamp extension wire through the two clips and rubber grommet, then along the rear cross member to the regular tail lamp wiring harness.
8. Cut the tail lamp extension wire where it reaches the regular wiring harness, allowing enough length for splicing.
9. Match the ribbed and plain extension wires to the ribbed and plain wires of the regular tail lamp wiring harness and splice, solder and tape these connections. Clip the extension wiring to the cross member flange with the two special clips as shown in Fig. 154.

PLATFORM INSTALLATION

1. With the weld nuts facing the rear, hold the tail lamp bracket support up inside the right side slot provided in the rear rub rail. Attach the bracket support to the rear cross sill with two bolts and lockwashers at the holes provided.
2. Mount the tail lamp to the bracket support with the lockwashers and nuts provided, keeping the tail lamp drain hole to the bottom as shown in Fig. 155.
3. Drill the 11/32 inch hole in the right side member 1-1/2 inches down and 3/4 of an inch from the rear. This hole is marked " Drill only rear hole for all platforms and pickups". See Fig. 153.
4. Using this hole, attach a wiring clip on the inside of the side member with the bolt, nut and lockwasher provided.
5. Install the rubber grommet in the hole in the right end of the rear cross member.
6. Route the tail lamp extension wire up over the right side sill through the frame clip and cross member grommet. Run the wire along the front side of the rear cross member to the regular tail lamp harness at the left side as shown in Fig. 155.
7. Fasten the tail lamp extension wire on the inside of the sill using one or two of the clips and nails as required. Use 2 clips for long overhanging sill and only one for the short overhang.
8. Cut the extension wire where it reaches the regular wiring harness, allowing ample wire for splicing.
9. Match the ribbed and plain extension wires to the ribbed and plain wires of the regular tail lamp wiring harness and splice, solder and tape these connections, as Fig. 154.
10. Clip the extension wire to the rear cross member flange.

CHASSIS INSTALLATION

1. If required, drill the two 11/32 inch holes in the end of the right frame side rail according to the model of truck. See Fig. 153.
2. Fasten the tail lamp bracket support to the frame side rail with the two bolts supplied, placing the clip on the inner bolt. See Fig. 154.
3. Attach the tail lamp to the bracket support keeping the tail lamp drain hole to the bottom. See Fig. 154.
4. Install the grommet in the cross member and route the extension wire through the clip and grommet, then along the rear cross member to the regular tail lamp wiring harness. See Fig. 154.
5. Complete the wiring installation in the same manner as Pickup Instructions No. 8 and 9.

ALL PASSENGER CARS

NOTE: Check lamp after installation by lowering the hood to within eight inches of the closed position. If the light does not go off, bend the bracket downword until the lamp goes off in this position.

Fig. 156.

Under Hood Lamp

All Passenger Cars and Trucks

1. Position the underhood lamp and bracket. assembly on the hood rear reinforcement Fig. 157. NOTE: LOCATIONS FOR 6-CYLINDER AND 8-CYLINDER ENGINES Hold the lamp bracket with its shoulder fitting the corner of the box section of the hood reinforcement Use the bracket as a template to locate the hole. Remove the lamp assembly.
2. Drill a 1/8 inch hole in the reinforcement and attach the lamp with the sheet metal screw.
3. Attach the two clips with the narrow wire opening to the hood reinforcement in the location Fig. 157 and assemble the wire.
4. Route the wire through the grommet and the dash Fig. 157.
5. Attach the clip with the large wire opening to the top of the dash mat in the location Fig. 157. Run the wire through this clip to the accessory junction block, add connector, and attach it to the hood lamp terminal. Insert the fuse Fig. 157.
6. Check lamp after installation by lowering the hood to within eight inches of the closed position. If the light does not go off, bend the bracket downward until the lamp does go off in this position.

ALL PASSENGER CARS

Step 1 remove lamp from lighter retainer and remove retainer from cigarette lighter housing.

Step 2 put bezel in place, insert housing through instrument panel, and reinstall retainer on the housing and the lamp on retainer.

Step 3 route lamp wire through the main wiring harness clips to the junction block. plug connector on terminal Fig. 158 in View A.

Step 4 connect the main wiring harness red wire, with connector attached, to the terminal of the lighter housing.

Cigarette Lighter

TRUCKS

1. Remove the dummy button or the existing production lighter.
2. Remove the lamp Assembly from the lighter retainer and the retainer from the housing assembly.
3. Insert the housing through the instrument panel and reassemble the retainer Fig. 159.
4. Tighten the retainer securely against the instrument panel. Attach the lamp assembly by inserting the lamp housing tabs through the slots. (if necessary to avoid lamp installation interference, loosen the retainer, rotate the housing, and retighten the retainer with the slots in the desired position.)
5. Route the lamp wire (black) through the clip behind the dash panel, to the tail light terminal (T) on the main light switch.
6. Route the lighter wire (red) to the battery terminal on the ignition switch.
7. To operate the unit, push in the knob and heating unit assembly to the heating position. It will return to the normal position when ready for use.

All Passenger Cars

Step 1 locate with template and drill hole 3/4 inch depth into windshield molding and pillar Fig. 207.

Step 2 secure top hole in bracket, gasket and molding with tapping screw Fig. 208.

Step 3 drill bottom hole and secure bracket Fig. 208 above.

Step 4 loosen set screw, (Fig. 209>) insert drill bushing in place and tighten set screw.

Step 5 drill 1/2 inch hole, using bushing as a guide, completely through pillar and garnish molding. Remove sheet metal screw if it appears as an obstruction to contemplated drilling. Replace on completion.

Step 6 remove bushing and clean up burrs in garnish molding.

Step 7 locate and drill hole for spot lamp wire Fig. 210 above.

Step 8 remove spot lamp switch housing Fig. 211

Step 9 insert the spotlamp shaft completely through the 1/2 inch drilled hole Fig. 212 being careful to seat properly. Tighten the bracket screw securely.

Step 10 install the spacer and retainer on the shaft and secure in place by inserting and tightening the set screw provided (Fig. 213).

Step 11 re -install the switch housing on shaft.

Step 12 insert spotlamp wire through grommet into 3/16 hole and extend as shown in illustration Fig. 213 and Fig. 214. CAUTION: Do not assemble connector to spot lamp wire terminal until lamp lead has been threaded through pillar

Step 13 install double connector wire extension as shown in illustration no. Fig. 214 and Fig. 215.

Step 14 install 14 amp fuse on fuse and terminal block as shown in Fig. 215.

Step 15 check for proper operation.

Right Hand Spot Lamp

All Passenger Cars

Step 1 locate with template and drill hole 3/4 inch depth into windshield molding and pillar Fig. 216.

Step 2 secure top hole in bracket, gasket, and molding with tapping screw Fig. 217.

Step 3 drill bottom hole and secure bracket Fig. 217 above.

Step 4 loosen set screw, (Fig. 218) insert drill bushing in place and tighten set screw.

Step 5 drill 1/2 inch hole using bushing as a guide, completely through pillar and garnish molding. Remove sheet metal screw if it appears as an obstruction to contemplated drilling. Replace upon completion.

Step 6 remove bushing and clean up burrs in garnish molding.

Step 7 locate and drill hole for spotlamp wire Fig. 219 above.

Step 8 remove spotlamp switch housing Fig. 220.

Step 9 insert the spotlamp shaft completely through the 1/2 inch drilled hole Fig. 221 being careful to seat properly. Tighten the bracket screw securely.

Step 10 install the spacer and retainer on the shaft and secure in place by inserting and tightening the set screw provided. (Fig. 222)

Step 11 re-install switch housing on shaft.

Step 12 insert spotlamp wire through grommet; into 5/16 inch hole as shown in illustrations numbered Fig. 222 & 223.

Step 13 assemble connector to terminal and plug onto spotlamp terminal on junction block shown Fig. 223 Fig. 224.

Step 14 insert 14 amp fuse in receptacle marked acc. lp. as shown in Fig. 224.

Step 15 check for proper operation.

Spot Lamp Installation Instructions

TRUCKS

1. FOR 3000 SERIES ONLY: Remove the existing standard mirror and bracket from the left hand front door and-discard all parts. Coat the three 3/8 inch truss head screws provided with sealer and install them in the holes in the door panel.
2. Locate the template on the left hand hinge cover panel according to the directions given on the template. Secure with tape. See Fig. 225.
3. Centerpunch the two holes to be drilled. Remove the template.
4. Using a No. 29 (.136) drill or 9/64 inch drill, drill two holes through the hinge cover panel and plenum chamber.
5. Attach the outside mounting bracket and gasket to the hinge cover panel with the two 3/4 inch long screws provided. See Fig. 225.
6. Using the mounting bracket as a guide, drill a 1/2 inch diameter hole through the hinge cover panel and instrument panel, Fig. 225. CAUTION: Feed the drill slowly and directly in line with the bracket.
7. From inside the cab, remove any burrs resulting from this drilling.
8. On the some vertical line as the centerline of the 1/2 inch hole just drilled, measure 5/8 inch down from the bottom edge of the hole and scribe a line on the instrument panel, At this line, centerpunch and drill a 5/16 inch diameter hole through the instrument panel only. Remove any burrs resulting from this drilling. See Fig. 226.
9. Detach the handle from the spotlamp shaft by removing the screw from the left side of the handle housing and loosening the screw at the bottom of the housing. See Fig. 226.
10. Remove the screws, mounting bracket and gasket described in step 5 and retain all parts.
11. Slide the mounting bracket over the spotlamp shaft making sure that the key in the lamp arm fits snugly into the notch in the bracket. See Fig. 227.
12. Slip the bracket retaining spring over the spotlamp shaft making sure that the end of the spring having the small tang is away from the bracket. Compress the spring into the bracket until the bend in the small tang fits into the hole in the shaft. See Fig. 228.
13. Slip the gasket over the shaft and fit it to the bracket.
14. Insert the shaft end of the now unitized spotlamp and bracket through the 1/2 inch diameter hole previously drilled, and attach this assembly to the door with the two topping screws removed in step 10.
15. Remove the friction nut from the spring bracket and, from inside the cob, slip the spring bracket over the shaft and bend the arms to fit the contour of the instrument panel. See Fig. 226 Note: The long arm on the bracket should be to the right of the shaft.
16. Hold the bracket in position against the instrument panel by threading the friction nut onto the spring bracket. Tighten until the bracket is held securely in place.
17. Using the holes in the spring bracket arms as a guide, drill two holes through the instrument panel with a No. 27 (.144) drill or a 9/64 inch drill.
18. Secure the spring bracket to the instrument panel with the two 3/8 inch screws provided.
19. Re-attach the spotlamp handle on the shaft. Refer to step 9. NOTE: The handle should be positioned on the shaft 30° to the rear of the vehicle when the spotlamp is in its normal position.
20. Pass the spotlamp wire through the 5/16 inch diameter hole previously drilled in the instrument panel. Route the wire along the top of the cowl kick panel and down to the accessory junction block.
21. Fasten the spotlamp wire to the terminal on the accessory junction block marked "Spotlamp". Add a 9 ampere fuse. See Fig. 226.
22. Position the spotlamp wire so that there is just enough slack to permit the handle to be rotated freely.
23. Press the rubber grommet on the spotlamp wire into the 5 /16 inch diameter hole in the instrument panel.
24. Adjust the nut on the spring bracket to obtain the proper horizontal friction.
25. Inspect the installation for proper rigidity, seal, fit and operation. Correct, if necessary.

CHASSIS AND PLATFORM MODEL TRUCKS

Step 1 the switch housing should match the color of the steering column. The lamp housing should match the color of the fender. Paint these parts when necessary.

Step 2 remove the steering wheel, discard the hub cover and attach the cancelling cam using the hub cover screws and lockwashers.

NOTE: The prong on the cancelling cam should be on the left side. Fig. 231.

Step 3 remove the wiring clamp from the steering column and feed the wires leading from the switch, through the slots on the underside of the steering column. Fig. 231.

Step 4 screw the signal lever into the switch assembly and tighten the locking nut.

Step 5 place the switch assembly loosely on the steering column with the lever on the left side.

Step 6 replace the steering wheel in the correct straight ahead position and secure in place.

Step 7 secure the switch assembly in position with the clamping screw, keeping 1/8 inch clearance between the top of the switch housing and the bottom of the steering wheel.

Step 8 remove any slack in the switch wires,and re-attach the wiring clamp to the steering column.

Step 9 from behind the instrument panel install the signal lamp wiring harness as directed in Fig. 232.

Step 10 plug the switch wires into the 3-way connector so that the wire colors match mating harness connector. See Fig. 232.

Step11 through the hole in the main harness grommet on the dash panel, route the directional signal harness into the engine compartment. Clip in place on the front of the dash and follow the main harness to the rear of the cab.

Step 12 connect the front extension wire and route it in the clips with the main harness along the left fender skirt and across the front end.

Step 13 refer to Fig. 233 to locate the holes to be drilled in each fender, for mounting the front signal lamps. at these points, drill two 15/32 inch diameter holes.

Step 14 mount the lamps on the fenders using the parts in the sequence shown in Fig. 233. Make sure the plate reinforcements are positioned to direct the lead wires toward the grommets in the fender skirt.

Step 15 route each lamp wire through the grommet as indicated in Fig. 234.

Step 16 remove the parking lamp plug from the main harness connector at the front end, and insert the directional signal lamp wire terminal in open hole of the plug. Insert extension wire terminal in the open hole in the main harness connector, replace plug, repeat on the opposite side.

NOTE: The front installation is not intended for use alone. For the flasher to operate properly the rear lamps must be installed either at this time as follows or later by an outside body builder.

Step 17 for platform trucks mount the rear signal lamps on the wood sill. locate the bracket as shown in Fig. 235. Attach with the wood screws provided and make sure the ground wires are used. Route the wires and clip as shown in Fig. 235.

Step 18 route the lamp lead wires as far forward as they will reach. Connect the rear extension under the rear of the cab, and route to the rear in the clips with the tail and stop lamp wires. Separate the rip cord wires, and cut the black wire to the length to reach the right hand lamp wire and the white stripe wire to reach the left hand lamp wire. Solder or crimp the terminals securely. Attach the connectors and plug in the lamp wires.

Step 19 for drive-away purposes prior to mounting a body. mount the rear signal lamps as indicated in Fig. 236. Connect as described in step 18, except loop up the excess wire for cutting to the proper length later.

Step 20 for truck bodies requiring rear flush mounted signal lamp, determine the desirable left and right hand mounting location, and install as directed in step 18.

Direction Signal Lamp Installation Instructions

FOR CAMEO CARRIER, SUBURBAN CARRY ALL, AND PANEL TRUCKS

Step 1 the color of the switch housing should match the color of the steering column. Paint when necessary.

Step 2 remove the steering wheel, discard the hub cover and attach the cancelling cam using the hub cover screws and lockwashers.

NOTE: The prong on the cancelling cam should be on the left side.

Step 3 remove the wiring clamp from the steering column and feed the wires leading from the switch through the slots on the underside of the steering column Fig. 237.

Step 4 screw the signal lever into the switch assembly. tighten the locking nut.

Step 5 place the switch assembly loosely on the steering column with the lever on the left side.

Step 6 replace the steering wheel in the correct straight-ahead position and secure in place.

Step 7 secure the switch assembly in position with the clamping screw keeping 1/8 inch clearance between the top of the switch housing and the bottom of the steering wheel.

Step 8 remove any slack in the switch wires, and re-attach the wiring clamp to the steering column.

Step 9 from behind the instrument panel, install the signal lamp wiring harness as shown in Fig. 238.

Step 10 plug the switch wires into the 6-way connector so that the wire colors match the mating harness connector.

Step 11 through the hole in the main wiring harness grommet on the dash panel, route the direction signal harness into the engine compartment. clip in place on front of dash and follow main harness to rear of cab.

Step 12 connect front extension wire and route in clips with main harness along fender skirt and across front end.

Step13 remove and retain both front parking lamp lens, lens gaskets and attaching screws.

Step14 remove and substitute lamp bodies and wiring. Retain the mounting pads and attaching screws.

Step 15 install the lamp bulbs and attach the lenses.

Step 16 insert extension wire terminal in the open hole in the main harness connector and insert parking and direction signal wire plug. (View B)

Step 17 from under the rear of the cab, disconnect the tail and stop lamp wire extension from the main harness. connect this and the signal harness extension Fig. 240.

Step 18 route the signal harness extension to the rear, clipping it in place along with the tail and stop lamp wire extension assembly on the left hand frame side member Fig. 241.

Step 19 cut off signal wiring harness extension where it reaches the R. H. tail & stop lamp wires. Solder or crimp the terminals securely and insert in connector so that wire colors match those in mating connector on the R.H. TAIL & stop lamp wires.

Step 20 disconnect the R. H. tail & stop lamp extension from the L.H. tail & stop extension and connect to the extension from the front. the jumper is not used.

Fig. 242.

Direction Signal Lamp Installation Instructions

CHASSIS AND PLATFORM MODEL TRUCKS

step 1 the switch housing should match the color of the steering column. The lamp housing should match the color of the fender. Paint these parts when necessary.

Step 2 remove the steering wheel, discard the hub cover and attach the cancelling cam using the hub cover screws and lockwashers.

NOTE: The prong on the cancelling cam should be on the left side. See Fig. 243.

Step 3 remove the wiring clamp from the steering column and feed the wires leading from the switch, through the slots on the underside of the steering column. Fig. 243.

Step 4 screw the signal lever into the switch assembly and tighten the locking nut.

Step 5 place the switch assembly loosely on the steering column ith the lever on the left side.

Step 6 replace the steering wheel in the correct straight ahead position and secure in place.

Step 7 secure the switch assembly in position with the clamping screw, keeping 1/8 inch clearance between the top of the switch housing and the bottom of the steering wheel.

Step 8 remove any slack in the switch wires, and reattach the wiring clamp to the steering column.

Step 9 from behind the instrument panel install the signal lamp wiring harness as directed in Fig. 244.

Step 10 plug the switch wires into the 3 -way connector so that the wire colors match mating harness connector. SEE Fig. 244.

Step 11 through the hole in the main harness grommet on the dash panel, route the directional signal harness into the engine compartment. Clip in place on the front of the dash and follow the main harness to the rear of the cab.

Step 12 connect the front extension wire and route it in the clips with the main harness along the left fender skirt and across the front end.

Step 13 refer to Fig. 245 to locate the holes to be drilled in each fender, for mounting the front signal lamps. At these points, drill two 15/32 inch diameter holes.

Step 14 mount the lamps on the fenders using the parts in the sequence shown in Fig. 245. Make sure the plate reinforcements are positioned to direct the lead wires toward the grommets in the fender skirt.

Step 15 route each lamp wire through the grommet as indicated inFig. 246

Step 16 remove the parking lamp plug from the main harness connector at the front end, and insert the directional signal lamp wire terminal in open hole of the plug. Insert extension wire terminal in the open hole in the main harness connector, replace plug, repeat on the opposite side.

NOTE: The front installation is not intended for use alone. For the flasher to operate properly the rear lamps must be installed either at this time as follows or later by an outside body builder.

Step 17 for platform trucks mount the rear signal lamps on the wood sill. Locate the bracket as shown in Fig. 247. Attach with the wood screws provided and make sure the ground wires are used. Route the wires and clip as shown in Fig. 247.

Step 18 route the lamp lead wires as far forward as they will reach. Connect the rear extension under the rear of the cab, and route to the rear in the clips with the tail and stop lamp wires. Separate the rip cord wires, and cut the black wire to the length to reach the right hand lamp wire and the white stripe wire to reach the left hand lamp wire. Solder or crimp the terminals securely. Attach the connectors and plug in the lamp wires.

Step 19 for drive-away purposes prior to mounting a body. mount the rear signal lamps as indicated in Fig. 248. Connect as described in step 18, except loop up the excess wire for cutting to the proper length later.

Step 20 for truck bodies requiring rear flush mounted signal lamp, determine the desirable left and right hand mounting location, and install as directed in step 18.

Parking Brake Alarm Installation Instructions

PASSENGER CARS

Step 1 loosen the left hand parking brake bracket mounting screw and slide the lamp bracket slotted flange between the parking brake bracket and the lockwasher. position Fig. 249 In main view and tighten securely.

Step 2 assembly the lamp assembly through the bracket hole Fig. 249 in View C.

Step 3 install the flasher clip and flasher on the cowl kick panel Fig. 249 in the main view and View A.

Step 4 attach the lamp wire to the flasher Fig. 249. (View A.)

Step 5 apply the parking brake and attach the switch clamp on the housing Fig. 249. (View D.) with the locating key against the lower end of the housing groove, tighten securely.

Step 6 install the wire assembly connector Fig. 249 in view b. plug the opposite ends of wire assembly into the switch assembly (View D).

Step 7 plug remaining wire into flasher.

Step 8 install fuse if needed.

Parking Brake Alarm

3000 Series With Instrument Panel Hand Brake Lever

1. Centerpunch and drill a 7/8 inch hole in the instrument panel midway between and in line with the choke control and the main light switch. See Fig. 251.
2. File a 1/16 inch radius slot at the bottom center of the hole just drilled.
3. Insert the lens and housing assembly in the drilled hole, and then slip the spring over the housing.
4. Install the lamp in the socket, and secure this assembly to the lens housing with a twisting motion, compressing the spring at the same time.
5. Pass the long wire (with female terminal) through the main wiring harness clip on the plenum chamber and connect it to the junction block terminal marked "BRAKE LP". Install the fuse. See Fig. 250.
6. Attach the flusher assembly to the reinforcement with the flasher clip, as shown in Fig. 250. Connect the short wire (with male terminal) to the top of the flasher assembly Fig. 250.
7. Attach the switch assembly to the switch bracket with the nut and washer provided and connect the short switch wire to the switch. See Fig. 252.
8. Remove the two forward bolts from the brake lever mounting plate assembly. With these bolts attach the switch assembly flush with the outside surface of the brake lever mounting plate. See Fig. 252. NOTE: One hole of the switch bracket is slotted for adjustment. With the brake lever in the released position, the switch plunger should be depressed so that it extends approximately 7/32 inch out of the switch. Tighten the bolts securely with the switch in this position, as shown in Fig. 252.
9. Connect the switch wire to the underside of the flasher assembly. See Fig. 250.
10. Test the installation for correct operation. When the parking brake is applied and the ignition key is turned on, the signal light should flash on and off. When the parking brake is released, the light should stop flashing. If this does not occur, readjust the switch according to the note in step 8.

1. Remove the rear seat cushions on all models except the Utility Sedan and Station Wagons.
2. Locate and drill 13/32 inch diameter holes through the floor pan as required. See Fig. 38.
3. Install a bracket, special flat washer, bolt, and two nuts at each drilled hole. Apply windshield sealer and tighten securely, locking in position with the additional nut Fig. 38 in Illustration No. 3.
4. Thread the seat belts through the seat crevice and attach to the seat belt brackets Fig. 38 in Illustration No. 4.

TWO PASSENGER REAR SEAT BELT INSTALLATION FOR TWO DOOR, FOUR DOOR, AND FOUR DOOR SPECIAL SEDAN

1. Remove the rear seat cushion and backrest.
2. Locate and drill 13/32 inch diameter holes through the floor pan as required. See Fig. 39.
3. Install a bracket, special flat washer, bolt, and two nuts at each drilled hole. Apply windshield sealer and tighten securely, locking in position with the additional nut Fig. 40 in Illustration No. 3.
4. Attach the seat belts to the brackets Fig. 40 in Illustration No. 5. Replace the seat backrest and cushion, threading the seat belts through the seat crevice Fig. 40.

TWO PASSENGER REAR SEAT BELT INSTALLATION FOR CONVERTIBLE AND SPORT COUPE

1. Remove the rear seat cushion and backrest.
2. Locate and drill 13/32 inch diameter holes through the floor pan as required. See Fig. 40.
3. Install a bracket, special flat washer, bolt, and two nuts at each drilled hole. Apply windshield sealer and tighten securely, locking in position with the additional nut Fig. 40 in Illustration No. 3.
4. Attach the seat belts to the brackets Fig. 40 in Illustration No. 4. Replace the rear backrest and seat cushion, threading the seat belts through the seat crevice.

THREE PASSENGER FRONT SEAT BELT INSTALLATION FOR ALL PASSENGER MODELS

1. Drill holes for mounting the seat belt brackets as per the instructions for two passenger belt installation on the individual models. See Fig. 41.
2. Locate and drill 13/32 inch diameter holes through the floor pan Fig. 41 for installation of seat belt brackets for a third front seat passenger. See Fig. 41.
3. Install a bracket, special flat washer, bolt, and two nuts at each drilled hole. Apply windshield sealer and tighten securely, locking in position with the additional nut Fig. 41 in Illustration No. 3.
4. Thread the seat belts through the seat crevice and attach to the brackets Fig. 41 in Illustration No. 7.

THREE PASSENGER REAR SEAT BELT INSTALLATION FOR TWO DOOR, FOUR DOOR, AND FOUR DOOR SPECIAL SEDAN

1. Drill the holes for mounting the seat belt brackets as per the instructions for two passenger belt installation on the individual models. See Fig. 41.
2. Locate and drill 13/32 inch diameter holes through the floor pan Fig. 41 for installation of seat belt brackets for a third rear seat passenger. See Fig. 41.
3. Install a bracket, special flat washer, bolt, and two nuts at each drilled hole. Apply windshield sealer and tighten securely, locking in position with the additional nut Fig. 41 in Illustration No. 3.
4. Thread the seat belts through the seat crevice and attach to the brackets Fig. 41 in Illustration No. 10.

THREE PASSENGER REAR SEAT BELT INSTALLATION FOR SPORT COUPE AND CONVERTIBLE

1. Drill the holes for mounting the seat belt brackets as per the instructions for the two passenger belt installation on the Sport Coupe and Convertible. See page 3.
2. Locate and drill 13/32 inch diameter holes through the floor pan Fig. 42 for the installation of seat belt brackets for a third rear passenger in the rear seat. See Fig. 42.
3. Install a bracket, special flat washer, bolt, and two nuts at each drilled hole. Apply windshield sealer and tighten securely, locking in position with the additional nut Fig. 42 in Illustration No. 3.
4. Thread the seat belts through the seat crevice and attach to the brackets Fig. 42 in Illustration No. 10.

THREE PASSENGER REAR SEAT BELT INSTALLATION FOR TWO DOOR AND FOUR STATION WAGONS

1. Fold the rear seat cushion to the load platform position.
2. Drill 13/32 inch diameter holes through the wheel house panel (left and right hand) and floor pan at the locations Fig. 43 in Illustration No. 11.
3. Install a bracket, special flat washer, bolt, and two nuts at each drilled hole. Apply windshield sealer and tighten securely, locking in position with the additional nut Fig. 43 in Illustration No. 3.
4. Attach the seat belts to the brackets. Fold the seat cushion back to seat position and thread the belts through the seat crevice.

THREE PASSENGER SEAT BELT INSTALLATION ON INTERMEDIATE SEAT FOR NINE PASSENGER STATION WAGON

1. Fold the intermediate seat forward to provide access to the floor pan. Roll back the floor mat from the right hand side.
2. Drill 13/32 inch diameter holes through the floor pan and wheel house Fig. 44 for the intermediate seat in Illustration No. 12.
3. Install a bracket, special flat washer, bolt, and two nuts at each drilled hole. Apply windshield sealer and tighten securely, locking in position with the additional nut Fig. 44 in Illustration No. 3.
4. Attach the seat belts to the brackets. Return the intermediate seat to seat position and thread the seat belts through the crevice.

THREE PASSENGER REAR SEAT BELT INSTALLATION FOR NINE PASSENGER STATION WAGON

1. Remove the rear seat cushion, back rest, and spare tire.
2. Drill 13/32 inch diameter holes through the floor pan Fig. 45 for the rear seat belts in Illustration No. 12.
3. Attach the seat belts to the brackets before making the installation.
4. Install a bracket, special flat washer, bolt, and two nuts at each drilled hole. Apply windshield sealer and tighten securely, locking in position with the additional nut Fig. 45 in Illustration No. 3.
5. Re-install the seat backrest, seat cushion, and spare tire. Thread the belts through the seat crevice.

CAUTION: Do not bleach or re-dye belts as this may cause severe loss of strength. Fig. 46.

Seat Belt Installation Instructions

CORVETTE

1. Remove the sealer tape from the existing holes in the floor tunnel.
2. Mount two adapter seat belt brackets at the center positions using a bolt, flat washer, lockwasher and nut Fig 47 in views "a" and "b". apply windshield sealer to the bolts before assembly.
3. Mount an adapter seat belt bracket onto the left hand folding top cylinder floor bracket with a bolt, nut, and lockwasher through the existing hole fig. 47 in view "c" repeat this installation on the right hand side.
4. Assemble the seat belts to the adapter brackets Fig. 47.
5. Remove sheet 9 of seat belt installation instructions no. 3730730 and place it in the glove compartment.

TRUCKS, CARRYALL PANEL, CAB

CAB TRUCK

1. Follow the dimensions in view "c" for locating and drilling holes for mounting the brackets and "u" bolts.
2. Locate and drill two 13/32 inch diameter holes for the two outer brackets.
3. Locate from the outer bracket holes and scribe for drilling the 11/32 inch diameter holes for "u" bolt installation.
4. Use a "u" bolt as a template for locating the second hole for each "u" bolt mounting.
5. Determine the hole location for seat belt hanger as required for adjusted length of belt, drill .136 hole (#29 drill). Fig. 48.

PANEL TRUCK

1. Using the existing hole as located in Fig. 49 discard production bolt, washer and nut and install the bracket Fig. 49 in view "C".
2. Measure.from existing hole Fig. 49 in view "B" and scribe for first "U" bolt hole. After locating position for first hole, use "u" bolt as a template for the second hole, then drill two 11/32 inch diameter holes and install "u" bolt Fig. 49 in view "A".

CARRYALL

1. View "a" to be used as a typical section for assembling all brackets with the exception of the two outboard brackets for driver and auxiliary seats.
2. For installing brackets and "u" bolts for front seats, refer to view "a" and view 'C", Fig. 50.
3. Bracket on left hand side nearest wheel housing for center seat, should be turned on slight angle Fig. 50, to allow seat belt to take a more direct course.

3, 4, 5, 6, 7, 8, 9, AND 10, OOO MODEL TRUCKS

CABS ONLY

1. Locate the dimple on the under side of the header panel. Center the mirror bracket over the dimple. See Fig.53.
2. Using the mirror bracket as a guide, scribe three circles through the top and bottom holes, onto the header panel.
3. Remove the mirror bracket and at the centerlines of the circles just scribed, centerpunch and drill three 9/64 inch diameter holes.
4. Reposition the mirror bracket and fasten it to the header panel with the self-tapping screws provided. See Fig. 53.
5. Tighten all of the screws securely.

PANEL BODIES

1. Remove and discard the sheet metal screw at the centerline of the body. Center the mirror bracket over this hole and attach it to the header panel with the self-tapping screw provided.
2. Using the two bottom holes of the mirror bracket as a template, drill two 9/64 inch diameter holes through the under side of the header panel and complete the attachment of the bracket to the header panel with the two self-tapping screws provided.
3. Tighten all of the screws securely. NOTE: The mirror bracket reinforcement is to be used only when installing a radio speaker unit.

MIRROR BRACKET INSTALLATION

USED WITH RADIO SPEAKER

NOTE: If there is a radio speaker previously installed remove the four screws holding the speaker assembly to the header panel, move speaker assembly away from header panel. See Fig. 53.

NOTE: The mirror bracket installation is identical to preceding installation except as follows.

1. Install the reinforcement onto the mirror, bracket with the self-tapping screw from the top hole in the mirror bracket.
2. Remove the speaker from the speaker housing, line up the reinforcement template cut-out with the cut-out in the bottom of the speaker housing. See Fig. 53.
3. Mark the center of the two circles on the reinforcement template, centerpunch and drill two 3/16 inch diameter holes in the bottom of the speaker housing, reassemble the speaker into the speaker housing. See Fig. 53.
4. Place the speaker assembly up to the mirror reinforcement and fasten it with the two self-tapping screws provided.
5. Replace the four screw previously holding the speaker assembly to the header panel.

1500 AND 2100 SERIES PASSENGER CAR

Step 1- remove instrument panel clock hole cover.

Step 2- insert the clock assembly in the clock opening.

Step 3- install bracket on clock assembly Fig. 62.

Step 4- attach clock lights and the clock feed connector.

Auto Compass

All Passenger Cars

1. Remove the screw holding the garnish molding escutcheon plate at the center of the windshield. Discard the screw.
2. Remove the screws holding the left hand garnish molding below the windshield, and lift the molding out.
3. Lay the wire in the exposed trough of the instrument panel, allowing the socket end at the center of the windshield to extend up about three inches.
4. Route the terminal end of the wire to the left end of the trough, then down through the left side of the instrument panel to the side trim panel, and clip in place, Fig. 63.
5. Add connector to wire terminal and connect wire Fig. 63.
6. Replace the garnish molding and secure with the same screws.
7. Put the compass bracket in place over the escutcheon plate, and fasten both parts to the garnish molding with the special screw furnished in the package.
8. Position the compass in the mounting bracket and fasten with the two screws.
9. Insert the light bulb and socket into the compass.

AUTO COMPASS COMPENSATION

After installation, check the compass to determine if the instrument gives an accurate reading. This must be done outside, away from steel constructed buildings, etc.

1. Turn the car to face North as accurately as the direction can be determined, with the car wheels in a straight ahead position.
2. Remove the compass compensator cover from the bottom of the compass by placing the index and middle finger at the rear of the cover and the thumb at the front. Press your thumb inward and pull the cover down from the compass body.
3. With the transmission selector in neutral and the doors closed,, start the engine and run the engine at a speed equal to approximately 20 miles per hour.
4. Turn the wheel, shown in methods "A" and "B',' to the left so that the magnets are straight up and down, which is the neutral position.
5. Read the compass. If the reading falls within two marks of "n" or within three marks of "S" Fig. 64 above, follow Method "A" to adjust the compass compensation. If the reading is beyond the above marks, follow Method "B" to adjust the compass compensation.
6. Replace the bottom cover of the compass by inserting the two rear ears of the cover in the body of the compass, and pressing in with the thumb at the front and pushing up to snap it into place.

DEALER NOTE: PLACE THE INSTRUCTION SHEET IN THE GLOVE COMPARTMENT.

WHEEL COMPENSATOR

METHOD A

• Turn the car to face East, as accurately as possible.
• Turn the compensator parallel to the direction of the car, Fig. 65 above.
• Slowly rotate the wheel to the right to correct for as much of the East error as possible. (if turning the wheel right causes the error to increase, turn the compensator around end for end, and again rotate the wheel to the right slowly to correct for as much of the East error as possible.)
• Turn the car to face South, as accurately as possible.
• Turn the compensator slightly to the right or to the left to correct for half the error.
• Turn the car to face West, as accurately as possible.
• Turn the wheel to the right or to the left to correct for half the error.
• Turn the car to face North, as accurately as possible.
• Turn the compensator slightly to the right or to the left to correct for half the error.
• You may repeat the above operations, if desired, to remove smaller and smaller parts of the error.

WHEEL COMPENSATOR

METHOD B

• With the car facing to the North, turn the compensator crosswise to the direction of the car, Fig. 65 above.
• Rotate the wheel slowly to the right to correct the error as much as is possible. (if rotating the wheel to the right causes the error to increase, turn the compensator around end for end, and again rotate the wheel to the right slowly to correct the error as much as is possible.)
• Turn the car to face East, as accurately as possible.
• Turn the compensator to the right or to the left to correct for half the error.
• Turn the car to face South, as accurately as possible.
• Rotate the wheel slightly to the right or to the left to remove half the error.
• Turn the car to face West, as accurately as possible.
• Turn the compensator slightly to the right or to the left to remove half the error.
• You may repeat the above operations, if desired, to remove smaller and smaller parts of the error.

For easier installation and improved fit, condition seat covers at 70 degrees Fahrenheit (room temperature) or above for a minimum of one hour prior to installation.

All Truck Cab Models

1. Detach the backrest from the seat cushion by removing the two bolts and flat washers from the backrest side arms. See Fig. 66.
2. Place the backrest, face side up, on a clean, flat surface. Fit the backrest cover to the backrest, keeping the seams aligned. Make sure the cord is looped over the side arms. See Fig. 66.
3. Turn the backrest over, and draw the sides of the backrest cover up over the sides of the backrest.
4. Hook the cord to the backrest springs with three S-hooks, Fig. 66 in illustration No. 3.
5. Keeping the card ends under tension, cross and tie them to the backrest springs. See Fig. 66.
6. Fit the seat cushion cover to the seat cushion, keeping the seams aligned.
7. Tie the length of cord provided to a S-hook. See Fig. 67, illustration No. 4.
8. At either end, reach under the seat cushion and attach the S-hook on the cushion cover elastic at the notch in the rear hem. Pull the S-hook forward with the cord, using one hand. With the other hand, draw the elastic at the notch in the front hem towards the rear and hook it onto the S-hook. Remove the cord from the S-hook. Refer to Fig. 67.
9. Repeat step 8 for opposite end.
10. At each rear corner of the seat cushion cover, slip the elastic over the backrest stop. See Fig. 67.
11. Place a S-hook on the elastic at the center notch of the front hem, and attach the S-hook, as indicated at point A inFig. 67, >. Repeat process at the center notch of the rear hem. See point B of Fig. 68.
12. Re-attach the backrest to the seat cushion, using the two bolts and flat washers removed in step 1.

ALL PASSENGER CARS

Step 1 measure 1/4 inch inboard from the ash tray opening to the outboard hole in the dispenser bracket.

Step 2 hold dispenser bracket lip tightly against rolled edge of lower flange, scribe the mounting bracket hole location.

Step 3 remove the dispenser, center punch the scribed holes and drill two 9/32 inch diameter holes in lower flange.

Step 4 attach the dispenser securely with the bolts, lockwasher, and nuts. Fig. 72.

Shoulder Harness Installation Instructions

1. For Two-door and Convertible install bracket A as shown in views B and C, Fig. 107.
2. For Four-door Sedan install bracket in an identical manner to that as three belt installation as shown in Fig. 108 of instruction sheet No. 3730730.

PASSENGER REAR SEAT SHOULDER HARNESS INSTALLATION FOR TWO DOOR, FOUR DOOR, FOUR DOOR SPECIAL, AND SPORT COUPE

1. Locate point "A" at center line of the rear compartment shelf and pierce a hole through from the top side.
2. Locate point "B" on the right hand end of the shelf and pierce a hole through the shelf from the top side. Pierce an identical hole at the left hand end of the shelf.
3. Enlarge the pierced holes to 13/32 inch diameter by drilling from the bottom side.
4. Install a bracket, special flat washer, bolt, and two nuts at each drilled hole. Tighten securely, locking in position with the additional nut as shown in View"AA"of Fig. 110.

REAR SEAT SHOULDER HARNESS INSTALLATION FOR TWO

DOOR AND FOUR DOOR SIX PASSENGER STATION WAGON

1. Drill 13/32 inch diameter holes through the load platform and floor pan at points "A" and "B". See Fig. 110.
2. Install a bracket, special flat washer, bolt and two nuts at each drilled hole. Apply windshield sealer and tighten securely, locking in position with the additional nut as they are shown in Fig. 110, View "A A".
3. Attach the shoulder harness to the brackets and the seat belts as shown in Fig. 108.

INTERMEDIATE SEAT SHOULDER HARNESS INSTALLATION

FOR NINE PASSENGER STATION WAGON

1. Cut slots through the forward section of the load platform and mount brackets onto the floor pan as shown in View. "A" of Fig. 108.
2. Attach the shoulder harness to the brackets and seat belts as shown in Fig. 108.

REAR SEAT SHOULDER HARNESS INSTALLATION FOR NINE PASSENGER STATION WAGON

1. Position the brackets, with shoulder harness attached, on the rear tail gate sill and use them as templates for drilling as shown in Fig. 112.
2. Attach the brackets to the tail gate sill using the method shown in View "A". Fig. 112. Thread the seat belts through the seat harness as shown in 108.

PASSENGER REAR SEAT SHOULDER HARNESS INSTALLATION FOR CONVERTIBLES

1. Locate and drill 13/32 inch diameter holes through the rear deck under body as shown in Fig. 113.
2. Install a bracket, special flat washer, bolt, and two nuts at each drilled hole. Apply windshield sealer and tighten securely, locking in position with the additional nut as shown in View"AA"of Fig. 110.
3. Loosen the top cover retainer from the back of the rear seat and insert the harness between the retainer and the seat back. Slit holes in the dust cover as illustrated Pass the harness through the slits and fasten to the brackets.
4. Attach the shoulder harness to the seat belts as shown in Fig. 109.

All Passenger Cars

NOTE: READ CAREFULLY PRIOR TO INSTALLATION

Step 1 apply first coat of * adhesive to the inside edge of pad Fig. 179. In the shaded areas "a" and allow to dry 15 minutes.

Step 2 second coat the same areas and allow to dry for an additional 15 minutes prior to installation on the instrument panel.

Step 3 remove side garnish moldings, rear view mirror (4 door sport sedan), escutcheon, lower windshield garnish moldings, radio speaker cover, instrument cluster caps (do not re-use) and trim plate (on 2400 series). Apply * adhesive tothe shaded area "b" of gutter and to the upper surface of the instrument panel Fig. 179. This must be done immediately after applying the adhesive in step 2 and allowed to dry 15 minutes.

STEP 4 Caution: apply * adhesive to the shaded area 'C of the instrument panel and install the pad immediately after cementing to insure movement of the pad for good alignment.

*NOTE: Adhesive to be applied liberally

Step 5 line up pad with instrument panel. Secure the lower edge first and then work remainder of pad into position being certain that the lower pad surface cements tightly and the pad ends "d" are flush with the instrument panel at the door opening.

Step 6 apply pressure completely across cemented area. drill 10 holes 3/16 dia. Fig. 180 and secure retainer mouldings to instrument panel. NOTE: Pad unit contains two sets of retainers. The longer is used on the 1500 series and the shorter is used on the 2100 series to allow clearance for the lower molding (not part of pad unit). Replace items which were removed in step 3.

NOTE: Trim plate acts as a retainer on bel air models.

NOTE: Use the molding as a template to locate and drill holes in trim panel.

Step 7 position clips on retainers approximately Fig. 180. When adding extra accessories, punch any additional holes through skin material.

Door Arm Rest Installation Instructions

Series One-Fifty Passenger Cars

FRONT DOORS

Step 1 locate holes in metal door panel and trim panel foundation. By following measurements shown at intersection of lines, the hole can be felt with the finger tips. Pierce through trim panel.

STEP 2 ATTACH AND SECURE Fig. 206.

Step 3 repeat for other front door. * NOTE: use chalk lines on trim panel for locating holes.

REAR DOORS

Step 1 locating procedure and assembly is the same as front doors with the exception of location measurements.

Utility Tray Installation Instructions

All Trucks

1. Assemble the two brackets to the utility tray with the four screws, lockwashers, and nuts provided in the package. The four nuts and lockwashers are to be attached to the inside of the tray.
2. Position the utility tray assembly in the cab Fig. 259. Now, using the holes in the tray assembly brackets as a template, center punch and drill two holes through the rear upper inner panel at each side. The top hole is to be 1/2 inch below line "A". SEE VIEW "A".
3. Attach the utility tray assembly brackets to the rear upper inner panel with the four sheet metal tapping screws and lockwashers provided.
4. Centerpunch and drill three holes (5/16 1nch diameter) through the rear outer panel and utility tray. These holes are to be located 9 inches below the upper hole in the bracket.
5. Secure the utility tray to the outer back panel with the three screws, lockwashers, and nuts provided. Apply windshield sealer to the screws before assembly. The nuts and lockwashers are to be installed on the inside of the tray.

Step 1- rollback floor mat. (NOTE: After completion of step 2, roll mat into place and cut hole to fit.)

Step 2- locate and drill two .144 diameter holes (#27 drill) using jack bolt as template.

Step 3- disconnect license plate lamp wire.

Step 4- beneath center of trunk latch in body panel drill a .144 diameter hole (#27 drill) and assemble the rubber bumper.

NOTE: Place jack and parts Fig. 56. (Place base in a position beside jack bolt.)

Step 5- follow instructions on template for locating and drillng 1/2 inch diameter hole in cross member. Fig. 57.

Step 6- locate template on frame side member and drill 1/2 inch diameter hole through prame and cross member.

Step 7- attach adapter to frame and cross member.

Step 8- attach accessory bumper face loosely to adapter.

Step 9- attach bumper face to bumper bracket and bumper ends.

Step 10- locate Fig. 58 to left and right center of car and cut rubber sealer strip to length of new rubber strip. discard center portion.

Step 11- crimp full length of flange that holds rubber sealer strip.

Step 12- fold center section of seal under rear edge of body and tape to floor panel.

Step 13- drill five holes 9/64 inch diameter using holes in filler panel as template.

Step 14- remove license plate attaching parts from deck lid and attach wheel carrier to bumper Fig. 59.

Step 15- redrill two existing holes in deck lid outer panel only, to 35/64 inch diameter.

Step 16- from inside deck lid center retainer over 7/16 inch diameter hole in inner panel, mark and drill two 5/32 inch diameter holes through inner panel and reinforcement. Assemble retainer Fig. 59 in View A.

Step 17- place shoulder spacers into two 35/64 inch diameter holes, at the same time installing pad and support assembly, using 5/16 x 3-1/8 bolts. do not tighten, draw up sufficiently. Next place anchor plates in position in support assembly. Install lock assembly to the support assembly. Tighten sufficiently to hold.

Step 18- swing wheel carrier into lock position. use vertical and horizontal adjustment on support assembly and vertical adjustment on lock assembly to align lock bolt with center of lock in operating position. Use nut on lock bolt to adjust lock bolt in or out.

Step 19- after adjustments have been made, scribe two places on deck lid through two lower holes on support assembly.

Step 20- remove support and lock assembly. drill two 3/8 inch diameter holes through outer panel, reinforcement and inner panel. Redrill holes in outer panel to 35/64 inch diameter. Install all parts into position, making certain upper support spacers are still in position. Tighten all bolts securely.

Step 21- before removing nut from end of lock bolt count the number of threads showing.

Step 22- remove nut from end of lock bolt, in turn releasing lock bolt from wheel carrier. Assemble all parts to wheel carrier in order shown. adjust adjusting nut so that same amount of threads appear above nut as before. Fig. 60.

Step 23- install license plate light in bumper, routing wire and using clips Fig. 61.

Step 24- attach license plate bracket to the bracket support. Attach license to bracket after tire cover has been installed.

Step 25- place tire cover on hinge plate. Install tire, using special nuts and lock case. Place retaining ring over cover and tire. Secure in position with retaining spring.

Step 26- lubricate lock assembly with gm lubriplate.

License Plate Frame Installation Instructions

All Passenger Cars

Fig. 74.

Windshield Glareshield Installation Instructions

All Passenger Cars

CAUTION: This glareshield must be installed by experienced personnel only. Rough handling can result in excessive scratching, marring, and possible breakage of the shield.

1. From a small diameter dowel, cut a piece 11-1/8 inches long. This dowel , can be used for other glare-shield installations.
2. Position the dowel vertically on top of the instrument panel, at the forward edge of the garnish molding, so the top end of the dowel contacts the inside contour of the windshield garnish molding.
3. Place a clip on top of the vertical dowel, with the hole facing the windshield garnish molding and the spike pointed toward the rubber molding, and push the spike of the clip into the rubber molding.
4. Install the other clip on the opposite side.
5. With the protective cover still on, install the glareshield in both clips. This is done by "bowing out" the shield and inserting the outer ends of the shield in the clips. Press the two bowed out portions of the glareshield against the windshield simultaneously. If excessive pressure is required to press the glareshield against the windshield, relocate the clips downward.
6. Inspect the installation of the glareshield for position to see that it touches the rubber molding at the top at all points, and that the bottom edge is firm against the windshield. If the installation does not meet these requirements, reposition the clips to suit.
7. Using the clips as templates (after they have been positioned correctly), indicate and drill a 3/32 inch hole in each GARNISH MOLDING ONLY. Do not drill too far. Secure the clips with the tapping screw.
8. Remove the glareshield and clean off the windshield.
9. Remove the protective covering and reinstall the glareshield.
10. Remove the two center screws from the windshield upper garnish molding, and loosen the other four screws which hold it. Loosen the mirror bracket screws.
11. Place the center support against the glareshield, adjacent to one side of the mirror bracket, and slide the support into position back and at the center of the mirror bracket, with the support flange under the glareshield.
12. Replace and/or retighten all screws.

Fig. 75.

Bumper Guard Installation Instructions

3000 SERIES TRUCKS

1. Remove the bumper attaching bolts from the left hand front bumper bracket and discard.
2. Place the left hand bumper guard in position and mount it to the bumper and bumper bracket using the lockwashers, flat washers and bolts furnished. Tighten securely.
3. Mount and attach the right hand bumper guard following the procedure outlined in Steps 1 and 2 above.
4. Remove the license plate and license plate bracket. Discard the bracket.
5. Locate and mark the center of the bumper by measuring 16 inches from the inside edge of either bumper guard.
6. Center the license plate with the mark made on the bumper. Using the horizontal centerlines of the two bottom holes in the license plate as a guide, mark the centers of the holes to be drilled in the bumper by extending these horizontal centerlines 1-7/32 inch above the peak line of the bumper.
7. At the locating marks just made, centerpunch and drill two 3/8 inch diameter holes through the bumper.
8. Following the assembly sequence indicated in the illustration, attach the license plate to the bumper with the bolts, spacers, lockwashers and nuts provided.

Fig. 76.

Bumper Guard Installation Instructions

SERIES 4000, 5000 AND 6000 TRUCKS

1. Measure 8 inches inboard from the centerline of the bumper bolt (left and right) and scribe a vertical line on the face of the bumper.
2. Temporarily position the bumper guards on the bumper so that the scribed vertical lines will bisect the mounting holes in the guards. Mark the mounting hole locations in the bumper face bar, using the bumper guards as templates.
3. Conterpunch and drill four 15/32 inch holes through the bumper face bar.
4. Attach the bumper guards to the bumper, using the four special bolts, plain washers, lockwashers, hex nuts, and the brackets, Fig. 77. Tighten securely.

PASSENGER CARS, STATE OF VERMONT

1. locate the template from edge of the license lamp and drill holes as required in Fig. 78. Recommendation: centerpunch the bumper and use 1/8 inch diameter pilot drill before drilling 3/4 and 1/2 inch diameter holes.
2. Fit the bumper guard to the bumper. Loosely install the upper bolt and spacer. Next install the lower bolt loosely. Adjust the bumper guard for vertical positioning, then tighten both bolts.
3. ATTACH WIRING Fig. 78. Repeat the same operation for mounting the right hand bumper guard.

All Passenger Cars

1. From the centerline of the front bumper, measure 11-15/16 inches to the right and scribe at the point indicated in the Fig. 79.
2. Loosely attach the upper guard clamp in position, using bolt provided.
3. Next attach bottom clamp loosely, adjust the bumper guard for vertical positioning, then tighten both clamps.
4. Repeat the same operation for mounting the right hand bumper guard.

REAR BUMPER GUARD

INSTALLATION INSTRUCTIONS

All Passenger Cars

1. Locate the template from edge of license lamp and drill holes as required Fig. 80 In illustration. Recommendation: centerpunch bumper and use 1/8 inch pilot drill before drilling 1/2 inch hole.
2. Fit the bumper guard to the bumper. Loosely install the upper bolt and spacer. next install lower bolt loosely, adjust the bumper guard for vertical positioning, then tighten both bolts.
3. Repeat the same operation for mounting right hand bumper guard.

All Passenger Cars

Step 1. remove production insert, discard insert and bolt, but retain all other attaching parts.

Step 2. place spacer furnished in package on bumper guard cushion bolt. Install bumper guard cushion onto bumper guard.

Step 3. secure bumper guard cushion in place with the production spacer, plain washer, and nut retained in step number 1.

Step 4. repeat above installation on opposite side.

Fig. 81.

Door Edge Guard Installation Instructions

All Passenger Cars

1. Locate and attach the special clips on the door edge as shown.
2. On Cars equipped with door lower moldings, separate the rear edge of the molding from the door panel sufficiently to permit the guard to slip under the molding.
3. Locate the guard to match the door contour. Complete the installation by tapping the guard in place by hand or with a rubber mallet. Start at the bottom and work up.

Fig. 82.

Fig. 83.

Fig. 84.

1. Locate and attach the special clips on the door edge as shown.
2. Separate the rear edge of the door lower molding from the door panel sufficiently to permit the edge guard to slip under the molding.
3. Starting at the top directly below the outside molding, locate the guard to match the door contour. Complete the installation by tapping the guard in place by hand or with a rubber mallet.

Fig. 85.

Fig. 86.

Door Edge Guard Installation Instructions

All Trucks

1. Attach the four clips on the door edge, spacing them Fig. 87.
2. Locate the chrome door edge guard on edge of the door, matching it with the contour of the door.
3. Apply the door edge guard by tapping with rubber mallet starting at crease line.

4-6000 Series Trucks

1. Place the template provided on the right hand section of the filler panel, as indicated in Fig. 88. Carefully follow the directions given on the template. Secure the template with tape and centerpunch the hole to be drilled. Repeat for opposite side making sure that the template has been REVERSED.
2. Remove the template and drill two 1-1/2 inch diameter holes at the locating points just made. Remove any burrs resulting from the drilling.
3. Remove and discard the two top bolts which attach the bumper to the right hand frame side member. Repeat for opposite side.
4. Place the grille guard on the bumper making sure that it aligns with the rear edge of the bumper flange. Fasten it loosely with the 7/16 inch bolts, nuts, lockwashers and flat washers provided.
5. Using the remaining 1/2 inch diameter holes in the base of the grille guard as a guide, scribe two circles on the bumper. NOTE: The two 5/8 inch diameter holes are for fog light installation only.
6. Remove the grille guard and at the centerlines of the circles just scribed, centerpunch and drill two 1/2 inch diameter holes through the bumper. See Fig. 88.
7. Remove any burrs resulting from the drilling and prime the holes with paint to prevent corrosion.
8. Position the grille guard over the holes just drilled and attach it loosely to the bumper with the 7/16 inch bolts, lockwashers, flat washers and nuts provided. See Fig. 88.
9. Drill two 1-1/4 inch diameter holes through the dimples on the baffle assembly panel. On models without dimples use measurements shown in Fig. 90.
10. Pass the right hand guard brace up through the right hand hole in the baffle assembly panel and the right hand hole in the filler panel. Attach the upper end of the guard brace loosely to the grille guard with the 3/8 inch bolt, lockwasher, flat washer and nut provided. See Fig. 91. Repeat for opposite side.
11. Using the slotted hole, attach the lower end of the guard brace loosely to the brace bracket with the 3/8 inch bolt, lockwasher, flat washer and nut provided. Repeat for opposite side. See Fig. 92.
12. Butt the bearing surface of the brace bracket against the frame and tighten the bolt assembly described in step 11. Repeat for opposite side. NOTE: Be sure that the braces are positioned in the center of the baffle holes previously drilled in step 9.
13. Mark location of the two holes in the bearing surface of the brace bracket on the frame. Remove the brace bracket from the brace and drill two 7/16 inch diameter holes through the frame. Repeat for opposite side.
14. Secure the bracket to the frame side member with two 3/8 inch bolts, lockwashers, flat washers and nuts. Tighten the brace to the bracket, keeping the brace centered in the hole in the baffle. Repeat for opposite side.
15. Check installation for alignment and tighten all bolts.

8000 Series Trucks

1. Radiator grille guard package 987213 to be used with the adapter unit.
2. Use template furnished with the grille guard to locate holes in the filler panel. Mark the right hand side first and turn template over for left hand marking. See Fig. 93.
3. Drill two 1-1/2 inch diameter holes Fig. 94. Remove burrs and prime paint holes.
4. Remove and discard the bolts attaching the bumper to the frame (2 on each side).
5. Attach the center spacers to the bumper with 7/16-inch bolt and attaching parts. See Fig. 94.
6. Loosely attach the outer spacers (Flange with smaller slot toward the grille guard) to grille guard lower bar. See Fig. 95.
7. Place the grille guard on top of the center spacers and attach loosely with 7/16-inch bolts and attaching parts.
8. Line up grille guard with the rear edge of bumper flange. Adjust the outer spacers for maximum contact with the bumper and tighten bolts. Then scribe locations for the holes in the bumper through the lower holes in the outer spacers. See Fig. 96.
9. Remove the grille guard from the center spacers. Drill a 1/2-inch diameter hole through the forward part of slots scribed above (see Fig. 97). Remove burrs and prime paint the holes to prevent rust and corrosion.
10. Line up the grille guard as before and attach to the spacers and bumper (see Fig. 93). Use additional plain washers on the outer spacers (top and bottom).
11. Attach brackets to right and left hand braces. Pass braces from the bottom through the holes drilled in Step No. 3 (see Fig. 98) and attach loosely to the grille guard. Use 3/8-inch bolts and attaching parts.
12. Center the braces in holes in filler panel and scribe locations for the holes in frame, using brackets as templates. See Fig. 99.
13. Remove brackets from the braces and drill 7/16-inch diameter holes in the frame Fig. 99.
14. Securely attach the bracket to the brace and to the frame, using 3/8-inch bolts and attaching parts. See Fig. 100.
15. Check installation for alignment and tighten all the bolts securely.

3000 SERIES TRUCKS

Step 1 remove license plate bracket.

Step 2 drill 2 inch dia. hole * (one each side) from below, through lower filler panel and radiator lower bar assembly at 1/8 inch dia. locating hole (SEE Fig. 101 )

Step 3 locate template along center line of bumper brace, tape securely in place and drill hole. Reverse template for other side. (See Fig. 101 )

Step 4 locate grille guard on bumper with spacers in place and drill (4) 1/2 inch dia. holes in bumper (SEE Fig. 102 )

*NOTE: Treat all drilled holes for corrosion.

Step 5 after holes are drilled, loosely attach the grille guard. (See Fig. 103)

Step 6 insert grille guard brace through hole in radiator lower bar assembly and lower filler panel. Attach both ends as shown in Fig. 104.

Step 7 check installation for alignment and tighten all bolts.

Step 8 notch holes in license plate bracketand mount to grille guard. (See Fig. 105)

Mud Flap Installation Instructions

3600 AND 3800 SERIES TRUCKS

1. The general location and mounting of flaps are shown in Fig. 106.
2. Locate and drll 11/32 dia. holes as shown in views Fig. 106
3. The distance from the flaps to the ground (dimension "x") will be approx. 5 to 7 inches with truck unloaded, but requirements in this respect vary according to state regulations. Make sure of local requirements and see that they are complied with.
4. Hold the flap at the required distance "x" from the ground and determine which holes in the brackets are to be used to give this distance. cut off the brackets 5/8 inch below the holes selected.
5. Attach the bracket reinforcements and flaps as Fig. 106.

All Passenger Cars

1. Position the bracket pad against the door crease molding, or corresponding crease line, and line up the grooved line on the pad with the rear edge of the ventilator glass as illustrated. CAUTION: Place the mirror temporarily on the pad at the indicated outline. Adjust the mirror for proper vision. Determine if this positioning of the mirror interferes with opening the ventipane. Relocate the pad, if necessary.
2. Center punch the door panel through the 1/8 inch hole in the pad. Remove the pad and drill a 1/8 inch hole.
3. Tape the pad in place on the door panel with the 1/8 inch holes lined up.
4. Drive the 5/8 inch tapping screw through the drilled hole until the screw head bearing surface measures 5/32 inch above the surface of the pad.
5. Fit the mirror base over the pad so the raised screw head indexes the round end of the keyhole slot in the retaining bracket.
6. Slide the mirror base forward until tight against the pad and fitting the indicated outline.
7. Hold the front of the mirror base firmly against the pad and, using the hole in the base as a guide, drill a 1/8 inch hole through the door panel.
8. Complete the attachment with the 3/4 inch trim screw provided and remove the excess pad.

Fig. 160.

Fig. 161.

Fig. 162.

Fig. 163.

Outside Rear View Mirror Installation Instructions

ALL TRUCKS

1. For mounting the front upper rear view mirror bracket, place the bracket 1/8 inch below the top edge of the side door, and locate the center of the rear hole of the bracket 2-3/8 inches forward of the ventilator division post. Using the bracket as a template, mark the location of the two holes. See Fig. 164.
2. For mounting the rear upper rear view mirror bracket, place the bracket 1/8 inch below the top edge of the side door, and locate the center of the front hole 12-1/2 inches to the rear of the rear hole in the front upper bracket. Mark the location of the two holes. See Fig. 164.
3. Center punch and drill (4) 5/16 inch diameter holes in the top of the side door, install the two upper brackets with the special tee bolts, lockwashers and nuts furnished. See Fig. 164.
4. For mounting the rear view mirror lower bracket, place the top edge of the lower bracket up to the belt crease line, now place the end with the least bend in it in line with the front edge of the ventilator division post. Using the bracket as a template, mark the location of the 4 holes. See Fig. 164.
5. Center punch and drill (4) .191 diameter holes in the side door. Attach the lower bracket to the door with the self tapping screws furnished. See Fig. 164.
6. Attach one of the long arms to each one of the upper brackets as shown in Fig. 165. Use the bolts, washers, lockwashers and nuts furnished.
7. Attach one short arm and one long arm to the front of the lower bracket. Use the attaching parts furnished. The long arm is used as a diagonal brace. Leave the lower arms loosely attached. See Fig. 165.
8. On the rear of the lower bracket attach the remaining short arm with the attaching parts furnished. See Fig. 165. Leave the arms loosely attached.
9. Attach the outside rear view mirror to the upper and diagonal arms, putting the diagonal arm under the two upper arms as shown in Fig. 165. Use the attaching parts furnished.
10. Attach the two lower arms to the bottom of the mirror. Use the remaining attaching parts furnished. See Fig. 165.
11. Tighten all the bolts and nuts securely.
12. To adjust the mirror, loosen the locking nut in the center of the arms, and slide the inner arms in or out. The inner part of the arms should retain at least 4 inches inside of the outer part of the arms, except the lower rear arm which will be 3 1/2 inches. See Fig. 165.

All Trucks

LEFT HAND INSTALLATION ALL TRUCKS EXCEPT 5000 SERIES.

1. Remove the existing standard mirror and discard all parts.
2. Attach the adjustable mirror and pad to the door using the three 5/16 inch bolts and lockwashers provided.
3. Adjust the mirror assembly to suit.

RIGHT HAND INSTALLATION-ALL TRUCKS EXCEPT 5000 SERIES.

1. Select the template from the kit marked "3000, 4000 and 6000 Series Outer". Align the template with the top edge and the front edge of the right hand door outer panel. Secure with tape. See Fig. 166.
2. Centerpunch the three places indicated on the template. Remove the template, and drill three 1/2 inch diameter holes through the door outer panel.
3. 3. Remove the interior trim panel and door hardware Refer to the 1955 Truck Shop Manual.
4. Insert the reinforcement through the access hole in the door inner panel, aligning the holes in the reinforcement with the holes in the door outer panel. See Fig. 167.
5. Holding the reinforcement in position, attach the mirror assembly and pad to the door outer panel with the three 5/16 inch bolts and lockwashers. See Fig. 167.
6. Align the template marked "Inner Edge of Door Inner Panel, 3000, 4000 and 6000 Series" with the inner edge of the door inner panel, and align the hole in the template with the existing dimple on the door inner panel. Secure with tape. See Fig. 168.NOTE: Further check the alignment by making sure that the holes indicated on the template for drilling are aligned with the holes in the reinforcement. If necessary, re-position the template.
7. Centerpunch the four places indicated on the template. Remove the template. Drill four 13/32 inch diameter holes through the inner panel, the drill passing through the four holes in the reinforcement.
8. Install the four flat head screws in the holes just drilled. Through the access hole, install the nuts and lockwashers on the screws and tighten until the screw heads are drawn into a position flush with the panel surface. See Fig. 169.
9. Re-install the trim panel-and door hardware.
10. Adjust the mirror assembly to suit.

LEFT HAND INSTALLATION 5000 SERIES ONLY.

1. Remove the existing standard mirror from the door. Retain the three bolts and lockwashers.
2. Attach the adjustable mirror and pad to the door, using the three bolts and lockwashers retained in step No. 1.
3. Adjust the mirror assembly to suit.

RIGHT HAND INSTALLATION-5000 SERIES ONLY.

1. Remove the hardware and trim panel from the inner panel.
2. Place the proper template on the outer panel of the door carefully following the directions given on the template. Secure with tape. See Fig. 170. CAUTION: Be sure to select the template marked " Right Hand Door, 5000 Series".
3. Centerpunch the holes to be drilled as indicated on the template. Remove the template and at the marks just made drill three 3/8 inch diameter holes. See Fig. 170.
4. Attach the adjustable mirror and pad to the door using the three 3/4 inch long bolts, flat washers, lockwashers and nuts provided. See Fig. 171.
5. Replace the trim panel and hardware on the inner panel and adjust the mirror assembly to suit.

Fig. 172.

All Trucks

Body Sill Moulding Installation Instructions

( ALL PASSENGER CARS )

1. Locate and drill hole in the fender. See Fig. 173.
2. Locate holes in body sill from door opening as shown in Fig. 173 in conjunction with template furnished and drill holes as required.
3. Place the retainer inside the sill moulding and slide forward until it fits securely. See Fig. 175.
4. Attach one clip to each of the five holes (Fig. 174) and secure with a tapping screw (Fig. 173)
5. Place the front edge of the moulding with retainer stud through the drilled hole being sure to locate the moulding over the fender lip. See Fig. 175.
6. Snap moulding into position as shown in Fig. 176.
7. Tighten retainer in place with lock nut provided.
8. Repeat the above on the opposite side of the car.

All Passenger Cars

Step 1 mount trim plate to deck lid panel center and line up bottom edge of trim to deck lid. Trim panel cannot overlap edge of deck lid. If it does raise trim panel.

Step 2 using trim panel as a template, drill three no. 18 or 11/64 diameter holes at "A". (MAIN VIEW)

Step 3 attach trim panel with "t" bolts, lockwashers, and nuts.

Step 4 drill a no. 29 or 9/64 diameter hole at "b" and "c". Remove trim panel and enlarge holes "c" with a no. 1 or 7/32 diameter drill.

Step 5 install special tubular fastener at holes "c".

Step 6 install trim panel using plain 't" studs at holes "c" sheet metal screws at holes "b" and "t" bolt, lockwasher, and crown nut at hole "a".

L.H. and R.H. body rear moulding

Step 1 line up end trim panels with deck lid trim panel and tail lamp housing.

Step 2 using trim panel as a template, drill two no. 18 or 11/64 holes ("D").

Step 3 attach trim panel with threaded "t" bolts, lockwasher and hex nut.

Step 4 repeat above installation on opposite side.

Fig. 177.

Hood Ornament Installation Instructions

SERIES 3000*, 4000, 6000, 8000, AND 10,000 TRUCKS

Step 1 start measuring from rear of hood, mark distances on surface of metal.

Step 2 drill six 7/16 inch diameter holes. Drill the two front holes completely through the hood front reinforcement.

Step 3 remove all burrs. Paint around holes to prevent corrosion.

Step 4 from the underside of hood drill two holes (1-3/8 inch diameter) in front hood reinforcement using a hole saw.

Step 5 place the ornament on the hood, and loosely attach the spacers and stamped nuts. Place the large spacer to the front. Fig. 178. Align the ornament vertically and tighten the nuts securely.

Door Handle Door Shield

ALL PASSENGER CARS

Fig. 229. NOTE: Using shield as a template center punch and drill two 1/8 inch diameter holes through the door panel.

Door Handle Door Shield Installation Instructions

TRUCKS

1. Fit the shield over the door handle flush against the door panel Fig. 230.
2. Using the shield as a template, scribe the two attaching holes on the door panel. Remove the shield.
3. Tape the door handle to prevent damage to the chrome.
4. Centerpunch the scribed circles and drill two 7/64 inch holes through the door outer panel using a No. 36 drill.
5. Replace the shield and attach with the two screws provided.

All PASSENGER CARS

Step 1 remove the hub cap.

Step 2 using the retainer as a template, drill four 13/64 inch diameter holes (Fig. 256).

Step 3 line up the holes in the retainer, and hub cap. Insert the ornament studs in place. Add the lockwashers and nuts. tighten each for equal torque upon the retainer.

Mechanical

ALL PASSENGER CARS

1. Locate the two bracket mounting holes and one bracket mounting dimple by using the bracket as a template. See Fig. 54.
2. Drill three holes in cowl Fig. 54In illustration no. 1. Pierce top holes through dash mat.
3. From inside the dash panel notch the dash mat and push the two bolts, with lockwashers provided, through the two top holes just drilled, from the front side of the dash panel. Install the two nuts on the protruding bolts. Tighten securely.
4. Place the bracket on the protruding bolt ends and attach with the two nuts and lockwashers provided. Complete the attachment with the self-tapping screw in the bottom hole. See Fig. 54.
5. Disconnect the existing output pipe from the master cylinder and bend it back toward the dash panel. NOTE: It will be necessary to make some provision for catching the escaping fluid when breaking the hydraulic line.
6. Install new pipe to existing connector on the master cylinder. Next install bolt, gasket, connector and gasket at input opening on power brake cylinder and install the remaining end of the new pipe.
7. Attach the adapter and gasket to the output opening of the power brake cylinder. See Fig. 55.
8. Attach the nipple to the vacuum inlet at the bottom of the power brake cylinder. SEE Fig. 55.
9. Attach the power brake cylinder to the mounting bracket with the nuts, lockwashers and one plain washer. tighten securely. Make sure that the bleeder screws are in an upright position. NOTE: Spread the mounting bracket slightly if necessary to facilitate mounting of the power brake cylinder.
10. Attach the output pipe to the adapter at the output opening of the power brake cylinder. Attach the union to the output pipe.
11. Bend the output pipe described in step 6 as required to connect it to the union.
12. Tighten all joints of the output line. Make sure that it is free from tension and clears all obstructions.
13. Attach input pipe to the connector on the master cylinder and the connector on the power brake cylinder. Tighten securely. see Fig. 55. NOTE: vacuum connections for the six and eight cylinder engines are different. Be sure to follow the proper instructions.

FOR EIGHT CYLINDER ENGINES ONLY

1. Disconnect any hose and/or pipe and remove any vacuum outlet fittings or plug from the base of the carburetor.
2. Install the check valve on the small threaded pipe tee.
3. Install the pipe tee and check valve in the base of the carburetor. See Fig. 55.
4. When the car has vacuum windshield wipers or a windshield washer, or both washer and wipers, re-connect the vacuum wiper and/or washer hose to the outlet on the pipe tee.
5. When the car has electric windshield wipers and no windshield washer, cap outlet on the pipe tee with the rubber plug provided. See Fig. 55.
6. Place the hose support on the power brake vacuum hose and a hose clamp at each end of the hose. attach the other end of the hose to the nipple on the vacuum inlet of the power brake cylinder. See Fig. 55.

FOR SIX CYLINDER ENGINES ONLY

1. Disconnect any hose and remove any vacuum outlet fittings or plug from the intake manifold.
2. Install the check valve on the large threaded pipe tee.
3. Install the pipe tee and check valve in the intake manifold with the opening of the check valve pointing down. See Fig. 55.
4. When the car has vacuum windshield wipers with or without a vacuum operated windshield washer, attach the fitting provided for the vacuum hose to the pipe tee and reconnect the vacuum hose. See Fig. 55.
5. When the car has electric windshield wipers and no vacuum operated windshield washer, insert the 1/8 inch pipe plug in the pipe tee.
6. When the car has electric windshield wipers and a vacuum operated windshield washer, install the 1/8 inch connector pipe assembly previously removed in step 1. Re-connect the vacuum washer hose.
7. Cut the power brake vacuum hose to a 14 inch length. Connect the hose between the manifold and power brake cylinder. shown in Fig. 55.

BLEEDING INSTRUCTIONS

NOTE: Do not run engine during the bleeding operation.

1. Make sure that all the connections have been tightened securely.
2. Fill the master cylinder with brake fluid and keep it at least half full throughout the bleeding operation.
3. Bleed the power brake cylinder at both bleed screws.
4. Bleed each wheel cylinder.
5. Refill master cylinder.

1. Install the rubber bumpers on the clips. Secure the bumpers in position by pushing them beyond the locking dimples on the clips.
2. Remove the hub caps.
3. Place a clip on the lip of the wheel rim opposite each raised section of the wheel hub between the lug nuts. NOTE: If balance weights interfere, re-arrange the spacing position by placing the clip not less than 1/2 inch from the balance weight(s). Also, do not place a clip over the valve stem.
4. Fasten the clips by pressing each clip firmly against the lip of the wheel rim and hit the extreme top of the clip with a hammer until the clip snaps securely over the lip of the wheel rim. See Fig. 69.
5. Replace the hub caps.
6. Attach the clips to the trim ring by pulling the free end of the clip away from the wheel and hooking it to the inner flange of the trim ring. See Fig. 69. NOTE:Start the operation from the top of the wheel.
7. Making certain that all of the clips are locked to the inner flange of the trim ring, push the trim ring with both hands until it snaps into position. See Fig. 70.

All Passenger Cars

Fig. 71.

Gasoline Filter Unit Installation Instructions

Passenger Cars & Trucks

Step 1 detach fuel line from carburetor. NOTE: Where fitting "a" is specified it is necessary to remove existing fitting.

Step 2 install fit in carburetor and filter as indicated and attach filter. When fitting "a" is used "d" is removed from carburetor.

Step 3 bend existing tubing to the shape required Fig. 73 in each illustration, and attach it to the fitting on the filter. NOTE: On v-8 jobs, if top of filter interferes with air cleaner install additional air cleaner to carburetor gasket or gaskets as required.

Windshield Washer Vacuum Reserve Tank Installation Instructions

(For Use With Electric Wipers)

Fig. 257

Fig. 258

Rain Deflectors Installation Instructions

1. Rain Deflectors will fit only the models Fig. 260 on the carton label.
2. Rain Deflectors are stamped to show their position-RF for right front door; LF for left front, etc.
3. Insert flange between the weather strip and vent wing division post. Then work the flange up between the weather strip and reveal molding. Flange should disappear and curves fit properly.
4. If weather strip bead overlaps the vent wing division post, clip off overlapping portion.
5. Centerpunch and drill the front screw hole first, using a 3/32 drill. Drill through reveal molding and door frame. (See sketch.) Insert screw.
6. Holding shade in position, centerpunch and drill remaining hole. Insert screw.
7. Run window glass up. If window binds spread glass channel to allow complete closing.

Passenger Cars and Trucks

1. Locate and drill Fig. 261.
2. Assemble parts according to illustration.
3. Tighten securely.
4. Adjust the viewer lens for minimum lines.

All Passenger Cars

1. Remove the molding caps from each end of the sun visor.
2. Mask the sun visor molding and point the top side of the visor and the roof mounting brackets to match the roof color.
3. Scrape the inside of the drip molding gutter 3-1/2 inches back from the windshield pillar to form a clean, even base for the sun visor ends. Point the scraped area the color of the roof.
4. Cut a wooden prop to the shape and dimensions illustrated to be used as a center support and height gage according to body model as Fig. 262.
5. Attach the roof mounting brackets finger tight to the sun visor supports with the bolts, flat washers, lockwashers and crown nuts in the order shown in Fig. 263. Use the upper ends of the elongated holes in the visor support on Sport Coupe and Four Door Special Sedan installation only. Use the lower ends of the elongated holes in installations for all other models.
6. Place the sun visor on the roof in its installed position with the wooden prop centered under the front edge of the sun visor and resting on the cowl near the windshield. See Fig. 262.
7. Fit the horizontal edge of the sun visor ends to bottom in the drip rail gutters and align the visor door jamb tabs flush with the edge of the door opening. Use the hole in each end, of the visor as a template for punching and drilling the windshield pillar.
8. Control the angle of drill according to body model as Fig. 264. Limit the depth by using an appropriate spacer as described in the illustration insert. Drill through the pillar and one inner reinforcement using a No. 27 (.144) or a 9/64 drill.
9. Fasten the sun visor to the windshield pillar at the drilled hole with one of the 3/4 inch tapping screws provided. The screw should be driven until it engages the inner reinforcement but not drawn up tightly. Repeat the operation on opposite pillar.
10. With the prop in position, and the leading edge of the visor in the notch, press the visor mounting bracket against the roof, and scribe the two holes in each bracket with a 90 degree bent scribing tool.
11. Remove the pillar screws and the sun visor.
12. Remove the four brackets from the sun visor supports.
13. Fit a No. 11 (.1910) or a 3/16 drill with a spacer to a depth of one inch. Drill the four scribed holes through the roof panel and header bar as Fig. 265.
14. Apply sealer to the underside of the visor mounting brackets and to one side of the bracket pods. Fit the pads to the brackets with the holes lined up. Apply sealer to the roof side of the pods.
15. Apply sealer to the hole recesses of the brackets and fasten the brackets to the roof using the eight 1 inch screws provided. The screws should engage the holes in the windshield header bar to assure a strong installation.
16. Tighten all eight screws to assure a water tight fit but do not strip the thread or bind the roof panel.
17. Mount the visor with the horizontal edges of the visor ends bottomed in the drip rail gutter. Attach the visor supports to the visor brackets finger tight.
18. Coat the threads of the visor-to-pillar screws with sealer and tighten in place without stripping the threads.
19. Wedge the sun visor end tightly against the drip rail using a wooden wedge block between the roof and the visor end as Fig. 266. To prevent roof damage, fit a limit spacer on the drill. Use a No. 35 (.109) or 7/64 inch drill to drill the two holes in each drip rail and Visor end, as illustrated in Fig. 266 and Fig. 268 keeping clear of the wedge block. Draw the visor end tightly to the drip rail using two of the 5/16 inch tapping screws provided. Repeat the same operation on opposite pillar and drip rail. Install the wood prop in position, and push the visor up until it rests on TOP of the prop (see Fig. 267). Then, tighten the sun visor nuts at the visor mounting brackets. Remove the prop.
20. Paint all the drip rails and windshield pillar screw heads roof color.
21. Replace the sun visor molding caps.
22. Retain the wooden prop for future sun visor installations. NOTE: Where sealer is specified use windshield sealer.

TRUCKS

1. Position the visor to the under side of the roof panel windshield peak. Hold in position until one of the center support bracket holes is scribed. Remove visor and drill a 3/32 inch hole where scribed.
2. Apply windshield sealer to the entire length of the attaching flange of the sun visor.
3. Press the sun visor gasket on to the flange of the sun visor. Match the holes of the sun visor to the holes in the gasket to assure a better fit.
4. Apply windshield sealer to the outside surface of the gasket.
5. Hold the visor up to the under side of the roof panel windshield peak. With the visor centered in position fasten the visor to the under side of the peak at the drilled hole with one of the screws and lockwashers provided. As Fig. 269.
6. Still holding the visor in position, and using it as a template drill and attach both ends next. Drill and attach the visor at the center and continue in the same process till completed.

Trucks

A dimple is provided in the top header at the upper right hand corner. The corner is also backed by inner reinforcements.

1. Pierce a small hole through the template at the point where the center lines of the large circle intersect. Center this hole over the dimple in the header and align the lower front edge of the template with the inner edge of the top header. Tape the template in place.
2. Punch the three outer centers and remove the template. Using the dimple as a center, drill a 1-1/2 inch diameter hole. Drill three 1/8 inch diameter holes through the punch marks.
3. Install the sunshade securely with the three screws provided.

Fig. 270

Windshield Washer Installation Instructions

VACUUM CO-ORDINATED-PUSH BUTTON-PASSENGER

Step 1 attach special parts and bowden cable to wiper motor Fig. 271.

Step 2 assemble push valve in wiper control, first pushing out plug in control knob. tighten set screw.

Step 3 take plug out of escutcheon plate and insert spray nozzle, hook hose to tube after step-5.

Step 4 drill four holes (no. 29 drill) through fender skirt dimples. assemble bracket and jar.

Step 5 hoses and routing of hoses are identified alphabetically from jar cover to point of installation.

Windshield Washer Installation Instructions

( Electric Co-ord-Foot Pedal-Passenger)

Step 1 disengage "u" clamp from wiper cable, by removing "U" clamp from bottom hole on slide. Assemble plate, foot pump control cable, and retainer Fig. 272. engage disc end of manual wiper cable into slot in tab on foot pump cable. Replace "U" clamp in upper hole in slide, at same time engage disc end of foot pump cable in slot in "u" clamp.

Step 2 drill 1/2 inch diameter hole in dash panel, 1-5/8 inches down from mat fastener. Remove mat fastener and install foot pump Fig. 272.

Step 3 remove plug from escutcheon plate and insert spray nozzle, hook hose to tube at step 5.

Step 4 drill four holes (no. 29 drill) in fender skirt Fig. 272. Assemble bracket and jar.

Step 5 hoses and routing of hoses are identified alphabetically from jar to point of installation.

Windshield Washer (Vacuum Coordinated Push Button)

ALL TRUCKS

Step 1 attach special parts and bowden cable to wiper motor Fig. 273.

Step 2 assemble push valve in wiper control, first pushing out plug in control knob. tighten set screw.

Step 3 take plug out of escutcheon plate and insert spray nozzle. Hook hose to tube after step 5.

Step 4 drill a 3/8 inch dia. hole through dimple in dash and toe panel and install special grommet.

Step 5 drill (2) 9/64 inch dia. holes through dimple in dash and toe panel assembly. Use bracket as a template to drill remaining two holes. Assemble bracket and jar Fig. 273.

Step 6 hoses and routing of hoses are identified alphabetically from jar to point of installation.

Installation Instructions Co-Ordinated Foot Pump Windshield Washer (Electric)

ALL TRUCKS

Step 1 disengage "u" clamp from wiper cable by removing "u" clamp from bottom hole on slide. assemble plate, foot pump control cable, and retainer Fig. 274. Engage disc end of manual wiper cable into slot in tab on foot pump cable. Replace "u" clamp in upper hole in slide. At same time engaging disc end of foot pump cable in slot in "u" clamp.

Step 2 remove plug from escutchion plate and insert spray nozzle. Hook hose to tube at step 5.

Step 3 drill two holes (1/8 diameter) through dimple in dash panel. Use bracket as template in locating the two remaining holes.

Step 4 drill 5/16 inch diameter upper hole and 1/2 inch diameter lower hole, locating from mat fastener with dimensions Fig.274. Remove mat fastener on 3000, 4000, 6000, 8000 and 10, 000 series only. Cut (2) 5/8 inch diameter holes in dash mat for spacers.

Step 5 hoses and routing of hoses are identified alphabetically from jar to point of installation.

NOTE: 3-3/4 inches from dash and 6-5/8 inches down from point Fig. 274, will be common point for drilling 7/16 dia. hole, for hose, on all trucks.