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SECTION 1 BODY

CONTENTS OF THIS SECTION

General Description
Body Lubrication
Service Operations and Adjustments
Assembly Manual

General Description

The 1957 bodies, while basically the same as in 1955, incorporate many changes and additions. This section is not supplementary to 1955 or 1956 but is complete in itself. Service and procedures are covered on all 1957 styles.

BODY LUBRICATION

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

The following parts should be lubricated twice a year.

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

Lubrication Points
Lubricant

Instrument Compartment Door Hinge
Dripless Oil

Front Door Hold Open Clips
Lubriplate or Equivalent

Door Jamb Light Switch
Lubriplate or Equivalent

Door Lock Bolt Housing
Stick Type Lubricant

Door Lock Striker Teeth
Stick Type Lubricant

Rear Door Hinge and Hold Open
Lubriplate or Equivalent

Deck Lid Hinge and Torque Rod Ends
Lubriplate or Equivalent

Deck Lid Lock Bolt
Lubriplate or Equivalent

Gas Filler Door Hinge
Dripless Oil

Folding Top Linkage Bearing Points
No. 10 Engine Oil

Side Roof Rail Mechanical Sealing Strip (Gasket Parts to be lubricated when access to parts can be obtained.)
Silicone Emulsion

Windshield Wiper Motor and Transmission Spools
Lubriplate or equivalent

Door Lock Parts
Lubriplate or equivalent

Window Regulator Rack and Cam Channels
Lubriplate or equivalent

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

Transmission Cable

Adjustment

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

To release cable tension for removal of components push in on transmission shaft end and have helper on the inside, pull on cables to obtain desired slack then release pressure on transmission shaft.

NOTE: Wiper blade snap or over-travel is indicative of loose transmission drive cables.

Windshield Wiper Motor and Auxiliary Drive Assembly

Removal

Remove instrument panel compartment box.
Adjust cables to slack position.
Observe attachment of cables to auxiliary drive, then detach cables from drums. IMPORTANT: Note how the right transmission cables are crossed.
Remove wiper motor from auxiliary drive assembly, then remove two screws securing drive to dash panel.

Installation

Install wiper motor and auxiliary drive to dash panel and secure with attaching screws.
Inside of body, attach transmission cables to auxiliary drive drums "A" and "B," fig. 2, as follows: Attach right transmission cables to auxiliary drive drum "A" in the following sequence:
- Cable No. 1 (cable leading from top of transmission pulley) to retainer No. 1.
- Cable No. 2 (cable leading from bottom of transmission pulley) to retainer No. 2. NOTE: Right transmission cables should "cross-over" approximately midway between the transmission and auxiliary drive.
- Attach left transmission cables to drum "B" in the following sequence:
- Cable No. 3 (cable leading to top of transmission pulley).
- Cable No. 4 (cable leading from bottom of transmission pulley). NOTE: Left transmission cables do not cross over.
Adjust cables to tensioned position.
Connect wiper motor parts as required and check operation of wiper motor. Install instrument panel compartment box.

Windshield Wiper Transmission

The attachment of the windshield wiper transmission is the same as on past styles with the exception of an additional support and attaching nuts which secure the transmission to the underside of the upper shroud.

Removal

Remove wiper blade and arm assemblies.
Remove instrument panel compartment box.
Adjust wiper transmission cables to slack position.
Observe attachment of transmission cables to auxiliary drive, then disconnect cables from auxiliary drive.
On outside of body at each transmission, remove escutcheon spanner nut and lift escutcheon from transmission.
Inside body, remove transmission support attaching nuts. Then pull each transmission down through upper shroud panel and remove from body.

Installation

Lubricate parts as specified.
Install gasket to each transmission and apply a medium bodied sealer around transmission shaft to gasket surface contacting body metal.
Position each transmission assembly in body and secure transmission support with attaching nuts to upper shroud.
Attach transmission cables to auxiliary drive drums. NOTE: If new transmission is being installed, it is necessary to remove plastic collar from transmission before cables can be tensioned.
Secure escutcheon with chrome plated spanner nut.
Reinstall wiper blade and arm assemblies. Check operation of wiper motor and transmission assembly.
Reinstall the instrument panel compartment box.

Windshield Wiper Control

Removal and Installation

Remove control cable from motor assembly by loosening screw at motor.
Loosen set screw in control knob at instrument panel and remove knob.
Remove spanner nut with Tool 5449, on Bel-Air models remove control escutcheon.
Remove control assembly from instrument panel and remove wiper hose after tagging for proper installation.
To install reverse this procedure.

Electric Windshield Wiper Assembly

The electric windshield wiper (Fig. 3) used on the 1957 Chevrolet is a 12-volt DC unit powered by an internally grounded motor containing both a series and shunt field. The armature of the motor is fitted with a worm shaft which drives the oscillating mechanism through a nylon gear.

A leaf contact-type switch enclosed within the motor housing controls the motor and has three positions; high speed, low speed, and a park, or off position. This switch is controlled by means of a nylon slider mounted externally over the switch on the motor housing which in turn is operated by a bowden cable from the dash panel.

To protect the motor from damage due to overheating, a thermal circuit breaker is built into the case at the commutator end of the motor.

Basically, the electric windshield wiper consists of the cast motor housing, electric motor, the switch mechanism, and the oscillating drive mechanism. A stamped steel case mounts the thermal circuit breaker and motor brushes and completes the encasement of the motor. Individual stamped covers are used over both the switch and oscillating drive recesses in the motor housing. The auxiliary drive mounting bracket which attaches the wiper unit to the dash panel is permanently fastened to the oscillating section cover. An oscillating drive arm is pressed onto the oscillating shaft in a fixed position and should not be removed in service.

Stopping the Wiper

With the unit operating, moving the wiper control on the instrument panel to the off, or park, position moves the nylon slider on the switch cover which moves the latch assembly switch arm (fig. 4) in the switch housing. The latch assembly switch arm is attached to the shaft of the latch assembly toggle (fig. 5), therefore switch arm movement results in like action by the latch toggle. As the spring-loaded latch assembly toggle snaps away from the oscillating drive mechanism, the latch assembly arm (fig. 5) reacts in the opposite direction, thus placing the arm in the path of the clockwise rotating drive assembly disc (fig. 5). After the latch arm contacts the ear of the drive assembly disc as shown in figure 6, the rest of the drive assembly continues to turn, tightening a spring attached to both the nylon gear (fig. 5) and the drive assembly disc. This build-up of spring tension forces the drive pin (fig. 7) to move toward the outer radius of the yoke in the drive assembly, thus increasing the arc-of-travel of the connecting rod (fig. 5). By this means, the additional angular travel required to bring the wiper blades to rest against the cowl molding is provided.

Attached to the opposite end of the oscillating shaft in the switch portion of the motor housing is the breaker arm (fig. 4). During operation of the wiper, the breaker arm oscillates freely inside the switch casting. However, once the drive pin arc-of-travel is increased as described above and as illustrated in figure 7, the oscillation range of the breaker arm (fig. 4) is altered causing the arm to hit the fiber cam and trip the contacts. This action trips contact No. 4 (fig. 4), moving it away from contact No. 3 which breaks the ground and moves No. 4 into contact No. 5 which results in a momentary short being thrown across the armature. This operation provides a dual purpose: First, the separating of contacts No. 3 and 4 breaks the circuit to the motor and finally, the closing of contacts No. 4 and 5 shorts the armature thus providing considerable braking action to overcome any coasting action of the motor when shut down. Figure 8 provides an electrical diagram of the unit with the switch contacts in their park relationship.

Starting the Wiper

Moving the switch slider (fig. 3) by means of the control located on the dash into slow speed, or the first operating position, trips the latch assembly toggle (fig. 5), knocking the latch assembly arm clear of the ear of drive assembly disc.

This releases the spring tension built up as the unit went into park, snapping the drive pin back to its original position in the yoke as shown in figure 6. By this means, the usual wiper pattern of the blade arms is re-established.

At the same time that the latch assembly toggle releases the spring tension in the drive and oscillating portion, the movement of the switch slider causes contact Nos. 1 and 2 to close and Nos. 3 and 4 to close, thus forming the wiper low speed circuit 9 .

Low Speed Circuit

In low speed and following the diagram shown in Fig. 9, contact Nos. 1 and 2 are closed and Nos. 3 and 4 are closed. From source, the current passes the circuit breaker and energizes the series field. After passing through the series field, the power is divided; part is directed to the armature and the remainder is eliminated by being diverted to ground through the shunt field, through contacts No. 1 and 2, then to contact No. 4, and finally to contact No. 3 which is grounded. In following this path, it is well to remember that current always follows the path of least resistance, therefore in low speed, no current passes through the resistor because of the more direct path to ground.

The major point to remember concerning low speed operation is that only about one-half of the power is used to drive the motor; the remainder is diverted to ground.

High Speed Circuit

Moving the wiper control on the dash panel further closes the high speed circuit (fig. 10A). For high speed operation, all contacts are open with the exception of Nos. 3 and 4 which produces the following electric flow: From the source, current flows through the circuit breaker and energizes the series field as in low speed operation. Upon leaving the series field, the current once again divides; half going directly to the armature and the remainder through the shunt field. However, with only contacts No. 3 and 4 closed, the current is forced to flow through the resistor to reach ground via the jumper to No. 4 and finally to No. 3 contact and ground. By forcing the current through the resistor, the flow through the shunt field is slowed considerably, consequently more current is forced to flow through the armature to reach ground and the motor speed is increased proportionately.

CARE, MAINTENANCE AND ADJUSTMENT

Three adjustments are required for proper functioning of the electric windshield wiper; armature and end-play adjustment, drive assembly end-play adjustment, and switch adjustment. Of these, both end-play adjustments would usually be performed either during or after complete overhaul of the unit. Drive assembly end-play is accomplished during rebuild of the unit whereas the armature end-play adjustment is made after reinstalling the wiper on the car. Loss of or incorrect switch adjustment accounts for the majority of wiper complaints, therefore it is with this adjustment that the serviceman should be most critical.

It is possible that adjustments within the switch compartment could be made with the wiper installed on car, however, due to the general inaccessibility of the wiper and its ease of removal, it is recommended that the unit be removed so that all service procedures may be made on the bench.

Switch

Adjustment

Remove the switch housing cover.
Move the latch assembly switch arm ( fig. 4) against the fiber cam until the switch contacts snap to the low speed position (fig.9). Further lateral movement of the latch switch arm should separate contacts Nos. 1 and 2 and hold contacts Nos. 3 and 4 closed, thus forming the high speed circuit (fig. 10).
If latch assembly switch arm travel is insufficient to move the fiber cam adequately to move the contacts into their low and high speed positions, loosen the two switch mounting screws (fig. 4) and shift the switch assembly as required.
When the unit is stopped, the breaker arm (fig. 4) should contact the fiber cam and move it sufficiently to snap the switch contacts into their park position (fig. 8). If the motor does not stop when the dash control is turned to the "OFF" position, the switch assembly mounting screws (fig. 4) should be again loosened and the switch shifted toward the breaker arm.

NOTE: Although seldom necessary, the breaker arm (fig. 4) may be bent toward the fiber cam if the unit cannot be stopped after shifting the switch its full limit. When the breaker arm is stopped at its park position, the minimum clearance between the arm and cam guide should be 1/32" (fig. 11).

Armature End-Play

Adjustment

This adjustment is generally required only after a rebuild of the wiper but can be made at any time with the unit installed.
Connect a DC ammeter in the circuit, start the electric wiper, and note the ampere draw.
Tighten the armature end - play adjusting screw located in the end of the cast motor housing until a rise in the current draw is noted, then back-off adjusting screw slowly until ampere draw returns to that in (1) above. As a safety factor, back off screw an additional 1/8 turn.
To lock adjustment, tighten jam nut.

Drive Assembly End-Play

Adjustment

Drive assembly end-play should be established within .005"-.008" during assembly through use of end-play washers beneath the snap ring on the portion of drive assembly shaft shown at the bottom center of figure 4.

MAJOR SERVICE OPERATIONS

As mentioned earlier, complete tear-down of the wiper assembly is seldom required as the majority of its malfunctions occur within the external controls to the wiper or within the switch housing.

The overhaul procedures are broken down into three major areas: switch assembly, oscillating and drive assembly, and motor. Both the switch and motor assemblies can be serviced without disturbing other sections of the wiper but to disassemble and assemble to the oscillating and drive portion it is also necessary to remove certain elements from the switch housing. Because of the general independence of each section of the wiper, complete disassembly, inspection, and assembly instructions are provided under the wiper component headings.

Switch

Disassembly

Remove four screws securing switch cover and remove cover.
Remove two switch assembly mounting screws (fig. 4) and lift out switch to extent of slack in connecting wires.
Complete removal of switch assembly by placing a hot soldering iron against the three lead connections to the switch. Code the connection points to insure that the color coded wires are connected at the proper locations at assembly.
Remove the switch breaker arm (fig. 4) from end of oscillating shaft by removing plastic retainer.

CAUTION: Do not remove latch assembly switch arm (fig. 4).

Cleaning and Inspection

Check all switch contacts for foreign matter or possible deformation. Contacts can be cleaned with a cloth dampened with carbon tetrachloride or small imperfections removed with emery paper. Broken contacts require replacement of the switch as an assembly.

Be especially careful to check that there is no foreign matter bridging the insulators at the base of the switch. Should any insulator be broken or oil soaked, these can be replaced by removing the two screws holding the contacts and insulators and replacing the insulators with like thicknesses of tag board or non-conducting gasket material.

Check that breaker arm fiber contact surface is in good condition.

Installation

NOTE: If work is necessary within the oscillating and drive section, delay reassembly of the switch components until that work is completed.

Place breaker arm (fig. 4) in slot in oscillating shaft and secure with plastic retainer.
Resolder electrical leads to switch assembly. If connection points were not coded during disassembly, hold switch assembly with fiber cam (fig. 4) downward and with switch mounting surface away from you. Then, from left to right, solder green wire to top-left terminal closest to mounting bracket, red wire to central terminal, and black wire to terminal at bottom right side or closest to the resistor side of the switch.
Fasten switch assembly with two mounting screws (fig. 4) and position as required to satisfy requirements outlined under "Switch Adjustments" earlier in these pages.
Reinstall switch cover and secure with four screws.

Oscillation and Drive Assembly

Disassembly

Perform all operations listed under "Disassembly of Switch" except that it is not necessary to unsolder the electrical leads to the switch. The only purpose is to remove the breaker arm retainer and arm to allow removal of the oscillation shaft.
Remove snap ring shown at bottom of figure 4 and any thrust washers secured by snap ring.
Remove four screws and external-teeth lock washers securing oscillating and drive section cover.
CHECK THAT THE LATCH ASSEMBLY IS NOT IN PARK POSITION, then carefully tap both the oscillating shaft on which the breaker arm (fig. 4) was attached and the drive assembly shaft shown at bottom center of figure 4 out of the housing from the switch compartment side with a soft drift. The latch assembly switch arm is shown in the low speed position in figure 4.
To separate the oscillating mechanism from the connecting rod, remove "E" type retaining ring ( fig. 5) from drive pin and lift out oscillating mechanism.
To complete the disassembly of the oscillating and drive section of the wiper, remove the snap ring (1, fig. 12) and separate the remainder of the parts (fig. 12).

NOTE: Further disassembly of the cover and linkage should not be attempted as these parts are furnished only as assemblies for service. No attempt should be made to remove the latch assembly toggle or arm (fig. 4) as these are fixed fast in the housing. If necessary, the latch spring (fig. 4) can be changed with the toggle installed.

Cleaning and Inspection

Clean all parts except the nylon gear with cleaning solvent and air-dry. Check all parts for deformations and repair or replace as necessary.

The nylon drive gear should be checked for worn or broken teeth. If either condition is present, replace the gear.

Clean the cover and connecting rod linkage of all old lubricant and check for bent parts. Replace the cover and linkage if any faults are found.

Assembly

To reassemble oscillating components (fig. 12), connect spring to drive disc as follows: Position pawl (7, fig. 12) on pin in drive disc (6), then place wire spring on pawl and catch hooked end under offset end of pawl. Straight leg of spring should be then forced against side of disc center hub as shown in figure 13.
Install drive disc and spring assembled in previous step on nylon gear (9, fig. 12).
Place cam and drive pin (5, fig. 12) and yoke (4) on disc as shown in figure 14. Be sure drive pin is cradled in slot on yoke.
To complete the assembly of the oscillation components, place end-play washers (3, fig. 12) and retaining washer (2) on lug and secure with snap ring (1). Measure total end-play within the unit with a feeler gauge and add or remove washers (3) until total end-play is .008" or less.
Lubricate between yoke, cam and drive pin, disc and at all pivot points on the cover linkage with light oil. Then place a light grease coating on the armature shaft, nylon gear teeth, and on the linkage pivot points previously oiled. DO NOT GREASE TOGGLE OR ARM.
Insert drive pin (fig. 5) through connecting rod and secure with "E" type retainer.
Check that toggle is not in park position, then insert oscillating shaft and gear shaft through bores in housing. Tap as required to fully seat shafts.
Secure cover with four screws and external teeth lock washers.
Install breaker arm (fig. 4) in slot of oscillating shaft and secure with plastic retainer.
Reinstall switch components as described under "Installation of Switch."
Place end-play washers as required on end of gear shaft shown at bottom center of figure 4 until total end-play is approximately .010", then complete installation by installing snap ring.

Motor

Disassembly

The motor may be serviced without disturbing other sections of the wiper.

NOTE: All number references are to fig. 15.

Remove two tie bolts (1) securing case (4) to housing (10).
Remove end-play adjusting screw (11) and lock nut (12).
Strike the steel case (4) lightly with a mallet to partially loosen it from the motor field (9) and wiper housing (10).
Insert a tool through the armature adjusting screw opening and push against the end of the armature to back off the case. This will retain the armature commutator between the brushes until ready to separate armature from the case.
To separate the case from the armature while still retaining the brush springs (2) and brushes (3) in place, fashion a separator similar to that illustrated in figure 16 from heavy wire and insert behind the brush leads as shown. The steel case may then be separated from the armature while being careful not to break the electrical connections. CAUTION: Be careful not to lose thrust ball (7) from commutator end of armature (8).
Once the armature is removed, insert brush retainer spring No. 5096576 between ends of brushes as shown in figure 17 to prevent possibility of pulling leads out of brushes through prolonged tension by the improvised separator (fig. 16).
If necessary, remove felt washer (6) and thrust disc (5) from motor case (4). Also, the armature (8) may be taken out of field (9).
Because the field is pressed into the die cast housing, further disassembly of the motor section is not recommended. However, should it be necessary to free the case assembly from the field, unsolder the field leads attached to the brush holders.

Cleaning and Inspection

Inspect both the field and armature for damage due to overheating such as unsoldered electrical connections.
Check that brush leads are firmly attached both to the brushes and their connections at the brush holders.
Check brushes for wear. If brushes are worn to within 3/16" of brush lead, or pigtail, they should be replaced.
Check contacts of circuit breaker shown at top of figures fig.16 and fig. 17. Clean as required or file lightly to remove irregularities.
Inspect all leads from the brush and circuit breaker plate for worn insulation or breaks. Be sure that green lead is held to base insulator by clip to prevent lead chaffing on armature.
If it was determined by inspection in step 3 above that brush replacement was required, proceed as follows:

Remove retainers installed during disassembly and remove brush springs (2, fig. 15).
Place a hot soldering iron against brush lead connection on brush holders, remove old brushes, and install new brushes. Check connections with diagram in figure 18.
To reinstall brushes in holders, compress spring within holder and hold fully compressed with a thin instrument inserted through the slot in the brush holder. Then push brush into holder with lead upward to project through slot in holder, hold brush tightly, and remove instrument retaining spring. Hold brush installed with improvised separator as shown in figure 19.
Repeat step c on other brush, then install brush spring retainer 5096576 as shown in figure 17A

Assembly

NOTE: All number references are to fig. 15.

If leads were disconnected to separate case (4) from remainder of wiper, resolder connections according to the diagram shown in figure 18.
Loop a 6" to 8" length of string around the brush spring retainer 5096576 shown between the brushes in figure 17. This is used to pull out retainer after armature commutator is inserted.
Insert thrust plate (5) and felt washer (4) into bushing in steel case. Put a few drops of light oil on felt washer.
If removed, start armature (8) into field (9). Twisting the armature slightly will aid in getting the armature worm shaft engaged with the nylon gear in the drive and oscillating section.
Using a high melting point grease, stick the 3/6" thrust ball (7) in commutator end of armature.
Holding the armature slightly extended from the field by means of a tool inserted through the armature end-play adjusting screw hole, push the steel case (4) onto commutator end of the armature. Check that the armature is fully seated, then pull out the brush retaining spring (fig. 17) by means of the string attached in step 2 above.
Line up the tie bolt holes in the steel case (4) with those in wiper housing (10) and push case into position. Then secure with two tie bolts (1).
Install end-play adjusting screw (11) and lock nut (12) to complete assembly.
After wiper is reinstalled, adjust armature end play as described earlier under "Adjustment." The nylon slider (fig. 3) should be lubricated with petroleum jelly prior to installation of the wiper.

TROUBLES AND REMEDIES

CAUTION: Disconnect unit from source of power before removing switch cover.

Trouble

Possible Causes

Remedies

A. Unit will not turn on.

1. No supply voltage at wiper unit.
1. Check wiring carefully.

2. Unit improperly grounded.
2. The wiper unit ground strap should be placed under one of the auxiliary drive mounting screws.

3. Defective soldering at switch terminals.
3. Resolder switch connections if necessary.

4. Defective motor-open field, brushes sticking.
4. Repair defective motor.

5. Contacts 3 and 4 not making contact when unit is turned on or contacts 3 and 4 dirty.
5. Bend contact 3 slightly so that it will make contact with contact No. 4. (Be sure switch is in the low or high speed position when doing this.)

6. Circuit breaker contacts dirty, defective circuit breaker.
6. Remove case and brush assembly and check circuit breaker contacts.

B. Unit will not shut off.

1. Failure of oscillating arm to trip contact 3 and 4 (fig. 4).
1. Adjust switch as follows:
a. Loosen switch assembly mounting screws.
b. Move switch toward oscillating arm and tighten mounting screws.
c. Test for slow, fast and park positions.
d. If proper adjustments cannot be obtained through steps a, b, and c, replace switch assembly.

2. Poor fit between oscillating arm and oscillating shaft slot which would allow excessive circular play of the oscillating switch arm.
2. Replace oscillating switch arm, or try staking it in position.

3. Jumper between contacts 2 and 4 ( fig. 8) shorting to ground.
3. If impossible to remove shorted condition, replace switch assembly.

C. Slow speed operation in both slow and fast switch positions.

1. Switch breaker arm which is operated by the external switch slide not opening contacts 1 and 2 (fig. 4).
1. Adjust as follows:
a. Loosen switch assembly mounting screws.
b. Move switch assembly toward motor section of wiper unit and tighten mounting screws.
c. Test for slow, fast and park positions.
d. If proper adjustment
cannot be obtained by steps a, b, and c, replace switch assembly.

2. Short between switch cover and switch assembly.
2. Caused by switch assembly resistor touching switch cover. Bend the resistor down so that it will
clear the cover.

3. Switch fiber cam not seated properly in slot and therefore, fails to open contacts 1 and 2.
3. Position the fiber cam in the slot and check for proper functioning.

D. Normal fast operation in both the slow and fast speed positions.

1. Speed control contacts No. 1 and 2 (fig. 4) not making contact at low speed position (resistor is in circuit in both slow and fast switch positions).
1. Check for dirty contacts and clean if necessary. If contacts 1 and 2 appear to be separated in the low speed switch position, it may be possible to bend contact No. 1 slightly so that it will make contact with contact No. 2. If the above repairs fail to correct this condition, replace the switch assembly.

E. Excessive speed in high speed positions, slow speed OK.

1. Switch assembly resistor open.
1. Replace switch assembly.

F. Excessive speed in both low and high speed positions.

1. Defective soldering of the black shunt field lead to the switch assembly.
1. Resolder black field lead to switch.

2. Open shunt field.
2. Replace entire motor unit.

Ventilating System

Description

The 1957 Chevrolet incorporates a new ventilating system with air intakes at the forward end of the car. The air flows through air ducts and into the body through openings in each side of the dash panel. The flow of air is regulated by the same type controls used on past styles.

Cowl Side Drain Gutter

Removal and Installation

A cowl side drain gutter is located on the right and left cowl side panel adjacent to the door opening as shown in fig. 20.

Remove three (3) screws indicated by arrows and remove gutter.
To install, reverse removal procedure. Apply body caulking compound between gutter and body metal as indicated at one "1" in inset. Be sure that seal is continuous at area marked "X."

Instrument Panel Cover (All Styles Equipped with Cover)

The instrument panel cover of plastic construction is serviced as a one-piece unit. In Service the cover is secured to the instrument panel by 3M Super Weatherstrip Adhesive (Neoprene) or equivalent around the perimeter of the cover and by metal retainers along the rear edge of the cover.

Removal

Cover front seat assembly.
Remove windshield side and lower garnish moldings and instrument panel finishing caps.
Along rear edge of instrument panel remove cover retainers.
Loosen or remove instrument panel parts necessary to facilitate cover removal.
Detach cemented area of cover from instrument panel and remove from car.

Installation

Clean and dry cementing surface of instrument panel.
Apply thin uniform coat of 3M Super Weatherstrip Adhesive (Neoprene) or equivalent to all cementing surfaces of instrument panel cover and allow to dry. See Fig. 21.
Apply a heavy coat of 3M Super Weatherstrip Adhesive (Neoprene) or equivalent to the rear cementing surface of the instrument panel. Immediately following this application of adhesive, carefully position cover on instrument panel. Check alignment of cover and press rear cemented surface of cover to instrument panel firmly and evenly. See Fig. 21.
Working a small area (approximately 6 inch lengths) at a time, apply 3M Super Weatherstrip Adhesive (Neoprene) or equivalent to front cementing surface of instrument panel and press cover to instrument panel firmly and evenly. See Fig. 21.
Install all previously removed parts and remove protective cover from seat assembly.

Front Body Hinge Pillar Weatherstrip

The weatherstrip is located along the upper portion of the front body hinge pillar and is secured in place by four snap-in clips which are formed from a wire insert.

Removal and Installation

Carefully position tip of mechanically retained weatherstrip inserting tool or other suitable tool under weatherstrip at each clip location and snap clip out of the hole. To install weatherstrip, reverse the removal procedure.

Windshield Assembly-All Styles

The 1957 Chevrolet incorporates a large one piece windshield which is retained in the windshield opening by a one-piece rubber channel.

Windshield Reveal Moldings

The sedan, sport sedan and sport coupe styles have reveal moldings of the same design. The convertible style takes a different windshield upper and side reveal molding, as shown in illustrations Fig. 22 Windshield Reveal Moldings and Fig. 23-Convertible Reveal Moldings.

Removal

Apply masking tape on the body at areas adjacent to the windshield lower reveal moldings.
Remove the wiper blade and arm assembly from each transmission.
Remove the transmission escutcheon spanner nut with Tool 5449, then remove escutcheon from each transmission.
With suitable tool, carefully slide escutcheon from the junction of the lower reveal moldings to expose clip attaching screw.
Remove screw securing retaining clip under escutcheon and slide clip into either molding.
On inside of body beneath instrument panel, remove nut and washer securing each windshield lower reveal molding clip located between transmission and lower corner reveal molding.
Carefully slide either lower reveal molding approximately l/2" toward center line of the body. NOTE: At this location, the reveal molding lower Range is cut out to permit disengagement of the lower edge of the molding from the inboard retaining clip.
Disengage molding from inboard clip, then slide molding toward center line of body until end of molding disengages from outboard clip. Repeat for opposite molding.
On sedan, sport sedan and sport coupe styles remove screw "A," fig. 22, securing lower corner reveal molding, pull molding out slightly and slide corner reveal molding down and remove. On convertible styles, remove screw "A," fig. 23, from lower comer of side reveal molding, then open door and remove three screws "C," fig. 23, securing molding to windshield side pillar and remove molding. Repeat operation at opposite side.
Remove screw "B," figs. 22 or fig. 23, at each end of upper reveal molding. On convertible styles note how rubber channel is notched at screw locations.

NOTE: On all styles, the upper reveal molding(s) can only be removed from the windshield rubber channel after the windshield is removed from the body.

Installation

To install moldings, reverse the removal procedure. Apply a medium-bodied sealer to screw holes indicated at "1" in fig. 24. Apply sealer inside of holes as indicated at "2" in section "A-A."
In addition at the windshield lower reveal moldings, apply a medium-bodied sealer around clip holes as indicated at "3."

Windshield Garnish Moldings

Removal and Installation

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

Convertible Bodies All Other Bodies

1. Upper Moldings 1. Side Moldings
2. Side Moldings 2. Escutcheon
3. Escutcheon 3. Upper Moldings
4. Lower Moldings 4. Lower Moldings

Figure 25 identifies the windshield garnish moldings.

To install, reverse this procedure.

Windshield Side Pillar Finishing Molding

Sport Coupe and Bel-Air Models

Removal and Installation

Remove windshield lower reveal and lower corner molding.
Remove screw securing end of upper reveal, open door and remove three screws (fig. 26) from face of windshield side pillar and carefully pry off molding.
To install, seal all attaching screw holes with a medium body sealer, then reverse the removal procedure.

Windshield Side Pillar Finishing Molding

Convertible Styles

Removal and Installation

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

Windshield Header Molding

Convertible Styles

Removal and Installation

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

Windshield

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

Removal

Place protective covering over the hood, front fenders, instrument panel and front seat assembly. On convertible models, lower the top.
Remove the windshield garnish moldings and rear view mirror support.
On sedans and sport coupes, remove the windshield lower and lower comer reveals. Carefully pry off escutcheon at junction of upper reveal. On convertibles, remove lower and side reveals.
Remove screws attaching ends of upper reveals. Also remove lower reveal attaching clips from body (fig. 27).
On the inside of the body, loosen the hp of the windshield rubber channel from the pinchweld flange along the top and at the sides by applying pressure with the palm of the hand to the edge of the glass. At the same time assist the lip of the rubber channel over the pinchweld.-flange with a flat bladed tool (fig. 28).
After freeing the rubber channel, with the aid of a helper, lift the windshield from the body and place it on a covered bench.
Disengage the "T" flange of the upper reveals from the rubber channel and remove moldings. NOTE: On convertible bodies a notch is cut at each end of the upper reveal molding in the windshield rubber channels.
Remove rubber channel from glass.

Body Windshield Opening Check

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

Check for the following conditions at the previous marked point of fracture.
- Chipped edges on glass.
- Irregularities in body opening.
- Irregularities in rubber channel.
Remove all sealer from flange and body around windshield opening.
Check flange area for solder, weld high spots, or hardened spot-weld sealer. Remove all high spots.
Check windshield glass to opening, by supporting glass with Tool 5742 (fig. 29). CAUTION: Do not strike glass against body metal. Chipped edges on the glass can lead to future breaks.
With the windshield supported and centered in its opening, check the relationship of the glass to the body opening flange around the entire perimeter of the glass.
Figure 30 is a cross section taken through the glass channel and body opening. Check the relationship of glass to opening as follows:
- Inside edge of glass to body flange, at any point, dimension 3/16" to 1/4".
- Outer edge of glass to parallel body metal at any point, dimension 5/6" to 7/16".
Mark areas of body metal or flange to be reformed, remove glass and correct as necessary.
Recheck windshield in its opening and if satisfactory, mark the glass and body so the glass may be accurately centered upon installation.

Installation

Check the windshield drain gutter and drain hoses for obstruction. Clean if necessary. Reseal each drain hose with medium bodied sealer (fig. 31).
Assemble rubber channel to glass and install upper reveal. To facilitate installation of reveal molding to channel apply a mild soap solution to rubber channel molding cavity and "T" flange of molding.
On convertibles, carefully center upper reveal molding in channel, and where a new rubber channel is being used, at each end of the molding cut a notch in rubber channel at the molding attaching screw locations (fig. 32).
Insert cord into pinchweld cavity of channel around the entire windshield. Tie cord loosely and tape ends to inside surface of glass (fig. 33).
Apply a heavy ribbon of medium bodied sealer at the base of the pinchweld flange around the entire perimeter of the opening.
Carefully place and center the windshield in the body opening with the aid of a helper.
Press firmly on the outside surface of the glass and have the helper, inside the body, slowly pull the cord outward from the lower center toward each lower corner to seat the lip of the rubber channel over the flange. (fig. 34).
Seal the outside lip of the rubber channel to the glass with weatherstrip adhesive.
Remove all excess sealer and adhesive with mineral spirits.
Reinstall moldings, sunshade supports, etc.

Instrument Panel Compartment

Instrument Panel Compartment Door

Removal and Installation

Scribe location of door hinge on door panel.
Remove door hinge attaching screws at door inner panel or at instrument panel flange.
Remove stop attaching screws from right side of door inner panel and remove door (fig. 35).
To install, position hinge within scribe lines and install attaching screws.

Adjustment

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

To reposition the door laterally, loosen hinge attaching screws at instrument panel flange and shift door in the desired direction.

The door lock striker may be adjusted by loosening the attaching screws and moving the striker either in or out.

Compartment Door Lock

Removal and Installation

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

Compartment Box

Removal and Installation

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

Rear View Mirror Support

Sport Sedan Models

The rear view mirror and support ( fig. 36) is located at the lower center area of the windshield opening and is secured to the instrument panel by two (2) nut and washer assemblies.

Removal and Installation

Remove windshield side and lower garnish moldings.
Remove two (2) attaching nuts and washers from rear view mirror support by reaching under instrument panel.
Remove rear view mirror assembly from car.
To install, reverse removal procedure.

All Except Sport Sedan

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

Door Assembly

Sedan and Station Wagon Front Door Assembly
Sedan and Station Wagon Rear Door Assembly
Sport Sedan Door Assembly
Convertible and Sport Coupe Door Assembly
Nomad Station Wagon Front Door Assembly

Sedan and Station Wagon Front Door Assembly

Figures fig. 37 and fig. 38 are the sedan front door assemblies with trim pads removed, showing various door component attaching and adjusting points.

Glass Run Channel
Window Garnish Molding Spacing Clip
Ventilator Regulator
Upper Hinge
Window Manual Regulator Attaching Screws
Lock Remote Control
Lock Remote Control Connecting Rod
Inside Lock Rod
Lock
Ventilator Division Channel Adjusting Stud
Window Regulator Stationary Cam Attaching Screws
Inner Panel Access Hole Covers
Trim Pad Retainer
Window Control Switch Terminal Block
Window Electric Regulator Attaching Screws
Hinge Pillar Electric Conduit
Window Regulator Motor Electric Connectors
Plastic Type Door Arm Rest Attaching Holes
Hanger Plate for Built-In Type Door Arm Rest

Inside Handles

Removal and Installation

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

Garnish Molding

Removal and Installation

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

Arm Rest-Plastic Type

Removal and Installation

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

Trim Pad

Removal and Installation

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

Window Control Switch

Removal and Installation

Remove door window garnish molding and ventilator regulator handle. Loosen trim pad at top to gain access to switch terminal and disconnect block from switch.
Carefully push switch assembly from trim pad. In some instances it may be necessary to pry open tabs "A" (fig. 39).
Remove switch from escutcheon by depressing clips with an awl at "B" and remove clips.
To install, reverse this procedure.

NOTE: On all styles except the Sport Sedan, the feed stud of the master control switch should point toward front of car. On Sport Sedan styles, the stud should point toward rear of car. Check switch operation before completing installation.

Front Door Window

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

Removal and Installation

Lower door glass window and remove trim pad. NOTE: On electric window lift installations, disconnect positive or negative battery cable.
Remove door ventilator assembly, then, remove large access hole cover and tape covering small circular hole between the two access holes.
Remove screws indicated at "A" attaching sash channel cam to glass channel (fig. 40). NOTE: On electric lift installations, remove conduit, disconnect motor leads and wire harness from door.
Disengage window from sash channel. cam, raise glass almost to a fully closed position, tilt glass inward and remove from door. NOTE: Do not operate electric window regulator with glass removed.
To install, reverse the removal procedure, then seal door inner panel as specified under Door Inner Panel Sealing.

Adjustment

To correct a glass slanted in the run channels, loosen the stationary cam screws "A", then adjust rear of cam up or down and retighten screws (fig. 41).
Loosen ventilator division channel adjusting stud lock nut "B" and turn stud in or out or position stud fore or aft, as required.
Between the inner and outer door panel, indicated at "C" loosen run channel attaching nut at the lock pillar and position channel in or out as required.

Glass Run Channel

Removal and Installation

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

Window Regulator

Removal and Installation

Lower door glass, remove trim pad, both access hole covers and tape from small circular access hole located at "A" (fig. 42). NOTE: On electric window lifts disconnect motor leads "C".
Remove screws at "A" and "B", disengage window from cam and prop glass in the up position. NOTE: Do not operate electric regulator in or out of body after window has been disengaged.
Remove division channel adjusting stud and nut "D" and stationary cam attaching screws "E", then disengage cam from regulator arm and remove stationary cam.
Disengage window sash channel cam from regulator arms and remove.
Remove regulator attaching screws "F" and remove regulator through large access hole.
To install, reverse this procedure, reseal door inner panel.

Weatherstrips

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

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

Removal

Insert tip of Tool 5757 under weatherstrip at the clips and carefully snap clips from retaining hole (fig. 43). Break cement seal and remove weatherstrip from door.

Installation

Service replacement weatherstrips are longer than necessary to insure a satisfactory joint. Do not cut weatherstrip until all clips are installed into retaining holes. Install weatherstrip clips into clip holes along sides and top of doors after positioning weatherstrip as follows:

On front doors, formed bend in weatherstrip should be located in the cove area of door (fig. 44).
Color mark on weatherstrip, should be located between the third and fourth clip holes on front doors and the fourth and fifth holes on rear doors (fig. 45).
Butt joint should be located at the bottom center of the door between two clips.
Across bottom of door and up each side, indicated at five in figure 44 or six in figure fig. 45, apply a full coat of weatherstrip adhesive to surface of door which will retain weatherstrip.
Install clips to door by placing notched end of Tool 5757 in loop of clip and pushing clip into retaining hole. Repeat operation along both sides and top of door. NOTE: Do not distort clips or unsatisfactory weatherstrip retention will result.
Carefully trim ends of weatherstrip to form butt joint, and install balance of clips. Make sure a complete bond is made at cemented area.
Coat ends of weatherstrip, with weatherstrip adhesive and form butt joint.
Remove door trim assembly and access hole cover(s). Working through access holes apply medium bodied sealer over and around
weatherstrip attaching clips indicated at "V in fig. 46. Seal all clips along door bottom and lower clip at each door pillar.
Reinstall weatherstrip retaining clips and previously removed parts. Seal door inner panel as specified in "Door Inner Panel Sealing."

Front Door Water Deflectors

All Two-Door Models

A door water deflector, consisting of waterproof paper secured to the door inner panel by elastic double sided sealing tape, is provided on front doors. The deflector covers the complete door inner panel and fits into a slot along the bottom of the door inner panel. This deflects water into the bottom of the door where it can drain out the door bottom drain holes. When work is performed on a door where the water deflector has been disturbed, the deflector must be properly sealed and attached to the inner panel as specified below. When loosening or removing a door water deflector, the seal between the double sided sealing tape and water deflector should not be broken.

Removal

Remove door belt finishing molding and door trim assembly.
Carefully detach water deflector with attached double sided sealing tape from door inner panel. Do not remove double sided sealing tape from deflector unless it is necessary to replace the sealing tape. Use caution that dirt or foreign matter does not get on exposed surface of tape and destroy adhesive qualities of tape.

Installation

Prior to installing water deflector, clean surfaces of inner panel contacted by sealing tape to insure satisfactory seal.
Inspect water deflector and where necessary repair any tears or holes with waterproof body tape applied to both sides of deflector.
Insert bottom edge of water deflector in slot across bottom of inner panel. Align holes in water deflector with regulator spindles and inside trim and hardware installation holes. When properly aligned press or roll edges of water deflector to inner panel to effect a watertight seal.
Tape upper and lower comers of water deflector to inner panel with 2 inch strips of waterproof body tape, as indicated in Fig. 47.
Install previously removed door trim and inside hardware.

Front Hinge Pillar Auxiliary Weatherstrip

Removal

Remove two snap fasteners "A" with flat bladed tool, break cement seal and remove weatherstrip (fig. 48).

Installation

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

Door Lock

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

Operation

A rotary bolt type door lock is used on all models. Figuresfig. 49 and fig. 50 show the door lock construction and striker with the names of component parts. When the door is being closed, the lock bolt rotates as it comes in contact with the striker, until it becomes firmly engaged with the teeth at the lower end of the striker. When the door is completely closed, the locking cam, shown in the illustration, is firmly locked by the detent lever (fig. 49). To open the door, the locking cam is released so that the bolt can rotate. This action is obtained by the operation of the push button or remote control handle.

When the push button on the door outside handle is depressed: the push button lever operates the intermittent lever contacting the multiplier lever and in turn lifts the detent lever free of the locking cam (fig. 50).
When the inside remote control handle is operated, the connecting rod from the remote control operates the remote lever on the lock contacting the detent lever and lifting it free of the locking cam.

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

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

Door Lock Remote Control

Removal and Installation

Remove door trim pad and remove remote control attaching screws "A" (fig. 51).
Detach connecting rod from clip "B" and disengage remote control from connecting rod and remove.
To install, reverse removal procedure.

Door Lock

Removal and Installation

Remove trim pad and access hole cover.
Remove remote control and Connecting rod (fig. 51).
Working through access hole remove nut securing lower end of glass run channel at lock pillar.
Remove screws "C" and remove lock and locking rod through access hole.
To install, reverse removal procedure.

NOTE: Before installing door lock, apply a ribbon of caulking compound across the face of the lock frame approximately 3/4' above the rotary bolt housing as shown at "I" (see fig. 52).

Door Lock Striker-All Styles

Front and rear door lock strikers incorporate the inter-lock feature consisting of a notch in the striker into which the lock bolt housing extension engages. With the inter-lock feature it is very important that the lock extension engages properly in the striker notch and that, where necessary, the correct striker emergency spacers are used to obtain proper engagement.

Removal and Installation

With pencil, scribe position of striker on body pillar.
Remove three door lock striker attaching screws and remove striker and adjusting plates from pillar.
To install, place striker and adjusting plates within scribe marks on pillar and tighten screws.

IMPORTANT: Whenever a door has been removed and installed, or realigned, the door SHOULD NOT be closed completely until a visual check is made to determine If the lock extension will engage in the striker notch. Where required, door lock striker emergency spacers should be installed so that door can be closed and an accurate check made to determine emergency spacer requirements.

Adjustments

To adjust striker "up", "down", "in", or "out" loosen striker plate screws and shift striker and adjusting plates as required, then tighten screws.
DIMENSIONAL SPECIFICATIONS FOR USE OF DOOR LOCK STRIKER EMERGENCY SPACERS.

Front door should be properly aligned and the body properly shimmed before checking door spacer requirements.
To determine if door lock striker emergency spacers are required, apply modeling clay or body caulking compound in the door lock striker notch where the lock extension engages, and then close the door to form a measurable impression in the clay or caulking compound, as shown in fig. 53.

When dimension "A" from inside face of striker teeth to center of lock extension is less than 3/16", install emergency spacers and proper length striker attaching screws as directed on next page.

NOTE: Dimension "B" from center of lock extension to inside face of striker notch should never be less than 1/8".

Dimension"A"     No. Spacers Required      Spacer Thickness      Striker Attaching 
                                                                       Screws*

3/16" to 1/8"             1                     1/16"             Original Screw

1/8" to 1/16"             1                     1/8"              Emergency Screw-
                                                                   (1/8" longer)

1/16" to 0           1-(1/8 Spacer)            3/16" (Total)      Emergency Screw-
                                                                   (1/8" longer)

0 to 1/16"          2-(1/8" Spacers)           1/4" (Total)       Emergency Screw-
Interference                                                       (1/4" longer)

*Zinc or cadmium-plated flat head cross recess screw with countersunk washer.

Front Door Assembly

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

Removal

Place suitable protective covering over front fender at door opening to protect finish, then remove door trim pad. NOTE: On bodies with manual window lifts, the trim pad does not have to be removed, if the door is to be removed with the hinges attached.
Scribe location of hinge box on front body pillar or location of hinge strap on door inner panel, depending on method of door removal.
On door with electric window lifts with the trim pad removed:
- Remove screws securing electric conduit and carefully slide conduit toward front pillar exposing wire harness.
- Detach wire harness from clips and disconnect motor leads. Disengage wiring from retaining clips and carefully pull harness from cutout in door hinge pillar.
Support door and remove bolts "A" or "B" (fig. 54). Two bolts "A" at upper hinge and one bolt "A" at lower hinge are located inside the hinge box. With the aid of a helper remove door from body.

Installation

Coat all hinge attaching surfaces, as indicated in figure 55, with a medium bodied sealer. Apply enough sealer at area "A" to insure a water tight seal.
Reinstall door to body with the aid of a helper. Align hinges within scribe marks and tighten bolts. Check door alignment.
On doors with electric window lifts, install wire harness to door and connect motor leads. Tighten wire harness clips, make sure spacers are properly installed and attach conduit to door hinge pillar.
Reseal and lubricate door as required.

Inner Panel Sealing

Some of the front door inner panel weatherseals have been changed for 1957 styles. These changes are covered 'below. Whenever work is performed on a door where any of the door inner panel weatherseals have been disturbed, the area must be resealed before the door trim assembly is reinstalled.

Figure 56 shows door inner panel openings which are sealed to prevent water leakage and possible damage to the door trim assembly.

At both access holes apply ribbon of medium bodied sealer across top and down side flanges of access hole opening to provide seal between cover plate and door inner panel (1).
Apply ribbon of medium-bodied sealer to access hole cover plate starting at point "2" above lower comers and extending downward and along edge of offset flange (2).
After access hole cover plates are installed, seal lower offset corners with sealer (3).
Apply sufficient body caulking compound to effect a watertight seal at:

All window regulator attaching holes (4).

Door inner panel cam attaching holes (5).

Ventilator division channel lower attaching stud and nut (6).

Ventilator tee-shaft access hole and ventilator regulator attaching screws. (7, View "A.")

Door trim assembly nail slots (8).

On electric styles-inner flanges of switch hole cover and to upper rear corners and
across top joint of cover and inner panel. (9, View "B.")

Door arm rest attaching holes (10).

Apply waterproof tape over the following door inner panel openings.

Cam access hole (11).

Lock access hole (12).

Lower hinge access hole (13).

Upper hinge access hole (14).

On electric styles-window regulator spindle hole (15).

Front Door Adjustment

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

Up or Down and In or Out

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

Up or Down and Fore or Aft

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

Should the door clearance at the body hinge and windshield pillars be parallel and fall within 1/16" to 3/16" clearances and the door at the center or lock pillar be tilted (close at the top, wide at the bottom or vice-versa) it is indicative of another type of correction, namely body shimming. In most cases, where adjustment of the doors cannot correct a door alignment problem, body shimming will be the answer. Figure 58 shows the location of all body mounting points and where shims may be added or removed to correct body alignment faults. In addition figure 57 gives the dimensional clearances of the doors at the pillars.

NOTE: After performing any door adjustments on a convertible or four-door sedan style the door ventilator and window should be checked for proper alignment with the side roof rail weatherstrip and adjusted where required. In addition, when performing adjustment on any style do not close the door completely without making a visual check to see that the door lock extension engages in the striker notch as specified.

Ventilator Regulator

Removal and Installation

Remove door garnish molding, trim pad and small access hole cover.

Remove screws "A" and "B" (fig. 59), disengage regulator from "Tee" shaft and lower it between door panels out through small access opening.

To install, seal as specified under, Door Sealing, reverse removal procedure.

Adjustment

Ventilator flutter, when the ventilator is open, may be eliminated by tightening "Tee" shaft screw "A." Tighten screw carefully to avoid stripping threads (fig. 60). Opening and closing effort may be increased or decreased by an adjusting friction clamp screw "B."

Ventilator and Division Channel

Removal and Installation

Lower door glass window, remove trim pad, small access hole cover and ventilator regulator.
Loosen upper section of glass run channel "A," remove attaching screws "B" and adjusting stud and nut "C" (fig. 61).
Work ventilator inward, then lift ventilator assembly from door.
To install, seal as specified under Door Sealing and reverse the removal operation.

Adjustment

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

Outside Handle

Removal and Installation

With the door glass in the closed position remove the trim pad.
Through access holes indicated at "A" and "B" (figure 62) remove two screws securing handle to door outer panel.
Remove handle and gaskets.
To install, reverse this procedure.

Lock Handle Push Button

Removal and Installation

Remove door handle from door.
Depress stop washer slightly and make quarter turn and remove stop washer, retainer, spring and push button and shaft (fig. 63).
To install, reverse this procedure.

Lock Cylinder

Removal and Installation

Pry retainer "C" out sufficiently to release cylinder (fig. 62).
Remove cylinder and gasket.
Remove retaining clip "A" and pawl (fig. 64).
Carefully bend open four cylinder housing scalp tabs "B" and remove scalp. CAUTION: When removing scalp, hold spring loaded cylinder cap depressed with finger. Note position of springs and cap for reassembly purposes.
Remove cylinder from housing. Figure 65 shows an exploded view of the door lock.
To install, reverse this procedure, insert cylinder with curved edge toward lock pillar and check operation of lock cylinder.

NOTE: A redesigned spring clip is used on the door lock lovers to secure the connecting rods to the lock lovers. A slot in the spring clip provides easier disengagement of the clip thereby facilitating easier detachment of the lock connecting rods from the lock. To disengage spring clips, use a screw driver or other suitable tool to slide clip out of engagement. Figure 66 shows a door lock spring clip engaged and disengaged.

Sedan and Station Wagon Rear Door Assembly

The manual regulator type rear door inner panel and the electric regulator type rear door Fig. 66-Door Lock Spring Clip

inner panels are shown in figures 67 and figure 68 respectively. The illustrations show the location of hardware parts and their attaching points.

Glass Run Channel
Upper and Lower Hinge Cover Plates and Hinges
Locking Rod and Lover
Lock Remote Control
Lock Remote Control Connecting Rod
Lock
Window Regulator
Window Regulator Stationary Cam Adjusting Screws
Access Hole Cover Plate
Trim Pad Retainers
Glass Run Channel Adjusting Screw
Window Control Switch Terminal block
Window Electric Regulator
Electrical Conduit Opening
Electric Connectors for Door Window Regulator Motor
Attaching Holes for Plastic Type Door Arm Rest
Hanger Plate for Built-In Type Door Arm Rest

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

Door Hinge

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

Removal

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

Installation

Clean all old sealing compound from hinge areas. Do not soil, adjacent trim.
Apply a full coat of heavy bodied sealer to attaching surface of hinge strap, this sealer acts as a weatherseal and anti-squeak (fig. 69).
Place door in body opening and install attaching bolts loosely. Align straps within scribe marks and tighten bolts. NOTE: On electric lift installation, install wire harness to conduit, conduit to hinge pillar and connect motor leads. Install access door, trim pad and inside hardware.
Apply medium bodied sealer to upper and lower hinge as indicated at "A" and "B" in figure 70.
Install hinge cover plates and remove excess sealer.

Adjustment

To check the rear door alignment in the body opening, remove the lock striker from the body lock pillar and allow the door to hang free. Then check spacing (fig. 57) between the door and body opening edges. Clearance between the door header and side roof rail and the door pillar and body pillar should be 1/16" - 3/16"- Clearance between the bottom of the door and rocker panel should be 1/8" - 1/4".

NOTE: Whenever a door has been adjusted, the door should not be closed completely until a visual check is made to determine if the lock extension will engage in the striker notch. Where required, door lock striker emergency spacers should be installed. See "Door Lock Striker Adjustments."

In or Out

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

Up or Down

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

Rearward

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

Forward

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

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

Rear Door Remote Control

Removal and Installation

Same as front door.

Rear Door Lock

Removal and Installation

Remove trim pad, access hole cover and remote control.
Remove inside locking rod lever attaching screw "B" and washer, disengage lever connecting rod from clip "C" and door lock (fig. 71).
Remove glass run channel screw "D" and four lock attaching screws "E".
Remove lock through access hole.
To install, reverse this procedure. Check operation of lock components and reseal as specified under Rear Door Inner Panel Sealing.

Free Wheeling Adjustment

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

Pull inside locking rod knob to the "up" position and remove rear door lock upper attaching screw.
Insert adjusting tool through screw hole as shown in illustration, (fig. 72).
Engage hooked end of rod in loop of remote control connecting link as shown in the illustration. Push rod forward to set lock "out" of free wheeling and pull rod rearward to set lock "in" free wheeling, (fig. 73).

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

Glass Run Upper Channel

Removal and Installation

Lower door window and remove trim pad and access hole cover (fig. 74).
Remove screw "E" at lower end of channel and carefully pry channel rose-bud fasteners from retaining holes at door header.
Carefully pull channel from door.
To install, reverse the removal procedure. Upper channel must fit properly into end of lower channel at "G". Align channel for free glass travel and reseal inner panel.

Glass Run Lower Channel

Removal and Installation

Lower door window, remove trim pad, access hole cover and screw "D" from end of glass run channel (fig, 74).
Detach upper channel from door lock pillar, then remove rose-bud fastener from retainer at "G."
Carefully pull lower glass run channel up through window opening.
To install, reverse this procedure making sure upper and lower run channels are properly aligned. Align channels for free glass travel and reseal inner panel.

Glass Run Front Channel

Removal and Installation

Lower door window and remove trim pad and access hole cover (fig. 75).
Remove screw "E" at lower end of channel and carefully pry channel rose-bud fasteners from retaining holes at door header.
Carefully pull channel from door.
To install, reverse the removal procedure. Upper channel must fit properly into end of lower channel at "G." Align channel for free glass travel and reseal inner panel.

Glass Run Upper and Rear Channel

Removal and Installation

Lower door window, remove trim pad, access hole cover and screw "D" from end of glass run channel (fig. 75).
Detach upper channel from door lock pillar, then remove rose-bud fastener from retainer at "G."
Carefully pull glass run channel up through window opening.
To install, reverse this procedure making sure upper and lower run channels are properly aligned. Align channels for free glass travel and reseal inner panel.

Rear Door Window

Removal and Installation

Similar procedure as front door except that door ventilator does not have to be removed.

Adjustment

Similar to front door.

Rear Door Window Regulator

Removal and Installation

Same procedure used as for front door except that there is no division channel adjusting stud and nut.

Rear Door Weatherstrip

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

Rear Door Outside Handle

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

Inner Panel Sealing

Whenever work is performed on a door where any of the door inner panel weatherseals have been disturbed, the area must be resealed before the door trim assembly is reinstalled. Fig. 76 shows the door inner panel openings which are sealed to prevent water leakage and possible damage to the door trim assembly.

Apply ribbon of medium-bodied sealer across top and down side flanges of access hole opening to provide seal between cover plate and door inner panel (1).
Apply ribbon of medium-bodied sealer to access hole cover plate starting at point "2" above lower comer extending downward and along edge of offset flange at bottom of cover (2).
After access hole cover is installed, seal lower offset corners (3).
Apply sufficient body caulking compound to the following locations:

Window regulator attaching holes (4).

Door inner panel cam attaching holes (5).

Door trim assembly nail slots (6).

Arm rest attaching holes (7).

Apply waterproof body tape over the following door inner panel openings:

Welding access holes (8).

Cam access holes (9).

Lock access hole (10).

Sport Sedan Door Assembly

Front Door Assembly
Rear Door Assembly
Center Pillar Assembly

The door section is divided into the following parts:

Service operations which are the same or similar for both front and rear doors.
Service operations for the front door.
Service operations for the rear door.

Special attention should be given the door lock striker adjustments and dimensional specifications for use of striker emergency spacers. Special attention should also be given to both front and rear door window adjustments to provide proper window frame contact with the side roof rail weatherstrip.

PROCEDURES FOR BOTH FRONT AND REAR DOOR

Door Belt Finishing Molding

Removal and Installation

Remove inside locking rod knob.
Remove screw securing each end of molding; disengage molding from clips and remove from door.
To install reverse removal procedure.

Door Arm Rest

Removal and Installation

The same procedure as on the plastic type on the sedan front door.

Door Trim Assembly

Removal and Installation

The same procedure as used on the sedan front door except that the door belt finishing molding must also be removed.

Side Roof Rail Weatherstrip

The side roof rail weatherstrip is a one-piece weatherstrip, with an "L" shaped metal insert through the entire length of the weatherstrip. The weatherstrip is secured to the side roof rail by fourteen screws and to the body front pillar by one screw.

IMPORTANT: The attaching holes in the side roof rail weatherstrip are elongated to provide "in" and "out" adjustment for proper contact with the front and rear door window frames. However, the amount of adjustment is small and is not intended to correct for improper ventilator or door window alignment. It is very important that the front door ventilator and the front and rear door windows are checked and, if necessary, aligned for proper contact with the side roof rail weatherstrip.

The following procedures may be used for removing, installing and adjusting the side roof rail weatherstrip.

Removal

Open both front and rear doors and lower the windows.
Remove one screw securing weatherstrip at body front hinge pillar and screws securing weatherstrip to side roof rail. Carefully detach weatherstrip from sealer and remove from body.

CAUTION: Use care when removing and handling weatherstrip so as not to bond metal insert.

Installation

Clean off all old sealer from weatherstrip attaching surfaces along side roof rail.
As a bench operation, apply a continuous ribbon of heavy-bodied sealer (3/16" diameter) along the inboard edge of weatherstrip as indicated at "1" (fig. 77), along entire length of weatherstrip.
At the front end of the weatherstrip apply a good grade of weatherstrip cement to the contacting surface of weatherstrip, indicated at "2"
Position weatherstrip to side roof rail and retain in position with one attaching screw at front center and rear of weatherstrip.
Install loosely all weatherstrip attaching screws.
With the doors and windows closed, position weatherstrip so that an even, continuous contact is made with the window frames and tighten weatherstrip attaching screws. Clean off excess sealer and cement with mineral spirits.
Lubricate. Apply a silicone rubber lubricant to surface of side roof rail weatherstrip indicated at "1" in fig. 77. Lubricant is to be applied along length of weatherstrip. In addition, apply lubricant to the top and inboard surface of the rear door window frame sash channel as indicated at "2". Apply lubricant to the upper front comer of the frame extending from the forward edge rearward for a distance of seven inches.

Adjustments

The attaching holes in the side roof rail weatherstrip are elongated to provide "in" and "out" adjustment for proper contact with the front and rear door window frames as shown in fig. 78. To adjust weatherstrip, loosen attaching screws along area requiring adjustment, move weatherstrip "in" or "out" as required and retighten screws. NOTE: The amount of "in" and "out" weatherstrip adjustment is small and is not intended to correct for improper ventilator or door window alignment. If proper weatherstrip contact cannot be obtained through the "in" and "out" weatherstrip adjustment, the door ventilator and/or windows must be aligned to obtain the proper weatherstrip contact.
The side roof rail weatherstrip can also be shimmed downward to provide proper contact with the ventilator frame and door glass frame. To perform this operation, detach weatherstrip from side roof rail sufficiently to install tapered waterproof shims between the weatherstrip and the side roof rail. DO NOT BEND THE INTEGRAL METAL INSERT. Shims should be securely cemented to side roof rail, and specified sealer should be re-applied to weatherstrip in affected area.

CAUTION: Shims should be well tapered and long enough to provide a continuous sealing surface along the length of the weatherstrip. Shims which are not tapered or too short may cause irregularities in the sealing surface.

Front Door Assembly

Assembly and Hinges

The front door hinges are the swing-out type with an integral door check and hold open, similar to the sport coupe. The hinges are attached to the front body hinge pillar and to the door assembly with bolts, cage nuts and anchor plates. Either of two methods may be used to remove the door from the body.

The door and hinges can be removed as an assembly from the body hinge pillar.
The door can be removed from the hinge straps.

Adjustment

Door adjustments are provided through the use of floating cage nuts and anchor plates in the door and adjacent hinge pillar. When checking the door for misalignment, remove the door lock striker from the body pillar to allow the door to hang free on its hinges.

IMPORTANT: After performing any door adjustments the front door ventilator and window should be checked for proper alignment with the side roof rail weatherstrip and adjusted, where required. In addition the door lock extension-to striker engagement should be checked and adjusted, if necessary.

Inner Panel Sealing

Fig. 79 shows the front door inner panel areas which must be sealed to prevent entrance of water and possible damage to interior trim. Whenever any work is performed on the door where the weatherseal has been disturbed, the area must be resealed before the door trim assembly is reinstalled.

Sealing Operations

Apply a ribbon (approximately 3/16" diameter) of medium-bodied sealer across the top and down the side flanges to a point 1/2"' beyond the access hole cover offset line to Provide a seal between cover and inner panel.
Apply a ribbon of medium-bodied sealer to the contacting surface of access hole cover at the lower corners.
After access hole cover is installed, seal lower comers of cover, at offset, with body caulking compound.
Apply body caulking compound at the following locations (fig. 79):

Over the window regulator attaching holes (1).

Over the window cam attaching holes (2).

Over the ventilator division channel lower attaching hole (3).

Over trim assembly nail slots (4).

Over the wiring clip attaching hole (5).

Over the arm rest attaching holes (6).

Apply waterproof body tape at the following locations:

Over both lower and upper hinge access hole (7).

Over the window cam access hole (8).

Over the manual window regulator spindle hole (9).

Over the door lock remote control connecting rod clip attaching hole-apply before
installing clip (10).

On styles equipped with electrically operated window regulators apply body caulking compound in the upper rear corners, across the top and clown the side joints of switch hole cover and inner panel. Sealer to be worked into openings to insure proper seal (11).

Apply a sufficient amount of body caulking compound to block off the ventilator tee shaft access hole (12).

Apply body caulking compound over ventilator regulator attaching holes (13).

Apply waterproof body tape over access hole (14).

Door Ventilator Cap Finishing Molding

Removal and Installation

At top of ventilator remove two screws securing cap finishing molding and remove molding from ventilator.
Before installing cap finishing molding apply a ribbon (1/4" in diameter) of body caulking compound from the front edge of the molding to a point rearward of the attaching hole then outboard to the outer flange as shown in fig. 80. Make sure window glass bumper assembly is properly fastened at top of ventilator division channel, then install cap finishing molding.

After installation, clean off excess sealer and make sure bumper assembly is properly positioned in finishing molding.

Door Window (Manual and Electric)

Removal and Installation

The procedure used is the same as the Sport Coupe front door except that the belt finishing molding does not apply.

Adjustments

Adjustment procedure is similar to that used on the Sport Coupe.

Door Locking Mechanisms

The operation of the front door locks on the sport sedan styles is the same as on other sedan styles; however, due to the new center pillar design the lock is located lower in the door requiring connecting rods from the door outside handle and lock cylinder assemblies.

Door Lock Spring Clip

Similar to that used on Sedan front doors.

Door Lock

Removal

Similar procedure to that which is used on Sedan front doors.

Door Outside Handle

The door outside handle is equipped with a bell crank lever which actuates the lock lever by means of a connecting rod. An adjusting nut is provided at the lower end of the outside handle connecting rod to provide adjustment for proper contact of the handle push button shaft with the bell crank.

Removal and Installation

Raise door window. Remove door trim assembly and large access hole cover.
See fig. 82. Through access hole detach outside handle connecting rod adjusting nut "C" from lock lever. To detach adjusting nut from lock, insert a screw driver between connecting rod and lock lever, then snap rod and adjusting nut from spring clip on lock lever.
Through access holes "H," fig. 83, remove handle attaching screws, then remove handle and gaskets with attached connecting rod from door. As a bench operation remove connecting rod from handle.
To install, reverse removal procedure. Before attaching the outside handle connecting rod adjusting nut "C," fig. 82, to lock lever, adjust nut so that door handle bell crank just contacts handle push button shaft, then attach adjusting nut to lock lever.

Check operation of outside handle before installing access hole cover, door trim assembly and hardware parts. Seal door inner panel as specified in "FRONT DOOR INNER PANEL SEALING".

Door Lock Cylinder

The front door lock cylinder operation differs from cylinders on other models in that the cylinder actuates the door lock by means of a connecting rod.

Removal and Installation

Raise door window. Remove door trim assembly and large access hole cover.
Through large access hole detach lock cylinder connecting rod "D" from lock lever (fig. 82). To detach connecting rod, insert a screw driver between connecting rod and lock lever, then snap rod from spring clip on lock lever.
With a suitable tool pry out retaining clip "I", shown in fig. 83, sufficiently to allow removal of lock cylinder with attached connecting rod from the door.
Door lock cylinder connecting rod may be removed from lock as a bench operation.
To install, reverse removal procedure. Check operation of lock cylinder and lock before installing access hole cover, door trim assembly and hardware parts. Seal door inner panel as specified in "DOOR INNER PANEL SEALING".

Door Lock Cylinder

Disassembly and Assembly

Remove cylinder assembly from door.
Remove door lock spring clip and pawl.
Carefully bend open four cylinder housing scalp tabs and remove scalp. NOTE: While removing scalp, hold cylinder cap, which is under tension from cap springs, depressed with finger. After scalp is removed, observe position of spring and cap so they can be reinstalled in same relative positions. See fig. 84.
Remove cylinder from cylinder housing.
To install, reverse removal procedure.

Door Outside Handle

Disassembly and Assembly (fig. 85)

Remove front door outside handle, as previously described.
Depress retainer sufficiently to turn bell crank lever and support one quarter turn. Remove bell crank lever and support, retainer, spring, push button and shaft and sealing ring from handle
To install, reverse disassembly procedure.

Door Inside Locking Rod and Knob

Removal and Installation

Raise door window. Remove door trim assembly and large access hole cover.
Through access hole detach inside lock rod "E," indicated in fig. 82 from lock lever and remove rod from door.
To install inside locking rod, reverse removal procedure. Seal door inner panel as specified in "FRONT DOOR INNER PANEL SEALING".

Door Lock Remote Control and Connecting Rod

Removal and Installation

Raise door window and remove door trim assembly.
Remove lock remote control attaching screws "A," indicated in fig. 83; detach remote control from connecting rod and remove from door.
To remove door lock remote control connecting rod, remove large access hole cover, then through access hole detach connecting rod from lock at "F," fig. 82, and from clip at location "J," shown in fig. 83, and remove rod from door.
To install, reverse removal procedure. If large access hole cover has been removed, seal cover and door inner panel as specified in "DOOR INNER PANEL SEALING".

Weatherstrips

Sport Sedan front door weatherstrip and hinge pillar auxiliary weatherstrip procedures are the same as previously outlined under "CONVERTIBLE AND SPORT COUPE DOOR" in this manual.

Rear Door Assembly

Removal and installation procedures are illustrated in fig. 86. Particular attention should be given the rear door window adjustments to provide proper window frame contact with the side roof rail weatherstrip, and to the door lock striker adjustments and dimensional specifications for use of striker emergency spacers.

Door Assembly and Hinges

The rear door assembly is attached to the body center pillar with two butt type hinges. The lower hinge, which has an integral type door check and hold open, is secured with three screws to an anchor plate at both the. door hinge pillar and center pillar. The upper hinge is secured with three screws to an anchor plate at the door hinge pillar and with three screws to an upper support at the center pillar.

Removal

Either of the following two methods can be used to remove the door from the body.

The door and hinges can be removed as an assembly from the center pillar.
The door can be removed from the hinge straps.

Operate window to down position.
Clean off excess sealer from around each hinge strap and scribe hinge location on door hinge pillar or center pillar depending on method of removal being used.
On bodies equipped with electrically-powered window regulators, proceed as follows:
Remove door trim assembly and access hole cover.
Remove two screws securing electrical conduit to center hinge pillar. Bend out conduit tab and remove conduit from wire harness.
Loosen or detach wire harness clips, as required, and disconnect motor leads from harness. Remove wire harness from between door panels through opening in door hinge pillar.
See fig. 86. With the door properly supported, remove three upper and lower hinge attaching screws "A" at door hinge pillar or screws "B" at center pillar, depending on the method of removal being used.
With aid of a helper, remove door from body opening.

Installation

With scraper and mineral spirits, clean off old sealing compound at hinge areas. This operation should be performed carefully to avoid possibility of soiling adjacent trim material.
Apply a coat of heavy-bodied sealer to attaching surfaces of hinge straps or corresponding surfaces of door and body. It is important to obtain complete coverage with sealer to obtain a proper seal.
With a helper, lift door into position. Install screws loosely, then align straps within scribe mark on pillar and tighten bolts. Check door for alignment.
If door and hinges were removed from the center pillar, the lower hinge must be weathersealed before the hinge cover plate is installed over the hinge strap. Seal hinge with medium-bodied sealer as outlined below:
- Prior to installing hinge cover plate, apply a sufficient amount of body caulking compound around hinge, as indicated at "I", fig. 87, to fill hinge depression at these points.
- Apply medium-bodied sealer to the top and bottom of the underside of the hinge cover plate, as indicated at "2," fig. 87. This seal must contact caulking compound
- Install hinge cover plate and clean off any excess sealer from around edges of cover plate.
On bodies equipped with electrically-powered window regulators, proceed as follows:
- Install wire harness to attaching clips between door panels and connect to motor leads. Check operation of window.
- Install conduit to hinge pillar and secure wiring harness in conduit with retaining tab.
- Install access hole cover and regulator attaching screw. Seal door inner panel as specified in "REAR DOOR INNER PANEL SEALING".
- Install door trim assembly and remaining door hardware.

Adjustments

Due to the center pillar upper hinge support, the rear door hinge adjustments are performed in a different manner than on other sedan styles. "In" and "out" adjustment is provided at the door hinge pillar while "up" and "down" adjustments can be made at the center pillar. In addition, waterproof shims can be installed between the door hinge pillar and hinge straps to adjust the door "rearward."

When checking the door for alignment, remove the door lock striker from the body pillar to allow the door to hang free on its hinges. Procedure for adjusting the door is outlined below.

NOTE: After performing any door adjustments the rear door window should be checked for proper alignment with the side roof rail weatherstrip and adjusted where required. In addition the door lock extension-to-striker engagement should be checked and adjusted, if necessary.

See fig. 86. If adjustment is being performed at center hinge pillar, remove lower hinge cover plate.
For "in" and "out" adjustment at center pillar, loosen hinge attaching bolts "A" at door hinge pillar; adjust door as required and tighten bolts.
For "up" and "down" adjustment, loosen hinge attaching bolts "B" at center pillar; adjust door as required and tighten bolts.
For "rearward" adjustment, prop door and remove upper or lower hinge attaching bolts "A" at door hinge pillar. (It is easier to adjust one hinge at a time.) Cement a full waterproof shim to hinge strap and reinstall bolts.
Seal hinges as previously specified and reinstall hinge cover plates.

Inner Panel Sealing

Fig. 88 shows the rear door inner panel areas which must be sealed to prevent entrance of water and possible damage to interior trim. Whenever any work is performed on the door when the weatherseal has been disturbed, the area must be resealed before the door trim assembly is reinstalled.

Sealing Operations

Apply body caulking compound at the following locations:

Over the window regulator attaching holes (1).

Over the trim assembly nail slots (2).

NOTE: The two nail slots shown at "2" in View "B" must be sealed prior to installing the lock connector assembly cover.

Over both the window front and rear guide lower attaching holes (3).
Over the window regulator lift arm stop attaching holes (4).
Over the arm rest attaching holes (5).
Over the window frame lower rear bumper attaching hole (6).
Over the wiring clip attaching holes (7).

Apply waterproof body tape at the following locations:

Over the access hole for the window sash channel cam rear attaching screw (8).
Over the access hole for the outside handle front attaching screw (9).

VIEW "B"

Prior to installing the lock connector cover apply body caulking compound over the attaching screw holes (10) .

Prior to installing the lock connector assembly apply a ribbon of body caulking compound to the contacting surface of the connector assembly along a line over the front and upper attaching holes, as indicated (11).

VIEW "C"

On styles equipped with electrically operated window regulators apply body caulking compound in the upper rear corners, across the top and down the side joints of switch hole cover and inner panel. Sealer to be worked into openings to insure proper seal (12).

Apply a ribbon (approximately 3/16" diameter) of medium-bodied sealer across the top and down the side flanges to a point 1/2" beyond the access hole cover offset line to provide a seal between cover and inner panel (13).

Apply a ribbon of medium-bodied sealer to the contacting surface of access hole cover at the lower corners, as indicated (14).

After access hole cover is installed, seal lower corners of cover, at offset, with body caulking compound (15).

Rear Door Locking Mechanisms

The rear door lock and striker incorporate the inter-lock feature consisting of an extended lock bolt housing which engages a mating notch in the striker. With the inter-lock feature it is very important that the lock extension engages properly in the striker notch and that, where necessary, the correct striker emergency spacers are used to obtain proper engagement. See "DOOR LOCK STRIKER ADJUSTMENTS."

The operation of the rear door locks on the sport sedan styles is the same as on other sedan styles, however, due to the door design and the use of an inside locking rod-to-lock connector assembly and cover, new door lock service methods are required.

Door Lock

Removal and Installation

Raise door window; remove door trim assembly and inner panel access hole cover.
Through access hole, insert a screw driver between lock lever and connecting rod, as shown in fig. 89, turn screw driver to detach connecting rod from spring clip on lock lever.
Detach connecting rod from lock lever at "A," fig. 89.
Remove door lock attaching screws "A", indicated in fig. 91, from face of door lock pillar.
Lower lock between door panels and remove through access hole. NOTE: Before installing door lock, apply a ribbon of caulking compound an the door lock facing at the top and side joints of the lock bolt cover. After installation of lock, clean off any excess caulking compound on lock facing or door lock pillar.
To install door lock, reverse removal procedure. Check all operations of door lock before installing access hole cover.

Install access hole cover. Seal door inner panel as specified in "DOOR INNER PANEL SEALING".

Free-Wheeling Adjustment

The procedure used is similar to that used on sedan rear doors.

Door Outside Handle

The rear door outside handle is secured to the door outer panel by two screws, which are removed and installed through two access holes in the door inner panel. To remove the handle rear attaching screw it is necessary to first remove the door lock assembly. The handle push button shaft can be adjusted (screwed) "in" or "out" of the push button to provide proper contact with the door lock push button lever.

Removal

Remove door trim assembly and access hole cover.
Remove door lock as previously described.
Remove rubber plug at rear access hole "B" and tape covering front access hole "B". See fig. 91.
Through access holes "B" remove handle attaching screws, then remove handle and gaskets from door.

Installation

Before installing handle assembly, apply Lubriplate or its equivalent on contacting end of handle push button shaft.
Install front and rear gaskets on handle and position handle on door outer panel, then install handle attaching screws.
Seal and install door lock.
Adjust handle push button shaft so that shaft just contacts door lock push button lever.
Seal door inner panel access hole cover as specified in "REAR DOOR INNER PANEL SEALING". Reinstall door trim assembly and inside hardware parts.

Door Outside Handle Push-Button Shaft

Adjustment

For proper lock operation the rear door outside handle push button shaft should just contact the door lock push button lever. The handle push button shaft can be adjusted, as described below, to provide the proper contact.

Remove door trim assembly and access hole cover.
Working through access hole turn handle push button shaft "in" or "out" until shaft just contacts the door lock push button lever when push button is NOT depressed.
Seal door inner panel access hole cover as specified in "REAR DOOR INNER PANEL SEALING". Reinstall door trim assembly and inside hardware parts.

Door Outside Handle

Disassembly and Assembly

fig. 90

Remove handle assembly as previously described.
Depress retainer, then with a suitable tool, turn stop washer one-quarter turn. Remove stop washer, retainer, spring and push button and shaft from handle. Push button shaft may be removed from push button, if desired.
To assemble handle assembly, reverse disassembly procedure. Install handle assembly and adjust push button shaft as described above.

Door Lock Connector Assembly

Removal and Installation

Raise rear door window. Remove door trim assembly and access hole cover.
Remove screws at locations "C" (fig. 91) and remove lock connector cover indicated by dotted lines.
Remove inside locking rod lever attaching screw "D." Detach connecting rod from clip at "E," then remove lever from connecting rod and connecting rod from lock connector.
Remove door lock remote control screws "F," detach remote control from connecting rod and connecting rod from lock connector.
Through access hole detach both connector rods from lock. This may be accomplished by inserting a screw driver between connector rod and lock lever, as shown in fig. 89, and snapping rod from spring clip on lock lever.
Remove three connector attaching screws "G," then lower connector between door panels and remove through access hole.
To install connector assembly, reverse removal procedure. Prior to installing connector cover, seal connector cover and door inner panel as specified under View "B" in fig. 88.

Door Window and Window Regulator

The following list identifies major component parts of the rear, door window with manual and electric window regulator assemblies. See figures 92 and figure 93.

a. Window Frame Lower Rear Bumper-Limits down travel of rear of window (adjustable).

b. Window Rear Guide-Controls "in" and "out" position of rear edge of window (adjustable).

c. Window Lower Sash Channel Frame.

d. Door Inner Panel Cam-Guides regulator balance arms, which control "up" and "down" position of front of window. (Front end adjustable.)

e. Window Center Guide Shoe-Maintains "in" and "out" position of upper portion of window. (Guide shoe adjustable.)

f. Window Center Guide-Maintains "in" and , out" position of upper portion of window. (Guide shoe adjustable.)

g. Window Lower Sash Channel Cam-Provides attachment for regulator lift arm to window sash channel. (Rear of cam adjustable for 94 up" and "down" position of rear of window.)

h. Window Regulator Short Balance Arm-The short and long balance arms lift and lower the front of the window by means of their attachment to the lift arm, inner panel arm and window frame pin.

i. Window Regulator Long Balance Arm-The short and long balance arms lift and lower the front of the window by means of their attachment to the lift arm, inner panel arm and window frame pin.

j. Window Regulator Lift Arm-Lifts window.

k. Window Regulator Lift Arm Stop- (On doors with electrically operated window regulators only) Cushions "up" and "forward" travel of window (adjustable).

l. Window Female Wedge Plate-When window is in "up" position, engagement of female wedge plate with male wedge plate (at hinge pillar) provides additional support for upper and front portion of window. (Adjustable "fore" and "aft.")

NOTE: Male wedge plate, located on hinge pillar, is adjustable "in" and "out" and "up" and "down".

m. Window Front Guide Assembly - Includes Window Anti-Rattle Support-Controls "in" and "out" position of lower front of window (adjustable). With window in "down" position anti-rattle support supports upper portion of window.

n. Window Front Guide Lower Bumper-Limits down travel of front of window.

o. Window Electric Motor and Regulator Assembly.

p. Window Manual Regulator Assembly.

Door Window-Electric and Manually Operated

Removal

See fig. 94. Remove door trim assembly inner panel access hole cover, window stop "A" and window glass run channel inner, lower front sealing strip.
Through access hole "B" loosen female wedge plate screw. Lower window, then through access hole remove wedge plate from front of window frame.
Remove bolt "C" and detach center guide from window lower sash channel frame. Position center guide so that it will not become detached from center guide shoe.
Insert a screw driver through access hole "D" and carefully spread spring clip on regulator balance arm. At the same time insert another screw driver, at location "E," and carefully pry regulator balance arm from window frame pin.
Through access hole "F" remove window sash channel cam upper screw. Remove lower screw "G," detach cam from regulator lift arm and remove from door. CAUTION: On doors with electrically operated window regulator, DO NOT OPERATE REGULATOR MOTOR after the window assembly is disengaged from the regulator. Operation of the motor with the food removed may damage the unit.
Lift window assembly from between door panels so that the lower sash channel comes out between the wide opening at front of panels, as indicated in inset of fig. 94.

Installation

Prior to installing the window assembly apply a coat of Lubriplate or its equivalent at the following locations:
- On the window lower sash channel frame lubricate the frictional surface on which the center guide rotates.
- Lubricate the channel portion of the window lower sash channel cam, the inner panel cam and the center guide.
Install window between door panels. Start rear of window in first inserting lower sash channel frame through wide opening at front of panels. Make sure window engages properly with the front and rear window guides.
Position window sash channel cam on regulator arm. Install cam attaching screw "G." Through access hole 'Y' install cam upper attaching screw.
Check that spring clip is properly installed on regulator balance arm. If clip is damaged, replace with new clip. Line up hole in regulator balance arm with pin on window frame, then with screw driver inserted through access hole "D," snap balance arm securely onto pin. IMPORTANT: Make sure spring clip on balance arm is properly engaged into notch of window frame pin.
Position center guide to window frame and install attaching bolt "C."
Install female wedge plate to outboard side of slot at front of window frame and tighten attaching screws by hand. Raise window to full "up" position. Install and adjust window stop "A." Back window off slightly (approximately 1/16"); position female wedge plate tight against male wedge plate and tighten attaching screw through access hole "B."
Check operation of window. Check for proper window frame contact with the side roof rail weatherstrip and window front frame weatherstrip contact with the front door window frame. If necessary, adjust window to obtain proper weatherstrip contact.
Seal door inner panel as specified in "REAR DOOR INNER PANEL SEALING." Install inner panel access hole cover, door trim assembly and inside hardware.

Adjustments

IMPORTANT: The rear door assembly should be properly aligned in the body opening before adjusting the rear door window.

Adjustments have been provided to insure proper contact of the rear door window frame with the side roof rail weatherstrip and with the door glass run channel outer sealing strip; also for proper contact of the rear door window front frame weatherstrip with the front door window frame. Unless otherwise specified, the following window adjustments are for both manual and electrically operated windows. See fig. 95.

"In" and "out" adjustment of the lower, front portion of the window: Loosen male wedge plate screws "A" located at hinge pillar. Loosen front guide upper attaching screws "B," located on hinge pillar and lower attaching stud nuts "C." Adjust both upper and lower ends of the guide the same amount "in" or "out" as required, then tighten screws "B" and stud nuts "C." With windows in FULL UP position tighten male wedge plate screws "A."
"In" and "out" adjustment of the rear portion of the window: Loosen rear guide upper and lower stud nuts "D." Adjust both upper and lower studs the same amount "in" or "out," as required, then tighten stud nuts "D."
"In" and "Out" adjustment of top of window frame. Loosen male wedge plate screws "A," located on door hinge pillar. Remove inner panel access hole cover and loosen center guide shoe jam nut "E." Adjust center guide shoe "in" or "out," as required, and retighten jam nut "E." With window in FULL UP position tighten male wedge plate screws "A."
"Up" and "down" adjustment of front of window. Loosen male wedge plate screws "A," located on hinge pillar. On doors with electrically operated window regulators loosen regulator lift arm stop screw "F." Loosen inner panel cam screws "G"; position front of cam and window "up" or "down," as required, and retighten cam screws "G." With window in FULL UP position tighten male wedge plate screws "A." On doors with electrically operated window regulators, position regulator lift arm stop tight against lift arm and tighten attaching screw "F."
"Up" and "down" adjustment of rear of window. Through access hole "H" loosen window lower sash channel cam rear attaching screw. Position rear of window and cam "up" or "down," as required, and retighten cam screw through access hole "H."
"Fore" and "aft" adjustment of window. Loosen female wedge plate screw through access hole "I" and on styles with electrically operated window regulators, loosen window regulator lift arm stop screw "F." Operate window to desired position, then back window off slightly (approximately 1/16")- Position female wedge plate tight against male wedge plate and tighten wedge plate screw through access hole "I." On styles equipped with electrically operated window regulators position regulator lift arm stop tight against lift arm and tighten screw "F."
To limit the "up" travel of the rear of the window, adjust window stop "K."
To limit the "down" travel of the rear of the window loosen bumper attaching screw "J"; position bumper, as required, and retighten screw "J".
To correct a binding condition when the door is lowered, adjust the window front guide lower attaching screws "C" and/or the rear guide lower attaching screws "D" "in" or "out" as necessary to relieve binding condition. Retighten screws "C" and "D."

Door Window Front Guide

Removal and Installation

Raise window. Remove door trim assembly and access hole cover.
On doors with electrically operated window regulators remove window center guide as described in Door Window Center Guide.
Remove front guide upper attaching screws "B," indicated in fig. 95 located on hinge pillar, and lower attaching nuts and studs "C".
Remove guide, with attached anti-rattle support and lower bumper, through access hole.
To install, reverse removal procedure. Adjust guide "in" or "out" for proper contact of the rear door window frame weatherstrip with the front door window frame.

Seal door inner panel as specified in "REAR DOOR INNER PANEL SEALING."

Door Window Center Guide

Removal and Installation

Lower window. Remove door trim assembly and access hole cover.
Remove center guide-to-window lower sash channel frame attaching bolt, shown at "C" in fig. 94.
Carefully detach guide from window frame, then slide guide off center guide shoe and remove from door. NOTE: If desired, center guide shoe may be removed by loosening jam nut at "E," indicated in fig. 95, and unscrewing shoe from weld nut on support.
To install, reverse removal procedure.

IMPORTANT: When installing center guide on shoe assembly make sure anti-rattle spring clip is installed into guide channel with nylon shoe.

Before reinstalling inner panel access hole cover check the window frame contact along the side roof rail weatherstrip and, if necessary, adjust center guide shoe to obtain proper contact.

Seal door inner panel as specified in "REAR DOOR INNER PANEL SEALING."

Door Window Rear Guide

Removal and Installation

Raise door window. Remove door trim assembly and inner panel access hole cover.
Loosen rear guide upper and lower attaching stud nuts "D," indicated in fig. 95, and remove studs.
Disengage guide from shoes on window frame, then lower guide between door panel and remove from door through access hole.
Before installing rear guide, lubricate the inboard and outboard surfaces of the guide with Lubriplate.

To install rear guide, reverse removal procedure. Make sure upper end of guide is between nylon shoes on window frame before securing guide to door inner panel.

Adjust guide studs "in" or "out" for proper contact of the rear of the window frame with the side roof rail weatherstrip and with the door glass run channel outer sealing strip. Seal door inner panel as specified in "REAR DOOR INNER PANEL SEALING."

Door Window Regulator

(Manual and Electric)

Removal

Lower window; remove door trim assembly and inner panel access hole cover.
Insert a screw driver through access hole "A," as shown in fig. 96, and carefully spread spring clip on regulator balance arm. At the same time insert another screw driver, at location "B," and carefully pry regulator balance arm from window frame pin.
Through access hole "C", remove window sash channel cam upper screw. Remove lower screw "D," then detach cam from regulator lift arm and remove from door. CAUTION: On doors with electrically operated window regulator, DO NOT OPERATE REGULATOR MOTOR after the window assembly is disengaged from the regulator. Operation of the motor with the load removed may damage the unit.
Lift window to "up" position; engage female wedge plate with male wedge plate, located on hinge pillar, then prop rear of window in "up" position.
Remove inner panel cam screws "E"; detach cam from regulator balance arm and remove from door.
On doors with electrically-operated windows, loosen center guide shoe jam nut "F," fig. 97, detach guide shoe from support and remove shoe from guide. Swing center guide upward in direction of arrow to provide clearance for removing electrically operated regulator.
On door with electrically-operated -window regulator detach regulator lead wires and remove regulator attaching screws "G." On door with manually-operated window regulator, remove regulator attaching screws "H," fig. 97, position regulator balance arms in line with lift arm to facilitate removal of regulator through access hole. To remove electric motor from regulator assembly see "WINDOW REGULATOR ELECTRIC MOTOR ASSEMBLY."

Installation

Before installing window regulator make sure regulator balance arm spring clip is properly installed on balance arm. If clip is damaged, replace with new clip.
To install window regulator, reverse steps 3 through 7 of the removal procedure.
To install regulator balance arm on window frame pin, line up hole in balance arm with window frame pin, then with a screw driver inserted through access hole "A," fig. 96. snap balance arm securely on pin. NOTE: Make sure spring clip is properly engaged into notch of pin.
Check operation of regulator and window.
Install inner panel access hole cover. Seal door inner panel as specified in "REAR DOOR INNER PANEL SEALING." Install door trim assembly and door inside hardware parts.

Door Window Regulator Electric Motor Assembly

The electric motor assembly which powers the window regulator on electrically-operated windows is a 12-volt reversible type motor with a built-in type circuit breaker and a self-locking gear drive. The motor is attached to the regulator assembly with three screws.

Removal and Installation

Remove electric window regulator assembly from door and clamp securely in a vise, as shown in fig. 98. NOTE: The position of the regulator clamped in the vise will vary with the type of regulator and position of the lift arm. CAUTION: BE SURE TO PERFORM STEPS 2 AND 3 BEFORE ATTEMPTING TO REMOVE THE MOTOR FROM THE REGULATOR. The regulator lift arm, which is under tension from the counter-balance spring can cause serious injury, if the motor is removed without locking the sector in position.
Drill a 1/4" hole through sector and back plate at location "A" indicated in Fig. 98. NOTE: Location of hole in backplate will vary depending on position of sector. Do not locate hole less than 1/2" away from edge of backplate or sector.
Insert a 3/16" bolt through hole in backplate and sector and install nut to bolt. (Do not tighten nut.)
Remove the three motor attaching bolts and remove motor assembly from regulator. NOTE: Clean off steel chips from the regulator sector and motor pinion gear after drilling operation.
To install, reverse removal procedure. Regulator motor rubber pad should be cemented to inner panel side of motor. NOTE: Be sure to remove temporary nut and bolt from regulator after motor is installed.

Door Weatherstrips

The rear door weatherstrip is a one piece mechanically-retained type with external clips formed from a wire insert extending through the length of the weatherstrip. The weatherstrip is secured to the door by snapping the weatherstrip, clips into holes around the perimeter of the door. At locations "A" and "B" indicated in fig. 99, tabs, which are an integral part of the weatherstrip, are secured to the door panel by screws. After the weatherstrip is installed, sealer is applied through the inner panel access hole to the weatherstrip attaching clips along the bottom of the door and up the lock pillar. A weatherstrip located at the front of the rear door window frame provides a weatherseal between the rear door window and the front door window. The weatherstrip is cemented into a channel type retainer at the front of the window frame.

Removal

Remove door belt finishing molding.
Remove screws securing weatherstrip tabs at locations "A" and "B" indicated in fig. 99.
Using a mechanically retained weatherstrip inserting tool or other suitable tool, carefully position tip of tool under weatherstrip at each clip location, and snap clips out of holes.

Installation

Position weatherstrip on door; install clips into clip holes and install secure weatherstrip tabs at locations "A" and "B," fig. 99. To install clips into holes, place "V-shaped" tip of weatherstrip inserting tool on loop of clip, then push clip into hole until it snaps into position. NOTE: Do not use excessive force or strike tool when pushing clips into holes, as it may distort shape of clip, resulting in improper weatherstrip retention.
Remove door trim assembly and inner panel access hole cover. Working through access hole apply medium-bodied sealer over and around weatherstrip attaching clips, indicated at "1" in section "C-C." Seal all clips along door bottom, lower clip at hinge pillar and five clips up lock pillar.
Seal and install inner panel access hole cover as specified in "REAR DOOR INNER PANEL SEALING." Reinstall door trim assembly and inside hardware parts.

Door Window Frame Weatherstrip

Removal and Installation

Operate window to raised position and open door.
Pull weatherstrip, downward to remove from retainer.
To install, first apply a 1/8" diameter ribbon of an approved weatherstrip cement to the lower six inches of weatherstrip retainer. Install weatherstrip in retainer. Installation of weatherstrip, will drag cement along balance of retainer resulting in a good bond with little or no clean up.

Center Pillar Assembly

Center Pillar Finishing Cap

Removal and Installation

Remove two screws from top of finishing cap and remove finishing cap from center pillar.
To install, position finishing cap on top of center pillar and install two attaching screws.

Center Pillar Cover

Removal and Installation

Remove center pillar finishing cap and front and rear finishing moldings as previously described,
Turn back floor mat or carpet; remove three screws securing edge of cover to floor pan and remove cover from center pillar.
To install cover, reverse removal procedure.

Center Pillar Front and Rear Finishing

Moldings

Removal and Installation

Remove center pillar finishing cap.
Remove three screws securing finishing molding to hinge pillar and remove molding from center pillar.
To install molding, slide molding down over center pillar flange and over edge of pillar cover starting at top of center pillar.
Install molding attaching screws using an awl to locate screw holes.

Convertible and Sport Coupe Door Assembly

Figures 100 and figure 101 indicate the various door parts.

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

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

Ventilator Garnish Molding

Removal and Installation

Remove door belt finishing molding and ventilator cap finishing molding.
At door hinge pillar remove one screw securing door weatherstrip tab and two screws securing garnish molding, then carefully remove garnish molding from door assembly.
To install reverse removal procedure.

Weatherstrips

The front door weatherstrip is a one piece mechanically retained type with external clips formed from a wire insert extending through the length of the weatherstrip. The weatherstrip is secured to the door by snapping the weatherstrip clips into holes around the perimeter of the door. At locations "A" and "B," indicated in fig. 102, a tab, which is an integral part of the weatherstrip, is secured to the door pillar. Along the cove area of the door the weatherstrip is cemented in place, and at location "C," a clip inserted into the weatherstrip is secured to the hinge pillar. After the weatherstrip is installed, sealer is applied through the inner panel access holes to the weatherstrip attaching clips along the bottom of the door.

A front door hinge pillar auxiliary weatherstrip is provided to direct any water in the cove area of the hinge pillar into a drainage hole in the hinge pillar. The auxiliary weatherstrip is cemented to the door hinge pillar and has two snap-on clips at the lower portion of the weatherstrip.

Removal

Remove front door ventilator cap finishing molding.
Remove screws securing weatherstrip tabs at locations "A" and "B," and weatherstrip clip at location "C" (fig. 102).
Using a mechanically retained weatherstrip inserting tool or other suitable tool, carefully position tip of tool under weatherstrip, at each clip location, and snap clip out of hole. NOTE: At top of hinge pillar carefully remove weatherstrip from under ventilator reveal molding. At cove area of hinge pillar carefully break cement bond at some time that weatherstrip clips are being snapped from holes.

Installation

Clean off old weatherstrip cement and sealer from door.
Insert tab at top of weatherstrip under ventilator reveal molding and install weatherstrip tab attaching screw at location "A" on upper hinge pillar.
Apply a ribbon of approved weatherstrip cement in comer of rabbet along cove area as indicated at "1" in fig. 102.
Install weatherstrip clips into clip holes starting at upper hinge pillar and cove area. Press or roll weatherstrip along cove area to assure a good cement bond. To install clips into holes, place "V-shaped" tip of weatherstrip inserting tool on loop of clip, then push clip into hole until it snaps into position. NOTE: Do not use excessive force or strike tool when pushing clips into holes as it may distort shape of clip, resulting in improper weatherstrip retention.
Install weatherstrip tab attaching screw at location "B" on lock pillar.
Insert weatherstrip clip into weatherstrip, at location "C," so that prongs of clip are on top of wire insert in weatherstrip, then secure clip to hinge pillar.
Remove door trim assembly and inner panel access hole covers. Working through access holes apply medium-bodied sealer over and around weatherstrip, attaching clips, indicated at "2." Seal all clips along door bottom and lower clip at each door pillar.
Seal and install inner panel access hole covers. Seal door inner panel as specified in "FRONT DOOR INNER PANEL SEALING." Reinstall door trim assembly and inside hardware parts. Seal and install ventilator cap finishing molding.

Door Lock

Removal and Installation

Similar procedure to that which is used on Sedan front doors.

Door Lock Cylinder Assembly

The door lock cylinder assembly on convertible and sport coupe front doors is very similar to the cylinder assembly used on the front door of sport sedan styles.

Door Ventilator

Removal and Installation

Same procedure used as for the sedan front doors except there is no upper glass run channel.

Adjustment

Same procedure as for sedan front doors.

Ventilator Regulator

Removal and Installation

Same procedure as for sedan front doors.

Adjustment

Same procedure as for sedan front doors.

Door Window

Removal and Installation

Lower door glass, remove belt finishing molding clips and trim pad. NOTE: On electric window lift, disconnect positive or negative battery cable.
Remove window stops "A" and bumper "B", then remove large access hole cover and tape from circular cutout "H," (fig. 104).
Remove screws at "C" and "H" from each end of sash channel cam and disengage window from sash channel cam.
Lift glass up and tilt to the rear to clear ventilator frame and remove. NOTE: Do not operate electric lift with window removed.
To install, reverse this removal operation and reseal door inner panel.

Adjustment

A cocked glass in run channel, may be corrected by loosening the stationary cam rear screw at "D" and adjust cam up or down as required, then tighten screw (fig. 104).
Compensating adjustments may be made by adjusting the division channel adjusting stud "E" in or out and moving the division channel fore or aft as desired.
Additional adjustment is provided by screws "F" which may be loosened to reposition the rear glass rear channel.

Glass Run Channel

Removal and Installation

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

Window Regulator

Removal and Installation

Remove trim pad, both access hole covers and window glass. CAUTION: Do not operate electric lifts with window removed.
Remove stationary cam screws "D", and disengage cam from regulator arm and remove. Disconnect motor leads on electric lift bodies through small access hole (fig. 104).
Disengage window sash channel cam from regulator arms and remove.
Remove division stud and nut "E" and regulator attaching screws "G", carefully remove regulator through large access hole.
To install, reverse this procedure, reseal and lubricate as specified.

Side Roof Rail Mechanical Sealing Strip

Special Coupe

Removal

Remove screws "A" and "B" and remove front and rear outer weatherstrip (fig. 105).
Remove screws "C" and remove sealing strip and attached gasket.

Installation

Clean old sealer from side roof rail and gasket. If gasket was removed, discard double coated tape from sealing strip.
Tape sealing assembly with flipper section held in the closed position.
Cement rubber gasket to sealing strip with a good weatherstrip adhesive by applying a film of adhesive to the sealing strip. NOTE: Do not apply cement to lip or awning of gasket nor to hinge portion of strip. Position gasket so it lies flat and the awning of lip is over the radius of the sealing strip hinge.
Apply bead of caulking compound along outside edge of gasket (fig. 106).
Position sealing strip assembly to side roof rail and install retaining screws snugly.
Apply weatherstrip adhesive to attaching surfaces of front and rear outer weatherstrips and install to body.
Align sealing strip with top of door window and ventilator, then uniformly tighten all attaching screws.
Lubricate inner side of awning with rubber lubricant.

Inner Panel Sealing

Special Coupe and Convertible

Whenever the sealing of the inner panel is disturbed, the inner panel should be resealed as outlined below (fig. 107).

Nomad Station Wagon

FRONT DOOR ASSEMBLY

Since the Nomad front door is much the same as the Convertible and Sport Coupe front door, most service procedures will be the same as already covered in that section.

The side roof rail weatherstrip shown here is peculiar to the Nomad Station Wagon.

Side Roof Rail Weatherstrip

The side roof rail weatherstrip consists of one section of a fabric covered rubber designed with a metal insert formed to the contour of the side roof rail. The weatherstrip is secured to the side roof rail with screws installed through the weatherstrip, into the side roof rail.

Removal

Remove screws securing weatherstrip to side roof rail and carefully remove weatherstrip.

Installation

Clean off old sealer from weatherstrip and side roof rail.
Apply bead of caulking compound along length of weatherstrip indicated at "1" in fig. 108. Apply seal along line just outboard of attaching holes as shown at "2" in section "B-B" and "C-C."
Assemble weatherstrip to side roof rail. Install attaching screws loosely, adjust weatherstrip as required, then tighten screws.
Clean off excess sealer.

Adjustments

To adjust side roof rail weatherstrip inboard or outboard, loosen attaching screws and position weatherstrip as required, then tighten screws.
To adjust side roof rail weatherstrip downward, loosen weatherstrip, and insert waterproof shim as required between weatherstrip and side roof rail.

Rear End Assembly

Back Window Assembly
Rear Compartment Assembly

Back Window Assembly

BACK WINDOW ASSEMBLY ALL STYLES BUT SPORT SEDAN

The back window consists of a large one-piece glass secured in the body opening by a one-piece rubber channel. Fig. 109; shows how the glass is retained by the back window reveal moldings, which consist of a one-piece upper reveal, right and left lower reveal, and a right and left corner reveal escutcheon. The removal and installation of the moldings and the glass is outlined and illustrated in this section.

BACK WINDOW ASSEMBLY

Back Window Garnish Moldings

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

Removal and Installation

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

Back Window Reveal Moldings

The back window reveal moldings are secured to the body by a combination of bolt and clip assemblies and clips. Each corner reveal escutcheon is secured by one bolt and clip assembly. The upper and lower reveal moldings are retained by one of two alternate methods depending on the assembly plant option. These optional methods control the removal and installation of the moldings as described below and in fig. 110 which shows typical sections taken through the back window glass, rubber channel and reveal molding.

Upper Reveal Moldings

Ist Assembly Method

Molding secured by clips which allow moldings to be removed from rubber channel before removing back window. This is the standard production method.

2nd Assembly Method

Molding secured by clips in rubber channel which require removal of back window in order to remove moldings from rubber channel. This method is optional, to be used only in production emergencies.

Lower Reveal Moldings

Ist Assembly Method

Lower moldings secured to body by clips which allow moldings to be removed without removal of back window as in Method 1 for upper reveal. Moldings may also be held to the body opening by three screws in production emergencies in conjunction with this method, necessitating the removal of the back window and rubber channel from the body opening before the molding can be removed.

2nd Assembly Method

Moldings secured to body by clips in rubber channel which require removal of back window in order to remove moldings from the rubber channel.

Removal and Installation

See fig. 110.

Mask off the outside body surfaces around the rear window opening to protect the paint finish and place a protective covering over rear compartment lid.
On sedan styles place protective covering over rear seat cushion and back and parcel shelf. On these styles no garnish molding removal is necessary. On coupe styles remove rear seat cushion and back, rear quarter belt finishing moldings, and then remove back window garnish moldings.
Turn back inner lip of rubber channel and remove corner reveal escutcheon attaching nut at each side, then remove escutcheons.
To remove upper reveal molding, place suitable flat-bladed tool between edge of roof panel and upper reveal molding, then carefully attempt to pry molding from body opening. NOTE: Molding should lift freely from rubber channel if installed with Clip No. 1. If optional Clip No. 2 was utilized in installation, the molding will not lift. In these cases, press upper edge of back glass out of body opening to remove molding from rubber channel.
To remove the lower reveal moldings insert a flat-bladed tool between rubber channel and molding, and carefully attempt to pry molding from body opening. NOTE: Moldings installed by 1st assembly method utilizing Clip No. I should readily pry loose. Moldings which do not pry loose may be attached to the body by screws in conjunction with the first assembly method, or held to the rubber channel by Clip No. 2, in conjunction with the 2nd assembly method.
When lower moldings do not pry loose, remove the back glass from the body, as outlined in "Back Window." NOTE: If moldings come out with back glass assembly, remove them separately from the rubber channel. If moldings do not come out, remove molding attaching screws for complete removal of moldings from body.
To install moldings, apply medium-bodied sealer around base of corner reveal molding bolt and reverse removal procedure. If lower reveal moldings were attached with screws, they must be screwed in place prior to glass installation. If lower reveal moldings and glass assembly were removed, seal window opening as specified in "Back Window."

Back Window Glass and Rubber Channel

Removal-Fig. 110

Place protective covering over the painted surfaces below the back window and over parcel shelf. On two- and four-door sedan styles cover the rear seat back and cushion. On coupe styles remove rear seat cushion and back, rear quarter belt finishing moldings, and back window garnish moldings.
Remove back window corner reveal escutcheon and if possible upper reveal molding. See "Back Window Reveal Moldings." Break seal between rubber channel and pinchweld flange around perimeter of glass. On sedan styles disengage garnish rubber lip from position over headlining rear edge.
From inside of body carefully push upper edge of window and channel outward until lip of rubber channel is disengaged from pinchweld flange.
With aid of helper, lift complete assembly from body opening. NOTE: Because lower reveal moldings may be secured to body with screws it is necessary to lift the back window and rubber channel up and over the molding when removing them from the body opening.
Place assembly on a covered bench or stand. If necessary, remove lower reveal moldings and clips from rubber channel, then remove rubber channel from glass.

Installation

Clean original sealer from back window body opening and rubber channel. Check body pinchweld flange for irregularities and correct if present. Check back window gutter and drain hoses for any obstructions and clean out if necessary.
Assemble rubber channel to glass.
Check reveal attaching clips for secureness at upper and lower pinchweld flange on installations utilizing Clip No. 1. When installing lower molding with Clip No. 2, be sure clips are properly secured to moldings, then apply medium-bodied sealer to clips as at "1" and install to rubber channel.
Insert a strong cord into pinchweld cavity of rubber channel and bring both ends around to the bottom center of the glass. Tie ends of cord together and tape to the glass.
Apply a bead of medium-bodied sealer to the base of the rubber channel, completely around its perimeter. Also apply a heavy bead of medium-bodied sealer at the rabbet (cross-section 2) of the pinchweld flange around the entire perimeter of the window opening. NOTE: In cases where upper or lower reveal molding clips of type No. 1 have been replaced, install a bead of medium bodied sealer in the corner of the clip and connect this bead of sealer with the sealer previously applied to the corner of the back window opening rabbet.
With the aid of a helper, place back window assembly into the body opening. On sedan styles, while helper is applying pressure to outside surface of glass, carefully draw large garnish lip of rubber channel over pinchweld into body.
Pull ends of cord from the pinchweld cavity of the rubber channel on inside of body to seat channel over the pinchweld flange around perimeter of glass.
Install reveal moldings, being sure to apply medium-bodied sealer to base of comer reveal escutcheon studs.
Apply approved weatherstrip cement between glass and the outer lip of the rubber channel completely around the perimeter of the glass.
Clean off excess cement and sealer. On coupe styles install garnish moldings and replace rear seat back and cushion and rear quarter belt finishing moldings. On sedan styles draw inner rubber garnish lip into position over headlining rear edge as shown in fig. 110, and remove all protective coverings and masking tape.

BACK WINDOW ASSEMBLY-SPORT SEDAN

The back window consists of a large, one-piece glass secured in the body opening by a one-piece rubber channel. Fig. 111 shows the glass and back window reveal moldings installed in the body. The removal and installation of the moldings and the glass is outlined and illustrated in this section.

Reveal Moldings

Each back window side reveal molding is secured by bolt and clip assemblies with attaching nuts on the inside of the body. See fig. 112.

Removal and Installation

Apply masking tape to body surface adjacent to the back window upper and lower reveal moldings and place protective covering over the rear compartment lid.
On inside of body, remove rear seat cushion and back, and on 2400 style, the right and left side roof rail rear finishing molding. Remove garnish moldings.
At right and left corner of back window, turn back inner lip of rubber channel to expose two nuts securing the back window side reveal molding, then remove attaching nuts.
Loosen rear end of side roof rail weatherstrip and remove screws securing back window side reveal molding, then carefully disengage molding from back window upper and lower reveal and side roof rail molding.
Insert a suitable flat-bladed tool between upper reveal molding and panel, as shown in fig. 113, and carefully pry molding from clips installed to pinchweld flange.
Slide back window lower reveal molding escutcheon to left reveal molding, then starting at the rear end of the molding, insert flatbladed tool between top portion of molding and channel and carefully pry each molding from clips installed to channel retainer. In addition, disengage front end of molding from slide-in clip secured to the body.
To install moldings, reverse removal procedure.

Back Window Glass

Removal

Place protective covering over rear compartment lid.
On inside of body, remove rear seat cushion and back and back window garnish moldings, then carefully break seal between inner lip of rubber channel and pinchweld flange around perimeter of glass.
Remove back window reveal moldings as outlined in "Back Window Reveal Moldings."
From inside of body, carefully push upper edge of window and channel outward until lip of rubber channel is disengaged from pinchweld flange.
With aid of helper, lift complete assembly from body opening and place on covered bench, then remove channel from glass.

Installation

Clean original sealer from back window body opening and rubber channel. Check body pinchweld flange and channel retainer for irregularities and correct if present. Check back window gutter and drain hoses for any obstructions and clean out if necessary.
Check installation of clips at pinchweld flange and channel retainer. If replacing clips, apply medium-bodied sealer to opening rabbet as Shown at "1" in View "A," fig. 114.
Insert strong cord into pinchweld cavity of rubber channel, tie ends together and tape them to bottom center of glass.
Apply bead of medium-bodied sealer to corner of back window opening rabbet, as indicated at "2" in Section "A-A" and View "A" in fig. 114, completely around perimeter of opening.
Apply bead of medium-bodied sealer to base of rubber channel as indicated at "3" in Section "A-A" completely around perimeter of glass.
With aid of helper, place back window assembly into body opening. While helper is applying pressure to outside surface of glass, carefully pull ends of string to seat lip of rubber channel over pinchweld flange and channel retainer.
Install back window reveal moldings. Apply weatherstrip, cement between rubber channel and glass as indicated at "4" in Section "A-A."
Clean off excess cement and install previously removed parts.

Rear Compartment Assembly

Rear Compartment Lid

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

Removal and Installation

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

Rear Compartment Lid Hinge

Removal

Place protective covering over paint finish at working area and place a suitable support under lid near the hinge being removed.
Scribe location of hinge strap on lid inner panel, then remove strap to lid retaining bolts.
Remove screws for the torsion rod cover at the left hinge (see insetfig. 115) and remove cover.
Mark notch engaging torsion rod, then install a suitable length of pipe over end of torsion rod and disengage torsion rod from retaining notches at inboard face of the opposite hinge box (fig. 116).
Disengage torsion rod from movable portion of hinge strap and remove rod.
Bend up hinge pin retaining tab "A" and remove pin, then remove hinge from hinge box. Figure 117 shows the various positions for adjusting the torsion rod.

Installation

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

Lid Lock Cylinder

Removal and Installation

Insert suitable hooked tool through inner panel of lid and pull lock cylinder retainer away from cylinder. See inset in figure 118.
Remove lock cylinder and gasket from lid outer panel.
To install, reverse this procedure, after sealing at cylinder opening in outer panel.

Lid Lock

Removal and Installation

Remove lock cylinder from compartment lid.
Remove lid lock and cover plate screws "B" and "C" and remove lock and cover plate assembly (fig. 118).
To install, reverse this procedure.

Rear Compartment Lid Weatherstrip

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

Removal

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

Installation

Service replacement weatherstrips are longer required, but should not be cut until weatherstrip is installed.

Locate two clip holes indicated at "A" in figure 119 near the lid lock bolt. These holes are closer together than the others.
Insert second clip on weatherstrip into clip hole "B" by placing notch of Tool 5757 on loop of clip and snapping clip to place. Do not use excessive force or clip may be distorted resulting in improper weatherstrip retention. This places the butt joint of the weatherstrip between clip holes "A".
Install all clips except those to be inserted into clip holes at "A".
Accurately cut and trim weatherstrip to proper length and apply weatherstrip adhesive to the surface of the compartment lid, a distance of 2% inches on each side of the butt joint.
Apply weatherstrip adhesive to the butt ends of the weatherstrip and install last two clips. NOTE: Ends should match evenly to provide a continuous seal.

Adjustments

Compartment Lid

Rear compartment lid may be adjusted forward, rearward or to either side by loosening hinge strap attaching bolts and shifting the lid in the desired direction and retighten bolts. Fig. 122

To raise or lower the lid at the hinge area, place shim under strap at "A" to raise the lid and at "B" to lower the lid fig. 120 . A combination of shims may be used under the lid hinge strap to tilt the lid in its opening. Lid Lock Bolt and Striker Engagement Check may be made by insert modeling clay, as shown infigure 121. Close the lid with moderate force, open the lid and check the engagement by measuring the distance between "U" in the clay and the base of lock. This dimension should be 1/8" to 5/32"- If necessary, adjust striker as follows:

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

Compartment Lid Torsion Rod

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

By placing the torsion rod in position three (fig. 117) the amount of effort required to open the lid is the least and conversely the amount of effort to close the lid the greatest. It is not necessary to adjust right and left rods at the same time, nor is it necessary to have the same final position of adjustment on both rods. If adjustment is required at the left hinge box it is necessary to remove the torsion rod cover.

Back Window Gutter Drain Hose

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

Removal

From inside rear compartment, remove drain hose from rear quarter inner panel (fig. 123).
Remove rear seat cushion, back and back window garnish moldings.
With a wide blade putty knife or some other suitable tool, carefully separate cemented parcel shelf trim from metal.
Loosen the cemented upper end of drain hose at "A" and carefully remove hose from outlet (see inset).

Installation

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

Rear Quarter Assembly Sedan Rear Quarter Assembly

Sport Coupe Rear Quarter Assembly
Station Wagon Rear Quarter Assembly

Sedan Rear Quarter Assembly

Rear Quarter Trim Panel

Two Door Sedan

Removal and Installation

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

Rear Quarter Trim

Four Door Sedan

Removal and Installation

Remove rear seat cushion and back.
Remove rear quarter window garnish molding.
Remove one drive nail from the upper rear comer of the trim panel.
Swing the rear edge of the trim panel forward to expose the tacks attaching the front edge of the panel to the rear body lock pillar.
Remove tacks attaching front edge of panel to lock pillar and remove panel from body.
To install, reverse procedure.

Rear Quarter Window

Two Door Sedan

The rear quarter window lower sash channel cam is welded to the lower sash channel in place of being attached by screws as on past styles. This change necessitates new service methods.

Removal and Installation

Operate rear quarter window to "up" position. On electric styles, disconnect positive battery cable to prevent accidental operation of window.
Remove rear seat cushion and back, rear quarter window garnish molding and, when present, remove rear quarter arm rest.
Remove rear quarter trim panel. NOTE: On electric styles, carefully disengage switch from switch terminal block.
Remove access hole cover.
Detach window front and rear guides from inner panel and disengage guides from window sash channel rollers.
On electric styles, temporarily connect power supply and carefully lower window to "halfdown" position, then disconnect power supply. On manual styles, lower window to "half-down" position.
Rotate rear edge of window upward until window lower sash channel cam is disengaged from window regulator arm roller, then remove window from body. CAUTION: On bodies equipped with electrically powered window regulators DO NOT OPERATE REGULATOR MOTOR after window assembly is disengaged from regulator. Operation of motor with load removed may damage the unit or make it inoperative.
To install, reverse removal procedure.

Adjustment

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

Rear Quarter Stationary Window

Four Door Sedan

Removal

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

Installation

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

Rear Quarter Window Regulator Two Door Sedan

Removal and Installation

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

Rear Quarter Glass Run Channel Two Door Sedan

Removal and Installation

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

Sport Coupe Rear Quarter Assembly

Belt Finish Molding

Removal and Installation

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

Quarter Arm Rest

Removal and Installation

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

Quarter Trim Panel

Removal and Installation

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

Quarter Window

Removal and Installation

Remove rear seat cushion, back, quarter hardware, arm rest, trim panel and access hole cover. NOTE: On electric quarter window lifts disconnect switch terminal and positive or negative cable of battery.

With window in up position remove window rear guide screws "A" and remove guide (fig. 124).
Lower window so the regulator roller cam can be disengaged from window channel. NOTE: Temporarily hook up power supply on electric lifts to lower window or install regulator handle on manual lifts.
Disengage front roller from guide channel and remove quarter window.
To install, reverse the removal operation.

Adjustments

Fore and Aft - Loosen rear guide channel screws "A" and "B" and front guide channel screws "C" and "D." Move window fore or aft as desired (fig. 125).

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

To move window in or out at the rear area, loosen stud nut "A" and turn adjusting stud in or out, then tighten lock nut.

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

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

Electric Window Regulator

Removal and Installation

Remove quarter window.
Remove access hole cover and disconnect motor wire.
Remove regulator attaching screws "A" and remove regulator (fig. 126).
To install, reverse this procedure, then reseal access hole cover and regulator attaching screws.

Window Guide-Rear

Removal and Installation

Remove rear seat cushion, back, quarter hardware and trim.
Remove access hole cover and with the window in the up position, remove attaching screws "A" ( fig. 127).
Disengage rear guide from window roller and remove guide from body.
To install, reverse this procedure.

Window Guide-Front

Removal and Installation

Remove quarter window and regulator.
Remove front guide screws "B" and remove guide from body through access hole (fig. 127).
To install, reverse this procedure.

Window Sealing Strip

Removal and Installation

With the window in the down position remove the side roof rail mechanical sealing strip.
Remove rear seat cushion, back, quarter belt finishing molding and side roof rail finishing molding.
Remove side roof rail near finishing moldings.
Remove screws attaching inner extension and outer extension.
Remove screws attaching sealing strip, pull sealing strip forward to disengage from outer molding and remove.

Adjustment

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

Convertible Rear Quarter Assembly

Folding Top Compartment Side Trim Panel

Removal and Installation

Remove rear seat cushion and back, on left side of body, disconnect courtesy lamp switch.

Remove attaching screws and top compartment side trim panel.

To install, reverse this procedure.

Trim Panel

Removal and Installation

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

Quarter Window-Electric and Manual

Removal and Installation

Remove rear seat cushion and back, then lower the folding top.
Place window in the half way position, on electric models disconnect positive battery cable.
Remove top compartment side trim panel and belt finishing molding. Break window switch circuit at terminal block and pivot quarter trim away from quarter inner panel.
Remove pivot bolt "A" and disengage male hinge from female hinge (fig. 128).
Disengage window lower sash channel cam from regulator arm and lift upward to remove from between quarter inner and outer panels.
Remove window from body, exercise caution to prevent scratching of glass on window stop. Disconnect power supply from electric lift.
To install, reverse this procedure.

Adjustment

In or Out - Loosen pivot bolt "A" and adjust stud nuts "B" in or out. Retighten lock nuts and pivot bolt (fig. 128).

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

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

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

Window Regulator

Removal and Installation

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

Window Guide

Removal and Installation

Remove quarter window.
Remove guide screw "B" at quarter lock pillar, two upper attaching screws at "C" and center stud nut and washer at "D" (fig. 129).
Remove guide assembly from window opening.
To install, reverse this removal procedure.

Station Wagon Rear Quarter Assembly

Rear Quarter Window Garnish Moldings

4 Door

Removal and Installation

The garnish moldings are secured to the body with screws, and consist of a garnish molding front and rear, and a garnish molding upper and lower escutcheon. To remove moldings, remove escutcheons and molding attaching screws. To install moldings, reverse removal procedure.

Rear Quarter Trim-4 Door

The rear quarter trim consists of a rear quarter side panel front and rear as shown in Fig. 130.

Removal and Installation

Remove rear quarter window garnish moldings. Disengage folding seat back from folding seat back retainers and remove retainers.
Remove screws securing side panels along wheelhouse. Remove side panel rear and rear quarter window front regulator handle.
With suitable tool, carefully pry front edge of side panel front from body lock pillar. On electric styles, disconnect window control switch from terminal block.
Carefully lift panel to disengage remaining tabs and remove panel from body.
To install, reverse removal procedure. Before installing trim, apply sealer around trim and seat back retainer attaching screw holes in inner panel.

Rear Quarter Window-4 Door

The one-piece, stationary, rear quarter window is secured in the body opening by a rubber channel. In addition, metal retainers are installed inside the body along the rubber channel to secure the assembly in place.

Removal

Remove rear quarter window garnish moldings and metal retainers along rubber channel.
With suitable tool, carefully break seal between rubber channel and body metal around perimeter of rear quarter window.
With helper supporting glass on inside of body, carefully push rear quarter window with rubber channel toward inside of body.
Remove channel and glass from body and place on a covered bench, then remove rubber channel from glass.

Installation

Clean off old sealer from body and rubber channel.
Check rubber channel and rear quarter window opening for any irregularities and correct if present.
See fig. 131. Apply bead of medium-bodied sealer along wall of rabbet as indicated at "1" in Section "A-A" completely around perimeter of glass.
Install rubber channel to glass, then install assembly into window opening in body.
See fig. 131. Apply good weatherstrip cement between rubber channel and glass as indicated at "2" in Section "A-A", around perimeter of glass.
Install metal retainers along rubber channel, clean off excess sealer, and reinstall garnish moldings.

Rear Quarter Window Garnish Moldings 2 Door

Removal and Installation

The garnish moldings are secured to the body with screws, and consist of a garnish molding front and rear, and a garnish molding upper and lower escutcheon. In addition, a molding is installed along the rear quarter window division rail between the rear quarter window front, and rear quarter window rear. To remove moldings, remove escutcheons and molding attaching screws. To install moldings, reverse removal procedure.

Rear Quarter Trim-2 Door

The rear quarter trim consists of a side panel front and rear, and wheelhouse finishing panel as shown in fig. 132. On 2400 styles, the wheelhouse is covered with trim.

Removal and Installation

Remove rear quarter window garnish moldings. Disengage folding seat back from retainers and remove retainers.
Remove screws securing wheelhouse finishing panel and remove panel.
Remove screws along wheelhouse securing side panel front and rear.
Remove screws securing finishing molding at rear edge of side panel and remove molding to expose tacks.
Carefully remove tacks securing rear edge of side panel rear and remove side panel.
With suitable tool, carefully pry front edge of side panel front from trim stick on body lock pillar and remove panel.
To remove wheelhouse trim, remove folding seat back from body, remove floor finishing moldings along bottom of wheelhouse panel and remove tacks securing bottom edge of trim. Carefully break cement bond along upper edge of wheelhouse trim and remove from body
To install, reverse removal procedure. Before installing trim, apply sealer around trim and seat back retainer attaching screw holes in inner panel.

Rear Quarter Window Front and Rear

1500 2 Door

The above style incorporates a stationary rear quarter window front and rear. To remove either window, remove garnish moldings and outer division molding inner retainer, then follow procedure outlined for the rear quarter window on 4 door styles.

Rear Quarter Window Front and Rear

2100 2 Door

The above style incorporates a movable rear quarter window front and a stationary rear quarter window rear. To remove the stationary rear quarter window, remove the outer division molding inner retainer and follow the procedure outlined for the rear quarter window on the 2400 4 door styles. The front window is the dropping type and is controlled by a manual or electric window regulator. The procedure for removing the rear quarter front window is outlined below.

Removal and Installation

See fig. 133. Remove escutcheons at top and bottom of rear quarter window inner division molding, then remove molding and outer division molding inner retainer.
Remove rear quarter window front garnish molding.
Remove two screws securing glass run channel along front edge, then carefully pry channel with attached clips from opening and pull upward to remove from retainer.
Carefully pry glass run channel rear with attached rosebud clips from body and pull upward to remove from retainer.
Remove rear quarter side panel front from body. See "Rear Quarter Trim."
Remove large access hole cover and tape covering small access hole "A".
Lower window until cam to window sash channel support attaching screws "B" are visible. On electric styles, disconnect positive battery cable.
Remove sash channel support attaching screws "B" and disengage supports from cam channel, then pull glass upward and tilt inward to remove from body. CAUTION: On electric styles, DO NOT OPERATE REGULATOR MOTOR after the window assembly is disengaged from the regulator or as a bench operation after the regulator is removed from the rear quarter. Operation of the motor with the load removed may damage the unit and make it inoperative.
To install, reverse removal procedure. Seal inner panel openings. See "Rear Quarter Inner Panel Sealing."

Adjustments

To correct a condition where the glass is it cocked" in the glass run channels, loosen rear quarter inner panel cam rear attaching screw "C", fig. 133, and adjust rear of cam up or down as required, then tighten screw.

Rear Quarter Window Front-Regulator

(Manual and Electric)-2100 2 Door

The rear quarter window regulator is similar to the door window regulator. An electrically powered window regulator is available as an option.

Removal and Installation

See fig. 133.

Remove escutcheons at top and bottom of rear quarter window inner division molding, then remove molding and outer division molding inner retainer.
Remove rear quarter window front garnish molding.
Remove rear quarter side panel front from body. See "Rear Quarter Trim."
Remove large access hole cover and tape covering small access hole "A".
Lower window until cam to window sash channel support attaching screws "B" are visible. On electric styles, disconnect positive battery cable.
Remove sash channel support attaching screws "B" and disengage supports from cam channel, then prop glass in "up" position. CAUTION: On electric styles, DO NOT OPERATE REGULATOR MOTOR after the window assembly is disengaged from the regulator or as a bench operation after the regulator is removed from the rear quarter. Operation of the motor with the load removed may damage the unit and make it inoperative.
Remove rear quarter inner panel cam attaching screws "C".
Working through loading hole, remove quarter window lower sash channel cam and rear quarter inner panel cam from regulator.
On electric styles, disconnect regulator electric motor leads from wire harness.
Remove regulator attaching screws "D" and carefully remove regulator assembly from between quarter panels through large access hole. NOTE: The procedure for removing the electric motor from the regulator is the same as performed an the electric door window regulator.
To install, reverse removal procedure. Seal inner panel opening. See "Rear Quarter Inner Panel Sealing."

Rear Quarter Window Front-Glass Run Channels-2100 2 Door

The run channel for the rear quarter window consists of a front and rear section. The front glass run channel extends along the front and upper edge of the window and is secured in place by two screws and snap-in clips. The rear glass run channel extends along the rear edge of the window and is secured in place with rosebud clips. The lower portion of both glass run channels is secured by a retainer. Figure 133 shows the front and rear glass run channels.

Removal and Installation

Remove escutcheons at top and bottom of rear quarter window inner division molding, then remove molding and outer division molding inner retainer.
Remove rear quarter window front garnish molding and garnish molding spacing clips.
Carefully pry glass run channel rear with attached rosebud clips from opening and pull upward to disengage lower portion of channel from retainer.
Remove two screws securing front glass run channel, then carefully pry channel with attached clips from opening and pull upward to disengage lower portion of channel from retainer.
To install reverse removal procedure.

Rear Quarter Window Garnish Moldings Nomad

Removal and Installation

The rear quarter window garnish moldings are secured to the body with screws and consist of a garnish molding front, garnish molding upper and lower front, garnish molding upper and lower rear, and garnish molding rear. To remove moldings, remove lift gate opening upper finishing molding and remove garnish molding attaching screws. To install moldings, reverse removal procedure.

Rear Quarter Trim-Nomad

Removal and Installation

The rear quarter trim consists of a side panel front and rear, and wheelhouse trim. The removal and installation of the side panel trim is similar to the procedure outlined for the rear quarter trim on the 2 door styles. The wheelhouse trim is removed in the same manner as outlined for the 2400 4 door style.

Rear Quarter Sliding Window and Rear

Quarter Window Rear-Nomad

The Nomad incorporates a sliding rear quarter window front, and a stationary rear quarter window rear. The stationary rear quarter window is removed and installed in the same manner as outlined for the stationary rear quarter window on 4 door styles. However, it is necessary to remove the rear quarter sliding front window before the stationary rear quarter rear window can be removed. The procedure for removing the rear quarter sliding front window is outlined below.

Removal and Installation

Remove rear quarter window garnish moldings.
Remove screw securing stop at rear end of lower glass run channel, then remove retainers securing rear portion of lower glass run channel.
Carefully pull loose portion of lower channel with glass toward inside of body, then disengage glass from upper and lower channels.
To remove rear quarter window rear, see "Rear Quarter Window" for 4 door style.
NOTE: When reinstalling rear window, be sure to install chrome molding with inner sealing strip to front edge of rear window channel.
To install windows, seal stationary window as specified and reverse removal procedure.

Rear Quarter Sliding Window Glass Run
Channels-Nomad

The rear quarter window glass run channels consist of an upper and lower section. The upper channel is secured by rosebud clips at the front end and by screws at the rear end. The lower channel is secured by rosebud clips at the front end and by retainers and a window stop at the rear end.

Removal and Installation

Remove rear quarter window garnish mold- ings.
Remove rear quarter window front as out- lined above.
To remove lower channel, disengage rosebud clips securing forward portion of channel to body.
To remove upper channel, remove attaching screws at rear end of channel, then disen- gage rosebud clips securing forward portion of channel.
To install, reverse removal procedure. Rear Quarter Inside Side Panel Moldings- Sedan Delivery

Removal and Installation

The rear quarter inside side panel moldings are secured with screws, Fig. 134 and consist of front and rear vertical moldings, upper and lower front moldings, upper and lower rear moldings, and escutcheons. To remove moldings, remove attaching screws. To install moldings, reverse removal procedure.

Rear Quarter Inside Side Panel - Sedan Delivery
Removal and Installation

The side panel consists of a foundation board, and is secured in place by three screws and by moldings installed along the edges of the panel as shown in the illustration above. To remove panel, remove screws indicated at "1", Fig. 134and the side panel moldings. To install, reverse removal procedure.

Rear Quarter Inner Panel Sealing

When ever work is performed on a rear quarter where the inner panel seals have been disturbed, the area must be resealed before the rear quarter trim is reinstalled. Fig. 135 shows the rear quarter inner panel openings which are sealed to prevent water leakage and possible damage to the trim.

All Styles

Apply medium-bodied sealer to seat back re- tainer attaching screws.
Apply bead of medium-bodied sealer around edge of cover plate to effect a seal between cover and inner panel.
Apply medium-bodied sealer to all trim panel attaching screw holes.
21002 Door
Apply bead of medium-bodied sealer along contacting surface of inner panel completely around access hole to effect a seal between cover plate and inner panel.
Apply body caulking compound to window regulator attaching holes and rear quarter inner panel cam attaching holes.
Apply water proof body tape over cam access hole.
On styles equipped with manual regulator, apply good weatherstrip cement over exposed surface of regulator spindle hole sealing washer.
On 2 door styles, apply waterproof body tape over gage hole.

Tail Gate Assembly-All Styles

The tail gate is secured to the body by two hinges located at the lower edge of the tail gate. Support cables with reel assemblies located between the inner and outer quarter panels support the tail gate when it is in the open position.

Removal

Either of the following two methods may be used to remove the tail gate from the body.

Tail gate and hinges may be removed as an assembly from the body.
Tail gate may be removed from the hinge straps.

Lower tail gate and raise lift gate.
Suitably support tail gate in open position to prevent damage to tail gate outer panel.
At each side of tail gate remove two screws "A", fig. 136, securing tail gate support retaining plate, then allow the reel to draw cable with support and retaining plate, until retaining plate contacts cable guide on body lock pillar.
If removing tail gate from hinge straps, carefully pry hinge escutcheons from tail gate outer panel. Loosen tail gate weatherstrips at hinge areas sufficiently to remove both hinge cover plates and remove hinge cover plates.
If removing tail gate and hinges, remove both cover plates from body.
Clean off excess sealer from edge of both hinge straps at body or tail gate, then scribe location of hinge straps.
Remove hinge attaching screws and remove tail gate from body.

Installation

Apply heavy-bodied sealer to contacting surface of both hinge straps as indicated at "1", fig. 137.
With aid of helper lift tail gate into position. Install attaching screws loosely, then align hinge straps within scribe marks and tighten screws. Check tail gate for alignment.
Before hinge cover plates are installed, tail gate hinges must be sealed with medium bodied sealer or caulking compound as outlined below (fig. 138):
- Apply body caulking compound in corners of hinge depression as indicated at "1".
- Apply continuous ribbon of medium bodied sealer along outside surface of cover plate flange as indicated at "2" and along inside surface of cover plate as indicated at "3"., Seals should connect with seal applied in corners of hinge depression. Seal cover plates on tail gate side in similar manner.
Install hinge cover plates and support cable retaining plates. Clean off excess sealer.

Adjustments

Remove both tail gate lock strikers.
To adjust tail gate sideways in the opening or to adjust bottom of tail gate forward or rearward, remove hinge cover plates and loosen hinge-to-body attaching screws. Adjust tail gate as required, then tighten hinge attaching screws. Reseal and install cover plates.
Reinstall tail gate lock strikers.
To adjust upper portion of tail gate forward or rearward, loosen screws securing both tail gate lock strikers. Adjust strikers as required then tighten screws. The strikers may also be adjusted up or down. See "Tail Gate Lock Striker" for additional adjustments.
The tail gate bumper stop support "B", fig. 136, may be adjusted fore or aft. The bumper should contact rabbet on body lock pillar when tail gate is closed.

Tail Gate Lock Outside Handle All Styles But Nomad

The tee-type handle is located at the upper center of the tail gate outer panel and is secured by two screws. The handle operates as follows:

When the handle is turned, the handle shaft actuates the remote control levers to which the connecting rods are attached. The connecting rods trip the lock lever at each side of the tail gate, thereby disengaging the lock bolt from the striker.

Removal and Installation

Lower tail gate and remove access hole cover "A", fig. 139.
Remove remote control assembly attaching screws, then lift remote control and disengage it from connecting rods.
Remove two screws securing handle to tail gate outer panel and remove handle and gasket from tail gate.
To install, reverse removal procedures. Be sure to reinstall clips at ends of remote control connecting rods.

Tail Gate Lock-All Styles

Removal and Installation

See fig. 139.

Remove access hole cover "A" and remove remote control assembly.
Remove four screws "B" securing lock, then remove lock and remote control connecting rod from tail gate.
To install, reverse removal procedure. Be sure to install clips at ends of remote control connecting rods.

Tail Gate Lock Striker-All Styles

Removal and Installation

Open tail gate and with pencil scribe the location of striker on body pillar.
Remove four screws "A", fig. 140, and remove striker and adjusting plates from body pillar.
To install, place striker and adjusting plates within scribe marks on body pillar and install screws.

Adjustments

To adjust tail gate lock striker up or down, or forward or rearward, loosen striker attaching screws "A", fig. 140, locate striker as required, then tighten screws.
To check engagement of tail gate lock with striker, proceed as follows:

Insert small quantity of modeling clay or its equivalent to bottom of lock bolt slot as shown in inset of fig. 140.
Close tail gate with moderate slam.
Open tail gate and measure distance "X" indicated in illustration Fig. 141 -Tail Gate Outside Handle-Nomad. Distance "X" should be 3/16" to 5/16" If distance is greater, install emergency spacer between striker and adjusting plates to obtain proper engagement.

Tail Gate Outside Handle-Nomad

The stationary-type, vertical handle, shown in fig. 141, is located on the tail gate outer panel directly below the push button, and is secured by two screws. To remove handle from the tail gate, it is necessary to remove tail gate access hole cover and remote control assembly to gain access to the handle attaching screws.

Removal and Installation

Remove tail gate access hole cover.
Remove four screws securing remote control assembly to inner panel and push button housing, then disengage remote control assembly from connecting rods and remove from tail gate.
Working through access hole, remove two screws securing tail gate handle and remove handle.
To install, reverse removal procedure. Be sure to install clip at ends of remote control connecting rods.

Tail Gate Lock Remote and Push Button

Control Assembly-Nomad

The tail gate lock remote and push button control is located at the center of the tail gate. The assembly operates as follows: When the push button is depressed, the button shaft actuates the remote control levers to which the connecting rods are attached. The connecting rods trip the lock lever at each side of the tail gate, thereby disengaging the lock bolt from the lock striker. When the push button lock cylinder is rotated to the locked position with a key, the push button shaft by-passes the remote levers when the push button is depressed; since the levers are not actuated, the tail gate remains closed. Figure 142 shows the remote and push button control assembly removed from the tail ate.

Removal and Installation

To remove remote control assembly, proceed as follows:
- Remove tail gate access hole cover.
- Remove screws securing control to inner panel and push button housing.
- Disengage remote control from connecting rods and push button shaft and remove from tail gate.
To remove push button assembly, proceed as follows:
- At tail gate outer panel, carefully pry off portion of tail gate outer panel center molding, located above tail gate handle, and remove screw securing push button housing.
- Remove remote control assembly from push button housing and tail gate.
- Remove screw securing upper edge of tail gate handle and lower edge of push button housing, then remove housing from tail gate.
To install, reverse removal procedure. Be sure to reinstall clips at ends of remote control connecting rods.

Push Button

Disassembly and Assembly

Remove push button assembly from tail gate and remote control assembly.
With suitable tool, remove retaining spring from housing, then remove stop washer, spring, detent washer and lock cylinder with push button shaft from housing.
To disassemble lock cylinder assembly, bend open tabs "A", fig. 143, and disassemble cylinder as required.
To install, reverse removal procedure.

Tail Gate Support Cable-All Styles

One end of the cable is secured to the tail gate by a retainer the other end of the cable is secured to a steel tape which is part of a reel assembly installed between the rear quarter inner and outer panels. When the tail gate is lowered, the steel tape unwinds from the reel assembly until the end of the support cable contacts a cable stop. A coil spring, located on the cable between the clevis and cable stop, provides a cushion action for the tail gate when it is in a fully lowered position. When the tail gate is closed, the steel tape winds up in the reel and draws the cable in between the quarter inner and outer panels.

Removal and Installation

Lower tail gate and raise lift gate.
Suitably support tail gate assembly to prevent damage to outer panel.
If the right tail gate support cable is affected, remove the right tail light assembly. Access to the left cable stop and ends of the left support cable and steel tape can be gained from beneath the car.
Disengage support cable from cable stop. Remove cotter pin and clevis pin from ends of cable and steel tape, then with a strong cord or wire, tie end of tape to stationary body part to prevent tape from winding up into the reel.
Remove cable retaining plate screws "A", fig. 136, and retainer from tail gate. Pull cable through cable guide in body lock pillar and remove from body.
To install, reverse removal procedure. Be sure coil spring on cable is located between cable stop and clevis.

Tail Gate Reel Assembly-All Styles Removal and Installation

Lower tail gate and raise lift gate, then suitably support tail gate to prevent damage to outer panel.
If the right reel assembly is affected, remove right tail light assembly from body. Access to the left cable stop can be gained from beneath fender. NOTE: On Nomad styles, a front and rear access hole is provided for removal and installation of the cable and reel.
Remove support retaining plate screws "A", fig. 136, and retainer from tail gate. Pull cable through cable guide in body lock pillar and disengage from cable stop.
Inside of body, remove rear quarter window rear garnish molding and side panel rear. On Nomad styles, remove side panel rear and loosen side panel front sufficiently to gain access to the reel assembly front access hole.
Remove four screws securing tail gate reel cover and support to quarter panel, then pull cover and reel assembly into body. On Nomad styles, remove cable and reel rear access hole cover.
To remove reel from cable, remove cotter pin and clevis pin from ends of cable and reel.
To install, reverse removal procedure. Seal inner panel as specified in "Rear Quarter Inner Panel Sealing".

Tail Gate Weatherstrip-All Styles

The mechanically-retained tail gate weatherstrip consists of a one-piece weatherstrip with an integral wire insert. The weatherstrip, is secured to the tail gate by clips which are formed from the wire insert and snapped into holes around the perimeter of the tail gate. In addition, the weatherstrip is cemented along the bottom of the tail gate, and secured by two screws at each upper corner of the tail gate.

Removal

Remove two screws at each upper comer of tail gate.
Using mechanically-retained weatherstrip inserting tool or other suitable tool, carefully position tip of tool under weatherstrip at each clip location, and snap clip out of hole.

NOTE: At cemented sections of weatherstrip, carefully break cement bond at same time that weatherstrip retaining dip is being snapped from hole.

Installation

Clean off old weatherstrip cement from tail gate.
On Nomad styles, apply bead of weatherstrip cement in corner of rabbet as indicated at "1" in Section "A-A". (Fig. 144.) Seal is to extend four inches in-board from each upper corner of tail gate.
Locate weatherstrip retaining tabs at upper corners of tail gate and using a mechanically retained weatherstrip, inserting tool or other suitable tool, place "V" shaped tip of tool on loop of clip and push clip into hole until it is secured in position. Install weatherstrip along upper edge of gate only. NOTE: Do not use excessive force or strike tool when pushing clips into holes, as it may distort the shape of the clip and result in improper weatherstrip retention.
Apply approved weatherstrip cement following manufacturer's directions, along bottom and side of tail gate as indicated at "2" in Figure "A" and Section "B-B".
Apply bead of approved weatherstrip cement along groove of tail gate weatherstrip, as indicated at "3" in Section "B-B". Apply cement across bottom and radius of outer .lower comers.
Cut ends of weatherstrip as required to form butt joint at bottom of tail gate, then install remaining weatherstrip attaching clips into holes in tail gate inner panel. Apply approved weatherstrip cement to ends of weatherstrip, and form butt joint.

NOTE: An inner weatherstrip is cemented to the inside facing of the back body opening pillar.

Lift Gate Assembly-All Styles But Nomad

The lift gate is secured to the back body opening roof rail by two hinges. A telescoping support at each side of the lift gate locks the lift gate in either a horizontal position or at a position slightly above horizontal. For instructions on locking lift gate in either open position, see "Lift Gate Support".

Removal and Installation

Either of the following two methods may be used to remove the lift gate from the body.

Lift gate may be removed from the hinge straps.
Lift gate and hinges may be removed as an assembly from the body.

If removing lift gate from hinge straps proceed as follows:

Open lift gate to horizontal position.
At each side of lift gate, remove two screws securing support to lift gate, then lower lift gate and remove lift gate window garnish molding.
Scribe location of hinge straps on lift gate. With helper supporting gate remove two screws "A", fig. 145, and reinforcement from each hinge strap and remove lift gate from body.
To install, align hinges within scribe marks and reverse removal procedure.

If removing lift gate and hinges as an assembly from the body, proceed as follows:

Open lift gate to horizontal position.
At each side of lift gate, remove two screws securing support to lift gate, then lower lift gate.
Inside of body, remove both lift gate hinge covers and finishing molding from above lift gate opening.
Detach headlining at hinge areas sufficiently to have access to hinge attaching screws "B", fig. 145.
Scribe location of hinges on body panel.
With helper supporting lift gate, remove hinge attaching screws "B" and remove lift gate.
To install, align hinges within scribe marks and reverse removal procedure.

Adjustments

To adjust top of lift gate forward or rearward, remove back window garnish molding and loosen hinge strap attaching screws. Position lift gate as required, then tighten screws and reinstall back window garnish molding.
To adjust lift gate sideways in the opening, remove hinge covers on inside of body and disengage headlining as required to loosen four attaching screws at both hinges. Position lift gate as required, then tighten screws and reinstall previously removed parts.

Lift Gate Window-All Styles But Nomad

Removal

Close lift gate and remove lift gate window garnish molding and retaining clips.
With suitable flat bladed tool, carefully break seal between rubber channel and metal panel completely around perimeter of window.
With palm of hand, carefully push glass with rubber channel toward front of car and remove glass with rubber channel from lift gate.

Installation

Clean off old sealer from around window opening and rubber channel.
Check window opening and rubber channel for irregularities, and correct if present.
Install rubber channel around glass, then apply weatherstrip cement between rubber and glass as indicated at "1", fig. 146, around perimeter of glass.
Apply bead of medium-bodied sealer around perimeter of window opening in lift gate as indicated at "2".
Install strong cord in rubber channel at outer lip around perimeter of lift gate window as shown at "3", then tie ends of cord to glass.
Install glass with rubber channel in opening, then pull ends of cord to seat lip of rubber channel on outer panel completely around window opening.
Install window retaining clips and garnish molding then clean off excess sealer and cement.

Lift Gate Supports-All Styles

A telescoping support which consist of an inner and outer channel is installed at the left and right side of the lift gate. The end of the inner channel is secured to the lift gate and the end of the lower channel is secured to the body pillar. The support is designed to lock the lift gate either in a horizontal position or in a position slightly above horizontal.

To lock lift gate in full open position, lower tail gate, then, raise lift gate until support stop levers "A" are engaged in slots in outer channel. To unlock lift gate from open position, push stop knobs "A", fig. 147, rearward to disengage stop levers and lower lift gate.

To lock lift gate in horizontal position, lower tail gate and raise lift gate until stop knobs "A" are accessible. Push knobs forward to spring load stop levers, then lower gate until stop levers which are under spring tension engage in slots "B". The gate is unlocked in the same manner as outlined above.

NOTE: Fig. 147 shows the lift gate supports installed on a Nomad style. The supports on other styles are similar.

Removal and Installation

Lower tail gate and lock lift gate in open position.
Remove screws securing ends of support to lift gate and body, and remove support.
To install, reverse removal procedure. Lubricate as required.

Lift Gate Weatherstrips-All Styles But Nomad

The mechanically retained lift gate weatherstrip consists of a one-piece weatherstrip with an integral wire insert. The weatherstrip is secured to the lift gate by clips which are formed from the wire insert and snapped into holes around the top and sides of the lift gate. In addition the weatherstrip is secured in place by two screws at each lower corner.

Removal and Installation

The basic steps of weatherstrip removal and installation are outlined in "Tail Gate Weatherstrip". To seal along top and side of lift gate weatherstrip apply bead of approved weatherstrip cement as indicated at "4" in Section "C-C" in fig. 144.

Lift Gate Assembly-Nomad

The lift gate frame assembly consists of a die cast lift gate window outer frame, right and left side inner frame, and lower inner frame. The assembly is secured to the body roof rail by two hinges which incorporate torque rods to assist in raising the gate. A telescoping support at each side of the lift gate locks the gate open in either a horizontal position, or a position slightly above horizontal. For instructions on locking lift gate in either open position, see "Lift Gate Support". For instructions on disassembling lift gate frame, see "Lift Gate Window".

Removal and Installation

Lock lift gate in open position.
With helper supporting gate in open position, remove three of the four screws securing gate to hinges at "A", fig. 148.
Remove screws securing right and left supports to lift gate, then removing remaining hinge attaching screw from each hinge strap and carefully remove lift gate. Place gate on covered bench.
To install, align hinges within scribe marks and reverse removal procedure.

Adjustments

To adjust lift gate assembly up or down, or sideways, proceed as follows (fig. 149):
- On inside of body, remove lift gate opening upper finishing molding, and detach headlining from trim sticks along length of lift gate opening.
- Scribe location of hinges and loosen screws "A". Adjust lift gate as required, then tighten attaching screws.
- Reinstall previously removed parts.
To adjust closed position of lift gate upper edge forward, perform steps (a) and (b) outlined directly opposite, then loosen hinge attaching screws "A" and install emergency spacers between hinges and roof rail. Tighten attaching screws and reinstall previously removed parts.
To adjust closed position of lift gate upper edge rearward, remove hinge attaching screws and install emergency spacers between hinge straps and lift gate frame.

Lift Gate Hinges-Nomad

Each hinge is secured to the roof rail by six screws, and to the lift gate by four screws. The torque rods must be disengaged from the hinges before one or both of the hinges can be removed from the body.

Removal and Installation

Remove lift gate from body.
Remove lift gate opening upper finishing molding and detach headlining from trim sticks along length of gate opening.
Remove center and side covers to expose hinge attaching screws "A", fig. 149.
With suitable length of pipe carefully disengage end of torque rod from support on roof rail. CAUTION: Perform above step carefully. The movement of the tensioned torque rod can cause injury if the end of the rod is disengaged carelessly.
Disengage opposite end of rod from lift gate hinge.
Remove remaining torque rod as outlined in steps 4 and 5.
Scribe location of hinges, then remove hinge attaching screws and hinges.
To install, reverse removal procedure. When installing end of torque rod in hinge, be sure to engage hinge link "A", fig. 150, to torque rod as shown. Lubricate areas indicated by arrows with Lubriplate.

Lift Gate Window-Nomad

The window is secured in the lift gate by the lift gate outer frame, right and left inner frame, and lower inner frame. These frames are bolted together to form the lift gate frame assembly. The frame must be disassembled in order to remove the glass.

Removal

Remove lift gate from hinges and place on covered bench.
Remove lift gate inner lower frame finishing covers "B," and lift gate lower corner weatherstrips "C", fig 148.
Remove screws securing frame assembly together, then disassemble side inner frames and lower inner frame from outer frame.
With palm of hand, carefully push edge of glass along bottom and sides of outer frame to disengage rubber channel from frame, then pull glass with rubber channel downward to disengage glass from upper portion of outer frame.

Installation

Clean off sealer from around lift gate outer frame and window rubber channel.
Assemble rubber channel to glass, then assemble strong cord along outer lip of rubber channel as indicated at "1", fig. 151, completely around perimeter of glass. Tie and tape ends of cord to bottom center of glass.
Apply approved weatherstrip cement between rubber channel and glass, as indicated at "2", around perimeter of glass.
Apply medium-bodied sealer to lift gate outer frame completely around perimeter of opening as indicated at "3."
Position glass and channel assembly to lift gate outer frame by sliding top of assembly into top of frame, then pull string to seat outer lip of rubber channel on top of outer frame around perimeter of opening.
Assemble right and left inner frames to outer frame making sure that inner lip of rubber channel is seated on top of frame. Install and tighten attaching screws.
Assemble lower inner frame to lift gate outer and side frames making sure that inner lip of rubber channel is seated on top of frame. Install and tighten attaching screws.
Install lift gate lower comer weatherstrip with two attaching screws, then reinstall finishing covers.
Clean off excess cement and sealer and install lift gate to body.

Lift Gate Weatherstrips-Nomad

See fig. 152.

The lift gate weatherstrips consist of a short section of weatherstrip at each lower corner of the lift gate, and of a cemented-on-type weatherstrip which is installed to the body rabbet along the sides and top of the lift gate as indicated by "1" in Figure " fig. 152." In addition a weatherstrip is cemented along the top of the lift gate as indicated at "2" in Figure " fig. 152."

Removal and Installation

To remove lift gate lower comer weatherstrips indicated at "C" in fig. 148, remove finishing covers "B" and two weatherstrip attaching screws.
To remove weatherstrip, from body or top of lift gate, use suitable tool and carefully break cement bond along length of weatherstrip. NOTE. To remove weatherstrip from body, it is necessary to bend open retaining flange of weatherstrip retainer.
To install weatherstrip to body or lift gate, clean off old weatherstrip cement, then apply approved weatherstrip cement following manufacturer's directions to surface indicated at "1" In Section "B-B", fig. 152.

Back Door Assembly-Sedan Delivery

The back door assembly is secured to the back body opening roof rail by two hinges which incorporate torque rods to assist in raising the back door. A telescoping support at each side of the back door locks the back door in an open position. The operation of the back door support is outlined in "Back Door Supports".

Removal and Installation

Remove back door window garnish molding and window retaining clips.
Remove screws securing supports to back door.
Scribe location of hinges, then with helper supporting door, remove screws indicated at "A", fig. 153, securing door to hinge straps, and remove door from body.
To install, align hinges within scribe marks and reverse removal procedure. Lubricate as required.

Adjustments

To adjust top of back door forward or rearward, remove back door window garnish molding and loosen back door attaching screws. Position back door as required, then tighten screws and reinstall garnish molding.
To adjust back door sideways in the opening, remove back door opening upper finishing molding on inside of body; loosen hinge attaching screw "B", fig. 153, and adjust door as required, then tighten screws and reinstall finishing molding.
For adjustment of back door strikers, see "Tail Gate Lock Strikers".

Back Door Hinges-Sedan Delivery

Each hinge is secured to the body roof rail by four screws, and to the back door by three screws. The torque rods must be disengaged from the hinges before one or both of the hinges can be removed from the body.

Removal and Installation

Remove back door from hinges.
On inside of body, remove back door opening upper finishing molding.
Insert suitable length of pipe to end of torque rod at "C", fig. 153. NOTE: Inside diameter of pipe should be approximately 1/2".
Carefully pull pipe downward to release tension of torque rod from hinge pin, fig. 153.
While hinge pin is free of torque rod, tap pin toward centerline of body, then slowly position pipe upward until tension in end of torque rod is released. CAUTION: Perform steps 4 and 5 carefully. The movement of the tensioned torque rod can cause injury, if the end of the rod is disengaged carelessly.
Disengage opposite end of torque rod from left hinge and remove from body.
Remove left torque rod as outlined in steps 3, 4, 5 and 6.
Scribe location of hinges and remove hinge attaching screws.
To install, reverse removal procedure. Lubricate hinges.

Back Door Supports-Sedan Delivery

A telescoping support which consists of an inner and outer channel is installed at the left and right sides of the back door. To lock the back door in the open position, turn lock handle to disengage door lock from strikers, then lift door upward until support cams engage in channel slots. To close door from the open position, lift door upward to disengage locking cams from channel slots, then lower door to closed position.

Removal and Installation

Open door and prop in the open position.
Remove screws securing ends of support to door and body, then remove support.
To install, reverse removal procedure. Lubricate as required.

Back Door Weatherstrips-Sedan Delivery

The mechanically-retained back door weatherstrip consists of a one-piece weatherstrip with an integral wire insert. The weatherstrip is secured to the back door by clips which are formed from the wire insert and snapped into holes around the perimeter of the back door. In addition, the weatherstrip is cemented along the bottom of the door at the butt joint.

Removal and Installation

The basic steps of weatherstrip removal and installation are outlined in "Tail Gate Weatherstrip".

When installing back door weatherstrip, locate weatherstrip color from marking on top of door between 5th and 6th hole from top right hand corner of door. In addition, apply an approved weatherstrip cement, following manufacturer's directions, to bottom of door for 2 1/2 inches on each side of weatherstrip butt joint.

The service procedures for the following back door parts are the same or very similar to the procedures outlined for tail gate and lift gate parts on the pages indicated below.

Back Door Lock Outside Handle

Back Door Locks

Back Door Lock Striker

Back Door Window

Trim Assemblies

Rear Seat Assembly
Front Seat Assembly

Construction of a typical seat is shown in figure 154. The springs are of a zigzag construction set in a box type frame. Covering the spring is 1/2" insulated jute pad which in turn is covered with a 1 1/4" foam rubber pad. On 1500 series models the foam rubber pad is replaced with a cotton pad. Finish trim is a combination cover of cloth and imitation leather on the 2100 and 2400 series, on the 1500 series it is all cloth.

Seat Side Panels-Divided Back

Removal and Installation

On the left side remove adjuster knob "A" by loosening set screw (fig. 155). NOTE: On electrically operated seat adjusters detach switch block from switch.
Remove screws "B" at front and rear of lower side panel and remove panel.
Remove screws "C" from upper side panel and rotate panel out of position.
To install, reverse this procedure.

Side Panels-Solid Back

Removal and Installation

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

Seat Regulator Switch

Removal and Installation

Remove screws from retaining escutcheon and pull escutcheon and switch assembly from side panel.
Detach terminal block from switch and through hole "A" depress clip tab and remove clip "B". Remove three remaining clips in the same manner, then remove switch from escutcheon (fig. 156).
To install, place switch in escutcheon and push retaining clips to place. Attach terminal block to switch and install assembly to side panel.

Horizontal Regulator Assembly

Removal and Installation

Move seat to extreme rearward position and disconnect regulator motor wires from wiring harness and remove motor ground wire from floor pan.
Remove retainers "A" from front and rear support pins, remove support pins and regulator from support (fig. 157). NOTE: This operation may be performed with the seat installed in the body. The seat in figure 157 has been removed for illustrative purpose only.
To install, reverse this procedure.

Seat Assembly

Removal and Installation

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

Adjustment

(All Styles Except Station Wagons and Sedan Deliveries)

If an additional forward adjustment of the seat assembly is desired, provisions have been made to relocate the seat assembly one inch forward on the floor pan. The following procedure can be used:

Remove front seat assembly from body.
Remove attaching bolts from floor pan front retainers. Rotate retainers 180 and reinstall at same attachment locations.
On styles that have an electric horizontal regulator, remove regulator rear support from floor pan and drill 5/16" diameter holes in floor pan one inch directly forward of the original holes.
Drill out to 5/16" diameter, the two rearmost holes in each seat adjuster rear leg.
Seal original regulator rear support holes in floor pan with body caulking compound.
On styles that have an electric horizontal regulator, reinstall regulator rear support to floor pan at new attaching holes.
Reinstall seat assembly, bolting adjuster rear legs in position by placing bolts through the rearmost holes of the legs and into the original floor pan holes.

In the event an additional rearward adjustment of the front seat is desired, provisions are made to relocate the seat assembly one inch back.

Remove the seat assembly from the body.

Remove front leg brackets from floor pan and drill 5/16" holes in the floor pan. These holes must be one inch to the rear of original attaching holes and on the same center line.
Drill out to 5/16" diameter, the forward two 1/4" pierced holes in each of the seat rear adjuster legs.
Seal the original attaching holes with body caulking compound.
Install front leg brackets, then install seat assembly. Use longer bolts to attach the rear legs to floor pan. NOTE: It is imperative that when the seat assembly is to be moved, all attaching points are also to be moved to insure adequate seat to floor pan retention.

Seat Adjuster

Removal and Installation

Remove seat assembly from body and place seat upside down on a covered bench.
Remove seat side panels. NOTE: On electric seat adjuster installations, remove tensioner spring "A" from right seat adjuster (fig. 158).
Move adjuster to extreme rearward position and remove bolt "B" from channel, move adjuster to full forward position and remove bolt indicated at "C"
Detach seat adjuster from frame, disengage locking rod and remove seat adjuster.
To install reverse this procedure. Seat adjuster attachment to frame must be made with the sliding mechanism in the same relative position.

Seat Back

Tilting Style

Removal and Installation

Remove seat lower side panel, then remove "C" clip from hinge pin (fig. 159).
Remove the center hinge post cover plate.
Tilt opposite seat back half forward, then pull seat back toward outside of body disengaging outer support arm from hinge pin.
Rotate the seat back forward, disengaging the hooked end of center hinge pin from its retainer and remove back.
To install, reverse this procedure.

Solid Back

Removal and Installation

Remove seat side panel and side panel extension.
Remove four seat back to frame bolts "A" at each lower comer of the seat back (fig. 160). NOTE: It is not necessary to remove seat, from body to perform this operation.
To install, reverse this procedure.

Driver's Seat Assembly-Sedan Delivery

The seat assembly is secured to the body by two bolts which are installed through the ends of the seat adjuster front frame into supports installed to the body. The seat back, which consists of a metal panel covered with padding and trim, is secured to the seat cushion by supports installed to the seat cushion bottom. The seat assembly is equipped with a seat adjuster. When the seat adjuster control handle is disengaged from the seat adjuster frame rack, the seat may be moved fore and aft.

Removal and Installation

To remove complete seat assembly from body, remove nuts and bolts securing seat adjuster front frame to supports. To install, reverse removal procedure.
To remove seat from seat cushion, pivot seat assembly forward to gain access to seat back attaching screws, then remove screws "A" shown in fig. 161.

To install reverse removal procedure.

Seat Adjuster Assembly-Sedan Delivery

The seat adjuster assembly consists of four slide tracks and a frame assembly as shown in fig. 161. The ends of the front frame, indicated at `B," are secured to supports installed to the body. When a fore or aft adjustment of the seat assembly is desired, pull the seat adjuster handle stop assembly "up" to disengage the stop from the adjuster rack, move the seat to the desired location, then release the handle to lock the seat in the new position.

Removal and Installation

Remove seat assembly from body and place on covered bench.
Remove screws securing slide tracks and remove seat adjuster assembly from seat cushion.
To install, reverse removal procedure.

Passenger's Seat Assembly-Sedan Delivery

The passenger's seat assembly is similar in design and construction and is removed and installed in the same manner as the driver's seat.

NOTE: The passenger's seat is not equipped with a seat adjuster.

Folding Seat Assemblies-6 Passenger Station Wagons

The folding seat cushion is secured in place by two hinges at the front corners. The folding seat back is secured in place by a hinge at each lower comer and by a support at each upper comer. The support pin enters a retainer installed to the right and left rear quarter inner panel.

If additional floor space is desired, the seat cushion and back are rotated forward to form a floor board. On all styles but the Nomad, the bottom of the seat cushion and the back of the seat back are covered with linoleum.

Operation of the Folding Seat For Additional Floor Space

Operate front seat assembly to forward position.
Pull rear edge of folding seat cushion upward until it is in vertical position.
Rotate seat cushion support rod around rear edge of seat cushion, then position seat cushion as shown in fig. 162.
Disengage seat back support pins from retainers on rear quarter inner panel and rotate seat back forward until back of seat back is flush with bottom of seat cushion.
To operate seat and cushion to original position, reverse procedure.

NOTE: Be sure to lift seat back to original position before attempting to lift seat.

Removal and Installation

To remove seat cushion with hinges from body, remove screws, indicated at "A" in fig. 162, from each hinge and remove seat cushion.
To remove seat cushion without hinges from body, operate seat cushion to position shown in fig. 162 and remove screws "B" from each hinge.
To remove seat back, operate seat cushion to position shown in fig. 162, then remove three (3) bolts securing hinge at each lower corner of seat back and disengage support pin from each retainer on rear quarter inner panel.
To install seat cushion and seat back, reverse removal procedure.

Folding Seat Assemblies 9 Passenger Station Wagons

The 1957 Station Wagon Styles include a nine passenger station wagon which is equipped with three seats. The front seat assembly is similar to that used on other styles. The folding center seat consists of a left and right seat assembly, both of which fold to obtain additional floor space. The right folding seat assembly is hinged so that it will pivot forward thereby allowing passenger access to the rear seat. The rear seat assembly consists of a rear seat cushion and back which may be removed to obtain additional floor space. Removal and installation procedures for the folding center seat assemblies, rear seat assembly and component parts are outlined below.

Operation of Seats to Obtain Floor Space

Operate front seat assembly to forward position.
Lift rear edge of either folding seat cushion upward until it is in vertical position.
Rotate seat cushion support rod around rear edge of seat cushion and lower seat cushion to floor pan as shown in fig. 163.
Rotate seat back forward until rear of seat back is flush with bottom of seat cushion. Repeat steps 2, 3 and 4 on other folding seat.
Remove rear seat cushion and back as described below.
Disengage floor board supports, see fig. 164, at each end of floor board by pulling floor board forward. Then, holding floor board by hand holes, unfold two sections of floor board and lower floor board to floor pan.
Engage floor board supports with support clips.

The procedure above describes the operation of the folding center and rear seats to obtain maximum floor space as shown in fig. 165. If less floor space is desired the seats may be adjusted in various combinations by performing only those operations required.

Right Folding Center Seat Assembly

Removal and Installation

To remove right folding center seat assembly from body, remove bolt "A" from support, and remove bolt "B" from left folding seat assembly side panel. See fig. 163.
To remove seat cushion, without outer side panels, from body, remove "C" from outer side panels. See fig. 163.
To remove seat back from body, lower seat back and remove bolts "D" from side panels. See fig. 166.
To install assembly or either component part, reverse removal procedure.

Left Folding Center Seat Assembly

Removal and Installation

See fig. 166.

To remove left folding center seat assembly from body, remove three bolts at "E" from floor pan, four bolts at "F" from floor pan and bolt "B" from side panel.
To remove seat cushion, without outer side panels, from body, remove bolts "G" from outer side panel.
To remove seat back from body, lower seat back and remove bolts "H" from side panels.
To install assembly or either component part, reverse removal procedure.

Rear Seat Assembly

Removal and Installation

See fig. 167.

To remove rear, seat cushion, lift the front edge of the cushion to disengage the locating tabs on the bottom of the cushion frame from the retaining holes "I" in the floor pan and slide the cushion forward.
To remove rear seat back, pull top of back forward to disengage upper retainers from hand holes "K" in floor board, lift back up to disengage tabs on seat back from retainers "J" in floor board.

Rear Seat Assembly

Rear Seat Cushion

Removal and Installation

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

Rear Seat Back- Sedan and Sport Coupe

Removal and Installation

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

Convertible

Removal and Installation

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

Headlining Assembly

Standard Sedan and Sport Coupe Styles

A one-piece extruded rubber glass channel has been adopted for use on certain styles. This channel incorporates a large rubber inner lip which, when installed in the body, overlaps the inner upper edge of the back window opening and covers the rear edge of the headlining assembly in the same manner as a back window garnish molding.

The use of this integral channel modifies the removal and installation of the headlining and back window assemblies in the above styles as follows:

Removal and Installation

The headlining rear edge on the affected styles is no longer tacked to a trim stick in the body opening but sewn to a new type backlight retainer trim stick (fig. 168). The installed headlining rear edge is then covered by pulling the inner lip into position as shown. No garnish molding installation is required, otherwise installation procedures remain the same as for other models.

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

Sedan Styles

Removal

Remove the following hardware and trim assemblies; rear seat cushion and back, rear view mirror, sunshades, dome lamp cover, coat hooks and all garnish moldings except the door garnish moldings.
Remove tacks or staples at windshield opening and carefully loosen cemented edge of headlining. NOTE: Clean hands are essential when working on trim assemblies.
Loosen edge of parcel shelf trim to gain access to headlining, then remove tacks or staples from headlining around quarter window and back window. Loosen cemented edge of headlining.
Carefully disengage headlining from metal retainer tabs along side roof rails (fig. 169).
Starting at the front, disconnect headlining support wires from side roof rails. Then bend down metal tabs retaining listing wire at center bow, roll headlining up with listing wires on outside to keep headlining clean.

Installation

Attach listing wires to side roof rails by starting at the rear of the body and working toward the front. NOTE: Center and align headlining in relation to back window, door openings and dome lamp opening. Hook number 3 listing wire to retainers at center roof bow (fig. 169).
Cement (trim cement) and stay-tack headlining at tacking areas of back window, rear quarter windows and windshield. Check alignment of sunshade opening in headlining with attaching screw holes.
Working from the front to rear remove all fullness and draws from headlining. Then permanently tack in place.
Carefully insert headlining under retainers at side roof rails with Tool 2772.
Cement parcel shelf trim in place with trim cement, then install hardware and trim assemblies.

Back Window Removal and Installation

The rubber glass channel on the affected styles cannot be seated over the pinchweld flange until the inner lip is pulled through the body opening using a suitable tool. No garnish molding installation is required, otherwise installation procedures remain the same as for other models.

Sport Sedan Style

The headlining assembly is secured to the body by listing wires which are inserted through listing pockets sewed to the headlining. The ends of the listing wires are inserted into holes in the side roof rail. In addition, the edges of the headlining are cemented and tacked or stapled to trimsticks installed to the roof rail along the door, windshield and back window opening.

NOTE: Be sure hands are clean before beginning work on interior trim.

Removal

Before removing the headlining, the following hardware and trim assemblies must be removed:
- Rear seat cushion and rear seat back Rear view mirror Sunshade assemblies Windshield and back window garnish moldings Dome lamp assembly Coat hooks 2100 Series-Wire-on-binding at side roof rails 2400 Series-Side roof rail finishing moldings
On 2400 Series, detach the rear end of the rear quarter trim panel to gain access to the headlining in the rear quarter area. On all styles, disengage headlining from cementing surfaces at the rear quarter area.
Remove tacks or staples securing edge of headlining over windshield, door and back window opening.
Carefully disengage ends of front headlining listing wire from holes in side roof rails. Proceeding rearward disengage remaining listing wires and roll up the headlining with the listing wires on the outside.
Carefully remove headlining with listing wires from body and place on a covered bench.

Installation

If listing wires were removed from headlining, carefully install the wires to the headlining. Typical listing wire installation is shown at "1" in View "A", fig. 170.
Lift the complete headlining assembly into the body, then starting at the rear and working forward, tilt listing wires to the rear, insert ends of wires into holes in side roof rail and swing wires to upright position to engage notch in rail.
Carefully stretch out and center headlining.
Starting at the windshield opening, carefully pull headlining snug, then cement and stay tack headlining to tacking strip as shown at "2" in View "B." Perform same operation at back window opening and along side roof rail indicated at "3" in View "C."
After headlining is free of all wrinkles and tack draws, permanently tack all areas of headlining which were previously stay tacked. On 2100 styles, install wire-on-binding as shown at "4" in View "C."
Install previously removed parts.

Station Wagons (Except Nomad)

The headlining assembly is secured in place by listing wires which are inserted through listing pockets sewed to the headlining. The ends of the listing wires are inserted into holes in the side roof rails. In addition, the edges of the headlining are cemented and tacked or stapled to trim sticks installed to the roof rail along the windshield, door, rear quarter and lift gate openings. On 2100 2 door and 4 door, and 2400 4 door styles, the edge of the headlining above the door opening is secured in place by metal retainers with lanced tabs.

Fig. 171 shows a headlining assembly installed in a 2100 and 2400 4 door style. The installation of a headlining is similar on the other styles except for the Nomad.

NOTE: BE SURE HANDS ARE CLEAN BEFORE BEGINNING WORK ON INTERIOR TRIM.

Removal

Remove following trim and hardware parts:
- Windshield side and upper garnish moldings Rear view mirror support Sunshade assemblies Rear quarter window garnish moldings Tail gate opening upper finishing molding Dome lamp assembly Coat hooks
With suitable tool, carefully remove tacks or staples securing edge of headlining over windshield, door, rear quarter window and lift gate opening.
On 2100 2 door and 4 door, and 2400 4 door styles with suitable tool carefully disengage headlining from metal retainer tabs above door opening.
Carefully disengage ends of front headlining listing wire from holes in side roof rails. Proceeding rearward, disengage remaining listing wires and roll up headlining with listing wires on outside. NOTE: At the roof bow the headlining listing wire is secured by retaining tabs.
Carefully remove headlining with listing wires from body and place on a covered bench.

Installation

Lift headlining assembly into body, then starting at the rear and working toward center roof bow, insert ends of listing wires into holes in side roof rail as shown at "1" in view "A", fig. 171. Swing listing wire in upright position until wire is engaged in notch as shown.
Attach listing wire to center roof bow, then working from roof bow toward front of body, insert ends of remaining listing wires into holes in side roof rail.
Center and align headlining as required for proper installation.
Cement and stay-tack headlining material, above lift gate opening as indicated at "2" in view "B", above rear quarter window opening as indicated at "3" in view "C", and above windshield opening as indicated at "4" in view "D." On Sedan Delivery styles, the headlining is also tacked above door openings.
Remove all fullness and "draws" from material, then permanently tack material in place.
On all styles except the Sedan Delivery, use a headlining inserting tool or other suitable tool, and carefully tuck edges of headlining above door opening to engage tabs of metal retainer shown at "5" in view "A", fig. 171.
Install previously removed parts.

Nomad

The headlining assembly is secured in place by exposed channel-type roof bows which are secured at each end to the side roof rail by two screws. In addition the headlining is cemented and tacked or stapled to trimsticks installed over the lift gate, rear quarter window, door and windshield opening.

NOTE: BE SURE HANDS ARE CLEAN BEFORE BEGINNING WORK ON INTERIOR TRIM.

Removal

Remove following trim and hardware parts:
- Windshield side and upper garnish moldings Rear view mirror support Sunshade assemblies Door opening finishing molding Rear quarter window garnish moldings Tail gate opening upper finishing moldings Side roof rail lamp assemblies Coat hooks
With suitable tool, carefully remove tacks or staples securing headlining over lift gate, rear quarter, door and windshield opening.
Remove screws securing ends of each exposed roof bow and carefully remove headlining with attached roof bows from body.
Place headlining on clean bench and if necessary detach roof bows from foundation on headlining.

Installation

If roof bows were removed, carefully install roof bows to headlining foundations. Typical roof bow and headlining foundation installation is shown at "1" in view "E", fig. 172.
Lift complete headlining assembly into body. Attach end of each roof bow loosely to the side roof rails.
Carefully stretch out and center headlining, then tighten center roof bow in full down position.
Starting at windshield opening, carefully pull headlining tight, then cement and stay tack headlining to tacking strips. Perform same operation at lift gate opening and side roof rails.
After headlining is free of all wrinkles and draws, permanently tack all areas previously stay tacked.
Adjust all roof bows to proper tension oh headlining, then tighten all roof bow attaching screws.
Reinstall previously removed parts.

Exterior Moldings

Center Body Exterior Moldings
Roof and Tail Panel Exterior Moldings

Front and Rear Door Exterior Moldings

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

Door Outer Panel Spear Molding

Fig. 173
On 1500 series two-door sedan, utility sedan, two-door six passenger station wagon and sedan delivery, the molding is secured to the door outer panel by a bolt and clip assembly and attaching nut at the front and by a clip and screw at the rear. Remove the screw securing the rear end of the molding at the door hemming flange. Remove the door trim assembly and water deflector; then remove the nut securing the front end of the molding and remove the molding. To install, reverse the removal procedure.

Rear Door Outer Panel Lower Molding

Fig. 174
On 1500 series four-door sedan, the molding is secured to the door outer panel by snap-on clips along the length of the molding, by a bolt and clip assembly with attaching nut at the front end of the molding and by a clip and screw at the rear end of the molding. Remove the door trim access hole cover and remove the forward attaching nut. Remove the screw at the rear end of the molding, then with a flat-bladed tool carefully pry the molding from the body. To install, replace clips where required and reverse the removal procedure.

Rear Door Outer Panel Diagonal Molding

Fig. 174
On 1500 series four-door sedan, the molding is secured to the door outer panel by three bolt and clip assemblies and attaching nuts. Remove the door trim and access hole cover, then remove the attaching nuts and remove the molding. To install, reverse the removal procedure.

Front Door Window Lower Reveal Molding

Fig. 177
On all 2100 series except the sport coupe, the molding is secured to the door outer panel by snap-on clips along the length of the molding and by a clip and screw at each end of the molding. Remove the screw securing each end of the molding at the door hemming flange; then use a flatbladed tool and carefully pry the molding from the door. To install, replace clips where required and reverse the removal procedure.

Rear Door Window Lower Reveal Molding

On 2100 series four-door sedan, the molding is secured to the door outer panel by snap-in clips along the length of the molding and by a screw and clip at each end of the molding. Remove the screw securing each end of the molding to the door hemming flange; then with a flat-bladed tool carefully pry the molding with attached clips from the body. To install, reverse the removal procedure.

Front Door Ventilator Reveal Molding

Fig. 175
On 2100 and 2400 series two-door sport coupe and four-door sport sedan and 2400 series convertible and, Nomad, the molding is secured to the hinge pillar extension by screws. Remove the door ventilator assembly and the front door window front reveal molding or door window reveal molding; then remove the screws securing the molding. Bend open the molding tabs and disengage the molding from extension. To install, reverse the removal procedure.

Front Door Window Front Reveal Molding

On 2100 and 2400 series two-door sport coupe and four-door sport sedan and 2400 series convertible, the reveal molding is secured to the return flange of the door outer panel by screws. To remove the molding loosen the door ventilator, and remove the screws. To install, reverse the removal procedure.

Front Door Window Rear Reveal Molding

Fig. 177
Fig. 180
On 2100 and 2400 series two-door sport coupe, four-door sport sedan and 2400 series convertible, the molding is secured to the return flange of the door outer panel by screws. Remove the door trim and access hole cover. Disengage the door window assembly from the sash channel cam and lower the window sufficiently to gain access to the molding attaching screws. Remove the rear molding attaching screws and the front molding rear attaching screw. Slide the molding upward and rearward and remove the molding. To install, reverse the removal procedure.

Rear Door Window Reveal Molding

Fig. 177
On 2100 and 2400 series four-door sport sedan, the molding is secured to the return flange of the door outer panel by screws. To remove the molding remove the door window to gain access to the attaching screws. To install, reverse the removal procedure.

Front Door Outer Panel Lower Molding

Fig. 175
Fig. 176
Fig. 177
On all 2100 and 2400 series except the 2400 series four-door six passenger station wagon, the molding is secured to the door outer panel by snap-on clips along the length of the molding and by a clip and screw at each end of the molding. Remove the screws securing each end of the molding to the door hemming flange; then with a flat-bladed tool carefully pry the molding from the body. To install, replace clips where required and reverse the removal procedure.

Rear Door Outer Panel Lower Molding

Fig. 175
Fig. 176
Fig. 177
On all 2100 and 2400 series four-door models except for the 2400 series four-door station wagon, the molding is secured to the rear door outer flange by snap-in clips along the length of the molding and by a clip and screw at each end of the molding. On the 2400 series four-door sedan and four-door sport sedan, two bolt and clip assemblies and attaching nuts are also located at the center of the molding. On the 2400 series four door sedan and four-door sport sedan styles, remove the door trim and access hole cover and remove the attaching nuts. On all styles, remove the screw securing each end of the molding at the hemming flange; then with a flat-bladed tool carefully pry the molding from the body. To install, replace clips where required and reverse the removal procedure.

Door Window Reveal Molding

Fig. 178
On 2400 series two-door six passenger station wagon, the molding is secured to the return flange of the door outer panel by screws. In addition the front end of the molding is secured to the door hemming flange by a screw. Remove the door trim and water deflector; then lower the window and disengage the window lower sash channel from the cam channel. Remove the screws securing the molding from the return flange of the door outer panel and the screw securing the front end of the molding from the door hemming flange. Bend back the tab at the door hemming flange and remove the molding. To install, reverse the removal procedure.

Rear Door Insert Molding

Fig. 176
Fig. 177
On 2400 series four-door sedan and four-door sport sedan, the molding is secured to the door outer panel by screws. To remove the molding remove the door upper and lower moldings and remove the screws securing the insert molding. To install, reverse the removal procedure.

Rear Door Outer Panel Upper Molding

Fig. 176
On 2400 and 2100 series four-door sedan and four-door sport sedan, the molding is secured to the door by a bolt and clip assemblies and by a screw and clip at the rear of the molding. The flange at the forward end of the molding is positioned under the lower molding. Remove door trim and access hole cover. Loosen the nuts securing center portion of lower molding and nuts and washers securing upper molding. Remove the screw securing end of upper molding at door hemming flange and remove molding. To install, position the end flange on upper molding under the lower molding and reverse the removal procedure.

Front and/or Rear Door Window Lower Reveal Molding

Fig. 175
Fig. 176
On 2400 series two-door and four-door sedan, the molding is secured to the return flange of the door outer panel by the screws and by a screw and clip at each end of the molding. Remove the door trim and the water deflector or access hole cover; then lower the window and disengage the window lower sash channel from the cam channel. Remove the screws securing the molding strip assembly from the return flange of the door outer panel and remove the screw securing each end of the molding to the door hemming flange and remove the molding. To install reverse the removal procedure.

Front and/or Rear Door Window Upper Reveal Molding

Fig. 175
Fig. 176
On 2400 series two-door and four-door sedan, the molding is secured to the door window frame by clips and screws along the upper flange and ends of the molding and by screws at the lower flange of the molding. Loosen the window glass run channel to gain access to the attaching screws. Remove the screws securing the ends and upper flange of the molding and the screws securing the tabs on the lower flange of the molding; then bend down the tabs and remove the molding from the body. To install, reverse the removal procedure.

Center Body Exterior Moldings

Center Pillar Upper Filler Cap

Fig. 174
On 1500 and 2100 series four-door sedan, a painted center pillar upper filler cap is secured to the center pillar by a bolt and clip with an attaching nut on the inside of the body under the center pillar trim. The filler cap is removed and installed in the same manner as the center pillar upper reveal molding on the 2400 series four-door sedan style.

Center Pillar Outer Panel Molding

Fig. 176
Fig. 178
On 2400 series four-door sedan and four-door six passenger station wagon, the molding is secured by one screw through the side face of the center pillar.

Center Pillar Lower Reveal Molding

Fig. 176
On 2400 series four-door sedan the molding is secured by one screw through the side face of the center pillar.

Center Pillar Upper Reveal Molding

Fig. 176
On 2400 series four-door sedan, the molding, together with a filler and sealing washer, is secured to the center pillar by a bolt and clip with an attaching nut on the inside of the body under the center pillar trim. Loosen headlining and upper portion of center pillar trim sufficiently to remove the attaching nut. To install, assemble center pillar filler and sealing washer to molding tee bolt and reverse removal procedure.

REAR FENDER AND REAR QUARTER

EXTERIOR MOLDINGS

Rear Fender Outer Panel Lower Molding

Fig. 174
Fig. 175

On all 1500 series, the molding is secured to the rear quarter outer panel by snap-on clips along the length of the molding and by a bolt and clip assembly and attaching nut at each end of the molding. Remove the rear quarter trim and access hole cover. Remove the attaching nut at each end of the molding; then with a flat-bladed tool carefully pry the molding from the body. To install, replace clips where required and reverse the removal procedure.

Rear Fender Diagonal Molding

Fig. 174
Fig. 175
On all 1500 series except four-door sedan and sedan delivery, the molding is secured to the rear fender by bolt and clip assemblies and attaching nuts. To remove the molding remove the rear quarter trim and access hole cover to gain access to the attaching nuts. To install reverse the removal procedure.

Rear Quarter Window Lower Reveal Molding

On 2100 series two-door sedan and club coupe, the molding is secured to the rear quarter outer panel by snap-in clips. Use a flat-bladed tool and carefully pry the molding with attaching clips from the body. To install reverse the removal procedure.

Rear Quarter Window Reveal Molding

On 2100 series four-door sedan, the molding is secured to the rear quarter outer panel by snap-on clips. Use a flat-bladed tool and carefully pry the molding from the body. To install, replace clips where required and reverse the removal procedure.

Rear Quarter Window Front Reveal Molding

On 2100 series sport coupe, the molding is outer panel by snap-in clips and screws. Remove the rear quarter window. Remove the front and rear attaching screws; then disengage the clips and remove the molding. To install, reverse the removal procedure.

Rear Fender Lower Molding

Fig. 177
On all 2100 series, and 2400 series four-door sedan and four-door sport sedan, the molding is secured to the rear fender outer panel by snap-in clips along the length of the molding and by a bolt and clip assembly and attaching nut and washer at each end of the molding. On two-door styles remove the rear quarter trim and access hole cover. On all styles remove the front and rear attaching nuts and washers; then with a flatbladed tool carefully pry the molding with attaching clips from the body. To install replace clips where necessary and reverse the removal procedure.

Rear Quarter Window Rear Reveal Molding

Fig. 177
On 2100 and 2400 series sport coupe, the molding is secured to the body by screws. To remove the molding remove the rear quarter window front reveal molding and the rear quarter sealing strip, then remove the molding attaching screws. To install, reverse the removal procedure.

Rear Quarter Window Rear Reveal Molding

Fig. 178
On 2400 series Nomad, the molding is secured to the body by self-tapping screws located beneath the lift gate weatherstrip which is cemented along the back pillar rabbet. Loosen weatherstrip as required, then remove rear reveal molding attaching screws. To install molding seal around window openings as specified and apply body caulking compound along edge of molding as shown at "2" and "3" in Fig. 179; then reverse removal procedure.

Rear Quarter Window Upper and Lower Reveal Molding Rear

Fig. 178
On 2400 series Nomad, each molding is secured to the body by self-tapping screws. Remove the rear quarter front and rear window, then remove molding attaching screws and disengage front end from under front molding. To install molding, seal around window openings as specified and reverse removal procedure.

Rear Quarter Window Lower Reveal Molding Front

Fig. 178
On 2400 series Nomad, the molding is secured to the body by self-tapping screws. Remove the rear quarter front window, the lower glass run channel and the upper reveal molding, then remove lower reveal molding attaching screws. To install molding, seal around window opening as specified and reverse removal procedure.

Rear Quarter Window Upper Reveal Molding

Front

Fig. 178
On 2400 series Nomad, the molding is secured to the body by self-tapping screws. Remove rear quarter front window, loosen upper glass run channel as required; then remove molding attaching screws. To install molding, apply body caulking compound between front and rear moldings as indicated at "1" in Fig. 179, then seal around window as specified and reverse the removal procedure.

Rear Fender Insert Molding

Fig. 175
Fig. 176
Fig. 177
On all 2400 series except Nomad, the molding is secured to the rear fender by screws. To remove the molding remove the rear fender upper and lower moldings and the rear fender emblem and ornament; then remove the screws securing the insert molding. To install reverse the removal procedure.

Rear Quarter Window Lower Reveal Molding

Fig. 175
On 2400 series two-door sedan, the molding is secured to the return flange of the rear quarter outer panel by screws and by a stud and attaching clip at the forward end of the molding. Remove the rear quarter window. Remove the screws along the return flange then with a flat-bladed tool carefully pry the forward end of the molding from the body. To install, replace clip where necessary and reverse the removal procedure.

Rear Quarter Window Rear Reveal Molding

Fig. 175
On 2400 series two-door sedan, the molding is secured to the window frame by a snap-in clip, screws, and at the rearmost end by a bolt and clip assembly and attaching nut and washers. To remove the molding remove the nut and washers which are accessible through the rear compartment. Remove the rear quarter window lower reveal molding. Loosen the glass run channel at the window opening to gain access to screws and rearward section of upper reveal molding. Remove the screws at the window opening, bend down the metal tabs; then with a flat-bladed tool carefully pry the molding from the body. To install replace clips where necessary and reverse the removal procedure.

Rear Quarter Window Upper Reveal Molding

Fig. 175
On 2400 series two-door sedan, the molding is secured to the rear quarter window header by snap-in clips along the upper flange of the molding and by screws along the lower portion of the molding. Loosen the glass run channel sufficiently to gain access to the screws. Remove the screws and bend down the tabs; then with a flat-bladed tool carefully pry the molding from the body. To install, replace clips where necessary and reverse the removal procedure.

Rear Quarter Pinchweld Finishing Molding

Fig. 180
On 2400 series convertible, the right and left moldings are secured over the pinchweld flange by retaining clips and by a screw at the forward end of each molding. A tab at the rear end of the right molding is secured to the body by a screw. The right molding overlaps the left molding at the center line of the body and must be loosened prior to removing the left molding. The forward end of each molding is located under the rear end of the rear quarter window reveal molding. Lower the top and remove the rear quarter belt finishing molding. Remove the screw securing the forward end of the molding and the screw securing the rear end of the right molding. Then with a cushioned block and hammer carefully detach the molding from the body. Slide the molding rearward to disengage it from underneath the rear quarter window reveal molding and remove from the body. To install, replace the waterproof tape over the pinchweld flange, replace clips where required, and reverse the removal procedure.

Rear Quarter Window Lower Reveal Molding

On 2400 series convertible, the molding is secured to the return flange of the rear quarter outer panel by screws. To remove the molding remove the rear quarter window to gain access to the attaching screws. To install, reverse the removal procedure.

Rear Quarter Window Front Reveal Molding

Fig. 177
On 2400 series sport coupe, the molding is secured to the return flange of the rear quarter outer panel by screws. To remove the molding remove the rear quarter window to gain access to the screws. To install, reverse the removal procedure.

Rear Fender Upper Molding

Fig. 176
On 2100 and 2400 series four-door sedan, the molding is secured to the rear fender by snap-in clips along the length of the molding, a stud and clip at the forward end of the molding, and by a clip and screw at the rear end of the molding. Remove the screw at the rear end of the molding; then carefully pry the molding from the body. To install, replace clips where required and reverse the removal procedure.

Rear Quarter Window Upper Reveal Molding

Fig. 176
On 2400 series four-door sedan, the molding is secured to the window frame by a snap-in clip, screw, and at the rearmost end by a bolt and clip assembly and attaching nut and washers. Remove the rear quarter window lower reveal molding. Remove the rear attaching nuts and washers which are accessible through rear compartment. Remove attaching screws, bend down the metal tabs; then with a flat-bladed tool carefully pry the molding from the body. To install, replace attaching clip where necessary and reverse the removal procedure.

Rear Quarter Window Lower Reveal Molding

Fig. 176
On 2400 series four-door sedan, the molding is secured to the window frame by screws. Remove rear quarter window to gain access to attaching screws. To install, reverse the removal procedure.

Rear Fender Upper Rear Molding

Fig. 175
Fig. 177
On all 2100 and 2400 series except four-door sedan, four-door six passenger station wagon and four-door sport sedan, the molding is secured to the rear fender outer panel by snap-in clips and by a clip and screw at each end of the molding. Remove the screw at each end of the molding; then with a flat-bladed tool carefully pry the molding with attaching clips from the body. To install, replace clips where necessary and reverse the removal procedure.

Rear Fender Upper Front Molding

On all 2100 and 2400 series except four-door sedan, four-door six passenger station wagon and four-door sport sedan, the molding is secured to the rear fender by a bolt and clip assembly and attaching nuts at each end of the molding. The flange at the front end of the molding is positioned under the lower molding. Loosen the forward end of the lower molding. Remove the nuts securing the molding; then carefully slide molding upward to disengage the tab from the lower molding and remove the molding. To install, reverse the removal procedure.

Rear Fender Lower Molding

Fig. 175
Fig. 177
On all 2400 series except four-door sedan, four door six passenger station wagon and four-door sport sedan, the molding is secured to the rear fender outer panel by bolt and clip assemblies and attaching nuts, and by snap-in clips. Remove the rear quarter trim and the access hole cover and remove the front attaching nut. Remove the center and rear attaching nuts; then with a flatbladed tool carefully pry the molding with attaching clips from the body. To install, replace attaching clips where necessary and reverse the removal procedure.

Rear Fender Crown Molding Assembly

On all series and models, the molding is secured to the fender crown by studs and clips. Use a flat-bladed tool and carefully pry the molding with its integral studs from the body. To install, replace clips where required and reverse the removal procedure.

Rear Fender Crown Molding Vertical Assembly

On all series and models, the molding is secured to the rear fender by screws. Remove the rear fender crown molding assembly and the tail lamp cover plate. Remove the screws securing the tabs at each end of the molding and remove the molding. To install, reverse the removal procedure.

NOTE: On the left fender the crown molding vertical assembly is of two piece construction. The upper section is secured in a similar manner. The lower section is division furnished and installed.

Roof and Tail Panel Exterior Moldings

Tail Gate Vertical Moldings

Fig. 178
On 2400 series Nomad, the moldings are secured to the tail gate outer panel by snap-in clips. To remove moldings use a flat-bladed tool and carefully pry moldings with attached clips from tail gate. To remove center vertical molding lower, remove tail gate handle before prying molding. To install, apply sealer around clip holes and reverse removal procedure.

Roof Drip Molding Scalp

Fig. 178
On 2400 series Nomad, the molding is secured to the roof rail by self-tapping screws. Remove side roof rail weatherstrip, then remove molding attaching screws and carefully remove molding. To install molding, apply bead of medium-bodied sealer to the top surface of roof drip molding scalp along a line over the attaching holes along the entire length of the molding. At the forward end of the scalp the sealer is to continue outboard along the forward edge. Then install the screws securing the molding. Reinstall the weatherstrip.

Electric Window Assembly

ELECTRIC WINDOW REGULATOR AND SEAT ADJUSTER

Description

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

A new feature of the electric motors in the 1957 series is the use of a newly designed socket and blade type connector which is attached directly to the motor case. The new connector (fig. 181) provides a more positive electrical connection and facilitates the connecting of the wire harness to the motor leads.

Operation

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

Window Regulator

Disassembly

Remove electric window regulator assembly from door or rear quarter.
Place regulator assembly in vise and drill a 1/4" hole through the back plate and regulator sector at either "A," "B," or "C" locations, at least 3/4" away from the edge of the back plate or sector, defending on the position of the lift arm (fig. 182). NOTE: Do not drill into the motor housing, which is indicated by clotted line.
Insert 3/16" bolt through holes and install nut loosely. NOTE: The regulator lift is under spring tension and must be locked in place to prevent possible injury when the motor assembly is removed.
Remove attaching bolts "D" and remove motor assembly from regulator. Clean drill chips from sector and pinion gear.

Assembly

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

Quarter Window Switch

Removal and Installation

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

Electrical Unit Checks

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

Checking Door Switch

Ground test light wire to body metal and insert test light prod into switch center feed terminal (fig. 184).
If test light fails to light, current is failing to reach switch. Back check over feed circuit to locate fault.
If test light operates, place a No. 12 jumper wire between the center terminal and either of the two switch motor terminals (fig. 185). If motor operates the switch is faulty. (Test each switch motor terminal). Check terminal block to make sure wires are secure in terminal block.
Place a No. 12 jumper wire between switch center terminal and switch or lead terminal being tested. Disconnect motor lead at motor and install light tester and check switch to motor wire (fig. 186). Test opposite motor lead wire in the same manner.
Check the ground of the motor at its attachment to the door inner panel. Scrape any paint away from under the attaching bolt which may be insulating the motor.
Check operation of the motor, by breaking the motor leads at the plastic connectors through the loading hole in the inner door panel and connecting a No. 12 jumper wire between the battery positive post and the motor lead (fig. 187). If the motor fails to operate, motor is defective or a mechanical stoppage exists. Check the other motor lead in the same manner.

Checking Circuit Breaker

A. Checking for current at circuit breaker.

Connect one light tester lead to battery side of circuit breaker and ground other light tester lead. If tester does not light, there is no current at battery side of circuit breaker.
To check circuit breaker, disconnect switch feed wire from breaker, and with light tester check for current at switch side of circuit breaker. If tester does not light, there is no current flowing through circuit breaker.

Trouble Diagnosis

Window will not operate from immediate control switch but will operate from master control switch.

Check feed wire to immediate switch.
Check immediate control switch.
Check motor leads from immediate control switch to motor.

Window will not operate from master switch but will operate from immediate switch.

Check operation of master switch.
Check two motor leads from master switch to motor.

Window will not operate from either immediate nor master switch. Operation of other windows is satisfactory.

Check for mechanical stoppage.
Check operation of immediate and master switches.
Check motor leads from each switch to motor for shorts or open circuit.
Check operation of motor.

Windows will not operate from master switch but will operate from immediate switches.

Check feed wire from circuit breaker to master switch.
Check operation of master switch.

Seat regulator will not operate, windows do operate.

Check for mechanical stoppage of seat adjuster.
Check feed wire from circuit breaker to seat adjuster switch.
Check operation of seat adjuster switch.
Check motor leads to motor from switch.
Check seat adjuster motor.

Neither windows or seat adjuster will operate.

Check battery.
Check circuit from battery to circuit breaker.
Check circuit breaker.
Check feed wire from circuit breaker to switches.
Check operation of all switches.

Quick Checks

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

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

Convertible Top

Side Roof Rail Weatherstrip

Description

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

Removal

Lower top halfway and remove weatherstrip attaching screws "A" (fig. 188).
Remove weatherstrip attaching nuts and washer "B" from inside the channel section of the side roof rail (see Inset).

NOTE: To remove the front section of the side roof rail weatherstrip it is necessary to loosen the front roof rail weatherstrip retainer.

Installation

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

Adjustment

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

Front Roof Rail Weatherstrip

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

FOLDING TOP

Description

The folding top linkage consists of three sections of right and left side roof rails and a front roof rail connected together by bolts, hinges, and a series of connecting links and bows. The top linkage is attached to the body at the rear quarter area by a male hinge bolted to an adjustable support. The front roof rail is locked in place at the windshield header by two cam locks which are an integral part of the locking handles.

To correct some top variations, only a single adjustment is required; other top variations require a combination of several adjustments. In addition to adjustment of the folding top, it may be necessary to adjust the door glass, rear quarter glass, or the side roof rail weatherstrips.

Adjustment of the door glass, rear quarter window and side roof rail are covered in this body section.

Adjustments

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

Correction:

Raise top slightly above windshield header and remove, screw from groove of side roof weatherstrip at front corner.
Loosen comer brace attaching screw "A" and bolt "B" and adjust front roof rail fore or aft as required (fig. 189). Repeat on opposite side if necessary.

NOTE: This adjustment is limited, should additional adjustment be required, it can be made at folding top male hinge.

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

Correction:

Raise top slightly above windshield header and loosen screws "A" and adjust the strikers up or down or from side to side as required (fig. 190).
If an additional downward adjustment is desired, install an emergency striker.
Align the sunshade supports with the front roof rail guide studs and tighten attaching screws.

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

Correction:

Loosen the four male hinges attaching bolts "A" and move hinge fore or aft, as required; then, tighten bolts (fig. 191).
Check side roof rail alignment and stacked position of top, and readjust if necessary.

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

Correction:

Place top midway in the operational cycle and loosen two nuts indicated at "B" (fig. 191).
Without changing the fore or aft location of the adjusting plate "C," move adjusting plate up or down as required. To lower side roof rail, move adjusting plate up, to raise side roof rail, move adjusting plate down.

Top will not stack properly in the folding top compartment.

Correction:

Lower top to stacked position and loosen nuts "B" (fig. 191) and move adjusting plate "C" forward or rearward as required. To lower the stacked position, move the adjusting plate rearward. To raise the stacked position, move the adjusting plate forward.

NOTE: Do not change the vertical position of the adjusting plate.

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

Correction:

Loosen attaching bolts "D" (fig. 191). The support is secured firmly in place by serrations on the contacting surfaces of support and brace.
Adjust support up or down as required; then tighten bolts.
Check side roof rail alignment and readjust if necessary.

Hydro-Lectric System

The hydraulic unit which is used in the Convertible bodies, consists of a 12-volt reversible type motor, a rotor-type pump, two hydraulic lift cylinders, and an upper and lower hydraulic hose assembly. It is important to note that the folding top cannot be operated manually. Figure 192 shows the unit installed in the body directly behind the rear seat back.

Figure 193 shows an exploded view of the motor and pump assembly. The parts indicated by numbers may be identified in the description.

Rotor-Type Motor and Pump Assembly

Removal

Operate the folding top to the full "up" position.
Disconnect the positive battery cable.
Place protective covering over the rear seat back and cushion.
Working inside the body, detach the front edge of the folding top compartment bag from rear seat back panel.
Working on the inside of the body over the rear seat back, remove the pump and motor shield attaching screws and remove shield.
Remove the clip "A", fig. 194, securing the wire harness.
Disconnect the motor leads from the wire harness, and remove the clips securing the hydraulic hose to the rear seat back panel.
To facilitate removal apply a rubber lubricant to pump attaching grommets "B", fig. 194, then carefully disengage grommets from floor pan.
Place absorbent rags below hose connections and end of reservoir.

With a straight-bladed screw driver, vent the reservoir by removing the filler plug indicated at "C", fig. 194, then reinstall plug. NOTE: Venting the reservoir is necessary in this "sealed-in" unit to equalize the air pressure in the reservoir to that of the atmosphere. This operation prevents the possibility of the hydraulic fluid being forced under pressure from disconnected lines and causing damage to trim or body finish.

Disconnect hydraulic lines at "D", fig. 194, and cap open fittings to prevent leakage of fluid. Use a cloth to absorb any leaking fluid, then remove the unit from the rear compartment.

Installation

If a replacement unit is being installed, fill reservoir unit with specified Delco No. 11 hydraulic fluid (G. M. Hydraulic Brake Fluid Super No. 11). See "Checking Fluid in Reservoir" for proper fluid level.
Connect hydraulic hoses, engage attaching grommets in panel and connect wiring.
Connect battery and operate top through its up and down cycle.
Check connections for leaks and check fluid level in reservoir. See "Checking Fluid in Reservoir" for proper level.
Reinstall previously removed parts.

Motor and Pump Assembly

Removal and Installation

Place protective covering over the rear seat cushion and seat back, then detach the front edge of the folding top compartment bag from the rear seat back.
Working inside the body over the rear seat back, remove the motor and pump assembly.
Fill replacement unit reservoir with Delco No. 11 hydraulic fluid (G. M. Hydraulic Brake Fluid Super No. 11). See "Checking Fluid in Reservoir" for proper level.
Obtain two special service adapter hoses and install male fittings to new rotor-type pump. One of the adapter hoses is shown in fig. 195.
Connect female fitting of each adapter hose to hydraulic hose tee as shown, then tape hoses to reservoir tube.
With suitable tool engage rubber grommets in holes in panel and connect wiring.
Operate top through its up and down cycle and inspect hose connections for leaks.
Check fluid level. See "Checking Hydraulic Fluid in Reservoir" for proper level.
Install the pump and motor shield and secure the folding top compartment bag to the rear seat back panel.

Disassembly of Reservoir Tube From Motor and Pump Assembly

Remove motor and pump assembly from body.
SCRIBE A LINE across the pump end plate, reservoir tube and reservoir tube end plate as shown opposite, to ensure correct assembly of parts.
With a straight-bladed screw driver, remove filler plug indicated at "A", fig. 196. Note sealing ring around plug.
Drain fluid from reservoir into a clean container.
With suitable tool remove bolt indicated at "B", fig. 196. Note the sealing ring around bolt, reservoir end plate, and between end of reservoir tube and pump assembly.

Assembly of Reservoir Tube to Motor and Pump Assembly

Position sealing ring on pump and assemble reservoir tube to pump according to scribe marks. NOTE: Bracket assembly on tube should be located at outer end when tube is assembled to pump.
Position sealing ring on tube end plate and place end plate on reservoir tube, lining up the scribe marks. Install and tighten attaching bolt.
Place unit in a horizontal position and fill with fluid until level of fluid is even with bottom of filler plug hole.
Make sure that sealing ring is on the filler plug, before installing filler plug.

OPERATION OF THE FOLDING TUBE

The principles of top operation with the rotor type pump are the same as those of the unit with the gear-type pump. When the control knob is pushed forward, the battery feed wire is connected to the red motor lead and the motor and pump assembly operate to force the hydraulic fluid through the hoses to the lower ends of the double-acting cylinders.

The fluid forces the piston rods in the cylinders upward, thus raising the top. The fluid in the top of the cylinders returns to the pump for recirculation to the bottom of the cylinders. When the control knob is pulled rearward, the feed wire is connected to the dark green motor lead and the motor and pump assembly operate in a reversed direction to force the hydraulic fluid through the hoses to the top of the cylinders. The fluid forces the piston rods in the cylinders downward, thus lowering the top. The fluid in the bottom of the cylinders returns to the pump for recirculation to the top of the cylinders.

Raising the Top

See fig. 197.

When the red motor lead is energized, the motor drive shaft turns the rotors clockwise as indicated by the large arrow. The action of the pump rotors forces the fluid under pressure to the bottom of each cylinder forcing the piston upward. This action causes the fluid above the piston in each cylinder to be forced into the pump, which recirculates the fluid to the bottom of the cylinders. The additional fluid required to fill the cylinder due to piston rod displacement is drawn from the reservoir as indicated.

Lowering the Top

See fig. 198.

When the green motor lead is energized, the motor drive shaft turns the rotors counterclockwise as indicated by the large arrow. The action of the pump rotors forces the fluid under pressure to the top of each cylinder. This action causes the fluid below the piston in each cylinder to be forced into the pump which recirculates the fluid to the top of each cylinder. The surplus hydraulic fluid due to piston rod displacement flows into the reservoir as shown.

Fluid Control Valve

The fluid control valve consists of a rocker arm installed in the pump cover plate, and two steel ball. Fig. 199 shows the top surface of the pump cover plate. The dotted lines indicate the cavities on the bottom side of the cover plate. The cavities are designed to permit fluid flow between pump rotors and the reservoir.

Figures 200 and figure 201 illustrate the operation of the fluid control valve.

Checking Procedures

The mechanical and electrical checking procedures for checking the Hydro-Lectric System, which incorporates the rotor-type pump assembly, remains the same. The hydraulic checking procedure is outlined below.

Hydraulic Check Procedure

Failures in the hydraulic system can be caused by lack of hydraulic fluid, leaks in hydraulic system, obstructions or kinks in hydraulic hoses or faulty operation of a cylinder or pump. A pressure gauge can be used to check the pressure of the pump. See "Checking the Pressure of the Pump".

Checking Hydraulic Fluid Level in Reservoir

Operate top to raised position.
Disconnect positive cable from battery.
At the rear compartment, remove pump and motor shield.
Place absorbent rags below reservoir at filler plug.
With a straight-bladed screw driver, remove filler plug indicated at "A", fig. 202. Fluid level should be at the lower edge of filler plug hole as indicated by the dotted line.
If fluid is low, add Delco #11 hydraulic fluid (G. M. Hydraulic Brake Fluid Super # 11) to bring to specified level.
Reinstall filler plug and pump and motor shield. Connect positive cable to battery.

Checking Operation of Lift Cylinders

Remove the rear seat cushion and folding top compartment side panel assembly.
Operate the folding top control switch and observe the lift cylinders during the " up" of and "down" cycles for these conditions:

If the movement of the cylinder rods is not coordinated or sluggish when the motor is actuated, check the hydraulic hoses from the motor and pump to the cylinder for kinks.
If one cylinder rod moves slower than the other, the cylinder having the slower moving rod is defective and should be replaced..
If both cylinder rods move slowly or do not move at all, check the pressure of the pump. See "Checking the Pressure of the Pump".

Checking the Pressure of the Pump

Remove the motor and pump assembly from the rear compartment.
Install plug in one port, and pressure gauge in port to be checked, as indicated in fig. 203.
Actuate motor with an applied terminal voltage within the range of 9.5 volts to 11.0 volts. Pressure gauge should show a pressure between 240 psi. and 280 psi.
Check pressure in other port. NOTE: A difference in pressure readings may exist between the pressure port for the top of the cylinders and the pressure port for the bottom of the cylinders. This condition is acceptable if both readings are within the limit of 240 psi. and 280 psi. 0
If the pressure is not within the specified limits, the unit is defective and should be repaired or replaced, as required.

Keys and Locks

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

The side bar type lock (fig. 204) is used for the ignition, door and trunk lid on passenger cars. Glove compartment locks are wafer tumbler single bitted type having 4 tumblers on passenger cars These locks are all coded the same allowing a usage of one key for all locks on the vehicle. To protect owners, automobile lock manufacturers stamp the lock number on the lock core, shaft, etc., where they will not show until the lock is removed.

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

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

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

Numbers may be transposed to letters to numbers as follows:

Code Book-Numbers Code Book-Letters

1 C
2 N
3 B
4 Y

All side bar locks furnished to the field by the Parts Department are uncoded, that is, they are furnished without tumblers, springs or spring retainers; these parts are serviced separately. The tumblers come in four different depths indicated by colors "C" for copper, "N" for nickel, "B" for black and "Y" for yellow.

The side bar locks have six tumbler positions, and in looking up the cutting code, the following may be used as an example. After key code number is determined, either from key or from number stamped on lock cylinder refer to your code book and record the key cutting information as follows:

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

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

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

In cases where a code book is not available, the diagram as shown in figure 205 may be used to determine the tumblers required to assemble an
Lay the key on the diagram (fig. 205) with the bottom of the key flush with the edge of the drawing, head and point carefully lined up.
Read the code in letters C-N-B-Y from the head of key to the end from positions 1 to 6 inclusive. As each depth is determined write that letter in the blank space provided above the position numbers (1-2-3-4-5-6).
With the key properly lined up on the diagram, all cuts that show in the first section are to be marked "C."
Cuts that fall in the first black section, mark "N."
Cuts that fall in the White section, mark "B."
Cuts that fall in the second black section, mark "Y."

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

Lock Cylinder Assembly

Hold cylinder with head of cylinder away and starting at the head of the cylinder, insert the tumblers in their proper slots in the order called for by the code, ribbed side toward you and long point down (fig. 206F).
After all tumblers are in place, check for correctness with the code. Then press tumblers down with one finger (fig. 207).
Insert one tumbler spring in the space provided above each tumbler (fig. 208). CAUTION: If the springs are tangled, do not pull them apart-unscrew them.
Reverse the lock cylinders so that the head of the cylinder is now toward you. Insert the spring retainer so that one of its six prongs enters into each of the springs and the two large end prongs slide into the slots at either end of the cylinder (fig. 209). Press the retainer down with one finger.
To check, insert proper key and if tumblers are installed properly the side bar will be allowed to drop down. If bar does not drop down, remove the key, spring retainer, springs and tumblers and reassemble correctly. NOTE: If the tumblers have not been assembled correctly and not according to the code, the tumblers can be removed from the cylinder by holding it with the tumbler slots down, pulling the side bar out with the fingers and jarring the cylinder to shake the tumblers out. This procedure is necessary because after the tumblers have been pressed down into the cylinder they are hold in their slots by the cross bar.
If after checking it is found that the lock is assembled properly, remove key and, place cylinder in a vise using leather or wood on each side to prevent damage to the cylinder.
Stake the retainer securely in place by staking the cylinder metal over both edges of the retainer ends using a suitable staking tool at right angles to the top of the retainer and from the cast metal of the cylinder over the retainer at each comer.

Care of Trim

This section contains general directions for the proper care of the interior trim of the car and the convertible top.

Several types of cloth material are or have been used in the Chevrolet; Nylons, Gabardines, Broadcloths, Pile fabrics. They are distinguished in part by flat woven yarns as in the broadcloths and pile surfaces, upright fibers densely woven at right angles to the base of the fabric.

General Instructions

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

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

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

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

Cleaning Pile Fabric

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

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

Cleaning Broadcloths, Nylons and Gabardines

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

Safety Precautions for Cleaning Fabrics

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

Cleaning Genuine Leathers and Imitation

Leather

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

Lukewarm water and a neutral soap should be used and a thick suds worked up on a piece of cheesecloth and applied to the surface.
The operation should be repeated, using only a damp cloth and no soap.
The leather should then be wiped dry with a soft cloth.

Polishes and cleaners used for body finishes, volatile and other clear cleaners, naphtha, furniture polishes, oils, varnishes or household cleansing and bleaching agents should never be used.

Cleaning Convertible Top Materials

The top should be washed frequently with neutral type soap suds and lukewarm water. A brush with soft bristles should be used. Generous quantities of clear water should be applied over the entire top to remove any trace of soap which might remain.

If the top requires additional cleaning after using soap and water, a mild foaming type cleaner can be used. A small hand brush having soft or nylon bristles should be used for scrubbing. Add water to the cleanser until a soapy consistency is attained and clean approximately two square feet of the top at one time. After scrubbing, remove the cleanser with a sponge. Care must be exercised to keep the cleanser from running down and across the body finish which may cause streaks. After the entire top has been cleaned, rinse the top generously with clear water to remove any trace of cleanser which might remain. If desired, the top can be supported from the underside during the scrubbing operations.

Volatile and other clear cleaners, naptha, gasoline or household cleaners and bleaching agents should not be used.

Cleaning Carpet Floor Coverings

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

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

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

Cleaning Convertible Plastic Back Window

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

Assembly Manual

Body
Dash and Toe Panel Hole Location - LD
Dash and Toe Panel Hole Location - RD
Dash Panel Mat
Instrument Panel Name Plate
Instrument Panel Accessory Hole Covers
Ash Tray
Instrument Panel Trim Plates
Instrument Cluster Moulding
Steering Gear Jacket Cover
Windshield Wiper
Dash Panel Heater and Valve Hole Cover
Air Ventilator
Rear Emblem and Name Plate
Body Moulding
Rear Shock Absorber Hole Cover
Access Hole Masking and Floor Mat Installation
No. 1 Body Mounting
No. 2 Inner Body Mounting and Gauge Hole
No. 2 Outer Body Mounting
No. 3 Inner Body Mounting
No. 3 Outer Body Mounting
No. 3-A Body Mounting - Convertible
No. 3-A Body Mounting - Sport Coupe
No. 4 Body Mounting
No. 5 Body Mounting
No. 5-A Body Mounting - Convertible and 9 Passenger Station Wagon
No. 6 Body Mounting
Body Shim Holding
Body Shim
Grille Bars
Front Bumper
Rear Bumper
Hood, Name Plate and Ornament
Rear Ornament and Name Plate
Auxiliary Seat
Electric Windshield Wiper
Taxi Cab Equipment
Seat Electrical Control
Window Electrical Control
Fuel Injection - Nameplate and Emblem Top of page