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Cadillac 60 Series 1963, Shop Manual

The Cadillac 60 Series 1963 Shop Manual is available for free download from our website. This comprehensive manual provides detailed instructions and diagrams for maintaining and repairing this iconic vehicle. Accessible and user-friendly, it's a must-have resource for Cadillac enthusiasts. Download yours today from manualshive.com.

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Summary of Contents for 60 Series 1963

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Page 3: ...n unit number plate located on lower left hand corner of trans mission case rear face Differential carrier serial number located on bottom side of rear carrier flange Gear ratio identification at end of oil return See Section 7 Note 1 Freon Compressor serial number plate located on compressor sC Radio serial number identification sticker located on right side of tuner unit Guide Matic Phototube un...

Page 4: ...n this subject more quickly SERVICE INFORMATION Three standard series of cars with twelve body styles are included in the 1963 Cadillac line In addition there is a Commercial Chassis The numeral six is used as the first digit in desig nating all 1963 Cadillac body style numbers Specifications are as shown GENERAL DESCRIPTION AND SPECIFICATIONS Description Sedan de Ville 4 Window Sedan de Ville 4 W...

Page 5: ...Air Conditioning Engine Unit No Prefix 36X 36K 37X 37K b Engine Unit Number Each Cadillac engine carries an engine unit number prefix that indicates the type of engine followed by numbers in numerical sequence de noting the order in which the engine was built regardless of type starting with one The letters L C are added immediately following the engine unit number on all engines built to low comp...

Page 6: ...ange unless Figure 2 1 Service Notice otherwise specified The recommended engine oil change interval is every 60 days or 6 000 miles regardless of season More frequent changes are required with stop and go operation prolonged idling periods dusty road travel or during extended cold or wet cli matic conditions In such cases an oil change is recommended after 2 000 or even 1 000 miles of driving The...

Page 7: ...re the temperature seldom drops below zero most 10W oils are satisfactory for easy starting of the engine Where the temper ature is frequently below zero a 5W 20 or 5W oil is recommended however some 10W oils may be satisfactory b Adding EngineOil Always maintain the correct oil level Oil should be added when the level reaches the Add One Quart mark on the dipstick Do not fill a bove the Full mark...

Page 8: ...ounted on a boss on the right side of the engine Fig 2 3 Access to the filter is gained from under the hood Replacement procedure is as follows 1 Drain engine oil at recommended time or mileage interval 2 Unscrew element from filter base and dis card element 3 Wipe gasket area of base clean 4 Install new gasket in groove of new element Place a light film of silicone on top of gasket and Figure 2 3...

Page 9: ...with SAE approved Heavy Duty brake fluid to a level 3 4 inch below the top of the filler cap boss Care should be taken to wipe all dirt from the filler cap area be fore removing the caps to avoid contamination of the fluid Figure 2 4 Power Steering Reservoir Figure 2 5 Power Brake Reservoirs Check the travel of the service brake pedal and the parking brake pedal at the first oil change and each Sp...

Page 10: ...le and add 1 1 2 to 2 quarts of fluid to bring level ondip stick to proper level as indicated by operating temperature Fig 2 6 7 Check for leaks at torus cover and drain plug and replace cover plate on bottom of flywheel housing and lower car to floor 8 Turn off ignition and replace dipstick NOTE The capacity of the Hydra Matic transmission is approximately 9 quarts for a refill but the correct le...

Page 11: ...haft bearings or rear wheel bearings as all of these bearings are packed with sufficient lubricant at time of assembly In addition to the above lubrication is not re quired at any of the following locations a Front upper and lower suspension arm pivot points b Pitman arm or idler arm pivots c Manifold heat control valve d Front or rear pivot points of rear lower con trol links e Upper control yoke...

Page 12: ...ith used oil in the crankcase Special consideration should be given when conditions of high humidity high temperature or outdoor storage are encountered Local ex perience will dictate the additional protection measures in each particular case 3 Maintenance Services and Schedule 2 Run engine until completely warmed up then drain and refill with fresh oil that has been formulated to MS specification...

Page 13: ...which according to the label are 1 intended for MS service and 2 represented as passing car makers tests or General Motors Standard GM 4745 M If there is danger of oil contamination by dust water or other foreign material during very extreme driving conditions then the engine oil should be changed more frequently than shown in the table In such cases an engine oil change is recommended after 2 000...

Page 14: ...ng system for leaks Check brake linings for wear Check underside of car for excess dirt mud gravel tar etc paying particular attention to propeller shaft wheels and brake drums Inspect engine air cleaner for dust leaks Leak test complete Air Conditioner system Check service and parking brake pedals for travel If park ing brake adjustment is necessary lubricate links and cables at this time Every F...

Page 15: ...cate links and cables at this time Clean and oil clock FLUID CAPACITIES Unit Engine Crankcase When Filter is Changed Cooling System With Heater Non Air Conditioned Cars With Heater Air Conditioned Cars 75 Series Only Non Air Conditioned Cars 75 Series Only Air Conditioned Cars Without Heater and Air Conditioning Air Conditioner Refrigerant 12 75 series Only A C Compressor Oil 525 Viscosity 75 seri...

Page 16: ... four digits and the suffix letter A SAE Approved Heavy Duty Brake Fluid SAE 90 Multi Purpose lu bricant conforming to MIL L 2105 B specifications Standard Differential only Special Hypoid Lubricant available from factory Parts Warehouse Standard and Con trolled Differential Cadillac Recommended Fluid Series 60 62 75 Comm l Chassis Front 24 24 28 24 Rear 24 24 28 32 When speeds in excess of 75 MPH...

Page 17: ...w O H o ...

Page 18: ...ary to fill the gap remaining between the body and frame after the mounting pads are in stalled The correct number of shims required at each bolt location may be determined by attempt ing to rotate the pad between the body and the frame If the pad can be rotated with the fingers add body shims until pad can no longer be rotated 2 Checking Frame for Twist 1 Place car on section of level floor and i...

Page 19: ...s Member B o d v Bracket 3 Cross Member 12 Body H Body Bracket Bracket Coupes 6257 6357 5 Body Bracket 1 Cross Member 1 Body Bracket 2 Body 4 Body Bracket A Q Convertibles 6267 6367 5 Body Bracket T E T 2 Cross Member 3 Cross Member 1 Cross Member 1 Body Bracket 2 Body Bracket Limousines 6723 6733 5 Body Bracket Figure 3 1 Body Bolt Locations ...

Page 20: ...lt Washer Plain Washer Lock Nut H Anti Rattle Bolt K Spacer Block Tapping Retainer Bolt V After Shimming 58 42 Shim As Required To Take Up Body And Frame Variations After Shimming Shimming Methods Pad Restricted Type Pad Non Restricted Type Pad Figure 3 2 Body Bolt installations ...

Page 21: ...7 1 16 89 29 32 2 5 8 A Overall width of 1 cross member B Maximum span of frame at 2 cross member C Outer left front body bolt to outer right front body bolt D Overall width of rear cross member E Front vertical surface of 1 cross member to centerline of front wheels F Centerline of front wheels to front body bolts G Front body bolt to outside rear corner of 4 body bracket H Outside rear corner of...

Page 22: ...FRAME 3 5 Figure 3 3 Frame Checking Locations ...

Page 23: ...8 ...

Page 24: ...ces an anti dive reaction during braking A rubber compression bumper on the lower suspension arm limits upward travel of the sus pension system and a rubber rebound bumper on the upper suspension arm limits downward travel Both bumpers are held in place by means of a pull through tab Diagonal tie struts are used on the front sus pension system to control the fore and aft move ment of the wheels Th...

Page 25: ...her Ground Strap B p l t Lock Washer W a s h e r Bushing Service Plug Upper Spherical Joint Rebound Bumper Garter Spring Spring Retainer Rubber Insulator Seal Garter Spring Lock Nuts r Lower Spherical Joint Service Plug Fig 4 1 Front Suspension Disassembled ...

Page 26: ...ommerical Chassis The front ends of the lower control links are attached to brackets that are riveted to the num ber 4 body brackets on 60 and 62 series cars Four bolts are used to attach the brackets on 75 series cars The rear ends of the lower control links are attached to brackets on the axle housing Rubber bushings are used at both front and rear mounts The two front arms of the upper control ...

Page 27: ... little as possible and the towing speed kept below 30 MPH Failure to follow these precautions may result in front wheel shimmy which could seriously overstress the steering gear and linkage 2 Hoist Recommendations Lifting equipment of the type that engages the suspension axle or wheels is preferred when lifting 1963 Cadillac cars Hoist support plates are provided on the under side of the lower fr...

Page 28: ...heck condition of spherical joints and all bushings Note 14 6 Check for looseness in steering gear and connections 7 Check caster and camber Notes 3c and 3d 8 Check toe in Note 3e and straight ahead position of steering wheel b Measuring Methods All wheel alignment equipment manufacturers provide detailed instructions for checking wheel alignment with their alignment equipment These instructions s...

Page 29: ... 4 6 Recheck to make sure adjustment is correct after lock nuts have been tightened Then install air deflector on underside of frame front cross member Before adjusting caster loosen tie struts at lower suspension arms This will allow tie strut to center itself and prevent damage to bushings and premature wear at frame front cross member To provide more negative caster lengthen tie struts by loose...

Page 30: ...ordance with instructions provided by the wheel alignment equipment manufacturer Before checking toe in make certain that drag link height is correct See Section 5 Note 5 The readings should be taken only when the front wheels are in a straight ahead position and with steering gear on its high spot The correct setting should be between 3 16 inch and 1 4 inch Toe in is adjusted by turning the tie r...

Page 31: ...2 inch diameter studs are used to mount the wheel All wheel mounting studs have right hand threads The spider section of the wheel is re versed to accommodate deep formed wheel discs Wheels used on Seventy Five series cars and commercial chassis are the same as those used on 60 and 62 series cars except that they are riveted together and are of heavier stock thick ness They are painted light gray ...

Page 32: ...g to the pattern shown in Fig 4 11 Right Front Left Front Left Rear Fig 4 1 1 Tire Rotation e Tire Noise Complaints Complaints of axle noise are frequently caused by tires rather than by differential gears or bearings To determine whether tires are causing the noise drive the car at various speeds and note the effect of part throttle sudden acceleration and deceleration on noise level Axle and exh...

Page 33: ...ad face Fig 4 13 Position knob Dial Indicator Support J 6126 so that it will be least affected by tread pattern Set indicator at zero 5 Rotate tire and wheel assembly note and record amount of runout Mark tire tread where minimum and maximum runout occurs Maximum runout as measured on tire should not exceed 050 inch NOTE If runout is excessive but does not exceed 090 inch it may be possible to red...

Page 34: ...o ex cessive tire runout bolt circle runout and or wheel flange runout If wheel flange or bolt circle is not the cause of excessive runout it is an in dication that the tire is responsible and it should be replaced If wheel runout measurements as made on car are excessive and total tire and wheel runout cannot be reduced by the above procedures the wheel should be replaced g Wheel and Tire Balance...

Page 35: ... in contact with the ground will drive when the opposite wheel is raised and rotated This type balancer may be used however by raising the complete as sembly and removing the wheel opposite the one being balanced 7 Start wheel in motion and allow it to stop by itself several times If it continually stops in the same position the assembly is not in static balance 8 Mark lowest or heaviest point and...

Page 36: ... be moved with finger vibration may cause it to wear and break ending its protection b Front Wheel Bearing Removal 1 Remove wheel disc 2 Raise front end of car 3 Remove wheel assembly from brake drum 4 Remove dust cap cotter pin spindle nut washer and outer cone and roller assembly Fig 4 16 5 Remove brake drum from steering knuckle spindle 6 Remove inner bearing grease retainer and cone and roller...

Page 37: ... assembly on flange area of hub 4 Install inner bearing cup using Front Hub Inner Bearing Cup Installer J 8458 and Handle J 8092 Use arbor press to install bearing cup in hub Fig 4 19 Inner Bearing Universal Handle J 8092 Fig 4 19 Installing Inner Bearing Cup 5 Place inner bearing cone and roller assembly in inner bearing cup 6 Install new grease retainer using Front Wheel Hub Grease Retainer Inst...

Page 38: ...l must be installed asex plained in Section 7 Note 8 6 Checking Standing Height Before checking standing spring height make sure that trunk is empty except for spare tire and jack and that there is a full tank of gasoline as all specifications are based on this curb weight Normalize position of springs by working bumper up and down release bumper and permit car to assume its normal position a Fron...

Page 39: ...ding lower end of shock ab sorber to lower suspension arm 3 Remove shock absorber through bottom of lower arm b Installation 1 Install retainer and rubber grommet on shock absorber upper stem and fully extend shock ab sorber rod 2 Insert shock absorber assembly up into coil spring and guide stem through tower in cross member Then place lower end in position on lower suspension arm and install bolt...

Page 40: ...sion Arm Nut 4 Install mounting brackets over rubber bush ings and secure with bolts Fig 4 24 Tighten bolts to 20 foot pounds 5 Install grommet retainer and nut on bottom of each link Tighten nut to end of threads 10 Tie Strut and Bushings Removal and Installation a Removal 1 Raise front end of car and place jack stands under frame 2 Remove four bolts that hold air deflector to underside of frame ...

Page 41: ...centric and steering knuckle to facilitate alignment at time of installation 5 Remove joint from knuckle using a 7 16 incla steel rod approximately 20 inches long rounded on one end Install a standard nut part way on stud and insert rounded end of rod inside nut Strike end of rod with a heavy hammer until joint is free from steering knuckle then remove standard nut 4 Camber Eccentric Fig 4 26 Remo...

Page 42: ...ight coating of grease on outside taper of camber eccentric and install camber eccentric on joint stud Fig 4 28 Installing Spring on Upper Spherical Joint Seal and install joint stud and camber eccentric in steering knuckle remembering to align scribe marks on eccentric and knuckle 18 Install standard nut on joint stud and tighten nut until camber eccentric locks in knuckle then remove standard nu...

Page 43: ...a red label can is used r 15 Install new service plug in spherical joint cover 16 Install new seal on spherical joint as des cribed in Note 11 Step 15 When installing garter spring use the larger flanged surface of Garter Spring Installer J 9148 Fig 4 29 and lubricate inside diameter of flanged surface with suspension lubricant red label 17 Guide spherical joint stud into steering knuckle support ...

Page 44: ...hould be checked by noting the amount of free play as the joint is worked verti cally in its socket Free play should not exceed 1 16 inch Replace joint if it exceeds this limit NOTE If joints are to be cleaned use a clean cloth only Do not use solvent 15 Front Upper Suspension Arm Removal and Installation a Removal 1 Raise front end of car place jack stands under lower suspension arms and remove w...

Page 45: ...al to facilitate removal of bushings from shaft Dimensions of the spacers are shown in Fig 4 33 Also provide two 1 2 inch x 2 inch bolts with nuts to hold spacers in position around shaft a Removal 1 Remove bolt lockwasher and flat washer from each end of shaft and remove ground strap 2 Install spacers on shaft between arm ends Secure spacers to shaft with bolts and nuts Fig 4 34 3 Apply a liberal...

Page 46: ...der However when bushing attaching bolts are tightened bushing inner sleeves will seat themselves 8 Remove arm assembly and installer tools from arbor press and remove spacer tool 9 Install ground strap on one end of arm 10 Install flat washer lockwasher and bolt on each end of shaft securing ground strap under bolt head NOTE Do not torque bolts until arm as sembly is installed on car Proper torqu...

Page 47: ...ng plate outward from bottom and raise arm into position Guide spring into position with tang end between raised edge on top of lower arm and center line of shock absorber Spring may have a tendency to rotate as arm is raised mispositioning tang end End of tang must Fig 4 36 Locating Tang End of Spring Fig 4 37 Coil Spring Installation be between raised edge of arm and center line of shock absorbe...

Page 48: ...lace Spacer J 8999 8 Fig 4 39 Installing Bushing in Lower Arm around bushing sleeve between flanged sides of arm 4 Position Bushing Remover J 8999 10 on bushing sleeve Fig 4 38 and press bushing out of arm b Installation 1 Position Support J 8999 2 on arbor press anvil and insert smaller diameter flanged end of bushing mount in Support 2 Install new bushing in arm smaller diameter end of bushing f...

Page 49: ... foot pounds 2 Guide lower spherical joint stud into steering knuckle lower support 3 Install standard nut on joint stud and tighten until stud locks in knuckle then remove standard nut and install lock nut tightening to 65 foot pounds 4 Position brake backing plate on steering knuckle spindle install locking plate and start anchor bolt into upper knuckle support 5 Install grease guard and support...

Page 50: ...because the welding process will change the grain structure of the metal making it unsafe 22 Rear Upper Control Yoke Spherical Joint Removal and Installation a Removal 1 Raise car and place jack stands under front and rear frame side rails 2 Place jack under forward end of differential housing and raise slightly to relieve tension on drive line 3 Remove nut from spherical joint stud Fig 4 41 Fig 4...

Page 51: ...lt Fig 4 42 5 Slowly lower jack and remove rear coil spring and rubber insulator 6 Remove nut from rear pivot bolt and remove pivot bolt Fig 4 42 7 Remove rear end of control link from mount ing bracket on axle housing and remove control link NOTE The front and rear bushings in the lower control links are serviceable and can be removed and installed by using an arbor press b Installation 1 Slide c...

Page 52: ...af Spring Removal and Installation Commercial Chassis a Removal 1 Jack up car so that weight of body is en Fig 4 43 Rear Leaf Spring Shackle tirely off the spring and support axle housing with adjustable stands 2 Remove front shackle bolt nut and drive out shackle bolt 3 Disconnect shock absorber from U bolt plate 4 Remove rear shackle nuts and link Fig 4 43 5 Remove U bolt nuts washers lower spri...

Page 53: ...ht Wheel bearings incorrectly ad justed or worn CORRECTION Adjust drag link height Inflate t i r e s to p r o p e r pressure Interchange tires Clean and adjust Check and adjust caster or camber as necessary Check alignment of rear wheels with front wheels Replace shock absorbers Check for binding with front wheels off floor Adjust and lubricate bearings Check spring height and re place if necessar...

Page 54: ...orbers inoperative Front springs weak or sagging Non standard or incorrect size tires used CORRECTION Balance wheels and tires Check for tire and wheel wob ble or out of round See that wheels and tires are properly mounted Isolate and replace Adjust or install new parts if necessary Check and adjust to specifica tions Replace lower joints and or upper arm assembly Replace and repack seals Adjust o...

Page 55: ... lbs 2750 2850 lbs 3200 lbs Front Standing Height 7 3 8 8 1 4 7 7 8 8 5 8 5 1 2 6 1 4 Rear Standing Height 5 13 16 6 9 16 6 5 8 7 3 8 4 1 4 5 Curb Weight is based on estimated weights that include radio heater power seat power windows full tank of gas andno passengers Add130lbs to front for Air Conditioned cars Approximate FRONT COIL SPRING CHART Series 60 and 62 Without Air Conditioner 60 and 62 ...

Page 56: ...ceed 1 2 Toe in car on ground 3 16 Turning radius 60 and 62 series 75 series Comm l Chassis Outside wheel angle with inside wheel at 20 is 22 11 Inside wheel angle with outside wheel at 20 is 18 10 Wheels Rim Diameter Rim Width Radial Runout Maximum Lateral Runout Maximum 6 r I Q LO l o to 3 8 0 1 4 1 1 2 1 to 1 4 22V 6 25T 27 15 6 035 045 All Series Item Unless Otherwise Tires Size Black 60 and 6...

Page 57: ...er clamp nuts Tie rod pivots to steering arms Tie strut to lower arm Tie strut to frame at front bushing Wheel mounting nuts Rear lower control link at front bushings Rear lower control link front mounting bracket 75 Series only Rear lower control link at rear bushings Upper control yoke pivot bolt nuts at front bushings Spherical joint to upper control yoke replacement only Spherical joint to top...

Page 58: ... Handle use with J 8456 J 8457 and J 8458 Front Hub Grease Retainer Installer Front Hub Inner Bearing Cup Installer Key E F G H I Tool No J 8457 J 8990 J 9231 J 9280 J 9148 Name Front Hub Outer Bearing Cup Installer Puller Front Suspension Camber E c c e n t r i c and Steering Linkage Joints Camber Adjusting Wrench Repacking Gun Spherical Joints Garter Spring Installer ...

Page 59: ...ELDORADO BIARRITZ CONVERTIBLE 6367 ...

Page 60: ... assemblies and a one piece forged steel drag link The pitman arm connects the left side ofthe drag link to the steering gear and the idler arm and bracket assembly connect the right side of the drag link to the frame The tie rods serve as connecting links between the drag link and steering arms Filler Ca ttJK Power Steering Pump Fig 5 1 Steering Pump Location Extended life spherical joints are us...

Page 61: ... balls act as a rolling thread between the steering worm and the rack piston The one piece rack piston assembly is geared to the sector of the pitman shaft The hydraulic rotary valve is concentric with the input shaft and is contained in the upper sec tion of the gear housing It contains a spool that is held in neutral position by means of a torsion bar The spool is attached to one end of the tor ...

Page 62: ...pump pressure and steering gear adjustment These should always be checked be fore any major service operations are performed Conditions such as hard or loose steering road shock or vibrations are not always due to steer ing gear or pump but are often related instead to such factors as low tire pressure and front end alignment These factors should be checked and corrected before any adjustment of t...

Page 63: ... than 5 seconds 6 To determine which unit is at fault check pump output separately by slowly closing gage valve When pressure peaks on gage note reading and quickly open gage valve Pressure reading should come up between 1100 and 1200 psi when valve is closed and between 1250 and 1275 psi on Seventy Five series cars and Commercial Chassis CAUTION Do not leave gage valve closed for more than 5 seco...

Page 64: ... nut and recheck preload to insure that plug did not move when nut was tightened Fig 5 6 Disconnecting Pitman Arm at Drag Link b Checking Worm and Ball Preload V2 Turn Off Center 1 Locate center of steering wheel travel and turn wheel 1 2 turn off center 2 With wheel 1 2 turn off center measure and record total pull through an arc not exceeding one inch Due to worm and ball preload the total pull ...

Page 65: ... jacks below the drag link midway between drag link and lower control arm 2 Adjust height of jacks so that distance A from top of bar to centerline of lower control arm inner pivot bolts is equal on both sides Fig 5 8 Adjusting jacks so that this distance is an even number of inches will simplify this mea surement NOTE Use a combination square as shown in Fig 5 8 when measuring this distance makin...

Page 66: ...be checked Proper adjustment between these two units is essential to prevent side loading on upper steering shaft lower bearing and stub shaft of steering gear Poor steering returnability transmission of steering gear noises through steering column and excessive wear of valve lands on valve bore in housing result from misalignment of steering shaft with steering gear stub shaft Alignment of steeri...

Page 67: ... at rear of pump reservoir Cap pump fittings to prevent drainage of fluid from pump Also cap or tape hose fittings 3 Loosen two bolts that hold pump mounting bracket to engine tilt pump toward engine center line and remove drive belt from pump pulley CAUTION Do not attempt to remove pulley with pump on car as there is not enough clear ance for puller tool 4 Remove bolts previously loosened and re ...

Page 68: ...late retaining ring so that one end of ring is over hole in housing Spring one end of ring with punch to allow screwdriver to be inserted to lift ring out Fig 5 13 7 Remove end plate End plate is spring loaded and will generally raise above the housing making removal easy However if end plate should stick a slight rocking action on top surface will free the plate 8 Remove pressure plate spring 9 R...

Page 69: ...Inspect pump shaft for score marks ex cessive wear or damage particularly at splines keyway and at bearing and seal surfaces Separate and inspect rotor and vanes for wear and general condition Seal Pump Housing Fig 5 14 Installing Pump Shaft Seal 5 Inspect shaft bushing in pump housing and replace pump housing if bushing is scored or excessively worn 6 If any internal parts are found to be worn or...

Page 70: ...uter circumference with a wooden hammer handle 13 Install pressure plate spring 14 Lubricate outside diameter of end plate Retaining Ring End Plate Fig 5 17 Installing End Plate Retaining Ring with petrolatum and install end plate in pump housing 15 Place pump housing in arbor press de press end plate below retaining ring groove and install end plate retaining ring Fig 5 17 Make certain that ring ...

Page 71: ...cking facing pulley end of shaft 7 Install seal using Pump Shaft Seal Installer J 21001 Fig 5 19 Tap tool lightly with small hammer until seal is properly seated in shaft hub 8 Install woodruff key on pump drive shaft 9 Install pump on car as described in Note 7B Steps 2 through 11 10 Steering Gear Assembly Removal and Installation a Removal 1 Disconnect pressure and return line hoses at rear of p...

Page 72: ... end plug is tightened to 50 foot pounds during assembly and could break during removal if not handled carefully 5 Remove lock nut from pitman shaft adjuster screw and discard 6 Remove four side cover to housing retaining screws and lock washers from cover 7 Rotate pitman shaft adjuster screw with an Allen wrench until side cover is lifted free from housing 8 Separate side cover from pitman shaft ...

Page 73: ...oulder in gear housing and pry out seal Be careful not to damage seal bore Discard seals 4 Inspect pitman shaft needle bearing and if rollers are broken or pitted drive needle bearing from gear housing bore with Pitman Shaft Bear ing Remover and Installer J 6657 Fig 5 25 Inspection 1 Inspect housing bore If badly scored or worn replace housing 2 Inspect high pressure line hose connector seat in ge...

Page 74: ...to bore using Seal Installer J 6219 Fig 5 26 Do not drive seal more than 1 8 inch below lip of bore 4 Remove tool and place steel washer on top Pitman Shaft Seal Installer J 6219 I 4 H I Fig 5 26 Installing Pitman Shaft Seal of seal Using Tool J 6219 drive seal approx imately 1 2 inch further into bore 5 Lubricate double lip seal with power steering fluid and install seal into housing bore Using S...

Page 75: ...ese conditions are found replace races and check thrust bearing and thrust bearing spacer Assembly 1 If adjuster plug needle bearing was previous ly removed install new needle bearing on Tool J 6221 with letters on bearing against tool Po sition bearing and tool over thrust bearing end of plug and drive bearing into plug Fig 5 28 End of bearing must be flush with bottom surface of stub shaft seal ...

Page 76: ...sion bar and valve cap assembly by holding valve assembly in both hands as before only with thumbs on valve body Tap torsion bar lightly against workbench This will dislodge cap from valve body to cap pin Stub shaft torsion bar and valve cap assembly can now be removed from valve body 5 If valve spool has become cocked as des cribed in Step 3 it can now be freed Visual in spection on a flat surfac...

Page 77: ...sing pin in stub shaft and carefully engage spool in valve body bore CAUTION Because clearance between spool and valve body is very small extreme care must be taken when assembling these parts Push spool evenly and slowly with a slight twisting motion until it reaches drive pin Ro tate spool slowly with pressure until notch engages pin Before pushing spool completely in make sure dampener O ring s...

Page 78: ...m to one ball return guide and install the 6 remaining balls into guide Place the other guide over the balls and ball guide and insert guides into guide holes of rack piston Make sure black ball in guide is installed next to white ball in rack piston Guides should fit loosely 7 Place return guide clamp over guides and secure with two screws and lockwashers Tighten screws to 12 foot pounds 8 Worm g...

Page 79: ...unit CAUTION Do not push against stub shaft as this might cause stub shaft and cap to pull out of valve body allowing spool seal to slip into valve body oil grooves Valve assembly can be installed by pushing on the outer diameter of the valve body housing with the fingers of both hands Make certain that Teflon rings are not binding on inside of housing Valve assembly is properly seated when oil re...

Page 80: ...r ring into place with fingers Slight tapping may be required to bottom retainer ring in the gear housing securely 21 Position gear assembly with stub shaft end up and adjust thrust bearing preload as follows Torque Wrench J 7754 flf Spanner Wrench J 7624 Fig 5 36 Adjusting Thrust Bearing PreLoad a Using Spanner Wrench J 7624 lightly tighten adjuster plug and then back off 1 8 turn b Install 0 25 ...

Page 81: ...tor seats using a 5 16 18 tap CAUTION Do not tap threads too deep in pressure hose connector seat as tap will bottom poppet valve against housing and damage it It is necessary to tap only 2 or 3 threads deep 4 Thread a 5 16 18 bolt with a nut and flat washer into tapped hole Fig 5 38 5 To pull connector seat hold bolt from ro tating while turning nut off bolt This will pull connector from housing ...

Page 82: ... and remove be fore attempting new seal installation b Installation 1 Clean end of pitman shaft bore to prevent entrance of dirt into housing or damage to seals as they are installed 2 Wrap tape around splines of pitman shaft to prevent damage to seals as they are installed Use only one layer of tape to assure adequate clear ance for seals 3 Install seals as explained in Note 12a steps 3 4 5 and 6...

Page 83: ... to the right of center Be careful not to damage joint seals when adjusting tie rods NOTE Tie rod adjustment should be made on a wheel alignment machine so that correct toe in setting is maintained 17 Steering Column Assembly Removal and Installation a Removal 1 Remove flexible coupling to upper steering shaft retaining screw 2 Disconnect lower shift lever from manual control rod and remove shift ...

Page 84: ...hat hold directional signal housing to column assembly and remove di rectional signal housing and harness and spring washer 5 Press upper shaft upper bearing out of di rectional signal housing being careful not to dam age nylon switch assembly 6 Remove transmission shift lever 7 Remove Hydra Matic shift indicator pointer mounting base from shifter tube 8 Working from lower end of steering shaft re...

Page 85: ...t rubber seal back up washer spring washer and snap ring on lower end of steering shaft 8 Install jacket on shifter tube 9 Install Hydra Matic shift indicator pointer mounting base in shifter tube 10 Install transmission shift lever 11 Install shift lever leaf spring 12 Press upper bearing into directional signal housing being careful not to damage nylon switch assembly NOTE Make certain that bear...

Page 86: ...s and nuts from outer tie rod pivots at steering arms 2 Remove tie rod pivots from steering arms using Puller J 8990 Fig 5 42 Be careful not to damage joint seals 3 Remove idler arm support mounting screws from frame side member 4 Remove nut and lock washer from end of pit man shaft Fig 5 42 Removing Tie Rod From Steering Arm 5 Break pitman arm loose from pitman shaft using Pitman Arm Puller J 917...

Page 87: ... Install new dust seal on pitman arm pivot stud and install pitman arm on drag link Tighten nut to 40 foot pounds and install cotter pin DIAGNOSIS CHART CONDITION Pump Noise Excessive Wheel Kick Back or Loose Steering CAUSE Loose belt Pressure hose touching other parts of car Low oil level Air in the oil Excessive back p r e s s u r e caused by hoses or steering gear Scored pressure plate thrust p...

Page 88: ...ve spool Rubber spacer binding in shifter tube Improper front wheel align ment Loose hose connections Damaged hose Side cover O ring seal Pitman shaft seals Housing end plug seal Adjuster plug seals Torsion bar seal CORRECTION Remove rack piston and worm Inspect for worn parts and re place as necessary Replace valve See Note 14 Tighten attaching screws to 45 foot pounds Tighten retaining screws to...

Page 89: ... level Loose pump belt Sticky flow control valve Top of reservoir Reservoir too full Air in the oil At reservoir O ring cut O ring improperly installed At pressure union o r cover screw Not tightened sufficiently Cross threaded or damaged seat Defective seat on hose end Damaged seals At the shaft seal Defective seal Damaged shaft Leaks in the metal part CORRECTION Adjust to specifications Check ge...

Page 90: ...n or replace belt Check pump pressure Note 2 Adjust to specifications Fill to proper level If exces sively low check all lines and joints for evidence of external leakage Replace seal and repack spherical joint Inflate to recommended pres sure Loosen bolt and assemble properly Align gaging position of flexi ble coupling see Note 6 Check and adjust as necessary Test steering system for bind ing wit...

Page 91: ...ve stuck or inoperative Loose screw in end of flow control valve Pressure plate not flat against ring Extreme wear of cam ring Scored pressure plate thrust plate or rotor Vanes not installed properly Vanes sticking in rotor slots CORRECTION Remove kink Remove hoses and remove re stricting object or replace hose Remove gear from car for dis assembly and inspection of ring and housing bore Remove ge...

Page 92: ...t the valve hiss into the car TORQUE SPECIFICATIONS Material Number 280M Special Special Special Special Special 280M Special 260M 280M Special 280M Special Special Special 280M 286M 260M Special NOTE Refer Application Steering Gear to Frame Screw Tie Rod Pivot to Steering Arm Nut Tie Rod Adjuster Clamp Nut Pitman Arm to Drag Link Nut Idler Arm to Drag Link Nut Inner Tie Rod Pivot to Drag Link N t...

Page 93: ...and Installer Adjuster Plug Seal Protector Adjuster Plug Bearing Remover and Installer Pulley Puller Pitman Arm Puller Key K L M N 0 P Q R S T U Tool No J 4245 J 1859 02 J 7576 J 6217 J 7539 J 21000 J 7624 J 21001 J 7754 J 8990 J 7316 Description Snap Ring Pliers 3 Steering Wheel Puller Rack Piston Seal Compressor Valve Connector Seat Installer Rack Piston Arbor Pump Shaft Oil Seal Protector Spann...

Page 94: ...sun gear This provides 1 55 to 1 reduction When the front unit coupling is filled with oil the sun gear and internal gear are driven at the same speed and the planetary gearset rotates as a unit providing direct drive Rear Unit Fig 6 1 Power from the front unit is transmitted to the rear unit through two shafts the intermediate shaft and the mainshaft Power is transmitted from the front unit plane...

Page 95: ...6 2 HYDRA MATIC TRANSMISSION Fig 6 1 Basic Construction of Hydra Matic Transmission ...

Page 96: ...he neutral clutch allowing the rear unit to free wheel so that no power is transmitted to the output shaft Drive 4 position applies the neutral clutch to place the transmission in normal operating range All four forward speeds will then occur in normal sequence Selector Position PARK NEUTRAL DR 4 DR 3 LO REVERSE Speed 1 2 3 4 1 2 3 1 2 FRONT UNIT Front Unit Coupling Front Sprag Clutch Overrun Clut...

Page 97: ...rect if neces sary a Oil Level b Manual Linkage Adjustment c TV Linkage Adjustment 4 When a shift is missing do not attempt an upshift by overspeeding the engine 5 Do not alter shift pattern by changing se lector lever position while car is in motion 6 If operation condition is not found in table use digit for normal 7 Connect a portable tachometer to engine whenever possible Engine RPM will ident...

Page 98: ... X 2ND 3RD x OR 4TH GEAR X Disconnect TV rod r ch ck in DR 3 for possible chang J NO 4TH GEAR Do not y exceed 76 MPH JS NO 3RD OR 1 4th GEAR NORMAL j i 1 W DR 3 g 7 NO 2ND OR 4th GEAR SKIPS 2ND GEAR y NO 1 S T O R 2ND GEAR mammmmmmmmammmmmmmmmmmmmmmmmmmm m v 2ND GEAR X ONLY SKIPS S 3RD GEAR DRive 3 Table NO ENGINE BRAKING IN REVERSE y Check obov 10MPH yS S L I P S IKl REVERSE i NORMAL See items 7 ...

Page 99: ...ndition Index Fig 6 5 and find Index Number that corresponds to 5 digit Con dition Number 2 Using Index Number refer to Diagnosis Index Fig 6 7 for cause or causes of condition h Summary For additional information in diagnosing the Hydra Matic transmission a summary of the various clutches overrun band and front unit coupling in the various speeds and driving ranges is found in Fig 6 2 A summary o...

Page 100: ...be observed to prevent fluid leaks are as follows 1 Use new gaskets and O ring seals whenever there is a disassembly 2 Use a very small amount of petrolatum to hold gaskets and thrust washers in place during assembly or to seal gaskets Never use gasket paste or shellac 3 Make sure that composition cork and paper gaskets are not wrinkled or creased when in stalled Make sure that gaskets have not st...

Page 101: ...ressure at idle speed with transmission in neutral If line pres sure of 95 lbs is found item a is indi cated If line pressure of 65 lbs is found Item b is indicated 9 Condition 2 7452 Rear unit fails to provide direct drive has reduction only a G2 governor valve stuck closed b 2 3 Shift valve stuck closed c No 1 governor ring broken d G2 passage through reverse piston cover to shift valve body obs...

Page 102: ...ee next paragraph Replace only the accumulator body leaving out the band servo piston and spring Replace oil pick up lines screen pan and oil to test Stall condition indicates item a If the car has a normal reverse item b is indicated Consult oil circuit chart for possible points where line pressure could leak into the passage found to be causing the stall con dition Check these points in the tran...

Page 103: ...eal retainer contacts flywheel 3 Flywheel screws not torqued to specifi cations 4 Front seal leak Check front seal to see that it is correctly installed and is not damaged When installing a new front seal make sure that bore is free from staking material and that garter spring on seal is correctly positioned Also check finish of torus cover neck and bearing sur face in flywheel housing 5 Flywheel ...

Page 104: ...maged F Oil Seal Ring Front unit torus cover to oil pump Inspect ring to determine whether it is correctly installed and not damaged G Bushing Front unit torus cover to driven torus shaft Inspect bushing to determine whether it is loose or worn excessively H Bushing Oil pump to front unit driven torus shaft Inspect bushing to determine whether it is loose or worn excessively I Oil Seal Ring Driven...

Page 105: ...mp The oil pump may produce a whine at any time the engine is running especially during 1 2 and 3 4 upshifts when hot This is distinguishable from gear noise because it remains through all gear ratios and noise will change with engine but not car speed 7 Linkage Adjustment a Manual Linkage 1 Remove slush deflector 2 Remove clevis from manual lever on trans mission Fig 6 11 3 Loosen lock nut on tra...

Page 106: ...t against trunnion until all slack is taken up Then tighten nut three full turns Fig 6 11 Manual and Throttle Levers Fig 6 12 T V Rod Adjustment 9 Turn rear adjusting nut into contact with trunnion and use two wrenches to tighten nuts Be careful not to put any binding force on carburetor plate 10 Remove drill shank from relay bracket 11 Road test car Adjustment may be altered as required to improv...

Page 107: ...luid 1 Remove lower flywheel housing cover plate 2 Remove drain plugs Fig 6 14 from trans mission oil pan and torus cover 3 Allow old fluid to drain completely and then reinstall drain plugs Replace lower flywheel housing cover plate 4 Pour seven quarts of Hydra Matic fluid into filler tube 5 Run engine at a speed of 800 RPM for ap proximately 1 1 2 minutes with selector lever in P Park 6 Reduce e...

Page 108: ...e seal lip 3 Install eight extension housing to case screws 4 Install speedometer drive gear and connect cable 5 Install rear engine support on frame 6 Remove transmission hoist and install sup port to extension housing screws 7 Install propeller shaft assembly See Section 7 Note 10 8 Install parking brake relay lever and re tracting spring in position in frame Connect brake cables to lever and ad...

Page 109: ... in Note 14 13 Removal of Transmission from Car 3 Drive old seal out of bore 4 Using a file carefully clean staked material out of bore 5 Place Flywheel Housing Support J 7027 on level area and position flywheel housing on support 6 Slide new seal on pilot of Flywheel Housing Oil Seal Installer and Staker J 7026 and position 1 Disconnect battery 2 Place car on hoist or on jack stands 3 Remove star...

Page 110: ...e into transmission case Avoid pulling back on the sleeve once installation has been made in the transmission case CAUTION If it becomes necessary to pull on the sleeve then completely remove sleeve from transmission case and reposition the seal to insure that seal is not damaged or mispositioned 5 Connect oil cooler lines to cooler sleeve hoses and secure with clamps Torque clamps to 20 inch poun...

Page 111: ...asher lock washer and retaining nut 26 Slide each cushion support toward bell housing until cushion support just touches housing NOTE Be sure that underside of cushion support bracket is flat against frame 27 Scribe a reference line on frame adjacent to each bracket 28 Slide each bracket 1 16 inch inboard toward bell housing letting rubber cushion ride up bell housing 29 Tighten each retaining nut...

Page 112: ...torus member together 6 Remove bronze thrust washer and steel se lective washer from front unit sun gear 7 Remove front unit sun gear from shaft of front unit coupling driven torus member 8 Remove intermediate shaft snap ring using Pliers J 8059 Driven Torus Assembly OMain Shaft Outer Snap Ring Cotter Pin Retaining Torus Check Valve and Spring Fig 6 22 Removing Driving Torus Snap Ring 9 Remove int...

Page 113: ...all lock pin in base with oil pan facing up c Remove Oil Pan Oil Strainer and Intake Pipe NOTE Units may be removed with trans mission in car 1 Take out fifteen cap screws and lock washers and remove oil pan and gasket Discard gasket 2 Loosen accumulator attaching screw that retains intake pipe clip and rotate clip away from intake pipe Fig 6 26 3 Pull oil strainer and intake pipe assembly straigh...

Page 114: ... pivot pin from trans mission case by pushing on inside end of shaft with a thin rod such as welding rod Fig 6 30 6 Remove parking pawl spacer from case Fig 6 29 7 Unhook parking brake spring from parking lever 8 Remove parking bracket and spring from shaft 9 Rotate parking lever and pawl and remove from parking brake pin 10 Remove attaching screw for detent spring and remove detent spring assembl...

Page 115: ...pump assembly taking care to prevent pump I Detent Spring And Roller Assembly Parking Brake Bracket f B i l l t L Parking BrakeSpring S fen9BrakeLever P w l Spacer HIMBBN J o ti Parking Brake Pawl 1 w v i j j u Pawl Pivot Pin cocking in bore If pump assembly is tight in its bore it may be necessary to remove two nearly opposite pump cover screws and install Slide Hammer J 6125 to remove pump Fig 6...

Page 116: ...withdrawn far enough so as not to score intermediate shaft during installation 2 Remove eight cap screws and remove breath er pipe and extension housing and gasket If hous ing sticks a light tapping will loosen housing Discard gasket Slide Hammer Assemblies J 6125 Neutral Clutch Retainer J 6135 inap Ring Center Support to Case ISWUfc Fig 6 34 Removing Center Support to Case Snap Ring 3 Remove gove...

Page 117: ...reverse internal gear thrust wash er and reverse internal gear from case Fig 6 36 18 CAREFULLY remove reverse stationary cone from case by gently working it free NOTE Reverse stationary cone is made of Fometl and is very brittle Do not use any tools to force cone free 19 Remove stationary cone stop key from case 20 Unhook overrun band from anchor in side of case and remove band through front of ca...

Page 118: ...e Note 20 for bushing replace ment procedure e Inspection of Transmission Case 1 Thoroughly clean transmission case with solvent 2 Blow out all oil passages through case Check for restricted leaking or interconnected passages For references See Fig 6 7 3 Inspect transmission case for cracks f Front Unit Coupling Fig 6 39 Disassembly 1 Install front unit coupling assembly in Clutch Unit Holding Fix...

Page 119: ...rus member remove burrs with crocus cloth Inspect driven torus shaft for signs of galling or nicks 2 Check bushing in front end of driven torus shaft for excessive wear See Note 20 for bushing replacement procedure 3 Check bushing in coupling cover neck for excessive wear See Note 20 for replacement procedure Assembly 1 Place driving torus member in Clutch Unit Holding Fixture J 6116 2 Install bro...

Page 120: ...m coupling cover and remove front unit coupling assembly from Holding Fixture Remove Coupling Valve Retainers J 6122 g Oil Pump Assembly Disassembly 1 Remove front sprag inner race if still in pump Front Unit Coupling Valve Retainer J 6122 01 m 1 1 1 1 mr i k 1 Studs Part CP of J 6121 r 1 Coupling Cover g S Driving lir Torus H M Assembly Fig 6 43 Installing Coupling Cover 2 Take pump cover from pu...

Page 121: ...essive wear and scoring 3 Pump vanes will have a tendency to show a polished surface on side bearing against pump slide If not excessive this is a normal condition Check freeness of vanes in rotor slots 4 Check bushing in pump rotor for scores or flaking Slight surface wear is a normal condi tion if not in excess See Note 20 for bushing replacement procedure 5 Check bushing in pump housing for exc...

Page 122: ...ck rotation of sprag by inserting inner race Inner race should turn counterclockwise but not clock wise Then remove inner race 14 Install spiral type snap ring to hold sprag assembly to pump body 15 Install interlocking oil ring on pump cover il Seal verrun Clutch Inner Oil Seal Overrun Clutch Outer Neutral Clutch Piston n Q Oil Seal Ring M x tr a e Neutra C utch nner Center Bearing Support Oil Se...

Page 123: ...ly 15 Remove clutch release spring retainer and eight springs Fig 6 51 16 Remove rear clutch piston from rear clutch cover 17 Remove seal rings from piston and hub of cover and discard 18 Remove intermediate shaft and rear clutch hub Fig 6 53 Rear clutch hub is retained on shaft by one snap ring located at rear end of hub 19 Remove steel backing washer and bronze thrust washers located on front an...

Page 124: ...horoughly clean 2 Inspect oil seal rings on center bearing support and be sure all grooves are clean 3 Inspect center bearing support for burrs 4 Check bushing in center bearing support for excessive wear See Note 20 for bushing replace ment procedure 5 Inspect five composition faced neutral clutch drive plates for damaged surfaces and worn teeth Plates should be flat If flakes of facing material ...

Page 125: ...it sun gear to rear clutch hub bronze thrust washer for wear scores burrs damage from overheating 20 Inspect mainshaft and rear unit sun gear for damaged splines teeth or bearing surfaces 21 Inspect seven rear unit composition faced clutch drive plates for damaged surfaces Plates should be flat If flakes of facing material can be removed by scratching surface with thumb nail plates should be repla...

Page 126: ...rust washer on front of rear clutch hub and retain with petrolatum 13 Position steel backing washer on top of thrust washer and retain with petrolatum 14 Install oil seal on clutch piston and oil seal on clutch cover hub Fig 6 51 15 Install rear clutch piston into rear clutch cover and insert rear clutch release springs into rear clutch piston Fig 6 51 16 Position rear clutch release spring re tai...

Page 127: ...inter mediate shaft 32 Rotate center bearing support so that right hand edge of cup plug in edge of center bearing support is aligned with left edge of first neutral clutch plate slot to right of neutral clutch drum key slot as shown in Fig 6 59 33 Install Clutch Retainer J 6135 over in termediate shaft by compressing center bearing support assembly into neutral clutch drum and tightening lock scr...

Page 128: ...se spring 3 Lift reverse piston from reverse piston housing 4 Remove and discard reverse piston inner and outer oil seals 5 Remove bearing to housing snap ring and tap rear bearing out of housing Inspection Figs 6 61 6 36 1 Inspect all parts to make sure they are free from dirt 2 Inspect reverse piston and piston housing for burrs scoring or other damage Remove burrs if present with fine crocus cl...

Page 129: ...reverse piston over special tool J 7577 and rotate piston to align with dowel pins 4 Compress outer piston seal into bore of housing using care not to damage seals during installation Fig 6 62 5 Remove special tool J 7577 6 Place release spring and retainer on piston and install large snap ring NOTE Rear bearing will be installed after housing is installed on transmission J Extension Housing 1 Ins...

Page 130: ... for burrs or other damage If burrs are present remove them using fine crocus cloth with light oil Replace all damaged parts 3 Inspect O ring seal If seal shows undue wear or damage discard and use new seal when assembling 4 Check regulator spring Replace if twisted sprung or set Assembly 1 Install O ring seal on pressure regulator plug O Ring Seal Pressure Regulator Plug Reverse Booster Plug Pres...

Page 131: ...coils 3 Inspect accumulator body for restricted passages scores or burrs 4 Inspect servo piston assembly for distorted rod damaged oil seal ring lands or broken oil seal ring 5 Inspect trimmer valves plugs and spring for scores or burrs Clean up with fine crocus cloth and oil if necessary Assembly 1 Install oil seal ring on accumulator piston 2 Install accumulator piston stem into piston with smal...

Page 132: ...nual valve is the only valve that may be serviced separately If other valves are de fective or damaged beyond repair a new valve body assembly should be installed 5 Before reassembly make certain springs can be accurately identified for correct assembly Fig 6 67 b Control Valve Assembly Disassembly Fig 6 68 CAUTION Handle control valve assembly very carefully after removal and after disas sembly i...

Page 133: ...e screw through the clip Do not tighten screw 4 Rotate plate over limit valve springs while holding springs compressed Install remaining screw and tighten both screws 5 Install coupling valve plug spring coupling valve and coupling signal valve 6 Place transition valve spring in transition valve and install valve and spring spring end first into coupling body 7 Install front end plate with three s...

Page 134: ...eutral clutch valve and 3 4 shift valve with largest diameter land facing outward 4 Place spacer on large end of 2 3 shift valve with rim of spacer against large land on valve and install valve and spacer in shift valve body 5 Install 2 3 and 3 4 shift valve springs and neutral clutch valve spring 6 Install regulator valve body to shift valve body with one screw in boss on regulator valve body Use...

Page 135: ...w completely disas sembled and an inspection of parts should be made see Note 17a before valve body is assembled h Manual Valve Body Assembly 1 Install reverse blocker piston slotted end out 2 Install reverse blocker spring and hold it compressed while installing new retaining pin 3 Crimp end of pin to retain 4 Install throttle valve large land first into manual body 5 Install TV spring and detent...

Page 136: ...y 18 Assembly of Transmission to Install Major Components a Install Center Bearing Support Neutral Clutch and Rear Unit Assemblies 1 Install neutral clutch drum stationary stop Stationary Stop Key Neutral Clutch Drum Transmission Case t Stationary Sto Reverse Stationary Fig 6 73 Installing Overrun Band key in transmission case using petrolatum to hold in place Fig 6 72 2 Install overrun band in tr...

Page 137: ...ust washer on reverse in ternal gear hub Fig 6 36 12 Install screens in main line pressure pas sage and in G 2 passage 13 Using new gasket install reverse piston housing assembly and attach with one screw Fig 6 77 14 Remove Clutch Retainer J 6135 from in termediate shaft 15 Install rear bearing over output shaft and into piston housing 16 Install snap rings retaining rear bearing to output shaft a...

Page 138: ...mbly c Install Parking Pawl Linkage and Detent Spring 1 Install detent spring and roller assembly on mounting pad in transmission case with attaching screw finger tight 2 Hold inside detent control in position in transmission case to act as guide while centering roller Fig 6 79 3 Center roller in one of the detents in detent control and tighten detent spring attaching screw 4 Install parking pawl ...

Page 139: ...lunger Be sure dowel pin in manual body indexes with hole in transmission case 2 Install five control valve assembly attaching screws and tighten Fig 6 27 3 Install servo release spring and servo accumulator assembly and secure with two at taching screws Make sure intake pipe clip is under long bolt and leave this bolt loose until intake pipe has been installed Fig 6 26 f Install OilPan OilStraine...

Page 140: ...ssion on trans mission hoist 4 Remove bracket from transmission case 5 Install front unit coupling 6 Install new square section seals and O rings on oil cooler sleeves and install cooler sleeves in transmission case Secure cooler sleeves with strap and strap retainer screw Tighten screw to 18 ft lbs h Install Flywheel Housing Torus Cover Torus Member and Flywheel Fig 6 20 1 Place Flywheel Housing ...

Page 141: ... holding flywheel to torus cover and remove flywheel NOTE Make sure parts are thoroughly dry before assembly into transmission 20 Bushing Replacement Procedures The special tools referred to in the following procedures are part of Bushing Service Tool Set J 8532 a General Instructions Before installing any precision bushing be sure that bore into which it is to be driven is clean and free of burrs...

Page 142: ... bush ing opens up then remove bushing 4 Install new bushing using Driver Head J 8400 4 and Handle J 8092 d Front Unit Internal Gear Fig 6 86 1 Place Support J 8400 30 on bench with ft f V f 1 1 i J 8092 J 8400 6 J 8400 30 Large End Up Fig 6 86 Installing Bushing in Front Unit Internal Gear large end up and position internal gear on Sup port with gear teeth up 2 Locate split in bushing and start p...

Page 143: ...092 J 8092 J 8400 8 Drive Recess J 8400 30 Fig 6 88 Installing Bushing in Front Coupling Cover Fig 6 89 Installing Bushing in Oil Pump Rotor g Oil Pump Rotor Fig 6 89 1 Place Support J 8400 30 on bench with large end up and position pump rotor on Support with drive recesses up 2 Locate split in bushing and start point of Chisel J 8400 1 beside split with flat side of Chisel facing in 3 Tap Chisel ...

Page 144: ...with a power source 9 Do not remove Reamer through bushing Re move Handle J 8400 36 and lift pump body from Reamer and Sleeve leaving tools in vise 10 Check location of half moon notch in bush ing Fig 6 90 If it has moved in relation to oil hole bushing is too loose and an oversized bush ing must be installed If bushing is still located properly disregard remaining steps 11 Perform steps 1 2 3 5 a...

Page 145: ... beside split with flat side of Chisel facing in 3 Tap Chisel with hammer until split in bush ing opens up then remove bushing 4 Install new bushing using Driver Head J 8400 16 and Handle J 8092 I N j I1 J 8092 r if Fig 6 94 Installing Bushing in Reverse Sun Gear i Reverse Internal Gear Fig 6 95 1 Place reverse internal gear on large end pf Support J 8400 30 with gear teeth down 2 Locate split in ...

Page 146: ...g on long end of Driver Head J 8400 25 and install bushing in extension housing using Handle J 8092 X J 8400 22 Fig 6 97 Staking Bushing in Extension Housing 7 Place new bushing on short end of Driver Head J 8400 25 and install bushing in extension housing using Handle J 8092 8 Stake both bushings securely using Staking Tool J 8400 22 Be certain that staker points enter oil groove of bushing to av...

Page 147: ...bly to case screw Inside detent lever to manual shaft screw Inside TV lever to TV shaft screw Detent spring to case screw Oil pan to case screw Oil pan drain screw Torus cover oil drain plug Governor body cover to governor driven gear screw Oil pump cover to body screw Oil pump to center bearing support screw Oil pump to case screw Strap oil cooler sleeves retainer screw Pressure regulator plug Fl...

Page 148: ...mover Rear Clutch Spring Compressor Clutch Spring Compressor Dial Indicator Set Dial Indicator Support Flywheel Housing Oil Seal Protector Key M N 0 P Q R S T U V w X Tool No J 6135 J 6282 J 7577 J 8059 J 4880 J 6083 J 6120 J 5907 J 8532 J 6122 J 8092 J 7073 Name Neutral Clutch Retainer Front Unit End Play Checking Gage Reverse Piston Inner Pilot Snap Ring Pliers Snap Ring Pliers Snap Ring Pliers ...

Page 149: ...Q CO U ...

Page 150: ...ditioner The 3 36 1 ratio is used on all Seventy Five series cars and the 3 77 1 ratio is used on the com mercial chassis as well as being optional on Seventy Five series cars Greased and sealed rear wheel bearings are used on all 60 62 and Seventy Five series cars The bearings are sealed on the outer side by a rubber grease seal that is an integral part of the bearing The inner oil seal however c...

Page 151: ...chassis in corporates standard universal joints at each end and in the center The propeller shaft is attached to the rear axle by two U bolts locks and nuts that attach the rear universal joint cross bearings to the yoke on the rear axle pinion Universal joints used on 1963 Cadillac cars cannot be repacked On original universal joints the injected nylon ring used to retain the bearing cup in the y...

Page 152: ...e turn passage Fig 1 1 In the case of a controlled differential the letter G precedes the axle ratio identification number For example G2 is a controlled dif ferential with a rear axle gear ratio of 2 94 1 The serial number of the differential carrier is stamped on the bottom of the carrier on the flange adjacent to the rear axle housing The gear ratios and corresponding identification numbers for...

Page 153: ...g pinion nut with socket Fig 7 5 until Installer Tool bottoms on face of carrier 3 Remove Pinion Nut Socket pinion nut and washer and Oil Seal Installer CAUTION Make certain that seal surface of flange is free from scratches or nicks If necessary clean with No 400 grit wet paper and kerosene Use only a circular motion when sanding seal surface of flange so as not to leave any spiraled marks on sea...

Page 154: ...ctory Parts Ware houses for cars equipped with a Controlled Dif ferential 12 Reinstall brake drums and rear wheels and lower car 3 Rear Axle Pinion Yoke and Oil Seal Removal and Installation 75 Series and Commercial Chassis When replacing the rear axle pinion yoke or oil seal follow the procedure outlined below Failure to do so may result in overloaded pinion bearings or drive pinion end play a Re...

Page 155: ...t overtighten and never back off on the nut to reduce pre load torque The average torque on an assembly with over 1 000 miles is between 15 and 20 inch pounds The torque on a new assembly is approximately 50 inch pounds 8 Stake pinion shaft into nut 9 Connect rear universal joint to pinion yoke Install U bolts locks and nuts tightening nuts to 15 foot pounds 10 Refill rear axle to correct level as...

Page 156: ...l 1 Using a cold chisel and hammer notch bear ing retainer next to bearing being careful not to damage bearing NOTE Bearing retainer need not be split Drive chisel into retainer only until retainer can be slipped off shaft then remove retainer 2 Wipe shaft and bearing clean 3 Remove oil seal from bearing using Oil Seal Remover J 21010 Fig 7 11 Hook slotted flange of remover tool under rolled edge ...

Page 157: ...ammer notch bear ing retainer next to bearing NOTE Bearing retainer need not be split Drive chisel into retainer only until retainer can be slipped off shaft then remove retainer 2 Place rear axle shaft and bearing assembly in U shaped piece of Rear Wheel Bearing Plate and Pin Assembly J 2986 1 and position on arbor press CAUTION Make certain that axle shaft flange is properly centered in arbor pr...

Page 158: ...ng re taining nut 3 Release parking brake and pull wheel hub and brake drum assembly off shaft Use a five jaw puller to reduce the possibility of warping or distorting the brake drum 4 Remove seven screws and lock washers that hold bearing retainer and backing plate to axle housing flange 5 Remove key from end of axle shaft and re move bearing retainer 6 Pull axle shaft and bearing assembly from h...

Page 159: ... washers that hold carrier to axle housing and remove entire assembly with gasket Provide container for collecting oil as differential carrier is removed from axle housing NOTE Whenever a carrier is removed be cause of scored gears worn bearings or any failure that might cause dirt or metal chips re move axle housing from car for thorough clean ing before new carrier is installed Also check axle s...

Page 160: ...mis sion Any vertical deviation from the correct installation that might cause propeller shaft vibration at low speed 0 50 mph can usually be corrected by adding 075 inch shims at the engine rear mount Not more than four shims should be used otherwise there will be insufficient clear ance between transmission and floor pan Usually the addition of shims will eliminate low speed vibration caused by ...

Page 161: ...holes in ends of cross arms making certain they are filled with universal joint grease 4 Install universal joint cross in position and guide into bearing already started Guide Cross Into Bearings Fig 7 17 Installing Universal Joint Bearings 5 Start opposite bearing into propeller shaft yoke and place in vise with jaws against bearings Fig 7 17 6 Tighten vise until cross is just ready to enter oppo...

Page 162: ... 5 Install new center bearing lock retainer on center slip yoke 6 Coat inner spline of front propeller shaft and spline of center slip yoke with center bearing slip yoke lubricant available from factory Parts Warehouses 7 Slide center slip yoke and rear propeller shaft into front propeller shaft spline 8 Tighten center bearing retaining nut to 55 foot pounds using Center Bearing Retaining Nut Remo...

Page 163: ...peller shaft assembly as de scribed in Note 10b TORQUE SPECIFICATIONS Material Number 300 M 300 M Special Special Special 300 M 286 M Special 280 M 280 M 286 M NOTE Refer t Application Brake Backing Plate to Axle Housing Bolts Commercial Chassis Brake Backing Plate to Axle Housing Nuts 60 62 and Seventy Five Series Axle Shaft Hub Nut Commercial Chassis Differential Carrier to Axle Housing Nuts Pin...

Page 164: ...aring Remover Center Bearing Retaining Nut Remover and Installer Rear Wheel Bearing Plate and Pin Assembly Rear Wheel Bearing Holding Tool Key J K L M N 0 P Q Tool No J 6257 J 21010 J 21011 J 8614 1 J 21044 J 8614 2 J 6544 J 6295 1 Name Rear Wheel Bearing Installer Rear Wheel Bearing Oil Seal Remover Rear Wheel Bearing Oil Seal Installer Pinion Flange Holding Tool Adapter 2 req d use with J 8614 1...

Page 165: ...nge to Inner End of Wheel Bearing Inner race 60 62 and 75 Series Cars Gear Ratio 60 and 62 Series Cars except cars equipped with an Air Conditioner 60 and 62 Series Cars when equipped with an Air Conditioner also optional on all 60 and 62 series cars Seventy Five Series Cars standard and when equipped with an Air Conditioner Commercial Chassis Standard optional on Seventy Five series cars All Seri...

Page 166: ...nd a vacuum port The reaction mechanism integral with the power piston assembly controls the degree of power brake application or release in accordance with pressure applied to the valve operating rod through the brake pedal linkage The reaction mechanism in the Bendix unit consists of a rubber disc whereas a reaction plate and levers are used in the Delco Moraine unit The master cylinder in both ...

Page 167: ...ermit dissipation of heat from the surface of the brake drum resulting in better brake per formance and longer lining life Finned cast iron brake drums with extended flanges are used on both the front and rear wheels to provide maximum brake cooling The parking brake assembly is mounted on the cowl to the left of the steering column The park ing brake will release automatically when the transmissi...

Page 168: ...just be rotated forward with a two foot bar placed between the studs 5 Disengage adjuster pawl from star wheel with a hooked tool and back off star wheel 40 notches with screwdriver or brake adjuster tool Fig 8 3 6 Install wheels and lower car 7 Drive car alternately forward and backward applying brakes moderately in each direction until pedal travel does not exceed 1 7 8 inch on a mod erate appro...

Page 169: ...the customer Those Service Departments that have adequate brake shoe relining equipment can obtain linings drilled and cut to size from factory Parts Ware houses Brake lining grinding equipments should incorporate brake shoe holders that locate the shoes accurately in relation to the anchor end as brake anchors are not adjustable and require accurately ground linings 4 Relining Brakes Fig 8 5 a Fr...

Page 170: ...ening brakes Be sure small diameter thin thrust washer Fig 8 6 is installed between end socket and large diameter spring steel washer in adjuster assembly 14 Position shoe assembly on brake backing plate so that shoes engage wheel cylinder con necting links 15 Position primary stabilizer plate over pri mary brake shoe and install hold down pins cups and springs Install red spring on primary shoe f...

Page 171: ...es on O D of pivot nut left hand threads are installed on right side of car and those with three narrow grooves on O D of pivot nut right hand threads must be installed on left side The three narrow grooves on the socket are for manufacturer s identification only Sockets are interchangeable left and right 18 Position shoe assembly on brake backing plate and connect parking brake cable to operating...

Page 172: ... car and remove wheel and brake drum Blow out dust and dirt from drum and linings being careful not to blow dirt around wheel bearing areas 2 Remove hydraulic brake hose as described in Note 11 3 Remove brake shoe retracting springs and link 4 Remove two screws holding wheel cylinder to backing plate 5 Disengage wheel cylinder connecting links from brake shoes and remove wheel cylinders CAUTION Be...

Page 173: ...t 1 Connect bleeder hose to front master cyl inder reservoir 2 Build up pressure in bleeder 3 Attach drain hose to bleeder fitting on each rear wheel cylinder in turn 4 Back off rear brake bleeder fitting three quarters of a turn and bleed brake fluid into a partially filled bottle of clean brake fluid until bubbles stop then close fitting 5 Connect bleeder hose to rear master cylin der reservoir ...

Page 174: ...n position Insert hex of hose fitting into the 12 point hole in support bracket in po sition that induces least twist in hose NOTE Do not twist hose any more than necessary during this operation as its natural curvature is absolutely necessary to maintain proper hose to suspension clearance through full movement of suspension and steering parts 4 Install U shaped retainer to secure hose in frame s...

Page 175: ...rneath car Fig 8 9 2 Disconnect hose from vacuum diaphragm 3 Remove two parking brake assembly to instrument panel mounting bolts 4 Position carpet and left cowl kick pad out of the way and remove KB board 5 Remove two parking brake assembly to cowl mounting nuts and move assembly away from cowl 6 Push brake lever to fully engaged position so that clevis on parking brake assembly is exposed and de...

Page 176: ...ower Brake Unit Removal and Installation a Removal 1 Disconnect hydraulic brake lines from mas ter cylinder on power brake unit Fig 8 10 Cap line fittings to prevent dirt from entering brake lines 2 Disconnect vacuum hose from vacuum check valve on power brake unit 3 Remove cotter pin washer and spring Fig 8 10 Power Brake Unit Installed spacer that attach power unit push rod to brake pedal relay ...

Page 177: ...gm plate assembly and remove power diaphragm from dia phragm plate Rear Shell Fig 8 13 Removing Bearing Seal From Rear Shell 10 Remove valve plunger lock and remove con trol valve and rod assembly 11 Remove hydraulic push rod from diaphragm plate 12 Press rubber reaction disc out of dia phragm plate 13 Remove front shell and master cylinder from vise and remove vacuum check valve by turning counte...

Page 178: ...hragm plate with groove in valve plunger and insert plunger lock 5 Install power diaphragm in groove of dia phragm plate 6 Slide air filter and air silencer over valve rod and guide into place in valve housing Press filter retainer on end of valve housing using care not to scratch or damage plastic housing 7 Install dust guard retainer over studs on rear shell W Bearing 5 4 Seal I lnstaller J 9540...

Page 179: ...r normal service will not require further adjustment When unit has been disassembled however adjustment should be checked to assure proper height 19 Place Push Rod Height Gage J 7723 01 over push rod with legs of gage resting on front shell of vacuum power unit Fig 8 15 Top of screw should just touch gage 20 If adjustment is necessary hold push rod with pliers at serrated end and turn adjusting sc...

Page 180: ... Primary Piston Protector Washer Retainer i Adjusting Screw y Springy fc V Spring Piston Seals Retainer Seal Retainer Protector s p W a s h e r W r Piston Seal W Secondary Piston Seal Retainer BendfM Primary Piston pisjassembleej Fig 8 18 Bendix Secondary Piston Disassembled 11 Remove seal retainer and two piston seals from secondary piston b Cleaning andInspection 1 Thoroughly wash all parts in c...

Page 181: ...d and dip secondary piston and seals in brake fluid Protector Washer Seat Spring SV Retainer Master Cylinder Shaft Seal Installer J 9719 01 1 Piston Stop andSeal Assembl Fig 8 20 Installing Piston Stop And Seal Assembly 8 Stack secondary piston assembly secondary spring with small diameter end of spring next to piston and spring stop Fig 8 16 9 Insert check valve spring in recessed end of check va...

Page 182: ...te rear shell counter clockwise until it disengages from front shell Fig 8 21 CAUTION Be careful when removing Sepa rator Tool as internal piston return spring may cause rear shell to fly off when pressure is released 8 Remove front shell and master cylinder from vise and remove vacuum check valve and grommet 9 Remove two nuts and lockwashers that retain master cylinder to front shell and remove m...

Page 183: ... pressing plate off small knurled end of push rod Do not remove adjusting screw from end of rod b Cleaning and Inspection 1 Thoroughly wash all parts in clean alcohol NOTE Use of gasoline kerosene anti freeze or any other cleaner with even a trace of mineral oil will damage rubber parts 2 Use air hose to blow out all passages ori fices and valve holes Air dry and place cleaned parts on clean paper...

Page 184: ...ng control valve 13 Spread thin film of special lubricant on O D of valve diaphragm Install floating control valve and diaphragm assembly in power piston making sure floating valve spring seats on spring retainer Fig 8 24 NOTE Make sure that rubber diaphragm is not distorted as the assembly is pressed into power piston 14 Install two power piston O rings in grooves on O D of power piston insert 15...

Page 185: ...scribe marks will line up 33 Install Power Unit Shell Separator J 9504 over mounting studs on rear shell and press rear shell into front shell making certain that oval lip of diaphragm is correctly positioned between edges of front and rear shells Rotate rear shell clockwise to lock shells together NOTE Master cylinder push rod is designed with a self locking adjustment screw to provide the correc...

Page 186: ...rimary seal protector washer and secondary seals from floating piston 14 Compress primary piston spring attached to primary piston remove small retainer ring from groove in end of piston and remove piston spring and floating piston stop 15 Remove spring retainer primary seal pro tector washer and secondary seal from primary piston b Cleaning and Inspection 1 Thoroughly wash all parts in clean alco...

Page 187: ...inst washer 9 Position spring retainer on one end of pri mary piston spring and floating piston stop on other end 10 Install primary piston spring on primary piston with spring retainer seated inside lips of primary seal 11 Compress piston spring until floating piston stop clears small groove in end of piston Install small retaining ring in this groove and release spring 12 Coat master cylinder bo...

Page 188: ...al position CAUSE Uneven wear on linings No fluid in reservoir Leaking front or rear brake line Air in brake system which causes a rubbery action of brake pedal Wheel cylinder piston cups swollen by mineral oil in sys tem or sub standard brake fluid Leaking master cylinder piston cups Disconnected unit linkage Cracked master cylinder cast ing Adjusters sticky Brake shoes improperly ad justed Leak ...

Page 189: ...arking brake adjust ment and make corrections as required Determine whether one or more wheels are dragging and heat ing and correct Check proximity of any brake pipe to the engine exhaust sys tem and correct Be sure car is using heavy duty brake fluid If in doubt drain flush and refill Replace Replace or correct Clean or replace Repair or replace Repair Clean Repair or replace Replace Resurface l...

Page 190: ... star wheel bent broken or missing Insufficient shoe retention CORRECTION Machine left and right brake drums or replace both if more than 030 inch radius has to be removed Machine both drums and sand linings or replace as required Clean or check for full pedal return Check vacuum piston to hydraulic piston push rod for correct adjustment Check for obstruction or bind ing Bleed system Investigate a...

Page 191: ...tio inside diameter Front 60 62 and 75 series cars 59 0 Rear 60 62 and 75 series cars 41 0 Front Commercial Chassis 52 8 Rear Commercial Chassis 47 2 Drums inside diameter Front and Rear 11 995 12 005 Run out of Inside Diameter maximum Front and Rear 007 Clearance Between Secondary Lining and Drums Minimum 010 Maximum 030 Remachined diameter maximum 12 060 Primary Lining length width thickness Fro...

Page 192: ...ation Brake fluid line connections Parking brake cable clamps at backing plate Front backing plate to knuckle Brake backing plate to rear axle housing except Commercial Chassis Brake backing plate to rear axle housing Commercial Chassis Front brake anchor pin to knuckle Brake unit to cowl Master cylinder to vacuum power unit Power piston to support plate screws Head Nut Master Cylinder Floating Pi...

Page 193: ...PARK AVENUE SEDAN 6389 ...

Page 194: ...ri butor and water pump to provide a new front end accessory drive arrangement The cast crankshaft with three inch journals is supported by five shell type main bearings of steel backed aluminum and steel backed babbitt End thrust of the crankshaft is taken by the center main bearing Six counter weights are integral with the crankshaft A harmonic balancer is pressed on the front end of the cranksh...

Page 195: ...9 2 ENGINE MECHANICAL Fig 9 2 Engine Longitudinal Section ...

Page 196: ...ENGINE MECHANICAL 9 3 Fig 9 3 Engine Transverse Section ...

Page 197: ...e in tegral with the base casting to assure that the engine oil supply is not interrupted if the element should become clogged Oil capacity of the engine crankcase is four quarts five quarts if the filter is changed ENGINE LUBRICATING SYSTEM FIG 9 4 The oil pump is mounted in the right side of the engine front cover Oil enters the pump through a screened intake pick up pipe and is pumped into a pa...

Page 198: ...e piston skirt and directed through a drilled passage to lubricate the piston pin Information pertaining to the Crankcase Venti lation System is described in Section 10 under General Description SERVICE INFORMATION 1 Cylinder Balance Test The cylinder balance test is used to obtain the power output of each cylinder compared with that of other cylinders It is performed by operating the engine on ea...

Page 199: ...cket to one side Do not disconnect hoses 8 Remove two cap screws that hold generator support bracket to cylinder head water outlet pipe and position generator and support bracket away from engine 1 9 Remove distributor assembly as described in Section 12 Note 21a NOTE It is not necessary to line up rotor cap before removing distributor 10 Remove fuel pump as described in Section 10 Note 15a 11 Rem...

Page 200: ... screw location and torque specifications 3 Lubricate new water outlet pipe to water pump O ring seal with silicone and install O ring against shoulder in bore in pump body 4 Brush gasket cement on water outlet pipe flange surfaces and place new gaskets in position on water outlet pipe 5 Install neck of water outlet pipe in bore in pump body position flange surfaces against cylin der heads and ins...

Page 201: ...o install harmonic balancer assembly without crankshaft turning over 14 When harmonic balancer assembly is ap proximately positioned on crankshaft remove Harmonic Balancer Remover and Installer Tool Thread a 1962 harmonic balancer to crankshaft screw and washer in end of crankshaft Tighten screw to 125 foot pounds 15 Remove screw and washer from end of crankshaft install cork plug in end of cranks...

Page 202: ...er plate Discard gasket CAUTION Be careful pump gears do not fall out of housing when cover plate is removed 4 Slide drive shaft and gear out of pump housing 5 Slide driven gear out of pump housing 6 Remove front cover oil seal only if defective as described in Note 4 b Assembly 1 Install pump drive shaft and gear in pump housing 2 Slide driven gear over stationary shaft in pump housing 3 Install ...

Page 203: ... and pump cover plate for wear and score marks b Assembly Fig 9 9 1 Install oil pressure regulator valve and spring in bore in pump cover plate 2 Install hex head plug with copper washer on cover plate and tighten plug to 25 foot pounds 3 Install pump drive shaft and gear in pump housing 4 Slide driven gear over stationary shaft in pump housing meshing driven gear with drive gear 5 Install pump co...

Page 204: ...e vacuum hose from fitting at rear of intake manifold NOTE If car is equipped with vacuum door locks disconnect vacuum door lock hose from same fitting 23 Disconnect transmission throttle valve rod at carburetor throttle lever 24 Disconnect throttle return spring and throt tle control linkage at carburetor throttle lever 25 Release rear ventilator valve hose clamp and remove hose from fitting on c...

Page 205: ... 8 Invert head in stand remove holding strap and remove valves from head being sure to keep them in order so that they can be reinstalled in the same locations 9 If it is necessary to remove valve guides be cause of excessive clearance between valve stem and valve guide as specified in Note 10 drive out valve guides from bottom side of cylinder head using Valve Stem Guide Remover J 3062 as shown i...

Page 206: ...ause when air is applied the crank shaft will turn quickly until the piston reaches bottom dead center position 11 Reinstall rocker arm cap screw nearest to affected valve position end of Valve Spring Com pressor J 5892 1 under head of cap screw and Suction Cup Retainer O Ring Valve Locks depress valve spring and retainer as shown in Fig 9 15 NOTE If No 8 cylinder intake or exhaust valve springs o...

Page 207: ...ure valve guide inside diameter with hole gage cross ways to engine at both top and bottom of guide measuring gage each time with micrometer Measure valve stem diameter with micrometer and subtract from greater of two guide measure ments to obtain maximum clearance If clearance is greater than 005 inch guide should be replaced to prevent excessive oil consumption and im proper seating of valves Af...

Page 208: ...ylinder head until shoulder on installer contacts plate on cylinder head Flat side of valve guide plate rests on cylinder head while notched portion which acts as a stop for driving tool is toward top b Installation of Valves 1 Install all valves in their respective guides and install Holding Strap J 3064 over valve heads to hold them in place while installing springs Coat valve stems liberally wi...

Page 209: ... exhaust manifold on cylinder head using new gaskets and secure with attaching screws Tighten screw to 60 foot pounds 2 Apply a coat of high compression gasket cement to both sides of new cylinder head gasket CAUTION Extreme care must be used when installing cylinder head gaskets to assure free dom from dirt particles between the gasket and the cylinder block or head Any foreign ma terial can caus...

Page 210: ...n Section 10 Note 26c 21 Connect throttle return valve vacuum hose and parking brake vacuum hose to fitting on rear of intake manifold NOTE If car is equipped with vacuum door locks connect vacuum door lock hose on same fitting 22 Connect power brake vacuum hose to fitting on carburetor 23 Connect distributor primary wire to nega tive terminal on ignition coil and ignition resistor wire to positiv...

Page 211: ...ner i Spring Body Arrangement Of Valves And Valves Lifters Valve Closed Valve Open Plunger Extended Maintaining Zero Clearance Ball Check Valve Open Oi Under Pressure Push Rod Presses Against Cap Oil Forced Upward Closes Check Valve Operation Of Valve Lifter Mechanism Slight Leakage Between Plunger And Body Fig 9 T9 Valve Lifter Mechanism ...

Page 212: ...in the engine lubrication system a stuck or improperly operating oil pressure relief valve scored parts worn bearings worn oil pump gears clogged oil intake strainer screen assem bly or poor operation of oil pump c Rusty or Varnished Valve Stems or Valve Guides This condition may be associated with short trip operation poor quality engine oil or failure to change oil regularly d Weak Valve Lifter ...

Page 213: ...rol unit 9 Check each lifter listed in following table Rotor at No 1 firing position pointing toward No 1 cylinder Check 1 Exhaust 1 Intake 3 Intake 3 Exhaust 5 Intake 7 Exhaust 2 Exhaust 4 Intake 8 Intake 8 Exhaust 10 Insert feeler gage of tool between valve stem and rocker arm and at the same time compress tool pop out spring to its stop against valve spring retainer Fig 9 20 NOTE Install tool a...

Page 214: ...openings keeping them in order as they are removed NOTE If because of gum and varnish lifters cannot be removed by the procedure outlined above perform the following additional steps 12 Remove intake manifold as described in Note 7 Steps 18 through 29 13 Remove front and center cap screws that hold valve compartment cover to cylinder block 14 Remove long screw that holds ventilator valve connector...

Page 215: ...e with front and center attaching screws Tighten screws to 25 inch pounds 3 Place ventilator valve connector over open ing in valve cover using new gasket and secure with long attaching screw Tighten screw to 25 inch pounds 4 Install intake manifold Note 13 Steps 11through 25 as described in 5 Install push rods through openings in cylin der heads Bottoms of push rods must be seated in hydraulic va...

Page 216: ...el cover plate to flywheel hous ing and engine oil pan and remove cover plate 10 Remove fourteen cap screws and four nuts that hold oil pan to cylinder block and engine front cover and remove oil pan 11 Remove side gaskets and rubber end seals from oil pan and discard them b Installation 1 Cement new gasket to both sides of oil pan lining up holes in gaskets with holes in oil pan 2 Install new rub...

Page 217: ...ION Do not nick lower edge of bore when pushing rod up 8 Remove remaining seven piston and con necting rod assemblies in same manner 21 Connecting Rod Bearing Replacement Worn bearings can be replaced without remov ing the rod and piston assembly by removing the cap and replacing the upper and lower halves The clearance between the connecting rod bearing and the crankshaft can be measured by the u...

Page 218: ...ends should be 015 inch to 061 inch 4 With compression ring on piston clearance between top surface of piston ring and ring land should be no greater than 005 inch If clearance is greater replace the ring If the new ring does not reduce the clearance to 005 inch or less new pistons should also be installed be 0022 inch to 0035 inch This can be checked with a 002 inch and a 004 inch feeler gage on ...

Page 219: ...nch from measurement for every 6 above 70 F An identification letter is stamped on the valve lifter compartment cover rail next to the lower inside edge of the cylinder head The letters are in groups of two for adjacent cylinders such as A B midway between the two cylinders This letter denotes the cylinder size as shown in the following table jtter A B C D E H J K L M Cylinder Size Diameter in inc...

Page 220: ... the same feel as when measuring the piston By this method even if the two micrometers do not agree in readings no error will result in arriving at the actual clearance of the piston in the cylinder 25 Cylinder Bore Reconditioning Worn cylinder bores can be reconditioned by reboring and honing If cylinders are being re conditioned to 020 inch or 030 inch oversize the bores should be finished as cl...

Page 221: ... described in Note 21 Bearing cap must be tightened to 95 foot pounds CAUTION If bearings are being measured with engine in chassis crankshaft must be sup ported in order to take up clearance between upper bearing shell andcrankshaft This canbe done by removing bearing caps adjacent to bearing being checked and placing a strip of 005 inch brass shim stock between lower bear ing shell and crankshaf...

Page 222: ... in either the lower or upper lo cation Both seal halves are pre lubricated with a film of wax for break in Do not remove or damage this film 8 To install upper half of seal in cylinder block start seal into groove in block with lip fac ing forward and rotate seal into position using care not to distort seal 9 Press firmly on both ends of seal to be sure that it is protruding uniformly on each sid...

Page 223: ...nstall engine front cover as described in Note 2h 32 Camshaft Removal 1 If car is equipped with Air Conditioner re move condenser as described in Section 13 Note 62a 2 Remove hood lock plate support as described in Section 14 Note 1 3 Remove timing chain and sprockets asdes cribed in Note 31a 4 Remove valve lifters as described in Note 16 5 Slide camshaft forward carefully until it is out of engin...

Page 224: ...ft bearing interchangeable bore to bore is available for field replacement Camshaft Bearing Remover and Installer Tool J 211 Puffer Collet J 3063 5 Shaft J 3063 11 Bridge J 3063 9 3 4 Open End Wrench Puller Nut Fig 9 35 Camshaft Bearing Removal Fig 9 36 No 5 Camshaft Bearing Removal a Removal 1 If car is equipped with Air Conditioner re move condenser as described in Section 13 Note 62a 2 Remove h...

Page 225: ...on front face of each bore Fig 9 37 3 Slide Drive Shaft J 21054 1 with Arbor J 21054 2 through No 1 2 3 and 4 bearing bores until arbor is positioned between No 4 andNo 5 bores 4 Place new bearing on arbor tool and install arbor in No 5 bearing bore lining upoil hole in bearing with scribe mark on front face of bore Fig 9 38 5 Using a hammer install bearing in bore un til oil hole in bearing is li...

Page 226: ...nkpin journals from rod bolts 3 Install connecting rod caps on crankshaft as described in Note 27 4 Install oil intake strainer screen assembly on cylinder block using new gasket and secure with three attaching screws Tighten screws to 18 foot pounds 5 Install flywheel flex plate and secure with six attaching screws Tighten screws to 75 foot pounds CAUTION If flex plate and end of crank shaft are ...

Page 227: ...mission oil pan screw to prevent leakage of transmission fluid 28 Disconnect transmission TV rod at trans mission and remove TV rod 29 Loosen engine side support cushions from transmission bell housing 30 Remove front transmission cooler pipe clamp from right front oil pan locating stud and rear cooler pipe clamp from upper flywheel hous ing cover plate 31 Remove engine front support stud nuts 32 ...

Page 228: ...Secure transmission filler tube bracket to right exhaust manifold with attaching screw 12 Install starter assembly and secure with two attaching screws Tighten screws to 40 foot pounds Be sure engine ground strap is connected to upper mounting screw 13 Connect wires to starter solenoid 14 Install transmission rear cooler pipe clamp on upper flywheel cover plate and secure with at taching screw 15 ...

Page 229: ...pport mountings are seated at an angle directly on the main front crossmember of the frame The rear support mounting at the transmission is on a bracket bolted to the engine rear support crossmember The side support cushions are positioned against each side of the bell housing and bolted to the No 3 frame cross member All engine support mountings have rubber cushions to absorb vibrations and road ...

Page 230: ...Cylinder Block Nut Oil Pan Drain Plug Valve Compartment Cover to Cylinder Block Screw Ventilator Valve Connector to Cylinder Block Screw Water Outlet Pipe to Cylinder Head Screw Thermostat Housing to Water Outlet Pipe Screw Heater Hose Clamps Rocker Arm Cover to Cylinder Head Screw Oil Filter Support Bracket to Front Cover Screw Fuel Pump to Front Cover Screw Intake Manifold to Cylinder Head Screw...

Page 231: ...RINGS Free length 2 250 Pounds required to compress to 1 946 Valve closed 60 65 Pounds required to compress to 1 496 Valve open 155 165 All Series Unless Other Items wise Noted ROCKER SHAFT ASSEMBLY Clearance between arm and shaft New limits 0007 0022 Worn limits 003 Clearance between shaft and bracket 0002 0017 Shaft Diameter 8108 8113 Diameter of hole in arm 812 813 Short Spring Center Free leng...

Page 232: ...0015 4 0095 4 0097 4 0097 4 0099 4 0099 4 0101 4 0101 4 0103 4 0103 4 0105 4 0105 4 0107 4 0107 4 0109 4 0109 4 0111 4 0111 4 0113 4 0113 4 0115 Aluminum Allov Piston skirt diameter for service replacement pistons Standard Size 3 9995 through 4 0015 010 oversize 4 0095 through 4 0115 020 oversize 4 0200 4 0210 030 oversize 4 0300 4 0310 Piston skirt top clearance 0003 0008 Piston skirt bottom clea...

Page 233: ...o compress to 1 7 16 6 1 4 to 6 3 4 Valve opens at 30 35 psi CAMSHAFT Chain Adjustment None Length 23 Type Silent Chain Number of Links 46 Pitch 500 Width 7 8 Bearing clearance New limits 001 0022 Worn limits not over 004 Bearing out of round not over 002 Number of bearings 5 Cam lift 273 PULLEY DRIVE RATIOS Pulley Standard Fan 96 1 Generator 2 78 1 Power Steering Pump 1 24 1 Refrigerant Compresso...

Page 234: ...r Gaging Block Front Cover Oil Seal Installer Set Hydraulic Valve Lifter Plunger Remover Valve Lifter Lock Ring Installer Valve Stem Guide Remover Key K L M N 0 P Q R S T Tool No J 3224 J 21052 J 8390 J 3049 J 8080 J 5569 J 3074 J 9388 J 5892 1 J 7412 Name Connecting Rod Bolt Guide Set Harmonic Balancer Remover and Installer Set Piston Pin Remover and Installer Set Valve Lifter Remover Main Bearin...

Page 235: ......

Page 236: ...ng engine conditions can be encountered when the valve is inoperative When fumes cannot enter the engine breather backflow occurs and fumes remain in the engine compartment Sludge varnish and acids will develop in the crankcase These corrosive agents may cause premature wear on engine parts and serious engine difficulty Carburetion problems will also occur when the fumes are not properly expelled ...

Page 237: ... turns fuel vapors to the fuel tank under high temperature conditions Fig 10 3 A carburetor air inlet baffle is installed on the underside of the hood This baffle lessens the possibility of ice forming inside the venturi when driving long distances in cool humid weather This icing would restrict the required volume of air from going into the engine resulting in poor power and fuel economy The carb...

Page 238: ...way 3 Release large ventilator hose clamp and re move hose from ventilator valve 4 Release first small clamp securing valve to short length of hose and remove valve 5 Insert 080 inch 090 inch wire in threaded end of valve to clean orifice inside of valve 6 Immerse in any good cleaning solvent and blow dry with compressed air NOTE The valve cannot be disassembled b Installation 1 To facilitate inst...

Page 239: ...utlet pipe from resonator b Installation 1 Install outlet pipe on resonator so there is not more than 5 8 inch between rim of resonator and forward end of outlet pipe Fig 10 4 2 Install resonator on rear intermediate pipe with small drain hole in front of resonator facing down 3 Install clamp that holds resonator to rear intermediate pipe 4 Install clamp that holds resonator and outlet pipe to sup...

Page 240: ...curing front intermediate pipe to rear intermediate pipe 5 Separate and remove front intermediate pipe from rear intermediate pipe b Installation 1 Fit front intermediate pipe to rear inter mediate pipe Fit front intermediate pipe to muffler bydriving muffler rearward 2 Align front intermediate pipe so there is at least 1 2 inch between pipe and No 4body outrigger 3 Position clamp so there is 1 8 ...

Page 241: ...k stands0 6 Lower car 8 Heat Control Valve Removal and Installation a Removal 1 Raise front end of car 2 Disconnect exhaust pipe from both exhaust manifolds 3 Remove heat control valve with upper and lower gaskets from left manifold 4 Remove all gasket material from heat con trol valve and exhaust manifold sealing surfaces b Installation 1 Install heat control valve with new gaskets and connect ex...

Page 242: ...isconnect fuel gage tank unit ground wire at rear frame cross member 10 Remove tank support strap nuts and remove tank b Installation 1 Raise tank into position and install tank support strap nuts Make sure fuel gage tank unit wire hangs over edge of tank NOTE Do not tighten tank strap nuts until filler pipe is installed 2 Position filler pipe in plate and tighten clamp on end of hose connector 3 ...

Page 243: ... clips on both sides of front and rear fuel line connection 14 Fuel Pump T sts 1 To check fuel pump capacity disconnect fuel line at fuel filter inlet and fuel pump outlet Being careful not to bend tubing reposition tubing on fuel pump outlet so that fuel may be dis charged into a container and secure line to fuel pump 2 Raise front end of car 3 Disconnect flexible line at steel fuel supply line o...

Page 244: ...6 Fuel Pump Disassembly and Assembly a Disassembly 1 Clean outside of pump in solvent and use compressed air to remove loose dirt and grease 2 Mark edges of fuel diaphragm cover and body with a file to assure correct positioning when reassembling 3 Remove four screws and lock washers and remove pulsator cover and pulsator diaphragm Fig 10 7 4 Remove rocker arm return spring 5 Remove ten screws and...

Page 245: ...ped sheet metal cage and gasket should go in first 7 Install pulsator diaphragm and cover on fuel diaphragm cover 8 Place cover assembly on body making sure that file marks line up 9 Push on rocker arm until diaphragm is flat across body flange Install top cover screws loosely just contact casting 10 With a suitable tool push rocker arm to full stroke and hold in this position while tighten ing co...

Page 246: ...er mounting stud and gasket 2 Disconnect fuel line at carburetor 3 Disconnect choke heat pipe from choke housing 4 Disconnect distributor vacuum line at car buretor body fitting 5 Disconnect vacuum line at idle speed up control if car is equipped wih Air Conditioner 6 Remove front lock nut from carburetor to transmission TV rod and rotate throttle lever to allow removal of rod from trunnion Leave ...

Page 247: ...tor parts Clean carbon out of throttle body heat passage 3 Make sure all calibrated restrictions such as idle ports air bleeds or vents are clean but do not pass drills through these passages Use compressed air only 4 Check all shafts and their corresponding bearing bores for wear Check each piston in its respective cylinder Check for worn or dam aged jets and worn holes in ends of various levers ...

Page 248: ...ting Lever Idle Speed Up Lever Vacuum Spark Advance Hole Fuel Inlet Nut Idle Mixture Screws Choke Counterweight Lever Accelerator Pump Lever Vent Valve Actuating Choke Trip Lever Secondary Actuating Lever Power Brake Vacuum Fitting Accelerator Pump Rod Secondary Actuating Rod Secondary Throttle Lever By Pass Screw Choke Rod Fast Idle Cam Throttle Lever Fast Idle Screw Fig 10 11 Throttle Linkage 5 ...

Page 249: ...elerator Pump Lever Cover Screw Lock Washer Float Balance Spring Primary Inlet Screen Secondary Inlet Screen Power Piston Spring Power Piston Gasket V Accelerator Pump Secondary Seat Inlet Needle Spring Clip Gasket Primary Seat Inlet Needle Spring Clip Secondary Float Fig 10 12 Bowl Cover Disassembled ...

Page 250: ... of secondary side 1 With bowl cover inverted remove float hinge pins floats and needles Remove needles with their clips from their floats Fig 10 12 2 Remove and discard bowl cover gasket 3 If necessary remove vacuum power piston from bowl cover by depressing plunger and allow ing it to snap back several times It may be necessary to remove burrs around power piston bore caused by staking Remove sp...

Page 251: ...ck washers from each Fig 10 14 Remove gaskets from clusters and discard gaskets Brass baffles in main wells under primary cluster may be removed if necessary Do not attempt to re move idle tubes or nozzles from venturi cluster 6 Remove hot idle compensator and gasket from secondary side by removing two small self tapping screws Fig 10 14 Discard gasket Do not bend or distort bi metal strip Idle co...

Page 252: ...etainer in slot in bore com pressing spring 2 Position smaller aluminum check ball on its seat in bottom of pump well Idle Mixture A Springs s Fast Idle Screw ff Spring Fast Idle 2 Cam S Pivot c Screw Torsion Spring 1 Speed Up Lever S c r e w s K LL Throttle Washer F Opening JJ Q L Vi I Center Screw Washer Connecting _x i ocrew Link Throttle I Lever Throttle Body i f s Spring Idle Air By Pass Scre...

Page 253: ...loat gage to toe of primary floats Lower surface of each float should just touch gage 6 If adjustment is necessary at either float carefully bend float arm as required Lower Floats Should Be Centered In Gage Gage J 7714 1 Gasket Lower Surface Of Floats Should Just Touch Gage Primary Floats Bending Tool J 7182 2 Fig 10 18 Bending Primary Float Arm surface of each float should be parallel with cover...

Page 254: ...ounce floats lightly before measuring distance Gasket M Primary Floats ii t 1 1 2 Leg Of Gage J 7714 1 Floats Should Be Centered In Gage Gage J 7714 1 Gasket jj Upper Surface Of Floats Should Just Touch Gage Fig 10 22 Float Level Adjustment Secondary 3 If adjustment is necessary bend tang at rear of float arm toward needle seat to decrease drop and away from seat to increase drop i Float Level Adj...

Page 255: ...screws One of the longer screws is also an inner bowl cover screw Gasket Secondary Floats V 1 5 16 Gage J 7714 3 3 Place choke rod with choke counterweight lever on choke shaft with collar inward and tang pointing outward and toward secondary side of carburetor Fig 10 25 4 Install choke trip lever with letters RP facing outward and with lever projecting above tang on choke lever Install retaining ...

Page 256: ...ston lever over intermediate choke lever shaft and retain with screw while holding lever toward choke housing 6 Install intermediate choke rod in choke shaft lever Grooved end of rod goes into choke shaft lever Retain with clip p Intermediate Choke Rod Adjustment Fig 10 27 Choke vacuum piston must be properly position ed with respect to vacuum slots in choke housing bore to provide proper choke pu...

Page 257: ...ve and dividing wall in cover Fig 10 29 Use Bending Tool J 5197 Fig 10 30 on fast idle cam tang Choke Valve 125 Gage J 7714 7 Throttle Lever Choke Unloader Tang Bending Tool J 5197 Choke Unloader Tang Fig 10 29 Choke Unloader Adjustment Fig 10 30 Bending Unloader Tang t Secondary Throttle Opening Adjustment 1 With carburetor inverted move choke to fully opened position 2 Rotate primary throttle to...

Page 258: ...Lever Fast Idle Camii 015 Wire Gage J 7714 8 Mounting Screws 1 Idle Speed up Control v Idle s i 4 H Speed up Lever Fig 10 33 Idle Speed Up Control 1 Float Alignment 2 Float Level 3 8 inch Gage No 1 3 Float Drop 2 inch Scale 4 Choke Piston Lever 120 inch Gage No 5 5 Choke One Notch Rich 6 Accelerator Pump 15 32 inch Gage No 3 7 Fast Idle 022 inch Gage No 6 8 Choke Unloader 281 inch Gage No 7 9 Seco...

Page 259: ...ctor rod from fast idle cam 6 Remove attaching screws with washers and remove power piston cover plates Fig 10 36 Hold cover plates against pressure when removing screws Power Piston Metering Ro Power Piston Sprin Cover Screw And Lock Washer i i Screw Outer Choke yS Shaft Lever f Washer r w j f Pum P A r m Inner Choke Shaft Lever Clip Throttle Connector Rod Clip Fast Idle Connector Rod Clip Pump C...

Page 260: ...ets 2 Remove and discard bowl cover gasket e Choke Disassembly 1 Remove three thermostatic coil housing at taching screws with retainers and remove thermo static coil housing with thermostatic coil Fig 10 37 Do not remove coil from coil housing 2 Remove gasket and baffle plate Fig 10 37 3 Remove choke lever attaching screw Fig 10 37 and remove choke piston lever and link assembly by rotating pisto...

Page 261: ...three complete turns from fully seated position 4 Install idle mixture screws and springs Turn screws in finger tight and then back out 1 1 2 turns for approximate adjustment 5 Place auxiliary throttle valves in position Fig 10 39 6 Install the two primary and the two second ary venturi gaskets NOTE The primary gaskets are different from the secondary gaskets and caution should be taken to make su...

Page 262: ...e Pump Jet Cluster Venturi Gasket Pump Jet Cluster Gasket Pump Discharge Check Needle Baffle Secondary Venturi Assembly Choke Side Auxiliary Throttle Valve Assembly Idle Adjustment Screws Screw Fast Idle Cam Lockout Lever Caged Check Ball Idle Air Adjusting Screw And Spring Idle Adjustment Screw Springs Bowl Throttle Operating Rod Inner Throttle Shaft Arm Throttle Shaft Tang Outer Throttle Shaft A...

Page 263: ...ach float to bowl cover gasket Fig 10 41 This distance should be 2 inches as measured with scale and is not meas ured to the seam To adjust bend stop tabs on float brackets d Bowl Cover Installation 1 Install accelerator pump assembly in pump well 2 Hold bowl cover assembly in upright position with the floats suspended and carefully lower cover into bowl assembly Be sure that baffles attached to c...

Page 264: ...44 Accelerator Pump Adjustment 5 Inside the choke piston bore on the left side approximately 1 2 inch down is a small slot Take 026 inch Wire Gage J 7712 4 and insert the 1 8 inch end into slot then close choke valve until piston stops against gage Opening between top edge of choke valve and web of bowl cover casting should be 120 inch Check this clearance with 120 inch Wire Gage J 7712 5 Fig 10 4...

Page 265: ...enter of fast idle screw h Choke Unloader Adjustment Fig 10 47 1 Rotate primary throttle to full open position 2 Insert 281inch Gage J 7712 7 between upper edge of choke valve and inner wall of bowl cover assembly Choke valve should give a slight drag on gage under finger pressure 022 Wire Gage Tool J 7712 28V Gage Tool J 7712 Fig 10 47 Choke Unloader Adjustment 3 If adjustment is required bend un...

Page 266: ...tilator valve should be serviced before making adjustments on the engine as this valve affects the air to fuel ratio Note 1 a Idle Speed and Mixture Adjustment 1 Disconnect parking brake vacuum diaphragm line from neutral safety switch and put tape over switch opening to prevent any air leak NOTE Hose must be disconnected at this location to include any calibrated leakage in the balance of the sys...

Page 267: ...r plate 7 Shut engine off c Throttle Rod and TV Rod Adjustment 1 Using two wrenches back off both locknuts on TV rod at carburetor to allow free movement of rod in trunnion 2 Remove cotter pin and washer from carbu retor rod trunnion and remove from relay bracket lever On cars equipped with Cruise Control Cruise Control rod and washer are also detached 3 Place 1 4 inch drill shank through gaging h...

Page 268: ...all during the above pro cedure Clearance between throttle check plunger and relay should be approximately 190inch with engine running NOTE Do not perform this operation re peatedly because transmission may become overheated g Idle Speed Up Control Adjustment 1 Start engine and allow it to warm up 2 Remove air cleaner 3 Turn Air Conditioner On 1 Apply foot brake firmly with left foot Place transmi...

Page 269: ...ool Key D E Number J 1137 J 7712 Name Bending Tool Carter AFB Gage Set FUEL PUMP SPECIFICATIONS NOTE Testing to be done with entire car at room temperature Fuel pressure at idle speed 5 1 4 to 6 1 2 p s i Fuel pump discharge per stroke at cranking speed 28 cc minimum Fuel pump discharge in 17 strokes at cranking speed 1 Pint minimum ...

Page 270: ...52 Main Metering Jets Primary 056 Secondary 075 Power Valve Restriction 050 Choke Setting 1 Notch Rich Float Level Primary Gasket to Float Top 15 64 Secondary Gasket to Float Heel Bottom 1 3 8 Primary Power Piston Up 1 3 32 Secondary Gasket to Dimple 3 8 Float Drop Gasket to Dimple Primary Power Piston Down 1 1 2 Secondary 1 5 16 Accelerator Pump Capacity 10 Strokes 9 12 cc Jets 026 Idle By Pass P...

Page 271: ...zle Bleed 028 Secondary Clusters Auxiliary Feed Bleed 052 Auxiliary Feed Restriction 063 Auxiliary Fuel Feed 063 Nozzle Bleed 031 Auxiliary Nozzle Bleed 043 Metering Jets Primary 098 Secondary 082 Float Level 3 8 Top of Floats to Gasket Float Drop 2 Bottom of Floats to Gasket Choke Setting 1 Notch Rich Accelerator Pump Capacity 10 Strokes 13cc Min Jets 028 Idle Mixture Screw Turns Open 2 1 2 Secon...

Page 272: ...eads After circulating through the heads it flows to the thermostat housing located at the top of the cylinder head water outlet pipe Fig 11 1 When the thermostat is closed coolant from the cylinder heads is drawn through a by pass passage in the cylinder head water outlet pipe to the water pump and recirculated When the engine is sufficiently warm the thermostat will open and coolant will flow to...

Page 273: ...nt is cold 3 Testing Anti Freeze Solutions A hydrometer test will indicate whether anti freeze or water or both should be added to bring the coolant to its proper level and to maintain the desired freezing point of the solution Some devices used for testing anti freeze solu tions will indicate the correct freezing point only when tested at a specific temperature Other testers provided with thermom...

Page 274: ...eaks b Radiator air passages for plugging caused by bugs leaves etc c Condition and tension of drive belts d Condition of hoses and tightness of clamps 5 Drain system by opening all drains 6 After the drain points have been closed add the required amount of ethylene glycol base anti freeze to protect engine to at least 20 F Also use inhibitor and sealer regardless of whether or not the anti freeze...

Page 275: ...and plug ends of lines to prevent loss of transmission fluid 4 Remove the two bottom and top cradle to shroud clamps This will allow shroud to be pushed away from radiator 5 Remove radiator by lifting straight up d Installation Air Conditioned Cars 1 Place radiator in position 2 Move shroud into place and connect the two bottom andtwotopcradle to shroud clamps 3 Connect two transmission cooler lin...

Page 276: ...on engine front cover 2 Install water pump on engine front cover lining up dowel holes in pump with locating dowels on front cover and loosely install ten attaching screws Fig 11 3 3 Install oil filter support bracket on engine front cover using new gasket and secure with Key A B C D Size 1 4 20x1 1 4 5 16 18x3 1 4 3 8 16x3 5 8 3 8 16x3 7 8 Torque 5 foot pounds 10 foot pounds 15 foot pounds 15 foo...

Page 277: ...nder head water outlet pipe and heater outlet hose at water pump 14 Remove four cap screws that hold cylinder head water outlet pipe to cylinder heads and re move water outlet pipe Discard flange surface gaskets and O ring seal from neck of water out let pipe 15 Remove ten remaining cap screws that hold water pump to engine front cover and cylinder block and remove water pump Fig 11 3 Dis card gas...

Page 278: ... assembly 4 Remove four cap screws that hold clutch assembly to fan blade and remove clutch from fan blade b Installation 1 Install clutch assembly on fan blade and secure with four attaching screws Tighten screws to 16 foot pounds 2 Position fan and clutch assembly on pulley and secure with four attaching screws Tighten screws to 26 foot pounds 3 Position fan shroud against radiator and secure wi...

Page 279: ...ssor 57 46 Tension Used 70 lbs New 100 lbs FAN Drive Ratio Non Air Conditioned Cars 96 to 1 0 Air Conditioned Cars 1 1 to 1 0 Number of Blades Non Air Conditioned Cars 4 Air Conditioned Cars 5 HOSES Hose thermostat housing to radiator Top Diameter inside 1 1 2 Type Molded Hose radiator to water pump Bottom Diameter inside 1 3 4 Type Molded All Series Item Unless Other wise Noted RADIATOR Capacity ...

Page 280: ... Non A C Heater Hose Clamp Thermostat Housing Screw Water Pump to Cylinder Block Screw Water Pump to Cylinder Block Screw Water Pump to Front Cover Screw Water Outlet Pipe to Cylinder Head Screw Refer to Fig 11 3 for proper screw location to back of manual Page 17 1 for bolt and nut markings Size 5 16 18 7 16 14 5 16 24 5 16 24 10 24 5 16 18 3 8 16 5 16 18 1 4 20 3 8 16 and Steel Foot Pounds 16 75...

Page 281: ...y K 1 1 1 f 1 n 1 jit 1 I Si j M 1 T l i l t i w o o ...

Page 282: ... Subject Page No General Description 2 Battery 4 Starting System 8 Ignition System 13 Charging System 21 Lighting System 34 Electrical Instruments 40 Windshield Wiper and Washer System 47 Radio and Antenna 61 Cruise Control 70 Guide Matic 82 ...

Page 283: ...s numerals 0 5 and 10 are lo cated on the engine front cover The pistons in number one and six cylinders are at top dead center when the 0 mark is in line with scribe line on the harmonic balancer The 5 mark and the 10 mark indicate the number of crankshaft degrees ahead of the 0 mark The oil impregnated ignition coil is mounted on top of the intake manifold in front of the carburetor The interrup...

Page 284: ...r voltage through the field relay contacts and across the voltage regulator shunt windings The magnetism developed in the windings causes the lower or series contacts of the voltage regulator to separate The field current then flows to ground through a resistor that reduces field current This reduced field current causes the generator voltage output to decrease thereby decreasing tke magnetic pull...

Page 285: ...he starter switch is combined with the ignition switch and is located to the right of the steering column The engine is started by turning the key to the right against spring tension to energize the starter solenoid When the engine starts releasing the key permits it to return to the On position The key may be turned to the extreme left to per mit the use of accessories with the ignition Off All a...

Page 286: ... differ by 05 volt or more the battery has a defect that will cause short life or poor performance O BODY FD I I S I I 25 URN SG 14 HORN I I 25 iTR AC I I I POWER WINDOW ACC ADIO I 7 5 J L O LOW READINGS If all cells read less than 1 95 volts the battery is too low to test properly and must have a booster charge NOTE Most defective batteries will fail the light load test However there are a few ba...

Page 287: ...r draw liquid into it several times to insure correct tem perature before taking reading ELECTROLYTE TEMPERATURE F 0 MPER TROL HERM TAKE TEMPERATURE l 0 0 OF ELECTROLYTE WITH THERMOMETER 90 TAKE SP GR OF ELECTROLYTE WITH HYDROMETER 80 50 EXAMPLE A 4 120 F so TEMPERATURE HYDROMETER READING 1 230 CORRECTION 120 F 016 TRUE SPECIFIC GRAVITY 1 246 20 SPECIFIC GRAVITY CORRECTION CHANGE HYDROMETER READIN...

Page 288: ... with household ammonia or with a solution of water and baking soda These alkaline solutions will neutralize any acid on parts being cleaned Felt washers soaked with engine oil should be installed under each terminal to retard corrosion CAUTION Care should be taken to keep cleaning solution out of battery cells otherwise the electrolyte will become permanently weak ened 5 Examine battery for crack...

Page 289: ...lubricant out onto the commutator where it would gum and cause high resistance resulting in poor Neutral Switch Ace B o t t e r y Starting Motor starter motor performance Never oil the com mutator 11 Starter Motor Circuit Resistance Test a Battery Cable and Starter Switch Test Insulated Circuit Test This test measures the resistance of the cables and switches that feed the starter motor The heavy ...

Page 290: ... The battery should be fully charged 1 Turn Battery Starter Tester control knob to Off position 2 Turn voltmeter knob to 16 volt position 3 Connect test leads as shown in Fig 12 10 4 Connect solenoid clicker switch from bat tery to starter solenoid 5 Disconnect primary lead of distributor from coil so motor will not start CAUTION Do not remove high tension lead from coil center for this purpose as...

Page 291: ... burned bars in the commutator it may indicate open circuited armature coils that may prevent proper cranking Inspect soldered connections at commutator rise bars and resolder these con nections and turn down the commutator as necessary Tight or dirty bearings will reduce armature speed or prevent the armature from turning A worn bearing bent shaft or loose pole shoe will allow armature to drag ca...

Page 292: ...val and Disassembly When the starter motor is disassembled for cleaning and inspection of parts the overrunning clutch armature and fields should not be cleaned in a degreasing tank or with grease dissolving solvents since these would dissolve the lubricant in the clutch mechanism and would damage the in sulation in the armature and field coils Worn parts should be replaced and the commutator shou...

Page 293: ...ssembly from arm ature shaft 5 To disassemble solenoid proceed as follows a Remove two screws retaining solenoid as sembly to starter drive housing and remove sole noid and solenoid return spring from housing by rotating solenoid assembly counterclockwise b Remove two nuts and seals from motor terminal and S terminal on solenoid housing c Remove two screws and seals retaining con tact cover to sol...

Page 294: ...od assembly in solenoid housing and install contact cover in position securing cover to housing with two screws and seals c Install twonuts and seals to motor and S terminals d Place solenoid return spring in position and install solenoid rotating assembly clockwise Se cure solenoid assembly to starter housing with two screws NOTE If seal between solenoid assembly and starter assembly has been dam...

Page 295: ...llen wrench into head of the adjusting screw and turn clockwise until points close Then turn screw counterclockwise 1 2 turn 6 Replace distributor cap 7 Adjust contact points as outlined in step d Fig 12 18 Primary and Condenser Lead Position d Adjustment of Contact Points Engine Running Preferred Method 1 Connect a dwell meter to distributor primary lead 2 Lift adjustment window and insert Allen ...

Page 296: ...in Fig 12 17 and position out of way 2 Disconnect distributor primary wire from coil 3 Disconnect vacuum advance pipe hose from vacuum advance unit on distributor 4 Crank engine until copper contact on top of rotor points directly to No 1 spark plug 5 Remove distributor hold down nut and clamp 6 Lift distributor from engine and discard gasket NOTE The distributor rotor will turn slightly countercl...

Page 297: ...d lead 5 Install breaker plate assembly over bushing so that assembly is positioned over vacuum ad vance operating arm 6 Install spring retainer 7 Place condenser and bracket over protru sions on breaker plate and secure with one screw 8 Install contact point assembly 9 Install condenser and primary leads asshown in Fig 12 18 10 Install shaft with camweight base assembly into housing 11 Install ge...

Page 298: ...ncer in relation to degree marks on front cover and rotate distributor so that light flashes when scribe mark and 5 mark are aligned The 5 mark is five degrees ahead of top dead center Fig 12 21 Fig 12 22 Secondary Efficiency Test 7 Tighten clamp nut to 18 foot pounds and re check timing to make sure that it did not change 8 Remove tape from vacuum advance pipe hose and connect hose to distributor...

Page 299: ...hecked for any change in readings 8 Test all wires for tightness Movethem about and not note any change in meter reading 9 Remove voltmeter leads and place them across the primary wires from coil to distributor as shown by dotted leads in Fig 12 23 Voltmeter should read less than 1 volt NOTE If voltmeter reading exceeds the specified maximum isolate the point of this resistance by placing the test...

Page 300: ...e brought to to operating temperature If the coil is on a car that has been operated for a sufficient period of time to bring the coil to normal operating tem perature the coil does not need additional heating before testing If however the coil is not up to temperature it must be heated with the Coil Heater as described below Fig 12 24 Calibrating Coil Tester Fig 12 25 Heating the Coil 1 Disconnec...

Page 301: ...stance NOTE A high reading will indicate an open or high resistance secondary winding while a low reading will indicate shorted winding 27 Condenser Tests a Preliminary Steps The condenser has two important functions First it aids in the collapse of the primary field and second it prevents arcing and pitting of the breaker points The condenser should be tested for 1 Series resistance 2 Correct cap...

Page 302: ...the air blast turned on press the cleaner hood down rock ing the plug Raise the cleaner hood to the air blast position for a few seconds Rotate the plug in its adapter and repeat the operations until the entire insulator is clean white It should be noted here that some spark plugs may have fused deposits on the lower insulator tips that are diffi cult if not impossible to remove Make sure that all...

Page 303: ... Note 33 3 If no circuit defects are found voltage regu lator setting is probably too high Refer to Note 40 to adjust voltage regulator setting 32 Testing Indicator Lamp Circuit a Testing for Defective Bulb Failure to Burn 1 Check for defective bulb or open in wiring 2 Disconnect wiring harness connector andin sert Adapter J 9782 3 3 Insert Jumper Lead J 9782 1 into wiring harness and make connect...

Page 304: ... the generator To determine which is at fault proceed as follows F 2 3 4 WIRING HARNESS CONNECTOR Fig 12 32 Testing Indicator Lamp Circuit Resistance Wire 1 Make connections as shown in Fig 12 33 2 Connect a tachometer in system and operate engine at 1000 rpm If voltmeter reading is five volts or above and relay fails to close field relay is defective and must be checked as described in Note 40d I...

Page 305: ...nd strap 2 Disconnect wires and connector from gen erator 3 Remove generator link adjusting screw 4 Remove front nut and washer from locating stud on manifold F 2 3 4 WIRING HARNESS CONNECTOR Fig 12 34 Testing Generator Output 6 Remove two cap screws that hold generator support bracket to exhaust manifold 7 Position generator away from support brace and slide generator with support bracket off loc...

Page 306: ...ove large collar from rotor shaft BRUSH HOLDER ASSEMBLY DIODES LEAD ATTACHING NUTS c Disassembly of Slip Ring End Frame Fig 12 36 1 Remove three nuts with lock washers retain ing diode and stator leads disconnect leads and separate stator from slip ring end frame 36 Inspection Testing and Replacement of Generator Components a Brushes and Brush Holder Fig 12 37 1 Inspect brush springs for any evide...

Page 307: ...ections or fails to light in both directions diode is defective When checking a good diode lamp will light in only one direction 4 If necessary replace defective diode as fol lows a Support inside of end frame or heat sink with Support Tool J 9717 2 and press out diode with Removal Tool J 9717 1 and an arbor press or vise CAUTION Do not remove diode by striking with a hammer as shock may damage ot...

Page 308: ...d OPENS Connect the leads of the test lamp to each slip ring If lamp fails to light windings are open SHORTS Connect a 12 volt battery and am meter in series with slip rings and note ammeter reading If above 2 3 amperes it is an indication that shorted windings exist 2 Inspect slip rings If they are dirty they may be cleaned and finished with 400 grain or finer polishing cloth Spin rotor in a lath...

Page 309: ...s shown in Fig 12 42 Adjusting lug should be directly above R and F terminals 3 Install rotor complete with drive end frame into slip ring end frame and retain with four through bolts 4 Remove wire or pin projecting through rear of slip ring end frame allowing brushes to seat on slip ring 38 Generator Installation 1 Slip generator over locating stud on mani fold and loosely install generator link ...

Page 310: ...m resistor will limit generator output to 10 amperes or less which is required when checking and adjusting voltage setting 2 Connect adapter as shown in Fig 12 45 Use a 25 ohm 25 watt variable resistor in series with regulator F terminal and connect jumper lead from adapter No 3 terminal to generator Temperature Gauge J 8529 STARTER SOLENOID 20OHM RESISTANCE WIRE GENERATOR Fig 12 44 Connections fo...

Page 311: ... setting on voltmeter b Adjusting Lower Contacts 1 With equipment used in upper contact setting in place check lower setting by slowly increasing resistance of variable resistor with engine oper ating at 2500 rpm until regulator begins to operate on lower set of contacts as evidenced by a drop in the voltmeter reading Operation on lower con tacts should be 1 3 volt lower than on upper contacts NOT...

Page 312: ... be cleaned 1 Clean contacts of voltage regulator unit by folding over a strip of No 400 silicon carbide paper and pulling paper back and forth between contacts 2 Wash contacts with trichlorethylene or al cohol to remove any residue VOLTMETER WIRING HARNESS CONNECTOR HEEL IRON BEND TO ADJUST CLOSING VOLTAGE I Fig 12 47 Checking Field Relay Closing Voltage Fig 12 48 Adjusting Field Relay Closing Vo...

Page 313: ...This test must be made with the engine off 1 Turn voltmeter selector switch to 4 volt position Fig 12 51 Checking Field Relay Air Gap 2 Connect one voltmeter lead to a ground on car body and the other lead to a ground on engine 3 Turn on all lights and accessories then note voltmeter reading This should not exceed 1 volt 4 If voltmeter reading exceeds 1 volt test voltage drop at ground strap conne...

Page 314: ...l inspection light load test or full charge hydro meter test as outlined in Notes 2 4 and 6 2 Inspect and test starting system This in cludes lubrication inspection starting motor cir cuit resistance test and amperage draw test on starting motor Notes 10 11 and 12 3 Inspect and adjust distributor contact points as explained in Note 19 4 Make certain engine idle rpm is correctly adjusted to 480 rpm...

Page 315: ...Aimers must have floor level com pensator readjusted for each new location if floor levels are different b Headlight Adjustment 1 Equalize tire pressure as recommended in Section 4 Note 4c and make certain car is at normal standing height Section 4 Note 6 2 Turn on headlight units to make sure none are burned out All four units should be on for high beam and only the two outer units should be on f...

Page 316: ...nts on inner set of headlights e Calibrating Aiming Fixture Aimer J 6663 is calibrated at the factory for use on a level floor These aimers require no further change in factory calibration unless they are dropped or damaged in some manner 1 With the aid of a good grade carpenter or stone mason spirit level locate a vertical plate glass window Fig 12 60 2 Set Down Up pointer on 2 down Set Right Lef...

Page 317: ...0 Curb Height 29 15 16 30 30 5 16 31 3 4 Move screen down until horizontal centerline of headlight is even with this point 4 Remove headlight doors 5 Set headlights on high beam Allfour head lights should light 6 Cover both left side headlights and right side outer light and adjust right inner light as required until hot spot centers at point B on screen Fig 12 63 7 Cover both right side headlight...

Page 318: ...ring with unit to backing plate securing with two screws 2 Secure connector plug to back of sealed beam unit 3 Position ring with sealed beam assembly on adjusting screws Connect retaining spring to ring 4 Install headlight door and secure with four screws 49 Bulb Replacement Except Instrument Panel Cluster A complete list of replacement bulbs required for 1963 cars is given in the Bulb Chart Page...

Page 319: ...light cover to the light base is located on the underside of the fender Remove headlight door remove cover screw and cover Replace bulb h Cornering Lights Remove seven screws and three washers se curing chrome bezel and lens assembly Remove bezel and lens to replace bulb When replacing make certain the four outer oval head retaining screws are positioned in the bezel The three inner round head scr...

Page 320: ...amps Are High Beam Lamps Only Outer Lamps Are Both High And Low Beam But Are To Be Aimed On Low Beam Only Fig 12 63 Headlamp Aiming Screen b Installation 1 Route parking lamp wire through bumper opening and connect wire to underhood harness connector 2 Install parking lamp from front 3 Tighten inner mounting bracket bolt to bumper 4 Install bracket and secure parking lamp to bracket with two mount...

Page 321: ...nk install nuts retaining light assembly to fender 2 Secure screw retaining top of light to fender 3 Install lens and secure with two screws 4 Connect feed wire at plastic connector in trunk 54 Cornering Light Removal and Installation a Removal 1 Raise front end of car and turn wheel outward 2 Disconnect cornering light wire orange from underhood harness connector 3 Remove one screw from front and...

Page 322: ...ng a straight edge on bottom surface of cover plate extending it outward toward end of float hingepin 2 With float arm in Full position against stop A Fig 12 66 bottom of float hinge pin Full Position Empty Position Fig 12 66 Checking for Bent Float Arm washer should align with top of straight edge If necessary bend float arm accordingly 3 Permit float arm to drop down to Empty position against st...

Page 323: ...ermogage unit if it tests satisfactorily Check following items according to nature of difficulty a If dash unit does not register when ignition switch is turned on and engine is warm it may be caused by a break in the line between dash unit and the ignition switch b If gage shows High Temperature under all conditions it may be caused by the left coil wire in dash unit being broken poor dash unit g...

Page 324: ...essure indicator light is connected in a circuit with the ignition switch and a pressure operated switch which is threaded into the oil header galley at the rear of the engine The indicator light warns the driver when the oil pressure is below seven pounds If the light does not come on when the ignition switch is turned on or if the light stays on after the engine is started either the pressure is...

Page 325: ...emove directional signal housing and switch assembly 7 Remove directional switch lever 8 Remove two switch retaining screws and switch wire clamp screw from back of direc tional signal housing and remove switch assembly and wires from housing b Installation 1 Install switch assembly in directional signal housing threading wires through housing Secure switch and wires with two retaining screws and ...

Page 326: ...orn should be removed for a bench check c Horn Operates Intermittently This condition may result from 1 Loose or intermittent connections in the horn relay or horn circuit 2 Defective horn switch 3 Defective horn relay 4 Defects within the horn d Checking Current Adjustment 1 Measure the current draw of the horn while the horn is operating The low note horn and the high note horn should have a cur...

Page 327: ...e thereby eliminating ac cumulation of errors A car clock is spring operated and electrically wound Time errors are accumulated day by day An automobile clock is considered a good time piece when at normal temperatures the consistent gain or loss does not exceed seven minutes per week Accumulation of this error during a month may amount to as much as thirty minutes The owner must therefore anticip...

Page 328: ...hts should operate when trans mission shift lever is placed in reverse c Parking brake should release in any drive range with engine running 71 Ignition Switch Removal and Installation The procedure for removing and installing the ignition switch is described in Section 15 Note 13 72 Cigar Lighter Unit Removal and Installation The procedure for removing and installing the cigar lighter units is de...

Page 329: ...DIUM SPEED Moving the dash control switch to the Medium position Fig 12 71 connects a second resistor located in the control switch in parallel with the resistor connected from the shunt field circuit These two resistors connected in parallel allow less current to flow in the shunt field resulting in medium speed HI SPEED Moving the control lever to the Hi speed position Fig 12 72 eliminates the p...

Page 330: ...l Battery White 1 id i 13 Medium Speed 1 Resistor Washer Off Lo hAed Hi Fig 12 71 Wiper Operation Medium Speed Wiper Unit Connector 20 Relay And Switch rzi 1 i Brown Series Field Shunt Field Circuit Breaker Yellow Green Black Washer Connector 1 Brown Orange Motor Black I Washer Relay Coil White Battery Washer Off Lo Med Hi 13 n Medium Speed Resistor Fig 12 72 Wiper Operation High Speed ...

Page 331: ...embly to open the motor circuit at the relay control switch as the blades arrive at the park position Washer Circuit Depressing the washer button on the control switch mechanically moves the switch lever tothe Lo speed position The washer relay coil is energized by the current flowing from the No 2 terminal on the wiper unit connector through the brown wire into the relay coil and from there throu...

Page 332: ...e action is repeated through the 21 teeth on the ratchet wheel As the ratchet wheel completes its rotation the tang on the armature slips into the recess of the ratchet wheel which then allows the ratchet pawl to disengage from the wheel and move freely through the armature and the washer is again in the idle position Washer Relay Ratchet Pawl Relay Armature Armature Tang Inlet Nozzle Wire Stop Pl...

Page 333: ...and washer securing lower arm to unit and remove arm 8 Remove upper crank arm from motor shaft and remove boot from shaft NOTE The crank arm is to remain as a part of the left wiper assembly 9 Remove four wiper unit mounting screws through air intake grille opening and remove wiper assembly from under hood b installation 1 Position wiper unit in cowl recess and se cure with four mounting screws Re...

Page 334: ...o inches from brush holder 7 Remove field coils by grasping one end and rotating it over pole shoe retaining flange Follow same procedure for remaining three sides of two field coils 8 Remove pole shoe from housing by using Field Coil Puller J 7844 as shown in Fig 12 78 NOTE Be certain that tool base is installed with flat side up and that puller flanges straddle sides of shoes b Gear Box Disassem...

Page 335: ...lay washers as required to obtain a snug 005inch clearance 7 Pack rubber seal with waterproof type grease and install seal over shield so that tangon shield is properly fitted to seal 8 Install crank arm and tighten securely with nut 9 Position relay control assembly in housing splice and solder wires 10 Solder leads to terminal board if board was removed 11 Solder new 20ohmresistor to No 3 termi ...

Page 336: ...n housing splice and solder wires Secure relay to housing with two screws 9 Install stop assembly retaining screw 10 Install E ring washer and spacer on pivot pin of stop assembly 11 Install latch and follower assembly on pivot pin and position moveable arm over relay arm tab 12 Secure latch and follower assembly to pivot pin with E ring retainer and connect small coil spring with large hook end i...

Page 337: ...ing clip securing relay to washer housing and remove relay with terminal board 5 Remove relay armature from relay by dis connecting spring Fig 12 75 NOTE Washer pump is not serviceable be yond rotor cam cam retainer outlet valve and relay Replace complete assembly if other de fects are found c Assembly 1 Position relay armature on relay and secure with spring Fig 12 75 2 Install relay and terminal...

Page 338: ...NOTE Wiper must operate in Lo speed to park or shut off correctly 3 To determine if washer pump unit or washer button switch is defective operate washer pump independently of washer switch as follows a Operate wiper unit as described above b Connect 12 volts to either washer pump ter minal and momentarily ground other terminal with jumper wire This will allow washer to operate through one cycle c ...

Page 339: ...it breaker contacts 3 Check field assembly for following circuit conditions a Disconnect yellow lead from relay control switch and connect test lamp between yellow lead and brush holder to which internal field lead is attached If lamp does not light an open series field is indicated b With yellow lead disconnected connect test lamp between yellow lead and terminal to which black motor lead attache...

Page 340: ...t and or reversing link shaft Defective relay switch Weak circuit breaker Shorted condition in wiper motor Armature end play adjustment too tight Gear end play adjustment too tight REMEDY Free up latching mechanism and lubricate as required Check relay control as de scribed in Note 80a R e p l a c e relay switch as sembly Replace drive pawl Replace terminal board as sembly Check dash switch as de ...

Page 341: ...nd ing or slipping Defective washer valve outlet assembly Defective washer valve outlet assembly Windshield lower reveal mold ing interferes with water spray 75 and Commercial Chassis Defective washer valve REMEDY Repair or replace hose or re move obstruction Check circuit from power source to washer Check dash switch as de scribed in Note 79b Replace relay coil or repair connections Replace valve...

Page 342: ...als are easily reflected and scattered by surrounding objects This scattering of the waves causes a strong FM signal to be picked up in areas where AM signals are weak such as in tunnels and underpasses When the FM receiver moves out of range of the FM transmitter it enters what is referred to as the fringe area In the fringe area the strength of the FM signal may vary rapidly causing a flutter or...

Page 343: ...y to the right and stops automatically at the point where that station is best received This action takes place each time the selector bar is depressed When the tuner has reached the point of highest frequency of the broadcast band it returns to the low frequency left side of the broadcast band and begins a new sweep to the right stopping at the first receivable station The above procedure is then...

Page 344: ...ote control overrides the front radio controls Once the remote control is turned ON the front controls with the ex ception of the push bottons and manual tuner will not operate the radio until the remote con trol is turned OFF The ON OFF volume control knob turns the radio ON and OFF and controls the volume The sensitivity control is located beneath the ON OFF volume control knob Rotating the cont...

Page 345: ...push button in all the way Whenever this button is pushed the pre set station will be selected 3 Repeat above procedure for the four remain ing buttons 84 Minor Repair Procedures Many conditions that affect radio operation may be corrected without removing set from car Check condition and using diagnosis chart at end of section perform the operation or operations necessary to correct the condition...

Page 346: ...ker Removal and Installation The procedure for removing and installing the front speaker is described in Section 15 Note 7 87 Transistor Removal and Installation a Removal 1 Remove receiver unit as described in Section 15 Note 6a 2 Remove two screws securing heat sink in receiver unit and remove heat sink from receiver 3 Remove nut that secures transistor to heat sink unsolder leads and remove tra...

Page 347: ...ol unit shaft to top of arm rest assembly 3 Connect electrical connector to remote con trol unit 4 Connect electrical connectors to heater switch and where present to air conditioner switch 5 Position arm rest assembly against rear quarter panel and secure with attaching screws 6 Position sensitivity control ring on remote control unit shaft 7 Install spring on top of sensitivity control ring on r...

Page 348: ...volts to the motor leads to retract cord into drive assembly Be certain to keep cord taut to prevent kinking 4 Place outer mast section over inner section aligning slots of pin and insulator assembly with ears in tubular fitting 5 Place support tube over mast assembly aligning tang on tube with slot provided in tubular fitting Pull mast wire through pin and insulator hole before securing support t...

Page 349: ...ing Spring Grounding Tab Escutcheon Top Insulator Screw Support Tube Outer Mast Section Inner Mast Section Screw Bottom Insulator Tubular Fitting Ground Wire Insulator Bushing Nylon Cord Deflector ERG Fig 12 86 Antenna Disassembled ...

Page 350: ...ntenna connection Wire against speaker cone Rattling speaker cone Rubbing voice coil REMEDY Check fuse See Note 84a Check antenna See Note 84d Check all ground connections Inspect connections Replace tube See Note 82f Test transistor Extend antenna Adjust trimmer See Note 83a Check antenna See Note 84d Clean and tighten connections Inspect connections Check all ground connections Charge battery Ti...

Page 351: ...nstrument Power Unit To Speedometer Cable Control Cable i Accelerator Linkage Power Unit Selector Control Power Unit Wiring Harness Power Unit To Transmission Cable panel and is located to the right of the selector dial When the switch is in the off position the unit has no effect at any speed Once the switch has been moved to the center or on position the unit is on and accelerator back pres sure...

Page 352: ...ve slide switch to lock position while holding down against accelerator back pressure and then re lease switch The car will now maintain the se lected speed automatically and the driver may remove his foot from the accelerator pedal if desired Selected speed will be maintained re gardless of road terrain within limits of engine performance When the unit is in automatic control car speed can be cha...

Page 353: ...remove power unit leaving mounting bracket attached to fender dust shield b Installation 1 Position power unit on mounting bracket and secure to bracket with two bolts 2 Connect accelerator linkage to locking arm on power unit Adjust linkage as described in Note 100 3 Install ball end of bowden cable in socket on power unit 4 Install dust shield in housing Dust shield has bayonet type retention Pu...

Page 354: ...ap Ring Snap Ring Wave Washer Nylon Gear Governor Spring Fabric Washer Clamp Contact Arm Actuator Spacer Governor Weights Serial No Plate Stop Stud Felt Seal Omni Switch Drive Screw Assembly Bushing Bearing Compressor Rod Guide Housing Lock Nut Ball Socket Speedometer Adapter Drive Adapter Retaining Ring Dust Shield Fig 12 91 Power Unit Disassembled ...

Page 355: ...securing drive adapter to housing and remove adapter if necessary NOTE The governor assembly and power unit housing are serviced as a single unit b Assembly 1 Install drive adapter on bottom of power unit NOTE The drive adapter and speedometer adapter are interchangeable 2 Lubricate nylon gear with cam and bearing lubricant and install gear in housing 3 Secure gear in housing with retaining ring 4...

Page 356: ... 27 Install compressor rod guide on housing 28 Lubricate compressor rod with cam and bearing lubricant install compressor rod through guide into housing and install locknut on threaded end of compressor rod Install governor spring in actuator 29 Move locking arm up against magnet and press down on armature plate to latch the unit similating automatic control Use a feeler gage to measure gap betwee...

Page 357: ... Control response 2 Constant pressure on accelerator pedal re gardless of selector setting 3 No automatic control when slide switch is moved to lock position 4 Automatic control engages at selected speed without pushing slide switch to lock position 5 Automatic control remains engaged when brake pedal is touched 6 Automatic control remains engaged when slide switch is pushed to the off position 7 ...

Page 358: ...ment as described in Note 100 4 Move locking arm against magnet and press down on armature plate to latch unit simulating automatic control 5 Move contact arm to touch grounding point on locking arm side of magnet Motor should rotate drive screw and close the throttle through Fig 12 95 Testing for Current at 1 Terminal 7 If motor will not open or close throttle through accelerator linkage motor ma...

Page 359: ...pitted however any build up on the points should be removed When filing points use a cloth to catch filings as they could become wedged between the small ball bearings in the nut on the drive screw and cause the drive screw to stick The locking arm latch must be properly ad justed before attempting to adjust the grounding points Point adjustment may be made at either set of grounding points on the...

Page 360: ... exterior arm freely NOTE Due to angle trunnion enters exterior arm it is possible for arm to be moved away from Gage when trunnion in inserted Make certain that arm is still against Gage after trunnion is installed 6 Install washers on trunnion and secure trun nion to exterior arm with cotter pin 7 Remove Gage and shut off engine 101 Control Cable Adjustment 1 Rotate selector dial counterclockwis...

Page 361: ... does not latch properly Blown fuse No current at 1 terminal Control cable improperly ad justed Control cable defective Inoperative motor or locked drive screw REMEDY Straighten or replace cables Lubricate Repair Check for short or ground Repair or replace if necessary Adjust accelerator linkage Check operation of motor If more than 7 amps at 12 5 volts are noted in either direction replace motor ...

Page 362: ...ment Improper carburetor or ac celerator linkage adjustment Weak throttle return spring Improper control cable adjust ment Selector dial not installed pro perly Speedometer drive gear in transmission defective Broken drive cable from trans mission to power unit Damaged drive gear or nylon gear in power unit REMEDY Check for ground and repair as required Perform Electrical Test Note 98b Perform Ele...

Page 363: ...R increases the sensitivity In this position Guide Matic will switch the headlights to lower beam when an approaching car is farther away than normal Rotating the control counterclock wise toward the word NEAR decreases the sen sitivity thus allowing an approaching car to come nearer before switching occurs OPERATION AUTOMATIC When the light from an approaching car s head lights strikes the photot...

Page 364: ...may be corrected in most cases by aiming and by hold and sensitivity adjustments a few preliminary tests should be made to determine if the condition is more serious With car in a lighted area check as follows 1 Pull light switch knob to full ON position After a few seconds warm up time lights should remain on lower beam regardless of position of foot switch 2 Depress override section of foot swit...

Page 365: ...ig 12 101 with three points on Aiming Device resting on top of photo tube unit and the Aiming Device touching front of unit 5 Adjust dial on Aiming Device until the number 6 is under pointer 6 Adjust vertical aiming screw on phototube unit until bubble is centered in level Fig 12 101 105 Dim and Hold Sensitivity Test on Car Use Guide Matic Tester J 8465 for all tests Phototube unit must be covered...

Page 366: ...t ted for screwdriver adjustment The controls are accessible for adjustment through the glove box b Hold Sensitivity 1 Rotate amplifier HOLD control adjustment Fig 12 99 completely clockwise 2 Rotate Tester Intensity control completely clockwise 3 Turn selector Dim Hold switch on Tester momentarily to DIM position to switch lights to lower beam then switch to HOLD position NOTE If lights do not sw...

Page 367: ...relay unit 5 Attach three way electrical plug and red wire to foot switch 6 Connect phototube plug to socket on amplifier unit 7 Attach negative cable to battery 8 Check and if necessary adjust DIM and HOLD sensitivity Notes 105 and 106 9 Install steering column lower cover as de scribed in Section 15 Note 2b 108 Amplifier Unit Disassembly and Assembly a Disassembly 1 Remove amplifier unit as desc...

Page 368: ... Driver Control Driver Control Knob Screw L Wave Washer T Retaining Clip Switch f Upper Tube yf Soldered C Connection Phillips Screws 4 i T P Fig 12 104 Removing Phototube Unit Fig 12 105 Phototube Unit Top Removed 4 Remove two Phillips head screws securing top to body at front of phototube unit 5 Remove retaining clip securing top to body at rear of phototube unit and remove top 6 Remove phototub...

Page 369: ...ce facility for servicing See Note 108 6 If phototube is inoperative proceed as follows a Replace tube assembly See Note 111 b Inspect all electrical connections When soldering use only rosin core solder If this procedure fails to correct the trouble phototube unit and amplifier unit will have to be sent to an a u t h o r i z e d service facility See Notes 107 and 110 7 If foot switch is inoperati...

Page 370: ...hite wire in amplifier at socket connection a If headlights switch to lower beam trouble is in phototube unit b If headlights do not switch to lower beam trouble is in the amplifier unit power relay unit or foot switch Proceed to step 2 2 Remove red wire from foot switch a If headlights go to lower beam trouble is in foot switch b If headlights do not go to lower bean pro ceed to Step 3 3 Disconne...

Page 371: ...rcuit Breaker on Headlamp Switch Location Fuse Panel Fuse Panel Fuse Panel Fuse Panel Fuse Panel Fuse Panel Fuse Panel Fuse Panel Fuse Panel Body Feed Fuse Body Feed Fuse Body Feed Fuse Body Feed Fuse Body Feed Fuse Body Feed Fuse Headlamp Switch Headlamp Switch Headlamp Switch Headlamp Switch Headlamp Switch Fuse Panel Fuse Panel Right Dustshield Cruise Control Brake Switch At Amplifier Unit Fuse...

Page 372: ...er Set Radio Control Knob Nut Wrench Ignition Switch Wrench Diode Installer Diode Tester Regulator Adapter Key I J K L M N O P Tool No J 9782 1 J 6663 J 8465 J 4880 J 7652 J 8547 J 7890 J 7844 Name Regulator Adapter Jumper Headlight Aimer Set Guide Matic T e s t e r and Aiming Device Snap Ring Pliers Locking Arm Gage Governor Weight Wedge Brush Retainer Spring Windshield Wiper Motor Field Coil Pul...

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Page 380: ... M Indicator Radio Rear Control Indicator Speedometer Stop Signal Tail Bumper Tail Fender Transmission Shift Indicator Trunk Compartment Trunk Lid Tell Tale Turn Signal Indicator Bulb No 53 1073 1816 1195 212 90 212 212 90 212 1004 90 57 57 57 4001 4002 57 53 53 67 57 212 1034 1891 1892 1892 53 57 1034 67 57 89 57 53 C P 1 32 3 50 6 6 6 6 6 6 15 6 2 2 2 37 5 W 37 5 W 50 0W 2 1 1 4 2 6 32 4 2 75 75...

Page 381: ...peres 52 Volts 14 Field Current Draw Amperes 1 9 2 3 Volts 12 Temperature F 80 REGULATOR Point Opening Inches 030 Closing Voltage 2 3 3 7 Set To 3 0 Voltage Regulator Air Gap Inches 060 Point Opening Inches 014 Normal Range Volts at 125 13 5 14 4 Lower Contact Point Setting 1 to 3 Volts Lower Than Upper Contact Setting DISTRIBUTOR Rotation Clockwise Dwell Angle Set To 30 Range 28 32 Condenser Capa...

Page 382: ...the air discharged into the car is controlled by a temperature valve Fig 13 1 inside the heater case This valve regulates the proportions of heated and unheated air which mix Water enters the heater core through the lower fitting and leaves the heater core through the upper fitting The water control valve is used only to prevent water flow when the heater is OFF The heater ventilation control pane...

Page 383: ...Valve Heater Core Fig 13 4 Defroster Valve Operation flow of water to the heater core Water enters the core at the lower fitting and leaves at the upper fitting The temperature lever on the 1963 heater ventilation control panel Fig 13 2 regulates the water control valve In the Off position water flow to the heater core is shut off completely As the lever is moved to the right the amount of water f...

Page 384: ...d a sliding door just above the right rear arm rest Fig 13 7 The Fig 13 5 Front Unit Heater Assembly 75 Series temperature knob regulates the water control valve thereby controlling the discharge air tem perature Turning the knob clockwise increases the amount of water entering the rear heater cores The fan knob turns the two rear blowers On and Off and controls their two speeds Left Rear Heater C...

Page 385: ...agms causing the air inlet valve to open admitting outside air into the system This move ment also completes the electrical circuit to the blower causing the blower to operate Outside air is drawn through the cowl air intake grille into the blower assembly The air is then forced across the heater core and delivered to the front passenger compartment and windshield Ventilation AirConditioned Cars F...

Page 386: ... CODE B BLACK R RED Y YELLOW DG DARK GREEN OR 0RANGE LBL LIGHT BLUE OR B ORANGE WITH BLACK STRIPE INSTRUMENT PANEL HARNESS IGNITION SWITCH UNDERHOOO HARNESS 14 DG 14 OG HEATER BLOWER IGNITION SWITCH HARNESS ...

Page 387: ...the blower control switch A separate circuit from the 25 ampere fuse Fig 13 10 is provided on 75 series with the extra heating units in the rear A single wire runs to the heater control switch in the rear seat right hand arm rest Hi i S 2 1 3 Fig 13 10 Heater Circuit Diagram 75 Series ...

Page 388: ... of heater case 5 Push water control valve down to stop and tighten clamp retaining screw while applying force to cam e Ventilation Control Cables Non Air Conditioned Cars 1 Remove cowl kick pads 2 Set ventilation levers in Off position 3 Loosen bowden cable clamp retaining screws on ventilation assembly 4 Push on control cable until valves are com pletely closed and tighten clamp retaining screw ...

Page 389: ...moved position blower motor and fan assembly to blower housing cover plate and secure with five screws 3 Attach blower motor feed wire 4 Connect blower motor ground wire 5 Position rubber boot on inlet duct and in stall clamp 6 Install radio antenna as described in Section 12 Note 91b 7 Install fender dust shield 8 Install wheel and lower car 5 Heater Inlet Duct Assembly Front Removal and Installa...

Page 390: ...wl kick pads 5 Connect defroster hoses to top of heater assembly 6 Connect bowden cables to defroster valve and temperature valve at pivot points on heater as sembly and adjust cables as described in Note 1 7 Connect electrical connectors to resistor panel 8 Install glove box assembly as described in Section 15 Note 17b 9 Connect heater water hoses to fittings on heater assembly 10 Fill cooling sy...

Page 391: ... studs on heater unit Install screws and nuts securing unit to cowl 3 Connect rubber boot to blower housing and install clamp 4 Connect electrical connectors to blower resistor 5 Install Air Conditioner outlet duct and evapo rator adapter and straighten carpet Install cowl kick pad 6 Connect defroster hoses to top of heater assembly 7 Connect bowden cables to selector and temperature control lever...

Page 392: ...ng 4 Remove four molding retaining clips from parcel shelf 5 Pull down on center arm rest and remove two fabric retaining screws and two cap screws securing seat back to body braces 6 Straighten four retaining clips along bottom of seat back 7 Pull out on bottom of seat back and lift seat back up and off top retaining brackets and remove seat back 8 Remove rear quarter window molding and trim pad ...

Page 393: ... vacuum power units that actuate air valves controlling the circulation and mixing of heated and cooled air Outside air for the front unit is supplied through the cowl vent located directly below the wind shield on all 1963 Cadillac cars Inside air is drawn from the passenger compartment into the blower assembly through a dash opening located just behind the blower assembly Cooled air is delivered...

Page 394: ...ing the com pressor pumping action needed to operate the system When the selector lever is moved to the OFF position the armature plate hub actuating springs move the armature plate away from the pulley If the Air Conditioning system was in use when the engine was turned off the armature plate may remain in contact with the pulley due to residual magnetism This will cause no trouble as the armatur...

Page 395: ...NG AND AIR CONDITIONING Dehydrator Receiver Sight Glass Throttling Valve Expansion Valve Air Conditioner Heater Control Panel ir O Evaporator Air Outlets Fig 13 12 Location of Air Conditioner Components 75 Series ...

Page 396: ...o decrease the effect of spring pressure thus decreasing the evaporator pres sure This design is permitted by the new Air Mixture heating Air Conditioning system where the temperature valve Fig 13 16 regulates the temperature of the air discharged into the pas senger compartment Two suction throttling valves are used on 75 series cars one with each evaporator The valves used on 75 series differ fr...

Page 397: ...ns at 5 psi differential pres sure and is fully open when the differential pres sure exceeds 12 psi Below the 5 psi differential the check valve is closed to prevent capacity loss This feature prevents refrigerant by passing the evaporator at traffic conditions when cooling de mands are greatest Condenser The condenser is an aluminum heat transfer unit similar in appearance to the radiator and loc...

Page 398: ... lower lever controls the temperature of the air The toggle switch on the upper center of the control panel regulates the blower speed Moving the selector lever to the Cool posi tion turns the blower and compressor on The air directional valves are activated delivering 100 outside air to the system When the lever is moved to the Recirc position the air direc tional valves deliver 20 outside air mi...

Page 399: ...r assembly Fig 13 18 by means of a bow den cable Moving the temperature lever to the left correspondingly reduces the amount of air passing through the heater core that is allowed to mix with the cooled air flowing from the eva porator With the lever in the Cooler position the temperature valve prevents any heated air from mixing with the cooled air When the temperature lever reaches a point appro...

Page 400: ...ed with vacuum modulators that regulate the suction throt tling valve thereby controlling the discharge air temperature Moving the controls toward the Cooler position reduces the vacuum to the suction throttling valve increasing the cooling capacities of the evaporator Electrical Circuit Fig 13 20 21 and 22 The Air Conditioner electrical circuit current flows from the accessory terminal of the ign...

Page 401: ...emperature air drawn through the condenser by the engine fan This high pressure liquid from the condenser is then forced into the receiver tank where the last of the bubbles condense so that they will not pass through the system From the receiver the liquid flows through the sight glass and the high pressure liquid line to the expansion valve on the evaporator assembly The high pressure liquid the...

Page 402: ... when working on Air Conditioned cars a Fan Assembly A five blade aluminum fan is used to provide more air flow and a thermostatically controlled limited slip clutch is used to reduce fan noise b FanPulley The fan pulley has three grooves and is smaller in diameter to drive the fan faster c Fan Shroud A fan shroud is utilized to assist in drawing air through the entire radiator core when engine is...

Page 403: ...L INSTRUMENT PANEL HARNESS FUSE BLOCK UNDERHOOD HARNESS I6B W COMPRESSOR CLUTCH SOLENOID I4BRN COLOR CODE B BLACK R RED Y YELLOW DG DARKCREEN LBL LIGHT BLUE BRN BROWN B W BLACK WITH WHITE STRIPE OR B ORANCE WITH BLACK STRIPE IGNITION SWITCH HARNESS ...

Page 404: ... CODE B BLACK R RED V ViOLET PURPLE Y YELLOW DC DARK GREEN GY GRAY LC LIGHT GREEN BRN BROWN DBL DARK BLUE LBL LIGHT BLUE B W BLACK WITH WHITE STRIPE OR B ORANGE WITH BLACK STRIPE W B WHITC WITH BLACK STRIPE ...

Page 405: ...ed cars 14 Service Precautions a Handling Refrigerant 12 Refrigerant 12 is stored and shipped as a liquid under piessure contained in heavy metal drums in 10 25 and 145pound sizes Correctly handled it is as safe as compressed air Incorrectly handled it can explode andcause serious damage In handling refrigerant drums always observe the following safety precautions 1 Do not leave drum uncapped The ...

Page 406: ...ines that have been disconnected for any reason to prevent entrance of moisture or dirt 5 Gage set and lines should be kept clean and free from moisture 6 Do not leave refrigeration oil container open any longer than necessary as the special oil is moisture free but will rapidly absorb moisture from the air 7 Use Vacuum Pump J 5428 or Charging Station J 8393 to remove any air or moisture that may ...

Page 407: ...ng the final tightening of all O ring and flare type connections 15 Maintenance and Inspection a Preliminary Check 1 Check air gap between frictional surfaces of pulley and clutch plate Air gap should be approx imately 1 32 inch 1 16 inch 031 inch O62 inch 2 Check drive belt tension and adjust if nec essary See Note 30 3 Observe clutch to make certain that it is engaging and disengaging 4 If there...

Page 408: ...hing needed ready and handy so that as little time as possible will be required to perform the operation Do not leave the system open any longer than is necessary 5 Any time the system has been opened and sealed again it must be properly evacuated as described in Note 21 6 Use only refrigerant from a reputable deal er as contaminated refrigerant will not only lower the efficiency of the system but...

Page 409: ...LLE AIR INLET TEMP F 75 SERIES PERFORMANCE CHART C O Z ID ex LL Q LU 80 70 60 50 40 30 REAR UNIT Outlet Air Temp OfRear U n i t e s Measured AtRH Roof Duct Grill Must Be A Minimum Of19 Lower Than Temp OfAir Returning To Rear Unit ou LE AIR TEMP a T S 1 1 ii 11111II11111 n I N 111 ii i 400 375 PERFORMANCE CHART D 350 ri 325 LU 225 175 150 125 HEAD PRESSURE iiii o 60 70 80 90 100 110 60 70 80 90 100...

Page 410: ...le head pressure and suction throttling valve pres sure 12 Refer to Fig 13 24 Chart A to determine if outlet air temperature is normal Use Chart C for 75 series cars If outlet temperature is the same or below reading on chart operation is normal 13 Refer to Fig 13 24 Chart B to determine if head pressure is normal Use Chart D for 75 series cars If head pressure is within 30 pounds below reading on...

Page 411: ...hours of operation A small amount of 150 vis cosity oil may be drawn into the pump occasion ally to insure protection of internal parts during n Charging Station J 8393 periods of disuse If the pump should fail to start check capacitor or relay 1 Purge system as described in Note 19 2 Connect Charging Station high and low pres sure lines as described in Note 20 3 Plug in Charging Station to 110 vo...

Page 412: ...t tube 4 pounds for all except 75 series 5 1 4 pounds for 75 series 3 Fully open valves 2 and 4 to allow refrig erant to flow into system NOTE If refrigerant does not flow freely into system it is probably due to valve cores in compressor fittings not being depressed far enough If this condition exists try another Gage Adapter J 5420 or build up an adapter depressor tongue with solder to depress v...

Page 413: ...ollows a Compressor only 1 Idle engine for 10 minutes at 1000 1500 rpm at maximum cooling and high blower speed to allow oil to distribute itself in system in a normal manner 2 Remove compressor from car and place it in a horizontal position with drain plug downward Drain oil measure and discard it 3 Drain oil from compressor that is to be in stalled in car 4 If oil drained in Step 2 is more than ...

Page 414: ...nings in both compressor and pressure line fitting to keep dirt out Use protective plate over compressor opening 4 Remove two screws securing compressor front adjusting bracket to cylinder head water pipe 5 Loosen rear pivot bolt pivot compressor toward engine and remove compressor drive belt 6 Disconnect clutch coil wires and remove screw securing ground wire to compressor 7 Remove two screws sec...

Page 415: ...formed without disturbing the internal mechanism assem bly or removing the compressor from the car Among them are replacement of the clutch plate and hub assembly the pulley andbearing assem bly andthe pulley bearing The clutch coil and housing assembly also may be replaced without removing the com pressor after clutch and pulley parts have been removed It is not necessary to disturb the shaft sea...

Page 416: ...earing Reed Front Discharge Valve Plate Assembly Fig 13 28 Compressor Disassembled from endof shaft using Thin Wall Socket J 9399 Fig 13 29 3 Thread Clutch Plate and Hub Assembly Re mover J 9401 into hub Hold body of tool with a wrench and tighten center screw to remove clutch plate andhubassembly Fig 13 30 4 Remove square drive keyfrom shaft 5 Remove hub retainer ring using Snap Ring Pliers J 540...

Page 417: ...Ring Pliers J 5403 21 in stall hub retainer ring with flat side of ring facing spacer 10 Install a new shaft lock nut with small diameter boss of nut against hub spacer using V 1 i Retainer Ring Snap Ring Pliers y P J 5403 21 k W l 1 Spacer Clutch Plate and Hub Assembly Installer J 9480 Fig 13 32 Installing Clutch Plate and Hub Assembly special Thin Wall Socket J 9399 Fig 13 29 Hold clutch hub wit...

Page 418: ...cing bearing is described in Note 34 3 Press or tap pulley and bearing assembly on neck of compressor until it seats using Pulley and Bearing Installer J 9481 with Universal Handle J 8092 Fig 13 36 Installer will apply force to inner race of bearing and prevent damage to bearing 4 Check pulley for binding or roughness Pulley should rotate freely 5 Install retainer ring using Snap Ring Pliers J 643...

Page 419: ...using Assembly Removal and Installation The coil has 3 85 ohms resistance at 80 F ambient temperature and should draw 3 2 amps at 12 volts a Removal 1 Remove clutch plate and hub assembly as described in Note 32a 2 Remove pulley and bearing assembly as described in Note 33a 3 Note position of terminals on coil housing and scribe location on compressor front head casting 4 Remove coil housing retai...

Page 420: ...Installer J 9393 Fig 13 42 Grasp seal seat with tool flanges and pull straight up on end of tool to remove seal seat 4 Remove shaft seal assembly using Seal Re mover and Installer J 9392 Fig 13 43 Press down on tool to overcome seal spring pressure and twist tool clockwise to engage tabs on seal assembly with locking tangs on tool Remove seal assembly by pulling straight out from shaft 5 Remove O ...

Page 421: ...s down on retainer ring until spring pressure of shaft seal is overcome and retainer ring snaps into its groove in casting bore Fig 13 45 NOTE The chamfer that can be seen from the shaft end is a land not a groove Fig 13 45 8 Install clutch plate and hub assembly as described in Note 32b 9 Perform compressor leak test as described in Note 43 Shaft Nut Retainer Ring Spacer Retainer Ring Seal Seat O...

Page 422: ...e 40 An inspection should be made of the internal mechanism assembly to determine if any service operations should be performed A detailed in spection of parts should be made to determine if it is economically feasible to replace them It may be more economical to replace the entire internal mechanism assembly rather than re place parts Before proceeding with disassembly wipe ex terior surface of c...

Page 423: ...rt Block resting on bench 17 Lift front head and compressor shell as sembly up leaving internal mechanism resting on internal assembly support block CAUTION Do not tap on end of compressor shaft to remove internal mechanism If mecha nism will not slide out of compressor shell tap on front head with a plastic hammer Reed Retainers Rear Discharge Plate Assembly Discharge Reeds Fig 13 48 Removing Rea...

Page 424: ...N Under no circumstances should shaft be struck at either end in an effort to separate upper and lower cylinder halves 4 Position complete internal mechanism rear cylinder down on Support Block J 9521 and remove front cylinder half 5 Pull up on compressor shaft and remove piston previously identified as 1 with balls and shoe discs from swash plate Piston Front Cylinder Half Support Block J 9521 Fi...

Page 425: ...aces and place bearing in rear bearing slot in Parts Tray 14 Examine surface of swash plate and shaft Replace as an assembly if necessary Examine front and rear thrust bearings and replace if necessary NOTE A certain amount of shoe disc wear on swash plate is normal as well as some markings indicating load of needle bearings on shaft 15 Remove discharge cross over tube from cylinder half using vis...

Page 426: ...ge cross over tube hole in front cylinder Tap into place using a plastic mallet Fig 13 57 Installing Shoe Disc on Ball in Piston 13 Position discharge cross over tube holes between a pair of Compressing Fixture bolts to permit access for feeler gage 14 Install top plate on Compressing Fixture J 9397 Tighten nuts to 15 foot pounds torque using a 0 25 foot pounds torque wrench 15 Measure clearance b...

Page 427: ...ns 2 and 3 20 Mount Dial Indicator J 8001 3 on edge of Compressing Fixture with Clamp J 8001 1 and Sleeve J 8001 2 Fig 13 60 Position Dial In dicator on rear end of shaft and adjust to zero Push front end of shaft upward and record measurement NOTE Dial Indicator increments are 001 inch therefore reading must be estimated to nearest 0005 inch 21 Select a thrust race with a number corres ponding to...

Page 428: ...ub 5 Position piston over 1 cylinder bore notch ed end of piston on bottom and piston straddling swash plate and lower shaft to allow piston to drop into its bore 6 Position piston ring gap toward shaft com press ring and lower ring into front cylinder half 7 Repeat steps 1 through 6 for pistons 2and 3 8 Install new discharge crossover tube in front cylinder half with bridged surface facing out bo...

Page 429: ... half Align with dowel pins suction ports oil return slot and discharge crossover tube Fig 13 67 Suction Crossover Cover Rectangular Gasket Fig 13 64 Installing Suction Crossover Cover 5 Install front discharge valve plate assembly aligning holes with dowel pins and proper openings in front suction reed plate Fig 13 68 NOTE Front discharge plate has a large diameter hole in the center Fig 13 69 6 ...

Page 430: ...rear cylinder half if previously removed Front Suction Reed Plate Oil Return Slot Discharge Crossover Tube Support Block J 9521 13 Install newO ring in oil pick up tube cavity 14 Lubricate oil pick up tube and install in cavity rotating compressor mechanism to align tube with hole in shell baffle Fig 13 73 15 Install new O ring and bushing on rear of discharge crossover tube 16 Install rear suctio...

Page 431: ... surface will contact rear discharge valve plate Front Head O Ring Support Block J 9521 Oil Sump Compressor Shell O Ring Support Block J 9521 Oil Intake Tube Hole Fig 13 72 Installing Compressor Shell on Internal Mechanism 21 Lubricate new head to shell O ring and install on rear discharge valve plate in contact with shell 22 Install suction screen in rear head casting using care not to damage scr...

Page 432: ...lief valve oil drain fitting compressor rear head seal compressor front head seal and compressor shaft seal After check ing shut off valve 1 and valve 2 on Charging Station 7 If an external leak is present perform the necessary corrective procedures and repeat steps 1 through 6 to make certain leak has been cor rected before proceeding with steps 8 through 12 to check for internal leaks 8 Disconne...

Page 433: ... as de scribed in Note 59a 2 Remove core from rear evaporator assembly as described in Note 60a 3 Disconnect low pressure hose from suction throttling valve and cap hose 4 Disconnect vacuum hose from diaphragm 5 Remove clamp screw securing valve to bracket on front face of core and remove clamp from valve 6 Unscrew flare nut fitting from rear of valve and remove valve 7 Remove and discard O rings ...

Page 434: ...empt to scrape stone or dress out any damage as it may result in im proper performance of valve 2 Install valve cores in connector ports if previously removed Install valve core with plain tip in evaporator gage connector port and valve with black tip in oil bleed line connector port The valves open at different pressures and if improp erly installed would affect operation of system 3 Examine exte...

Page 435: ...ck to assure that vacuum is being applied to the sec tion throttling valve diaphragm 5 Operate system for five minutes and check low pressure gage reading Low pressure should 30 psi If adjustment is necessary perform steps 6 and 7 If adjustment is not needed proceed to step 8 6 Loosen jam nut on suction throttling valve turn diaphragm clockwise to increase pressure or counterclockwise to decrease ...

Page 436: ...3 and leak test all connections 8 Check operation of system 9 Install right front fender rear dust shield 10 Straighten wheels and lower car 49 Expansion Valve Rear Removal and Installation 75 Series a Removal 1 Remove rear evaporator assembly as de scribed in Note 59a 2 Remove core from rear evaporator assembly as described in Note 60a 3 Remove power element bulb from evaporator outlet pipe 4 Dis...

Page 437: ...tor and fan assembly in blower housing and secure with five screws 3 Connect motor ground wire 4 Install shelf panel inside trunk compartment 53 Blower Inlet Assembly Removal and Installation 60 and 62 Series a Removal 1 Remove four bolts holding right hood hinge to mounting brackets on cowl and dust shield 2 Position hood panel out of way 3 Remove eight nuts and bolts securing front and rear halv...

Page 438: ...tlet hoses and in stall hose clamps 3 Install rubber boot on blower housing and secure with clamp 4 Install three vacuum hoses on vacuum diaphragms 5 Connect resistor panel electrical leads 6 Connect blower motor ground wire 7 Fill cooling system 55 Air Conditioner Heater Assembly Removal and Installation 60 and 62 Series a Removal 1 Drain cooling system 2 Remove glove box assembly from instrument...

Page 439: ...4 Remove radio antenna as described in Sec tion 12 Note 91 5 Remove blower inlet assembly as described in Note 53a 6 Disconnect low pressure vapor line from suction throttling valve and cap line 7 Disconnect high pressure liquid line from expansion valve and cap line 8 Remove 8 screws securing assembly to cowl and remove assembly b Installation 1 Add refrigeration oil as described in Note 25 2 Pos...

Page 440: ...heel and lower car 58 Evaporator Core Front Removal and Installation a Removal 1 Remove evaporator assembly as described in Note 56a or Note 57a 2 Disconnect oil bleed line and equalizer line from suction throttling valve 3 Disconnect suction throttling valve from evaporator outlet pipe 4 Remove insulation and power element bulb from evaporator outlet pipe 5 Disconnect expansion valve from evapora...

Page 441: ...60 Evaporator Core Rear Removal and Installation 75 Series a Removal 1 Remove rear evaporator assembly as de scribed in Note 59a 2 Remove six screws at rear four screws on top and four screws on bottom of evaporator case and remove back cover NOTE The screws at top and bottom are covered with a sealer which must be removed in order to gain access to the screws 3 Remove six screws securing core to ...

Page 442: ...nser pipe at inlet side of sight glass 7 Remove two bolts securing dehydrator to support bracket and remove dehydrator from condenser Cap fittings if original dehydrator is to be installed 8 Remove and discard all O rings b Installation 1 Add refrigeration oil as described in Note25 2 Install dehydrator on support bracket on condenser and secure with two bolts 3 Connect condenser pipe to inlet sid...

Page 443: ...Block Dial Indicator Sleeve Clamp Belt Tension Gage Universal Handle Pulley Bearing Remover Key Q R S T U V w X Y Z A A B B C C D D E E F F Tool No J 9481 J 9392 J 9396 J 9401 J 9480 J 9403 J 8433 J 9395 J 9399 J 9527 J 9393 J 9397 J 5139 J 6435 J 5403 J 8393 Name Pulley and Bearing Installer Seal Remover and Installer Holding Fixture Clutch Plate and Hub Assem bly Remover Clutch Plate and Hub Ass...

Page 444: ... side and evaporator Obstruction in air hoses ducts or passageways Fan switch will not operate on high speed Evaporator icing No vacuum supply to Air Con ditioner diverter valve vacuum power unit Mechanical interference with Air Conditioner diverter valve or Heater Air Conditioner valve Shut off valves in air outlets closed Hose disconnected from outlet Evaporator core freezes Remedy Instruct owne...

Page 445: ...ing valve stuck in wide open position evapo rator pressure pulls down be low 30 psi resulting in icing of evaporator and loss of cooling air flow Suction throttling valve stuck in closed position evaporator pressure will not pull down to 30 psi Expansion valve thermal bulb and c a p i l l a r y discharged causing valve to close tight Remedy Leak test repair and recharge system Check for leak repai...

Page 446: ...witch to recircu lated air which gives maxi mum cooling capacity Water control valve on 60 and 62 series cars remains open in maximum cooling position Mispositioned t e m p e r a t u r e valve Leakage of hot air into passen ger compartment through dash or floor pan openings at grommets around door open ings in shroud sides at vent duct openings through or around heater etc Remedy Replace expansion...

Page 447: ...turn air boot disconnected or loose Rear evaporator suction throt tling valve not adjusted properly Expansion valve not operating properly Fresh air intake doors rear not operating properly Insufficient r e f r i g e r a n t in system Suction throttling valve or ex pansion valve stuck open allowing too much refrigerant flow to compressor Compressor not pumping at full capacity Remedy Connect and a...

Page 448: ...aged compressor shell or worn internal parts Defective expansion valve System operates on Recirc air at all times even though set for Cool air operation Odor producing substances de posited on evaporator core Remedy Adjust belt tension Tighten compressor mountings Repair or replace compressor Replace expansion valve Check and repair vacuum sys tem to obtain proper Cool and Recirc operation Wash ev...

Page 449: ...FRONT VIEW 1963 ...

Page 450: ...nged at the cowl and opens from the front The hood lock assembly is attached to the hood inner panel Access to the hood lock operating lever is obtained through the top of the grille just to the right of center between the hood molding and the upper grille support bar The hood lock pilot that makes up the remainder of the hood locking mechanism is attached to a support in front of the radiator cra...

Page 451: ... lock or the pilot assembly Failure to do so may result in damage to the locking assemblies due to misalignment when the hood is closed 2 Hood Panel Removal andInstallation a Removal 1 Scribe hinge locations on underside of hood panel to aid in repositioning the hood when it is re installed Fig 14 4 Hood Lock Pilot 2 Remove six screws retaining hood panel to hinge assembly three on each side 3 Wit...

Page 452: ...e Variable Rubber Bumpers Hood Panel Fig 14 6 Adjusting Hood to Cowl 5 Fender Adjustment 1 Loosen all screws at the following locations a Fender reinforcement to dustshield mounting b Cowl c Front hinge pillar d Rockersill to frame at underside of fender e Fender to dustshield at top center dustshield to fender reinforcement and at front end of fender to dustshield f Upper grille to fender g Fende...

Page 453: ...ove fender by lifting outward and slightly forward b Installation All fender attaching screws should be loosely installed until proper alignment of fender is ob tained then tighten to proper torque specification where applicable 1 With the aid of a helper place fender in po sition place the correct number of shims in place on cowl and install retaining screw 2 Place the correct number of shims on ...

Page 454: ... in the same manner with exception of the various supports and fins a Disassembly 1 Remove upper or lower described in Note 7a or 8a grille section as 2 In disassembling upper grille remove six screws holding upper grille support to grille and separate support from grille 3 If lower section is to be disassembled re move eight screws two at each bracket that retain grille to bumper mounting bracket...

Page 455: ...rectional and cornering lamp wires to their connectors on both sides of the grille 7 Position air deflector in place and secure with four screws 11 Front Bumper Upper End Impact Bar Removal and Installation Right or Left a Removal 1 Remove front bumper assembly as described in Note 10a 2 Remove two nuts at rear of cornering lamp assembly 3 Remove one bolt sleeve and nut at front of cornering lamp ...

Page 456: ...sely install eight bolts four each side to lower end bars 2 Loosely install eight bolts four each side securing lower center bar to upper center bar Also install shims removed 3 Align lower center bar and tighten all bolts installed in steps 1 and 2 4 Install and align front bumper assembly as described in Note 10b 15 Rear Bumper Removal and Installation a Removal 1 Open rear compartment lid and m...

Page 457: ...y as described in Note 15a 2 Remove four screws two each side se curing finish panel to center impact bar and li cense guard 3 Remove two bolts securing finish panel at end impact bar 4 Disconnect license lamp assembly at license guard and remove filler panel b Installation 1 Position filler panel on center impact bar and connect license lamp assembly at license guard 2 Install two bolts securing ...

Page 458: ...aining finish panels to center impact bar 4 Remove four screws securing right and left license guards to center impact bar 5 Remove eight bolts four each side securing right and left end impact bar to center bar 6 Remove center impact bar from bumper assembly b Installation 1 Position center impact bar to end impact bars and loosely install eight bolts four each side 2 Align center impact bar to e...

Page 459: ... Q w CO u w CO CO Q O O ...

Page 460: ...eft windshield garnish moldings by removing three screws in each molding 3 If car is equipped with Cruise Control re move press fit on and off button and remove two screws securing Cruise Control escutcheon to upper instrument panel cover Remove escutcheon 4 Remove five screws retaining upper panel cover to lower panel Three screws are located above instrument cluster assembly and two screws at in...

Page 461: ...ower end of steering column lower cover and remove cover 4 Disconnect left hand cigar lighter jumper wire 3 way connector b Installation 1 Connect 3 way electric connector to rear of convertible top control switch 2 Connect left hand cigar lighter jumper wire 3 way connector 3 Hold cover in position andloosely install one screw and washer in lower left side of cover and one screw and washer in low...

Page 462: ...bly if so equipped 19 Remove wire terminal and bulb retainer assembly and also trunk lid tell tale bulb socket if so equipped Fig 15 3 20 Remove two lower screws securing bezel to lower instrument panel and remove bezel b Installation 1 Position bezel on instrument panel and in stall two screws retaining bezel assembly to instrument panel one left of headlamp switch and the other right of clock 2 ...

Page 463: ...e front radio speaker as described in Note 7a 4 Disconnect speedometer cable at speed ometer head 5 Disconnect trip odometer reset cable from bracket on lower flange of instrument panel 6 Disconnect ignition switch wire and remove ignition switch light bulb socket 7 Remove four instrument cluster mounting screws 8 Remove four cluster bulb sockets 9 Remove wire terminal and bulb retainer assembly a...

Page 464: ...emove radio knobs springs and rings using an Allen wrench to remove screw 4 Using Radio Control Knob Nut Wrench J 6968 remove retaining nuts on both control shafts Fig 15 2 5 Disconnect antenna lead in carble and 4 way electrical connector 6 Disconnect foot control unit from bottom of A M radio if so equipped 7 Remove seven Phillips head screws at bot tom front of glove box and remove glove box as...

Page 465: ... securing speaker to mounting support 2 Connect speaker wire connector and position speaker on studs at cowl mounting bracket 3 Loosely install four nuts and lock washers securing speaker to cowl mounting bracket 4 Align speaker to scribed marks and tighten four mounting nuts 5 Install steering column lower cover as de scribed in Note 2b 6 Install upper instrument panel cover as de scribed in Note...

Page 466: ...ive foot piece of wire or heavy string to end of bowden cable disconnected at power unit andthen pull cable through cowl grom met from inside car with selector assembly Re move wire or string from cable andleave in cowl NOTE The piece of wire or heavy string attached to the bowden cable will insure cable being routed properly when installed Donot bend or kink bowden cable b Installation 1 Attach w...

Page 467: ...ht Remove wire 4 Install retaining ring and tighten securely using Ignition Switch Wrench J 21109 Fig 15 7 5 Install steering column k eer cover as de scribed in Note 2b 6 Connect negative battery cable at battery 14 Heater Ventilation Control Assembly Removal and Installation a Removal 1 Remove upper instrument panel cover as de scribed in Note la 2 Remove steering column lower cover as de scribe...

Page 468: ... off base and remove phototube unit and harness Fig 15 8 b Installation 1 Insert connector end of phototube harness through phototube base and connect it to ampli fier harness 2 Position phototube unit on base and secure with Phillips head pivot pin 3 Install five screws securing upper instrument panel cover to lower panel 4 Connect negative battery cable at battery Fig 15 8 Removing Guide Matic P...

Page 469: ...nsion 5 Install upper instrument panel cover as de scribed in Note lb 19 Front Cigar Lighter Removal and Installation a Removal To remove left hand cigar lighter first remove steering column lower cover as described in Note 2a 1 To remove either right or left hand cigar lighter disconnecting negative battery cable at battery 2 Remove ash receptacle from ash tray as sembly to gain access to cigar l...

Page 470: ...S Subject Page No General Information 2 Lubrication 2 Front End 5 Headlining and Fabric Roof Covering 12 Doors 18 Seats 50 Rear Quarter 60 Rear End 69 Exterior Moldings 74 Convertible Top and Hydro Lectric System 81 Electrical 100 ...

Page 471: ... plate carries the style number trim number body number and paint number If the car is painted two tone the first two digits of the paint number cover the lower body shell and the chassis sheet metal the next two digits identify the color of the top The color code number for a convertible top is opposite the word TOP in the lower left corner of the body name plate The series of letters that follow...

Page 472: ...BODY 16 3 D Stick Type Lubricant Fig 16 2 Lubrication Points ...

Page 473: ...n contact with any painted or trimmed parts of the body J Door Jamb Switch Wipe off dirt and apply a thin coat of lubricant to the end surface of switch plunger Wipe off excess lubricant k Gas Tank Filler Door Hinge Apply a few drops of dripless oil to frictional points of door hinge Work door several times and wipe off excess lubricant I Rear Compartment Lid HOiges and Torque Rods Apply lubricant...

Page 474: ...arm compress andguide assembly on trans mission shaft NOTE When installing the wiper arm as semblies be sure the left blade is abovethe right blade in park position inasnieia wiper Arm Remover ool No J 8966 b 75Series and Commerical Chassis 1 Remove armandblade assembly by pulling outer section of armassembly toward center of car to disengage cam follower from cam ring 2 Pull outward on lower sect...

Page 475: ...frame screw attaching holes 2 Position ventilator frame and with front edge raised slightly engage washer hose to wash er nozzle adapter 3 Carefully slide frame rearward to engage rear edge of frame between windshield lower reveal moldings andmolding attaching clips 4 Install seven screws securing front and side edges of frame to cowl 5 Position escutcheon on transmission shaft and secure with esc...

Page 476: ...attaching screws 4 Install upper windshield garnish molding 10 Sunshade Support Removal and Installation 1 Remove attaching screws and support NOTE On 67 styles raise top before re moving support 2 To install position support and install at taching screws 11 Windshield Reveal Moldings Removal and Installation The windshield reveal moldings consist of a one piece upper right and left side and right...

Page 477: ...eld pillar and roof rail Raise top to loosen windshield pillar weatherstrip remove screws and molding 8 On all except 67 styles carefully remove up per reveal molding with Tool J 7898 01 Fig 16 9 or flat bladed tool as required On 67 styles remove screws at outer ends of molding then re move upper garnish molding to gain access to stud nuts Remove nuts and molding b Installation Make certain there...

Page 478: ...dure outlines the method to be used in checking the windshield opening 1 Remove windshield from body 2 Check windshield rubber channel for any irregularities 3 Clean off old sealer around windshield open ing and check entire body opening flange for any irregularities 4 Install five Windshield Checking Blocks J 8942 Fig 16 11 as follows along lower re taining flange place one block twelve inches in...

Page 479: ...lange Cord should be pulled first across bottom of windshield then up each side and finally across top of windshield 9 Using a pressure type applicator seal inner and outer lips of rubber channel to glass with an Fig 16 13 Windshield Installation approved weatherstrip adhesive as indicated at 4 in Fig 16 14 Seals are to extend completely around rubber channel 10 Clean of excess sealer from windshi...

Page 480: ...el to glass with an approved weatherstrip adhesive shown at 4 in Fig 16 14 Seals are to extend completely around rubber channel 6 On outside of windshield apply medium bodied sealer between windshield rubber channel and opening across top and sides 5 in Fig 16 14 7 Clean off excess sealer 8 Re install all previously removed parts in reverse sequence and remove protective coverings 14 Shroud Side F...

Page 481: ...wnward and remove door 4 To install pry door hinge pin downward to position outlet door 5 Connect end of control cable to door pin 6 Install shroud side foundation Note 14 HEADLINING AND FABRIC ROOF COVERING This section not only covers headlining andfabric roof covering but in addition provides information on removal and installation of side roof rail weatherstrips Information for the covering of...

Page 482: ... se curing rear listing wire shown at O Fig 16 17 On 57 styles install rear listing wire and pocket on rear listing wire support 3 Center headlining so material hangs evenly on both sides At upper center of back window secure 1 inch to 2 inches of headlining material to cemented surface of tacking strip 4 Working forward install listing wires into holes in side roof rails At front roof bow bend up...

Page 483: ...trip at front body hinge pillar 2 Carefully disengage inner lip of side roof rail weatherstrip from retainer Using a flat bladed tool carefully break cement bond between VIEW B Tacks VIEW K 6039 STYLE VIEW M 62 6339 STYLES Tacks 6039 STYLE Fig 16 17 Headlining Installation 39 Styles ...

Page 484: ... and reveal molding assembly Side Roof Rail SECTION B B Weatherstrip 39 89 STYLES Fig 16 19 Side Roof Rail Weatherstrip 57 and 39 Styles 3 Remove side roof rail weatherstrip from body d lnstallation 57 and 39 Styles 1 Clean old cement from side roof rail weatherstrip and weatherstrip retainer to insure a clean cementing surface 2 Apply a continuous bead approximately 3 16 inch diameter of weathers...

Page 485: ...fabric roof covering applied to the roof panel A felt pad is located between the fabric cover and roof panel The fabric covering is made of three parts with center section dielectricaliy joined to side section seams The roof covering is attached at the wind shield and back window opening by drive nails Screws or drive nails are used at the belt line of the rear quarter area In addition nitrile typ...

Page 486: ...permit easier fitting and removing of wrinkles from new cover assembly where possi ble install new cover at room temperature approximately 72 3 Lay out new fabric cover on clean protected surface with inner layer of material exposed 4 Apply nitrile type non staining weatherstrip cement to attaching surfaces of body Also apply Weatherstrip Cement Inside Perimeter of Fabric Fig 16 21 Cementing Fabri...

Page 487: ...d rear of body carefully drive retainer downward with blunt edged tool Working toward front of body install remaining portion of retainer Retainer fingers should be seated under flange of drip molding 20 Install all previously removed moldings and assemblies NOTE If after cover installation is com pleted minor creases or fold marks are still visible they may be removed by applying heat to area aff...

Page 488: ...h Channel Cam Front Door Lock to Locking Lever Rod Front Door Window Rear Up Stop Front Door Window Rear Guide Assembly I J K L M N 0 P Front Door Outside Handle Assembly Front Door Lock Cylinder and Connecting Rod Front Door Lock Assembly Front Door Window Inner Panel Cam Front Door Remote Control To Lock Connecting Rod Front Door Remote Control Assembly Front Door Window Lower Stop Front Door Wi...

Page 489: ... front door venti lator and window should be checked for proper alignment with side roof rail weatherstrip and adjusted as required In addition door lock to striker engagement should be checked and ad justed if necessary 1 For in and out or up anddown adjustments loosen hinge to door pillar attaching bolts Fig 16 23 Adjust door as required andtighten bolts NOTE When performing in and out adjust me...

Page 490: ... of weatherstrip is needed 3 Beginning at either front or rear section of door install snap fasteners Install weatherstrip fasteners by pressing fasteners into door panel piercings A protected hammer can also be used if necessary NOTE In the event a weatherstrip becomes damaged at a fastener location and will not properly retain the fastener remove fastener and cement weatherstrip into place If ho...

Page 491: ... On 57 67 29 and 39 styles remove door window rear glass run channel lower attaching screw and loosen upper attaching screws on lock pillar facing of door and at top of door inner panel to permit removal of lock 4 Remove door lock attaching screws from lock pillar facing of door and remove lock assembly from door Fig 16 27 5 To install reverse removal procedure Prior to installation apply a ribbon...

Page 492: ...used on past models When selector valve is actuated upward all door locks will unlock simultaneously When selector valve is actuated downward all door locks will lock Either front door selector valve may be actuated to lock or unlock all doors The red color coded hose is main vacuum supply line Vacuum is supplied at all times to the selector valve Only when the selector valve is actuated is vacuum...

Page 493: ...s parts 27 Door Lock Vacuum Storage Tank and Check Valve Assembly Removal and Installation The door lock vacuum storage tank is attached to the front of the power brake mounting support on left side of body Fig 16 31 The vacuum storage tank is connected to the engine manifold by a hose from the tank check valve to the manifold Red To Remote Control Check Valve Mounting Support Storage Tank Attachi...

Page 494: ...selector valve hoses small crossed at remote valve Actuator supply hoses large crossed at remote valve Valve selector hoses crossed at one door valve Door selector valve reversed in trim assembly Vacuum supply hose pinched or disconnected at affected door valve Lock or unlock selector valve hose pinched or disconnected from affected door valve CHART REPAIR Reverse hoses at vacuum supply tank Strai...

Page 495: ... check in side locking control rod for freedom of movement Check drive link for free dom of movement in lock trip lever Rear Door Lubricate lock and check in side locking control rod and linkage for freedom ofmove ment Check clearance of lock and actuator to door hardware Coupe Lubricate lock and check in side locking control rod for freedom of movement Check freedom of movement of actuator and lo...

Page 496: ... air continues to leak tank is defective Connect hose or check for pinched hose at front door hinge pillar conduit at rear door hinge pillar conduit or at remote control valve B then actuate door lock selector valve If actuator does not op erate actuator is defective Check remote valve for pinched or disconnected hose s If bal ance of system is checked and found to be in satisfactory con dition re...

Page 497: ... Valve Color Code Identification Red S White i i i i i Yellow Yffffffffffffffft Green Orange Selector Valve Front Door Actuator Front Shroud Dash Panel Rear Door Actuator Rear Door Actuator Fig 16 32 Schematic Diagram Vacuum Door Locking System ...

Page 498: ...imilar trans parent tubing may be substituted provided tubing has the specified inside diameter a Installation of Testing Device Into Vacuum System The testing device is installed between the vac uum storage tank and remote control valve To install testing device proceed as follows 1 Raise hood and remove storage tank to remote control valve attaching hose red from bottom of check valve on storage...

Page 499: ... is leaking If bubbles stop see Step 6 6 If bubbles stop forming in testing device air leak is at either door valve Discontinue pinching left valve hose at hinge pillar 7 Check testing device If bubbles appear in water left door valve is leaking NOTE Before replacing a door lock selector valve tighten screws on back of valve then recheck valve If valve continues to leak re place left door lock sel...

Page 500: ...ipping threads in regulator spiral gear shaft 32 Front Door Ventilator Assembly Manual and Electric Except 23 and 33 Styles a Removal and Installation 1 Remove door trim assembly and detach in ner panel water deflector 2 Lower door window Remove ventilator to door outer panel return flange attaching screw Fig 16 35 3 At front of ventilator assembly break cement bond securing front door hinge pilla...

Page 501: ...channel cam from window regu lator arm rollers 4 On styles equipped with electric window regulators remove door ventilator assembly and front door window 5 On styles equipped with electric window reg ulators disconnect wire harness feed wires from regulator motor at connector CAUTION Do not operate regulator motor after window assembly is disengaged from reg ulator Operation of motor with load rem...

Page 502: ...e removal procedure Be fore installing window lower sash channel cam lubricate entire length of cam Check window for proper operation prior to installing inner panel water deflector and door trim pad b Adjustments The door window glass may be adjusted to pro vide proper contact with side roof rail weather strip Adjustments have also been provided to relieve a binding door glass due to misalignment...

Page 503: ...e hinges are secured to the center pillar and door hinge pillar by screws and anchor plates The lower hinge Fig 16 37 Rear Dooi Assembly 39 Styles A B c D E F G H Rear Door Rear Door Plate Rear Door Cam Rear Door Plate Rear Door Rear Door Rear Door Rear Door Window Window Window Window Outside Lock to Assembly Front Female Wedge Lower Sash Channel Rear Female Wedge Handle Assembly Locking Lever Ro...

Page 504: ...rically powered window regulators proceed as follows a Remove door trim assembly and detach inner panel water deflector sufficiently to gain access to wire connector at motor b Detach wire harness from door inner panel and disconnect regulator motor from harness at connector Fig 16 38 Rear Door Assembly 29 Styles A B c D E F G H Rear Door Rear Door Plate Rear Door Cam Rear Door Plate Rear Door Rea...

Page 505: ...eration should be performed carefully to avoid possibility of soiling adjacent trim material 2 Apply a coat of heavy bodied sealer to attach ing surfaces of hinge straps or corresponding surfaces of door or body Fig 16 41 3 With a helper lift door into position Install screws loosely align strap within scribe marks on pillar and tighten bolts Check door for proper alignment 4 On doors equipped wit...

Page 506: ...ps are further retained by a single weatherstrip attach ing clip and screw at upper radius of lock pillar panel Cement usage is limited to door lock pillar panels at belt line and at forward lower corners of door Cement however can be applied at any point where additional retention of weatherstrip is needed a Removal 1 Remove snap fasteners securing ends of weatherstrip at belt line of door hinge ...

Page 507: ...fety interlock feature With the safety interlock fea ture it is very important that lock extension engages properly in door lock striker notch and that where necessary striker emergency spacers of the proper thickness can be used to obtain proper engagement 1 Raise door window Remove door trim as sembly and detach inner panel water deflector 2 Through access hole disengage spring clips and detach ...

Page 508: ...am from window regulator balance arm roller and remove camfrom door 3 To install reverse removal procedure Prior to installation of inner panel cam lubricate entire length of cam NOTE Forward end of inner panel cam is adjustable up or down This adjustment can be used to help correct a rotated or cocked door window Inside Locking Rod Attaching Bolt SpringClip Inner Panel CamAttachinq Bolts TRemote ...

Page 509: ...tor 2 Remove rear cam upper attaching screws and lower adjusting stud and nut Fig 16 47 3 Carefully disengage cam from roller on window guide assembly and remove rear cam through large access hole 4 To install reverse removal procedure Prior to installation lubricate entire length of cam If exposed seal cam lower adjusting stud and nut with body caulking compound 5 Check operation of window assemb...

Page 510: ...anel 47 Rear Door Window Assembly Manual and Electric a Removal and Installation 29 39 and 89 Styles 1 Raise door window Remove door trim as sembly and detach inner panel water deflector 2 Through access holes in door inner panel remove screws securing rear door window front and rear male wedge plates to window lower sash channel and remove wedge plates Fig 16 47 3 Lower door window and remove low...

Page 511: ... in or out as required and adjust front female wedge plate accordingly then tighten wedge plate attach ing screw 5 Adjust front guide cam lower adjusting stud in or out as required and tighten nut Tighten front guide cam support attaching screws on door hinge pillar facing 6 Reseal lower adjusting stud and nut with body caulking compound 7 Position window assembly in or out as re quired then tight...

Page 512: ...embly NOTE Front and rear window adjustments must be coordinated a With window in a full upposition loosen ad justing stud nut at lower end of front guide cam assembly and guide cam attaching screws at top of door inner panel b Loosen ventilator division channel lower ad justing stud nut andventilator assembly adjusting stud nut c Adjust top of window and or ventilator as semblies in or out as req...

Page 513: ...ntilator assembly fore or aft a Remove door trim assembly and detach upper portion of inner panel water deflector b Loosen ventilator division channel lower ad justing stud and nut c Loosen ventilator assembly adjusting stud nut and ventilator attaching bolts d Adjust window fore or aft as required check window for proper operation and alignment and tighten adjusting stud nuts and ventilator attac...

Page 514: ...compound in door lock striker notch where lock extension engages and then close door to form a measurable impression in clay or caulking compound Fig 16 52 Clip Engaged Clip Disengaged Fig 16 53 Door Lock Spring Clip When Dimension A from rear face of striker teeth to rear edge of depression in clay is less than 11 32 inch install service spacers and prop er length striker attaching screws as indi...

Page 515: ...inner panel a Removal 1 Remove door trim assembly 2 Remove strips of waterproof body tape se curing lower corners of water deflector 3 With a putty knife or other suitable flat bladed tool carefully break cement bond securing upper corners of water deflector to door inner panel Make sure string located within sealer is against water deflector and carefully slide putty knife between sealer and door...

Page 516: ... 2 Remove trim pad andpull handle pal nuts 3 To install reverse removal procedure It may be necessary to seal pull handle and lamp assembly attaching screw holes with body caulking compound prior to installation 57 Front and Rear Door Inside Handles Removal and Installation A On styles equipped with door inside remote control paddle handles proceed as follows 1 Remove door arm rest 2 On styles equ...

Page 517: ...1 Remove door pull handle or pull handle and lamp assembly attaching screws 2 Remove arm rest cover plate see b below 3 Where applicable remove switch plate and mounting base 4 Remove door inside handles and door trim pad 5 Remove arm rest screw and washer assem blies and remove arm rest from door trim pad This should be done as a bench operation 6 To install reverse removal procedure b Arm Rest C...

Page 518: ...iner is an integral part of this molding which is attached to the door outer panel by three screws Fig 16 56 Onstyles not equipped with a molding the outer strip assembly is attached to the door outer panel by a series of attaching clips andis further retained by twoattaching screws On all styles the inner strip assembly remains in a stationary position during operation of door glass On the outer ...

Page 519: ...e spacers are installed between adjuster front and rear supports and floor pan Fig 16 57 b Front Seat Adjuster Manual Removal and Installation 1 Remove seat assembly with attached seat adjusters from body and place upside down on a clean protected surface Seat Bottom Frame Seat Adjuster Spacer 6229 6239 and 6257 2 When removing left adjuster it is necessary to remove seat adjuster control knob 3 S...

Page 520: ...emove adjuster from assembly 5 To install reverse removal procedure c Front Seat Adjuster Gear Nutand Jackscrew Assembly Removal and Installation 1 Remove front seat assembly with attached adjusters and place upside down on a clean pro tected surface 2 Detach power drive cable from gear nut and jackscrew assembly to be removed 3 Using a suitable tool preferably a clutch type screwdriver remove two...

Page 521: ...d seat control switch The large center control knob controls movement of the entire seat assembly horizontally The smaller forward control knob controls vertical move ments of the front of the seat assembly causing the seat assembly to tilt In the same manner the rear control knob controls vertical movement of the rear of the seat assembly To obtain maxi mum vertical travel it will be necessary to...

Page 522: ...l actuator yellow cable to front vertical gear nut and blue cable to rear vertical gear nut IMPORTANT When installing seat assembly in body seat adjusters should be parallel and in phase with each other In the event ad justers are out of phase that is one adjuster reaches its maximum horizontal or vertical travel in a given direction before the other adjuster proceed as follows jackscrew Attaching...

Page 523: ...uld have cable attachment at bottom of inner side of adjuster d Front Seat Adjuster Horizontal Actuator or Upper and Lower Channels Removal and Installation 1 Remove front seat adjuster 2 Remove screws securing horizontal actuator and remove actuator from seat adjuster 3 Slide seat adjuster lower channel from upper channel and if required remove plastic shoes from lower channel track 4 To install ...

Page 524: ...ts Fig 16 60 g Front Seat Adjuster Transmission Removal and Installation 1 Remove front seat assembly from body with attached adjusters motor and transmission and place upside down on a clean protected surface 2 Disconnect wire harness connector from transmission Fig 16 60 3 Remove screws securing horizontal and ver tical cable end plate on both sides of transmission and detach cables from transmi...

Page 525: ...ch con tacts are opened a return spring returns the solenoid plunger to its original position disen gaging it from the driving gear dog a Bucket Type Front Seat Assembly Driver or Passenger Manual or Power Operated Removal and Installation 1 Turn back floor carpeting sufficiently to expose seat adjuster to floor pan attaching nuts or bolts 2 Operate seat assembly to rearward position 3 Remove atta...

Page 526: ...Remove bolts securing back assembly to seat cushion frame assembly 4 On all styles using a flat bladed tool care fully remove retainer from outer hinge pin Fig 16 66 Support Attaching Nuts Retainer Washer Retainer Hinge Pin Washer Fig 16 66 Bucket Seat Back Removal 5 On all styles tilt seat back forward and remove retainer from inner hinge pin Fig 16 66 6 On all styles carefully disengage front se...

Page 527: ...g horizontal actuator assembly to adjuster lower track then remove actuator from adjuster assembly Fig 16 64 6 To install reverse removal procedure NOTE When installing horizontal actuator adjust actuator so that drive gear is fully en gaged with teeth on lower channel When hori zontal actuator attaching screws are tightened there should be no free motion between upper and lower channels Check sea...

Page 528: ...support to inboard adjuster Fig 16 65 4 Carefully disengage adjuster from support and torque tube assembly then remove adjuster from seat 5 Disengage torque tube from opposite adjuster and remove tube from seat assembly 6 To install reverse removal procedure Check seat adjuster for proper operation m Motor and Transmission Support Four Way Tilt Removal and Installation 1 Remove front seat assembly...

Page 529: ...s from hangers on seat back panel support 5 Remove seat back assembly from body 6 Install by replacing parts in reverse sequence making certain that all attaching body tabs and hangers have waterproof body tape ap plied to them to act as an anti squeak b 67 Styles Only 1 Remove rear seat cushion assembly 2 Disconnect rear seat back speaker wire 3 Working over rear of rear seat back remove screw se...

Page 530: ...est assembly carefully detach arm rest from rear quarter inner panel sufficiently to disconnect wire harness connectors 4 Remove arm rest assembly from rear quarter panel Fig 16 70 Rear Quarter Window Assembly 67 Styles A Rear Quarter Window Electric MotorAnd Regulator Assembly B Rear Quarter Window Assembly C Rear Quarter Window Hinge Bolt D Rear Quarter Window Hinge Adjusting Plate E Rear Quarte...

Page 531: ...ation 29 Styles 1 Remove back window side garnish molding and side roof rail rear finishing molding 2 Carefully break cement bond securing trim foundation to roof extension inner panel then re move trim assembly 3 To install first apply trim cement to con tacting surfaces of trim foundation and roof ex tension inner panel Position trim and press or roll to assure a good cement bond Install back wi...

Page 532: ...ont and rear guide loosen front and rear guide adjusting stud nuts Fig 16 71 Operate window to full up position and tighten upper stud nuts on front guide and forward attaching screw on rear guide Operate window to full down and tighten remaining nuts 6 To limit forward and upward travel of rear quarter window adjust regulator lift arm stop as required Fig 16 71 7 To limit down travel of rear quar...

Page 533: ...at cushion and seat back Re move back window side garnish molding and rear quarter window front garnish molding Remove rear quarter lower trim assembly 2 Remove screws securing three glass rubber channel retainers at bottom of window and retainer at top of window Using a suitable tool carefully break sealer bond between rubber channel and body opening 3 Carefully push rear quarter glass and rub be...

Page 534: ...rse removal procedure Prior to installation of front guide assembly lubricate channels of guide along full length of channels Adjust front guide assembly for proper window alignment and operation as necessary Seal front guide attaching screws as specified in Note 75 b Rear Guide 57 Styles 1 Remove rear seat cushion and back assem blies Remove rear quarter arm rest and trim assemblies Remove rear q...

Page 535: ...strip adhesive black over attaching screws Fig 16 75 Rear Quarter Inner Panel Sealing 67 Styles 4 Electric Window Regulator Attaching Screws Apply weatherstrip adhesive black over attach ing screws 5 Window Regulator Spindle Hole Sealing Washer Apply weatherstrip adhesive over ex posed surface of washer to seal pores of sponge rubber and joint between inner panel and washer On convertible coupe st...

Page 536: ...ding and rubber channel b Removal and Installation With the exception of the side andupper reveal moldings on 29 styles the back window reveal moldings are retained entirely by pinchweld type clips The procedure for removing a molding se cured in this manner is described below c Pinchweld Clip Disengagement Insert point of tool J 7898 01 between back window rubber channel and reveal molding Slide ...

Page 537: ...ould be exercised to make certain glass does not strike body metal during installation as edge chips can cause solid tempered safety plate glass to shatter Do not attempt to grind glass b Installation 1 Clean original sealer from back window body opening and rubber channel and install rubber channel to glass IMPORTANT Before installing back window glass check the back window body opening and pinch...

Page 538: ...he rear compartment lid employs two torsion rods that are mounted be tween the lid and hinge assemblies to act as a counterbalance and hold open for the lid Notches at the hinge end of the rods allow for adjustment of the rods to increase or decrease operating effort of the lid The rear compartment lid lock employs a side action snap bolt mechanism that has provisions at the attaching locations fo...

Page 539: ... face of opposite hinge box 5 Check alignment of rear compartment lid and make any necessary adjustments 6 Replace wire harness if left hinge was re moved 80 Rear Compartment Torque Rod Adjustment The amount of effort required to open and close the rear compartment lid is determined by the position of the torque rod in the notches on the in board face of the hinge boxes If the torque rod is locate...

Page 540: ...r striker up or down to obtain proper engagement then tighten screws 82 Rear Compartment Lid Vacuum Lock System The rear compartment lid vacuum lock system is a rotary bolt type lock with a vacuum release unit attached that unlocks the lock upon introduc tion of vacuum in the unit Fig 16 80 The vacuum is stored in a storage tank located on the shroud panel It is controlled by a switch located in t...

Page 541: ...d cable conduit from pull down unit Remove screw securing instrument panel light jamb switch and free switch from pull down unit Fig 16 82 Conduit to Bracke Retaining Clip SCable Adjusting Bracket Attaching Vacuum Release Hose Link Assembly Actuating Arm Mechanical Closing Unit Link Assembl Link Assembly Attaching Screws ft Hydraulic Cylinder Cable Retaining Clip Cable Conduit Retainina Clio MMech...

Page 542: ... cable results in a les sening of pull down effort in the unit and conse quently a misaligned high rear compartment lid To greatly increase cable tension position hy draulic cylinder end of cable in the upper slot on the lower end of the cylinder at 1 in Fig 16 83 If more tension or finer adjustment is required loosen cable adjusting bracket attaching screw Fig 16 82 Adjust bracket downward to inc...

Page 543: ... exterior molding chart in this section the following information will be helpful when installing or removing exterior moldings 1 Screw locations the exact location for each screw is not shown or mentioned but when hidden the general location is indicated by naming the molding or other part which conceals the screw and therefore must be removed to gain access to the screw A FRONT DOOR WINDOW REVEA...

Page 544: ... bead of medium bodied sealer along the full length of the inner attaching surface Door window scalps and center pillar scalps require a 1 8 inch x 1 4 inch x 1 4 inch bead of caulking compound at 5 inch intervals for anti rattle purposes Pinchwelds require medium bodied sealer on both sides when pinchweld clips are used The exception is the rear quarter pinchweld on convertible styles which requi...

Page 545: ... is indicated when necessary in the Starting Location column of the molding chart 85 Molding Clips Removal and Installation If it is necessary to replace a damaged bath tub molding clip use the following procedure for removal and installation The following groups of moldings are listed with the name or description of the tool which is suitable for molding removal Roof Drip Scalps pointed hook tool...

Page 546: ...id Outer Panel Compartment Lid Inner Panel Attaching Screw Molding Molding VIEW C Screw On Clips VIEW E Body Outer Panel Stud Retaining Clip Molding VIEW B Molding Snap On Clip Body Outer Panel VIEW D Rear of Rear Fender Fig 16 87 Typical Methods of Exterior Molding Attachment ...

Page 547: ...es Quarter Belt Reveal 6039 Style Quarter Window Front Reveal 29 Style Quarter Window Lower Reveal 29 Style Method of Retention Screws X ViewC X X X X X X Spring Self Retained Snap On Clips or Retainers On Panel X View A X Snap On Clips On Molding X View D Studs With Attaching Nuts X X Engages With Other Moldings Slides Under Back Window Lower Reveal Clip Quarter Win dow Upper and Lower Reveal Qua...

Page 548: ... Rear of Rear Fender Outer at Tail Lamp 6039 and 6367 BODY EXTERIOR MOLDINGS Cont d Method of Retention Screws X X X X X X ViewF X X View F X Spring Self Retained Snap On Clips or Retainers On Panel X ViewA X View B Snap On Clips On Molding X View D X View D Studs With Attaching Nuts X X X X X Engages With Other Moldings Roof Panel Side Rear and Rear End Center Belt Remove Hardware or Trim Quarter...

Page 549: ... Self Retained X X X X X Snap On Clips or Retainers On Panel X View E X Pinchweld Snap On Clips On Molding X ViewD mm Studs With Attaching Nuts X Engages With Other Moldings Quarter Win dow Lower Reveal Wheel Open ing Molding Windshield Pillar Drip Molding Scalp Overlapped by Roof Drip Front Scalp Windshield Pillar Drip MoldingScalp Roof Panel Front Roof Panel Side Front Roof Panel Front Wind shie...

Page 550: ...ually during servicing hands must be kept clear of side roof rail hinges and connecting linkages a Front Roof Rail Corner Brace If the top when in a raised position is toofar Attaching Bolts Front Roof Rail Side Roof Rail Front forward or does not move forward enough to allow the guide studs on the front roof rail to enter holes in the striker assemblies proceed as follows 1 Unlatch top and raise ...

Page 551: ...to permit adjustment ofplate c Without changing up ordown location of ad justing plate move adjusting plate forward or rearward horizontally over serrations as re quired to obtain desired height then tighten bolts NOTE If topcannot be fully lowered even after control link plate hasbeen adjusted re adjust male hinge assembly asrequired Check top for proper operation d At Male Hinge Support Prior to...

Page 552: ...ck height and proper alignment of side roof rails over door and quarter windows Where required adjust control link adjusting plate as previously de scribed NOTE If top cannot be fully raised or lowered even after control link plate has been adjusted readjust male hinge assembly as re quired Check top for proper operation 87 Folding Top and Back Curtain Trim Assembly Removal and Installation 1963 c...

Page 553: ...o establish relationship of right and left inner vertical edge of old top material to back curtain assembly at rear trim stick location mark back curtain vinyl at both locations with a grease pencil Fig 16 96 Reference marks should be transferred to new back curtain when step 7 of installation procedure is performed NOTE Reference marks must be made be low upper edge of rear trim stick 9 Remove re...

Page 554: ...21 inches Mark Curtain Below Upper Edge Of Rear Trim Stick Upper Edge Of Rear Trim Stick Grease Pencil Marks On Vinyl Material Indicating Ends of Trim Sticks Fig 16 97 Marking Ends of Trim Sticks While exerting rearward pressure on rear bow to draw side stay pads taut extend spacer sticks until they fit snugly between center bow and rear roof bow then tighten wing nuts 15 Spacer stick may be fabri...

Page 555: ...h tacks to center bow and side roof front rail with screws b Installation 1 If new top is being installed but it was im possible to perform step 14of removal procedure preset spacer sticks to shortest length and in stall between center and rear roof bow Fig 16 98 Adjust sticks so that dimension X in Fig 16 98 measured along spacer stick from front upper rolled edge of rear roof bowto center of cen...

Page 556: ...dge of pad should be located within 1 4 inch of outboard edge of front bow felt silencer Install pad to center bow with screws Make sure inboard edge of pad is properly aligned within depression in bow Install stay pad wadding in conventional manner using an approved trim cement Fig 16 100 3 Trim selvage end of side stay pads just for ward of rear rolled edge of rear roof bow Fig 16 101 4 Distance...

Page 557: ...Fig 16 105 Tacking Back Curtain at Rear Bow edge of rear trim stick New webbing may be cut from a piece of non staining type webbing 2 inches x 19 inches Excess webbing should be trimmed off at rear trim stick 1 2 inch above back curtain lower edge Fig 16 103 NOTE Webbing used in build up of side roof rail stay pads is recommended for the above operation 13 Inspect rubber trim stick fillers cement...

Page 558: ...body Folding Top Assembly Fig 16 109 Marking Top Material at Deck Seam 22 Apply convertible top sealer nitrile around each tack head used to secure back curtain ma terial and webbing to rear and or rear quarter trim sticks Fig 16 108 NOTE It is not necessary to seal tacks which secure back curtain vinyl to rear trim stick 23 Lay out new top material on clean protected surface with outer layer of m...

Page 559: ... of rod then pull cable through pocket When cable attaching bracket is exposed at front end of hold down pocket disengage hooked portion of rod from cable attaching bracket Repeat above operation on opposite side of top assembly 34 After cables have been filtered or pulled through hold down pockets in top material fasten cable attaching brackets to side roof front and rear rails Fig 16 94 NOTE Cab...

Page 560: ...king on inner Back Curtain Material Compartment Bag Material Top Material Nitrile S e a l e r Nitrile Sealer l 2 to 3 8 Fig 16 114 Tacking Top to Roof Bow lining of back curtain material See A A in Fig 16 113 Trim top material as required 44 Apply convertible top sealer nitrile onto all trimmed edges around each tack head and around each trim stick attaching bolt hole See A Ain Fig 16 113 CAUTION ...

Page 561: ...ension is desired in top trim unlock top from header and reposition top trim by pulling trim further for ward Stay tack and recheck top appearance 54 Complete tacking of top trim to front roof rail and trim off excess material 55 Permanently tack top material to rear roof bow Apply bead of neoprene type weatherstrip adhesive around each tack head and into two holes pierced into top material for wi...

Page 562: ...ut Zipper Stop Along Dotted Line with attached back curtain and compartment bag material from body and place on a clean pro tected surface 13 Using chalk or other suitable material mark ends of rear and rear quarter trim sticks on vinyl surface of back curtain material Fig 16 97 Reference marks for trim sticks should be transferred to new back curtain material when step 5 of installation procedure...

Page 563: ... a stop for the slide fastener Fig 16 120 14 Tack zipper tape to rear quarter trim stick Fig 16 120 Zipper tape should not be pulled taut as zipper teeth may show through top ma terial after top has been properly installed 15 Install trim sticks with attached back cur tain assembly into body NOTE Make sure that all trim stick bolts are driven in completely to represent finished condition 16 Check ...

Page 564: ...1 Hydro Lectric System Motor and Pump Assembly The 6267 and 6367 convertible coupe styles incorporate a high pressure hydro lectric system to raise and lower the folding top After the top has been unlatched and raised above the wind shield by hand it can be lowered or raised by actuating a power control switch located on the lower part of the instrument panel to the left of the steering column Hyd...

Page 565: ... at F Fig 16 121 and cap open fittings to prevent leakage of fluid Use a cloth to absorb any leaking fluid then remove unit from rear compartment b Disassembly Disassembly of pump and motor assembly is limited to those parts illustrated in Fig 16 122 1 Remove motor and pump assembly from body 2 Scribe a line across pump end plate reser voir tube and reservoir tube end plate as shown in Fig 16 123 ...

Page 566: ... a Drill 1 4 inch diameter hole through center of spare reservoir filler plug b Install two inch length of metal tubing 1 4 inch O D x 3 16 inch I D into center of filler plug and solder tubing on both sides of filler plug to form air tight connection Fig 16 124 2 Filling and Bleeding of Reservoir a With top in raised position remove folding top compartment bag material from rear seat back panel R...

Page 567: ...anical failure has been completed the hydro lectric system should then be checked for electrical or hydraulic failures as explained in Notes 93 and 94 93 Electrical Checking Procedure A failure in the electrical system may be caused by a low battery breaks in wiring faulty con nections mechanical failure of an electrical com ponent or wires or components shorting to one another or to body metal Be...

Page 568: ...mp to cylinder for kinks b If one cylinder rod moves slower than the other cylinder having slower moving rod is de fective and should be replaced c If both cylinder rods move slowly or do not move at all check pressure of the pump c Checking Pressure at the Pump 1 Remove motor and pump assembly from rear compartment 2 Install plug in one port and pressure gage in port to be checked Fig 16 126 3 Ac...

Page 569: ...installation of lift cylinder piston rod to folding top side of rear rail connect bat tery and use power to raise cylinder piston rod to extended position b Operate folding top assembly down and up to insure proper linkage alignment of side rails Where required adjust male hinge assembly as described in Note 86 c Operate folding top assembly down and up several times then check and correct level o...

Page 570: ...he right and left harnesses a r e connected to the front cross over harness beneath the outer ends ofthe instrument panel The power windows and ventilators are operated by a rectangular shaped twelve volt series wound motor with an internal circuit breaker and a self locking rubber coupled gear drive The har ness to motor connector is designed with a locking embossment to insure a positive connect...

Page 571: ...nnectors beneath the outer ends of the instrument panel for proper engagement 97 Power Window Circuit Checking Procedures Failures in a circuit are usually caused by short circuits or open circuits Open circuits are usually caused by breaks in the wiring faulty connection or mechanical failure in a component such as a switch or circuit breaker Short cir cuits are usually caused by wires from diffe...

Page 572: ...n open or short circuit in harness be tween control switch and motor connector Fig 16 133 e Checking Door Window Motor 1 Check window regulator and channels for possible mechanical bind of window d Checking Wires Between Door Window Switch and Door Window Motor 1 Disengage harness connector from window motor connector The thumb release on harness connector must be depressed before it can be diseng...

Page 573: ...ED IT REAR WINDOW DOWN CYCLE RT REAR CV OPEN CYCLE RT FRON LT FRON IT REAR RT FRON IT FRON RT FRON RT FRON r WINDOW DOWN CYCLE WINDOW DOWN CYCLE WINDOW DOWN CYCLE WINDOW UP CYCLE T C V CLOSE CYCLE r C V CLOSE CYCLE CV OPEN CYCLE COURTESY LAMP AND JAMB SWITCHES WINDOW DOWN CYCLE C V OPEN CYCLE RIGHT REAR DOOR CV WINDOW MOTOR I DUUK LU3C r Kl UUUN U U IT DOOR CIOSE7 LT DOOR CLOSE AR DOOR DOWN RT REA...

Page 574: ...eck feed connection to power harness beneath in strument panel 3 Check the feed circuit wires for possible short or open circuit 1 Check harness connectors beneath outer ends of in strument panel for proper installation 2 Check wires in power win dow front harness for pos sible short or open circuit 3 Check operation of rear door window control switch 4 Check circuit from window control switch to ...

Page 575: ...t adjuster 4 Check operation of motor with No 12 gage jumper wire Connect one end of jumper wire to power source and the other end to one of the seat motor ter minals Motor should oper ate Perform same check at the other motor terminal If motor does not operate r e p a i r or replace as required The seat motor operates in only one direction 1 Defective switch 2 Open or short circuit in motor feed ...

Page 576: ...ms to become familiar with the seat circuit 1 Checking for Current at Circuit Breaker a Connect one light tester lead to battery side of circuit breaker located in fuse block and ground other lead If tester does not light there is no current at battery side of circuit breaker b To check circuit breaker disconnect switch feed wire from breaker and with a light tester check for current at switch sid...

Page 577: ...ION SWITCH FEED FIELD FEED REARWARD UP CYCLE SOLENOID HORIZONTAL MOVEMENT FIELD FEED FORWARD DOWN CYCLE SOLENOID VERTICAL MOVEMENT Fig 16 137 Four Way Seat Switch Block 1 To raise seat place jumper wire in loca tions 1 2 and 5 2 To lower seat place jumper wire in loca tions 1 4 and 5 3 To operate seat forward place jumper wire in locations 1 3 and 4 4 To operate seat rearward place jumper wire in ...

Page 578: ... wire and switch or defec tive switch d Check other wire in same manner NOTE One wire in connector is a blank Check wiring diagram for colors of wires ac tually used 9 Checking the Solenoid a Check solenoid ground strap attachment for proper ground b Connect one end of a 12 gage jumper wire to battery positive pole and other end to lead of solenoid being checked CAUTION To prevent damaging solenoi...

Page 579: ...enoid plunger dog engaging the gear mecha nism to rotate the control cable The same switch action which energized the solenoid produces a current flow through the motor control relay to one of the motor field coils The current flows through the relay closes the contacts between the relay power source and the armature motor lead wire and results in the operation of the seat motor 104 Six Way Electr...

Page 580: ...ter does not light there is no current at end of feed wire Failure is caused by an open or short in feed circuit NOTE In the following operations which specify the seat control switch to be actuated a switch that has been checked for proper oper ation may be connected to the switch block If a switch is not available a three way jumper wire can be made to perform the switch func tion The jumper wir...

Page 581: ...e light tester lead into the motor field connector slot on harness and ground the other lead 3 Actuate seat switch to energize field wire being tested 4 If tester does not light there is no current at end of wire Failure is caused by an open or short circuit between end of wire and switch Check other motor field wire in same manner f Checking Relay Assembly 1 Disconnect three motor leads from rela...

Page 582: ...e in seat unit solenoid is defective j Three Way Jumper Wire for Checking Seat Switch To make jumper wire obtain two pieces of 12 gage wire each 4 1 2 inches long Join one end of each wire as shown in Fig 16 140 The joined end can be inserted in the feed location in the switch block one of the remaining ends can be inserted into one of the field locations in the switch block the other end can be i...

Page 583: ...OWER WINDOW HARNESS RIGHT FRONT DOOR COURTESY LAMP LEFT REAR QUARTER READING LAMP SEAT BACK SWITCH RIGHT REAR QUARTER CORNER LAMP LEFT FRONT DOOR JAMB SWITCH TRIM PAD LAMP GROUND LEFT REAR QUARTER CORNER LAMP LEFT DOOR COURTESY WARNING LAMP GROUND FRONT SEAT BACK SWITCH READING LAMP GROUND READING REAR COMPT LAMP BODY FEED RIGHT STOP SIGNAL LAMP FEED BACK UP LAMP FEED GAS GAUGE SENDING UNIT TAIL L...

Page 584: ...GR 1 RIGHT DOOR JAMB SWITCH MAP LAMP GROUND RIGHT REAR DOOR CIGAR LIGHTER LEFT REAR DOOR CIGAR LIGHTER LEFT FRONT DOOR JAMB SWITCH MAP LAMP GROUND QUARTER REAR COMPARTMENT LAMP BODY FEED RIGHT STOP SIGNAL LAMP FEED BACK UP LAMP FEED GAS GAUGE FEED TAIL LICENSE LAMP FEED LEFT STOP SIGNAL LAMP FEED REAR RADIO SPEAKER RIGHT REAR CORNER COURTESY LAMP LEFT REAR DOOR JAMB SWITCH DOME LAMP GR LEFT REAR C...

Page 585: ...S MAP LAMP GROUND QUARTER CORNER LAMP GROUND QUARTER REAR COMPT LAMP BODY FEED RIGHT STOP SIGNAL LAMP FEED BACK UP LAMP FEED GAS GAUGE SENDING UNIT BLANK TAIL LICENSE LAMP FEED LEFT STOP SIGNAL LAMP FEED RIGHT DOOR JAMB SWITCH MAP LAMP GROUND LEFT DOOR JAMB SWITCH 14 13 14 RIGHT REAR QUARTER CORNER LAMP 14 LEFT REAR QUARTER CORNER LAMP 14 13 REAR RADIO SPEAKER s CONNECTOR TO REAR BODY WIRING HARNE...

Page 586: ...R COURTESY LAMP POWER TOP MOTOR UNIT LEFT DOOR COURTESY LAMP RIGHT DOOR JAMB SWITCH REAR QUARTER COURTESY LAMP GROUND FRONT SEAT BACK SWITCH FEED FROM POWER WINDOW I REAR RADIO SPEAKER LEFT DOOR JAMB SWITCH LEFT REAR QUARTER COURTESY LAMP CONNECTOR TO CHASSIS WIRING CD O S LEFT DOOR JAMB SWITCH DOOR COURTESY LAMP GROUND LEFT DOOR JAMB SWITCH MAP LAMP GROUND COURTESY REAR COMP LAMP BODY FEED RIGHT ...

Page 587: ...ND FRONT SEAT BACK SWITCH EXCEPT BUCKET SEATS GROUND FOR RT REAR DOOR COURTESY LAMP DOOR PULL HANDLE IT FRONT DOOR COURTESY LAMP DOOR PULL HANDLE LT REAR DOOR COURTESY LAMP DOOR PULL HANDLE 14 LEFT FRONT DOOR JAMB SWITCH MAP LAMP GROUND oo REAR RADIO SPEAKER FEED FROM POWER WINDOW HARNESS 14 LEFT REAR DOOR JAMB SWITCH CONNECTOR TO CHASSIS WIRING CD O o LEFT FRONT DOOR JAMB SWITCH MAP LAMP GROUND L...

Page 588: ...RTESY LAMP TRIM PAD RT REAR QUARTER COURTESY LAMP TRIM PAD LT REAR QUARTER COURTESY LAMP TRIM PAD LEFT REAR QUARTER ARMREST LIGHTER Q RIGHT REAR QUARTER ARMREST LIGHTER CONNECTOR TO REAR BODY WIRING HARNESS DO o a LT COURTESY LAMP GROUND JAMB SWITCH LT FRONT DOOR JAMB SWITCH MA LAMP GROUND REAR QTR LIGHTER COURTESY REAR COMPT LAMP BODY FEED RIGHT STOP SIGNAL LAMP FEED BACK UP LAMP FEED GAS GAUGE F...

Page 589: ...K WHITE TRS DK GREEN WHITE TRS REAR RADIO SPEAKER REAR QUARTER TRIM PAD COURTESY LAMP GROUND FRONT SEAT BACK SWITCH FOLDING TOP MOTOR LEFT DOOR JAMS SWITCH FEED FROM POWER WINDOW LT REAR QUARTER TRIM PAD COURTESY LAMP CD O a LEFT DOOR JAMB SWITCH COURTESY LAMP GROUND LEFT DOOR JAMB SWITCH MAP LAMP GROUND LIGHTER COURTESY REAR COMP LAMP BODY FEED RIGHT STOP SIGNAL LAMP FEED BACK UP LAMP FEED GAS GA...

Page 590: ...ER LT STOP SIGNAL LAMP LOWER RT BACK UP LAMP RT STOP SIGNAL GAS GAUGE LAMP LOWER SENDING UNIT LT TAIL LAMP LOWER o LICENSE LAMP RT TAIL LAMP UPPER RT TAIL LAMP LOWER COLOR CODE WIRE NO 1 2 3 4 5 6 COLOR RED VIOLET LT GREEN BROWN DK GREEN PINK ...

Page 591: ...own and rearward but will not move the seat up and forwwrd CAUSE 1 Short or open circuit be tween power source or switch and motor 2 Defective motor 1 Short or open circuit be tween switch and affected solenoid 2 Defective solenoid 1 Short or open circuit be tween one of the motor field wires and seat control switch 2 Defective field coil in motor CORRECTION 1 Check circuit from power source and s...

Page 592: ...Hog Ring Pliers Weatherstrip Retaining Clip Forming Tool Weatherstrip Installer Rear Window Reveal Molding Remover Weatherstrip and Folding Top Well Trim Retainer Remover Key H I J K L Tool No J 7160 J 8074 J 8966 J 6335 J 8942 Description Molding Retaining Clip Installer Hydro Lectric Top Pressure Gage Windshield Wiper Arm Remover and Installer Trim Pad Remover Windshield Alignment Block Set ...

Page 593: ...REAR VIEW SERIES 62 ...

Page 594: ...AL NO HEAD MARKING STRENGTH 260 M 280 M 300 M None 120 60 Standard Medium High HEX NUT STEEL CLASSIFICATION G M MATERIAL NO MARKING STRENGTH Conventional Type 286 M 301 M 1 USUAL T OPTIONAL None 120 120 Standard High Prevailing Lock Type Stover B None 120 60 Standard Medium High ...

Page 595: ...4 pecks 1 bushel bu 105 quarts 1 barrel CUBIC MEASURE 1 728 cubic inches 1 cubic foot 27 cubic feet 1 cubic yard COMMON WEIGHT 16 ounces 1pound 100 pounds 1 hundred weight cwt 2000 pounds 1 ton COMMON U S A EQUIVALENTS LENGTH 1 inch 25 4001 millimeters 1 millimeter 0 03937 inches 1 foot 0 304801 meters 1 meter 3 28083 feet 1 yard 9 914402 meters 1 meter 1 093611 yards 1 mile 1 609347 kilometers 1 ...

Page 596: ...1770 0 1730 0 1695 0 1660 0 1610 0 1590 0 1570 0 1540 0 1520 0 1495 0 1470 0 1440 Wire Gage Sizes 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 Drill Diam Inches 0 1405 0 1360 0 1285 0 1200 0 1160 0 1130 0 1110 0 1100 0 1065 0 1040 0 1015 0 0995 0 0980 0 0960 0 0935 0 0890 0 0860 0 0820 0 0810 0 0785 0 0760 0 0730 0 0700 0 0670 0 0635 0 0595 0 0550 Wire Gage Size...

Page 597: ...125 140625 15625 171875 1875 203125 21875 234375 25 265625 28125 296875 3125 328125 34375 359375 375 390625 40625 421875 4375 453125 46875 484375 5 1 2 5 8 4 4 32 3 i4 5 3 2 2 5 4 3 32 1 515625 53125 546875 5625 578125 59375 609375 625 640625 65625 671875 6875 703125 71875 734375 75 765625 78125 796875 8125 828125 84375 859375 875 890625 90625 921875 9375 953125 96875 984375 ...

Page 598: ...Propeller Shaft 2 6 Rear Axle 2 3 Tire Pressure 2 11 SECTION 3 FRAME Frame Body Bolts 3 1 SECTION 4 CHASSIS SUSPENSION Chassis Suspension Alignment Front Wheel Caster Camber Toe in 4 5 Bent Parts Straightening 4 27 Car Weights and Standing Heights 4 32 Diagnosis Chart 4 30 Front Suspension System Lower Suspension Arm Bushing Removal and Installation 4 25 Lower Suspension arm and Coil Spring Remova...

Page 599: ...Seats and Poppet Check Valve Replacement On Car 5 22 Pitman Shaft Seal Replacement Gear on Car 5 23 Service Information 5 3 Special Tools 5 34 Steering Column Bearing Lower Removal and Installation 5 26 Bearing Upper Removal and Installation 5 27 Disassembly Inspection and Assembly 5 25 Removal and Installation 5 24 Steering Gear Gear Design 5 2 Major Components Disassembly Inspection and Assembly...

Page 600: ...15 Specifications 7 16 Torque Specifications 7 14 SECTION 8 POWER BRAKES Brakes Cont d Bendix Power Brake Unit Disassembly Cleaning Inspection and Assembly 8 11 Bleeding Brakes 8 8 Brake Drums Machining 8 6 Brake Shoe Assemblies 8 4 Brake Shoes Manual Adjustment 8 3 Brake System Testing 8 22 Delco Moraine Master Cylinder Disassembly Cleaning Inspection and Assembly 8 20 Delco Moraine Power Brake U...

Page 601: ...al Height 10 31 Engine Fuel and Exhaust Cont d Carburetor Cont d Idle Speed and Mixture 10 31 Idle Speed Up Control 10 31 Throttle Check 10 33 Throttle Rod and TV Rod 10 32 TV Rod 10 32 Inspection and Cleaning 10 12 Removal and Installation 10 11 Carburetor Carter Adjustments off Engine Accelerator Pump 10 30 Choke 10 29 Choke Unloader 10 30 Fast Idle and Choke Connector Rod 10 30 Float Level 10 2...

Page 602: ...12 32 Back Up Light Switch Service 12 47 Electrical System Cont d Battery Care When Not In Use 12 8 Causes of Undercharged Condition 12 6 Filling Instructions 12 4 Hydrometer Test 12 6 Light Load Test 12 5 Removal and Installation 12 7 Use of Hydrometer 12 5 Visual Inspection 12 7 Bulb Data Chart 12 99 Bulb Replacement 12 37 Bulb Replacement Instrument Panel 12 38 Charging Circuit Analyzing Troubl...

Page 603: ...e and Repair Procedure 12 67 Removal and Installation 12 66 Controls Operation 12 62 Rear Seat Remote 75 Series Removal and Installation 12 66 Electrical System Cont d Controls Cont d Design Features 12 61 Diagnosis 12 69 FM AM Radio 12 61 Noise Suppressors 12 63 Receiver Unit Removal and Installation 12 65 Repair Procedures Minor 12 64 Signal Seeking Tuner 12 62 Speaker Removal and Installation F...

Page 604: ...llation 60 and 62 Series 13 58 75 Series Front 13 58 75 Series Rear 13 59 Evaporator Core Removal and Installation Front 13 59 Rear 75 Series 13 60 Heating and Air Conditioning Cont d Expansion Valve Removal and Installation Front 13 55 Rear 75 Series 13 55 Leak Detectors 13 27 Maintenance and Inspections 13 26 Major Components of System Blower Assembly 13 17 Compressor 13 12 Condenser 13 16 Contr...

Page 605: ...d Installation 14 6 Bumper Rear Center Impact Bar Removal and Installation 14 9 End Impact Bar Right or Left Removal and Installation 14 8 Finish Panel Right or Left Removal and Installation 14 8 Fuel Tank Filler Door and License Holder Removal and Installation 14 8 License Guard Right or Left Removal and Installation 14 8 Rear Bumper Removal and Installation 14 7 Fender Front Right or Left Adjust...

Page 606: ... Lock to Locking Lever Rod Rear Removal and Installation Door Outside Handle Assembly Front and Rear Removal and Installation Door Outside Handle Push Button Disassembly and Assembly Door Pull Handle and Lamp Assembly Front and Rear Removal and Installation Door Pull Handle Front and Rear Removal and Installation Door Remote Control Assembly and Connecting Rod Front Removal and Installation Rear R...

Page 607: ...ter Inner Panel Sealing 16 66 Rear Quarter Trim Assembly Removal and Installation 16 61 Rear Quarter Window Assembly Manual and Electric Removal and Installation and Adjustments 16 62 Body Cont d Rear Quarter Window Guide Assembly Removal and Installation 16 65 Rear Quarter Window Regulator Manual and Electric Removal and Installation 16 64 Rear Quarter Window Regulator Motor Removal 57 and 67 Sty...

Page 608: ...41 Rear Quarter Manual and Electric Removal Installation and Adjustment 16 62 Body Cont d Window Guide Assembly Rear Quarter Removal and Installation 16 65 Window Regulator Assembly Front Door Manual and Eiectric Removal and Installation 16 32 Rear Door Manual and Electric Removal and Installation 16 40 Rear Quarter Manual and Electric Removal and Installation 16 64 Window Regulator Motor Assembly...

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