Oldsmobile Supreme 1971 Workshop Manual

Released by: www.78ta.com

Serial Number: 71BDY-001-1026

TABLE OF ,CONTENTS

BODY

SERVICE

MANUAL

FOR ALL BODY SYLES

(Except "H" Body)

This publication contains the essential removal, installa- tion, adjustment and maintenance proceduresfpz_servicing all U.S. and Canadian built 1971 Fisher Body W l e s . All information, illustrations, and specifications contained in this publication are based on the latest product informa- tion available a t the time of publication approval. The right is reserved to make changes a t any time without notice.

Arrangement of the material is shown by the table of contents on the right-hand side of this page. Black tabs on the first page of each section can be seen on the edge of the book below section title. A more detailed table of contents precedes each section, and an alphabetical index is included in the back of the manual.

1

I

GENERAL INFORMATION

WINDSHIELD WIPER SYSTEM

3

4

5

6

7

8

10

9

1

UNDERBODY

I

STATIONARY GLASS

1

FRONT END

I

DOORS

1

REAR QUARTERS

1

I

REAR COMPARTMENT LID

,

TAIL GATE

1

HEADLINING

-

12

13

14

15

16

,

17

ROOF

1

FOLDING TOP

1

DOOR AND QUARTER TRIM

I

SEATS

(

ELECTRICAL

I

EXTERIOR MOLDINGS

1

INDEX

O 1970 GENERAL MOTORS CORPORATION

LllHO IN U.S.A.

AUGUST 1970

FISHER BODY DIVISION

PART NO. 8704198

GENERAL INFORMATION 1- 1

SECTION

1

INDEX

SUBJECT PAGE

Manual Description

....................................................

1-1

Introduction

................................................................

1-1

............................................................................

,,I-1 Index

Page and Figure Numbers

Reference Tabs

Introduction

.................................

..........................................................

1-1

Text

...............................................................................

1-1

Illustrations

.................................................................

1-1

Model Identification Chart

.......................................

1-2

Model Identification

...................................................

1-3

................................................................

1-1

1-3

................................................

1-3 Body Series Number

Body Style Identification

.........................................

Body Style Name

......................................................

Body Number Plate

...................................................

Vehicle Identification Number

................................

Lock Cylinder Coding

...............................................

1

1

1

1-5

1-5

SUBJECT PAGE

Five Bitting Level Lock Cylinder and Key

Cutting Keys

......

1-5

..............................................................

1

Replacement Lock Cylinders

.................................

6

1 6

Assembly and Coding Lock Cylinders ................

1 6

Assembly and Coding Glove and Console

Compartment Lock Cylinders

................................

1-7

Glass Polishing

............................................................

1-8

Description

..................................................................

1-8

Glass Polishing Procedure

Wood Grain Transfer

Description

Removal

......................................

...............................................

..................................................................

.......................................................................

Installation

..................................................................

1-1 0

Lubrication

....................................................................

Gas Tank Fuel Emission Separator

......................

Special Tools

................................................................

1-8

1-9.

1-9

1-1 1

1-1 1

1-1 1

MANUAL DESCRIPTION

INTRODUCTION

This publication contains essential removal, installa- tion, adjustment and maintenance procedures for servicing all 1971 Fisher Body Styles. This information

is

current as of time of publication approval.

The preceding page contains a "Table of Contents" which lists the section number and subject title of each main body area section. The first page in each main body area section has an index to the subjects included

in

that section. An alphabetic index covering entire manual is located

in

section 17.

PAGE AND FIGURE NUMBERS

All page numbers and figure numbers consist of two sets of digits separated by a dash. The digits preceding dash identify main body area section. Digits following dash represent consecutive page number or figure number within the particular body area section.

REFERENCE TABS

The first page of each section is marked with a ready- reference black tab corresponding with table of contents page.

TEXT

Unless otherwise specified, each service procedure covers all body styles. Procedures covering specific styles are identified by style number, body series number, body

type

letter or similar designation. A description of these designations is covered in this section under "Model Identification".

ILLUSTRATIONS

Where possible, illustrations are placed

in

close proximity to accompanying text and should be used as part of the text.

1.2 GENERAL INFORMATION

Division.

MODEL IDENTIFICATION CHART

Sales Name Body Type Series Styles

Chevrolet Chevelle Nomad

Chevelle "300" Deluxe

Chevelle Malibu

Concours Estate

Monte Carlo

Biscayne

Be1 Air

Impala

Caprice

Camaro

Nova

A

A

A

A

A

B

B

B

B

F

X

Pontiac Tempest T-37

Tempest LeMans

Tempest LeMans Sport

Tempest GTO

Grand Prix

Catalina

Brougham

Bonneville

Grand Ville

Firebird

Oldsmobile F-85

Cutlass

Cutlass Supreme

442

Vista-Cruiser

Delta 88

Delta Custom 88

Delta Royale 88

Delta .Cruiser 88

Ninety Eight

Ninety Eight Luxury

Toronado

Toronado Deluxe

GENERAL INFORMATION 1-3

MODEL IDENTIFICATION CHART (Cont'd.)

Division

Buick

Sales N,ame

Skylark

GS

Skylark Custom

Le Sabre

Le Sabre Custom

Estate Wagon

Centurion

Electra "225"

Electra "225" Custom

Riviera

Body Type Series Styles

27-37-69

36-37-67 (36 Sport Wagon)

37-39-67-69

C

C

E

A

A

A

B

B

B

B

Cadillac

Fleetwood Brougham Sedan

Calais

DeVille

Fleetwood Seventy-Five

Eldorado

GM of

Canada

Acadian

Acadian

GM of

Canada

Pontiac

Laurentian

Parisienne Brougham

MODEL IDENTIFICATION

BODY SERIES NUMBER INTRODUCTION

Due to variety of body styles available, certain body styles have been grouped in this publication as an aid to identification. These group designations may be used individually or in various combinations. In addition to model identification chart, an explanation of principal categories follows:

The body series number may be used to indicate two possibilities:

1. Division

- first digit and four zeros (ex. 10000

Chemlet; 20000 Pontiac).

1-4 GENERAL INFORMATION

2. Division, Car Line and Style Group

- first three digits and two zeros (ex. 25200 Catalina; 25800

Brougham).

BODY STYLE IDENTIFICATION

The last two digits of the body series number indicate body style

type

as follows:

STYLE DESCRIPTION

23

27

33

35

36

37

39

45

46

43-

49

56

57

66

67

69

4-Door

2-Door

4-Door

4-Door

4-Door

2-Door

4-Door

-

Limousine with Auxiliary Seat

-

Notch Back

-

Pillar Coupe

-

Limousine with Auxiliary Seat and Center Partition Window

-

Station Wagon

-

2 Seat

-

Station Wagon

Acting Tail Gate

-

Notch Back

-

Hardtop Coupe

-

Notch Back

-

-

2 Seat

-

Dual

Hardtop (4 Win-

4-Door

4-Door

2-Door

4-Door

4-Door

2-Door

4-Door

2-Door

4-Door dow) Sedan

-

Station Wagon

-

3 Seat

-

Station Wagon

-

3 Seat

-

Dual

Acting Tail Gate

-

Notch Back

-

Hardtop Coupe

-

Notch Back

-

Hardtop (4 Win- dow) Sedan

-

Station Wagon

-

2 Seat

-

Dual

Acting Tail Gate

-

Notch Back

-

Hardtop Coupe

-

Station Wagon

-

3 Seat

-

Dual

Acting Tail Gate

-

Convertible Coupe

-

Notch Back

-

Pillar (4 Win- dow)Sedan

BODY

The body number plate identifies the model year, car division, series, style, body assembly plant, body number, trim combination, paint code and date build

D I V I S I O N SERIES

77

80

87

2-Door

2-Door

2-Door

-

Plain Back Pillar Coupe

-

Pick-Up Delivery

-

Plain Back

-

Hardtop Coupe

BODY STYLE NAME

Body style names are used for group classification as follows (style numbers suffix shown in brackets):

1. Closed Style

A.

Two-door coupe (27,77)

B. Four-door sedan (69)

C. Limousine (23,33)

2. Hardtop

A. Sport coupe hardtop (37,47, 57, 87)

B. Sedan hardtop (39,49)

3. Station Wagon

A. Station wagon two seat (35-36, less skylight; 56 with skylight)

B. Station wagon three seat (45-46 less skylight;

66 with skylight)

4. Convertible Coupe (67)

5. Sedan Delivery (80) code (Figs. 1-1 and 1-2). On all "B", "C", "D" and

"EM bodies, plate is located on right upper portion of horizontal surface of shroud. On all other bodies, plate is located on left upper portion of horizontal surface of shroud.

Fig. I-l-Body Number Plate

-

U.S. Models

THIS VEHICLE CONFORMS TO ALL U S FEDERAL

MOTOR VEHICLE SAFETY STANDARM APPLICABLE

AT TIME OF MANUFACTURE

- -- - --

Fig. I-2-Body Number Plate

-

Canadian Models

GENERAL INFORMATION 1-5

VEHICLE IDENTIFICATION NUMBER

The Vehicle Identification Number (serial number) is located- on left horizontal surface of instrument panel which is visible from outside the car (Figure 1-3 shows a typical installation).

Fig. 1-3-Typical Vehicle Indentification Number

LOCK CYLINDER CODING

FIVE BITTING LEVEL LOCK CYLINDER

AND KEY

AU

1971 style cars are equipped with new lock cylinders and keys. The keyway has been revised

so

that prior model keys will not enter current model lock cylinders. h o non-interchangeable keyways are used on 1971 model cars. One keyway, known as type "A", is used

-

-

POSITION LEVELS

1-6 GENERAL INFORMATION in all ignition, front door and station wagon tail gate lock cylinders. Type "A" keys will have,a square head and be marked similar to keys used for 1970 styles, except that capital letter "A" will be located on shank just below coining on head, in place of capital letter

"J". In addition, a code number within the series OAOO to 9A99, or OBOO to 9B99 will be stamped on knock-out portion on keyhead. This number identifies the lock combination and is used when ordering or making new keys.

The second keyway, known as type "B", is used in instrument panel compartment, console compartment, rear compartment and station wagon rear floor compartment lock cylinders. Type "B" keys will have oval heads and will be similar to keys used for 1970 styles, except that capital letter "B" will be stamped on shank just below coining on head, in place of capital letter "K". In addition, a code number within the series OCOO to 9C99, or OD00 to 9D99 will be stamped on knock-out portion of key head. This number identifies the lock combination and is used when ordering or making new keys.

Keycode numbers are stamped on "knockout" plug in key head (to facilitate replacement or duplication of key). After code number has been recorded by owner, plugs should be knocked out of key head. From these numbers, lock combination can be determined by use of a code list (available to owners of key cutting equipment from equipment suppliers). If key code numbers are not available from records or from

"knock-out" plug, lock combination (tumbler numbers and position arrangement) can be determined by laying key on diagram in Figure 1-4.

CUTTING KEYS

After the special code has been determined, either from code list or Key Code Diagram (Figure 1-4) cut blank key to the proper level for each of six tumbler positions, and check key in lock cylinder. The new key should agree with combination opposite code number in code list.

REPLACEMENT LOCK CYLINDERS

New lock cylinders are available from Servicing Parts

Warehouses with new lock cylinder locking bar staked in place. Tumblers are also available and must be assembled into cylinder according to procedure outlined below.

ASSEMBLY AND CODING LOCK

CYLINDERS

All Lock Cylinders Except Glove And

Console Compartments

Tumblers for all locks except glove and console compartments are shaped exactly alike, with the exception of notch position on one side. As the key is inserted in lock cylinder, tumblers are raised to correct height so that notches on each tumbler are at same level. When the notches on all six tumblers line up, locking bar is pushed into the notches by two small springs, allowing cylinder to turn in its bore. Five types of tumblers are used to make all various lock tumbler combinations and each is coded according to a number, 1 through 5, stamped on its side.

1. Determine lock cylinder tumbler numbers and tumbler arrangement by use of numerical key code lock cylinder code list. Code lists are made available to owners of key cutting equipment by equipment suppliers.

NOTE: To determine which tumblers should be installed in what position for a given key, when a code list is not available, proceed as follows: a. Lay key on Key Code Diagram (Figure 1-4) with key outlined by diagram as accurately as possible. b. Starting at head of key blade, determine and record lowest level (tumble& number) that is visible in position No. 1 and subsequent position numbers 2 through 6. After tumbler numbers and arrangement have been deter- mined, assemble as outlined in following steps.

2. Starting at open end (head) of cylinder, insert tumblers in their proper slots in the order called for by the code, as shown in Figure 1-5.

3. Pull out side bar with fingers so that tumblers will drop completely into place (Fig. 1-5). Insert one tumbler spring in space provided above each tumbler.

\

Fig. 1-5-Installing Tumblers

GENERAL INFORMATION 1-7

TUMBLER S P R I N G R E T A I N E R 7

;TAKE

! E T A l N E R

{ E R E

L O C K C Y L I N D E R H

4 TUMBLER

C Y L I N D E R

5 TUMBLER

LOCK CYLINDER

( L O C K I N G D E V I C E

Fig. 1-6-Installing Spring Retainer Fig. 1-7-Glove Compartment Lock Cylinder

NOTE: IF THE SPRINGS BECOME TANGLED,

DO NOT PULL THEM APART

-

UNSCREW

THEM

4. Insert spring retainer so that two end prongs slide into the slots at either end of cylinder. Press retainer down (See Figure 1-6).

5. To determine if tumblers have been properly installed, insert key into lock cylinder. If tumblers are installed properly, side bar will drop down. If bar does not drop down, remove key, spring retainer, springs and tumblers and reassemble correctly.

NOTE: If tumblers have not been assembled correctly, they can be removed from cylinder by holding cylinder with tumbler slots down, pulling side bar out with fingers and jarring cylinder to shake tumblers out. This procedure is necessary because once tumblers have been pressed down into the cylinder they are held in their slots by side bar.

6. If, after checking, it is found that lock cylinder is assembled properly, remove key and secure cylinder in a vise with spring retainer exposed.

NOTE: Use leather or wood at each vise jaw to prevent damage to cylinder.

7. Using suitable staking tool, stake spring retainer securely in place by staking cylinder metal over retainer at each end. Refer to Figure 1-6.

ASSEMBLING AND CODING GLOVE

AND CONSOLE COMPARTMENT

LOCK CYLINDERS

Only one

type

of tumbler is used to make various l d k tumbler combinations for glove and console compart- ment locks. Tumblers for these two lock cylinders are pre-assemblied in service replacement lock cylinder and require that correctly coded key be inserted in cylinder before and during cylinder coding.

As key is inserted in coded lsck cylinder, each tumbler is depressed so that no part of any tumbler is exposed above level of lock cylinder thereby allowing cylinder to turn in its bore.

NOTE: These two lock assemblies are equipped with four or five tumblers rather than six as used in other locks. Tumblers are used in positions 3-4-5-6 or 2-3-

4-5-6 only. Tumblers which correspond to positions 1 and/or 2 on key are not used. The non-brass, black

"tumbler" that is closest to head of four tumbler lock cylinder is a locking device and must NOT be removed or filed See Figure 1-7.

1. Insert properly coded key in cylinder.

2. Place cylinder in vise, bottom side up, using

I

L O C K C Y L I N D E R R E T A I N E R

4 T U M B L E R

I

3 5 4 9

Fig. 1-8-Coded Glove Compartment Cylinder

1-8 GENERAL INFORMATION leather or wood at each vise jaw to prevent damage to cylinder.

3. File tumblers down so that no part of any tumbler extends above lock cylinder.

NOTE: Do not file any part of the non-brass, black "tumbler" (retainer) on four tumbler lock cylinders. This is a locking bar and should not be altered.

4. Reverse lock cylinder position in vise and repeat step No. 3 for top of tumblers See Figure 1-8.

GLASS POLISHING

REMOVAL OF MINOR SCRATCHES

AND ABRASIONS

Description

Minor glass scratches and' abrasions can be effectively removed or substantially reduced by utilizing proce- dure and precautions presented in this section. The phases of glass polishing discussed in this section include equipment required, recommended procedure and precautions necessary.

There are two basic types of automotive glass: (1) laminated safety plate (all windshield and skylight glass) and (2) solid tempered safety plate (all side windows and back glass, except skylight).

A major concern in glass polishing is preventing double vision from developing in areas that will distort driver's vision. For this reasbn, less polishing can be done on windshield in driver's line of vision than in other areas. Distortion is most likely to result when attempting to remove deep scratches.

Glass polishing is an operation that must be performed with reasonable care.

NOTE: This operation must not be performed on inside surface of rear window glass equipped with rear window electric grid defogger (heating elements in glass).

The equipment and procedures recommended here were developed using cerium oxide compound (Glass-

Nu or equivalent). Follow manufacturer's directions if other materials are used.

The following equipment is recommended for glass polishing:

1. A low speed (600-1300 RPM) rotary polisher (Ski1

Model No. 570 or equivalent).

2. A wool felt rotary-type polishing pad, approxi- mately three inches in diameter and two inches thick.

3. Powdered cerium oxide (Glass-Nu or equivalent) mixed with water as the abrasive compound.

I

1

1

4. A wide mouth container to hold the polish.

Glass Polishing Pracedura

1. Mix at least three heaping tablespoons of cerium oxide (Glass-Nu or equivalent) with sufficient water to obtain a creamy consistency.

NOTE: If a larger proportion of cerium oxide

(Glass-Nu or equivalent) is used, compound cakes on the felt pad faster. If a smaller proportion is used, polishing time required will increase.

2. Agitate mixture occasionally to maintain a creamy consistency. Powdered cerium gxide is insoluable in water and tends to separate.

3. Draw circle around scratches on opposite side of glass with marking crayon or equivalent. Draw other lines directly behind scratches to serve as guides

1-9).

in

locating scratch during palishing (Fig.

4. Use masking paper where needed to catch drippings or ipat&ed polish.

MOLD PAD FLA

Fig. 1-9-Minor Glass Scratch Removal

GENERAL INFORMATION 1-9

Dip felt pad attached to polisher into mixture several times to insure that pad is well saturated.

NOTE: Never submerge or allow pad to stay in mixture as it may loosen bond between pad and metal plate.

Using moderate, but steady, pressure, hold pad flat against scratched area of glass, and with a feathering-out motion, polish affected area as shown in Figure 1-9.

NOTE: Avoid excessive pressure. It does not speed-up operation and may cause overheating of glass.

Cover sufficient area 'around scratch with a feathering-out motion as shown in Figure 1-9, to eliminate any possibility of a "bulls-eye".

NOTE: Never hold tool in one spot or operate tool on the glass any longer than 30 to 45 seconds at a time. If glass becomes hot to touch, let it air cool before proceeding further. Cooling with cold water may crack heated glass.

8. Dip pad into mixture about every fifteen seconds to insure that wheel and glass are always wet during polishing operation. A dry pad causes excessive heat to develop.

9. After removing scratch or abrasion, wipe body clean of any polish.

10. Clean polishing pad.

NOTE: Care should be taken during polishing and storage to keep pad free of foreign material such as dirt, metal filings, etc.

WOOD GRAIN TRANSFER

(STATION WAGON STYLES)

DESCRIPTION AND

GENERAL INFORMATION

Wood grain transfers of all-vinyl construction are used on 1971 model station wagons. The transfers incorporate a pressure sensitive adhesive. The transfers are designed with an appealing wood grain pattern and a 50 degree or semi-gloss finish.

For service replacement, transfers are available through parts warehouses. When placing orders for transfers, carefully indicate "~ivision"( "Model Year''

"Body Style" and applicable car panel to determine correct part.

The following general information and procedures apply to replacement of transfers in service.

For quality results, the temperature of transfer, panel surface and work room should be between 65 degrees fahrenheit and 90 degrees fahrenheit. Transfers should not be replaced in temperatures below 65 degrees fahrenheit. the rocedure, by adding 114 ounce of detergent

("Jof', "Vel", or equivalent) to one gallon of dean water.

Use of wetting solution, as specified, insures a better bond between transfer and painted surface. Deviating from specifications, such as using too much detergent or using a soap solution, is detrimental to bond of transfer.

\

Transfer replacement invojving collision damage, or damage to underlying acryllc paint finish requires that metal repair and/or refinish operations be carried to completion before transfer is installed.

The purpose of a proper squeegee sequence is to drive out all water and air. With proper tool, use progressive, overlapping strokes and work from center outwardly. At the same time, firm squeegee strokes provide required pressure for proper bonding of transfer adhesive to painted surfaces.

Scuff-sanding an acrylic finish before transfer installation with No. 360 or No. 400 sandpaper promotes better adhesion, and removed dirt nibs and high spots.

The following equipment and materials are necessary in making d quality transfer installation. Equivalent products ahn be used.

Liquid detergent: "Joy", "Vel" or equivalent.

Wax and Silicone Remover: "Prep-Sol", "Pre-

Kleano", "Acryli-Clean" or equivalent.

3-M vinyl Trim Adhesive or equivalent; brush or

/ spray-can. /

\

Squeegee: 4" to 5" wide; plastic or hard rubber.

Water bucket and sponge.

Sandpaper, No. 360 or No. 400, Type.

Infra-red heat bulb and extension cord

1-10

GENERAL

INFORMATION

8. Clean wiping rags or paper towels.

9. Sharp knife.

10. Scissors.

1 1. Fine pin or needle.

Removal

Wash and clean repair surfaces and adjacent panels and openings as required.

Remove transfer finishing moldings, handles, side marker lamps, and/or other transfer overlapping

Pa".

Remove affected transfer by starting at one edge and by peeling transfer as sheet from surface.

Application of heat to affected transfer at point of removal aids removal operation.

IMPORTANT: Avoid using pointed or sharp instruments during transfer removal as they may damage paint finish.

Installation

1. Scuff-sand acrylic painted surface with No. 360 or

No. 400 sandpaper by dry sanding. Freshly painted surfaces must be allowed to dry thoroughly. Residual solvents in fresh paint can lead to subsequent blistering problems.

2. Clean acrylic painted surface with wax and silicone remover, such as: Prep-Sol; Pre-Kleano;

Acryli-Clean; or equivalent. Wipe surface with clean cloth, and allow to dry. Use compressed air to blow away loose dirt from area of repair.

3.

Apply vinyl trim adhesive to door hem flanges and to rear body lock pillar facing that will be covered by transfer.

4. Peel paper backing from transfer atid lay transfer, face down, on clean table.

5. Using clean sponge, apply ample wetting solution to transfer adhesive and to repair panel surface.

6.

Align

upper edge and ends of transfer with panel surface and press down lightly across top.

7. Squeegee outboard from middle to edges of transfer with firm strokes to remove all air bubbles and wetting solution and to assure bonding of film to painted surface. On large transfers, the following sequence of operations will simplify transfer installation: a. Squeegee a short, 4 to 6 inch, horizontal section of transfer at center of panel. Lift right or left side of transfer, position it straight and close to panel, and squeegee toward lifted edge.

Avoid stretching transfer at lifted end.

Squeegee progressively from middle with firm, overlapping strokes. b. Lift upper area of transfer (up to bonded area of step "a" above) and, working upward from

- into place. c. Lift lower area of transfer (up to bonded area) and, working downward from bonded section at middle, squeege transfer into place.

IMPORTANT: If wrinkle is trapped during squeegee operations, stop immediately. Care- fully lift affected transfer section. Align affected section to surface and progressively squeegee it into place. Do not lift transfer if only a few tiny bubbles are trapped. d. Secure opposite half of transfer to surface as described;n steps "a", "b" and "cu, above.

8. Notch out corner or curved edges of transfer where necessary. Where necessary, trim off excess material at edges.

9. With heat lamp, heat inboard side of door hem flanges (or body lock pillar facing, etc.) and edges of transfer film (to approximately 90 degrees fahrenheit).

10. Fold ends of transfer over door hem flanges (or over corners at panel ends) and press to secure edges of transfer to panel surfaces. Avoid undue pulling or stretching at ends as tearing could result.

11. Apply heat to transfer at door handle holes, side marker lamps and other depressions. Press transfer uniformly into depressions to obtain formed bond.

12. With sharp knife, carefully cut out excess transfer at side marker lamps, door handle holes, and other openings in panel.

/

13. Inspect transfer installation from critical angle using adequate light reflection to detect any irregularities that may have developed during installation. Remove all air or moisture bubbles by piercing each at an acute angle with a fine pin or needle and by pressing the bubble down.

(4. Install previously removed parts and clean up car as required.

GENERAL INFORMATION 1

-

1 1

.GENERAL MAINTENANCE

The mechanical parts of the body that have contacting surfaces which operate in relative motion with other body parts are lubricated during assembly. To maintain,ease of operating effort, it is recommended that these parts be lubricated on a periodic basis with lubricants as follows:

1. All hinges (door, compartment lid and tail gate) are to be lubricated every six (6) months with

Auto-Lube "A", Part No. 10501 10, or Spray-Lube

"A", Part No. 1050520 or equivalent.

2. All locks (door, compartment lid and tail gate) are to be lubricated every six (6) months with Auto-

Lube "A", Part No. 10501 10, or Spray-Lube "A",

Part No. 1050520 or equivalent.

3. Torque rods and hold-open supports (compart- ment lid a@ "B" style tail gate) are to be lubricated every six (6) months with Auto-Lube

"A", Part No. 10501 10, or Spray-Lube "A", Part

No. 1050520 or equivalent.

The lubrication requirements for seat mechanism, door window hardware, convertible top mechanism, tail gate hardware, and windshield wipers are covered in the specific body area sections in this manual.

DESCRIPTION

GAS TANK FUEL EMISSION SEPARATOR

On all coupe and sedan style bodies, gas tank fuel emission separator extends upward through piercing in rear compartment pan and is attached by screws to both rear compartment pan and to forward side of rear seat back panel (cargo barrier). Tkcompartment pan attaching area requires a gasket to assure a positive seal against intrusion of fumes, dust, or water into body interior.

For information regarding removal, installation or general service procedures of fuel emission separator, refer to the applicable car division chassis service

I manual.

SPECIAL BODY TOOLS

Fig. 1-10 lists special body tools that are recommended as aids in servicing the various body components. It is to be noted that these tools may be substituted with equivalents.

NOTE: Tools 5,6 and 7 shown in Fig. 1-10 and tools 1,

2, 15 and 16 shown in Fig. 1-1 1 are new type tools for

1971.

1-12 GENERAL INFORMATION

Fig. 1

-

10-Special Body Tools

1. J-23091

-

Fabric Roof 3. J-22810

-

Door Hinge

Cover Repair Tool- Wrench-"A, B, C, E

Chevrolet. Pontiac.

Styles

2. J-21550 - Door Hinge

Wrench-"Xu Styles

(Bolt-On Service

Replacement Hinges) and F" Swles

4. J-21412 -

ear

Compartment Lid

Torque Rod Removal and Adjusting Tool-

"A and X" Styles

5. BT-7102

-

Rear

Compartment Lid

Toraue Rod Removal

"A" and Oldsmobile

"Eff Styles

6. J-23722-Rear

Compartment Lid

Torque Rod Removal and Adjusting Tool

-

Cadillac "C and E"

Styles

7. J-23719-

Retractable Tail Gate

Torque Rod

Adjusting Tool

-

"B"

Styles

8. J-23497

-

Door Hinge

Spring Compressing

Tool

-

"X" Styles

GENERAL INFORMATION 1

-

13

1. J-21549- 10

-

Reveal

Molding Remover

-

"B, C, D, E and F"

Styles (Left Hand

Operation)

2. J-2 1549- 1 1-Reveal

Molding Remover

-

"B, C, D, E and F"

Styles (Right Hand

Operation)

3. 1-21549-5

-

Reveal

Molding Remover

(Left Hand

Operations)

-

"A and

X" Styles

4. 5-21549-6

-

Reveal

Molding Remover

(Right Hand

Operations)

-

"A and

X" Styles

Fig. 1

-

1 1 -Special Body Tools

5. J-21214

-

Molding

Clip Pliers (Bath-Tub

Type Clips)-AU Styles

6. J-9886-Door Handle

Clip and Trim Pad

Remover

7. J-23394

-

All Styles

-

Glass

9.

Alignment Gauge

Block Set

-

"A and

F" Styles, Except

Convertibles

8. J-23457 or BT-7107

Door Lock Striker

-

Remover and

Adjusting Tool

-

All

Styles

J-22055

-

Window

Nut Remover-AU

,

Styles

10. J-22 128-Windshield

Wiper Arm

Removing Tool

F and X" Styles

-

"A,

1 1. J-8966-Windshield

Wiper Arm

Removing Tool

-

"A,

F and X" Styles

12. J-21092

-

Fabric Roof

Cover Trim Knife-AU

Styles

13. J-21104

-

Weatherstrip

Removing Tool-All

Styles

14. J-2772

-

Headlining

Installer-AU Styles

15. J-237 1 1-5-Glass

Alignment Gauge

Block

-

68169 Style

Rear Doors

16. J-237 1 1-Glass

Alignment Gauge

Block Set-"B, C and

EM Styles

17. J-8074

-

Hydraulic

Pressure Gauge (0-

600 1bs.)-"A"

Convertible Styles

18. J-23554-Door Trim

Pad Applique

Remover

-

All Styles

WINDSHIELD WIPER SYSTEM 2- 1

SECTION 2

INDEX

SUBJECT PAGE

Windshield Wiper System ........................................ 2-1

Description ..................................................................

2-1

Control Switches ...................................................... 2-1

Two Speed Rectangular Motor ............................. 2-1

Description

................................................................

"Lo" Speed Circuit

"Hi" Speed Circuit

Parking Circuit

................................................

.... ...........................................

2-1

2-2

2-2

........................................................ 2-2

Diagnosis

...................................

Diagnosis Chart .

......................

2-4

Wiper Motor Removal and Installation

...........

2-4

Wiper Arm Removal and Installation

Wiper Arm Adjustment

..............

........................................ 2-5

Wiper Blade Removal and Installation ............

2-5

2-5

Wiper Transmission Removal and Installation .. 2-5

Diagnosis Chart

.....................

2-8

Disassembly and Assembly Procedure

Description

. Off Car

Two Speed Round Motor

..............

2-8

.......................................

................................................................

Wiper Off Circuit ...................................................

"Lo" Speed Circuit ................................................

"Hi" Speed Circuit ................................................

Medium Speed Circuit

Parking Circuit

..........................................

........................................................

Diagnosis .

Diagnosis Chart

..................................

.....................

2-1 3

2-1 3

2-13

2-13

2-14

2-14

2-1 6

Wiper Motor Removal and Installation

Wiper Arm Removal and Installation

..........

2-17

.............

2-19

WINDSHIELD

DESCRIPTION

A two-speed wiper motor equipped with a windshield washer system is standard equipment on all models .

The non-depressed park system uses a rectangular shaped motor with wiper . blades that are visible above the hood line when in the park position

.

The depressed park system incorporates a round motor and wiper blades that park below the hood line

.

SUBJECT

Wiper Arm Adjustment

........................................

2-19

Wiper Blade Removal and Installation

............

2-20

Wiper Transmission Removal and Installation 2-21

Diagnosis Chart . Off Car

.....................

2-22

Motor Disassembly and Assembly Procedure

.

2-25

Gear Box Disassembly and Assembly

Procedure

...................................................................

Wiper Motor Adjustments

Demand Wiper System

....................................

2-26

2-29

........................................... 2-29

Description ................................................................ 2-29

Switch in First Detent Position ..........................

2-29

Diagnosis Chart

Washer System

......................................................

2-30

............................................................

2-34

Description

Rectangular Motor Washer System

.....................

Checking Procedures

Washer Pump

..............................................

Disassembly

Procedures

Round Motor Washer System

Checking Procedures

............

...............................

2-35

2-37

2-38

2-39

..............................................

............

2-41

Washer Pump Disassembly Procedures

Programmed Washer System

Description

.................................

................................................................

2-42

2-43

2-43

Switch in Second Detent Position

Washer Disassembly

...................... 2-45

........................................ 2-46

Washer Assembly .................................................... 2-48

Diagnosis-Wiper Motor on Car ..........................

Diagnosis Chart

2-49

......................................................

SYSTEM

Both systems use a tandem wipe pattern. however the depressed park system incorporates an articulated arm and blade on the left hand (drivers) side

.

CONTROL SWITCHES

For service information on control switches. refer to

Car Division Service Manuals .

DESCRIPTION

TWO SPEED-RECTANGULAR

The system consists of a compound wound rectangu- lar-shaped motor attached to a gear box containing a

\ parking switch in addition to the gear train

.

The gear train consists of a motor armature helical gearshaft which drives an intermediate gear and pinion assembly

.

The pinion gear of the intermediate gear

2-2 WINDSHIELD WIPER SYSTEM

RECMGULAR MTOR APPLICATION

I

CAB DIVISION

(

SERIES

I

GERR RATIO

I

CRAMURH I E T I g R

I

BUICK A 36:

1 AC

5055

Fig. 2-l-Rectangular Motor Application Chart and pinion drives an output gear and shaft assembly

(Fig. 2-10). A rectangular motor application chart is shown in Fig. 2- 1.

"LO" SPEED CIRCUIT

Turning the wiper switch to the "LO" speed position completes the circuits from the wiper terminals 1 and

3 to ground. Current then flows from the battery via wiper terminal No. 2 through the series field and divides; (1) part passes through the armature to ground via wiper terminal No. 1 to the wiper switch and (2) part passes through the shunt field to ground through wiper terminal No. 3 to the wiper switch (Fig.

2-2).

NOTE: The wiper switch must be securely grounded to body metal.

"HI" SPEED CIRCUIT

Moving the wiper switch to the "HI" speed position

I opens the shunt field circuit to ground at the switch.

However, the shunt field is connected to a 20 ohm resistor which is connected across wiper terminals 1 and 3. The shunt field current then flows via terminal

NO. 3 through the resistor to terminal No. 1 to the switch, to ground (Fig. 2-3).

PARKING CIRCUIT

This circuit covers that portion of wiper operation when the wiper switch is turned "off' and the wiper blades have not reached the park position.

When the wiper blades are not in the normal park position, the parking switch contacts are still closed.

The wiper will continue to operate until the wipet output gear is turned to a position where it's cam opens the park switch. Referring to Fig. 2-4 it can be seen that the wiper motor circuits are completed to ground through the parking switch.

NOTE: The wiper motor must be securely grounded to body metal.

The shunt field circuit is completed from terminal No.

3 via the switch to terminal No. 1 thjough the parking switch to ground. The series field and armature circuit is also completed from terminal No. 1 through the parking switch to ground.

NOTE: The shunt field is connected direct to ground by-passing the resistor. This results in "LO" speed operation during the parking operation.

When the output gear cam opens the park switch contacts, the wiper is "OFF".

DIAGNOSIS-WIPER ON CAR

1. Inspect for the following items:

SWITCH

SHUNT F

-

NAT

.

WIRE

SWITCH

Fig. 2-2-"Lo" ~ p & d

3992

WINDSHIELD WIPER SYSTEM 2-3 a. Wiring harness is securely connected to wiper and switch. b. Wiper motor is securely grounded to body. c. Wiper switch is securely mounted and grounded. d. Check fuse.

2.

If items in Step 1 check out, try operating wiper in both "LO" and "HI" speeds, then turn wiper off

(blades should return to park position). If wiper fails to operate correctly, proceed to Step 3.

3. Disconnect wiring harness from wiper and try operating wiper as shown in Fig. 2-5.

I

Fig. 2-3-"Hi" Speed Circuit a. If wiper operates correctly iqdenpendently of switch and car wiring, refer'to the DIAGNO-

SIS CHART

-

WIPER ON CAR. b. If wiper still fails to operate correctly in Step 3, disconnect wiper linkage from motor cran- karm and try operating wiper again. If wiper operates correctly independently of linkage, check linkage for cause of wiper malfunction. c. If wiper fails to operate correctly indepen- dently of linkage, remove wiper motor from

-.

-

LAK.

DASH

Fig. 4-4-Parking Circuit

SWITCH

2-4

WINDSHIELD WIPER SYSTEM

DIAGNOSIS CHART

-

WIPER ON CAR

IMPORTANT: electrical tests.

Ignition switch must be "on" for all

NOTE: wiper wiring and switch.

CONDITION APPARENT CAUSE correctly independently of car

CORRECTION

1. Wiper Inoperative or intermittent

A. Blown fuse. A. Locate short circuit and repair. Replace fuse.

B. Locate broken wire and repair. B. Open circuit in feed wire

(No. 2 terminal on wiper motor)

C. Loose mounting of wiper switch C. Tighten switch mounting

D. Defective wiper switch

E. Open circuit in wire to wiper switch (No. 1 terminal on wiper motor)

D. Replace switch

E. Locate broken wire and repair

2. Wiper will not shut off:

A. Wiper has both "Lo" and

"Hi" speeds

B. Wiper has "Lo" speed only

A. Grounded Wire (No. 1 terminal on wiper motor) to wiper switch

A. Locate short circuit and repair

A. Defective wiper swi.tch

B. Grounded wire (No. 3 terminal on wiper motor to wiper switch)

A. Defective wiper switch

A. Replace wiper switch

B. Locate and repair short circuit

A. Replace wiper switch. C. Wiper has "Hi" speed only

B. Open circuit in wire (No. 3 terminal on wiper motor) to wiper switch.

B. Locate and repair broken wire.

3. Wiper has "Hi" speed only

-

A. Open circuit in wire (No. 3 terminal on wiper motor)

- to wiber switch

- - - --

4.

Wiper has "Lo" speed only A. Grounded wire (No. 3 terminal on wiper motor to wiper switch)

A. Locate broken wire and repair.

- - -

A. Locate short circuit repair

&

5. Blades do not return to full park position

A. Loost wiper ground strap connection

B. Replace wiper switch

A. Tighten strap connection

Wiper Motor Removal and Installation

1 . Raise hood and remove cowl screen or grille.

2.

Reaching through cowl opening, loosen the transmission drive link attaching nuts to motor crankarm.

3. Disconnect transmission drive link from motor crankarm.

4. Disconnect wiring.

5. Disconnect washer hoses.

6. Remove three motor attaching screws.

7. Remove motor while guiding crankarm through hole.

-8. To install, reverse the removal procedure.

WINDSHIELD WIPER SYSTEM 2-5

LO SPEED

-

AS SHOWN

H I SPEED

-

DISCONNECT JUMPER WIRE FROM

TERMINAL NO. 3.

OFF

-

LEAVE JUMPER CONNECTED TO NOS. 1 & 3 BUT

D l SCONNECT I T FROM GRD. STRAP. W l PER SHOULD

STOP WITH GEAR SHAFT FLATS AS SHOWN. the arm(s) from the serrated transmission shaft, rotate the arm(s) the required distance and direction and reinstall to transmission shaft.

NOTE: Wiper motor must be in park position.

Wiper Blade Removal and Installation

Two methods are used to retain wiper blades to wiper arms (Fig. 2-7).

One method uses a press type button. When the button is depressed the blade assembly can be separated from the arm.

W l PER

GROUND STRAP

Fig. 2-5-Jumper Wire Connedons

3999

The other method uses a coil spring retainer. A screw driver must be inserted on top of the spring and the spring pushed downward (Fig. 2-7). The blade assembly can then be segaxated from the arm.

Wiper Arm Removal and Installation

1. To remove the wiper arm and blade assemblies use tool J-22128 or J-8966, or equivalent, to minimize the possibility of windshield or paint finish damage during removal operation.

2. To install the wiper arm and blade assemblies, with the wiper motor in the park position, install the wiper arm on the serrated transmission shaft in a position where the wiper blades will rest in the proper parked position.

The parked position for "F" styles is indicated in

Figure 2-6. On "A-Xu styles, the tip of the left blade should rest 1.50" above top edge of windshield lower reveal molding. The tip of the right blade should rest 1.95" for "A" styles and

125" for "Xu styles above top edge of windshield lower reveal molding. The outwipe dimension shown in figure 2-6 is as follows:

A. All "A" styles

-

1.54" plus 1 .lou or minus .5"

B. All "F" styles maximum.

-

.5" minimum to 2.25"

C. "Xu styles

-

7/8".

Wipetr Arm Adjustment

\

The only adjustment of the wiper arm(s) is to remove

Two methods are also used to retain the blade element in the blade assembly (Fig. 2-7).

One method uses a press type button. .When the button is depressed, the two-piece blade assembly can be slid off the blade element.

The other method uses a spring type retainer clip in the end of the blade dement. When the retainer clip is squeezed together, the blade element can be slid out of the blade assembly.

When installing a blade element into a blade assembly, be certain to engage the meial insert of the element into all retaining tabs of the blade assembly.

IMPORTANT: When properly installed, the element release button, or the spring type element retaining clip should be at the end of the wiper blade assembly nearest the wiper transmission.

Wiper Transmission Removal and lnstallation

1. Remove wiper arms and blades as described under

Wiper Arm Removal and Installation.

2. Raise hood and remove cowl vent screen or grille.

3. Loosen, do not remove, transmission drive link to motor crankarm attaching nuts (Fig. 2-6) and disconnect drive link from crankarm.

2-6 WINDSHIELD WIPER SYSTEM

DRIVE LINK

/

VIEW "A"

4239

Fig. 2-6-Wiper Installation and Wipe Pattern

-

"F" Styles

-- -

WINDSHIELD WIPER SYSTEM 2-7

4. Remove right and left transmission to body attaching screws and guide transmission

and

linkage assembly out through cowl plenum chamber opening.

5. To install, place transmission and linkage assembly in plenum chamber and install transmis: sion.to body attaching screws loosely.

6. Connect transmission drive link to motor cran- k a r q and tighten attaching nuts (20-28 inch pounds torque).

NOTE: Wiper motor must be in park position.

7. Align transmission assemblies and tighten trans- mission to body attaching screws.

8. Install cowl vent screen or grille.and close hood.

9. Install wiper arms and blades and check wiper operation, wipe pattern and park position-of blades.

TEST LIGHT PROBES FOR

GROUND CHECK. I F LAMP

LIGHTS, ARMATURE I S

GROUNDED,

Fig. 2-7-Wiper Blade Assemblies

COMMUTATOR HOOK

CHECK FOR

/ fi

TEST LIGHT

PROBES,

POOR WELD

JOINTS

BAR TO BAR CHECK

FOR OPENS

-

LAMP

SHOULD LIGHT BETWEEN

ADJACENT BARS

4068

Rg. 2-8-Checking Armature Fig. 28-Testing Field Coils

2-8 WINDSHIELD WIPER SYSTEM

DIAGNOSIS CHART

(SEE FIGURES

-

WIPER OFF CAR

2-5,

2-8 and 2-9)

I

CONDITION APPARENT CAUSE CORRECTION

1. Wiper Inoperative or

Intermittent

A. Broken or damaged gear train

(only if inoperative)

B.

Poor solder connections at terminal board

C. Loose splice joints at brush plate

D. Brushes binding in brush holder

A. Replace gears as required

B. Resolder wires at terminals

C. Recrimp or solder splice joints

D. Clean holder or replace brush,

Spring or brush plate assembly.

E. Replace armature E. Open circuit in armature

2. Wiper will not shut-off:

A. Wiper has normal "Hi" and

"Lo" speed

A. Defective park switch

B. Grounded red lead wire

3. Wiper shuts off in park position

- but not

4. "Hi" speed to fast

A. Grounded shunt field coil

B. Grounded black wire

A. Open circuit in shunt field coil

B. Open circuit in black wire

A. Park switch defective or contacts dirty

A. Resistor defective

A. Replace terminal board assembly

B. Repair short circuit in red wire

6

A. Replace frame and field assembly

B. Repair short circuit in black wire

A. Replace frame and field assembly

B. Repair broken wire or poor solder connection

A. Replace terminal board assembly or clean contacts

A. Replace terminal board assemblv

DISASSEMBLY-ASSEMBLY PROCEDURE

The disassembly-reassembly procedures for the wiper are broken down into two major areas: the motor section and gear box section.

Gear Box Disassembly

1. Remove washer pump as follows: a. Remove the two washer pump mounting screws and carefully lift the washer pump off the wiper motor. b. Remove the washer pump four lobe drive cam.

The cam is a press fit on the wiper gearshaft and it may be necessary to pry off with a screw driver or similar tool. c. Remove the felt washer from the wiper gearshaft.

2. Clamp crankarm in a vise and remove crankarm retaining nut.

NOTE: Failure to clamp crankarm may result in

, stripping of wiper gears.

I N T E R M E D I A T E

WINDSHIELD WIPER SYSTEM 2-9

G E A R $ O X C O V E R

AND T E R M I N A L

BOARD ASSEMBLY CRANK A R M

Fig. 2-10-Gear Box

3. Remove crankarm, seal cap, Tru-Arc retaining ring and end play washers (Fig. 2-10). assembly are included with a replacement assembly.

NOTE: Seal cap should be cleaned and repacked with a waterproof type grease before reassembly.

4. Drill out staking that secures gear box cover (Fig.

2-1 1). Use a 9/32" drill.

NOTE: Mark ground strap location and save glpund strap for reassembly.

5.

Remove output gear and shaft assembly; then, slide intermediate gear and pinion assembly off shaft.

I

'

6. If required, remove terminal board and park switch assembly as follows:

I

I

\ a. Note position of motor leads on terminals, then unsolder.

I

1 b. Drill out rivets that secure terminal board and park switch ground strap to plate. Use a 7/64" drill.

NOTE: Screws, nuts and washers for attaching a replacement terminal board park switch

I

Gear

Box Reassembly

NOTE: Lubricate all gear teeth with lubricant noted on specifications chart Fig. 2- 17.

1. If park switch and terminal board assembly were

GROUND STRAP

LOCATION

I

ALIGNMENT MARKS FOR

I

INSTALLING CRANKARM

--

Fig. 2-1 1-Staking Locations

2-10 WINDSHIELD WIPER SYSTEM

Fig. 2-12-Parking Switch and Terminal Board removed, reinstall replacement assembly using the attaching screws and nuts included in the service package. Resolder leads to terminals (Fig. 2-12).

2. Install wave washer and intermediate gear on intermediate gearshaft.

3. Install output gear and shaft assembly with cam at least 90 degrees away from park switch (Fig.

2- 13).

4. Assemble gear box cover to wiper. Be careful to locate cover over locating dowels and intermedi- ate gearshaft.

5. Secure cover to gear mounting plate over dowels.

Be sure to reinstall ground strap.

NOTE: Screws, nuts and lockwashers for reassem- bling cover to wiper are contained in a Service

Repair Package.

6. Reassemble end play washers and retaining ring over output gearshaft (Fig. 2-10). Use end play washers as required to obtain .005" maximum end play

7. Install seal cap.

8. To reassemble crankarm in proper position, operate wiper to park or "OFF" position (Fig.

2-5) and install crankarm so that index marks on crankarm line up with those on the gear box cover

(Fig. 2-1 1).

NOTE: Clamp crankarm in vise before securing the retaining nut.

9. Operate wiper (Fig. 2-5) and check performance per data in specification chart (Fig. 2-17).

I

Fig. 2-13-Gear Installation

10. Reinstall washer pump to wiper.

Reinstall washer pump to wiper, reversing removal

Steps 1 (a) through 1 (c). Observe precautions listed below.

1. Support crankarm end of wiper output shaft

(threaded end) and using a suitable mallet, drive the four lobe cam on the wiper output shaft until it bottoms against the shoulders of the shaft flats

(Fig. 2-10).

2. Position four lobe cam as shown in Fig. 2-14. It may be necessary to manually rotate crahcarm.

\

Fig. 2- 14-Cam Positioning

WINDSHIELD WIPER SYSTEM 2-1 1

- --

Motor Disassembly

1. Disassemble gear box as required to gain access to internal solder connections at wiper terminal board and unsolder motor leads from terminals.

NOTE: Step 1 necessary for frame and field replacement only.

2. Remove motor tie bolts (Fig. 2-15).

3. Hold end cap against frame and field and disengage complete motor section from gear box.

4. Turn motor section as required to gain access to brush plate assembly and release brush spring pressure against brushes (Fig. 2- 16).

5. Move brushes away from armature commutator and remove armature and end cap from frame and field assembly.

6. Remove end cap from end of armature shaft.

NOTE: Be careful not to lose the plastic thrust plug in end of armature.

7. Remove end play washers from commutator end of armature shaft. When reassembling armature in wiper, install washers as shown in Fig. 2-15.

8. To replace brushes, cut brush pigtail approxi- mately 114" from splicing clip. Splice the new brush pigtail to the 114" of pigtail left from the original brush.

NOTE: Splicing clips are provided in the replacement brush packages.

I

BRUSH RAM AND RAT W A S M 3 S DID U P

I

I REMOVE BRUSH SPRING FROM SLOT AND

PLACE IT IN GROOVE AS SHOWN

Fig. 2-16-Removing Brush Spring Tension

6

Motor Reassembly

Reverse disassembly Steps 1 through 7 and reassemble gear. Lubricate the motor assembly as indicated in

Specification Chart, Figure 2-17.

I

NOTE: Insure brush plate mounting brackets are properly seated into housing.

SPECITICATION CHART

I

Operating voltage

. . . . . . . . . . . . . . . . . . . .

12 Volta D.C.

Current Draw (No Load)

"Lo" S p e e d .

"Hi" Speed

. . . . . . . . . . . . . . . . . . . . . .

4 AMPG W.

. . . . . . . . . . . . . . . . . . . . . . .

3.5

IUIP6 W.

S t a l l (Cold k t o r )

. .

#

. . . . . . . . . . . . . . . .

1 2 AMFS MY..

I

E n n k a n Speed ( E l l ' . )

H n . "Lo" Speed

" H i U S p e e d . .

12 V

1 2 V

I

I

I

WASHER ARRANGEMENT

Fig. 2- 15-Wiper Motor-Exploded View

Washer Pmp k t o r T i e B o l t s

. . . . . . . . . . . . . . . . . . . . . . k t o r Crankarm Attsching Nut k t o r To m d y Attaching m l t a

. . . . . . . . .

18

. . . . . . . . . . . . . . . . 30

65 k t o r Crsnkarm To Tnnemimion Drive Link

R a n m i s s i o n To Body Attsching m l t a

20

-

28

35

. . . . . . . . . . . .

35

Lubrication

Armature S h s f t end

A l l Gear Teeth

1016

Fig. 2-17-Specification Chart-Rectangular Motor

2-12 WINDSHIELD WIPER SYSTEM

DESCR l PTlON

TWO SPEED-ROUND MOTOR

The round motor used on the "B", "C", "Do and "E" styles is approximately 4 1/2" in length (Fig. 2-18).

The motor uses a light gray colored drive gear with a gear ratio of 5 1 : 1.

The round motor used on "A" and "F" styles is

A . F

-

STYLES

-

4"

,C,D, 4%"

Fig. 2-18-Wiper Assembly mrirc

A

B

P

WICK

CIDTLUC

I

A

8-C-E

I

C-&I

4 "

4 "

46"

46"

Oreen

Lt. G r y

Green

45:L

5 1 : l

4 5 : l

I

O n e n

Lt. G r y

Green

Lt. O n y

I

4 5 : l

5 1 : l

45:L

5 1 : l

5 1 : l

I

Fig. 2-19-Round Motor Application Chart

AB

A?

Y

AB

U

AB

AP

A?

$057

DASH SWITCH

/

nBnmmnrtnm

12V FEED V I A RELAY SW l TCH TO MOTOR nrrr~crrr COIL CIRCUIT i-5-

SHUNT FIELD CIRCUIT

SERIES FIELD

-

ARMATURE CIRCUIT

- - - -

Fig. 2-20-"Ot?" Position

WINDSHIELD WIPER SYSTEM 2-13 approximately 4" in length (Fig. 2-18). The motor uses a green colored drive gear with* a gear ratio of 45: 1.

The service procedures for both motors are the same.

A round motor application chart is shown in Fig. 2-19.

In the round two speed motor the brush plate and circuit breaker assembly is attached to a field assembly that is staked into the end cap. The end cap and field assembly will be serviced as a unit (Fig. 2-36). The brush plate and circuit breaker must be detached from the field assembly in order to replace the armature.

The motor has only two external leads.

WIPER OFF CIRCUIT

Fig. 2-20 illustrates the internal wiring with wiper in the "OFF" position. The 12 volt circuit to the center terminal of the wiper terminal board is completed through the ignition switch and fuse.

" L O

SPEED CIRCUIT (Fig. 2-21)

Moving the wiper switch to the "LO" speed position completes the relay coil circuit to ground at the wiper switch. With the relay coil energized, the relay contacts close completing the 12V circuit to the motor windings.

Current then flows through the series field coil and divides, part passing through the shunt field coils, the other through the armature to ground via the internal circuit breaker. The shunt field circuit is completed to ground at the wiper switch.

"HIw SPEED CIRCUIT (Fig. 2-22)

Moving the wiper switch to the "HI" speed position maintains the relay coil circuit to ground at the wiper switch, but opens the shunt field circuit to ground at the switch. The shunt field current then flows through the resistor located on wiper terminal board to ground.

With a weakened shunt field, the motor runs faster.

MEDIUM SPEED CIRCUIT

-

(Cadillac Only)

Moving the wiper switch to the "Med" speed position connects a 13 ohm resistor, located in the switch, in parallel with the 20 ohm resistor from the shunt field circuit. These two resistors, connected in parallel,

'SPLICE

RELAY

COIL

- "20 OW

RESISTOR

'1

I 12V FEED V I A RELAY SWITCH TOMOTOR r

E D a

SERIES FIELD

-

ARMATIJRE CIRCUIT

Fig. 2-2 1-"Lo" Speed Circuit

I

2-14 WINDSHIELD WIPER SYSTEM

SPLICE

DASH SWITCH

BL

.

7 - -

11-N FEED V I A RELAY SWITCH m

IRoroR

- / i -

RELAY COIL C I RUCIT FROM 12V

'

==--=Ctr_=r SHUNT FIELD CIRCUIT

SERIES

FEED

Fl

ElD

-

ARMATURE ClRCUlT t wovide sliahtlv less than 8 ohms resistance in the shunt field:

he

difference in resistance results in medium speed.

PARKING CIRCUIT (Fig. 2-23)

- -

Fig. 2-22-"Hi" Speed Circuit

Turning the wiper switch off is merely the first step in shutting the wiper off. The wiper motor itself actually completes the shutting off operation. When the wiper switch is moved to the "OFF" position, two simultaneous functions are accomplished:

1. The relay coil circuit is opened and this allows the spring loaded relay latch arm to move out into the path of the gear drive pawl (Fig. 2-24). The relay- switch contacts, however, are still closed at this stage of operation and the wiper motor continues to run.

2. The shunt field circuit is connected to ground at the switch and the wiper operates in "LO" speed during this stage.

Since the wiper motor continues to run when the switch is first turned off, the continuing rotation of the gear causes the drive pawl to engage the relay latch arm (Fig. 2-25). This action unlocks the gear from the drive pawl, lock pawl and the drive plate and output shaft assembly. With the drive plate and output shaft unlocked from the gear, and since the output shaft extends thru the gear shaft off center, the continuing rotation of the gear at this point causes a cam action between the output shaft and the gear shaft. This cam action causes the gear drive pawl to move into the relay switch slot. As the drive pawl moves into the switch slot, it pushes the relay latch arm against the relay-switch flexible contact. This action opens the relay-switch contacts which cuts the 12V feed to the motor windings (Fig. 2-26).

DIAGNOSIS

-

WIPER ON CAR

1. Make a preliminary check of the following items:

The wiper gear mechanism completes shutting off the wiper as follows:

A. Body wiring properly connected to wiper terminal board and wiper switch.

WINDSHIELD WIPER SYSTEM 2-15

Fig. 2-23-Parking Circuit

B. Wiper motor to dash mounting screws tight. D. Fuse.

C. Wiper switch securely mounted.

E. With ignition switch turned on, there is a 12- volt supply at center terminal of wiper terminal board.

2. When checking wiper operation, operate wiper independently of the car wiring or wiper switch, as shown in Fig. 2-27. Check wiper operation in

"OFF", "LO" and "HI" positions.

-

RELAY MAGNET

A. If wiper operates correctly, see DIAGNOSIS

CHART-WIPER ON CAR.

B. If wiper still fails to operate correctly, disconnect wiper linkage from wiper motor and recheck for proper wiper motor operation.

1. r or breakage.

2. If wiper fails to operate correctly in Step 2, remove wiper from car and check per instructions DIAGNOSIS WIPER OFF

CAR. Fig. 2-24-Gear in Normal Run Position

2-16 WINDSHIELD WIPER SYSTEM

LATCH ARM

5009

Fig. 2-25-Wiper Shutting "08' Fig. 2-26-Wiper Shut " 0 8 ' ig Park Position

DIAGNOSIS CHART WIPER ON CAR LESS DEMAND WIPER SYSTEM

NOTE: For Demand Wiper System see diagnosis and NOTE: Wiper operated correctly independently of car diagnosis chart in the Programmed Washer System wiring and switch. section. IMPORTANT: Ignition switch must be "on" for all electrical tests.

I

CONDITION

1. Wiper inoperative or intermittent

-

2. Will not shut off (Blades make full wipe stroke)

3. Will not shut off (Blades move up and down about 15 degrees from park position).

APPARENT CAUSE CORRECTION

A. Open lead wire from wiper terminal No. 1 to wiper switch

B. Wiper switch not securely mounted.

A. Repair broken wire

B. Tighten switch mounting

C. Wiper. switch defective.

A. Grounded lead wire from wiper terminal No. 1 to wiper switch.

C. Replace wiper switch

A. Tape uninsulated portion of wire

B. Corroded wiper terminals.

B.

Clean terminals.

C. Defective wiper switch.

A. Open in lead wire from wiper terminal No. 3 to wiper switch.

B.

Wiper switch mounting loose.

I

C. Wiper switch defective.'

C. Replace wiper switch

A. Repair broken wire

B. Tighten switch mounting.

(

C. Replace wiper switch.

1

WINDSHIELD WIPER SYSTEM 2-17

4. "Hi" speed only. A. Open lead wire from wiper ter- minal No. 3 to wiper switch.

A. Repair broken wire.

I 5. "Lo" speed only

B. Wiper switch defective. B. Replace wiper switch.

I

I A. minal No. 3 to wiper switch.

I

Grounded lead from wiper ter- A. Tape uninsulated portion I of wire.

B. Defective wiper switch. B. Replace wiper switch.

6. "Hi" speed in W e d " position

(Cadillac only)

A. Open medium speed resistor. A. Replace wiper switch.

Wiper Motor Removal a n d Installation

1. Raise hood and remove cowl screen.

2. Reaching through opening, loosen the transmis- sion drive link to crankarm attaching nuts (Fig.

2-28).

.

, crankarm.

POWER SOURCE

3

R M l NAL

INS CON-

NECTED TO GROUWt

PARK OR RECONNECT JUMPER TO TERM I NAL NO. 3

SHUT OFF BUT D I SCONNECT I T FROM TERMINAL

NO. 1. ( W I PER GEAR MECHANISM SHOULI

STOP I N POSITION SHOWN

4057

Fig. 2-27-Bench Checking Wiper Motor

2- 18 WINDSHIELD WIPER SYSTEM

VIEW "A"

Fig. 2-28-Round Motor Installation

- "B-C-D-E"

WINDSHIELD WIPER SYSTEM 2-19

4. Disconnect wiring and washer hoses.

5. Remove the three motor attaching screws.

6. Remove motor while guiding crankarm through hole.

7. To install, reverse the removal procedure. Motor must be in park position when assembling crankarm to transmission drive link(s).

Wiper Arm Removal and Installation (Fig. 2-29)

Raise hood to gain access to wiper arms.

On "A" and "F" styles, use tool 5-22128 or 5-8966, or equivalent, and lift arms off transmission shaft.

On left arm slide articulating arm lock clip (Fig.

2-28) away from transmission pivot pin and lift arm off pin.

On "B", "C", "D" and "E" styles, lift wiper arm and slide latch clip (Fig. 2-29) out from under wiper arm.

Release wiper arm and lift wiper arm assembly off transmission shaft.

On left arm, slide articulating arm lock clip away from transmission pivot pin (Fig. 2-28) and lift arm off pin.

To install left wiper arm assembly, on all styles, position the articulating arm over the transmis- sion pivot pin and slide the lock clip toward the pivot pin until it locks in place on the pin. Install the left wiper arm assembly to the transmission shaft aligning the keyway to the shaft.

On "A" and "F" styles align the right wiper arm

Fig. 2-29-Wiper Arm Latch Clips assembly in the proper park position and install wiper arm to transmission shaft.

8. On "B", "C", "D" and "E" styles, align keyway in right wiper arm assembly to transmission shaft and install arm assembly to shaft.

9. On "B", "C", "D" and "E" styles, lift the wiper arm assemblies and slide latch clips (Fig. 2-29) under the arms. Release wiper arms and check wipe pattern and park position.

Wiper Arm Adjustment

If the wiper arms and blades were in correct adjustment prior to wiper arm removal, adjustment should not be required. However, if adjustment is required, it can be performed as follows:

Raise the hood and remove cowl vent screen.

On "A" and "F" styles, remove the right arm and blade assembly.

Loosen, do not remove, the transmission drive link to motor crankarm attaching nuts (Fig. 2-28). On

"B", "C", "D" and "JYstyles, if only one arm and blade assembly requires adjustment, loosen only the drive link to crankarm attaching nuts for the unit requiring adjustment.

Rotate the left arm assembly on "A" and "F" styles and both arm assemblies on "B", "C", "D" and "E" styles to a position 1" below the blade stops.

NOTE: On "B", "C", "D" and "E" styles, even if only one arm and blade assembly requires adjustment, the right and left assemblies must be rotated 1" below the stops.

Tighten the attaching nuts on the transmission drive link(s) to motor crankarm (20-28 inch pounds torque).

On "A" and "F" styles, position the right arm and blade assembly 1" below the blade stop and install arm assembly to transmission shaft.

Lift the right and left arm and blade assemblies over the stops.

8. Check wipe pattern (Fig. 2-30) and park position.

Dimension "A" shown in Figure 2-30 for various body styles is as follows: a. All "A" styles

-

1.6 1

" plus 1.10" or minus .5" b. "B-35-45-49-69" and 26847 styles

1 S O " or minus .00"

-

2.00" plus

2-20 WINDSHIELD WIPER SYSTEM

Fig. 2-30-Wipe Pattern c. "B-39-47-5747'' (less 26847) styles

1 S O " or minus .00"

- 1 S O " plus d. "C-39-49-69-37-47" styles

-

2.00" plus 1.50" or minus. .00" e. "D-23-33" styles

.00"

-

2.00" plus 1.50" or minus f. "E-47-57-67-87" styles minus .00"

-

1.50" plus 1.50" or g. All "F" styles - 1.25" plus 1.10" or minus .5"

9. Install cowl vent screen.

Wlpr Blade Removal and Installation l b o methods are used to retain wiper blades to wiper arms (Fig. 2-3 1).

1. One method uses a press type button. When the button is depressed the blade assembly can be slid o,ff the wiper arm pin.

!

2. The other method uses a coil spring retainer. A screw driver must be inserted on top of the spring and the spring pushed downward (Fig. 2-31). The blade assembly can then be slid off the wiper arm pin.

Two methods are also used to retain the blade element in the blade assembly (Fig. 2-3 1).

1. One method uses a press type button. When the button is depressed, the two-piece blade assembly can be slid off the blade element.

2. The other method uses a spring type retainer clip in the end of the blade element. When the retainer clip is squeezed together, the blade element can be slid out of the blade assembly.

When installing a blade element into a blade assembly, be certain to engage the metal'insert of the element into all retaining tabs of the blade assembly.

IMPORTANT: When properly installed, the

WINDSHIELD WIPER SYSTEM 2-2 1 element release button, or spring type element retaining clip should be at the end of the wiper blade assembly nearest the wiper transmission.

Wiper Transmission Removal and Installation

1. Raise hood and remove cowl vent screen.

2. On "A" and "F" styles, remove right and left wiper arm and blade assemblies. On "B", "C",

"Dlr, and "E" styles, remove arm and blade assembly only from the transmission to be removed.

3. Loosen (do not remove) attaching nuts securing transmission drive link(s) to motor crankarm (Fig.

2-28).

NOTE: On "B", "C", "D" and "E" styles, if only the left transmission is to be removed, it will not be necessary to loosen attaching nuts securing the right transmission drive link to motor crankarm.

4. Disconnect the transmission drive link(s) from the motor crankarm.

5. On "A" and "F" styles, remove the right and left transmission to body attaching screws. On "B",

"C", "D" and "E" styles, remove the attachin8 screws securing the transmission(s), to be re- moved, to the body.

6. Remove transmission(s) and linkage assembly by guiding it through plenum chamber opening.

7. To install transmission(s) and linkage assemblies, position assembly in plenum chamber through the openings.

8. Loosely install transmission to body attaching screws.

9. Install transmission drive link(s) to motor crankarm and tighten attaching nuts to 20-28 inch pounds torque (Fig. 2-28).

NOTE: Wiper motor must be in park position.

10. Align transmission(s) and tighten attaching screws to body.

11. Install wiper arm and blade assemblies and adjust as described under WIPER ARM

ADJUSTMENT.

12. Check wiper operation, wipe pattern and park position.

13. Install cowl vent screen.

Fig. 2-3 1-Wiper Blade Assemblies

DRIVE PLATE (L

SHAFT ASSEMBLI

DRIVE PAWL I N

PARK POSITION I N

RELAY SWITCH SLO

Fig. 2-32-Testing Relay Switch

2-22 WINDSHIELD WIPER SYSTEM

DIAGNOSIS CHART WIPER OFF CAR

-

LESS DEMAND WIPER SYSTEM

NOTE: (For Demand Wiper System see Diagnosis and shown in Fig. 2-27. Check if wiper has "LO" and

Diagnosis Chart in the Programmed 'Washer System "HI" speeds and shuts off correctly. Match the trouble section. found with the trouble shown in the chart. Use checking procedure following this chart by letter as

NOTE: Before using chart, try operating wiper as indicated to locate cause of trouble.

CONDITION APPARENT CAUSE CHECKING PROCEDURE

.

Wiper Inoperative (Motor loesn't run)

. Wiper will not shut off

Crankarm rotates through

160 degrees)

1. Open relay coil

2. Circuit breaker open

3. Open armature

4. Motor series field open

5. Brushes sticking

6. Defective solder joints-relay switch

7. Binding condition-relay latch arm

I. Relay coil grounded

2. Relay latch spring disconnect- ed or broken

3. Latch arm binding

'.

Wiper will not shut off

Crankarm moves back and orth in a horizontal plane ccompanied by a loud

'knock") together

2. Drive pawl spring disconnected

3. Wiper has one speed, "HI", caused bv oDen shunt field

-

1.

,.

Wiper has one speed, "HI" 1. Shunt field open

2. Defective soldering at terminal No. 3 on wiper terminal

- board

- -- - -

Wiper has one speed, "LO" 1. Shunt field internally grounded

2. Shunt field lead to terminal board (black) grounded

3. Shorted armature i. ,., Wiper has excessive speed u ~ i u .

1.

2.

Open speed resistor

Poor resistor ground connection

'.

Wiper stops at random

Crankarm stops rotating mmediately and does not

,eturn to full park losition.

1. Relay switch contacts dirty or broken

I. Intermittent Operation

1. No apparent trouble on

)ench test but fails masionally on car.

1. Defective circuit breaker

(weak)

2. Circuit breaker tripping because of shorted armature and/or fields causing motor to draw excessive current

.

1. Armature end play tight

2. Gear assembly end play tight

3. Loose solder or weld ioints

Clean or replace relay switch assembly as required

See Adjustments

NOTE: ACTUATE LATCH

ARM I N DIRECTION

O F ARROW

EAR MECHANISM

WINDSHIELD WIPER SYSTEM 2-23

4023

Fig. 2-33-Latch Mechanism

PROCEDURE "A" (WIPER. INOPERATIVE)

1. Remove washer pump to gain access to relay switch assembly.

2. Connect 12-volt source to wiper, feed side to center terminal, ground side to gear housing (Fig. 2-27).

Do not connect jumper to terminal 1 and 3.

3. To determine if relay coil is open, connect test lamp to wiper terminal No. 1. Test lamp should light.

4. Test relay switch as follows: a. If gear mechanism is in full park position, insert a small screwdriver into the switch slot

(between the drive pawl and the relay latch arm) and push relay latch arm downward and toward the relay coil in direction of the arrow in Fig. 2-32. Next, remove a small amount of insulation from black lead with pink tracer and touch test lamp to exposed wire. b. If test lamp lights but motor doesn't run.

Proceed to Step 5. c. If test lamp doesn't light, relay switch defective.

NOTE: Cover exposed wire with tape after the test.

5. Disassemble motor section and check the following: a. Hung brush.

Fig. 2-34-Brush Plate Assembly b. solder connections at brush holders. c. Splice joints at field coil connections to leads. d. Open armature. e. Circuit breaker ground connection on field lamination. f. To check the circuit breaker, disassemble motor section of wiper and visually inspect the circuit breaker for dirty or burned contacts or solder connections to circuit breaker terminals (Fig.

2-34).

PROCEDURE "6" (WIPER WILL NOT SHUT

OFF-CRANKARM ROTATES 360 DEGREES)

1. Observe if relay latch arm spring is connected properly (Fig. 2-33).

2. Manually operate latch arm to check it for possible binding condition.

I

3. If items in 1 and 2 check out, connect power source to wiper and connect jumper wire* from terminal No. 3 to wiper housing. DO NOT make any connections from terminal No. 1. Manually actuate latch arm in direction of arrow (Fig. 2-33) and observe if it remains in energized position

(inside plastic switch housing out of path of gear drive pawl). If it remains in energized position, check for grounded red lead from coil to terminal

2-24 WINDSHIELD WIPER SYSTEM

No. 1. If red lead is not grounded, coil is probably grounded internally and relay switch should be replaced.

PROCEDURE "C" (WIPER WILL NOT

SHUT OFF-RECYCLES)

NOTE: Crankarm oscillates in a somewhat horizontal plane and is accompanied by a loud "knock" with each revolution of the gear.

1. Check that drive pawl and relay latch arm springs are properly connected (Fig. 2-33).

2. Check wiper for "LO" speed operation (Fig. 2-27).

If wiper has "HI" speed only, check the following items: a. Solder joint at No. 3 wiper terminal. b. Splice joint

2-36).

- field coil cross-over splice

-

(Fig. c. Splice joint

- black lead to field coil.

3. Check relay switch as follows: a. Remove small amount of insulation from black lead with pink stripe and connect test light between exposed wire and wiper housing. b. Connect positive side of power source to terminal No. 2 and negative side to motor case. Install jumper wire from terminal No. 1 to motor case. Observe if test light goes out once for each revolution of gear or if light glows steadily. If light glows steadily, relay switch contacts are not opening and switch is defective. If light goes out each time drive pawl moves into relay switch slot, relay switch is functioning correctly.

PROCEDURE "D" (WIPER HAS

ONE SPEED, "LO")

1. Check for grounded condition in the internal black lead that connects to wiper terminal No. 3.

Refer to Fig. 2-27 for terminal No. 3 location.

2. Disassemble motor section of wiper and check for grounded shunt field coil (Fig. 2-35).

PROCEDURE "E" (WIPER HAS EXCESSIVE

SPEED I N "HI" BUT "LO" SPEED IS

NORMAL)

1. Check for open 20 ohm resistor and the resistor ground connection (Fig. 2-39).

PROCEDURE "F" (INTERMITTENT

OPERATION)

1. Check solder connections at wiper terminal board.

Fig. 2-35-Testing Field Coils

2. Connect wiper to operate in "LO" speed (Fig.

2-27). Connect ammeter (range 0-30 amps.) in feed wire circuit to wiper and observe current draw. Allow motor to run until it becomes hot (see

Specification Chart Fig. 2-46).

, a. If current draw is normal and wiper cycles on and off, a weak circuit breaker is indicated.

Replace brush plate assembly. b. If current draw exceeds specification, proceed to Steps 3, 4 and 5.

3. Adjust armature end play as required and recheck current draw.

Fig. 2-36-Field and End Cap Assembly

WINDSHIELD WIPER SYSTEM 2-25

4. Adjust gear assembly end play as required and recheck current draw.

5. If adjustments in Step 3 and 4 fail to correct excessive current draw condition, disassemble motor section of wiper and check armature on growler for shorted or grounded condition.

MOTOR DISASSEMBLY AND ASSEMBLY

PROCEDURE

Brush Plate and Circuit Breaker

Removal

1. Scribe a reference line along the side of the casting and end cap to insure proper reassembly.

2. Remove the two motor tie bolts.

3. Feed exposed excess length of motor leads through the casting grommet and carefully back the case and field assembly plus the armature away from the casting (Fig. 2-36).

NOTE: It may be necessary to remove the armature end play adjusting screw and insert a rod through the opening in order to apply pressure against the end of the armature.

4. Unsolder the black lead from circuit breaker.

5. Straighten out the 4 tabs that secure the brush plate to the field coil retainers (Fig. 2-34).

NOTE: Be careful not to break any of the retainer tabs.

6. Install "U" shaped brush retainer clip over brush holder that has brush lead attached to circuit breaker (Fig. 2-34).

7. Holding the opposite brush from that retained in

Step 6, carefully lift the brush holder off the mounting tabs far enough to clear the armature commutator.

8. Allow the brush held in Step 7 to move out of its holder. Remove the brush spring and lift the brush holder off the armature shaft.

NOTE: Thrust ball may be easily removed with a magnet.

Case and Field Assembly Removal

1. Remove brush plate and armature.

2. The end case and field assembly is serviced as a unit. To free the field and case assembly, cut the solid black and black with pink stripe leads in a location convenient for splicing preferably near the wiper terminal board (Fig. 2-34).

3. Remove steel thrust plate and rubber disc from case bearing.

Motor Reassembly

1. If new field and case assembly is being installed, splice the black and black with pink stripe leads of the new field with the corresponding leads oP the wiper.

2. Install the rubber thrust disc, steel thrust disc and felt lubricating washer in the case assembly bearing in the order ifidicated.

3. Lubricate end of armature shaft that fits in case bearing with recommended type grease (Fig.

2-46). Next, install thrust ball in end of shaft.

4. Assemble armature in the case and field assembly.

5. Position the partially assembled brush plate, Fig.

2-37 over the armature shaft far enough to allow reassembly of the remaining brush in its brush

1

BRUSH PLATE ASSEMBLY

Armature Removal

1. Follow Steps 1 thru 8 under brush plate removal.

2. Lift armature out of case and field assembly.

3. Remove thrust ball from end of armature shaft and save for reassembly.

BRUSH RETAINER \

BRUSH S P R I N G sol

2

Fig. 2-37-Brush Plate Assembly

-

Removed

2-26 WINDSHIELD WIPER SYSTEM holder; then position the brush plate assembly on the mounting tabs in the position shown in Fig.

2-34.

NOTE: Circuit breaker ground lead will not reach circuit breaker terminal if brush plate is positioned wrong.

6. Center the brush plate mounting holes over the mounting tabs and bend the tabs toward the brush holders as required to secure the brush plate in position.

NOTE: Be sure tabs are centered in brush plate mounting holes.

7. Remove brush retainer clips and resolder circuit breaker ground lead to circuit breaker.

8. If new case and field assembly is used, scribe a line on it in the same location as the one scribed on the old case. This will insure proper alignment of the new case with the scribed line made on the housing.

9. Position armature worm shaft inside the housing and, using the scribed reference marks, line up as near as possible the case and field assembly with the housing.

10. Maintaining the armature in its assembled position in the case, start the armature worm shaft through the field and housing bearing until it starts to mesh with the drive gear. At the same time carefully pull the excess black and black with pink stripe leads through the housing grommet.

NOTE: It may be necessary at this point to rotate armature slightly before the armature worm will engage with drive gear teeth.

11. Rotate the case as required to align the bolt holes in the case with those in the housing.

12. Secure the case to the housing with the two tie bolts.

GEAR BOX

-

DISASSEMBLY AND

ASSEMBLY PROCEDURES

Relay Switch-Latch Assembly

Terminal Board Removal

1. Remove washer pump.

1

2. If wiper gear drive pawl is in full park position

(Fig. 2-32), remove gear assembly. (See drive gear disassembly).

If wiper gear mechanism is not in park position

RELAY COIL LEADS

I

BOARD

R E L A Y SWITCH TERMINAL

WITH RED

BLACK WITH

PINK STRIPE

501 3

I

Fig. 2-38-Terminal Board and Latch Relay

(drive pawl away from latch @arm Fig. 2-33, proceed to Step 3).

3. Remove relay switch attaching screw and carefully lift the relay switch assembly out of the gear box.

Unsolder leads from switch terminals as required.

Refer to Fig. 2-38 when resoldering leads.

kf

1

Fig. 2-39-Positioning Resistor Lead

WINDSHIELD WIPER SYSTEM 2-27

SHIM WASHERS

SPACEK WASHER

FTAINING RING

Fig. 2-40-Crank Arm Components-Exploded

View

4. To remove terminal board assembly, simply slide it out of housing and unsolder leads as required.

NOTE: Tan wire to No. 2 terminal black wire to

No. 3 terminal.

Reassembly of Relay Switch

Board

-

Latch and Terminal

1. Resolder red coil lead to wiper terminal board as required (Fig. 2-38).

2. Slide terminal board into wiper housing being careful to position the terminal board resistor lead as s h o i n in Fig. 2-39.

NOTE: With the relay switch assembly replaced in the housing and washer pump reinstalled, the relay switch plastic housing applies pressure against the resistor lead to form a positive ground connection to the wiper housing.

3. Resolder leads to relay switch assembly as required.

4. Position relay switch assembly in housing.

NOTE: Be very careful to route leads in such a manner as to avoid having them pinched between relay and wiper housing.

5. Install relay switch attaching screw.

6. Reassemble washer pump to gear (reassemble drive gear assembly if removed).

NOTE: Refer to "washer system"

- round motor, assembly of washer pump to wiper motor.

Drive Gear Disassembly

1. Remove crankarm retaining nut, crankarm, rubber

INNER SPACE

LOCK PAWL

\

DRIVE

PAWL

BE REMOVED WITHOUT REMOVING

SWITCH OR TERMINAL BOARD

RELAT

Fig. 2-4 1-Removing Gear

DRIVE SHAFT AND

PLATE ASSEMBLY

Fig. 2-42-Gear Removed

2-28 WINDSHIELD WIPER SYSTEM

Fig. 2-43-Lock Pawl seal cap, retaining ring, shim washers, shield and spacer washer in the order indicated (Fig. 2-40).

2. Slide gear assembly out of housing (Fig. 2-41).

3. Slide drive plate and shaft out of gear and remove the drive pawl, lock pawl and coil spring as required (Fig. 2-42).

Drive Gear Reassembly

1. Position drive pawl on drive plate.

2. Assemble lock pawl over drive pawl as shown in

Fig. 2-43.

3. Slide gear and tube over the drive shaft. (Move drive and lock pawls as required to allow their respective pins to fit in the gear guide channel.)

4. Holding the gear, manually rotate the drive plate in the direction of the arrow until the drive and lock pawl guide pins snap into their respective pockets in the gear (Fig. 2-44).

5. Reinstall coil spring between lock and drive pawls.

NOTE: Be very careful to maintain lock and drive pawl guide pins in their respective pockets during

Step 6.

6. Assemble inner spacer washer over gearshaft and assemble gear mechanism in housing so that it is positioned with respect to t k housing in the approximate location shown in Fig. 2-41.

Fig. 2-44-Lock Pawl and Drive Pin Positioning

WINDSHIELD WIPER SYSTEM 2-29

Fig. 2-45-Wiper Motor and Crank Arm in Park

Position

7. Reassemble the outer spacer washer, shield, shim washers, as required to obtain .004" (plus or minus .002") end play, snap ring and rubber seal cap in the order indicated. Refer to Fig. 2-40.

8. Operate wiper to "park" position and install crankarm in the approximate position shown in

Fig. 2-45.

9. Reassemble washer pump to gear.

NOTE: Refer to "washer system"

- round motor

- assembly of washer pump to wiper motor. o p e r s t i n a Val-e

. . . . . . . . . . . . . . . . . . . . . .

12 Volta D.C.

Bench Check (No L a d ) m r m n t Draw (AMPS) C n n k a m S p e d

"A-P" " B - c - D - ~

"ran

S p e d

' w i s , s p e d

. . . . . . . . . .

5.0 bbx.

. . . . . . . .

6.0 bbx

. .

4.0bbx. 4 . 5 n x .

35

70

-

50

- go s t a l l (Cold I b t a r )

"In" Spccd

. . . . . . . . . . l8.0 ILx. 29.0 ILx. 0

Torque munu

Washer mmp h n t i n g S c m r e

Annature Adjusting Screw Jam

I b t o r T i e B o l t a .

. . . . . . . . . . . . . . . . . .

Gear Box Relay A t t a c h i n g Scrcr

I b t o r Crankam A t t a c h i n g Nut

Nut

. . . . . . . . . . . . . . . 1 8

50

30

30

65

Hotor To Body

T m a m i e a i o n To Body

. . . . . . . . . . .

X)

. . . . . . . . . . . . . . . . . . . . .

-

35

35

28 h b r i c a t i o n

Gear Teeth

Cellr S h a f t

Cear Camtrack

S e a 1 Cap ( h a i d e )

R e s t i g e No. 42

ION

Fig. 2-46-Specification Chart-Round Motor

WIPER MOTOR ADJUSTMENTS

Armature End Play

1. Loosen adjusting screw locknut (Fig. 2-45) and tighten or loosen the adjusting screw as required until end of screw barely touches end of armature.

2. Back off adjusting screw 114 turn and tighten locknut.

Gear Assembly End Play

I . Add or remove shim washers as required to obtain

.004" (plus or minus .002) end play (Fig. 2-40).

DEMAND WIPER SYSTEM

Description

The wiper motor used with the demand wiper system is the same motor used for the depressed park system.

However, this system requires the use of an extra relay

(demand relay), a dual set of holding switches (Fig.

2-47) and an extra switch located in the end of the shift lever. The shift lever switch is a two-position, button-type plunger. Depressing the switch button to the first detent provides "Demand Wiper" operation.

Weather conditions such as light rain, mist, fog, etc. that do not normally require continous wiper operation cause the driver to continually reach down and turn the wiper control switch "on" and "off".

With the demand wiper system the driver merely depresses the shift lever button to the first detent

'position and releases it. The wipers will then make one complete wiping stroke and automatically shut "off'.

If the button is held in the first detent position, the wiper will operate until the button is released.

Switch in First Detent Position

I . The coil circuits of the wiper gear box relay and

2-30 WINDSHIELD WIPER SYSTEM

Fig. 2-47-Demand Wiper Assembly the demand relay are completed to ground simultaneously at the shift lever switch. Fig. 2-48 shows wiper circuits in "off' position. Fig. 2-49 shows the shift lever switch in the first detent position and the completed relay coil circuits.

2. With both relay coils energized, the gear box relay contacts close completing the feed circuit to the wiper motor windings and at the same time the demand relay contacts close completing a holding circuit to ground through the normally closed holding switch contacts "A" (Fig. 2-50).

NOTE: Without the holding circuit, quick release of the shift lever switch would cause the wiper blades to return to "park" before making a complete wiping stroke.

3. When the gear box relay switch contacts close, the wiper motor starts to run. The gear box relay coil will remain energized until the holding circuit is interrupted.

NOTE: The wiper motor operates in "lo" speed during this type of operation. The wiper motor shunt field circuit is completed directly to ground at the wiper control switch even though the switch is in the "offf position.

4. As soon as the wiper motor has run long enough to move the blades out of the park position and started the normal wiping stroke, the following occurs: a. The washer pump 4-lobe cam has a fin which opens holding switch contacts "A" when the cam is rotated (Fig. 2-5 1).

NOTE: The 4-lobe cam is connected to the wiper gear and anytime the gear is rotating the cam will also rotate. The holding switch contacts will open once during each revolution of the 4-lobe cam. b. When the fin momentarily opens the holding switch contacts "A", the holding circuit for both the gear box relay coil and demand relay coil is interrupted to ground. The demand relay switch contacts then opens and the gear box relay latch arm is releasrd and moves out into the path of the gear drive pawl (Fig.

2-52). At this stage of operation the gear box relay switch is still closed and the wiper motor continues to run. c. The continuing rotation of the wiper gear and

4-lobe cam moves the fin away from the holding switch contacts "A" allowing them to close. Since the holding switch is in series with the demand relay switch which is now open, the holding circuit will remain open until the shift lever switch is again actuated. d. Further rotation of the wiper gear causes the gear drive pawl to engage the relay latch arm

(Fig. 2-53). This action unlocks the output shaft from the gear. The output shaft extends through the gear tube off center and as the gear continues to rotate, a cam action results.

The cam action causes the gear drive pawl to push the latch arm into the relay housing where it pushes against and opens the relay switch (Fig. 2-54) shutting off the wiper.

Diagnosis Chart

Refer t o . trouble shooting procedure and diagnosis chart in Programmed Washer System Section.

WINDSHIELD WIPER SYSTEM 2-3 1

BLACK W/PINK I

I

'WIPER CONTROL SWITCH

' I O F F L O H I

I

--

- 0 - w - w -

GEAR BOX RELAY

-

GREEN

/YELLOW

'"'

-

I

-

DEMAND

RELAY

RATCHET

RELAY

ORANGE

HOLD SW. FIN ON 4 LOBE

"

AU

CAM

C

- -- -

-*

- t--1

C*-"_Y~J

SHIFT LEVER SWITCH

-

WIPER CONTROL SWITCH

WASH BUTTON

5028

Fig. 2-48-Demand Wiper Circuits

-

Off Position

2-32 WINDSHIELD WIPER SYSTEM

BLACK W/PINK

'

I

TCH

SW FUSE

GEAR BOX RELAY

I

1

_,

1 t

#YELLOW

DEMAND

RELAY

ORANGE

RATCHET

RELAY

-t

&

4

HOLD SW. F I N ON 4 LOBE CAM

I #

SHIFT LEVER S W I T C H

\iRST DETENT

4

WIPER C O N T R O L S W I T C H

WASH BUTTON

-

-

- -

Fig. 2-49-Button in First Detent Position

WINDSHIELD WIPER SYSTEM 2-33

I '

GEAR BOX RELAY t

BLACK W/PINK

STRIPE 0

!

! -

;SERIES FIELD

I

I

----------

I

WIPER CONTROL SWITCH

I G N 25 AMP t

'Ir{

;REEN

"-'

RATCHET WHEEL

DEMAND

- -

-..

RELAY

RATCHET

RELAY

ORANGE -

HOLD

MAN

S'W.

FIN ON 4 LOBE CAM

I

SHIFT LEVER SWITCH

1

WIPER CONTROL SWITCH

WASH BUTTM

Fig. 2-50-Demand Wiper Circuits

2-34 WINDSHIELD WIPER SYSTEM

Fig. 2-53-Gear Drive Pawl Engaged

Fig. 2-51-Demand Washer 4-Lobe Cam

I

RNIY

5

HELD

QlJT OF PATH OF GEAR BY

RELAY MAGNET.

5032

Fig. 2-52-Gear in Normal Run Position Fig. 2-54-Wiper Shut Off In Park Position

DESCRl PTlON

WASHER SYSTEM

The washer pump used on both the rectangular and round motor is a positive displacement type pump employing a small piston, spring and valve arrange- ment. The plastic valve assembly is .identical for both, however the programming (starting and completion of wash cycle) which is accomplished electrically and mechanically by a relay assembly and ratchet wheel arrangement differs and will be explained separately.

WINDSHIELD WIPER SYSTEM 2-35

WASHER PUMP

ASSEMBLY /

When the pump is attached to the wiper motor, the four lobe cam actuates a spring loaded cam follower arm and pin assembly. Fig. 2-55 has the pump tilted back to show the relationship of cam follower lower pin to four lobe cam.

The cam follower actually has two pins

- an upper and lower. The lower or bottom pin is actuated by the four lobe cam. The upper pin, which extends through an elongated opening in the piston actuator plate has a ratchet pawl assembled on it (Fig. 2-56). Thus, whenever the wiper motor is running, the four lobe cam is rotating and in turn actuates the cam follower assembly. However, no pumping action occurs because the washer pump pumping mechanism is held in a

"lock-out" position.

C A M

FOLLOWER

LOWER P I N

Fig. 2-55-Four Lobe Cam

RECTANGULAR MOTOR WASHER

SYSTEM

The following outlines the principles of operation.

Washer Pump Off

-

Wiper Motor On

A four lobe nylon cam assembled on the output shaft of the wiper motor powers the washer pump mechanism. The cam rotates whenever the motor is running.

Pumping Mechanism Lock-Out Position

Referring to Fig. 2-56, note that the piston actuator plate has a tang that is resting against a ramp on the lower surface of the ratchet wheel. This tang holds the spring loaded piston actuator plate in a retracted position. With the actuator plate held in a retracted position, the cam follower upper pin will merely move back and forth in the actuatm plate elongated opening and no pumping action occurs. The ratchet pawl is held away from the ratchet wheel by a spring loaded solenoid plunger.

Starting the Wash Cycle

Depressing the control switch washer button completes the pump solenoid circuit to ground at the control switch and mechanically actuates the wiper switch to tum the wiper motor on (Fig. 2-57).

With the coil energized, the solenoid plunger is pulled toward the coil and this allows the ratchet pawl to engage the ratchet wheel teeth. (Keep in mind that the ratchet pawl moves back and forth when the wiper is

RATCHET PAWL VALVE ,ASSEMBLY

C A M FOLLOWE

EACH SIDE

40

Fig. 2-56-Actuator Plate

I BATTERY

-

Fig. 2-57-Pump Wiring Circuit

5069

2-36 WINDSHIELD WIPER SYSTEM on). Thus when the ratchet pawl engages the ratchet wheel teeth, it will start to rotate the ratchet wheel.

Each stroke of the ratchet pawl rotates, the wheel one tooth.

The first stroke of the ratchet pawl rotates the ratchet wheel one tooth and accomplishes the following functions:

1. The "lock-out" ramp on the lower surface of the ratchet wheel is moved away from the tang on the piston actuator plate releasing the pumping mechanism from the "lock-out" position.

When the piston actuator plate is released from the "lock-out" position the piston spring, which had been held in a compressed position, expands pushing the piston toward the valve assembly resulting in the first exhaust stroke (Fig. 2-58).

The movement of the piston toward the valve assembly also pulls the piston actuator plate in the same direction causing the back edge of the elongated opening in the actuator plate to move up tight against the upper cam follower pin.

2. Rotating the ratchet wheel one tooth from the lock-out position also maintains the solenoid plunger in the coil energized position. The plunger will be held in this position until the ratchet wheel has been rotated 360 degrees or 12 teeth.

Wash Cycle Intake Strokes

The continuing rotation of the four lobe cam actuates the pumping mechanism as follows:

As each lobe actuates the follower, the cam follower in turn moves the piston actuator plate and piston away from the valve assembly compressing the piston spring. The movement of the piston away from the valve assembly creates a vacuum in the pump cylinder which draws the wash solution into the pump cylinder through the intake valve (Fig. 2-58).

Exhaust Stroke

As the high point of each lobe passes the cam follower lower pin, the piston spring is allowed to expand

FROM

WASHER

JAR

TO

NOZZLES

DIRECTION OF TRAVEL

ACTUATOR PLATE

E l H A U S T S T R O K E '

- - - -

Fig. 2-58-Intake and Exhaust Stroke

WINDSHIELD WIPER SYSTEM 2-37

SOLENOID COIL

Fig. 2-59-Washer Assembly Internal Gear forcing the piston toward the valves. The movement of the piston toward the valves forces the wash solution out the two exhaust valves to the spray nozzles.

The intake and exhaust strokes occur four times for each revolution of the wiper motor output gear.

During each intake stroke, the ratchet wheel is rotated one tooth.

Completion of the Wash Cycle

The pumping operation is completed automatically when the ratchet wheel has been rotated through 360 degrees or 12 teeth.

After the ratchet wheel has been rotated through 12 teeth, ,two simultaneous functions are accomplished.

1. The spring loaded solenoid plunger pushes through an opening in the rim of the ratchet wheel. As the plunger moves through the opening, it pushes the ratchet pawl away from the ratchet teeth (Fig. 2-59).

2. The ramp on the lower surface of the ratchet wheel has moved to a position where. it is holding the piston actuator plate in a lock-out position as shown (Fig. 2-56).

CHECKING PROCEDURES:

Washer Pump Inoperative (On the Car)

1. Check the following items: a. Jar has adequate quantity of washer solution. b. Hoses are not damaged and hose connections are tight.

NOTE: re~laced and the hose connections have been disturbed, it may be necessary to cut a short length off the end of each hose to insure an air tight connection. c. Screen at end of jar cover hose is not plugged. d. Electrical connections to washer pump and wiper switch. e. Nozzles are not plugged.

2. If items in step 1 check out, start wiper motor first, then push washer button and listen for "click" as washer solenoid pulls in. If no "click" is heard, check power supply (12 volt) at washer pump wiring connector. No voltage indicates open circuit in feed wiring.

3. If correct voltage reading was obtained in step 2, start wiper first, then connect 12 volt supply to one washer terminal and ground other. If washer relay

"click" is heard, an inoperative wiper switch is indicated.

4. If washer relay "click" is not heard in step 3, a faulty washer pump ralay coil is indicated.

5. If relay "click" is heard in step 2, 3 or 4 listen for the "soft clicking" as the pump ratchet wheel is rotated. If "soft clicking" is not heard, the pump mechanism is faulty and should be removed from the wiper motor and checked. See "Washer Pump

Detached".

6. If "soft clicking" is heard but no pumping action occurs, replace the valve assembly and recheck pump.

WASHER PUMPS CONTINUOUSLY WHEN

WIPER IS ON (ON THE CAR)

1. Disconnect wiring from washer pump. If pump shuts off, trouble is in wiring or switch.

2. If pump fails to shut off in step 1, remove pump assembly from car for further checking.

WASHER PUMP DETACHED

,

1. Manually actuate the solenoid plunger and check for binding condition.

2. Check relay coil as follows: Connect 12 volt supply to one washer terminal and ground the other.

Observe if solenoid plunger pulls in. Failure of solenoid plunger to pull in indicates an open solenoid coil or Door solder connections.

2-38 WINDSHIELD WIPER SYSTEM

3. If solenoid plunger pulls in correctly, manually actuate the cam follower lower pin and observe if pump operates as previously described. Binds and other types of malfunction can usuillly be located in this manner.

WASHER PUMP DISASSEMBLY

PROCEDURES

Solenoid Assembly

-

Ratchet Dog

1. Remove the ratchet dog retaining screw. Hold the spring loaded solenoid plunger in position and carefully lift the solenoid assembly and ratchet dog off the frame of the pump.

2. Separate the ratchet dog from. solenoid mounting plate as required (Fig. 2-61).

Ratchet Pawl

1. Disconnect ratchet pawl spring (see Fig. 2-60 for proper location of spring).

2. Remove ratchet pawl retaining ring and slide ratchet pawl off cam follower shaft.

Ratchet Wheel

1. Follow step 1 under solenoid assembly.

- ratchet dog

2. Move ratchet wheel spring out of shaft groove and slide ratchet wheel off its shaft (Fig. 2-62).

Pump and Actuator Plate Assembly

1. Remove solenoid assembly

- ratchet dog, ratchet pawl and ratchet wheel as outlined in their iespective procedures.

RAT

RETAIN

RETAINER

Fig. 2-61-Pump Assembly - Exploded View

0

2. To separate the pump and pump actuator plate from the frame, pull the pump housing in the direction toward the valve end until the grooves in the housing clear the frame. Then remove the actuator plate from the ratchet wheel and cam follower ;hafts.

RATCHET

WHEEL

SPRING

TCHET

+EEL

RATCHET DOG

RATCHET PAWL SPRING

/

SOLENOID PLUNGER

AND SPRING RATCHET WHEEL

SPRING

Fig. 2-60-Ratchet Pawl Spring Location Fig. 2-62-Pump Ratchet Wheel

WINDSHIELD WIPER SYSTEM 2-39

TRIPLE

5072

Fig. 2-63-Valve Assembly

Valve Assembly

1. Remove the four (4) screws that attach the valve assembly to the pump housing.

NOTE: During reassembly be sure gasket between housing and valve plate is properly positioned in the housing and valve plate grooves. Also be sure triple 0 ring (Fig. 2-63) is properly installed between valve body and pipe assembly.

ROUND MOTOR WASHER SYSTEM

The explanation of operation is divided into three general areas (1) Assembly of Washer Pump to Wiper

Motor, (2) Pumping Action and (3) Programming

(starting and stopping the pump action).

Assembly of Washer Pump to Wiper Motor

NOTE: Wiper Motor Gear must be in PARK position

(Fig. 2-65)-to assemble pump to wiper motor. -

1. Remove plastic pump cover.

2. Rotate the +lobe cam until index hole (.125" dia.) in the cam is aligned with the hole in the pump mounting plate. Insert a pin through both holes to maintain cam in position (Fig. 2-64).

3. Position pump on wiper so that slot in 4-lobe cam fits over the gear drive pin (Fig. 2-65). Secure pump to gear housing and remove locator pin, temporarily connect wiring connector.

4. Turn on wiper and washer pump to check pump operation.

NOTE: A loud knocking noise would indicate that the pump cam has not engaged the drive pin properly.

5. Install pump cover.

Basic Pump Action

NOTE: This explanation covers only that part of the washer assembly that actually does the pumping.

Fig. 2-64-Cam Alignment Pin Installation Fig. 2-65-Installing Washer to Pump

2-40 WINDSHIELD WIPER SYSTEM

The basic pumping mechanism consists of a spring- loaded piston assembly enclosed in a plastic cylinder.

Attached to the piston and extending out of the cylinder housing is an actuator plate. A valve assembly consisting of two exhaust valves and one intake valve is attached to the opposite end of the cylinder housing and controls the flow of washer solution.

Referring to Fig. 2-66, note that the elongated slot of the piston actuating plate fits over a pin. This pin is a part of a cam follower assembly which is actuated by the 4-lobe cam located on the underside of the pump mounting plate. When the wiper is running, the drive gear rotates the 4-lobe cam which in turn causes the cam-follower to move back and forth.

TRELAY ARMATURE

\

/ARMATURE LEG

-

OF RATCHET WHEEL

Intake Stroke

When the cam-follower moves in the direction indicated by the arrow in Fig. 2-66, the cam-follower pin, which extends thru the piston actuating plate, pulls the actuator plate away from the valve assembly compressing the piston spring. As the piston moves away from the valve assembly, a vacuum is created in the cylinder which opens the intake valve, drawing washer solution into the cylinder (Fig. 2-58).

Exhaust Stroke

As the 4-lobe cam continues to rotate, the cam- follower pin moves in the opposite direction described in the Intake Stroke. This permits the piston spring to expand which in turn pushes the piston toward the valve assembly creating pressure between the piston and valve assembly. This pressure "build-up" forces the washer solution out the two' exhaust valves to the nozzles (Fig. 2-58).

NOTE:

For purposes of explanation, only one exhaust valve opening is shown.

-

PUMP ASSEMBLY

7

CAM FOLLOWER P I N 7 l a

/

Fig. 2-67-Pump Mechanism

The intake and exhaust stroke cycle will occur four times for each revolution of the wiper drive gear while the washer pump is operating.

Pro ramming (Starting and stopfing k

The programming section of the pump mechanism consists of a relay, ratchet pawl, ratchet wheel, and ratchet wheel dog (Fig. 2-67).

Pump Idling (No Pumping Action)

Refer to Fig. 2-68 and note that a tang on the piston actuator plate is resting against a ramp on the lower surface of the ratchet wheel. This, in effect, holds the piston actuator plate in a lock-out position. With actuator plate in this position and the wiper running, the cam-follower pin merely moves back and forth in the elongated slot of the piston actuator plate and no pumping action can occur.

The ratchet wheel, which, if rotated, would move the ramp away from the tang of the actuator plate releasing the pump action, is prevented from rotating as follows:

The relay assembly, consisting of a coil and armature, is constructed in such a way that the ratchet wheel pawl extends through an opening in the relay armature; preventing it from engaging the ratchet wheel teeth.

Starting the Pump

Actuating the washer button to obtain windshield washer pump operation starts the wiper motor and energizes the pump relay. When relay is energized, the

Fig. 2-66-Pump Intake Stroke

WINDSHIELD WIPER SYSTEM 2-41 relay armature is pulled suddenly toward the coil, allowing the ratchet wheel pawl to drop out of the relay armature opening and engage the teeth of the ratchet wheel.

The ratchet wheel pawl, which is actuated by the same cam-follower pin that moves the piston actuating plate, begins to rotate the ratchet wheel. Rotating the ratchet wheel one tooth moves the ratchet wheel ramp away from the tang of the piston actuating plate (Fig.

2-68), permitting the piston spring to expand which in turn forces the piston toward the valve assembly resulting in the first exhaust stroke. This sequence then repeats through the remaining cycles.

Stopping the Pump

(Completion of the Wash Cycle)

The pumping operation is terminated automatically when the ratchet wheel has rotated a full 360 degrees and the 12th cycle is completed. This is accomplished as follows.

As the ratchet wheel approaches the completion of its

360 degrees travel, two functions occur simultaneously:

1. A leg on the relay armature rides up a ramp located on the outer surface of the ratchet wheel.

When the leg reaches the top of the ramp, it moves over the top edge of the ratchet wheel. This action allows the ratchet wheel pawl to re-enter the armature opening preventing further rotation of the ratchet wheel until the next time the relay coil is energized from the washer button. (Refer to Fig. 2-67 for position of armature leg while pump is idling.)

2. The tang on the piston actuating plate is resting once more against the ramp on the lower side of the ratchet wheel (Fig. 2-68). d. Electrical connections to washer pump and wiper switch. e. Nozzles are not plugged.

2. If items in step 1 check out, start wiper motor first, then push washer button and listen for "click" as washer relay pulls in. If no "click" is heard, check power supply (12 volt) at washer pump wiring connector. No voltage indicates shorted or inoperative car wiring.

3. If correct voltage reading was obtained in step 2, start wiper first, then connect 12 volt supply to one pump tefminal and ground other. If washer relay

"click"

IS heard, an inoperative wiper switch is indicated.

4. If washer relay "click" is not heard in step 3, a faulty washer pump relay coil is indicated.

5. If relay "click" is heard in step 2, 3 or 4 listen for the "soft clicking" as the pump ratchet wheel is rotated. If "soft clicking" is not heard, the pump mechanism is faulty and should be removed from the wiper motor and chwked.

6. If "soft clicking" is heard but no pumping action occurs, replace the valve assembly and recheck

Pump.

Washer Pumps Continuously When

Wlper is On

1. Disconnect wiring from washer pump. If pump shuts off, trouble is in wiring or switch. asskmbiy from car for further ciecking.

CHECKING PROCEDURES

Washer Pump Inoperative (On the Car)

1. Check the following items: a. Jar has adequate quantity of washer solution. b. Hoses are not damaged and hose connections are tight.

NOTE: If a valve has been previously replaced and the hose connections have been disturbed, it may be necessary to cut a short length off the end of each hose to insure an air tight connection. c. Screen at end of jar cover hose is not plugged. Fig. 2-68-Ratchet Wheel-Ramp

2-42 WINDSHIELD WIPER SYSTEM

Fig. 2-69-Removing Four Lobe Cam

Washer Pump Detached

1. Connect 12 volt supply to one washer terminal and ground other. Manually rotate 4-lobe cam and observe if relay armature pulls in. Failure of relay to pull in indicates an open relay coil or poor solder connections.

If relay pulled in, in step 1, manually rotate 4-lobe cam (counterclockwise looking at cam) through complete cycle (ratchet wheel rotated through 360 degrees or 12 teeth), carefully observing if performance matches that as explained under washer operation. Binds or any other type of malfunction can usually be located in this manner.

WASHER PUMP DISASSEMBLY

PROCEDURES

Four-Lobe Cam

1. Remove "E" retaining ring and slide cam off shaft

(Fig. 2-69).

Ratchet Wheel

1. Remove plastic pump cover.

2. Pry ratchet spring out of slot in shaft, hold relay armature against relay coil and slide ratchet wheel off shaft.

NOTE: When reassembling ratchet wheel be careful not to damage ratchet dog.

Ratchet Pawl and Pawl Spring

1. Disengage pawl spring from pawl and slide pawl off cam-follower pin.

Ratchet Dog

1. Remove attaching screw and lift ratchet dog off mounting plate.

Relay-Terminal Board Assembly

1. Remove 4-lobe cam.

2. Remove ratchet pawl and pawl spring.

3. Remove relay armature and spring.

4. Chisel off the four bent-over tabs that secure the coil mounting bracket to the base (Fig. 2-69).

Remove relay coil and terminal board assembly.

To mount a replacement relay assembly, hold it securely against the base mounting surface and bend locking tabs over.

NOTE: Be careful not to dama e coil winding or terminals.

3

5. To check the pump programming mechanism, manually rotate the 4-lobe cam through complete

12-tooth cycle (360 degrees) and observe if pump is operating as previously explained.

Valve Assembly

1. Note position of valve assembly relative to the pump housing for reassembly then remove four screws that secure valve assembly to housing.

2. Remove housing-to-valve-body gasket and save for reassembly.

Pump Assembly

1. Remove ratchet wheel, ratchet wheel dog, ratchet pawl and spring.

2. To release the plastic pump housing from the sheet-metal base, pull it in the direction toward the valve end until the grooves in the housing clear the base. Next, detach the assembly from the cam-follower pin (Fig. 2-66).

NOTE The piston and plastic housing is serviced as a complete assembly.

WINDSHIELD WIPER SYSTEM 2-43

P R O G R A M M E D W A S H E R SYSTEM

DESCRIPTION

The programmed washer system (Fig. 2-70) is used in conjunction with the demand wiper system and provides a fully automatic windshield washer cycle of operation as follows:

1. The shift lever switch is depressed to the second detent position to start the cycle of operation and is immediately released.

2. Wiper motor and washer pump start to operate.

3. Washer pump operates through a pumping cycle and stops pumping, but the motor continues to operate.

4. The wiper motor provides two additional drying wipes and then automatically shuts off.

NOTE: If the wiper control switch washer button is used to provide a wash cycle, it is necessary to move the control switch to the "OK" position to

I

RATCHET RELAY,

HOLDING

Fig. 2-70-Washer Assembly shut off the wipers after the wash cycle is completed.

MOTOR WINDINGS

GEAR BOX RELAY

RE LAY

SHIFT LEVER SWITCH

WIPER CONTROL SWITCH

WASH BUTTON

5035

Fig. 2-71-Shift Lever Button in Second Detent Position

2-44 WINDSHIELD WIPER SYSTEM

SWITCH IN SECOND DETENT POSITION

Pushing the shift lever switch to the second detent position and then releasing it immediately starts a cycle of operations as follows:

1. Three relay coil circuits (gear box relay, demand relay and pump ratchet relay) are completed to ground at the shift lever switch momentarily (Fig.

2-7 1).

2. With the three relay coils energized, the following completed circuits result almost simultaneously. a. The gear box relay switch contacts close completing the feed circuit to the wiper motor windings and the motor starts operating. b. The washer pump demand relay switch contacts close completing a holding circuit to ground through holding switch contacts "A".

This holding circuit is required to maintain the ground circuit for both the gear box relay and the washer pump demand relay coils when the shift lever switch is released.

HOLDING

CONTACTS

Fig. 2-72-Pump in Idling 9osition

GEAR BOX RELAY

-

I

-

BLACK W/PINK

STRIPE

-

I

MOTOR WINDINGS

I -

'

-

!

-I1

FIELD ;SERIES

I

I

I WIPER CONTROL

I

I

---..--.

!

(-*

I If

I SHUNT F I E L D J

I--------

I

;

*+&

RATCHET

RE LAY

CONTACTS F I N ON 4 LOBE CAM

"A"

1

I SHIFT LEVER SWITCH

* V I l l

WIPER CONTROL SWITCH

WASH BUTTdN

5037

-

- -

-

Fig. 2-73-Holding Circuit for Washer

c. Momentarily energizing the washer pump ratchet relay coil releases the washer pump mechanism from its "lock-out" or idling position and the pump starts to operate. The holding circuit is not required for this relay.

3. When the washer pump is released from its "lock- out" or idling position, the pump ratchet wheel starts to rotate. With the pump in the idling position, a cam on the ratchet wheel keeps holding contacts "B" open (Fig. 2-72). However, when the pump starts and the ratchet wheel is rotated one tooth, holding switch contacts "B" closed providing an alternate ground for both the gear box relay coil and the washer pump demand relay coil (Fig. 2-73). The alternate ground circuit through switch contacts "B" is required because contacts "A" are opened once for every revolution of the washer pump 4-lobe cam (Fig. 2-76). Without the alternate circuit, the washer pump demand relay coil circuit would open when contacts "A" open causing the demand relay switch to open which in turn would open the gear box relay coil circuit to ground. This would cause the wiper motor to park the blades and automatically shut off after one wiping stroke.

NOTE: Holding contacts "B## will remain closed until the washer pump ratchet wheel has been rotated 360 degrees.

4. The washing cycle is completed when an extended ramp on the lower surface of the ratchet wheel moves into position where the tang on the piston actuating plate rests on the ramp stopping the movement of the actuating plate (Fig. 2-74).

However, the wiper motor continues to run to provide two additional drying wipes.

The additional wipes are accomplished as follows:

Although the pump has discontinued pumping,

NOTE: DEMAND RELAY AND HOLDING SWITCH ASSEMBLY

REMOVED IN ORDER TO SEE EXTENDED RATCHET

WHEEL RAMP

5038

Fig. 2-74-Ratchet Wheel Ramp

WINDSHIELD WIPER SYSTEM 2-45 the pump ratchet wheel has not completed its 360 degree rotation and holding contacts "B" are still closed maintaining the gear box and demand relay coil circuits to ground which in turn maintains the feed circuit to the wiper motor windings.

During the two wiping strokes, the ratchet wheel continues to rotate.

5. Automatic "shut off' of the wiper is completed when the washer pump ratchet wheel has been rotated 360 degrees and the "shut off' occurs as follows: a. The pump ratchet relay armature moves into a position that prevents the ratchet pawl from engaging the ratchet wheel teeth (pawl extends through window in the armature). This action prevents further ratchet wheel rotation. b. The cam on the edge of the ratchet wheel opens holding contacts "B" (Fig. 2-75).

However, contacts "A" are still closed at this stage of operation. With contacts "A" still closed, the gear bosrelay coil is still energized completing the feed circuit to the motor windings, asd the motor continues to run.

NOTE: The washer pump 4-lobe cam rotates in unison with the wiper gear. c. Next, the fin on the washer pump 4-lobe cam opens holding contacts "A". This interrupts the ground circuit for both the gear box and washer pump demand relay coils. The demand relay switch contacts then open and the relay coil circuits will remain open until the shift lever switch is again used. At this stage of operation the gear box relay latch arm moves out into the path of the gear drive pawl.

However, the gear box relay switch contacts remain closed and the motor continues to run. d. The continuing operation of the wiper motor causes the gear drive pawl to engage the relay latch arm. When the pawl engages the latch arm, the clutch mechanism disengages the gear from the output shaft. e. The output shaft extends through the gear tube off center and the continuing rotation of the gear results in a cam action. This cam action causes the gear assembly drive pawl to push the relay latch arm into the relay housing.

When the latch arm is pushed into the housing far enough it opens the switch contacts shutting off the wiper motor.

2-46 WINDSHIELD WIPER SYSTEM

DEMAND RELAY 7

HOLDING SWITCH

f CONTACTS "B"

RATCHET WHEEL DOG-

Fig. 2-77-Pump Assembly

Fig. 2-75-Ratchet Wheel Cam

WASHER DISASSEMBLY

1. Remove retaining ring and slide 4-lobe cam off shaft (Fig. 2-76).

2. Remove holding switch retaining screw and lift the holdine switch assemblv and relay assembly off the p u k p mounting suiface (Fig. i-75). relay assembly from holding switch.

~ e p k a t e

3. Remove ratchet dog retaining screw and lift dog off the mounting surface.

4. Remove ratchet relay armature spring, ratchet pawl spring and remove ratchet relay armature

(Fig. 2-77).

5. Move leg of ratchet wheel spring out of the groove in the shaft and slide ratchet wheel and spring off the shaft.

6. Remove retaining ring and slide ratchet pawl off the cam follower pin.

7. Pull pump housing out until housing grooves clear the mounting surfaces; then lift the pump off the ratchet wheel shaft and cam follower pin (Fig.

2-78).

FOUR LOBE CAM

RET

RATCHET WHEE CAM FOLLOWER

V

-

Fig. 2-76-Four Lobe Cam Fig. 2-78-Pump Assembly

WINDSHIELD WIPER SYSTEM 2-47

Fig. 2-79-Aligning Pump to Motor

I

I

-lwinamm.weWamA1 ormr*cw- u r * o r r r r a P s l r a r n a

Fig. 2-8O:Wiper Operation

-

Fig. 2-81-Wiper Operational Cneck

2-48 WINDSHIELD WIPER SYSTEM

8. Carefully chisel off the four bent over tabs that secure the coil mounting bracket to the base.

9. Remove the coil and terminal board assembly.

NOTE: To mount the replacement relay assembly, hold it securely against the mounting surface and bend the four tabs over.

10. Note position of valve assembly relative to the pump housing for reassembly purposes, then remove the 4 screws that secure the valve ports to the pump housing.

NOTE: Save reassembly. haying to valve body gasket for

WASHER ASSEMBLY

1. Install pump over ratchet wheel shaft and cam follower pin with the tang on pump actuating plate facing up.

NOTE: WIPER

-

WASHER SHOULD START,

COMPLETE A WASH CYCE AND AUTOMATICALLY SHUT OFF.

(WIPER SHOULD OPERATE I N "LO" SPEED)

2. Align grooves in pump housing with mounting surface then release pump housing.

3. Move leg of ratchet wheel spring and install ratchet wheel on shaft.

4. Move pump actuating plate tang away and push ratchet wheel down until spring locks in groove of the shaft.

5. Install ratchet pawl over pin and install retaining ring.

6. If washer relay coil was removed for replacement, install new washer relay coil on base and bend tabs to securely hold relay coil in position.

7. Install relay armature.

8. Install relay armature spring.

9. Install ratchet pawl spring.

JUMPER CONNECTED TO #3

GROUND SIDE OF

POWER SOURCE

JUMPER FROM

#'

TERMINALS TO GROUND O N

PUMP COVER. D O NOT ALLOW

TERMINALS TO CONTACT EACH

OTHER.

5045

Fig. 2-82-Wiper

-

Washer Operational Check

WINDSHIELD WIPER SYSTEM 2-49

10. Install ratchet wheel dog and screw.

11. Position holding switch on demand relay and install unit on pump base with retaining screw.

NOTE: Align the two plastic guide pins with holes in pump mounting plate.

12. Connect wire connector to outboard connector

(one nearest to pump outlets).

13. Position 4-lobe cam over shaft and install retaining ring.

NOTE: Wiper motor must be in "PARK" position to assemble pump to wiper motor.

14. Rotate the 4-lobe cam so the index hole is aligned with the hole in the pump mounting plate. Insert a .120" to .125" diameter pin through both holes so the drive slot in the cam will be in the proper position for the drive pin (Fig. 2-79).

NOTE: Make sure the pump is in the free wheeling position before installing the pin.

15. Position pump on wiper so that the slot in the

4-lobe cam fits over the gear drive pin.

16. Install the three attaching screws and remove locator pin installed in step 14.

17. Connect wiring connectors to demand relay.

18. Install cover on washer pump.

DIAGNOSIS

-

WIPER MOTOR ON CAR

NOTE: To duplicate the various types of operation

LAW SHOOULO L l G M

-

I F NOT.

CHECK SWITCH c m A m

Y

Fig. 2-84-Checking Procedure independently of the car wiring and wiper control and shift lever switches refer to Figs. 2-80,2-81 and 2-82.

Preliminary Inspection

4

1. Car wiring securely connected to wiper motor and/or switches.

2. Wiper motor securely grounded.

3. With ignition switch "on", there is 12 v at center terminal of wiper motor.

4. Wiper control and shift lever switches are securely grounded.

Preliminary Operational Checks to Determine Type of Trouble

1. Check regular operation of wipers using wiper

Fig. 2-83-Checking Procedure

CHECKING I F HOLD W I T M

CONTACTS 'A' ARE CLOSED

LlWP SHWLD LIGHT

Fig. 2-85-Checking Procedure

M48

2-50 WINDSHIELD WIPER SYSTEM control switch. Check operation in all speeds and determine if wipers shut off correcbly.

If wipers operate correctly

- proceed to step 2. If wipers do not operate correctly

- proceed to step 4.

2. Demand Wiper Operation: a. To check Demand Wiper operation, momen- tarily depress the shift lever switch to the first detent position. The wiper should operate, making one complete wiping stroke and then automatically shut off. b. If the wipers operate correctly

3.

- proceed to step c. If the wipers do not operate correctly

- proceed to step 4.

3. Programmed Washer Operation: a. Momentarily depress shift lever switch to second detent position. The wipers and washer pump should operate with the pump delivering one cycle of pumping strokes and shutting off.

The wipers should make two .wiping strokes after the pumping action stops, and then automatically shut off. b. If the wipers and washer pump still do not operate correctly, proceed to step 4.

4. Quick check to determine if trouble is in washer pump programming mechanism: a. Remove washer pump cover and disconnect green lead from demand relay terminal and yellow lead from holding switch terminal.

NOTE: Be sure lead terminals do not touch wiper inetal. b. Connect wiring to washer pump and using the control switch re-check wiper operation as described in step 1.

If the wipers operate correctly, the trouble is located in the washer pump programming mechanism (demand relay and/or holding switches). See Figs. 2-83,2-84 and 2-85.

If the wipers and/or w s h e r pump do not operate correctly, refer to the Diagnosis Chart and select the condition that matches the existing trouble.

DIAGNOSIS CHART-DEMAND WIPER AND PROGRAMMED WASHER

Unless otherwise indicated. most of the following diagnosis procedures may be performed with the wipers installed on car.

CONDITION APPARENT CAUSE

. Wiper motor operates correctl: rith wiper control switch but d l not start when shift lever witch is used in either detent

,osition.

A. Shift lever switch ground connection loose.

B. Light blue wire to shift lever switch open.

2. Wiper inoperative when eithe~ the wiper control or shift lever switches are used.

C. Shift lever switch defective.

A. Fuse blown.

CORRECTION

A. Check shift lever switch ground connection.

B. Check harness connectors-

Shift lever switch to wiper control switch.

C. Disconnect It. blue wire from shift lever switch and momentarily touch it to ground. If wiper operates correctly, trouble is in shift lever switch.

A. Check for 12v at center terminal of wiper motor. If no voltage, check fuse or open circuit in feed wire.

WINDSHIELD WIPER SYSTEM 2-5 1

3. Wiper operates correctly with wiper control switch but when shift lever switch is depressed to the first detent and released quickly, the wiper blades start out of the park position but quickly return to park without making a complete wiping stroke.

4. Wipers will not shut off.

Blades operate through normal wipe pattern.

B. Lt. blue wire from wiper terminal No. 1 open.

C. Wiper Linkage locked or binding. Disconnect transmission drive link from wiper motor crank arm and check operation by observing motor crank arm.

A. Demand Relay Coil Open

B. Connect wiper terminal No. 1 to ground, and leave harness connector attached to wiper terminals. If wiper operates, check car wiring connectors, wiper control switch connections to locate open circuit in light blue wire.

C. Operate wiper independently of car wiring and wiper control or shift lever switches.

(Fig. 2-83).

If wiper operates correctly, recheck fuse and It. blue wire.

If wiper motor is still inoper- ative, remove motor and refer to

Diagnosis Chart

-

Wiper Off Car

(round motor)

A. Refer to'~ig. 2-83 for checking procedure.

B. Refer to Fig. 2-83 for checking procedure.

C. Refer to Fig. 2-84 for checking procedure.

D. Refer to Fig. 2-85 for checking procedure.

B. Demand Relay switch contacts dirty or not closing.

C. Holding contacts "A" not closing.

D. Yellow and/or prange leads not connected to demand relay or poor solder connections.

A. Holding switch contacts "A" or "B" (Fig. 2-70) not open- ing.

B. Wire between wiper terminal

No. 1 and wiper control switch or shift lever switch grounded.

A. Turn ignition switch " o f ' then back "on". If wipers shut off, the trouble is in the holding switch contacts. Repair or adjust holding switch as required. If wipers don't shut off, proceed to following step.

B. Remove washer pump cover and disconnect green lead from demand relay terminal and yellow lead from holding switch terminal. Be sure the lead terminals do not touch wiper metal. Re-connect

Ear wiring to washer pump and using wiper control switch re-check wiper operation through all speeds and park.

I

2-52 WINDSHIELD WIPER SYSTEM

3. Defective wiper control

)r shift lever switch.

3. Wiper gear box relay

:oil grounded.

5. Wipers won't shut off.

Blades move up and down approximately 15 degrees in and out of park

'position and wipers have

"Hi"

speed only.

9. Wiper motor defective.

Shunt field open.

B. Wire between wiper terminal No. 3 and wiper

:ontrol switch open.

E. Wiper controI switch lefective.

If the wipers shut off recheck holding switches and/or a grounded yellow or orange demand relay lead.

If the wipers. do not shut off, proceed to step C below.

C. Remove light blue wire from connector that plugs on wiper terminals and re-install connector on wiper terminals.

If the wipers shut off, locate grounded condition in light b h e wire.

D. If the wipers did not shut off in step C, the wiper motor gear box relay coil is grounded or the red lead between the coil and wiper terminal No. 1 is grounded.

@

A. To eliminate wiper motor leave harness connector on wiper ter- minals and connect terminal

No. 3 to ground.

If the wiper motor then has "Lo" speed and shuts "off', the trouble is in the car wiring or wiper control switch. Proceed to steps

B and C.

If the wiper motor still has

"Hi" speed only and will not shut off, remove the motor and refer to Diagnosis Chart

-

Wiper Off

Car (round motor)

B. Check for loose harness connectors and/or wiper control switch connections.

C. Remove harness from wiper control switch. Ground the black and light blue wire terminals to start motor, then disconnect the light blue lead from ground.

If the wiper motor runs in "Lo" speed and shuts off, the wiper control switch is defective.

WINDSHIELD WIPER SYSTEM 2-53

Washer pump pumps ntinually when wiper motor is "on". Wiper motor operates normally otherwise.

17. Wipers have "Hi" speed only.

8. Wipers have

"Lo"

speed only and shut off correctly.

A. Dark blue wire between washer pump and control switches grounded.

B. Defective wiper control switch.

C. Washer pump defective.

Washer pump ratchet wheel not being rotated by ratchet pawl.

A. See item 5

A. switch.

B. Black wire from wiper terminal No. 3 to w i p r control switch is grounded.

If the wiper motor still has "Hi" speed only and recycles, there is an open in the black wire.

A. Disconnect harness connector from washer pump terminals.

If the washer stops pumping, the trouble is in the wiring or wiper control switch.

If the washer continues to pump, proceed to step C.

B. Connect harness to pump and disconnect dark blue wire from wiper control switch.

Turn motor "on".

If washer pump shuts "off", trouble is in wiper control switch.

If washer keeps pumping, proceed to step C.

C. Remove washer pump cover and connect wiring to wiper control switch and pump. Observe if ratchet wheel is rotating while pump is operating.

If ratchet wheel is not rotating, check for a sheared tooth on ratchet wheel. Check for broken ratchet wheel dog or dog not engaging ratchet wheel teeth.

Repair or replace parts as required.

A. See item 5

-

A. Remove solid black wire from connector that plugs on wiper terminals.

B. If wipers have "Hi" speed after step A, locate ground in black wire or replace wiper control switch as required.

2-54 WINDSHIELD WIPER SYSTEM

I.

Intermittent operation iith wiper control witch "on".

C. Wiper motor defective.

A. Loose wiper ground strap.

C. Loose wiring connection

D. Defective wiper motor.

C. If wipers still have "Lo" speed only after step A, remove wiper motor and refer to Diagnosis Chart-

Wiper Off Car. (round motor)

A. Check ground strap for secure ground.

B. Check switch mounting for looseness and secure ground.

C. Check all wiring connections for proper engagement.

D. Remove motor and refer to

Diagnosis Chart-Wiper Off

Car (round motor).

UNDERBODY 3-1

SECTION

3

INDEX

SUBJECT PAGE SUBJECT

Underbody Alignment

. . . . . . . . . . . . . . . . . . . . .

3-1 Horizontal Dimensions -"F" Bodies

. . . . . . . . . . .

3-2

General Bodv Construction

Alignment Checking.

Reference Point Dimensions.

.................

. . . . . . . . . . . . . . . . . . . . . .

3-1

3-1

Vertical Dimensions -"F" Bodies

Horizontal Dimensions

-

"X" Bodies

. . . . . . . . . . . . .

. . . . . . . . . . .

3-3

3-3

. . . . . . . . . . . . . . . . .

3-1 Vertical Dimensions

-

"X" Bodies

. . . . . . . . . . . . .

3-4

I

UNDERBODY ALIGNMENT

GENERAL BODY CONSTRUCTION

The "F and X" series bodies are of unitized construction. A stub frame supports the front end sheet metal, front suspension, engine and other mechanical components. Unitized construction de- mands that underbody components be properly aligned to assure correct suspension location. In the event of collision damage, it is important that the underbody be thoroughly checked and, if necessary, realigned in order to accurately establish proper dimensions.

Since each individual underbody component contrib- utes directly to the over-all strength of the body, it is essential that proper welding, sealing and rust- proofing techniques be observed during service operations. Underbody components should be rust- proofed whenever body repair operations, which destroy or damage the original rust-proofing, are completed. When rust-proofing critical underbody components, it is essential that a good quality type of air dry primer be used (such as corrosion resistant zinc chromate). It is not advisable to use combination type primer-surfacers.

There are many classifications of tools that may be employed to correct the average collision damage situation including frame straightening machines, lighter external pulling equipment and standard body jacks.

ALIGNMENT CHECKING

An accurate method of determining the alignment of the underbody utilizes a measuring tram gage. The and tram gage required to perform all recommended measuring checks properly must be capable of extending to a length of 90 inches. At least one of the vertical pointers must be capable of a maximum reach of 18 inches.

Dimensional checks indicafkd in the upper portion of

Figure 3-1 and 3-3 are calculated on a horizontal plane parallel to the plane of the underbody. Precision measurements can be made only if the tram gage is also parallel to the plane of the underbody. This can- be controlled by setting the vertical pointers on the tram gage according to the dimensional checks shown in the lower portion of Figure 3-1 and 3-3. For actual dimensions, see applicable charts in text.

A proper tramming tool is essential for analyzing and determining the extent of collision misalignment present in underbody construction.

To assist in checking alignment of the underbody components, repairing minor underbody damage or locating replacement parts, the following underbody dimensions and alignment checking information is presented.

Reference Point Dimensions-(Fig. 3-1 and 3-3)

Dimensions to gage holes are measured to dead center of the holes and flush to adjacent surface metal unless otherwise specified. The master gage holes, adjacent to the No. 1 body mount and in the side rails near the

,rear spring front attachment, are key locations and should be used wherever possible as a basis for checking other reference points.

3-2 UNDERBODY

Fig. 3-1 Horizontal and Vertical Checking Dimensions - "F" Bodies

Horizontal Dimensions

-

"F" Bodies (Fig. 3-1)

Fig.

Ref. Dimension Location

Between rear edges at centerline of 1-5/ 16" holes in lower surface of rails directly below radiator support mounting location.

Between inboard surface of rails at steering gear lower front mounting location and steering idler arm lower mounting loca- tion. (These locations are not equally distant from frame centerline).

Rear edge at centerline of 1-5/

16" hole in lower surface of rail directly below radiator support mounting location to center of

518" master gage hole adjacent of No. 1 body mount on same side of frame.

Fig.

Ref. Dimension Location

D 57-1/4 Rear edge at centerline of 1-5/

16" hole in lower surface of rail directly below radiator support mounting location to center of

5/8" master gage hole adjacent to No. 1 body mount on opposite side of frame.

E 45-114

F 32-7/8

Between centers of 5/8" master gage holes adjacent to No. 1 body mount in frame or body.

Center o<5/8" master gage hole adjacent to No. 1 body mount to center of No. 2 body mount location on same side of frame or body.

,

G 33-7/16 Between centers of No. 2 body mount bolt holes.

UNDERBODY 3-3

Fig.

Ref. Dimension Location

,

Center of 5/8" master gage hole adjacent to No. 1 body mount to center of 11/16" master gage hole in compartment side rail on opposite side of body.

Center of 5/8" master gage hole adjacent to No. 1 body mount to center of 11/16" master gage hole in compartment side rail on same side of body.

Between centers of 1 1 / 16" rnas- ter gage holes in compartment side rails.

Center of 11/16" master gage hole in compartment side rail to a point at inboard lower edge of opposite side rail on centerline of shackle bolt hole (see Fig.3-2).

Center of 11/ 16" master gage hole in compartment side rail to a point at inboard lower edge of same side rail on centerline of shackle bolt hole (see Fig. 3-2).

Between inboard lower edges of compartment side rails on centerline of shackle bolt hole

(see Fig. 3-2).

Between centers of rear bumper lower attaching bolt holes.

Vertical Dimensions

-

"F" Bodies (Fig. 3-1) a b c d

9-11/16

9-1/16

9-15/16

6-9/16 e 3- 15/ 16"

Rear edge at centerline of 1-51

16" hole in lower surface of rail directly below radiator support mounting location.

5/8" master gage hole in frame adjacent to No. 1 body mount.

5/8" master gage hole in body adjacent to No. 1 body mount.

Floor pan adjacent to No. 2 body mount gage nut.

Compartment side rail adjacent to 11/16" master gage hole.

I

Q OF BODY

'

FRONT OF BODY

Fig. 3-2 Side Rail at Rear Spring Shackle

Bushing - "F" Bodies

Fig.

Ref. Dimension Location f 17-1/16 Lower horizontal surface of compartment side rail above rear 20tle housing. g 13-114 Lower surface of compartment side rail at centerline of shackle bolt hole (see Fig. 3-2).

Horizontal Dimensions-

"X" Bodies (Fig. 3.3)

Rear edge at centerline of 7/8" hole in lower surface of rail approximately 2" rearward of lower front edge of rail.

Rear edge at centerline of 7/8" hole in lower surface of rail approximately 2" rearward of lower front edge of rail and center of master gage hole ad- jacent to No. 1 body mount on same side of body.

'

Rear edge at centerline of 7/8" ho'le in lower surface of rail approximately 2" rearward of lower front edge of rail and center of master gage hole ad- jacent to No. 1 body mount on opposite side of body.

Center of master gage hole adjacent to No. 1 body mount.

3-4 UNDERBODY

Fig. 3-3-Horizohtal Vertical Checking Dimensions

Fig.

Ref. Dimension Location

Rear edge at centerline of No. 2 body mount bolt hole.

Center of master gage hole ad- jacent to No. 1 body mount and center of master gage hole in side rail on opposite side of body.

Fig.

Ref. Dimension Location

Center of master gage hole in side rail and a point at inboard edge of opposite side rail at centerline of shackle bolt hole

(See Fig. 3-4).

Inboard edge of side rail at centerline of shackle bolt hole

(See Fig. 3-4).

Center of master gage hole ad- jacent to No. 1 body mount and center of master gage hole in side rail on same side of body.

Center of master gage hole in side rail.

Center of rear bumper lower attaching bolts.

Vertical Dimensions-

"X" Bodies (Fig. 3-3)

Center of master gage hole in side rail and a point at inboard edge of same side rail at cen- terline of shackle bolt hole (See

Fig. 3-4).

\ a 10-1/8 7/8" hole in lower surface of rail approximately 2" rearward of lower front edge of rail.

UNDERBODY 3-5

Fig.

Ref. Dimension Location

Master gage hole adjacent to No.

1 body mount in frame.

Master gage hole adjacent to No.

1 body mount on body.

Floor pan adjacent to No. body mount bolt cage nut.

Master gage hole in side rail.

2

Lower surface of side rail at kick-up either side of rear axle housing.

Lower surface of side rail at centerline of shackle bolt hole. b

O F BODY

FRONT O F BODY

/

/

-

CI.

Fig. 3-4-Side Rail at Rear Spring Rear Shackle

Bushing ("Xu Bodies)

STATIONARY GLASS 4- 1

SECTION 4

SUBJECT PAGE

Adhesive Caulked Glass ............................................ 4-1

Description ................................................................ 4-1

Removal

.......................................................................

Installation (Short Method)

4-2

.................................

Installation (Extended Method)

4-3

.............................

4-4

SUBJECT PAGE

Waterleak Correction

...............................................

Bonded Rear View Mirror Support

4-7

.......................

4-7

Description

Installation

..................................................................

..................................................................

Removal

4-8

.......................................................................

ADHESIVE CAULKED GLASS

DESCRIPTION

The windshield and back window on all styles are bonded to body opening with a synthetic, self-curing, rubber adhesive caulking compound.

To replace a window installed with this material requires either partial or complete replacement of caulking compound. Partial replacement of material is referred to as "short method". Complete material replacement is known as "extended method".

The "short method" can be used in those situations where original adhesive eauk material remaining on window opening pinchweld flanges after glass removal can serve as a base for the new glass. This method would be applicable in cases of cracked windshields or removal of windows that are still intact. In these situations, the amount of adhesive that is left in window opening can be controlled during glass removal.

The "extended method" is required when the original adhesive caulking compound remaining in window opening after glass removal cannot serve as a base for replacement glass. Examples of this latter situation would be in cases requiring metal work or paint refinishing in the opening, or where there is a considerable loss of adhesion between original caulk and body metal. In these cases, original caulk is removed and replaced with fresh material during window installation.

Adhesive Caulking Kit No. 4226000 or equivalent contains some of the materials needed to remove and replace an adhesive caulked glass. This kit can be obtained through service parts systems. Ofher materials that may be required are available as service parts or can be readily obtained through local supply shops.

The components of adhesize caulking kit No. 4226000 are as follows:

1. One tube of Adhesive Caulking material.

2. One dispensing nozzle (cut for "short method" but can be notched-out for "extended method").

3. Steel music wire (.020 diameter).

4. Adhesive Caulking Primer (for priming original adhesive material in window opening).

Additional material required:

1. Caulking gun

- standard household cartridge type reworked as follows:

A. Widen end-slot to accept dispensing end of adhesive caulking tube.

.

B. Reduce diameter of plunger disc on rod so that disc can enter large end of adhesive caulking tube.

2. Two pieces of wood'for wire handles.

3. Black weatherstrip adhesive.

4. Paint Finish Primer

- available as service part No.

4226001 or equivalent

- use only with "extended method".

5. Rubber glass spacers

- for "extended method".

4-2 STATIONARY GLASS

6. Lower support spacers methods".

- for "short and extended

NOTE: When glass is originally installed, a rubber sealing strip "dam" is used around edges of window to prevent excessive squeeze-out of adhesive caulk material. Service installations do not utilize this part. By applying masking tape around inner perimeter of glass prior to window installation, excess squeeze-out material is picked- up and removed with tape.

ADHESIVE CAULKED WINDOW

REMOVAL

The window removal procedure is the same for both the "short" and "extended" installation methods with one exception. If the "short method" installation is to be used, more care must be used during removal to make certain that an even, uniform bead of adhesive caulk material remains on window opening to serve as a base for replacement glass. Also, make certain that glass lower support spacers are not disturbed.

1. Place protective coverings around area where glass is being removed.

2. Remove all trim and hardware immediately adjacent to glass being removed. Depending on the window involved, this could involve window reveal moldings, garnish moldings or finishing lace, and windshield wiper arms.

NOTE: Reveal molding removal is covered in

Exterior Molding Section 16.

3. On styles equipped with optional rear window electric grid defogger (heating elements in glass), disconnect wire harness connectors from glass.

Refer to style usage and connector location chart in electric back window grid defogger portion of

Electrical Section 15 for style usage, location of feed and ground wire connectors, and if trim removal is required to service connectors. If glass is to be reinstalled, tape leads to inside surface of glass to protect them during handling.

NOTE: For quarter upper trim removal, refer to

"Door and Quarter Trim", Section 13.

4. On styles equipped with radio antenna built into windshield glass, disconnect antenna lead at lower center of windshield. If glass is to be reinstalled, fold and tape lead wire back onto outer surface of windshield to protect it during glass removal and installation.

5. Secure one end of steel music wire to a piece of wood that can serve as a handle. Using long nose pliers, insert other end of wire through caulking

I

\

Fig. 4-1-Cutting Adhesive Caulk Material material at edge of glass; then, secure that end of wire to another wood handle (Fig. 4- 1).

6

6. With aid of helper, carefully cut (pull wire) through caulking material around entire perime- ter of window. If "short method" will be used to install new glass, hold wire close to inside plane of glass to prevent cutting an excessive amount of adhesive caulking from window opening. Keep tension on wire throughout cutting operation to prevent wire from kinking and breaking (Fig.

4-1).

NOTE: Optional methods of glass removal which requires only one man are: (1) electric hot-knife

Fig. 4-2-Electric Hot-Knife Removal Method

STATIONARY GLASS 4-3

Fig. 4-3-One Man Wire Removal Method

(not recommended due to inaccessibility at lower corners of windshield glass), and (2) pulling cutting wire through upper and lower edges of glass simultaneously. For latter optional method, insert one end of wire through caulking material at inner upper edge of glass and other end of wire through caulking material at inner lower edge.

Attach handles to both wire ends outside of body

(Figs. 4-2 and 4-3).

7. If glass being removed is to be reinstalled, place it on a protected bench or holding fixture; remove old caulking material using a razor blade or sharp scraper. Any remaining traces of caulk can be removed with toluene or thinner dampened cloth.

IMPORTANT: When cleaning laminated glass, avoid contacting edge of plastic laminate material

(on edge of glass) with volatile cleaner. Contact may cause discoloration and deterioration of plastic laminate by "wicking" action.

IMPORTANT: DO NOT use a petroleum base solvent such as kerosene or gasoline. The presence of oil will prevent adhesion of new caulking material.

ADHESIVE CAULKED GLASS

INSTALLATION-"Shortw Method

The "short" method of glass installation can be used if original adhesive caulk material remaining on window opening flanges after glass removal can serve as a base for replacement glass. If there is substantial loss of adhesion between adhesive caulk material and body metal. or window o ~ e n i n e must be reworked' or refinished, "extended" method of replacement will be required.

Installation-"Short" Method

1. Inspect reveakmolding retaining clips. Replace or re-shape clips which are bent away from body metal 1/32" or more.

2. Position glass in the window opening. If new glass is being installed,'check relationship of glass to adhesive caulk material on pinchweld flange.

Gaps in excess of 1/8" must be corrected by shimming or by applying more adhesive caulk material than specified in Step 7. For further alignment of glass refer to Step 8 of extended method.

3. When glass is in proper position in opening, apply piece of masking tape over each side edge of glass and adjacent body pillar. Slit tape vertically at edge of glass. During installation, tape on glass can be aligned wi h tape on body to guide window into desired posit

!

4. Using clean lint-free cloth liberally dampened with Adhesive Caulking Primer (furnished in Kit

No. 4226000) or equivalent, briskly rub primer over original adhesive material remaining on pinchweld flange. Perform the following steps while allowing primer to dry for 5 to 10 minutes.

IMPORTANT: Use care so as not to spill or drip primer on painted or trimmed surfaces.

5. Apply 1" wide masking tape to inside of windshield glass 1/4" inboard from edge of glass, across top and down each side, to facilitate clean- up after installation.

6. Wipe surface of glass to which adhesive caulking material will be applied (around edge of inside surface) with a clean, water-dampened cloth. Dry glass with clean cloth.

7. Apply smooth continuous bead of adhesive caulking material around entire inside edge of glass. Material should be 1/8" to 3/16" in diameter (Fig. 4-4). i

IMPORTANT: Due to fast curing characteristics of adhesive caulking material, glass' installation should be completed within 15 minutes from start of application of material to glass.

8. With aid of helper, lift glass into window opening.

On back window installations it will be necessary to use suction cups to position glass in opening.

Windshield glass can.be positioned without aid of carmine devices. As shown in Figure 4-5, carry

4-4 STATIONARY GLASS

~

-- - - ~

N O Z Z L E I N KIT

C A U L K I N G MATERIAL

\

118 T O 3 / 1 6

D I A . BEAD

Fig. 4-4-Adhesive Material Application-Short

Method glass with one hand on inside of glass and one hand on outside. At window opening, put glass in horizontal position. While one man holds glass in this position, second man can reach one arm around body pillar and support glass while other man assumes same position. Quarter window glass can be installed in same manner.

9. Using tape guides applied in Step 3, carefully position glass in window opening. Guide outer lower surface of glass along rear edge of front fenders, making certain glass is properly centered and positioned on lower metal supports.

10. Press glass firmly to "wet-out" and ''set" caulking material. Use care to avoid excessive squeeze-out which would cause an appearance problem.

11. Watertest car immediately using cold water spray.

Do not direct hard stream of water at fresh adhesive material. If any leaks are encountered, paddle-in extra adhesive material at leak point using a stick or flat-blade tool.

12. Install window reveal moldings. Remove clean-up masking tape from inner surface of glass and install remaining parts.

ADHESIVE C4ULKED GLASS

INSTALLATION-"Extended" Method

If adhesive caulk material remaining in window opening after window removal is damaged, or must be removed to permit refinishing of window opening, or has insufficient adhesion to body metal to serve as a base for replacement glass, it will be necessary to use

"extended" installation method.

Installation-"Extended Method

1. Remove screw-retained lower glass supports

(windshield only).

2. Using sharp scraper or chisel, remove MAJOR portion of old caulking material from window opening flanges around entire opening. It is not necessary that all traces of material be removed, but there should not be any mounds or loose pieces left.

3. Inspect reveal molding retaining clips. If upper end of clip is bent away from body metal more than 1 /32", replace or reform clip.

4. Using black weatherstrip adhesive or adhesive caulking material, cement flat rubber spacers No.

4459429 or equivalent to window opening pinchweld flanges. As shown in Figure 4-6,

Fig. 4-5-Glass Installation

\

'A' LOCATION ' 0 ' LOCATION

Fig. 4-6-Glass Spacer Installation

STATIONARY GLASS 4-5 location "B", spacers should be positioned to provide equal support around entire perimeter of glass.

NOTE: If weatherstrip adhesive is used, apply sufficient material to obtain watertight seal beneath soacer. however. DO NOT allow exces- sive squeke-obt. weatherstrip adhesive is not compatible with replacement adhesive caulking material and waterleaks may develop at locations where these two materials are used together to form seal.

5. Figure 4-6, location "A", illustrates rectangular spacers positioned in typical back window installation. Re-install metal supports at lower edge of windshield glass (in lieu of two lower "A" spacers indicated in back window installation).

6. With aid of helper, lift glass into window opening.

On back window installations it will be necessary to use suction cups to position glass in opening.

The windshield glass can be positioned without aid of carrying devices as described in Step 7

(Figure 4-5).

7. With one hand on each side of glass, put window in vertical position and support it on lower glass support spacers. While one man holds glass in this position, second man can reach one arm around body pillar and support glass while other man

. assumes the same position. Quarter window glass can be installed in same manner.

8. With glass positioned in opening, check relation- ship of glass to pinchweld flange around entire

LOCATION

& STYi3s

SPACER REQUIREMENTS FOR ADHESIVE CAULKED GLASS

I

7694478

.34x. 44x. 75

SPACER PART NUMBERS AND SIZE

9848544

.52xV44x.75

9842329

.75x. 44x. 75

9831753

.36x.44x.75

I

WINDSHIELD

ALL STYLES

QUARTER WINDOW

A-36-46-56 & 66

B-35-45

BACK W I N D O W

A,B,C39-49-69,

D , F J

C37-47

OLDS & CAD "El1

BUICK "EM

SKYLIGHT FRONT

A-56-66

SKYLIGHT SIDE i

A-56-66

2

2

3

5

2

2

2

2

*

Spacer No. 4459429 i s used only i n extended method of glass i n s t a l l a t i o n and i s i n s t a l l e d between pinchweld flange and g l a s s .

4459429

*

.X1x.63x1.O

I

7

6

6

6

6

4

4

6

6

Fig. 4-7-Spacer Requirement Chart

4-6 STATIONARY GLASS perimeter. Overlap of pinchweld flange should be equal with minimum overlap of 3/16". Overlap across top of windshield may be corrected by repositioning lower metal support spacers. Over- lap across top of back window may be varied by shimming or shaving lower glass support spacers.

For spacer requirements refer to chart (Figure

4-7). Spacers are available as service parts.

Equivalent spacers may be used.

9. Check relationship of glass contour to body opening. Gap space between glass and pinchweld flange should be no less than 1/8" nor more than

1/4". If difficulty is encountered staying between these limits, correction can be made by any one of the following methods: a. Reposition flat spacers. b. Apply more caulking material than is specified at excessive gap areas. Material can be applied to pinchweld flange or by allowing bead on glass to exceed 318" height at gap areas. c. Change glasses better.

- another glass may fit opening d. Rework pinchweld flange.

10. After final adjustments have been made and glass is in proper position, apply pieces of masking tape over edges of glass and body, depending on window being installed. Tape on glass can be aligned with tape on body to guide glass into opening during installation.

11. Remove glass from opening and apply one-inch masking tape around inner surface of glass 1/4" inboard from outer edge. On windshield installa- tions, apply tape to top and sides only. Do not use tape across bottom. Removal of tape after glass installation will aid in clean-up and give a smooth, even edge to adhesive material (Fig. 4-8).

12. Using clean lint-free cloth liberally dampened with Adhesive Caulking Primer or equivalent

(supplied in Kit No. 4226000), briskly rub primer over original adhesive material remaining on pinchweld flange. Perform the following steps while allowing primer to dry for 5 to 10 minutes.

NOTE: If pinchweld flange has been repainted, prime pinchweld flange with Paint Finish Primer

No. 4226001 or equivalent. Paint Finish Primer is available as a service part.

IMPORTANT: Use extreme care to avoid spilling either primer solution on trim or painted surfaces.

Wipe any spills immediately as primers will etch trim or painted surfaces on prolonged contact.

13. Nozzle furnished in kit is designed for "short" method. For "extended" method, enlarge nozzle opening by removing material within score lines as indicated in Figure 4-8. Do not notch nozzle beyond score lines.

14. Wipe surface of glass to which bead of adhesive caulking material will be applied (between masking tape and edge of glass) with clean water- dampened rag. Dry glass with clean cloth.

15. With caulking gun and nozzle positioned as illustrated in Figure 4-8, carefully apply smooth continuous bead of caulking material 3/8" high by 3/16" wide at base completely around inside edge of glass.

NOTE: Adhesive caulk material begins to cure after fifteen minute exposure to air; therefore, install glass in opening as quickly as possible.

16. Using tape guides applied in Step 10, carefully position glass in window opening. Guide lower outer surface of glass along rear edge of front fenders to avoid smearing fresh adhesive caulk material on instrument panel (Figure 4-5). Make certain glass is properly aligned &o tape guides on pillars, and positioned on lower metal supports.

Apply light hand pressure to "wet-out" adhesive material and obtain bond to body opening.

17. Watertest immediately using cold water spray. Do not direct stream of water at fresh adhesive material. Allow water to spill over edges of glass.

FOR EXTENDED M E T H O D , ENLARGE

N O Z Z L E B Y C U T T I N G - O U T MATERIAL

W I T H I N SCORE LINES

Fig. 4-8-Adhesive Material Application

Extended Method

STATIONARY GLASS 4-7

If waterleak is encountered, use flat-bladed tool to work-in additional caulking material at leak point.

18. Install window reveal moldings. Then, carefully remove masking tape from around inner periph- ery of window. Pull tape toward center of glass to give a clean-cut edge to adhesive caulk, and to prevent excess squeeze-out material on tape from creating an additional clean-up problem.

19. Install all other previously removed parts and clean-up.

WATERLEAK CORRECTION OF

ADHESIVE CAULKED .GLASS

Adhesive caulked glass installation waterleaks can be corrected in the following manner without removing and reinstalling glass.

NOTE: The following procedure is applicable only with use of adhesive caulking material and primer furnished in Kit Part No. 4226000 or equivalent.

1. Remove reveal moldings in area of leak. In some

OPERATION A

OPERATION C OPERATION D '

( 2 9 4

Fig. 4-9-Adhesive Caulked Glass Waterleak

Correction

DESCRIPTION

BONDED

PRIME

OPERATION B

The rear view mirror support on "B, C, D, E and,FU styles is bonded to windshield glass with a p l y vinyl- cases, it may become necessary to remove garnish moldings or finishing lace to locate source of leak.

2. Mark location of leak(s).

IMPORTANT: If leak is between adhesive caulking material and body or between material and glass, carefully push outward on glass in area of leak to determine extent of leak. This operation should be performed while water is being applied to leak area. Mark extent of leak area.

3. From outside body clean any dirt or foreign material from leak area with water; then dry area with air hose.

4. Using a sharp knife, trim off uneven edge of adhesive caulking material (see Operation "A"

Fig. 4-9) at leak point and 3 to 4 inches on both sides of leak point or beyond limits of leak area.

5. Using small brush, apply adhesive caulking material primer over trimmed edge of adhesive caulking material and over adjacent painted surface (See Operation "B" Fig. 4-9).

6. Apply adhesive caulking material, as shown in

Operation "C" (Fig. 4-9), at leak point and 3 to 4 inches on both sides of leak point or beyond limits of leak area.

7. Immediately after performing Step 6, use flat stick or other suitable flat-bladed tool to work adhesive caulking material well into leak point and into joint of original material and body to effect watertight seal along entire length of material application (See Operation "D" Fig. 4-9).

8. Spray watertest to assure that leak has been corrected. DO NOT run heavy stream of water directly on freshly applied adhesive caulking material.

The quarter window on the Cadillac "E-47" style is retained by a rubber channel and integral metal retainer fastened by attaching screws. Quarter inner upper trim must be removed to gain access (refer to

Door and Quarter Trim, Section 13). For glass replacement use a light bodied sealer between rubber channel and glass and medium bodied sealer between rubber channel and outer panel to attain a water tight condition.

MIRROR SUPPORT

butyral patch, through assembly plant.

'heat induction process, at

Service replacement windshield glass may have rear view mirror support bonded to windshield glass as an

4-8 STATIONARY GLASS assembly. When glass replacement is required, simply transfer rear view mirror from one glass to another.

If rear view mirror support must be removed or installed on original windshield glass, or if rear view mirror support is not attached to a replacement windshield glass, installation may be performed with use of Loctite Minute-Bond Adhesive 3 12, Catalog No.

33-33, as available from all Loctite distributors, or an equivalent.

Depending upon operation to be performed some or all of the following materials will be required:

1. Loctite Minute-Bond Adhesive 3 12 two component pack, Catalog No. 33-33, or equivalent.

2. Replacement rear view mirror support, Service

Part No. 9831062, (or equivalent) or original mirror support, prepared per Steps 4 and 5 of installation procedure.

3. Wax marking pencil, or crayon.

4. Heat Gun (air blower type), 250 to 350 degree range (required only if rear view mirror support must be removed).

5. Domestic scouring cleanser, glass cleaning solu- tion, or glass polishing compound.

6. Rubbing alcohol.

7. Clean paper towels.

8. Fine grit emery cloth or sand paper (No. 320 or

No. 360).

9. Clean toothpick.

10. Asbestos cloth or paste.

INSTALLATION

1. Determine rear view mirror support position on windshield. Support is located at center of glass at one of following dimensions from base of glass to base of support (dimension "A" Figure 4-10):

A. 20 1/4"

-

"B"-39-47-57 and 67 styles (less

26847) and "E"-47-57 and 67 styles.

B. 20 3/4"

-

"BU-35-45-49-69 and 26847 styles and "C"-37 and 47 styles.

2. When location is determined, mark location on outside of glass with wax pencil or crayon. Also make larger diameter circle around the mirror support circle, on the outside glass surface (see

Figure 4- 10).

3. On inside glass surface, clean large circle with paper towel and domestic scouring cleanser, glass cleaning solution or polishing compound. Rub until area is completely clean and dry. When dry, thoroughly clean area with an alcohol saturated paper towel, to remove any traces of scouring powder or cleaning solution from this area.

4. With piece of fine grit (No. 320 or No. 360) emery cloth or sandpaper, completely sand bonding surface of new rear view mirror support, Part No.

9831062, (or equivalent) or factory installed support.

NOTE: If original rear view mirror support is t o be reused, all traces of factory installed vinyl patch must be removed prior to re-installation.

5. Wipe sanded mirror support with clean paper towel saturated with alcohol, and allow to dry.

4

6. With spray can of accelerator material provided in

Loctite Kit (or equivalent), lightly spray minute- bond accelerator to bonding surfaces of mirror support and windshield glass, and allow to dry completely.

NOTE: DUE TO RAPID BOND OF ADHESIVE

THE FOLLOWING STEPS MUST BE PER-

FORMED WITHOUT HESITATION.

7. When both bonding surfaces have dried, apply two drops of adhesive to mirror support, and with toothpick quickly distribute adhesive evenly over entire bonding surface of mirror support.

D. 2 1 1 /4"

-

"C"-39-49 and 69 styles and "D"

23 and 33 styles.

-

\

Figure 4-10-locating Bonded Rear View Mirror

Support on Glass

STATIONARY GLASS 4-9

8. Properly position support to its pre-marked location, with rounded end pointed upward; press support against glass for, 30 to 60 seconds, exerting steady pressure against glass. After five minutes, any excess adhesive may be removed with an alcohol moistened paper towel or glass cleaning solution.

REMOVAL

1. Remove rear view mirror from support.

2. Protect windshield glass adjacent to mirror support by placing water dampened asbestos cloth or powdered asbestos paste on inside of glass, around support.

3. From inside of glass, heat mirror support with an air blower type heat gun to 250 to 350 degrees; then, carefully exert gentle sideward pressure on support with pliers until it disengages from glass,

'as shown in Figure 4- 1 1.

IMPORTANT: Care must be exercised during this operation because insufficient heat will not free mirror support, and pressure on support may result in damage to glass. If excessive heat is

Figure 4-1 I-Removal of Bonded Rear View

Mirror Support From Glass applied, plastic laminate in windshield glass may become damaged.

4. After removal of rear view mirror support carefully scrape any remaining traces of adhesive or vinyl patch from glass surface. Both windshield glass and mirror sup ort may now be prepared and installed per insta

! lation Steps 1 through 8.

FRONT END 5-1

SECTION 5

SUBJECT

Body Ventilation

Ventilation System Components

Conditioned Styles

Description

-

Non-Air

......................................................

-

Non-Air Conditioned Styles

........

5-1

Shroud Center Duct High Level Air Outlet and

Door

-

"B-C-E" Styles

"B- C-EM Styles

............................................

Low-Level Air Duct Outlet, Door and Grille

-

5-2

.........................................................

Shroud Center Duct High-Level Air Outlet

Door

-

"A" Styles

.....................................................

Shroud Center Duct High-Level Air Outlet and

Door

-

"F" Styles

....................................................

5 4

High-Level Ventilation Blowers

Styles

-

Buick "A"

.............................................................................

INDEX

PAGE SUBJECT PAGE

Shroud .Side Finishing Panel

Styles

-

"A-B-C-E-F-X"

............................................................................

5-5

Pressure Relief Valve

-

"A-F" Styles

.................

Hood Latch Release Cable

......................................

5-7

Description

..................................................................

5-7

Removal and Installation

........................................

5-7

Instrument Panel

.........................................................

5-8

Instrument Panel Compartment Door

-

Buick

"A" Styles

..................................................................

5-7

5-8

Instrument Panel Compartment Door Lock and

Cylinder

-

All Styles

................................................

5-8

Instrument Panel Cover

-

"Xu Styles

................. 5-9

BODY

VENTILATION SYSTEM COMPONENTS

(Non-Air Conditioned Styles)

Body ventilation systems on non-air conditioned styles are comprised of only a low-level system; or a combination of a low-level and a high-level system depending upon body style.

All Body styles are furnished with a fresh air intake at the front plenum chamber. On "A-F-X" styles the low- level ventilation system consists of fresh air outlets in each shroud side panel and is standard equipment on all styles. On "B-C-E" styles, the low-level system air outlets are located in the lower wall of the right shroud vent side duct panel and the lower wall at left end of shroud vent duct center panel (Fig. 5-1).

The high-level ventilation system is standard equip- ment on all "B-C-E-F" styles; and on all "A" two door hard-top and convertible styles. The high-level system is optional on Buick "A-27, 39 and 69" styles.

High-level ventilation systems include the following components:

1. High-level air outlet@) on the instrument panel.

2. Pressure relief valves (air exhaust outlets) on body lock pillars on all "A-F" styles with high-level ventilation, and air exhaust louvers in rear compartment lid or tail gate on all "B-C-E" styles.

I

3. High-level blower assemblies available as an option on Buick "A" styles.

The optional blowers provide high-level ventilation at low car speeds. For instructions on operation of the body ventilation system, refer to the "Owner's

Manual".

DESCRIPTION

(Non-Air Conditioned Styles)

Ventilating air enters the front plenum chamber through an air intake grille and/or screen. Air is

I

CENTER

Fig. 5- l -Air Duct Outlet Locations

5-2 FRONT END

LEFT S I D E ~ H O W N

RT. SIDE TYPICAL

\

4233

LEFT

(LOW-LEVEL)

CENTER

(HIGH-LEVEL)

Fig. 5-3-High-Level and Low-Level A u Outlets and Doors - "B-C-E" Styles

VIEW A

Fig. 5-2-Plenum Chamber Drain Tube

NOTE:

If the gasket becomes damaged, the duct outlet can be sealed to the center duct panel with medium bodied sealer. directed through the plenum chamber to the high-level air outlet door(s) and/or to the low-level air outlet doors. When ventilation controls are operated, air enters past the respective doors, and into the body.

On styles with high-level ventilation, air passes through the body, under the rear seat, and into the rear compartment. On "A-F" styles, the air then passes into the rear quarters and leaves the body passing through the pressure relief valves located on the rear body lock pillars (Fig. 5-14, 5-15). On "B-

C-E" styles the air leaves the body passing through the air exhaust louvers in the rear compartment lid or tail gate.

Water entering the front plenum chamber on "A-F-X" styles is channeled to the base of the shroud side panels where it is drained through openings provided for that purpose. On "B-C-E" styles the water is channeled to the outboard ends of the plenum chamber where it is discharged through drain tubes

(Fig. 5-2).

LOW-LEVEL AIR DUCT OUTLET, DOOR

AND GRILLE

-

"B-C-E" ~ t y l &

To remove grille from air duct outlet, remove grille to air outlet attaching screw(s). The left grille is retained by one screw and the right grille by two screws (Fig.

5-4). Disengage grille from retaining tabs on outlet and remove grille. To install, reverse removal procedure.

I

To remove air outlet door, remove grille as previously described, remove control cable to door crank retainer and disengage control cable from crank (Fig. 5-5).

Disengage crank end of door from snap-in slot of air outlet and remove door. To install, reverse removal procedure.

SHROUD CENTER DUCT HIGH-LEVEL AIR

OUTLET AND DOOR

-

"B-C-E" Styles

The outlet and door are shown in Figures 5-3 and 5-1.

To remove door from air duct outlet, disengage control cable from door and slide crank end of door from snap-in slot in duct assembly and remove door.

The high-level air duct outlet is sealed with a gasket at the attaching flanges and is secured to the center duct panel with screws.

\

I

I

LEFT SIDE

RIGHT SIDE

4235

Fig. 5-4-Low-Level Air Outlet Grilles

FRONT END 5-3

.

!

1

'

CABLE TO CRANK

VlEW B

VIEW A 4236

Fig. 5-5-Low-Level Air Outlet Control Cables

To remove air' duct outlet, remove grille and disconnect control cable as previously described.

Remove air duct outlet attaching screws and remove duct outlet assembly.

NOTE:

In

case of gasket damage, seal the duct otltiet to duct opening with medium bodied sealer.

SHROUD CENTER DUCT HIGH-LEVEL AIR

OUTLET DOOR-"A" Styles

The door and control cable attachment is illustrated in

Figure 5-6.

The air duct outlet is welded to the center duct panel.

The door can be removed by loosening the control cable retaining clip and rotating end of control cable out of crank on door. .Remove door retaining clip from duct assembly and slide door out of duct opening. To install reverse the removal procedure.

\

L O W E R V E N T C O N T R O L C A I L E

Fig. 5-6-Shroud Center Duct High-Level Air

Outlet Door

-

"A" Styles

5-4 FRONT END

SHROUD CENTER DUCT HIGH-LEVEL AIR

OUTLET AND DOOR

-

"F"

Styles

The air duct outlet, door and control cable attachment is illustrated in Figure 5-7.

The door can be removed by removing retaining clip

(Item 1, Fig. 5-7) removing control cable from retaining clip (Item 2, Fig. 5-7) and rotating control cable out of crank on door. Disengage snap-in type control rod from duct assembly and slide door out of duct opening.

I

To remove duct outlet, disengage control cable from door and remove duct outlet to center duct panel attaching screws. To install, reverse the removal procedure:

NOTE: In case of gasket damage, seal the duct outlet to center duct panel with medium bodied sealer.

HIGH-LEVEL VENTILATION BLOWERS

Buick "A" Styles

The power ventilation option, available on some Buick

"A" styles, consists of blower assemblies on each side of the body which provide upper-level ventilation at law car speeds. The blowers are located inside the plenum chamber on the right and left sides of the body. A motor ground wire is secured by a screw.

Removal and Installation

1. Remove shroud side finishing panel.

2. Unplug electrical wiring, disengage wiring grom- met, and remove sctew securing ground wire (Fig.

5-8).

3. Remove sheet metal screw securing lower support of blower housing.

4. Remove two attaching nuts from studs securing blower to shroud upper panel and remove blower through shroud duct-outlet.

5. To install, reverse removal procedure.

Fig. 5-7-Shroud Center Duct,High-Level Air Outlet and Door - "F" Styles

FRONT END 5-5

1 . Left Blower Location

2. Right Blower Location

3. Blowers Before

Installation

--

Fig. 5-8-High-Level Ventilation Blowers Buick "A" Styles

4. Upper Support

Ataching studs

5. Lower Support

6. Grommet

7. Motor Ground

8. Electrical Connector

9. Front Plenum

Chamber

SHROUD SIDE FINISHING PANEL

"A-F-B-C-E

and X"

Styles

.On "A-F-Xu styles, the shroud side finishing panel is designed with an integral air duct outlet and hinge pillar pinchweld finishing lace. The following are

PPER 6 L O W E R LEVEL

E N T S Y S T E M W N T R O L

3211

Fig. 5-9-Shroud Side Finishing Panel

Styles

-

"Af'

1

7

RELEASE CABLE

SECTION A-A

4237

Fig. 5-10-Shroud Side Finishing Panel

-

"B-

C-E'' Styles

5-6 FRONT END

INTEGRAL

FINISHING

LACE

ATTACHING

SCREWS added to the finishing panel before installation; air outlet door; upper and/or lower vent control cables; and medium-bodied sealer on attaching flanges (Fig.

5-13). The finishing panel is secured by screws. at the side panel. A snap-in type grille completes the installation on the "A-X" styles. The grille on the "F" style is. an integral part of the finishing panel.

CONTROL CABLE

Fig. 5-ll-Shroud Side Finishing Panel - "F"

Styles

R E T A I N E R

3213

Fig. 5-13-Shroud Side Finishing Panel Sealing

"A-F-X" Styles

-

G R I L L E

I

\

Fig. 5-12-Shroud Side Finishing Panel

-

"X" Styles

3214

FRONT END 5-7

2 DOOR S T Y L E S 4 DOOR S T Y L E S

-

Fig. 5-14-Pressure Relief Valve -

"A" Styles

Removal of the low-level air duct door and/or upper and lower vent control cable requires removal of the finishing panel. (Figures 5-9, 5-10, 5-11 and 5-12 depict types of finishing panels and their installation)

On "B-C-E" styles the shroud side finishing panel is designed with an integral hinge pillar pinchweld finishing lace. A lower vent control cable is added to each finishing panel and a hood latch release cable to the left panel before installation. The left finishing panel is secured by two screws, the right by one screw, at the shroud side panel, and one screw in each panel at the hinge pillar (Fig. 5-10).

-

- --

Fig. 5-15-Pressure Relief Valve - "F" Styles

PRESSURE RELIEF VALVE-

"

Styles

Used with high-level ventilation systems on "A-F" styles, pressure relief valves are attached to rear lock pillars with $crews. Figure 5-14 shows the "A" style pressure relief valve installation. Figure 5-15 shows the

"F" style pressure relief valve installation.

HOOD LATCH RELEASE CABLE (REAR

SECTION

)

'B-C-E

STYLES"

DESCRIPTION

includes the pull handle, control cable and housing.

The control cable is installed through the left shroud side finishing panel (Fig. 5-16). A sealing grommet at the dash panel completes the assembly.

Removal and Installation

1. Raise hood and disengage rear cable from connector.

2. Remove sealing grommet from dash panel and remove grommet from cable.

3. Remove left shroud side finishing panel, includjng

I in dash panel,

Fig. 5-16-Hood Release Cable

5-8 FRONT END

4. Disengage control assembly housing from snap-in slot of finishing panel (Fig. 5-16) and remove cable assembly from panel pulling toward pull handle end.

5. To install, reverse the removal procedure. When installing grommet, hold the cable taut and force grommet into hole in dash panel.

INSTRUMENT PANEL

INSTRUMENT PANEL COMPARTMENT

DOOR-Buick "Av Styles

The instrument panel compartment door is secured to the instrument panel by screws. A door stop holds the door in the open position.

Removal and Installation

To remove door, open door and remove attaching screws from door or from instrument panel. Rotate door stop counter-clockwise to disengage it from the instrument panel opening, and remove door. To install, reverse removal operations.

Adjustments

Provisions in door and instrument panel allow for adjustment of door. Adjustments can be made by loosening necessary hinge attaching screws. The lock striker is secured by screws. Adjustment of striker to desired position can be made by loosening attaching screws.

INSTRUMENT PANEL COMPARTMENT

DOOR LOCK AND CYLINDER-

All Styles

Removal

1. With door open, set fork bolt in latched position.

Cylinder retainer will come into view in lock case in 12 o'clock position (Figure 5-17). Alternate retainer position, 3 o'clock position, may be obtained by rotating lock cylinder (key inserted) to locked position (Figure 5- 17).

NOTE: A "View Slot" is located on all instrument panel compartment door lock cases in the 12 o'clock and in the 3 o'clock position.

2. With key removed from cylinder, depress retainer with paper clip or other suitably pointed tool.

Reinsert key to hold retainer in retracted position.

3. Squeeze latched fork bolt to relieve pressure from lock cylinder and remove cylinder, with key inserted, from lock case.

4. Insert octagonal bar wrench, wide-blade screw- driver or other suitable tool into lock escutcheon, unscrew and remove lock case assembly.

Installation

I.

Position lock case with locating tang aligned with notch in opening (Fig. 5-17).

2. Slide plastic washer over escutcheon and screw escutcheon into lock case and tighten.

3. To install lock cylinder, depress cylinder retainer and insert key.

4. Push lock fork bolt to latched position. Align cylinder tumblers with lock case view slot. Push jlinder assembly, key installed,into lock case.

1

Fig. 5-17-Instrument Panel compartment Door

'

Lock and Cylinder-All Styles

1. Door

2. Fork Bolt

3. Lock Case View Slots

4.

'

Washer

6. Retainer

7. Lock Cylinder

8. Unlocked Position

9.

10.

Locked Position

Locating Tana

FRONT END 5-9

5. While holding lock cylinder firmly in lock case, remove key to engage retainer to lock case.

(Removal of key at this time releases retainer to lock against lock case.)

6. Before closing door, reinsert key and turn full right to release latched fork bolt.

IMPORTANT: Failure to unlatch fork bolt could result in damage to striker and/or lock if door is closed.

INSTRUMENT PANEL COVERS-

Chevrolet " X u Styles

The instrument panel cover is secured to the instrument panel by a combination of screws, stud and clip assemblies, clips, and stud and nut asseniblies. The cover attachment locations are shown in Figure. 5-18.

NOTE: For instrument panel covers on other series and body styles, refer to the chassis service manuals.

SECTION A - A

SECTION 0 - 0

,

Fig. 5-18-Instrument Panel Cover - Chevrolet

"X" Styles

2 9 4 0

DOORS 6-1

SECTION

6

DOORS

INDEX

SUBJECT PAGE

FRONT AND REAR DOORS

Introduction

................................................................

Weatherstrips

.............................................................

6-1

Door Bottom Drain Hole Sealing Strip

.............

6 4

Inner Pan'el Water Deflectors

...............................

6 4

Door Window Belt Sealing Strips

........................

6-5

Side Roof Rail Weatherstrip and Retainer

......

6-7

Side Roof Rail Weatherstrip Adjustment

..........

6-8

Specified Body Opening Clearance Tolerances

.

6-8

Spring Clips

...............................................................

Outside Handles

.....................................................

6-8

Lock Strikers All Styles

Electric Lock Solenoid

..........................................

.............................................

Window Regulator Electric Motor-All Styles

5

6-17

....

6-17

FRONT DOORS

Description-All Styles

...............................................

Door Hinges-All Except "X" Styles

6-17

....................

6-39

Door Removal and Installation-All Except

"Xu Styles

..................................................................

Hinge-All Styles without Power Option-Except

"Xu Styles

...................................................................

Hinge-All Styles with Power Option-Except

"Xu

Styles

..................................................................

Hinge-Adjustment-All Except "X" Styles

Door-Removal .

Door-Installation

Hinge-Removal

Hinge-Installation

Hinge-Adjustment

.

.

.

Styles

Styles

...........

...................................

..............................

.................................

.............................

...........................

6-39

6-39

6 4 0

6 4 0

6 4 1

6 4 2

6 4 2

Inside Locking Rod

....................

6 4 2

Lock Remote Control and Connecting Rod

All

Styles

.....................................................................

Lock Assembly All Styles

Lock Cylinder Assembly .

...................................

..................

6 4 3

Mirror, Door Outside Remote Control

Styles

..........................................................................

Mirror, Face Replacement .

Styles Except Cadillac

........................................

6 4 5

Mirror. Door Outside-Standard Mirror

Inner Panel Cam .

..............

6 4 6

"A. B. C and "E" Two Door Hardtop and

Convertible Styles

...................................................

Ventilator Regulator

Ventilator Assembly

.

Ventilator Assembly

Window Assembly

.

.

.

.

.......................

..........

.........................

........................

6 4 6

6 4 6

6 4 7

6 4 7

6 4 9

Styles

............................................................................

SUBJECT PAGE window Assembly

Window Assembly

Styles

.

.

.....................

6 4 9

............................................................................

Window Assembly

Window Assembly

.

.

6-51

.............

6-54

............................

6-54 Hardtop and Convertible Styles

Window Assembly .

Styles

............................................................................

Window Assembly

...........................

6-60

Window Regulator-Manual-"A and X" Closed

Styles

............................................................................

Window Regulator-Electric-"A" Closed Styles

..

6-63

Window Regulator-Manual and Electric-"A-39'

Styles

............................................................................

Window Regulator-Manual and ElectricJ'A. B.

C and E" Two Door Hardtog and

Convertible Styles

...................................................

6-63

Window Regulator-Manual-All "B and C" Four

Door Styles

.................................................................

Window Regulator-Electric-A11 "B and C" Four

Door Styles

.................................................................

Window Regulator-Manual and Electric-"F"

Styles

............................................................................

Window Rear Guide-"A-39" Styles

6-64

.....................

6-64

Window Guide Tube."A. B. C and E" Two

Door Hardtop and Convertible Styles

................

6-64

Window Front Guide-"B and C" Four Door

Hardtop Styles

...........................................................

Window Rear Guide-"B and C" Four Door

Hardtop Styles

...........................................................

Window Rear Guide-"B" Closed Styles

.............

6-65

6-65

Window Upper and Lower Sash Guide Assembly

"A,B, C and E" Two Door Hardtop and

Convertible Styles

.................................................

Window Front GuideJ"'" Styles

6-65

.........................

6-65

Window Rear Guide-"F" Styles

.........................

6-65

Window Glass Run Channel-"A-B and X"

Styles

............................................................................

Door Wedge Plates-"67" Styles ............................

6-66

6-66

.

REAR DOORS

Description-All Styles

....................

6-67

Hinges-All Styles

.......................................................

Hinges-Adjustment-All Styles

.................................

...........................

.................

6-67

6-67

Lock Assembly-All styles

6-67

........................................

Inner Panel Cam-"A-39 and B-35-45 and 69"

Styles

............................................................................

Window Assembly-"A" Closed Styles 6-81

6-2 DOORS

SUBJECT PAGE

Window Assembly-"A-39" Styles

..........................

6-81

Window Assembly-"B" Closed Styles

.................,

684

Window Assembly-"B and C" Four Door

Hardtop Styles-Except 68169 Style

..........................

6-85

Window Assembly-68 169 Style

..............................

687

Window Stationary Ventilator Division Channel-

"X-69" Styles

............................................................

6-89

Window Stationary Ventilator Assembly-"X-69"

Styles

...........................................................................

690

Window Assembly-"X-69" Styles

.........................

690

Window Regulator-Manual-"A" Styles

Window Regulator-Electric-* Styles

...............

690

................

690

Window Regulator-Manual and Electric

Closed Styles

-

"B"

...............................................................

691

Window Regulator

"B-C"

-

Manual and Electric

/

Four Door Hardtop

Styles-Except 68 169 Style

...................................

6-91

SUBJECr PAGE

.............................

6 9 1

Window Regulator-Electric Motor Removal-All

Styles 1........................................................................... 691

Window Regulator-"X-69" Styles

.........................

6-9 1

Window Front Guide and Bracket Assembly

"A- 39" Styles

............................................................

6 9

Window Rer Guide

-

"A-39" Styles

...................

6-92

Window Center Guide Cam-"B-C" Four Door

Hardtop Styles-Except 68169 Style

........................

6-92

Window Guide Tube48169 Style

.........................

692

Window Lower Sash Upper and/or Lower

Guide Assembly48 169 Style

.....................................

692

Window Glass Run Channel-"A-B and X"

Closed 1 Styles

..............................................................

692

REAR DOORS

INTRODUCTION

This section of the manual contains the service operations that are necessary for the removal, installation, adjustment and sealing of door assemblies and individual door hardware. components. The procedures are arranged in the sequence that they would be performed when servicing a door. To locate specific procedures, refer to the "Door Index".

Hardware items are divided into three categories.

Those which are common to all doors are found under

"Front and Rear Doors", which also includes door and side roof rail weather strips. Items which are peculiar to front or rear doors &re found under "Front Doors", or "Rear Doors" respectively.

Door trim service procedures are covered in Section 13 of this manual (See Index).

Body series or style references in the procedures

are

explained under "General Information" in Section 1 of this manual.

FRONT AND REAR DOOR

WEATHERSTRIPS

Both the front and rear doors use nylon fasteners to retain the door weatherstrips. The fasteners are a component part of the weatherstrip and secure the weatherstrip to the door by engaging piercings in the door panels. The serrations on the fastener retain the fastener in the piercing and also seal the operlings from water entry (Fig. 6-1).

On closed styles, nylon fasteners are used below the beltline only. Weatherstrip adhesive retains the weatherstrip around the door upper frame (Fig. 6-2).

On all styles, in addition to the fastener, use weatherstrip adhesive at the beltline and down the front door hinge pillar.

To disengage nylon fasteners from door panel piercings use tool J-2 1104 or equivalent (Fig. 6-1).

This tool permits removal of the weatherstrip without damaging the serrations on the fasteners so that the weatherstrip can be reinstalled if desired.

Althou'gh a replacement door weatherstrip will include nylon fasteners, individual fasteners are also available as service parts.

Removal

On all hardtop and convertible styles, remove door trim pad to gain access to weatherstrip fasteners hidden under trim assembly and remove fasteners

(Fig. 6-3).

Use a flat-bladed tool to break cement bond between door and weatherstrip. A tool applicable to this usage can be fabricated from tool 5-2

1

104 or equivalent (Fig. 6-4). On all styles, weatherstrip adhesive is used for a distance of 9" on door lock pillar and the entire length of the front door hinge pillar (Fig. 6-2). In addition, on closed styles, weatherstrip is retained by weatherstrip

Released by: www.78ta.com

Serial Number: 71BDY-001-1026

DOORS 6-3

R E T A I N E R

Fig. 6-I-Door Weatherstrip Removal adhesive completely around door upper frame

(Fig. 6-2).

A-BLACK WEATHERSTRIP ADHESIVE

Fig. 6-3-Door Weatherstrip - Hardtop Styles

3. On all styles, use tool 5-21104 or equivalent to disengage weatherstrip from door where weather- strip is retained by nylon fasteners.

Installation

1. If previously removed weatherstrip is to be reinstalled, inspect nylon fasteners and replace those that are damaged.

2. Clean off old weatherstrip adhesive from door.

3. On closed styles, apply black weatherstrip adhesive around door upper frame (Fig. 6-2).

4. On styles without door upper frames, position weatherstrip to door and install plastic fasteners at front and rear ends of weatherstrip.

5. On styles with door upper frames, position weatherstrip to door as follows:

SECTION A-A

N Y L O N F A S T E N E R 7

I

L O C K C O N N E C T I N G R O D

L O C K LEVER L O C K LEVER

Tiw

SECTION B.B

*

Fig. 6-2-Door Weatherstrip

-

All Styles

I

I

C L I P ENGAGED CLIP'DISENGAGED

Fig. 6-4-Weatherstrip Removal Tool

6-4 DOORS a. On front doors, locate weatherstrip from rear upper corner. b. On rear doors, locate weatherstrip from molded front upper corner.

6. Tap nylon fasteners into door piercing using a hammer and blunt caulking tool.

7. After all fasteners have been installed on sedan stfles, apply weatherstrip adhesive between door and weatherstrip outboard surface at the follow- ing locations: a. For 5" around rear upper corner of front door upper frame and/or 9" down door lock pillar starting at beltline and down entire hinge pillar facing. b. On sedan rear doors, 9" down both door lock pillar and door hinge pillars starting at beltline.

NOTE: If weatherstrip becomes damaged at fastener location and will not retain fastener, remove fastener and secure weatherstrip to door with weatherstrip adhesive. If more than two consecutive fastener locations become damaged, replace weatherstrip.

Although weatherstrip adhesive is specified only at specific locations, it can be used at any point where additional retention or sealing is required.

DOOR BOTTOM DRAIN HOLE SEALING

V I E W I N CIRCLE " A "

Fig. 6-5-Door Bottom Drain Hole Sealing Strips front or rear doors where the water deflector has been disturbed, the deflector must be properly sealed and taped to the inner panel to prevent waterleaks (Fig.

6-6 for "A, F and X" styles and 6-7 for

"B,

C and

E"

Styles). For service sealing, body caulking compound

Door bottom drain slot sealing strips are attached to door inner panels over door bottom drain slots to prevent entry of road- noise, dust and cold air at these locations (Fig. 6-5).

To remove sealing strips, use a flat-bladed tool to pry retaining plugs from door inner panel piercings.

To install, insert a blunt pointed tool such as a dull ice pick or scratch awl into strip retaining plugs and push plugs into door panel piercings.

FRONT AND REAR DOOR INNER

PANEL WATER DEFLECTOR

A waterproof deflector is used to seal the door inner panel and prevent entry of water into the body. The deflector is secured by a string-loaded sealing material along both front and rear edges and by the application of waterproof sealing tape at front and rear lower corners. Whenever work is performed on

-

X" Styles)

- -

DOORS 6-5

Fig. 6-7-Door Inner Panel Sealing ("B, C and

E" Styles) or strip caulking is recommended if additional sealing material is required.

When access to the inner panel is required to perform service operations, the deflector may be completely or partially detached from the inner panel. If the existing water deflector is damaged so that it will not properly seal the door, replacement of the deflector is required.

Roll stock of water deflector paper is available as a service part.

The following procedure covers complete removal and installation of the water deflector. If only partial removal of the deflector is required, perform only those steps which are necessary to expose the required area of the door inner panel.

Removal (Refer to Figure 6-6 for "A, F and X"

Styles and Flgure 6 7 for "B,

C

and EM Styles)

1. Remove the door trim assembly.

2. Remove waterproof body tape securing top of water deflector to door inner panel.

3. Using a flat-bladed tool such as a putty knife, or side roof rail weatherstrip removal tool as described in Fig. 6-4, carefully break sealer bond between water deflector and door inner panel down both sides of deflector. Make certain tool bhde is between inner panel' and string that is embedded in sealer.

4. When seal has been broken down both sides of deflector, carefully remove tape from inner panel at lower corners of water deflector. Disengage water deflector from inner panel drain slot and remove deflector.

Installation

1. Inspect water deflector and, where necessary, repair any tears or holes with waterproof body tape applied to both sides of deflector.

2. If a new deflector is to be installed, use old deflector as a template.

3. Position water deflector to door inner panel and insert lower edge of deflector in retaining slot.

Then, firmly roll or press edges of deflector to obtain a good bond between deflector and door inner panel.

If old sealer does not effect a satisfactory seal, apply additional body caulking compound or strip caulking to inner panel at unsealed areas.

4. Seal lower comers of deflector by re-applying previously removed tape or new pieces of 2" or

2- 1 /2" waterproof body tape. attachments that are outboard of water deflector, seal attaching bolt head and panel piercing with body caulking compound.

DOOR WINDOW BELT SEALING STRIPS

Door window belt sealing strips are used to form a seal between the door inner and outer panels and the window at the beltline. The construction and attachment of these strips vary with the body style involved.

On styles with a door window belt reveal molding, except Pontiac "F" styles, the outer strip assembly is clipped to the molding and, therefore, removed with the molding (See "Exterior Moldings"). The entire assembly is available as a service part, as is the strip assembly itself. On Pontiac

"F"

styles, the molding is installed over the outer belt sealing strip and must be removed prior to strip removal (moldings and belt sealing strips are serviced independently). Refer to

Exterior Molding Section for removal instructions.

On styles without door window belt reveal moldings, the outer strip assembly is an independent part that is secured to the door outer panel return flange by clips, screws or rivets (rivets pertain to "F" styles only).

NOTE: To remove strip assemblies, glass must be low enough to gain access to the attachments. In many cases, this will require removal or adjustment of window lower stop bumpers to permit further lowering of window assembly.

6-6 DOORS

Fig. 6-8-Clip Retained Belt Sealing Strip

Assembly Removal

Removal and Installation

1. On styles with screw retained strip assemblies, remove strip assembly by removing attaching screws.

2. On styles with clip retained inner or outer strip assemblies, remove strip assembly as follows: a. Apply cloth-backed tape as a protective cover over painted surface of door panel adjacent to strip assembly. b. Using a flat-bladed tool that is slotted to fit over tang of clip, disengage clips from slots in door panel return flange as shown in Figure

6-8. c. To install strip assembly, position strip so that the tangs of each clip starts into slot in door panel; then, engage clips by pressing down- ward. Prior to installation, re-form tangs on clip to assure positive retention when installed.

NOTE: To fabricate strip assembly removal flat-bladed headlining inserting iool (tool

J-2772 or equivalent).

3. On "F" styles equipped with rivet retained strip assemblies, drill-out rivets. When installing new

V I E W C

FASTENER

S E C T I O N A

51 01 S E C T I O N B

Fig. 6-9-Side Roof Rail Weathersuip and Weathersuip Retainer

-

Typical All Styles,

Except " F Styles ("A-39" Styles Shown, Other Styles Similar)

DOORS 6-7

S l D E R O O F R A I L W I S T R I P R E T A I N E R

F R O N T A N D R E A R

I ROOF

RA; WISTRIP

*

S C R E W

1

"h

S E C T I O N A - A

$r&

S E C T I O N B - B 3

"8%

3 9 2 7

Fig. 6-10-Side Roof Rail Weatherstrip and Weatherstrip Retainer

-

"F" Styles strip assemblies, use 1/8" diameter by 5/16" reach aluminum "pop" rivets or equivalent.

SlDE ROOF RAIL WEATHERSTRIP

AND RETAINER

The side roof rail weatherstrip is sealed to a side roof rail weatherstrip retainer, (front and rear) which, in turn is secured with plastic fasteners at the front and rear edges, except "F" styles which are retained by screws at the rear edge. The sealer that retains the weatherstrip also protects against air noise and water entry between the retainer and deatherstrip. An integral section of closed cell nitrile foam material bonded to the weatherstrip retainers during retainer manufacture prevents water entry between the retainer and side roof rail or body lock pillar above belt. (Item

1, Figure 6-10).

Removal-All Styles

1. Remove plastic fasteners at front of side roof rail weatherstrip (Fig. 6-9 is typical of all styles at front hinge pillar) with tool J-2 1104 or equivalent.

2. On all "39, 49 and 69" styles, open rear door and remove plantic fastener stcuring rear 2hd of side roof rail weatherutrip to rear door lack pillar (Fig.

6-9). On "F" styles, remove screw retaining weatherstrip to rear body lock pillar (Fig. 6-10).

Beginning at the front body hinge pillar, carefully pull weatherstrip out of retainer while breaking sealer bond bettieen weatherstrip and retainer with a flat-bladed tool. A tool for this use can be fabricated from tool J-21104 or equivalent by trimming 1/4" from the blade and 1-1/2" from the handle, then filing a sharp edge on the blade.

Figure 6-1 1 illustrates fabrication of this tool.

IMPORTANT: This operation must be performed carefully to prevent damaging side roof rail weatherstrip.

6-8 DOORS

LOCK CONNECTING ROD

CLIP E N G A G E D CLIP.DISENGAGED

Fig. 6- 1 1-Weatherstrip Removal Tool

4. With weatherstrip removed, screws securing weatherstrip retainer to side roof rail are exposed.

Mark position of retainer on rail or pillar and remove screws from retainer (Figures 6-9 and

6- 10).

Installation (All Styles)

1. Scrape off any excess sealer from weatherstrip retainer.

2. Apply a continuous bead of a "pumpable" type body caulking compound 4" rearward and 4" down from front upper corner of retainer that mates with side roof rail ("2", Figs. 6-9 and 6-10).

Apply bead outboard of attaching screw holes.

3. Position retainer to body and install attaching screws.

4. Apply a continuous bead of "pumpable" sealer to inboard flange of weatherstrip retainer ("3", Figs.

6-9 and 6-10). Then, apply black weatherstrip adhesive or pre-cut mastic sealing: strips (available as a service part) to the front and rear end details of the side roof rail weatherstrip.

5. Position front end of weatherstrip to body and install plastic fasteners. Then, using a flat-bladed tool, engage weatherstrip with retainer, inboard lip first, then, outboard lip (refer to Sections "A-

A" and "B-B", Figures 6-9 and 6-10).

NOTE: Replacement plastic fasteners are availa- ble as service parts.

6. After weatherstrip has been installed along length of retainer, install screw at rear end of weatherstrip on styles so equipped.

Sick Roof Rail Wrathrrstrip (Retainer) Adjustment

The side roof rail weatherstrip can be adjusted either inboard or outboard to obtain a better seal with the door or quarter window by repositioning the weatherstrip retainer:

1. Remove the weatherstrip from the retainer as previously described and loosen retainer attaching screws.

2. Adjust retainer inboard or outboard as required and replace screws. Reinstall weatherstrip and seal with a "pumpable" sealer.

For proper relationship of weatherstrip to door window, refer to "Front Door Window

Adjustments".

NOTE: Major retainer adjustments will require resealing retainer to body at front upper corner of retainer as described in Step 2 of weatherstrip installation procedure ("2" of Figures 6-9 and

6- 10).

If additional inboard or outboard adjustment of the retainer is required, it can be accomplished by either elongating the adjusthg slots in the retainer or repositioning the retainer and drilling new attaching holes in the rail or pillar assembly.

SPECIFIED BODY OPENING CLEARANCE

TOLERANCES-All Styles

Figures 6- 12 through 6- 16 show specified body opening gap spacing tolerances and deviations from flush alignment permissible between fender and front door and front to rear door on all 1971 body styles.

SPRING CLIPS

Spring clips are used to secure remote control connecting rods and inside locking rods to door lock levers and door outside handle push rods to door outside handle. A slot in the clip provides for disengagement of the clips, thereby facilitating detachment of linkage.

To disengage a spring clip, use a screwdriver, or other suitable thin bladed tool, to slide clip out of engagement (See Fig. 6- 17).

FRONT AND REAR DOOR OUTSIDE

HAND& ASSEM BLY-All Styles

There are four basic types of door outside handles: push-button; lift-bar; "flush" pull-out; "bail" pull-out.

However, the removal and installation procedure is similar.

YtCl?ltD BODY OCRNINO CLCARANQS

"A" Bod* WIes

DOORS 6-9

FENDER

I

DOOR-

-i?I,?ENDER AND FRONT DOOR FLUSH AT

POINTS "Z", FRONT DOOR SWING CLEARANCE

AT POINT " W " IS*

SECTION THRU POINT " W "

Chev.

Pont.

-

5 / 6 4 " PLUS OR MINUS 1/16"

-

3 / 3 1 " PLUS OR MINUS 1/16"

Olda.

-

5 / 6 4 " PLUS OR MINUS 1/16"

B u i c h

-

5 / 6 4 " PLUS OR MINUS 1 / 1 6 ' '

Fig. 6-12-Specified Body Opening Clearance Tolerances

-

"A" Styles

6-10 DOORS

S P E C I F I E D B O D Y O P E N I N G C L E A R A N C E T O L E R A N C E S

" A , B a n d C " B o d y 4 D o o r S t y l e s

FLUSH T O PLUS OR M I N U S

1 / 1 6 " RELATIONSHIP 1

FRO

FRONT T O REAR D O O R G A P S P A C I N G IS

7 / 3 2 " PLUS OR M I N U S 1 / 3 2 "

VIEW B

SECTION S H O W I N G CLEARANCE BETWEEN FRONT A N D REAR D O O R

Fig. 6-13-Specified Body Opening Clearance Tolerances

-

"A" Body Four Door Styles

VlEW A

VlEW B

'

VlEW C

Fig. 6-14-Specified Body Opening Clearance Tolerances

-

"B, C and E Styles

DOORS 6-1 1

6-12 DOORS

EXCEPTIONS TO NORMAL BODY OPENING CLEARANCES

VIEW A VIEW

W€ClflED BODY OPENING CLEARANCE TOLERANCES

Char). II few-Dmor

5 ~ I a s

DOORS 6-13

PEAK

2 3/16"

WITH FENDER A N D FRONT DOOR

F L u s n A T POINTS a

D.- FRONT

DOOR S W I N G CLEARANCE

ALLOWANCE A! PEAK IS 3/32"

FRONT DOOR LUSH TO 1/16" w l T n FRONT AND

AT POINTS " Y 4 W".

DOORS FLUSH

REAR DOOR S W I N G

OUTBOARD OF REAR DOOR AT

POINTS " Y 4 W "

CLEARANCE ALLOWANCE AT PEAK I S 7

13/32'' ,AND 1/16" AT POINT " X "

SECTION S H O W I N G CLEARANCE

BETWEEN FENDER A N D FRONT DOOR

FRONT TO REAR DOOR GAP

SPACING IS 3/16" PLUS 1/32''

1 / 1 6 u

SECTION S H O W I N G CLEARANCE

BETWEEN FRONT A N D REAR DOOR

Fig. 6-l6-Specified Body Opening Clearance Tolerances

-

"X" Styles

6- 14 DOORS

LOCK C O N N E C T I N G R O D

PUSH R O D

Y

-

.

\ D O O R O U T S I D E H A N D L E

I

1

C L I P E N G A G E D C L I P ' D I S E N G A G E D

Fig. 6-17-Door Lock Spring Clip

Removal and Installation (Refer to Figures

6-19 and 6-20)

6 1 8 ,

1. Raise door window. Remove door trim assembly and detach upper rear corner of inner panel water deflector sufficiently to gain access to door outside handle attaching screws.

NOTE: On "F" styles remove rear guide upper bracket to inner panel and guide assembly attaching bolts ("6" and "7", Figure 6-44) and remove guide bracket from door. Then, working through access hole, disconnect door outside handle to lock push rod at handle assembly

(Figure 6- 19).

2. On all other styles, remove handle attaching

Fig. 6-19-Door Outside Handle Removal (Lift

Bar Type)

SCREWS

ANDLE

2081

Fig. 6-18-Door Outside Handle Removal (Push-

Button Type)

Fig. 6-20-Door Outside Handle Removal

(Pull-Out Type)

DOORS 6-15

T A P P E D C A G E

PLATE

Fig. 6-21-Front Door Outside Handle

-

Push-

Button Handles ("A and X"

Styles Shown, Other Styles Similar) screws through access hole and remove door handle and gaskets from outside of body.

3. To install, reverse removal procedure.

DOOR OUTSIDE HANDLE DISASSEMBLY

ALL PUSH BUTTON TYPE HANDLE

ASSEMBLIES

-

1. Remove door outside handle as pre.viously described.

2. Depress retainer slightly and rotate 114 turn in either direction. Remove retainer, spring, push button and shaft and sealing washer from handle

(refer to Figure 6-2 1).

NOTE: "B and

C"

style rear door handle push buttons, springs and retainers are serviced as an assembly. The die cast handle is serviced separately. Front door handle components are serviced separately as shown in Figure 6-2 1. Lift- bar, "bailf' pull-out and "flush" pull-out handles are serviced as an assembly.

3. To assemble, reverse disassembly procedure,

FRONT AND REAR DOOR LOCK

STRIKERS-All Styles

The front and rear @r lock striker consists of a single metal bolt and pasher assembly that is threaded into a tapped, floating cage plate located in the body lock pillar. With this design, the door is secured in the closed position when the door lock fork-bolt snaps- over and engages the striker bolt.

Removal and Installation

1. Mark positiop of striker on body lock pillar using a pencil.

-

-

Fig. 6-22-Door Lock Striker Installation

2. Insert tool 5-23457, BT-7107 or equivalent into the star shaped tool recess in the head of the striker bolt and remove striker (refer to Figure 6-22.

3. To install, reverse removal procedure. Make certain striker is positioned within pencil mark. If striker is positioned outside of pencil marks, touch-up any exposed unpainted surface on lock pillar adjacent to striker assembly. Torque striker bolt 34-46 foot pounds.

NOTE: THE DOOR LOCK STRIKER IS AN

IMPORTANT AlTACHING PART IN THAT IT

COULD AFFECT THE PERFORMANCE OF

VITAL COMPONENTS AND SYSTEMS, AND/

OR COULD RESULT IN MAJOR REPAIR

EXPENSE. IT MUST BE REPLACED WITH

ONE OF THE SAME PART NUMBER OR

WITH

AN EQUIVALENT PART IF REPLACE-

MENT BECOMES NECESSARY. DO NOT USE

A REPLACEMENT PART OF LESSER QUAL-

ITY OR SUBSTITUTE DESIGN. TORQUE

VALUES MUST BE USED AS SPECIFIED

DURmG REASSEMBLY TO ASSURE PROPER

RETENTION OF THIS PART.

IMPORTANT: Whenever a door has been removed and reinstalled or realigned, the door should not be closed completely until a visual check is made to deiermine if lock fork-bolt will

- correctly engage with striker.

Adjustments

1. To adjust striker up or down, or in or out, loosen striker bolt and shift striker as required, then tighten striker.

6-16 DOORS

Fig. 6-23-Lock to Striker Engagement

2. To determine if striker fore or aft adjustment is required, proceed as follows: a. Make certain door is properly aligned. b. Apply modeling clay or body caulking compound to lock bolt opening as shown in

Figure 6-23. c. Close door only as far as necessary for striker bolt to form an impression in clay or caulking compound as shown in Figure 6-23.

NOTE: Do not close door completely. Com- plete door closing will make clay removal very difficult. d. Measure striker impressions as follows: Striker head should be centered fore and aft as shown, however, some tolerances are allowed.

In any alignment, it is important that minimum dimensions, as outlined in Figure

6-23 be strictly maintained. The following spacers are available as service parts and can be used individually or in combination to achieve the desired alignment.

1. 5/64" spacer-Part No. 4469 196 or equivalent

("A, F and X" styles)

2. 5/64" spacer-Part No. 98271 54 or equivalent

("B, C and E" styles)

6

Fig. 6-24-Front Door Lock

Electric Solenoid Installation

Fig. 6-25-Rear Door Lock

Electric Solenoid Installation

DOORS 6-17

3. 5/32" spacer-Part No. 4469197 or equivalent

("A, F and X" styles)

4. 5/32" spacer-Part No. 9827155 or equivalent

'

("B, C and E" styles)

5. 114" spacerupart No. 4469194 or equivalent

("A, F and X" styles)

6. 5/16" spacer-Part No. 4469195 or equivalent

("A, F and X" styles)

ELECTRIC DOOR LOCK SOLENOID

Removal and Installation

1. Raise door window, remove trim pad and detach inner panel water deflector.

2. Disconnect wire harness from solenoid.

3. On front doors, remove lock pillar attaching screws, disconnect rod and remove through access hole (Fig. 6-24).

4. On rear doors, remove electric solenoid to door inner panel attaching screws and connecting rod to door inside locking rod connecting link attaching clip9 Remove through access hole (Fig.

6-25).

5. To install, reverse removal procedure.

DOOR WINDOW REGULATOR

ELECTRIC MOTOR

The electric motor assembly, which powers the electrically operated window regulators, is a twelve volt reversible direction motor with an internal circuit breaker and a self-locking gear drive. The motor is secured to the regulator assembly with bolts.

Removal and Installation-AU

Styles

1. Remove door trim assembly and inner panel water deflector. Disconnect harness connector at motor.

2. Refer to Figures 6-26, 6-27, 6-28, 6-29 and 6-30 and select the appropriate template for locating window motor to regulator attaching bolts by using window regulator to door inner panel attaching bolts as reference points.

3. Align regulator bolt locations specified on template with appropriate regulator attaching bolts on door. Secure template in place with a piece of tape.

4. Using a center punch, dimple the door inner panel at the center of each of the 314" holes to be drilled as indicated on the template.

5. Using a 3/4" hole saw, drill three 314'' motor to regulator attaching bolt access holes as indicated.

6. Remove motor attaching bolts and remove motor through access hole.

NOTE: Although window regulator lift arm is under tension of counterbalance spring, weight of window assembly prevnts lift arm from moving.

If necessary, window can be moved manually to clear access holes.

7. After replacing motor and prior to trim installa- tion, apply waterproof tape to seal any motor bolt access hole that is outside of the sealing area of the water deflector.

DOOR HARDWARE LUBRICATION

The Mechanical components of the door assembly are lubricated during assembly. If additional lubrication is required to any door hardware mechanism, lubricate with Fisk Bros. No. 777 Lo-Temp Lubriplate or equivalent.

FRONT

DOORS

DESCRIPTION

All doors fall into two basic categories, closed styles

(those with door upper frames) and hardtop or convertible styles (those without door upper frames).

Although both types of front doors utilize similar hardware, the presence or lack of a door upper frame usually determines the removal or installation sequence of any particular part.

Any work performed on door hardware usually requires removal of trim pad and inner panel water deflector. The procedures for water deflectors are covered in the preceding "Front and Rear Doors" section. Trim procedures are in Section 13 (see index).

Unless otherwise stated, the front door service

. procedures listed here pertain to all body styles.

Figures 6-31 through 6-46 are typical of front doors with the trim assembly and inner panel water deflector removed. These figures identify the component parts of the front door assembly (by style), their relationship and various attaching points.

6-18 DOORS

A L I G N TEMPLATE. W I T H APPROPRIATE UPPER A N D L O W E R

L E F T R E G U L A T O R A T T A C H I N G BOLTS O N D O O R

R E G U L A T O R BOLT L O C A T I O N

I

7 / 1 6 "

I -+-

I -+-

I

DRILL THREE 3 / 4 " M O T O R

A T T A C H I N G BOLT A C C E S S

H O L E S

I

Fig. 6-26-Window Regulator Upper and Lower Left Attaching Bolt Reference Points for

Locating Window Motor to Regulator Attaching Bolts

-

"A-27 and 77" Styles

A L I G N TEMPLATE W I T H UPPER A N D L O W E R LEFT

REGULATOR A T T A C H I N G BOLTS O N D O O R

DOORS 6-19

DRILL THPEE

3 / 4 "

M O T O R

A T T A C H I N G BOLT ACCESS

REGULATOR BOLT L O C A T I O N

Fig. 6-27-Window Regulator Upper and Lower Left ~ttaching Bolt Reference Points for

Locating Window Motor to Regulator Attaching Bolts

-

"A-35, 39, 45, 55, 69" Style Front Doors

6-20 DOORS

A L I G N TEMPLATE U S I N G REFERENCE P O I N T S

"I

O R n "

WITH A P P R O P R I A T E R E G U L A T O R L O W E R A T T A C H I N G BOLTS O N D O O R

THREE 3 / 4 " M O T O R

H l N G B O L T ACCESS

H O L E S

Fig. 6-28-Window Regulator Lower Attaching Bolt Reference Points for Locating Window Motor to Regulator Attaching

Bolts: "I" for "A-35,45,39 and 69" Style Rear Doors; "11" for "A-37,57,67 and 87" Style Front Doors

A L I G N T E M P L A T E U S I N G R E F E R E N C E P O I N T S

-I,ZI,OR

m e #

W I T H R E G U L A T O R L O W E R A T T A C H I N G BOLTS O N D O O R

DOORS 6-21

/

4"

1 - 1 1

/l6"

2 9 0 7

DRILL THREE

314"

M O T O R

A T T A C H I N G BOLT A C C E S S

H O L E S

Fig. 6-29-Window Regulator Lower Attaching Bolts Reference Points for Locating Window Motor to Regulator Attaching.

Bolts: "I" for "B, C and E-1 1 , 3 7 , 4 7 , 5 7 and 67" Style Front Doors; "11" for "C-69" Style Rear Doors

"111" for "B-36,39,46 and 69" and "C49 and 69" Style Front and Rear Doors

6-22 DOORS

A L I G N TEMPLATE W I T H APPROPRIATE REGULATOR

L O W E R A T T A C H I N G BOLTS O N D O O R

DRILL THREE 3 1 4 "

M O T O R A T T A C H I N G

BOLT ACCESS H O L E S

Fig. 6-30-Window Regulator Lower Attaching Bolt Reference Points for Locating Window

Motor to Regulator Attaching Bolts

-

" F Styles

DOORS 6-23

1. Front Door Window

Assembly

2. Ventilator Regulator

3. Window Regulator

Fig. 6-31-Fiont Door Hardware - "A" Closed Styles

4. Ventilator Division

Channel

5. Door Lock

Control

Remote

6. Window Down Stop

~ " P P *

7. Inner Panel Cam

8. Door Lock

9. Lower Sash Channel

Cam

6-24 DOORS

1 . Window Regulator

Attaching Bolts

2. Ventilator Division

Channel Lower

3.

Adjusting Stud

Ventilator Regulator

Attaching Bolts

Fig. 6-32-Front Door Hardware-"A" ,Closed Styles

4. Ventilator Frame to

Outer Panel

Attaching Bolt

5. Door Lock Remote

Control Attaching

Bolts

6. Door Lock Attaching

Screws

7. Down Stop Support

Attaching Bolt

8. Ventilator to Door

Upper Frame

Attaching Screws

DOORS 6-25

1. Ventilator Regulator

2. Window Regulator

3. Ventilator Division

Channel

Fig. 6-33-Front Door Hardware

-

"A-39" Styles

4. Front Door Window

Assembly

'

5. Rear Guide

6. Inner Panel Cam

7. Door Lock

8. Door Outside Handle

9. Lower Sash Channel

Cam

6-26 DOORS

Door Lock Attaching

Screws

Rear Guide Lower

Attaching Bolt

3. Window Rear Upper

Stop Bolt

4. Ventilator Division

Channel Lower

Adjusting Stud and

Nut

Fig. 6-34-Front Door Hardware

-

"A-39"

5. Rear Guide Upper

Attaching Bolts

6. Inner Panel Cam

7. Lower Sash Channel

Cam Attaching

Screws Access Holes

8. Door Lock Remote

Control Attaching

Bolts

9. Window Regulator

Attaching Bolts

10. Window Front Upper

Stop Access Hole

1 1. Ventilator Frame to

Door Outer Panel

Attaching Bolts

12. Ventilator Regulator

Attaching Bolts

13. Ventilator Lower

Frame Adjusting Stud and Nut

14. Ventilator "T" Shaft to Regulator Screw

Access Hole

DOORS 6-27

1. Window Assembly

2. Stabilizer Strips

3. Trim Pad Adjusting

Plates

4. Tube Assembly,

Window Guide

Fig. 6-35-Front Door Hardware

-

"A-37, 57, 67 and 87" Styles

5. Guide Assembly,

Lower Sash Lower

6. Plate Assembly,

Lower Sash Guide

7. Guide Assembly,

Lower Sash Upper

8. Rod, Inside Handle to

Lock

9. Regulator Assembly

10. Stop, Front Up-Travel

1 1. Stop, Rear Up-Travel

12. Plate, Door Outer

Panel Bearing

.

13. Support, Window

Bumaer

14. ~ a n & , - Door Outside

(Pull Type)

15. Retainer, Door

Outside Handle

16. Door Lock

17. Rod, Inside Locking

6-28 DOORS

Tube Assembly,

Window Guide

Attaching Bolts

Guide Assembly,

Lower Sash Lower

Attaching Bolts

Plate Assembly,

Lower Sash Guide

Attaching Bolts

Fig. 6-36-Front Door Hardware

-

"A-37, 57, 67 and 87" Styles

4. Door Lock Attaching

Screws

5. Regulator Assembly

Attaching Bolts

6. Guide Assembly,

Lower Sash Upper

Attaching Bolts

7. Stop, Front Up-Travel

Attaching Bolt

8. Stop, Rear Up-Travel

Attaching Bolt

9. Support, Front

Window Bumper

Attaching Bolt

10. Support, Rear

Window Bumper

Attaching Bolt

I I. Strip, Anti-Rattle

Front Attaching Bolt

12. Strip, Anti-Rattle

Rear Attaching Bolt

13. Plate. Trim Pad

Hanger Attaching

Bolts

14. Remote Control, Door

Lock Attaching Bolts

DOORS 6-29

1. Window Assembly

2. Trim Support Hangers

3. and Stabilizer Suips

Lower Sash Channel

Cam

Fig. 6-37-Front Door Hardware - "B-69" Styles

4. Window Regulator

Handle

5. Window Regulator

6. Remote Control and

Handle Assembly

7. Window Down-Travel a

Support and Bumper

8. Inner Panel Cam

9. Remove Control to

Lock Connecting Rod

10. Rear Guide Assembly

1 1. Inside Locking Rod

12. Lock Assembly

13. Outside Handle

14. Lock Cylinder

6-30 DOORS

1. Rear Guide to Guide

Bracket Attaching

Bolt

2. Rear Guide Bracket to Inner Panel

Attaching Bolts

3. Rear Guide Lower

Attaching Bolt

Fig. 6-38-Front Door Hardware

-

"B" Four Door Closed Styles

4. Inner Panel Cam

Attaching Bolts

5. Window Down-Travel

Support Bracket

Attaching Bolt

6. Door Lock Remote

Control and Handle

Assembly

7. Door Lock Attaching

Screws

8. Door Lock Electric

Solenoid Attaching

Screws

9. Trim Pad Hanger

Plates and Stabilizer

Strips Attaching Bolt

10. Lower Sash Channel

Cam STUD Nuts

Access Holes

1 1. Window Regulator

'Attaching Bolts

DOORS 6-31

CBN~ROL

(RIGHT SIDE "E" STYLES O N L V p p

-

-

-

Fig. 6-39-Front Door Hardware

-

"B, C and E" Two-Door" Hardtop and Convertible Styles

1. Front Door Window

Assembly

2. Suip, Stabilizer and

Suvport, Trim

~ & ~ e r

3. Stop, Window Front

Upper

4. Stop, Window Rear

Upper

Electric

6. Door Lock Remote

Control and Handle

Assembly

7. Glass Bearing Plate

.8. Tube Assembly,

Window Guide

9. Door Lock

10. Door Lock Cylinder

1 1. Door outsid; Handle

'

12. Guide Assembly,

Lower Sash Lower

13. Guide Assembly,

Lower Sash Upper

14. Plate Assembly,

Lower Sash Guide

15. Support, Window

Bumper

16. Rod, Inside Locking

17. Rod, Remote Control to Lock

6-32 DOORS

Fig. 6-40-Front Door Hardware - "B, C and EM Two-Door Hardtop and Convertible Styles

1. Tube Assembly,

Window Guide

Attaching Bolts

2. Guide Assembly,

Lower Sash Lower

Attaching Bolts

3. Plate Assembly,

Lower Sash Guide

Attaching Bolts

4. Regulator Assembly,

Attaching Bolts

5. Guide ~ s s e m b l ~ ,

Lower Sash Upper

Attaching Bolts

6. Stop, Front Up-Travel

Attaching Bolt

7. Stop, Rear Up-Travel

Attaching Bolt

8. Support, Front

Window Bumper

Attaching ~ o l i

9. Suppoit, Rear

Window Bumper

Attaching Bolt

10. Strip, Stabilizer Front and Trim Support

Hanger Attaching

Bolt

11. Strip, Stabilizer Rear and l'rim Support

Hanger ~ t t a d h g

Bolt

12. Retainer, Inside

Locking Rod

13. Remote .Control, Door

Lock Attaching Bolts

14. Glass Bearing Plate

Attaching Bolts

DOORS 6-33

1. Window Assembly

2. S t a b k r Strips and

Trim Support

3. Lower Sash Channel

Cam

Fig. 6-41-Front Door Hardware

-

"B and C-39 and 49" Styles and "C-69" Styles

4. Front Guide

5. Window Regulator

6. Door Lock Remote

7.

Control

Inner Panel Cam

8. Rear Guide

9. Door Lock

10. Door Outisde Handle

13. Inside Locking Rod

14. Lock Cylinder

1 1. Window Down-Travel

.

15. Remote Control to

Support Bracket and Lock Connecting Rod

Bumper 16. Window UpTravel

12. Window Regulator

Handle

Stops

6-34 DOORS

Fig. 6-42-Front Door Hardware

-

"B and C-39 and 49" Styles and "C-69" Styles

I. Window Rear Upper

Stop Attaching Bolt

2. Rear Guide Upper

Bracket Attaching

Bolp

3. Rear Guide to Upper

Bracket Attaching

Bolt

4. Rear Guide Lower

Attaching Bolt

5. Window Stabilizer

Strip Attaching Bolts

6. Window Front Upper

Stop Attaching Bolt

7. Front Guide Upper

Attaching Bolts

8. Window Regulator

Attaching Bolts

9. Inner Panel Cam

Attaching Bolts

10. Door Lock Remote

Control Attaching

Bolts

1 1. Front Guide Lower

Attaching Bolt

12. Door Lock Attaching

Screws

13. Window Lower Sash

Channel Cam Stud

Nuts Access Holes

14. Door Lock Solenoid

Attaching Screws

1 5. Window Down-Travel

Bumper Support

Attaching Bolt

DOORS 6-35

I. Window Assemblv

2. Trim Pad ~ a n ~ e ;

Plates

3. Trim Pad Hanger

Plate and Stabilizer

Strip

4. Door Outside Handle

Fig. 6-43-Door Hardware

-

"F" Styles

5. Lock Cylinder

6. Lock ~ i s e m b l ~

7. Inside Locking Rod

8. Rear Guide

9. Inner Panel Cam

10. Window Down Travel

Bumper Support

1 I . Remote Control to

Lock Rod

12. Window Regulator

(Manual)

13. Lower Sash Channel

Cam

14. Remote Control

Handle Assembly and

Escutcheon

15. Window Regulator

Handle

16. Front Guide

1. Window Front Up-

Travel Stop Attaching

Bolt

2. Window Rear Up-

Travel Stop Attaching

Bolt

3. Window Stabilizer

Strip and Adjustable

Trim Hanger Plate

Attaching Bolt

Fig. 6-44-Door Hardware

-

" F Styles

4. Trim Support Hanger

Attaching Screws

5. Front Guide Upper

Attaching Bolts

6. Rear Guide Upper

Bracket Attaching

Bolts

7. Rear Guide Upper

Attaching Bolts

8. Front Guide Lower

Attaching Bolt

Attaching Bolt

10. Window Regulator

Attaching Bolts

1 1. Inner Panel Cam

Attaching Bolts

12. Window Bumper

Support Attaching

Bolt

13. Window Lower Sash

'

Channel Cam Nuts

Access Holes

14. Door Lock Attaching

Screws

DOORS 6-37

1. Window Regulator

2. Ventilator Division

Channel

Fig. 6-45-Front Door Hardware

-

"X-27 and 69" Styles

3. Door Lock Remote

Control

4. Window Down-Travel

Stop Support

5. Front Door Window

Assembly

6. Lower Sash Channel

Cam

7. Door Outside Handle

8. Door Lock

6-38 DOORS

1. Door Lock Remote

Control Attaching

Bolts

2. Ventilator Division

Channel Lower

Adjusting Stud

Fig. 6-46-Front Door Hardware

-

"X-27 and 69" Styles

3. Window Regulator

Attaching Bolts

4. Door Lock Attaching

Screws

5. Door Upper Frame

Attaching Screws to

Ventilator Frame

6. Ventilator Frame to

Door Outer Panel

7.

Attaching Bolt

Window Down Stop

Support Attaching

Bolt

DOORS 6-39

Fig. 6-47-Typical Front Door Hinge Attachment

-

All Except "Xu Styles

FRONT DOOR HINGES

Styles

-

All Except

"X"

All hinges are constructed of steel and incorporate a two stage hold-open feature in the lower hinge on "A and Xu styles and upper hinge on "B, C,

E

and F" styles.

The front door is mounted to the front body hinge pillar with an upper and lower hinge. Figure 4143 illustrates typical front door bolt-on hinge installation, except for " X u styles. "X" style hinges are welded to door and body hinge pillars. All styles use a "swing- in" type hinges, which means the leading edge of the door swings inboard of the front fender when opened.

Door Removal and Installation

"X" Styles

-

All Except

Although the door can be removed from the body with or without the hinges attached to the door, it is recommended that when removing the door only, remove the door from the hinges. Accessibility to the door side hinge bolts is better than to the body side bolts.

1. Prior to loosening any hinge bolts, mark position of hinge on door to facilitate adjustment when reinstalling door on hinge.

2. On doors equipped with power operated windows, power door locks, etc., remove trim pad and detach inner panel water deflector sufficiently to disconnect harness assembly(ies) and remove same from door.

3. With aid of a helper, support door in open position and remove upper and lower hinge to door hinge pillar attaching bolts (Figure 6-47).

4. To install, reverse removal procedure. Adjust door as outlined in subsequent adjustment procedure.

Hinge Removal

-

All Except "Xu Bodies

(Styles Not Equipped With Power Options

In The Door)

1. Remove front door as previously described. Mark position of hinge on body hinge pillar and remove hinge to body hinge pillar attaching bolts

(Figure 6-47).

2. To install door, reverse.remova1 procedure. Prior to installation, apply a coat of heavy body sealer to surface of hinge that contacts door and front body hinge pillar for protection against corrosion.

Adjust door hinge as subsequently described.

NOTE: On all styles, removal of upper and lower hinges from body hinge pillar can be accom- plished with the door removed without loosening front fender.

Hinge Removal (Styles Equipped With

Power Options In The Door)

1. Loosen front fender along the lower edge as outlined in Car Division Service Publications.

2. Support door in the full-open position and remove hinge to door and body hinge pillar attaching bolts (Figure 6-47). Then, remove hinge from

MY

3. To install, reverse removal procedure. Prior to installation of hinge, apply a coat of heavy bodied sealer to surface of hinge that contacts door and body hinge pillar for protection against

. corrosion. Align door as subsequently described.

Front

Styles

Door Hinge Adjustment

-

All Except " X u

Door adjustinents are provided through use of floating anchor plates in door and front body hinge pillars.

When checking door for alignment, and prior to

6-40 DOORS making any adjustments, remove door lock striker from body to allow door to hang freely on its hinges.

Loosen front fender where required.

NOTE: When making door adjustments, refer to door gap spacing and lock striker engagement specifications in the "Front and Rear Door" section of this manual.

1. Adjustments provided at body hinge pillars and down and fore and aft on all body styles.

- up

NOTE: If REARWARD adjustment of either front door is made, replace the jamb switch.

(Refer to Electrical section of this manual for door jamb switch replacement).

2. Adjustments provided at door hinge pillars and out on all body styles.

.

- in

3. For removal or adjustment of all front door hinge to body attaching bolts, use tool 5-22810

-

1/2" wrench (or equivalent) (Figure 6-48).

FRONT DOOR HINGES

-

"X" STYLES

Front door hinges on "Xu body styles are welded to the door and body hinge pillars. Because of the positive attachment, all adjustment provisions have been eliminated. However, a removable hinge pin has been provided for removal of the door assembly from the body. Replacement hinges are serviced as an assembly and are pierced to permit bolt-on installation into tapped anchor plates. Tapped anchor plates must be used instead of nuts and washers to insure structual integrity when replacing a hinge assembly. Anchor plates are not furnished with the hinge assembly and must be ordered separately. In addition, hinge pins, bushings and "E" rings are available as separate service parts. Service replacement hinge assemblies

Fig. 6-48-Front Door Hinge Tool 5-22810

"A, B, C, E and F" Styles

-

Fig. 6-49-Front Door Hinge "EM Ring Removal will include a removable pin and "E" ring retainer so that the hinges can be separated for individual door side and/or body side strap replacement (refer to

Figure 6-49).

DOOR REMOVAL

-

" X u Styles

#

1. Remove "E" ring (snap retainer) from lower end of both upper and lower hinge pins (Fig. 6-49).

2. Disengage door hold-open spring from lower hinge assembly by prying upward against spring with a suitable prying tool (Fig. 6-50). Use care not to damage hold-open link.

CAUTION: Cover spring with shop towel to prevent spring from "flying" and possibly causing personal injury or damage.

3. Using tapered type tool, drive wedge between head of hinge pin and hinge. This will raise pin sufficiently to force serrated shoulder on the upper end of the hinge pin out of hinge.

4. With aid of a helper to support door at rear edge, remove loosened hinge pins. Then, remove door assembly.

DOOR INSTALLATION

-

"X" Styles

1. With aid of a helper, place door into position and insert hinge pins and "E" rings.

2. Using spring compressing tool (5-23497 or equivalent), install hold-open spring in lower hinge (Figs. 6-5 1 and '6-52).

NOTE: When installing hold-open spring on tool

5-23497 or equivalent, position spring so that the cut end of the spring is in line with the center of

DOORS 6-41

LINK

(HOLD-OPEN)

AND RIVET

Fig. 6-50-Front Door Hinge "Hold-Open

Spring" Removal the blade on the straight jaw. Figure 6-51 illustrates position of spring for right side installation (left side installation would utilize the other end of the blade). The other end of the spring should be seated over the hook on the opposite jaw of the tool.

CAUTION: Be sure spring is seated properly before compressing to prevent the spring from slipping out of the tool and possibly causing damage or personal injury.

IGHT SPRING LOADING POSITION

Fig. 6-5 i -Hold-Open Spring, Loading Positions

Using Tool (5-23497 or equivalent)

Fig. 6-52-Front Door Hinge Hold-Open Spring

DOOR SlDE AND/OR BODY SlDE HINGE

STRAP

-

"X" Styles

Removal

1. When removing door side hinge straps, remove door trim assembly and inner panel water deflector. For body side lower hinge straps, remove front fender and shroud side trim panel.

For upper hinge removal, anchor plate can be installed through the access opening in the body hinge pillar.

2.

Remove door from body as previously described.

3. Scribe location of hinge on hinge pillar.

4. Center punch visible weld marks on hinge base as shown in Figure 6-49 and drill a 1/8" pilot hole completely through welds at center punch marks.

5. Using 1/8" hole as a guide, drill out welds with a

1 /2" drill bit.

IMPORTANT: When drilling out welds, drill only deep enough to penetrate hinge base to release hinge from panel as s'hown in Fig. 6-53).

6. A slight amount of weld may still retain hinge base to panel. Drive a. chisel between panel and hinge base to separate hinge from panel.

6-42 DOORS

HINGE PILLAR

REINFORCEMENT r

HINGE' PILLAR

HINGE BASE

RILL THROUGH

INGE BASE TO

EINFORCEMENT

GUIDE HOLE

Fig. 6-53-Typical Weld lnstallatlon

1. Position the replacement bolt-on hinge within scribe marks on the hinge pillar facing and center punch bolt hole locations.

2. Using a 1/2" drill bit, drill hinge attaching holes.

The 1/2" holes in the hinge pillar will provide for some adjustment when reinstalling the door assembly.

3. Coat surface of hinge that mates with hinge pillar with medium bodied sealer and install hinge using specified 5/ 16" x 1-1/2" bolts and service hinge anchor plates previously described.

4. Install door to body as previously described.

Front Door Hinge Adjustments

Replacement Hinges Only)

("X" Style Senice

1. In and out adjustment provided on door side hinge strap.

2. Fore and aft adjustment provided on body side hinge strap. (use tool. J-21530 or equivalent,

Figure 6-54).

NOTE: Prior to making door adjustments, remove door lock striker from body and allow door to hang freely on its hinges. Also, refer to door gap spacing and lock striker engagement specifications

Fig. 6-54 Front Door Hinge Tool 5-21550 (1/2"

Box)-"X" Styles in the "Front and Rear Door" section of this manual.

INSIDE LOCKING ROD

-

All Coupe Styles

6

Removal and Installation

1. On "A, F and X" styles, remove door trim assembly and peel inner panel water deflector back sufficiently to gain access to inside locking rod retainers (Fig. 6-40). On "B, C and E" styles, remove upper and lower portion of door trim assembly. It is not necessary to remove the water deflector.

2. Slide inside locking rod to door inner panel plastic retainers in direction of arrows shown in Figure

6-40.

3. Disengage rod from lock and lower locking rod through belt line to remove.

4. To install, reverse removal procedure.

FRONT DOOR LOCK REMOTE CONTROL

AND CONNECTING ROD

There are two basic types of remote controls; spindle

type

and pull-in type remote control and handle assembly.

All spindle type and pull type remote control assemblies are secured to the door inner panel by attaching bolts. On some styles, the remote is attached to the inboard surface of the inner panel and on other styles to the outboard surface. The removal and installation is similar, however, for either method of attachment.

NOTE: Pontiac 27657 styles and 26200 series and "F" styles with standard trim utilize, a pull-in type remote control and handle assemblies that can be removed from the door without trim removal. For removal, refer to door trim assembly removal in Section 13 of this manual.

,Removal and Installation (All Styles Except Pontiac

27657 and 26200 series and "F" styles with standard trim).

1. Raise door window, remove door trim pad (on "B,

C and E" styles, remove upper and lower portion of door trim assembly) and detach inner panel water deflector.

NOTE: Some "E" body styles are equipped with two remote controls, one front (pull-in type) and one rear (spindle type). Attachment of both is similar.

2. Remove bolts securing remote control to door inner panel (Refer to Figure 6-40 for pull-in type and Figure 6-34 for spindle type).

3. Pivot remote control to disengage lock connecting rod and remove remote control assembly.

4. If remote control to lock connecting rod is to be removed, refer to "Front and Rear Door" section for method of disengaging spring clip at lock end of rod.

5. To install, reverse removal procedure.

FRONT DOOR LOCK ASSEMBLY

All styles use the fork bolt lock design which includes an interlock feature. Where necessary, striker spacers should be used to insure satisfactory lock and striker engage- ment. Refer to "Front and Rear Door" section for spacer usage.

Removal and Installation

1. On "B, C and E" styles, raise door window and remove upper and lower portion of trim pad. On

"A, F and X" styles, remove door trim assembly and peel back the inner panel water deflector sufficiently to gain access to lock assembly.

2. Working through large access hole, disengage remote control to lock connecting rod at lock as specified under "Door Lock Spring Clips" in preceding "Front and Rear Door" section.

NOTE: On coupe styles, it may be necessary to remove inside locking rod, on other styles, it may be necessary to remove the remote control assemblv and then remove the lock and connect- ing rod i s an assembly.

3. On styles equipped with electric door locks, remove electric solenoid as described in "Front and Rear Door" section.

4. Remove three screws securing lock to door lock pillar ("12", Figure 6-42) and remove lock assembly from door.

NOTE: On four-door styles, the design of the lock to inside locking attaching clip does not allow disengagement of rod from lock with lock in an installed position. This rod can be removed from lock in a bench operation after removal of lock assembly.

5. To install, reverse removal procedure.

FRONT DOOR LOCK CYLINDER

ASSEMBLY

Removal and Installation

1. On "B, C and E" styles, remove upper and lower portion of door trim assembly, then raise door window. On "A, F and X" styles, remove door trim assembly and pecl back inner panel water deflector. lock cylinder retaining clip (on boor outer panel) out of engagement and remove lock cylinder from door (Figure 6-55).

S E A L I N G

L O C K C Y L I N D E R

( R E M O V E D )

'L ..,-

V I E W A

3087

Fig. 6-55-Front Door Lock Cylinder Removal

All Styles

-

6-44 DOORS

3. To install, reverse removal procedure.

Disassembly and Assembly

1. Remove lock cylinder from door as previously described.

2. With a pointed tool, disengage pawl retaining clip and remove pawl (Figure 6-56).

3. With a flat-bladed tool, straighten out crimped- over edges of lock cylinder housing scalp and remove scalp and lock cylinder from housing.

NOTE: Refer to General Information Index

(Section 1 of this manual) for lock cylinder coding.

4. To install, reverse removal procedure.

NOTE: Lock cylinder housing scalp is usually damaged in removal procedure and, therefore, must be replaced. Replacement scalps are available as service parts.

DOOR OUTSIDE REMOTE CONTROL

MIRROR

On all styles, except Cadillac styles, the mirror face is serviced separately. On Cadillac styles the mirror is serviced as an assembly. For mirror face replacement, refer below.

Removal and Installation

" A Styles

-

Buick and Oldsmobile

1. Lower window to a full-down position. Remove remote cable escutcheon to door trim assembly attaching screws and disconnect cable to escutch- eon attaching clip (Figure 6-57).

2. On Oldsmobile ventless styles, remove cable support arm from end of cable (Figure 6-57). On

Buick ventless styles working through the remote cable escutcheon access hole in door trim assembly and/or through the beltline, detach remote cable from retaining tab on door hinge pillar (Figure 6-58).

Fig. 6-57-Door Outside Remote Mirror Trim

Removal

Pad Escutcheon

-

Buick and Oldsmoblle "A" Styles

OLDSMOBILE STYLES I U I C K STYLES

O FOR

Fig. 6-56-Door Lock Cylinder Assembly

Fig. 6-58-Door Outside Remote Mirror Removal

-

Buick and ~ldsmobile "A" Styles

DOORS 6-45

3. On Buick styles, remove remote control mirror to mounting bracket

attach in^

screw, in base of mirror, and mounting bracket to door outer panel attaching screws (Figure 6-58). Then remove mirror and cable assembly from door.

4. On Oldsmobile styles, using a 1/8" hex wrench, loosen mirror base to door outer panel attaching bolts by turning bolts clockwise (Figure 3616).

Then slide mirror rearward, then upward to remove.

5. To install, reverse removal procedure.

Removal and Installation

"A and

Frr

Styles

-

Chevrolet and Pontiac

1. Remove door trim assembly and peel inner panel water deflector back sufficiently to gain access to remote mirror cable. Then, on ventless styles, detach remote cable from retaining tabs on inner panel reinforcements (Refer to Figure 6-59 for

"A" styles and Figure 6-60 for " F

2. On Chevrolet and Pontiac "A" styles, remove mirror base to door outer panel stud nuts (Figure

6-59) and remove mirror and cable assembly from door.

3. On Chevrolet and Pontiac "F" styles, remove attaching screw in base of mirror and mounting bracket to door outer panel attaching screws

Fig. 6-59-Door Outside Remote Mirror Removal

-

Chevrolet and Pontiac "A" Styles

R E M O T E M I R R O R I N S T A L L A T I O N

391 2

Fig. 6-60-Door Outside Remote Mirror Removal

"B, C, E and F" Styles, Except Cadillac

-

" F

Styles Shown, "B, C and E" Similar

(Figure 6-60). Then, remove mirror and cable assembly from door.

4. To install, reverse removal procedure.

Removal and Installation

-

"B, C and E" Styles

1. Remove upper portion of door trim assembly as described in Section 13 of this manual. Then, detach remote cable from retaining tab on inner panel reinforcement (Figure 6-60).

2. Remove attaching screw in base of mirror and mounting bracket to door outer panel attaching screws (Figure 6-60) On all styles, except Cadillac.

On Cadillac styles the mirror is retained to the outer panel by stud nuts similar to Chevrolet and

Pontiac "A" styles (Figure 6-59). Remove mirror and cable assembly from door.

3. To, install reverse removal procedure.

Remote Mirror Face Replacement (All Styles,

Except Cadillac)

1. To remove a scratched, broken, stained, etc. mirror face from the mirror frame. break the mirror

6-46 DOORS glass and remove the broken glass and fiber pad from the mirror frame.

NOTE: Protect painted surface on door assembly when breaking mirror face to remove from mirror frame.

2. Wipe inside of mirror frame clean.

3. On replacement mirror faces so equipped, remove paper backing from mirror face and install.

Center mirror in mirror frame and press firmly.

DOOR OUTSIDE MIRROR

MIRROR

-

STANDARD

Removal and Installation

-

All Styles

1. Remove attaching screw in base of mirror and remove mirror (Figure 6-6 1).

2. To install, reverse removal procedure.

FRONT DOOR INNER PANEL CAM

-

All

Except "A and X-69" and "A,

B,

C, and

E" Two Door Hardtop and Convertible

Styles

Removal and Installation

1. On "A, F and

X"

styles, remove door trim assembly and detach inner .panel water deflector sufficiently to gain access to the inner panel cam.0n "B and C" styles remove upper and lower portion of door trim assembly.

2. With window in raised position, remove inner panel cam attaching bolts ("9", Figure 6-42) and slide cam off regulator balance arm roller.

3. To install, reverse removal procedure.

NOTE: The ends of the cam have provisions for up and down adjustment to correct a "cocked" window (not parallel with top of door upper frame or side roof rail weatherstrips).

FRONT DOOR VENTILATOR

REGULATOR-"A" Styles

Removal and Installation

1. With front door window in full-up position, remove door trim assembly and partially detach inner panel water deflector.

2. Remove ventilator T-shaft bolt ("ti", Figure 6-62) and ventilator regulator to inner panel attaching bolts ("4". Figure 6-62).

Fig. 6-61-Door Outside Mirror

Styles

-

Typical All

Rg. 6-62-Front Door Ventilator and Window

Removal and Adjustments

-

"A" Closed Styles

I. Ventilator Division

Channel Lower

Adjusting Stud

2. Window Down Stop

Support Attaching

Bolt

3. Ventilator to Door

Upper Frame

Attaching Screws

4. Ventilator Frame to

Door Outer Panel

5.

Attaching Bolt

Ventilator Regulator

6. Ventilator Regulator to "T-Shaft"

Attaching Bolt Access

Hole

DOORS 6-47

3. Pull regulator down to disengage from ventilator

T-shaft and remove regulator through access hole.

4. To install, reverse removal procedure.

FRONT DOOR VENTILATOR ASSEMBLY

"A" Closed Styles

-

Removal and lnstallation

1. Remove door trim assembly and inner panel water deflector.

2. With window in up position, loosen down stop support attaching bolts and remove support ("2",

Figure 6-62).

3. Remove ventilator regulator as previously described.

4. Lower window to full down position and remove bolt securing ventilator lower frame to door outer panel ("4", Figure 6-62).

5. Remove division channel lower adjusting stud nut

(" l", Figure 6-62).

6. Remove ventilator to door upper frame attaching screws ("3". Figure 6-62). Disengage upper front end of glass run channel from door upper frame to permit rearward movement and removal of vent from door upper frame (refer to glass run channel removal procedure).

7. Tilt vent assembly rearward and remove vent inboard of door upper frame.

8. To install, reverse removal procedure.

Adjustments

Some in-and-out, or fore-and-aft adjustment of the ventilator division channel is available at the lower adjusting stud ("l", Figure 6-62). Adjustment at this location is required only to eliminate any misalign- ment between the ventilator. division channel and window glass run channel.

D I V I S I O N CHANNEL TO\

F R A M E S C R E W /1

VENT W/STRI

-

BEND-OVER TABS

D I V I S I O N C H A N N E L

STRIP ASSEMBLY

2 3 8 4

Fig. 6-63-Front Door Ventilator Assembly

-

"A" Clwed Styles

FRONT DOOR VENTILATOR ASSEMBLY-

"A-39" Styles

Removal and Installation index for removal procedures).

I

VENTlLATOR DISASSEMBLY AND

ASSEMBLY-"A" Closed Styles

The ventilator front frame is attached to the division channel with rivets at the bottom and a screw at the top (Figure 6-63).

The parts that can be replaced are the division channel strip assembly, ventilator weatherstrip (on division channel) and the vent glass.

Fig. 6-64-Front Door Ventilator Assembly

Removal and Adjustment "A-39" Styles

1. Ventilator Frame to

Door Panel Bolts

2. Ventilator Lower

Frame Adjusting Stud

3. Division Channel

Lower Adjusting Stud

4. Ventilator Regulator

Attaching Bolts

6-48 DOORS

2. Remove ventilator frame to door panel bolts (" 1 ",

Figure 6-64) and trim pad hanger plate retained by rear bolt.

3. Remove ventilator lower frame adjusting stud

("2", Figure 6-64).

4. Remove division channel lower adjusting stud

("3", Figure 6-64).

5. Lift the ventilator upward, then rotate it so that division channel lower attaching bracket can clear the beltline adjacent to rear guide.

6. To install, reverse removal procedure. Adjust ventilator for proper operation and alignment as described below.

Ventilator Adjustments

The ventilator assembly can be positioned up or down and fore or aft. In addition, the top of the vent can be adjusted in or out in relation to the side roof rail.

-

To reposition the ventilator assembly up or down or fore or aft, it is necessary to have the vent completely loose at all attaching locations, including the ventilator regulator attaching bolts ("4", Figure 6-64).

To adjust the top of the ventilator in or out, loosen only the adjusting stud nuts ("2" and "3", Figure 6-64) and adjust the studs in or out as required.

It is not necessary to loosen the vent to outer panel bolts ("3", Figure 6-64).

Ventilator Disassembly and Assembly

Styles

-

"A-39"

The "hardtop" style ventilator permits more disassem- bly than does the "closed" style vent. The parts that can be removed and replaced are as follows: upper glass run channel; division channel and component lower glass run channel and vent lower frame; ventilator casting; ventilator window assembly; ventilator weatherstrip (on casting); ventilator rear weatherstrips (on division channel).

As shown in Figure 6-65, it is necessary to remove the vent from the door to gain access to the vent casting to vent frame screws.

The vent window and sash channel assembly can be removed without removing the vent from the door; however, the vent regulator must be removed (see preceding removal procedure). With the regulator out, open the vent window to align the bosses on the

T-shaft with the slots in the vent lower frame. Then, press the vent window downward to disengage the vent upper pivot from the vent casting. Remove the vent window by lifting upward.

I

UPPER G

R U N C H

V E N T W E A ? H E R S T R I P

B E N D - O V E R TABS

7

LOWER GLASS

R U N C H A N N E L

Fig. 6-65-Front Door Ventilator Assembly

39" Styles

-

"A-

The division channel to casting screw (Figure 6-65), also retains the top of the division channel strip assembly. To remove the strip assembly, or to gain access to the vent weatherstrip bend-over tabs

(weatherstrip on division channel), remove the screw and pull the strip assembly out of the division channel.

V E N T

U P P E R

F R A M E SCREWS

A

V E N T TO DOOR

O U T E R P A N E L SCREW

/

V E N T D I V I S I O N C H A N N E L

A D J U S T I N G S T U D A N D N U T

VIEW A VIEW B

3080

VIEW C

Fig. 6-66-Front Door Ventilator Removal

DOORS 6-49

FRONT DOOR VENTILATOR ASSEMBLY

"X" Styles

-

The front door ventilator is a manually operated friction type unit on all styles.

Removal and Installation

Remove door trim assembly and inner panel water deflector.

With window in "full-up" position loosen down stop support attaching bolt and remove support

("I", Figure 6-46).

Lower door window and remove ventilator division channel lower adjusting stud nut and ventilator to door outer panel attaching screw

(View "A" in Figure 6-66).

Remove ventilator to door upper frame attaching screws (View "A", in Figure 6-66).

Lift ventilator rearward and upward until lower forward corner of assembly is free of door upper frame (View "B" in Figure 6-66).

Rotate ventilator assembly in an outboard movement and remove unit outboard of door upper frame (View "C" in Figure 6-66).

7. To install, reverse removal procedure.

Fig. 6-67-Front Door Window Removal and

Adiustment - "A and X" Closed Styles

Adjustment

A slight fore and aft adjustment of the ventilator division channel is available at the lower adjusting stud by loosening attaching nut and sliding stud in slot provided. The division channel can also be positioned in or out by loosening nut and turning stud in or out as required.

FRONT DOOR WINDOW ASSEMBLY and X" Closed Styles

-

"A

The front door window assembly consists of a frameless piece of solid tempered safety plate glass pressed into a thin section lower sash channel. When cycled, the glass operates within the ventilator division channel and window glass run channel.

Removal and Installation

Remove front door ventilator assembly as previously described.

Slide window lower sash channel cam off window regulator lift arm and balance arm rollers on two door styles and off lik arm roller on four door styles. Remove window inboard of door upper frame.

To install, reverse removal procedure. Adjust window for proper alignment as described in the following procedure.

Adjustments

1. To adjust lower portion of ventilator division channel for proper alignment with door window assembly, lower door window and loosen ventila- tor adjusting stud nut (Figure 6-67). Turn adjusting stud in or out or position lower end of channel fore or aft as required; then, tighten adjusting stud nut.

2. On two-door styles, the door window inner panel cam is adjustable at the front and can correct a rotated (cocked) front door window (Refer to index for inner panel cam adjustment).

FRONT DOOR WINDOW ASSEMBLY

39"

Styles

-

"A-

The front door window assembly consists of a solid

. tempered safety plate window and a combination pressed-on and bolt-on lower sash channel assembly which includes a screw-on lower sash channel cam.

With this design, the dour glass and sash channel are removed from the door as a unit and replacement glasses installed in bench operations.

Figure 6-68 is an exploded view of the front door

6-50 DOORS

Fig. 6-68-Front Door Window Assembly

39" Styles

-

"A-

1. Front Door Window

2. Glass to Sash

Channel Bolt Nut

3. Glass to Sash

Channel Bolt Spacers

4. Glass to Sash

5.

Channel Bolt

Glass to Sash

Channel Filler

6. Glass Lower Sash

Channel window assembly and identifies the various compo- nents and their assembly sequence.

IMPORTANT: When installing the glass to sash charinel bolts, torque nuts to 72 inch pounds (6 foot pounds). Also, when replacing door glass, replace glass spacers.

Removal and lnstallatlon

1. Remove door trim assembly and inner panel water deflector.

2. Operate window to a one-quarter down position; remove front up travel stop from lower sash channel and rear up stop from rear guide ("1" iad "2", Figure 6-69).

3. Loosen rear guide to door inner panel attaching bolts ("3", Figure 6-69).

4. With window in a three quarter down position, remove'screws securing lower sash channel cam to lower sash channel ("4", Figure 6-69).

5. Support window and disengage lower sash channel cam from regulator lift and balance arm rollers.

Fig. 6-69-Front Door Window Removal and

Adjustments - "A-39" Styles

1. Window Front Upper

Stop Access l old -

2. Window Rear Upper

Stop Bolt

3. Rear Guide Upper

4.

Attaching Bolts

Lower Sash Channel

Cam Attaching

Screws Access Holes

5. Vendlator Lower

Frame Adjusting Stud and Nut

6. Ventilator Division

Channel Lower

Adjusting Stud and

Nut

7. Inner Panel Cam

Attaching Bolts

6. Push regulator lift arm inboard, to clear glass sash channel; remove window by lifting straight-up.

7. To install, reverse removal procedure. Adjust window for proper alignment as described in the following procedure.

Adjustments

1. A rotated window condition (glass cocked in opening) may be caused by any one or a combination of the following (Reference: Figure

6-69). a. Improperly adjusted inner panel cam ("7"). b. Front or rear upper stop improperly adjusted

("1 or 2").

2. To adjust upper rear corner of window in or out in relation to side roof rail weatherstrip, loosen rear guide upper attaching bolts ("3", Figure 6-69) and position guide further inboard or outboard.

Outboard adjustment at this location tends to

DOORS 6-51 move the door window upper rear corner inboard.

Conversely, inboard adjustment moves the top of the glass outboard.

If this adjustment proves inadequate, obtain additional adjustment at the ventilator front frame adjusting stud ("5", Figure 6-69).

3. To adjust window up-travel, loosen front and rear upper stops ("1 and 2", Figure 6-69), then operate window to desired up position and tighten stop bolts.

4. Adjustment has been provided to relieve a binding door glass due to a misaligned ventilator division channel ("6", Figure 6:69).

FRONT DOOR WINDOW ASSEMBLY

37, 57, 67, 87" Styles

-

"A-

The front door window assembly consists of a solid tempered safety plate glass window, with a bolted-on lower sash guide plate assembly, which operates on a single vertical guide tube located in the center of the door.

Figure 6-70 is an exploded view of the window assemblv and identifies the various comDonents and their as&mbly sequence.

Fig. 6-71-Front Door Window Removal and

Adjustment

-

"A-37, 57, 67 and 87" Styles

I. Stop, Front Up-Travel

.

6. Strip Stabilizer

7. Plate Assembly, Bolt

Lower Sash ~ u i d e 2. Stop. Rear Up-Travel

Bolt

3. Support, Front

Window Bumper Bolt

4. Support, Rear

Window Bumper Bolt

5. Plate, Trim Pad

Bolts

8. Guide Assembly,

Lower Sash Upper

Bolts

9. Guide Assembly,

Lower Sash Lower

Bolts Adjusting

Fig. 6-70-Front Door Window Assembly "A-37,

57, 67 and 87" Styles, ("B, C and E" Coupe

Styles Shown, "A" styles Similar)

I. Stop, Up-Travel (On

.

Glass)

2. Nut

3. Bolt

4. Spacer

5. Washer

6. Fastener, Glass

Bearing ("B, C and

E" Styles Only)

Removal .and Installation

1. Remove door trim assembly and inner panel water deflector.

2. Remove front and rear up-travel stops ("1 and 2",

Figure 6-71) and front and rear stabilizer strips

("6", Figure 6-7 1).

NOTE:

Removal of rear stabilizer strip necessi- tates removal of trim pad adjusting plate ("5",

Figure 6-7 1).

3. Remove lower sash guide plate assembly to glass attaching bolts ("7", Figure 6-71). Tilt upper edge of glass inboard to disengage glass from guide plate, then remove the window from the door by lifting straight-up.

4. To install, reverse removal procedure. Adjust window for proper alignment and operation as described in the following adjustment procedure.

6-52 DOORS

Adjustments

1. In And Out Adjustment of the glask is controlled by the in and out adjustment available at the front door window lower sash lower guide ("9",

Figure 6-71) and the in and out position of the glass stabilizer strip assemblies ("6", Figure 6-71).

The lower sash lower guide assembly and stabilizer strips are slotted to permit in and out adjustment of the glass. Outboard adjustment of the lower sash lower guide moves the top of the glass inboard. Conversely, inboard adjustment moves the top of the glass outboard.

2. Fore And Aft Adjustment of the window assembly is controlled by the position of the lower sash channel guide plate assembly ("7", Figure 6-71).

The guide plate to glass attaching locations are slotted to permit fore and aft adjustment of the glass.

3. Ease Of Window Operation And Window Stability depend to a great extent on the adjustment of the window stabilizer strip assemblies at the beltline

("6", Figure 6-71). The stabilizing strips ("6") should contact the glass throughout the full cycle of the window. Due to slight variations in glass contour, however, in some cases the strip may lose contact with the glass halfway through the cycle.

This is permissible provided it does not result in loose glass. Contact should be sufficient to stabilize glass, but not restrict ease of window operation.

4. A Window That Is Rotated (Cocked) In The

TOOL J 23394-2

(BLUE)

TOOL J 23394-1

(RED)

Figure 6-73-Glass Alignment Gauge Blocks -

Tool J23394 (Consists of a Set of Three Blocks)

Window Opening may be the result of an improperly adjusted lower sash upper guide assembly ("8", Figure 6-71) or poorly adjusted up-travel stops (" 1" and "2", Figure 6-7 1).

Control up-travel at front or rear of window through up or down adjustment of either front or rear up-travel stop.

6

Correct a poorly adjusted lower sash upper guide assembly by loosening upper guide assembly attaching bolts ("8", Figure 6-71 and rotating front edge of glass up or down in relation to rear edge of glass as necessary.

5. Up-travel Of The Window is determined by the adjustment of the front and rear window up- travel stops ("1" and "2", Figure 6-71). To adjust window up-travel, loosen front and rear up-stops

Figure 6-72-Front Door Window Adjustment

Two-Door Hardtop Styles

Figure 6-74-Front Door Window Alignment

(Fore and Aft and Rotated

"Cocked Glasswin Body Opening Adjustment)

DOORS 6-53 and operate window to desired position to establish proper glass to side roof rail weather- strip contact.

Down-travel of the window is determined by the position of the front and rear window down-travel bumper supports ("3" and "4", Figure 6-71). To adjust window down-travel, loosen front and rear window bumpers and lower window to desired glass height. Then, position front and rear bumper against lower edge of glass and tighten bumper attaching bolts.

GLASS ALIGNMENT GAUGE BLOCKS

"A-37, 57, and 87" Styles

-

With the elimination of front and rear guides and the incorporation of a single vertical guide tube in the center of the door, most window adjustments will be made from a guide plate attached to the lower edge of the glass (Figure 6-72). Fine adjustment of this glass will be more sensitive than conventional styles utilizing front and rear guides, as relatively small movements at adjusting locations will result in large movements at the upper edge of glass.

To facilitate adjustment of glass, use glass alignment gauge blocks Tool J-23394 or equivalent (Fig. 6-73).

For proper use of gauge blocks refer to the following procedure:

Adjustment

1. Remove door trim assembly and inner panel water deflector.

2. Detach side roof rai1,weatherstrip at lower front corner and carefully remove from retainer over front door window as shown in Figure 6-74.

3. Lower front door and rear quarter windows and install gauge blocks, tool J-23394-2(blue) or equivalent into side roof rail weatherstrip retainer above upper front and rear comers of glass as shown in Figure 6-74. Then, install gauge block, tool 5-23394-1 (red) or equivalent into windshield pillar retainer slightly above beltline.

IMPORTANT: Grooves on sides of gauge blocks must be fully engaged with side roof rail weatherstrip retainer.

4. Working from inside body, with door in closed position, loosen front and rear up-travel stops

("1" and "2", Figure 6-71) and stabilizer strips

("6", Figure 6-7 1).

5.

Raise door window assembly until contact is established between upper and/or forward edge of glass and one or more of three gauge blocks.

If upper and forward edge of glass contact all three gauge blocks simultaneously (as shown in

Figure 6-74), proceed with step number six (6). If, however, upper and forward edge of glass does not contact all three blocks simultaneously, completely loosen lower sash channel guide plate

("7" Figure 6-71) and lower sash upper guide assembly ("8" Figure 6-71) and manipulate glass by hand until.upper and forward edge of glass contacts all three gauge blocks in full-up position

(as shown in Figure 6-71). Tighten guide plate and upper guide assembly attaching bolts.

6. Loosen lower sash lower guide assembly ("9",

Figure 6-71). Apply firm outboard pressure against bottom of lower sash guide plate assembly to remove slack in system and to hold upper inner edge of glass inboard against outer edge of gauge blocks, as shown in Figure 6-75. Then, tighten lower guide assembly attaching bolts.

IMPORTANT: Inner surface of glass must contact outer surface of the upper gauge blocks during this adjustment. Excessive outboard pressure can tilt glass too far inboard at top, resulting in excessive glass to side roof rail weatherstrip contact.

6

7. With glass in full-up position against the upper gauge blocks as shown in Figure 6-75, tighten adjustable up-travel stops on glass (Figure 6-71) against inner panel. Adjust stabilizer strips('/6",

Figure 6-71) for proper tension against glass.

8. Lower window and remove gauge blocks from weatherstrip retainer. Reinstall and reseal weatherstrip as previously described.

GAUGE BLOCKS

TOOL J 23394-2

(BLUE)

Figure 6-75-Front Door Window Alignment (In and Out and Up-Travel Adjustment)

6-54 DOORS

Fig. 6-76-Window Removal and Adjustment

"B" Closed Styles

-

1. Window Trim Support

Hanger and Statilizer

Strip Bolts

2. Window Lower Sash

Channel Cam

Attaching Stud Nut

Access Holes

3. Window Rear Guide to Guide Bracket

Bolt

4. Window Rear Guide

Bracket to Inner

Panel Bolts

5. Window Rear Guide

Lower Bolt

6. Inner Panel Cam

Bolts

7. Window Down-Travel

Support Bracket Bolt

FRONT DOOR WINDOW ASSEMBLY

Closed Styles

-

"B"

The front door window assembly consists of a solid tempered safety plate glass window and an individu- ally bolted-on roller at the rear. The lower sash channel cam is bolted to the glass, but is removed in the process of removing the window.

Removal and Installation

1.

Remove upper and lower portion of door trim assembly and inner panel water deflector.

2: Loosen window stabilizer strips ("I", Figure 6-76).

3. Operate window to a three-quarter-down position and remove window lower sash channel cam to glass attaching stud nuts ("2", Figure 6-76). Tilt front edge of glass downward and remove window inboard of door upper frame.

4. To install, reverse removal procedure. Adjust glass for proper alignment and operation by perform- ing the following procedure.

Adjustments

1.

The. rear guide is adjustable in and out ("3"

Figure 6-76) and fore and aft ("4" Figure 6-76) to relieve a binding door glass.

2. The door window inner panel cam ("6", Figure

6-76) is adjustable at the front to correct a rotated

(cocked) window.

3. The window down-travel is controlled by the position of the down-travel bumper support ("7"

Figure 6-76).

FRONT DOOR WINDOW ASSEMBLY

C and Eu Two-Door Hardtop and

Convertible Styles

.

"B,

The front door window assembly qonsists of a solid tempered safety plate glass window, with a bolted-on lower sash guide plate assembly, which operates on a single vertical guide tube located in the center of the door.

Figure 6-77 is an exploded view of the window assembly and identifies the various components and their assembly sequence.

-

"B,

C and E" Two-Door Hardtop and Convertible Styles

1. Stop, Up-Travel (On

Glass)

2. Nut

3. Bolt

4. Spacer

5. Washer

6. Fastener, Glass

Bearing

DOORS 6-55

Fig. 6-78-Front Door Window Removal and

Adjustment - "B, C and E" Two-Door Hardtop and Convertible Styles

Support, Front

Window Bumper Bolt

Support Rear Window

Bumper Bolt

Stop, Front Up-Travel

Bolt Location ("B, C and E" Styles)

Stop, Rear Up-Travel

Bolt Location ("B, C and E" Styles)

Trim Pad Adjusting

Plates and Stabilizer

Strips

Plate Assembly,

Lower Sash Guide

Bolts

Guide Assembly,

Lower Sash Upper

Bolts

8. Guide Assembly,

Lower Sash Lower

Bolts

9. Glass Bearing Plate

Inner Panel Bolts

10. Glass Bearing Plate

Adjusting Stud

1 1. Guide Assembly,

Lower Sash Upper

Adjustment Access

Hole (Rotated

"cocked" glass

Adjustment)

12. Plate Assembly,

Lower Sash Guide

Adjustment Access

Hole (Fore and An

Adjustment) to

Removal and Installation

Remove upper portion of door trim assembly.

Remove front and rear up-travel stops ("3 and 4",

Figure 6-78) and stabilizer strips ("5", Figure

6-78).

Remove glass bearing plate adjusting stud nut

("lo", Figure 6-78) and turn adjusting stud clockwise until bearing plate is out of contact with bearing button on glass.

Remove lower sash guide plate assembly to glass attaching bolts ("6", Figure 6-78). Tilt upper edge of glass inboard to disengage glass from guide plate, then remove the window from the door by lifting straight-up.

To install, reverse removal procedure. Adjust window for proper alignment and operation as described in the foIIowing adjustment procedure.

Adjustments

1. In and out adjustment of the glass is controlled by the in and out adjustment available at the front door window lower sash lower guide ("8", Figure

6-78) and the in and out position of the glass stabilizer strip assemblies ("5", Figure 6-78). The lower sash lower guide assembly and stabilizer strips are slotted to permit in and out adjustment of the glass. Outboard adjustment of the lower sash lower guide moves the top of the glass inboard. Conversely, inboard adjustment moves the top of the glass outboard.

2.

Fore and aft adiustment of the window assembly is controlled b i the position of the lower sash channel guide plate assembly ("6", Figure 6-78).

The guide plate to glass attaching locations are slotted to permit fore and aft adjustment of the glass.

3. Ease of window operation and window stability depend to a great extent on the adjustment of the window stabilizer strip assemblies at the beltline

("5", Figure 6-78) and glass bearing plate ("9 and lo", Figure 6-78). The stabilizing strips ("5") should contact the glass throughout the full cycle of the window. Due to slight variations in glass contour, however, in some cases the strip may lose contact with the glass halfway through the cycle.

This

is

permissible provided it does not result in loose glass. Contact should be sufficient to stabilize glass, but not restrict ease of window operationyThe glass bearing plate is adjustable in and out and should contact a glass bearing button

(on glass) when glass is in a full-up position. ahjusteYd low& sash upper guide assemthy {"7';,

Figure 6-78) or poorly adjusted up-travel stops

("3" or "4", Figure 6-78).

Control up-travel at front or rear of window through up or down adjustment of either front or rear uptravel stop.

Correct a poorly adjusted lower sash upper guide assembly by loosening upper guide assembly attaching bolts ("V, Figure 6-78) and rotating front edge of glass up or down in relation to rear edge of glass as necessary.

5. Up-travel of the window is determined by the adjustment of the front and rear window up- travel stops ("3" and "4", Figure 6-78). To adjust window up-travel, loosen front and rear up-stops

6-56 DOORS

Fig. 6-79-Front Door Window Adjustment ("A"

Styles Shown, "B, C and E" Styles Similar) and operate window to desired position to establish proper glass to side roof rail weather- strip contact.

6. Down-travel of the window is determined bv the position of the front and rear window down-;ravel bumper supports ('/I" and "2", Figure 6-78). To adjust window down-travel, loosen front and rear window bumpers and lower window to desired glass height. Then, position front and rear bumper against lower edge of glass and tighten bumper attaching bolts.

GLASS ALIGNMENT GAUGE BLOCKS

-

("B, C and EM Two-Door Hardtop Styles)

With the elimination of front and rear guides and the incorporation of a single vertical guide tube in the center of the door most window adjustments will be made from a guide plate attached to the lower edge of the glass (Figure 6-79). Fine adjustment of this glass will be more sensitive than conventional styles utilizing front and rear guides, as relatively small movements at adjusting locations will result in large movements at the upper edge of glass.

To facilitate adjustment of this glass, use glass alignment gauge blocks tool 5-2371 1 or equivalent

(Fig. 6-80). For proper use of gauge blocks, refer to the following procedure:

1. Remove upper portion of door trim assembly.

(Refer to the index for door trim assembly removal).

2. Detach side roof rail weatherstrip at lower front corner and carefully remove from retainer over

3. Lower front and rear quarter windows and install gauge blocks, tool 5-2371 1-2 (black) or equivalent into side roof rail weatherstrip retainer above upper front and rear corners of the glass as shown in Figure 6-82. Then, install gauge block, tool

5-237 1 1-1 (grey), or equivalent into windshield pillar retainer slightly above beltline.

IMPORTANT: The grooves on sides of the gauge blocks must be fully engaged with side roof rail weatherstrip retainer.

TOOL J 23711.5 (BIIGEI

68169 STYLE ONLY

TOOLS J 23711-2 (BLACK)

A i'r

Figure 6-80

-

Glass Alignment Gauge Blocks

-

Tool J-23394

(Consists of a set of four blocks)

Figure 6-81 - Front Door Window Alignment

(Rotated "Cocked"

Glass in Body Opening Adjustment)

DOORS 6-57

Figure 6-82-Front Door Window Alignment

(Fore and Aft Adjustment)

Working from inside body, with door in the closed position, loosen front and rear up-travel stops

("3" and "4", Figure 6-78), stabilizer strips ("5",

Figure 6-78) and glass bearing plate ("10", Figure

6-78). To loosen bearing plate, remove stud nut and turn adjusting stud "10" clockwise until bearing plate is out of contact with bearing button on glass.

With glass in partially-down position loosen rear stationary up-travel stop on glass ("l", Figure

6-77). Then, raise door window assembly to approximately 1" from the full-up position, as illustrated in Figure 6-81. If distance (space) between the upper edge of glass and the front and rear gauge blocks is equal (as shown in Figure

L A U G E BLOCKS

TOOL J 23711-2 @~rn

Figure 6-83-Front Door Window Alignment (In

Adjustment) and Out and Up-Travel

6-81), proceed with step number six (6). If distance (space) between the upper edge of the glass and both upper gauge blocks is not equal, loosen lower sash lower guide attaching bolts

("7", Figure 6-78) through access holes ("1 l",

Figure 6-78) and adjust glass as necessary.

Raise front door window assembly until contact is established between the upper and forward edge of glass and one or more of the three gauge blocks.

If upper and forward edge of glass contacts all three gauge blocks simultaneously (as shown in

Figure 6-88), proceed with step number (7). If upper and forward edge of glass does not contact all three gauge blocks simultaneously, loosen fore and aft adjustment on lower sash guide plate ("6"

Figure 6-78) through access holes ("12", Figure

6-78) and move glass forward or rearward until the edge of glass contacts all three gauge blocks in the full-up position.

Completely loosen lower sash lower guide assembly "7", Figure 6-78). Apply firm outboard pressure against upper end of front guide to remove slack in syste and to hold upper inner ? the gauge blocks, as shown in Figure 6-89. Then, tighten lower sash lower guide assembly attaching bolts.

IMPORTANT: Inner surface of glass must contact outer surface of two upper blocks during this adjustment.

With glass in full-up position against upper gauge blocks, tighten up-travel stops ("3" and "4",

Figure 6-78) and adjust stabilizer strips ("5",

Figure 6-78) for proper tension against glass.

Then turn glass bearing plate adjusting stud counterclockwise until the plate assembly contacts the bearing button on glass.

Lower window and remove gauge blocks from weatherstrip retainer. Then, tighten rear station- ary up-travel stop on glass ("I", Figufe 6-77) and reinstall and seal weatherstrip as previously described.

FRONT DOOR WINDOW

ASSEMBLY

and C-39 and 49" and "C-69" Styles

-

"B

The front door window assembly consists of a solid tempered safety plate glass window and an individu- ally bolted-on roller at the rear and a roller assembly

(bell-crank) at the front. The lower sash channel cam is bolted to the glass, but is removed in the process of removing the window.

6-58 DOORS

1. Window Assembly

2. Widow Assembly

(Bell Crank)

3. Bushing

VIEW " 0

4187

Fig. 6-84-Front Door Window Assembly and C-39-49" and "C-69" Styles

-

"B

4. Bolt, Inner Panel

Cam

5. Washer (Plastic)

6. Nut

7. Window Roller

8. Washer (Metal)

Figure 6-84 is an exploded view of the window assembly and identifies the various components and their assembly sequence.

Removal and Installation

1. Remove upper and lower portion of door trim assembly and inner panel water deflector.

2. Remove front and rear window up-travel stops

("1" and "2", Figure 6-85).

3. Loosen front and rear window stabilizer strips

("3", Figure 6-85).

4. With window in three-quarter-down position, remove lower sash channel cam to glass attaching nuts ('Y", Figure 6-85). Remove window by lifting straight up and aligning rollers with notches provided in the door inner panel. Remove rear end of window first, then front end.

5. To install, reverse removal procedure. Adjust window for proper alignment and operation as described in the following adjustment procedure.

Adjustments

NOTE: All adjustments can be accomplished without removal of lower portion of door trim assembly, except inner panel cam and window down travel.

Fig. 6-85-Window Removal and Adjustment

"B and C-39-49" and "C-69" Styles

-

I . Window Front UD-

Bracket Bolts

6. Front Guide Upper

7.

Bolt

Rear Guide to Guide

Upper Bracket Bolt

8. Inner Panel Cam

Bolts

9. Window Down-Travel

Support Bracket Bolt out adjustment of glass is controlled by in adjustment available at the top of the rear guides ("6" and "7", Figure 6-85) in and out position of the glass stabilizer strip

("3", Figure 6-85). Outboard adjust- mynt of guides moves top of the glass inboard.

Cdnversely, inboard adjustment moves top of the outboard.

2. Fore and aft adjustment of window assembly is controlled by position of rear guide. Upper attaching locations in the inner panel ("5", Figure

6-85) are slotted to permit fore and aft adjustment of guide. Because the roller assembly

(bell-crank) which attaches to the glass at the front pivots, the front guide does not have to be adjusted during fore or aft window alignment.

3. Ease of window operation and window stability depends a great extent on adjustment of window stabilizer strip assemblies at beltline ("3", Figure

6-85). The stabilizing strips

"3"

should contact glass throughout full cycle of window. However, in some cases due to slight variations in glass contour, the strip may loose contact with glass halfway through the cycle. This is permissible provided it does not result in loose glass or restrict ease of window operation.

DOORS 6-59

4. A window that is rotated (cocked) in window opening may be the result of an improperly adjusted inner panel cam ("8", Figure 6-85) or poorly adjusted up-travel stops ("1" or "2",

Figure 6-85).

Correct a poorly adjusted inner panel cam by loosening cam attaching bolts ("8", Figure 6-85) and adjusting front end of cam up or down as required. Adjustment of cam repositions front edge of glass up or down in relation to rear edge of glass.

5. Up-travel of window is determined by adjustment of front and rear up-stop ("1" and "2", Figure

6-85). To adjust window up-travel, loosen front and rear up-stops and operate window to desired position to establish proper glass to side roof rail weatherstrip contact.

GLASS ALIGNMENT GAUGE BLOCKS

("B and Cw Four-Door Hardtop Ventless

Styles)

To facilitate adjustment of this glass, use glass alignment gauge blocks tool 5-2371 1 or equivalent

(Fig. 6-86). For proper use of gauge blocks, refer to the following procedure:

1. Remove upper and lower portion of door trim assembly and peel back water deflector sufficiently to gain access to the inner panel cam. (Refer to the index for door trim assembly removal).

2. Detach side roof rail weatherstrip at lower front corner and carefully remove from retainer over door window, as shown in Figure 6-88.

3. Lower front and rear door or auarter windows and install gauge blocks, tool 52371 1-2 (black) or

TOOL J 23711-5 [BEIGE)

68169 STYLE ONLY

/

(BLACK]

Figure 6-87 - Front Door Window Alignment

(Rotated "Cocked" Glass in Body Opening Adjustment) equivalent into side roof rail weatherstrip retainer above upper front and rear corners of glass as shown in Figure 6-88.,Then, install gauge block, tool 5-23394-1 (Red), or equivalent into the windshield pillar retainer slightly above beltline.

IMPORTANT: Grooves on sides of gauge blocks must be fully engaged with side roof rail weatherstrip retainer.

4. Workine from inside bodv. with door in the closed positioi, loosen front &d rear up-travel stops

("1" and "2", Figure 6-85) and stabilizer strips

("3". Figure 6-85).

Figure 6-86

-

Glass Alignment Gauge Blocks

-

Tool 5-2371 1 or equivalent for "B and C" styles

(Consists of a set of four blocks)

Figure 6-88

-

Front Door Window Alignment

(Fore and Aft Adjustment)

6-60 DOORS

GAUGE BLOCKS

TOO1 J 23fi1-2

Figure 6-89

(In

- Front Door Window Alignment and Out and Up-Travel Adjustment)

5. Raise front door window assembly to approxi- mately 1" from full-up position, as illustrated in

Figure 6-87. If distance (space) between upper edge of glass and front and rear gauge blocks is equal (as shown in Figure 6-87), proceed with step number six (6). If distance (space) between upper edge of glass and both upper gauge blocks is not equal, loosen inner panel cam attaching bolts

("8", Figure 6-85) and adjust glass as necessary.

6. Raise front door window assembly until contact is established between upper and forward edge of glass and one or more of the three gauge blocks.

If upper and fomard edge of glass contacts all three gauge blocks simultaneously (as shown in

Figure 6-88), proceed with step number (7). If upper and forward edge of glass does not contact all three gauge blocks simultaneously, loosen fore and aft adjustment on rear guide ("5" Figure

4186) and move glass forward or rearward until the edge of glass contacts all three gauge blocks in full-up position.

7. Completely loosen upper ends of front and rear guides. Apply firm outboard pressure against upper end of the front guide to remove slack in the system and to hold upper inner edge of glass inboard against outer edge of gauge blocks, as shown in Figure 6-89. Then, tighten upper guide attaching bolts. Repeat operation with rear guide.

Guides will now be coordinated to the plane of the glass.

IMPORTANT: Inner surface of glass must contact outer surface of both upper blocks during this adjustment.

8. With glass in full-up position againsi upper gauge blocks, tighten up-travel stops ("1" and "2",

Figure 6-85) and adjust stabilizer strips ("3",

Figure 6-85) for proper tension against glass.

9. Lower window and remove gauge blocks from weatherstrip retainer. Reinstall and seal weather- strip as previously described.

DOOR WINDOW ASSEMBLY

-

"F"

Styles

The door window assembly consists of a solid tempered safety plate glass window and an individu- ally bolted-on roller at the rear and a roller assembly

(bell-crank) at the front. The lower sash channel cam is bolted to the glass, but is removed in the process of removing the window.

Figure 6-90 is an exploded view of the window assembly and identifies the various components and their assembly sequence.

Removal and Installation

1. Remove door trim assembly and inner panel water deflector.

#

2. Remove window front and rear up-travel stops

("1" and "2", Figure 6-91).

3. Loosen window front and rear stabilizer strip ("3",

Figure 6-9 1).

Fig. 6-90 Door Window Assembly

1.

2.

3.

4.

5.

6.

Window Assembly

Window Roller

Washer (Plastic)

Bolt Inner Panel Cam

Nut

Glass Bearing

Fastener

7.

8.

9.

Glass Bearing

Fastener Cap

Bushing

Roller Assembly (Bell

Crank)

10. Washer (Metal)

DOORS 6-61

Fig. 6-91-Window Removal and Adjustment

1. Window Front Up-

Travel Stop Bolt

2. Window Rear Up-

Travel Stop Bolt

3. Window Stabilizer

Strip Bolt

4. Window Lower Sash

Channel Cam Nuts

Access Holes

5. Rear Guide Upper

Bracket Bolts

6. Front Guide Upper

Bolts

7. Rear Guide to Guide

Upper Bracket Bolts

8. - .

Bolts

9. Window Down Travel

Bumper Support

4. With window in three-quarter-down position, remove lower sash channel cam to glass attaching nuts ("4", Figure 6-91). Remove window by lifting straight up and aligning rollers with notches provided in the door inner panel.

5. To install, reverse removal procedure. Adjust window for proper alignment and operation as described in the following adjustment procedure.

Adjustments

1. In and out adjustment of the glass is controlled by the in and out adjustment available at the top of the front and rear guides ("5" and "6", Figure

6-91) and the in and out position of the glass stabilizer strip ("3", Figure 6-91). Outboard adjustment of the guides moves the top of the glass inboard. Conversely, inboard adjustment moves the top of the glass outboard.

2. Fore and aft adjustment of the window assembly is controlled by the position of the rear guide. The upper end of the guide to guide bracket attaching locations ("7", Figure 6-91) are slotted to permit fore and aft adjustment of the guide. Because the roller assembly (bell-crank) which attaches to the glass at the front pivots, the front guide does not have to be adjusted during fore and aft window alignment.

3. Ease of window operation and window stability depends a great extent on the adjustment of the window stabilizer strip assembly at the beltline

("3", Figure 6-91). The stabilizing strip should contact the glass throughout the full cycle of the window. However, in some cases due to the slight variations in glass contour, the @rip may loose contact with the glass halfway through the cycle.

This is permissible provided it does not result in loose glass or restrict ease of window operation.

4. A window that is rotated (cocked) in the window opening may be the result of an improperly adjusted inner panel cam ("8", Figure 6-91) or poorly adjusted up-travel stops ("1" or "2",

Figure 6-9 1).

Correct a poorly adjusted inner panel cam by loosening cam attaching bolts ("8", Figure 6-91) and adjusting front end of cam up or down as required. Adjustment of cam repositions front edge of glass up or down in relation to rear edge of glass.

5. The up-travel of the window is determined by the adjustment of the front and rear up-stop ("1" and

"2". Figure 6-91). T@ adjust window up-travel, loosen front and rear up-stops and operate window to desired position to establish proper glass to side roof rail weatherstrip contact. Then, tighten stops.

6. The down-travel of the window is determined by the position of the window support bumper ("9",

Fig. 6-91). To adjust window down-travel, loosen bumper support and operate window to desired position. Then, raise bumper against lower edge of glass. Tighten bumper attaching bolt.

GLASS ALIGNMENT GAUGE BLOCKS ("F"

STYLES)

To facilitate adjustment of this glass, use glass alignment gauge block tool 5-23394 (or equivalent)

(Fig. 6-92). For proper use of gauge blocks, refer to the following procedure.

1. Remove door trim assembly and inner panel water deflector as described in Section 13 of this manual.

2. Detach side roof rail weatherstrip at lower front and rear corners and carefully remove from retainer.

3. With glass in a partially down position, install gauge blocks, tool 5-23394-2 (blue) or equivalent, into side roof rail weatherstrip retainer above upper front and rear corners of the glass as shown

6-62 DOORS

TOOL J 23394-2

(BLUE)

*

TOOL J 23394-1

(RED)

Fig. 6-92-Glass Alignment Gauge Blocks

5-23394 or Equivalent

(Consists of a Set of Three Blocks)

- Tool in Figure 6-93. Then, install glass suction cups on interior surface of glass (Figure 6-93) to enable adjuster to shift glass when making adjustments with door in a closed position.

IMPORTANT: When installing gauge blocks

(blue) or equivalent into upper retainer on "F" styles, handle portion of blocks must protrude outboard (Figure 6-93). Also, grooves on sides of blocks must be fully engaged with side roof rail weatherstrip retainer.

4. Working from inside body, with door in a closed position, loosen front and rear up-travel stops

("1" and "2", Figure 6-91) and stabilizer strips

("3", Figure 6-91).

5. Raise door window to approximately 1" from full- up position as illustrated in Figure 6-93. If distance (space) between upper edge of glass and front and rear gauge blocks is equal (as shown in

Figure 6-93), proceed with step number six. If distance (space) between upper edge of glass and both upper gauge blocks is not equal loosen inner pannel cam attaching bolts ("8", Figure 6-91) and adjust as necessary.

6. Lower glass and install gauge block, tool 5-23394-1

(red), or equivalent into the windshield pillar retainer slightly above the beltline (Figure 6-94).

IMPORTANT: When installing gauge block (red) or equivalent into windshield pillar retainer, handle portion of block must protrude inboard.

Also grooves on side of block must be fully engaged with retainer.

Raise door window assembly until contact is established between upper and forward edge of glass and one or more of the three gauge blocks.

If upper and forward edge of glass contacts all three gauge blocks simultaneously (as shown in

Figure 6-94), proceed with step number seven. If upper and forward edge daes not contact all three gauge blocks simultaneously, loosen fore and aft adjustment on rear guide ("7", Figure 6-91) and move glass forward or rearward until edge of glass contacts all three gauge blocks in full-up position.

7. Completely loosen upper and lower ends of front and rear guides ("5" and "6", Figure 6-91). Apply firm outboard pressure against upper end of front guide to remove slack in system and to hold upper inner edge of the glass inboard against outer edge of tab on gauge block. Then, tighten front guide upper, then lower attaching bolts. Repeat operation with rear guide. Guides will now be coordinated to plane of glass.

8. With glass in full-up position against gauge blocks, tighten up-travel stops ("1" and "2",

I

GAUGE BLOCK TOOL

1 13394-1 [RED)

GAUGE BLOCKS TOOL

J 23394-2 (BLUE)

I

Fig. 6-93-"F" Style Door Window Alignment

(Roated "Cocked"

Glass in Body Opening Adjustment

Fig. 6-94-"F" Style Door Window Alignment

(Fore and Aft Adjustment)

DOORS 6-63

Figure 6-91) and adjust stabilizer strips ("3",

Figure 6-9 1) for proper tension against glass.

9. Lower window and remove gauge blocks from weatherstrip retainer. Reinstall and seal weather- strip with a pumpable sealer.

FRONT DOOR WINDOW REGULATOR

Manual "A and X" Closed Styles

-

Removal and lnstallation

1.

Remove front door trim assembly and inner panel water deflector.

2. Operate window to "full-up" position and secure in place with pieces 'of cloth-backed body tape applied over door frame.

3. On two door styles, remove inner panel cam as previously described.

4. Remove ventilator division channel lower adjust- ing stud and nut and window regulator attaching bolts (Figure 6-95).

5. Press ventilator division channel outboard to permit disengagement of regulator spindle from

Fig. 6-95-Door Ventilator and Regulator

Attachment - p p ~ p p

Styles inner panel then slide regulator balance arm roller and lift arm roller out of lower sash channel cam at front. Remove regulator through large access hole.

6. To install, reverse removal procedure.

FRONT DOOR WINDOW REGULRTOR-

Electric-"A" Closed Styles

Removal and lnstallation

1.

Remove front door trim assembly, inner panel water deflector, window and ventilator as previously described.

2. Disconnect wire harness connector at window regulator motor.

3. Remove window regulator attaching bolts ("l",

Figure 6-32) and remove regulator through access hole.

4. To install, reverse removal procedure.

FRONT DOOR WINDOW REGULATOR-

Manual and Electric-"A-39" Styles

Removal and lnstallation

1. Remove door trim assembly and detach inner panel water deflector.

2. On manually operated regulators, prop window in full-up position and remove inner panel cam attaching bolts ("6", Figure 6-34). Remove regulator attaching bolts ("9", Figure 6-34) and remove regulator through large access hole.

3. On electrically operated regulators, h i o v e door window as previously described and disconnect wire harness connector at window regulator motor. Remove the regulator attaching bolts ("9",

Figure 6-34). Raise the regulator lift arm up through the beltline and rotate the regulator clockwise so that the regulator can be removed through the large access hole, motor coming out first.

4. To install, reverse removal procedure.

L

FRONT DOOR WINDOW REGULATOR

Manual and Electric

-

"A,

B,

C and E"

-

Two-Door Hardtop and Convertible Styles

Removal and lnstallation

1. Remove door trim assembly (on "B, C and E" stvles. remove uDDer and lower ort ti on of door

6-64 DOORS trim assembly) and detach inner panel water deflector.

Remove inside locking rod as previously described.

Lower window to half-down position and remove regulator attaching bolts ("4", Figure 6-40).

Disengage regulator lift arm roller from lower sash channel cam and prop window in full-up position. On manual styles, remove regulator assembly through large access hole. On electric styles, rotate regulator .assembly clockwise so that motor portion of regulator assembly comes out access hole first.

To install, reverse removal procedure.

FRONT DOOR WINDOW REGULATOR

Manual

-

-

All "B and C" Four Door Styles

Removal and lnstallation (Refer to

Figure 642)

1. Remove upper and lower portion of door trim assembly and inner panel water deflector.

2. Lower window and remove lower sash channel cam attaching stud nuts, except on

"B"

closed styles. On "B" closed styles, the regulator lift and balance arms can be disengaged from lower sash channel cam without removal of cam from glass.

NOTE: On "B" closed styles, raise window to full- up position and secure in place with pieces of cloth-backed body tape applied over door upper frame. On Hardtop and Convertible Styles, prop the window in the full-up position.

3. Remove inner panel cam attaching bolts.

4. Remove window regulator attaching bolts, then remove regulator through large access hole.

5. To install, reverse removal procedure.

FRONT DOOR WINDOW REGULATOR

-

Electric All "B and C" Four Door Styles

Removal and lnstallation (Refer to Figure 6-42)

Remove upper and lower portion of door trim assembly and detach inner panel water deflector.

Remove door window and inner panel cam as previously described.

Disconnect wire harness connector at regulator motor.

Remove window regulator attaching bolts ("8",

Figure 6-42), remove regulator through large access hole.

5. To install, reverse removal procedure.

DOOR WINDOW REGULATOR (MANUAL

AND ELECTRIC)

-

"F" Styles

Removal and lnstallation (Refer to Figure 6-44)

1. Remove door trim assembly and detach inner panel water deflector.

2. Remove door window and inner panel cam as previously described.

3. On electric styles, disconnect wire harness connector at regulator motor.

4. Remove window regulator attaching bolts (Figure

6-44), remove regulator through large access hole.

5. To install, reverse removal procedure.

FRONT DOOR WINDOW REAR GUIDE wA-39" Styles

#

-

Removal and lnstallatlon

1. Remove front door trim assembly and inner panel water deflector.

2. With window in full-up position, loosen rear guide window uptravel stop attaching bolt ("3", Figure

6-34), remove stop from guide.

3. Remove rear guide lower attaching bracket to door inner panel attaching bolt ("2", Figure 6-34).

4. Remove rear guide upper attaching bolts ("5",

Figure 6-34).

5. Work lower edge of guide past bumper bracket and disengage from roller. Remove guide through access hole.

6. To install reverse removal procedure. For adjust- ment, refer to door window adjustments.

FRONT DOOR WINDOW GUIDE TUBE

"A,' B, C and E" TWO-Door Hardtop and

Convertible Styles

-

Removal and Installation

1. Remove door trim assembly and inner panel water deflector as previously described.

2. With window in a full down position, remove

DOORS 6-65 guide tube upper and lower attaching bolts ("l",

Figure for

6-36 for "A" styles and "I", Figure 6-40

"B, C and E" styles).

,

3. On "A" styles, remove guide by lifting straight-up through the beltline. On "B, C and E" styles, remove upper and lower sash guide assembly as subsequently described and remove tube assembly through access hole.

4. To install, reverse removal procedure.

FRONT DOOR WINDOW FRONT GUlDE

"B and Cm Four-door Hardtop Styles

-

Removal and lnstallation (Refer to Figure 6 4 2 )

Remove upper and lower portion of door trim assembly and inner panel water deflector.

With window in a full-up position, remove front guide upper and lower attaching bolts.

Pull guide downward and rearward to disengage from window front roller. Remove guide through large access hole.

To install, reverse removal procedure. For adjustment, refer to door window adjustments.

FRONT DOOR WINDOW REAR GUlDE

"B and C" Four-Door Hardtop Styles

Removal and lnstallation (Refer to Figure 6-42)

Remove upper and lower portion of door trim assembly and inner panel water deflector.

With window in a full-up position, remove rear guide upper and lower -attaching bolts.

Pull guide down and forward to disengage from window rear roller. Remove guide through large access hole.

To install, reverse removal procedure. For adjustment, refer to door window adjustments.

FRONT DOOR WINDOW REAR GUlDE

"B" Closed Styles

-

Rehoval and lnstallation

I.

Remove upper and lower portion of door trim assembly and inner panel water deflector.

2. With window in full-up position, remove rear guide upper and lower attaching bolts ("2" and

"3" Figure 6-38).

3. Pull guide down and forward to disengage from window roller and remove from door through large access hole.

4. To install, reverse removal procedure. For adjustment, refer to door window adjustments.

FRONT DOOR WINDOW UPPER AND

LOWER SASH GUlDE ASSEMBLY

-

"A,

B, C and E" Two-Door Hardtop and

Convertible Styles

Removal and lnstallation

1. Remove upper portion of door trim assembly.

2. Remove window guide tube as previously described.

3. Remove lower sash upper or lower guide assembly attaching bolts ("5" and "2", Figure 6-40). Then, remove guide tube assembly as previously described.

4. To install, reverse removal procedure. For adjustment, refer to door window adjustments.

#

DOOR WINDOW FRONT GUlDE

Styles

-

"F"

Removal and lnstallation (Refer to Figure 6-44)

Remove front door trim assembly and inner panel water deflector.

With window in full-up position, remove front up- stop from guide.

Remove front guide upper and lower attaching bolts.

Pull guide down and rearward to disengage from window front roller. Remove guide through large access hole.

To install, reverse removal procedure. For adjustment, refer to door window adjustments.

DOOR WINDOW REAR GUlDE

Styles

-

"F"

Removal and lnstallation (Refer to Figure 6 4 4 )

1. Remove door trim assembly and inner panel water deflector.

2. Remove rear guide upper and lower attaching bolts.

6-66 DOORS

DOOR WEDGE PL

I DOOR SIDE

I

VIEW "A"

INTERFERENCE BETWEEN WEDGE PLATES

SHOULD BE 1/32 OF A N INCH

\

SECTION "C-C"

51 04

Fig. 6-96-Door Wedge Plates "67" Styles

3. Pull guide down and forward to disengage from window rear roller. Remove guide through large access hole.

4. To install, reverse removal procedure. For adjustment, refer to door window adjustments.

FRONT DOOR WINDOW GLASS RUN

CHANNEL

-

"A,

B

and Xu Closed Styles

Removal and Installation

1. On "A aid X" styles, remove front door window as previously described. On "B" styles, lower glass

2. Starting at the upper front corner of the door upper frame, press (finger pressure) sides of run channel together and pull channel from frame.

3. To install, reverse removal procedure.

DOOR WEDGE PLATES-"67" Styles

Door wedge plates are used on convertible styles to give additional support to the door when it is in the closed position. One plate is installed to the body lock pillar and the other to the door lock pillar (Figure

6-96). The plates should contact each other to the extent of a 1/32" interference when the door is closed.

Body side wedge plate shims are available as a service part

so

that this interference can be obtained.

DOORS 6-67

REAR

DESCRIPTION

Information in this section concerns operations applicable to rear doors only. Procedures for removal of water deflectors, door handles and weatherstrips are outlined in the "Front and Rear Door" section of this manual

- see index. Door trim assemblies are covered in Section 13 - see index.

Illustrations 6-97 through 6-108 are typical of rear doors with the trim assembly and inner panel water deflector removed. These figures identify the compo- nent parts of the rear door assembly (by style), their relationship and various attaching points.

REAR DOOR HINGES-All Styles

All rear door hinges are constructed of steel or a combination of steel and malleable iron. A two stage hold-open feature is incorporated in all lower hinges, except on "X" styles which do not have a hold-open feature.

Door Removal and lnstallation

Doors can be removed by either removing the door from the hinges or by removing the door and hinges as an assembly from the center pillar.

Prior to loosening any hinge bolts, mark location of hinges on door or center pillar, depending on removal method being used.

On styles equipped with electric window regulators or power operated locks, proceed as follows: a. Remove door trim assembly and inner panel water deflector. b. Disconnect wire harness connector from regulator motor and/or wire harness connector from electric lock solenoid. c. Remove electric conduit from door, then remove wire harness from door through conduit access hole.

With door properly supported, loosen upper and lower hinge attaching screws or bolts from door or center pillar and remove door from body.

Figure 6-109 is typical of rear door hinge attachment.

Prior to reinstalling the door to the body, clean off old sealer at hinge attaching areas and apply a coat of heavy-bodied sealer to surface of hinge that mates with center pillar or door hinge pillar to prevent corrosion.

5. With aid of a helper, lift door into position and loosely install hinge screws. Align hinges within pencil marks previously made and tighten hinge screws.

6. Install all previously removed parts. and check door for proper alignment.

NOTE: When replacing or adjusting door hinges, torque bolts to 14 to 22 foot pounds.

Hinge Removal and Instailation

1. If both hinges are to be removed, remove rear door as previously described. Mark position of hinge on door or center pillar depending on which door removal method was used and remove hinge attaching bolts.

2. With door properly su;,orted, remove upper or lower hinge to door and center pillar attaching bolts and remove hinge from door.

3. To install, reverse removal procedure. Apply a coat of heavy-bodied sealer to surface of hinge that mates with the center pillar and door hinge pillar to prevent corrosion. Adjust door as outlined below.

NOTE: When replacing or adjusting door hinges, torque bolts to 14 to 22 foot pounds.

Rear Door Hinge Adjustments

In-or-out and up-or-down adjustment is available at the door side hinge attaching screws. Fore-or-aft and a slight up-or-down adjustment is available at the body side (center pillar) hinge attaching screws.

REAR DOOR LOCK REMOTE CONTROL

There are two basic types of door lock remote controls; the "spindle" type (Figure 6-98) which rotates upward when actuated and the "pull-in" type (Figure 6-104) which rotates inboard when actuated. Remote controls are secured to the door inner panel by three attaching bolts. On some styles, it is mounted on the inboard surface of the door inner panel, and on others, on the outboard surface.

Removal and Installation

1. Remove rear door trim assembly (upper and lower

6-68 DOORS

I . Inside Locking Rod

2. Window Regulator -

Manual

Fig. 6-97-Rear Door Hardware - "A" Closed Styles

3. Door Lock Remote

Control

4. Inner Panel Cam

5. Rear Door Window

6. Lower Sash Channel

Cam

7. Door Outside Handle

8. Door Lock

9. Glass Run Channel

DOORS 6-69

1. Inside Locking Rod to Lock Connecting

Link Attaching Bolts

2. Window Regulator

Attaching Bolts

Fig. 6-98-Rear Door Hardware'

-

"A" Closed Styles

3. Door Lock Remote

Control Attaching

Bolts

4. Inner Panel Cam

Attaching Bolts

5. Lower Sash Channel

Cam Attaching

Screws Access Holes

6. Door Lock Attaching

Screws

,

7. Glass Run Channel

Upper Attaching Bolt

8. Glass Run Channel

Lower Attaching Bolt

I . Front Guide

2. Inside Locking Rod

3. Rear Door Window

Fig. 6-99-Rear Door Hardware - "A-39" Styles

4.

5.

Window Regulator

Manual

Door Lock Remote

Control

-

6.

7.

8.

Inner Panel Cam

Rear Guide

Door Lock

9. Door Outside Handle

10. Lower Sash Channel

Cam

DOORS 6-71

I

1. Door Lock Remote

Control Attaching

Bolts

2. Inner Panel Cam

Attaching Bolts

3. Window Stabilizer

Strip

Fig. 6-100-Rear Door Hardware

-

"A-39" Styles

4.

5.

6.

Widow Rear Up-

Travel Stop

Window Front Up-

Travel Stop

Rear Guide Upper

7.

Attaching Bolts

Rear Guide Lower

Attaching Bolts

'

8.

9.

Front Guide Upper

Support Attaching

Bolt

Front Guide Lower

Attaching Bolt

10. Window Regulator

Attaching Bolts

I I. Front Guide to Upper

12.

Support Attaching

Bolts

Window Lower Sash

C h a ~ e l Stud

Nuts

6-72 DOORS

1. Window Assembly

2. Lower Sash Channel

3.

Cam

Outside Handle and

Sealing Gaskets

Fig. 6-101-Rear Door Hardware

-

"B'" Closed Styles

4.

5.

Door Lock

Remote Control

Connecting Rod

6: Inner Panel Cam

7. Remote Control

8. Glass Run Channel

9: Inside Locking Rod

10.

1 1.

Window Regulator

Window Regulator

Handle

DOORS 6-73

1. Lower Rear Glass

Run Channel Lower

Attaching Bolt

2. Inside Locking Rod

Connecting Link Bolt

Fig. 6-102-Rear Door Harddare

-

"B" Closed Styles

3. Lower Rear Glass

Run Channel Upper

Attaching Bolt

4. Door Lock Remote

Control Attaching

Bolts

5.

6.

Inner Panel Cam

Attaching Bolts

Window Lower Sash a

Channel Cam Stud

Nuts Access Hole

7. Door Lock Attaching

Screws

8. Window Regulator

Attaching Bolts

6-74 DOORS

Fig. 6-103-Rear Door Hardware

-

"B and C-39 and 49'! and "C-69" Styles, Except 68169

Styles

1. Window Assembly

2. Trim Support ~ i n ~ e r s and Stabilizer Strips

3. Window Front Up-

Travel Stop

4. Window Rear Up-

Travel Stop

5. Inside Locking Rod

6. Lower Sash Guide

Plate

7. Guide Cam Support

8. Guide Cam

9. Window Regulator

Handle

10. Window Regulator

1 1. Door Lock Remote

Control and Handle

Assembly

12. Remote Control to

Lqck Connecting Rod

13. Lock Assembly

14. Door Outside Handle

15. Lock Cylinder

DOORS 6-75

Fig. 6-104-Rear Door Hardware - "B and C-39 and 49" and "C-69" Styles, Except 68169

Style

1. Trim Support Hanger and Stabilizer Strip

Attaching Bolts

2. Window Front Up-

Travel Stop Bolt

3. Window Rear Up-

Travel Stop Attaching

Bolt

4. Guide Cam Support . to Inner Panel Bolts

5. Guide Cam to Guide

Cam Support Bolts

6. Guide Cam Lower

Bolt

7. Window Regulator

Attaching Bolts

8. Lower Sash Guide

Plate Attaching Bolts

9. Door Lock Remote

Control Attaching

Bolts

10. Door Lock Attaching

Screws

1 1. Inside Locking Rod to Lock Connecting

Link Attaching Bolt

6-76 DOORS

1. Window Assembly

2. Trim Support Hangers and Stabilizer Strips

3. Window Front Up-

Travel Stop

Fig. 6-105-Rear Door Hardware

-

68169 Styles

4. Window Rear Up-

Travel Stop

5. Lower Sash Upper

Guide Assembly

6. Lower Sash Guide

Plate Assembly

7. Lower Sash Lower

Guide Assembly

8. Window Guide Tube

9. Remote Control to

Lock Connecting Rod

10. Window Down-Travel

Support and Bumper

11. Inside Loclcing Rod

12. Door Outside Handle

13. Door Lock

14. Window Regulator

DOORS 6-77

1. Tube Assembly,

Window Guide Tube

Attaching Bolts

2. Guide Assembly,

Lower Sash Lower

Attaching Bolts

3. Plate Assembly,

Lower Sash Guide

Attaching Bolts

Fig. 6-106-Rear Door Hardware

-

68169 Styles

4. Guide Assembly,

Lower Sash Upper

,Attaching Bolts

5. Regulator Assembly

Attaching Bolts

6. Stop, Front Up-Travel

Bolt

7. Stop, Rear Up-Travel

Bolt

8. Hangers, Trim

Support and Strip

Assembly, Anti-Rattle

Bolts

9. Remove Control,

Door Lock Attaching

Bolts

10. Door Lock Attaching

Screws

6-78 DOORS

I . Rear Door Window

2. Inside Locking Rbd

3. Window Regulator

Fig. 6-107-Rear Door Hardware

-

" X Style

4.

5.

Lower Sash Channel

Cam

Door Lock

6. Door Lock Remote

Control

7. Ventilator Division

Channel

DOORS 6-79

1. Ventilator Division

Channel Lower

Adjusting Stud

2. Door Lock Attaching

Screws

Fig. 6-108-Rear Door Hardware

-

" X Style

3.

4.

Door. Lock Remote

Control Attaching

Bolts

Ventilator Division

Channel Upper

Attaching Screw

5. Window Regulator

Attaching Bolts

6. Inside Locking Rod to Lock Connecting

Link Attaching Bolt

6-80 DOORS ment. Refer to "Front and Rear Door" section for spacer usage.

Removal and Installation

1. Remove upper portion of door trim assembly as described in Section 13 and operate glass to full- up position.

'

2.

Working through access hole, disengage lock connecting rods from spring clips on door lock

(for clip disengagement refer to "Door Lock

Spring Clips" in Front and Rear Door Section).

3. Remove door lock attaching screws ("6", Figure

6-98) and remove lock from door.

4. To install, reverse removal procedure.

REAR DOOR INNER PANEL CAM-

"A-39" and "0-35, 4 5 and 69" Styles

Removal and Installation

1. Remove door trim assembly (on "B" and "C"

Fig. 6-109-Typical Rear Door Hinge Installation portion on "B water deflector. and C" styles) and inner panel

2. Remove remote control attaching bolts ("3",

Figure 6-98).

3. Pivot remote to disengage it from remote control to lock connecting rod and remove remote control from door.

4. To install, reverse removal procedure. Make certain anti-rattle clip on lock connecting rod is properly positioned.

REAR DOOR LOCK ASSEMBLY

All Styles

-

All styles use the fork bolt lock design which includes an interlock feature. Where necessary, striker spacers should be used to insure satisfactory lock striker engage-

Fig. 6-1 10-Rear Door Window Removal and

Adjustments

-

" A Closed Styles

I. Lower Sash Channel

Cam Attaching Screw

Access Holes

2. Rear Glass Run

Channel Upper and

Lower Attaching

Bolts

3. Inner Panel Cam

Attaching Bolts

DOORS 6-81 styles, remove upper and lower trim assembly) inner panel cam attaching bolts ("4", Figure

6-98). Then disengage cam from regulator balance arm roller and remove cam from door through access hole.

2. To install, reverse removal procedure. Adjust front end of cam for proper window operation. Correct adjustment of cam will prevent a rotated (cocked) door window.

REAR DOOR WINDOW ASSEMBLY

Closed Styles

-

"A"

The rear door window assembly consists of a frameless solid tempered safety plate glass window and a pressed-on lower sash channel assembly. When handling window make certain glass does not develop edge chips or deep scratches which could cause glass to shatter.

Removal and Installation

1. Remove door trim assembly and inner panel water deflector.

2. With window in a three-quarter lowered position, remove window lower sash channel cam attaching screws ("1". Figure 6- 1 10).

3. Loosen rear glass run channel upper and lower attaching screws ("2", Figure 6-1 10).

4. Rotate rear edge of glass downward and remove window by lifting front edge of glass upward outboard of door upper frame.

5. To install, reverse removal procedure. Adjust window for proper operation and alignment as described in the following adjustment procedure.

Adjustments

Adjustments have been provided to relieve a binding door glass due to misalignment of the glass run channel ("2", Figure 6-110). In addition, the doox window inner panel cam ("3", Figure 6-110) is adjustable which can correct a rotated (cocked) rear door window.

REAR DOOR WINDOW ASSEMBLY "A-

39"

The rear door window assembly consists of a solid tempered safety plate glass window and an individu- ally bolted-on roller at the front and window roller cam assembly at the rear. The lower sash channel cam is bolted to the glass, but is removed in the process of removing the window.

Fig. 6- 1 1 1 -Rear Door Window Assembly

39" Styles

"A-

1.

2.

3.

4.

5.

6.

Roller Assembly

Glass Bearing

Fastener Cap

Glass Bearing

Fastener

Stud Inner Panel Cam

Washer (Metal)

Washer

7.

8.

9.

1 1.

Glass Bearing

Fastener Cap

Bushing

Nut

10. Rear Guide Cam

Assembly

Glass Bearing

Fastener

Figure 6-111 is an exploded view of the window assembly and identifies the various components and their assembly sequence.

Removal and Installation

1. Remove door trim pad and inner panel water deflector.

2. Remove window front up-stop from guide ("I",

Figure 6-112) and rear up-stop from door inner panel ("2", Figure 6- 1 12).

3. Loosen front and rear window stabilizer strip assembly bolts ("3", Figure 6- 1 12) and remove stabilizer strips.

4. With window in full-up position, remove lower sash channel cam to glass attaching stud nuts

("4", Figure 6- 1 12).

5. Disengage front roller from front guide, then rear roller from rear guide.

6. Remove window from door by aligning rollers with notches provided in inner panel. Remove rear end of window first, then front end.

6-82 DOORS

7. To install, reverse removal procedure. Adjust window for proper alignment and operation as described in the following adjustment procedure.

Adjustments

1. In-and-out adjustment of the glass is controlled by the in-and-out adjustment available at the top of the front and rear guides ("5" and "6", Figure

6-1 12) and the in-and-out position of the glass stabilizer strip assemblies ("3", Figure 6-1 12).

Outboard adjustment of the guides moves the top of the glass inboard. Conversely, inboard adjustment moves the top of the glass outboard.

2. Fore-and-aft adjustment of the window assembly is controlled by the position 'of the front guide.

The upper attaching locations in the front guide upper support ("7", Figure 6-1 12) are slotted to permit fore-and-aft adjustment of the guide.

Because of the free floating roller in the window rear sash channel cam (Figure 6-1 l l ) , the rear guide does not have to be adjusted during fore-or- aft window alignment

-

3. Ease of window operation and window stability depend to a great extent on the adjustment of the window stabilizer strip assemblies at the beltline

("3". Figure 6- 1 12).

The stabilizing strips should contact the glass throughout the full cycle of the window. Due to slight variations in glass contour, however, in some cases the strip may lose contact with the glass half-way through the cycle. This is permissible provided it does not result in loose glass. Contact should be sufficient to stabilize glass, but not restrict ease of window operation.

4. A window that is rotated (cocked) in the window opening may be the result of an improperly adjusted inner panel cam ("8", Figure 6-1 12) or poorly adjusted up-travel stops ("1" or "2",

Figure 6- 1 12).

5. The up-travel of the window is determined by the adjustment of the front and rear up-stop ("1" or

"2", Figure 6-1 12). To adjust window up-travel, loosen front and rear up-stops and operate window to desired position to establish proper glass to side roof rail weatherstiip contact (Figure

6-1 13). Tighten up-stop attaching bolts.

GLASS ALIGNMENT GAUGE BLOCKS ("A"

Body Four-Door Hardtop Styles)

To facilitate adjustment of glass, use glass alignment gauge blocks Tool 5-23394 or equivalent (Figure

6-114). For proper use of gauge blocks, refer to the following procedure:

1. Remove door trim assembly and inner panel water deflector.

2. Detach the side roof rail weatherstrip at the lower rear corner (screw retained at rear edge) and remove from the retainer over the door window, as shown in Figure 6- 1 15.

GLASS 8 E H l N D

O U T E R

)

Fig. 6-1 12-Rear Door Window Removal and

Adjustments - "A-39" Styles

I . Window Front Up-

Travel Stop

2. Window Rear Up-

Travel Stop

3. Window Front and

4.

Rear Stabilizer Strips

Window Lower Sash

Channel Cam Stud

Nuts

5. Front Guide Upper

Support Attaching

Bolts

6. Rear Guide Upper

Attaching Bolts

7. Front Guide to Upper

Support Bracket

Attaching Bolts

8. Inner Panel Cam

Attaching Bolts

.

,

MERE 'CONTACT AT

EITHER POINT IS

N O T SUFFICIENT

INCORRECT

SLIGHT COMPRESSION

OF INNER LIP

2149

CORRECT

Fig. 6-1 13-Window to Side Roof Rail

Weatherstrip Alignment

DOORS 6-83

TOOL J 23394-2

IBLUEl

Figure 6-1 14 - Glass Alignment Gauge Blocks

-

Tool

J-23394 or equivalent (Consists of a set of Three Blocks)

IMPORTANT: To prevent damaging weatherstrip when removing from the retainer, insert a flat bladed tool between the weatherstrip and the retainer and carefully break the bond between the weatherstrip and the retainer. A tool applicable to this usage may be fabricated from tool 5-21 104 or equivalent (Figure 6- 1 1 8).

3. Lower front and rear door windows and install gauge blocks, tool 5-23394-2 or equivalent (Blue), into the side roof rail weatherstrip retainer above the upper front and rear corners of the glass, as shown in Figure 6- 1 15.

IMPORTANT: The grooves on the sides of the

Figure 6-1 16

-

Rear Door Window Alignment

(Fore and Aft Adjustment) . gauge blocks must be fully engaged with the side roof rail weatherstrip retainer.

4. Working from inside the body, with the door in the closed position, loosen front and rear up- travel stops ("1" and "2" Figure 6-112) and stabilizer strips ("3", Figure 6-1 12).

5. Raise the rear door window assembly to approxi- mately 1" from the full-up position, as illustrated in Figure 6-1 15. If the distance (space) between the upper edge of the glass and the front and rear gauge blocks is equal (as shown in Figure 6-1 15), proceed with step number six (6). If the distance

(space) between the upper edge of the glass and both upper gauge blocks is not equal, loosen inner

GAUGE BLOCKS

TOOL J 23394-2

Figure 6-1 15

-

Rear Door Window Alignment

(Rotated "Cocked" Glass in Body Opening)

Figure 6-1 17 - Rear Door Window Alignment

(In and Out and Up-Travel Adjustment)

6-84 DOORS

Fig. 6- 1 18- Weatherstrip Removing Tool panel cam attaching bolts ("8", Figure 6-1 12) and adjust glass as necessary.

6. Raise rear door window assembly until contact is established between upper edge of glass and both upper gauge blocks. Then raise front door window assembly. If the front edge of the r?ar door window assembly is properly positioned in relation to rear edge of front door window assembly, as shown in Figure 6-1 16, proceed with step number seven (7). If rear door window assembly is not properly positioned in relation to front door window assembly, loosen fore and aft adjustment on front guide ("7", Figure 6-1 12) and move glass forward or rearward as necessary.

7. Completely loosen upper ends of front and rear guides ("5" and "6", Figure 6-1 12). Apply firm outboard pressure against the upper end of the front guide to remove slack in the system and to hold the upper inner edge of the glass inboard against the outer edge of the gauge blocks, as shown in Figure 6-1 15. Then, tighten upper guide attaching bolts. Repeat operation with rear guide.

The guides will now be coordinated to the plane of the glass.

IMPORTANT: Inner surface of glass must contact outer surface of the upper blocks during this adjustment.

REAR DOOR WINDOW ASSEMBLY

Closed Styles

-

"B"

The rear door window assembly consists of a frameless solid tempered safety plate glass window and a bolt-on lower sash channel cam. When handling window, make certain glass does not develop edge chips or deep scratches which could cause glass to shatter.

Removal and Installation

I . Remove upper and lower portion of door trim assembly and inner panel water deflector. attaching bolts ("1" and "2", Figure 6-1 19) and remove run channel from door.

3. Partially lower rear door window, remove lower sash channel cam to glass attaching stud nuts

("3", Figure 6-1 19). Press lower sash channel cam inboard to disengage from attaching studs and lower window regulator to full-down position.

8. With the glass in the full-up position against the upper gauge blocks, tighten up-travel stops and adjust stabilizer strips for proper tension against glass.

9. Lower window and remove gauge blocks from weatherstrip retainer. Reinstall and seal weather- strip as previously described.

Fig. 6-1 19-Rear Door Wi-ldow Removal and

Adjustments -

I . Rear Glass Run

Channel Upper

Attaching Bolt

2. Rear Glass Run

Channel Lower

Attaching Bolt

3. Window Lower Sash

Channel Cam Stud

Nuts Access Holes

4. Inner Panel Cam

Bolts

DOORS 6-85

4. Tilt front edge of glass downward and remove inboard of door upper frame, rear edge first, then front edge.

5. To install, reverse removal procedure. Adjust window for proper operation as described in the following procedure.

Adjustments

Adjustments have been provided to relieve a binding door glass due to misalignment of the glass run channel ("1" and "2", Figure 6-1 19). In addition, the door window inner panel cam is adjustable which can correct a rotated (cocked) front door window ("4",

Figure 6- 1 1 9).

REAR DOOR WINDOW ASSEMBLY "B and

C"

Four-Door Hardtop Styles, Except

68169 Style

The rear door window assembly consists of a solid tempered safety plate glass window and a bolted-on lower sash guide plate roller assembly that operates in a double vertical guide assembly located in the center of the door.

Figure 6-120 is an exploded view of the window assembly and identifies the various components and their assembly sequence.

Removal and Installation

1. Remove upper portion of door trim assembly as subsequently described.

2. With glass in a partially down position, loosen front and rear window stabilizer strips ("l",

Figure 6-121) and up-travet stops ("2, and 3",

Figure 6-121). Then rotate the stops sufficiently to allow glass to bypass stops when removing.

3. With window in a partial-down position, remove lower sash guide plate to glass attaching stud nuts

("7", Figure 6-121), then tilt upper edge of glass inboard to disengage guide plate from studs from glass. Remove glass from door by lifting rear edge of glass upward, then slide glass rearward to align guide plate studs with notch provided at rear of door inner panel.

4. To install, reverse removal procedure. Adjust for proper window alignment and operation as described below.

Adjustments

I . In-and-out adjustment of the glass is controlled by the position of the upper end of the center guide and the position of the glass stabilizer strips. The upper attaching locations in the center guide support ("5", Figure 6-121) and door inner panel

Fig. 6-120-Rear Door Window Assembly

-

"B

and C"

Four Door Hardtop Styles, Except 68169 Styles

1. Tee-Nut

2. Bushing

3. Washer (Plastic)

4. Washer (Metal)

5. Stop, Up-Travel

6. Bolt

Fig. 6-121-Rear Door Window Removal and

Adjustments -

"B and C-39-49" and "C-69", Except 68169 Styles

1. Trim Support Hangers and Window

2. Window ~ r o n i

Travel Stop Bolt

3. Window Rear Up-

Travel Stop Bolt

4. Center Guide Cam

'

5. Center Guide Cam to

Upper Cam Support

Bolts

6. Center Guide Cam

Lower Bolt

7. Lower Sash Guide

Plate Stud Nuts

6-86 DOORS

("I", Figure 6-121) are slotted to permit in-and- out adjustment of the guide and stabilizer strips, respectively.

2. Fore-and-aft adjustment of the window assembly is controlled by the position of the upper center guide support. The upper attaching locations in the upper center guide support ("4", Figure

6-121) are slotted to permit fore-and-aft adjust- ment of the guide.

3. Ease of window operation and window stability depends to a great extent on the adjustment of the window stabilizer strip assemblies (" 1 Figure

6-121).

The stabilizer strips should contact the glass throughout the full cycle of the window. Due to slight variations in glass contour, however, in some cases the strip may lose contact with the glass half-way through the cycle. This is permissible provided it does not result in loose glass. Contact should be sufficient to stabilize glass, but not restrict ease of window operation.

4. A window that is rotated (cocked) in the window opening may be the result of an improperly adjusted lower sash guide plate ("7", Figure

6-121) or poorly adjusted up-travel stops ("2" or

"3", Figure 6- 12 1 ).

5. The up-travel of the window is determined by the adjustment of the front and rear up-stops ("2" and "3", Figure 6-121). To adjust window up- travel, loosen front and rear up-stops and operate window to desired position to establish proper glass to side roof rail weatherstrip contact.

Tighten up-stop attaching bolts.

GLASS ALIGNMENT GAUGE BLOCKS ("B-

C" Four-Door Hardtop Styles, Except

68169 Styles)

To facilitate adjustment of this glass, use glass alignment gauge blocks Tool 5-237 11 or equivalent

(Figure 6-122). For proper use of gauge blocks, refer to the following procedure:

1. Remove upper portion of door trim assembly as described in Section 13 of this manual.

2. Detach the side roof rail weatherstrip at the lower rear corner (screw retained at rear edge) and carefully remove from the retainer over the door window, as shown in Figure 6-123.

3. Lower front and rear door windows and install gauge blocks, tool J-237 1 1-2 (Black), or equivalent

I

TOOL i 23711.5 (BEIGE)

68169 STYLE ONLY I

/ TOOLS 1 23711-2 ( B L A C K )

TOOL 1 23711-1 (GREY)

5088

Figure 6-122 - Glass Alignment Gauge Blocks.

Tool J-23711 or equivalent into the side roof rail weatherstrip retainer above the upper front and rear corners of the glass, as shown in Figure 6-123.

IMPORTANT: The grooves on the sides of the . roof rail weatherstrip retainer.

4. Working from inside the body, with the door in the closed position, loosen front and rear up- travel stops ("2" and "3" Figure 6-121) and stabilizer strips (" l", Figure 6- 12 1).

5. Raise the rear door window until contact is established between upper edge of glass and one or more of the two gauge blocks.

If upper edge of glass contacts both gauge blocks simultaneously (refer to Figure 6-123), proceed with step number six (6).

Figure 6-123 - Rear Door Window Alignment

DOORS 6-87

If upper edge of glass does not contact both blocks simultaneously, completely loosen lower sash guide plate stud nuts ("7". Figure 6-121) and manipulate the glass until the upper edge of glass contacts both blocks in the full-up position.

Tighten guide plate stud nuts.

6. Raise rear door window assembly until contact is established between upper edge of glass and both upper gauge blocks. Then, raise front door window assembly. If the front edge of the rear door window assembly is properly positioned in relation to rear edge of front door window assembly, as shown in Figure 6-123, proceed with step number seven (7). If rear door window assembly is not properly positioned in relation to front door window assembly, loosen fore and aft adjustment on guide cam sup ort "4", Figure

S

necessary.

7. Completely loosen upper end of (center) guide cam support ("5". Figure 6-121). Apply firm outboard pressure against the upper end of the guide cam to remove slack in the system and to hold the upper inner edge of the glass inboard against the outer edge of the gauge blocks, as shown in Figure 6-123. Then, tighten (center) guide cam support attaching bolts.

IMPORTANT: Inner surface of glass must contact outer surface of the upper blocks during this adjustment.

8. With the glass in the full-up position against the upper gauge blocks, tighten up-travel stops and adjust stabilizer strips for proper tension against glass.

9. Lower window and remove gauge blocks from weatherstrip retainer. Reinstall and seal weather- strip with a pumpable sealer.

REAR DOOR WINDOW ASSEMBLY

68169 Style

-

The rear door wind? assembly consists of a solid tempered safety plate glass window with a bolted-on lower sash guide plate assembly, which operates on a single vertical guide tube located in the center of the door.

Figure 6-124 is an exploded view of the window assembly and identifies the various components and their assembly sequence.

Removal and Installation

1. Remove upper portion of door trim assembly as subsequently described.

Figure 6-124-Rear Door Window Assembly-

68169 Styles

1. Tee-Nut

2. Bushing

3. Washer (Plastic)

4.

5.

6.

Washer (Metal)

Stop,

Bolt uP-~rav&

2. Loosen stabilizer strip %olts ("It', Figure 6-125) and remove front and rear up-travel stops ("2" and "3", Figure 6-125).

3. Remove lower sash guide plate assembly to glass attaching stud nuts ("4", Figure 6-125). Tilt upper edge of glass inboard to disengage glass from guide plate, then remove the window from the door by lifting straight-up.

4. To install, reverse removal procedure. Adjust window for proper alignment as described

in

the following adjustment procedure.

Adjustments

1. In and out adjustment of the glass is controlled by the in and out adjustment available at the front door window lower sash lower guide assembly

("6", Figure 6-125) and the in and out position of the

glass

stabilizer strip assemblies ("1". Figure

6-125). The lower sash lower guide assembly are slotted to permit in and out adjustment of the glass. Outboard adjustment of the lower sash lower guide moves the top of the glass inboard.

Conversely, inboard adjustment moves the top of the glass outboard.

2. Fore and aft adjustment of the window assembly

is

controlled by the ,position of the lower sash channel guide plate assembly ("4". Figure 6-125).

The guide plate to glass attaching locations are slotted to permit fore and aft adjustment of the glass.

6-88 DOORS

TOOL J 23711-5 (BEIGE)

68169 STYLE ONLY

/ TOOLS J 23711-2 (BLACK)

A

TOOL J 23711-1 (GREY)

5088

Fig. 6-126-Glass Alignment Gauge Blocks

5. Up-travel of the window is determined by the adjustment of the front and rear window up- travel stops ("2" and "3", Figure 6-125). To adjust window up-travel loosen front and rear up- travel stops and operate window to desired position to establish proper glass to side roof rail weatherstrip contact. Tighten stop.

Figure 6-125-Rear Door Window Removal and Adjustment - 68169 Styles

I.

2.

3.

Trim Support Hangers and Stabilizer Strip

Bolts

Front Up-Travel Stop

Bolt

Rear Up-Travel Stop

Bolt

4.

5.

Lower Sash Guide

Plate Assembly Bolts

Lower Sash Upper

Guide Assembly Bolts

6. Lower Sash Lower

Guide Assembly Bolts

3. Ease of window operation and window stability depend to a great extent on the adjustment of the window stabilizer strip assemblies at the beltline

("I", Figure 6-125). The stabilizing strips should contact the glass throughout the full cycle of the window. Due to slight variations in glass contour, however, in some -:ases the strip may loose contact with the glass halfway through the cycle. This is permissible provided it does not result in loose glass. Contact should be sufficient to stabilize glass, but not restrict ease of window operation.

4. A window that is rotated (cocked) in the window opening may be the result of an improperly adjusted lower sash upper guide assembly ("S",

Figure 6-125) or poorly adjusted up-travel stops

("2" and "3", Figure 6-125).

Control up-travel at front or rear of window through up or down adjustment of either front or rear up-travel stop.

Correct a poorly adjusted lower sash upper guide assembly by loosening upper guide assembly attaching bolts ("S", Figure 6-125) and rotating front edge of glass up or down in relation to rear edge of glass as necessary.

GLASS ALIGNMENT GAUGE BLOCKS

(68169 Styles)

With the elimination of front and rear guides and the incorporation of a single vertical guide tube in the center of the door, most window adjustments will be made from a guide plate attached to the lower edge of the glass. Fine adjustment of this glass will be more sensitive than conventional styles utilizing front and rear guides, as relatively small movements at adjusting locations will result in large movements at the upper edge of glass.

To facilitate adjustment of this glass, use glass alignment gauge blocks tools 5-2371 1-2 and 5 or equivalent (Fig. 6-126). For proper use of gauge blocks refer to the following procedure:

Adjustment

1. Remove upper portion of door trim assembly and inner panel water deflector.

2. Detach side roof rail weatherstrip at lower front

,and rear corners and remove from retainer.

3. Lower front door window and install gauge blocks. tool 5-2371 1-2 (black), or equivalent into the side roof rail weatherstrip retainer above the upper front and rear corners of the glass as shown in

Figure 6-127. Then, install gauge block, tool

J-23711-5 (Beige), or equivalent into the center pillar retainer above the beltline.

DOORS 6-89

GAUGE BLOCKS

TOOL J 23711-2

Fig. 6-127-Rear Door Window Alignment (Fore and Aft and Rotated "Cocked" Glass in Body Opening

Adjustment

IMPORTANT: The grooves on the sides of the gauge blocks must be fully engaged with the weatherstrip retainer.

4. Working from inside the body, with the door in the closed position, loosen front and rear up- travel stops ("2" and "3", Figure 6-125) and stabilizer strips ("

1

", Figure 6- 125).

5. Raise door window assembly until contact is established between the upper and/or forward edge of glass and one or more of the three gauge blocks.

If upper and forward edge of glass codtact all three gauge blocks simultaneously (as shown in

Figure 6-127), proceed with step number six (6).

If, however, upper and forward edge of glass does not contact all three blocks simultaneously, completely loosen lower sash channel guide plate

("4" Figure 6-125) and lower sash upper guide assembly "5" Figure 6-125) and manipulate the glass by hand until upper and forward edge of glass contacts all three gauge blocks in the full-up position (as shown in Figure 6-127). Tighten guide plate and upper guide assembly attaching bolts.

6. Loosen lower sash lower guide assembly "6",

Figure 6-125). Apply firin outboard pressure against the bottom of the lower sash guide plate assembly to remove slack in the system and to hold the upper inner ed& of glass inboard against outer edge of gauge blocks. Then, tighten lower guide assembly attaching bolts.

IMPORTANT: Inner surface of glass must contact outer surface of the upper gauge blocks during this adjustment. Excessive outboard pressure can tilt the glass too far inboard at the top resulting in excessive glass to side roof rail weatherstrip contact.

7. With the glass in the full-up position against the upper gauge blocks as shown in Figure 6-127. tighten adjustablk up-travel stops. Adjust stabi- lizer strips for proper tension against glass.

8. Lower window and remove gauge blocks from weatherstrip retainer. Reinstall and reseal weatherstrip with a pumpable sealer.

REAR DOOR WINDOW STATIONARY

VENTILATOR DIVISION CHANNEL

-

"X-

69" Style

The stationary ventilator division channel is held into place by one division channel to door upper frame attaching screw and one lower adjusting stud and nut.

Fig. 6-128-Rear Door Window Removal and

Adjustments - "X-69" Styles

1 . Ventilator Division

Channel Lower

Adjusting Stud

2. Ventilator Division

Channel Upper

Attaching Screw

6-90 DOORS

This assembly acts

as

a rear door window rear glass run channel and also holds the stationary ventilator window in proper position.

Removal and Installation

1. Remove door trim assembly and detach inner panel water deflector sufficiently to gain access to the lower adjusting stud and nut ("1". Figure

6-128).

2. Remove door window lower stop '(rubber bumper) from down stop support bracket on door inner panel.

3. Remove ventilator division channel lower adjust- ing stud and nut. ("1". Figure 6-128).

4. Carefully lower door window and remove division channel to door upper frame attaching screw.

("2", Figure 6- 128).

5. Rotate upper section of division channel forward and inboard and remove assembly from door.

6. To install, reverse removal procedure. In-or-out and fore-or-aft adjustment of this part is available at the lower adjusting stud and nut only.

REAR DOOR WINDOW STATIONARY

VENTILATOR ASSEMBLY

-

"X69" Style

The rear door stationary ventilator assembly is set within a rubber channel and held into place by pressure of the ventilator division channel.

Removal and Installation

1. Remove door trim assembly and detach inner panel water deflector.

2. Remove stationary ventilator division channel as previously described.

3. Pull stationary ventilator window forward and remove from door.

4. To install, reverse removal procedure.

REAR DOOR WINDOW ASSEMBLY

69" Style

-

"X-

The rear door window assembly consists of a frameless solid tempered safety plate glass window and a pressed-on lower sash channel assembly.

Removal and Installation

1.

Remove door trim assembly and inner panel water deflector.

2. Remove rear door window stationary ventilator assembly as previously described.

3. Slide wGdow regulator lift arm roller out of window lower sash channel cam and remove glass inboard of door upper frame.

4. To install, reverse removal procedure. Adjust window for operation as described in the following procedure.

Adjustments

Adjustment has been provided to relieve a binding door glass due to misalignment of the ventilator division channel. ("1". Figure 6-128).

REAR DOOR WINDOW REGULATOR-

Manual-All "Au Styles

Removal and Installation-Refer to

Figure 6 9 8 for "Closed" Styles and

Figure dl00 for "A-39" Styles

1. Remove door trim assembly and inner panel water deflector.

6

2. Lawer window and remove lower glass sash channel cam attaching screws, While supporting glass, disengage cam from rollers on regulator lift and balance arms and remove cam.

NOTE: On closed styles, raise window to a full-up position and secure in place with pieces of cloth- backed body tape applied over door frame. On hardtop styles, prop the window in a full-up position.

3. Remove inner panel cam attaching bolts.

4. Loosen window regulator attaching bolts and remove window regulator through large access hole.

5. To install, reverse removal procedure.

REAR DOOR WINDOW REGULATOR

Electric

-

All "Au Styles

-

Removal and Instaliation-Refer to Fig. dl00

1. Remove door window as previously described.

2. Remove inner panel cam attaching bolts.

3. Disconnect body wire hamess from window regulator at regulator motor.

4.

On

"A-39" styles, remove the window rear guide

as

subsequently described.

DOORS 6-91

5. Remove window regulator attaching bolts and remove regulator through large access hole.

6. To install, reverse removal procedure.

REAR DOOR WINDOW REGULATOR

-

Manual and Electric-"B" Closed Styles

Removal and Installation-Refer to

Figure 6-102

Remove upper and lower portion of door trim assembly and inner panel water deflector.

Lower window to a three-quarter-down position, retnove lower sash channel cam to glass attaching stud nuts. While supporting glass, disengage cam from rollers on regulator lift and balance arms and remove cam.

NOTE: Raise window to full-up position and secure in place with pieces of cloth-backed body tape applied over door upper frame. On hardtop styles, prop the window in a full-up position.

Remove inner panel cam attaching bolts.

Loosen window regulator attaching bolts and remove window regulator through access hole.

To install, reverse removal procedure.

REAR DOOR WINDOW REGULATOR-

Manual and Electric-"B and Cw Four-Door

Hardtop Styles, Except 68169 Styles

Removal and lnstallation (Refer to Figure 6-104)

1. Remove upper and lower portion of door trim assembly and inner panel water deflector (refer to

Index for door trim assembly and inner panel water deflector removal).

2. Remove center guide cam as subsequently described and prop glass in a full-up position.

3. Remove window regulator attaching bolts ("7",

Figure 6-104), then slide regulator lift arm roller out of lower sash channel cam and remove regulator through large access hole.

4. To install, reverse removal procedure.

REAR DOOR WINDOW REGULATOR

68169 Styles

-

Removal and lnstallation

-

Refer to Figure 6-106

1. Remove upper and lower portion of door trim assembly and inner panel water deflector.

2. Remove window regulator attaching bolts. Disen- gage regulator lift arm roller from lower sash channel cam and prop window in a full-up position. On manual styles, remove regulator through large access hole. On electric styles, rotate regulator assembly clockwise so that motor portion of regulator assembly comes out first.

3. To install, reverse removal procedure.

REAR DOOR WINDOW REGULATOR

ELECTRIC MOTOR

-

All Styles

Removal and lnstallation

If it is necessary to remove the electric motor from the regulator, refer to "Front Rear Door" section for the proper procedure. The tension on the lift arm assist spring can cause serious injury if the motor is removed without use of the cautionary measures described in the procedure.

REAR DOOR WINDOW REGULATOR

69" Style

-

"X-

Removal and Installation

4

1. Remove door trim assembly and inner panel water deflector.

2. Remove inside lockine rod to lock connectine link bolt ("6", Figure 6 - b 8 ) and disconnect &king rod at lock.

3. Operate window to full-up position and secure in place with pieces of cloth-backed body tape applied over door frame.

4. Remove regulator attaching bolts ("5", Figure

6-108). Slide regulator lift arm roller out of lower sash channel cam and remove regulator through large access hole.

5. To install, reverse removal procedure.

REAR DOOR WINDOW FRONT GUIDE

AND BRACKET ASSEMBLY-"A-39" Styles

Removal and lnstallation

1. Remove door trim assembly and inner panel water deflector.

2. Remove window front up-travel stop from guide

("5", Figure 6-100).

.

3. Remove inside locking rod to lock connecting link bolt. Pull Locking rod assembly downward through guide bracket.

6-92 DOORS

With window in full-up position, loosen front guide upper and lower attaching bolts ("8" and

"9", Figure 6-100) and remove guide through access hole.

To install, reverse removal procedure. Adjust guide for proper window operation as described in door window adjustment procedure.

REAR DOOR WINDOW REAR GUIDE

39" Styles

-

"A-

Removal and Installation

1. Remove door trim assembly and inner panel water deflector.

2. With window in full-up position, remove rear guide upper and lower attaching bolts ("6" and

"7". Figure 6-100). Remove guide through access hole.

3. To install, reverse removal procedure. Adjust guide for proper window operation as described in door window adjustment procedure.

REAR DOOR WINDOW CENTER GUIDE

CAM

-

"B and C" Four-Door Hardtop

Styles, Except 68169 Style

Removal and lnstallation

1. Remove upper and lower portion of door trim assembly and inner panel water deflector.

2. With window in full-up position, remove center guide cam upper and lower attaching bolts ("4 and 6", Figure 6-104).

3. Pull guide downward to disengage from window lower sash guide plate roller assembly. Remove guide through access hole.

4. To install, reverse removal procedure. Ad.just guide for proper window operation as described in door window adjustment procedure.

REAR DOOR WINDOW GUIDE TUBE

68169 Style

-

Removal and lnstallation

1. Remove umer and lower mrtion of door trim

I I assembly and inner panel water deflector.

2. Remove upper and lower sash guide assembly as subsequently described, then remove tube assem- bly through access hole.

3. To install, reverse removal procedure.

REAR DOOR WINDOW LOWER SASH

UPPER AND/OR LOWER GUIDE

ASSEMBLY

-

68169 STYLE

Removal and lnstallation

1. Remove upper portion of door trim assembly

(refer to Index for door trim assembly removal).

6

2. For removal of lower sash upper and/or lower guide assembly, remove attaching bolts "2" and/ or "4", Figure 6-106. Then remove guide tube assembly, as previously described, to completely remove lower sash assembly.

3. To install, reverse removal procedure.

REAR DOOR WINDOW GLASS RUN

CHANNEL-"A, B and

X"

Closed Styles

Removal and lnstallation

1. Remove door window as previously described.

2.

With finger pressure, squeeze run channel together and gently pull run channel out of rear door upper frame.

3. To install, reverse removal procedure.

REAR QUARTER 7-1

SECTION

7

SUBJECT PAGE

Rear Quarter

................................................................

7-1

Description

..................................................................

7- 1

Rear Quarter Inner Panel Sealing

.......................

7-1

Rear Quarter Rear Vertical Inner Sealing Strip-

A-57 Styles

........................................................

Rear Quarter Window Rear Vertical Outer

7-2

Sealing Strip-Chevrolet

Pontiac and Oldsmobile '"A-57"

.........................

7-2

Rear Quarter Window-"A-27-77" and "X-27"

Styles.

............................................................................

Rear Quarter Window Rear Run Channel-All

Closed Styles .............................................................

Rear Quarter Window Front Run Channel-All

Closed Styles

.............................................................

Rear Quarter Window Inner and Outer Strip

Assemblies-All "B-C-E"

Coupe and Convertible Styles

.............................

7-4

Rear Quarter Window Assembly-"A-37-57-87-67"

Styles

...........................................................................

DESCRIPTION

Closed style rear quarter windows operate within glass run channels. Hardtop and convertible styles employ nylon rollers that are component parts of the lower sash or bolt directly to the glass. These rollers operate within a center guide.

All quarter glass is constructed of solid tempered safety plate. Caution must be applied when handling glass, as glass may shatter if it is chipped or scratched.

DO NOT

When performing any service operations to the rear quarter window hardware, it is usually necessary to remove the rear quarter trim assembly.

REAR QUARTER INNER PANEL SEALING

All rear quarter inner panels are sealed with one or a combination of water deflectors, access hole covers, sealing plugs (or grommets) and body sealer. Service procedures for inner panel water deflectors are outlined in the "Front and Rear Door" section of this manual (see index). Figure 7-1 is typical of a water deflector installation.

Inner panel access hole covers are retained by screws and sealed with a non-hardening body sealer. Usually,

SUBJECT PAGE

Rear Quarter Window Assembly-"B-C-E" (Except

Cadillac) Hardtop and

"B-E" Convertible Styles

......................................

7-1 3

Rear Quarter Window Regulator (Manual or

Electric)-"A-27-77" and

"X-27" Styles

...........................................................

5

Rear Quarter Window Regulator Assembly

(Manual or Electric)-"A"

Hardtop and Convertible Styles

......................... 7-1 5

Rear Quarter Window Regulator (Manual or

Electric)-"B-C-E" Hardtop

(Except Cadillac "E" Hardtop) and Convertible

Styles

........................................................................... -

1 5

Rear Quarter Window Motor-"A-27-37-57-77-87"

Styles

...........................................................................

7-1 7

Rear Quarter Window Guide Assembly-"A"

Hardtop and Convertible

Styles

.......................................................................... removal of either the water deflector or access hole cover will provide the clearance required for service procedures of rear quarter hardware. Whenever any seal has been disturbed, however, the area must be

7

W A T E R D E F L E C T O R

S E A L I N G T A P E

Fig. 7-1-Rear Quarter Inner Panel Sealing -Typical of

Water Deflector Installation

7-2 REAR QUARTER

Fig. 7-2-Typical Rear Quarter Inner Panel

Sealing

-

"67" Styles

1. Manual Regulator

Attaching Bolt Slots

2. Electric Regulator

Attaching Bolt Slots

3. Access Hole Covers

4. Window Guide and

Lower Stop Adjusting

Stud Slots

5. Electrical Harness

Grommet carefully resealed to prevent waterleaks. Body caulking compound is recommended for service sealing. Figure

7-2 illustrates quarter inner panel sealing on 'styles which use individual seals at all hardware attaching locations.

REAR QUARTER WINDOW REAR

VERTICAL INNER SEALING STRIP

57" Styles

-

"A-

The rear vertical inner sealing strip is attached to the quarter inner upper panel with clips that are an integral part of the sealing strip (Figure 7-3).

To remove the strip assembly, lower quarter window and disengage side roof rail finishing molding adjacent to sealing strip. Slide strip assembly forward to disengage clips and remove sealing strip -from window opening.

REAR QUARTER WINDOW REAR

VERTICAL OUTER SEALING STRIP

-

Chevrolet, Pontiac and Oldsmobile "A-57"

On the remaining "A" styles, the sealing strip is an independent part, and is retained with screws.

To remove either type of installation, remove the quarter upper trim assembly (above belt) and quarter window rear vertical inner strip assembly to gain access to the attaching screws (Figure 7-4).

)OF DRIP MOLDING iAR SCALP ASSEMBLY ith i n t e g r a l s e a l i n g

Fig. 7-3-Rear Quarter Window Rear Vertical

Inner Sealing Strip Assembly

Fig. 7-4-Quarter Window Rear Vertical Outer

Sealing Strip

- Typical of "A-57'' Styles

REAR QUARTER 7-3

REAR QUARTER WINDOW and "X-27" Styles

-

u ~ - 2 7 - 7 7 u

Removal and Installation

1. Remove rear quarter trim assembly and inner panel water deflector.

2. Operate quarter window to the position illustrated in Figure 7-5.

NOTE: Figures 7-5 and 7-6 are typical of rear quarters with the inner panels removed. These figures identify the component parts of the rear quarter hardware (by style), their relationship and various attaching points.

3. While supporting glass, disengage clip retainer securing regulator lift arm to glass.

4. Manually lower glass until both front and rear bottom edges are sufficiently free of their respective run channels to rotate front edge of window down between rear quarter inner and outer panels. Remove window, rear edge up, inboard of side roof rail.

5. To install, reverse removal procedure.

Adjustments

All window assembly adjustments are provided at the window regulator attaching screws.

1. To obtain proper seating of the glass in the upper glass run channels, or proper contact between belt sealing strips and lower sash channel, loosen regulator attaching screws and adjust window as required.

2. To eliminate a fore and aft bind between the glass run channels (hard operating window), or a condition where window will not stay in rear run channel, loosen rear run channel attaching bolt and adjust run channel fore or aft as required.

REAR UARTER WINDOW REAR RUN

CHANN

%

Removal and Installation

1. Remove rear quarter window as previously described.

2. Remove run channel to inner panel attaching bolt

(Fig. 7-7).

3. Remove screws securing run channel to side roof rail along length of run channel.

4. Using a flat-bladed tool, carefully pry run channel retaining clips (rosebud fasteners) from piercings in side roof rail.

NOTE: If difficulty is encountered disengaging run channel, inspect inside of channel for the presence of screws.

5. Prior to installation, inspect foam sealing material for any damage that would result in waterleaks, and replace as necessary.

6. To install, reverse removal procedure.

REAR QUARTER WINDOW FRONT

RUN CHANNEL-All Closed Styles

Removal and lnstallation

L

Remove rear quarter window as previously described.

2. Remove screws along length of run channel securing channel to body (Fig. 7-8).

3. On all styles, using a flat-bladed tool, pry run channel from body pillar and remove run channel.

4. To install, reverse removal procedure. Prior to installation inspect sealing material on body pillar or run channel and replace or add to as required.

\

R E G U L A T O R

L I F T A R M

2 1 2 3

Fig. 7-5-Rear Quarter Window Attachment

Typical "A" Closed Styles

-

7-4 REAR QUARTER

1. Rear Glass Run

Channel

2. Rear Window Glass

Fig. 7-6-Rear Quarter Hardware

-

"X-27" Styles

3. Retainer and Pivot

Pin

4. Regulator Lift Ann

5. Regulator Assembly

6. Front Glass Run

Channel

7. Front Run Channel

Retaining Screws

REAR QUARTER WINDOW INNER AND

OUTER STRIP ASSEMBLIES-All "B-C-E"

Coupe and Convertible Styles

The rear quarter glass outer sealing strip on "B-C and

E" hardtops and convertibles is retained by rivets. In some cases it may be necessary to lower the glass and guide assembly down into the quarter to gain access to the attaching rivets.

All "B-C-E" inner sealing strips are attached to a support. The support and strip assembly may be removed by removing the bolt at the front of the w i n d h guide upper support, and, depending on style, two or three screws at the rear.

Removal and Installation (Outer sealing Strip)

1. Remove rear seat, quarter trim panel and quarter water deflector.

REAR QUARTER 7-5

Fig. 7-7-Rear Quarter Window Glass Run Channels

-

Typical of All Closed Styles

7-6 REAR QUARTER

S E C T I O N B - B 3 2 9 7

Fig. 7-8-Rear Quarter Window Front Glass Run

Channel

-

Typical of

AU

Closed Styles

2. Scribe bolt locations at upper and lower support to guide bolts.

3. Remove upper support to guide bolts ("1" Fig.

7-48 and 7-19). Remove lower support guide bolt

("6" Fig. 7- 18 and 7- 19) and lower window glass and guide assembly into quarter panel to gain access to outer sealing strip attaching rivets.

4. Attaching rivets can be removed by drilling out the rivet with a 1/8 inch drill bit.

IMPORTANT: Using larger than 1 /8 inch drill bit, would enlarge the hole and prevent the use of rivets, for installation. Substitution of screws for rivets could result in scratched glass.

5. To install, align holes

in

outer panel and sealing strip and attach with "pop" rivets or equivalent

(Fig. 7-9).

REAR QUARTER WINDOW ASSEMBLY

"A-37-57-87-67" Styles

- design, as shown in Figures 7- 10, 7- 1 1 and 7- 12. These illustrations identify the component parts of the rear quarter hardware (by style), their relationship and various attaching points.

Removal and Installation

1. Remove rear seat cushion, seat back, rear quarter trim and inner panel water deflector and/or loading hole cover. On "67" Styles, lower folding top.

2. Remove all stops.

3. Loosen and remove window guide attaching bolts, and remove guide through access hole.

4. Lower window and tilt glass to enable disengage- ment of lift arm roller from sash channel cam.

5. On All "A" styles except Pontiac "A-57" lift glass straight up and remove inboard of side roof rail.

6. On Pontiac "A-57'' styles lower glass into quarter section and rotate 180 degrees rearward. Remove glass, bottom side first, thrmgh the belt line opening out board of side roof rail.

7. To install, reverse removal procedure.

All

"A" body rear quarter hardware is similar in

Fig. 73-Quarter Window Outer Sealing Strip

[nstallation ("E-57" Style Shown

Rivet

-

All "B-C-EM Similar)

REAR QUARTER 7-7

1. Rear Up-Stop

2. Regulator Lift Arm

Roller

3. Regulator Lift Arm

Fig. 7-10-Rear Quarter Hardware

-

"A-37 and 87" Styles

4. Front Up-Stop

5. Window Guide

6. Down Stop

7. Lower Guide Support

Bracket

8. Electric Motor

9. Regulator Assembly

10. Front Roller

1 1. Upper Guide Support

Bracket

12.Front Vertical

Weatherstrip

13. Rear Roller

14. Sash Channel Cam

7-8 REAR QUARTER

1. Front Vertical

Weatherstrip

2. Upper Guide Support

Bracket

Fig. 7-1 I-Quarter Hardware

-

"A-67"

3. Regulator

4. Lower Stop

5.

6.

Lower Guide Support

Guide

7. Regulator Lift Arm

8. Stop Assembly

9. Sash Channel Cam

10. Rear Up-Stop

REAR QUARTER 7-9

I . Window @ass

2. Regulator

3. Lower Stop

Fig. 7-12-Quarter Hardware - "A-57"

4. Support Guide Lower

5. Support Guide Upper

6. Front Upper Stop

7. Sash Channel Cam

8. Rear Upper Stop

9. Regulator Lift Arm

10.

1 I .

Front Roller

Guide

7-10 REAR QUARTER

GUIDE

LOWER SUPPORT

BRACKET

S E C T I O N 0 - 0

" I E W A 3 2 9 6

Fig. 7-13-Rear Quarter Window and Guide Assembly -

"A-37, 67, 87" Styles

Adjustments

The rear quarter window guide is secured to the quarter inner panel at the bottom and top with support brackets. These support brackets provide both in and out and fore or aft adjustment of the glass. One down-stop and two up-stops are provided for alignment operations.

Figure 7-13 is typical of most hardtop or convertible styles utilizing a single window guide.

Fig. 7-15-Rear Quarter Window Assembly - "A- 37, 87"

Styles Shown, "A-57'" Style Typical

1. Glass

2. Lowpr Sash Channel

Filler

3. Lower Sash Channel

4. Lower Sash Channel

Cam

5. Glass to Sash Bolt

6. Guide Front Roller

7. Guide Roller Spring

8. Guide Lower Roller

9. Guide Roller Washer

Rubber

10. Washer

-

Rubber

11. Glass to Sash Bushing

12. Glass to Sash Nut

13. Front Vertical

Weatherstrip

Fig. 7-14-Rear Quarter Window

87" Styles,

- "A-37, 57,

1. Quarter Window Glass

2. Filler

3. Channel

4. Sealer

REAR QUARTER 7-1 1

-

Fig. 7-16-Quarter Window Hardware

-

"B, C and E" Hardtop

-

"B and E" Convertible Styles

1. Quarter Window

Glass

2. Veitical Sash Channel and Weatherstrip

3. Upper Support

Assembly

4. Regulatcr Assembly

5. Guide

6. Lower Guide Support

Assembly

7. Lower Down Stop

Assembly

8.

9.

Upper Front Stop

Assembly

Upper Rear Stop

Assembly

7-12 REAR QUARTER

-

---

Fig. 7-17-Quarter Window Hardware - "B-C and E" Styles (Power Window)

--

1. Quarter Window

Glass

2. Vertical Sash Channel and Weatherstrip

3.

4.

5.

Upper Support

Assembly

Regulator Assembly

Guide Assembly

6. Support Assembly

Guide Lower

7. Down Stop

8. Front Up-Travel Stop

9. Rear Up-Travel Stop

10. Motor and Drive

Assembly

REAR QUARTER 7-13

Fig. 7-18-Rear Quarter Hardware

-

"B-C-47, 57" Styles (All "E" Body Styles Similar)

1. Upper Support to

Window Guide'

Attaching Bolts

2. Upper Support to

Inner Panel Attaching

Bolts

3. Front Up-Travel Stop

4. Window Regulator

Attaching Bolts

5. Down-Travel Stop

6. Window Guide Lower

Support to Inner

Panel Attaching Bolt

7. Rear Up-Travel Stop

NOTE:

When reinstalling glass to sash channel bolts, or nylon roller nuts, torque to 72 inch pounds (6 foot pounds). The rear quarter window is constructed of solid tempered safety plate glass and cannot be drilled or ground.

REAR QUARTER WINDOW ASSEMBLY

."B-C-E" (Except Cadillac) Hardtop and "B and E" Convertible Styles

Description

All "B-C-E" (except Cadillac hardtop) body rear quarter hardware is similar in design, as shown in

7-14 REAR QUARTER

Fig. 7-19-Rear Quarter Hardware - "E-47-57" (Buick "E-87" Style Similar)

Upper Support to

Window Guide

Attaching Bolts

Upper Support to

Inner Panel Attaching

Bolts

3. Front Up-Travel Stop

.

4. Window Regulator

Attaching Bolts

5. Down-Travel Stop

6. Window Guide Lower

Support to Inner

Panel Attaching Bolt

7. Rear Up-Travel Stop

Figures 7- 16 and 7- 17. These illustrations identify the component parts of the rear quarter hardware their relationship and various attaching points. "E" Cadillac hardtop quarter glass is stationary and therefore has no operating hardware.

Figures 7-14 and 7-15 illustrate "A" body rear quarter window glass and hardware components that make up the window assembly.

Removal and Installation

1. Remove rear seat cushion, seat back, rear quarter trim and inner panel water deflector or loading hole cover. On "67" styles, lower folding top.

2 . Lower glass to half down position.

3. Remove rear up-travel stop bolt ("7" Figure 7-18 and 7- 19) and remove stop from inner panel.

4. Remove lower down-travel stop bolt ,("5" Figure

7-18 and 7-19) and remove stop from inner panel.

5 . Remove attaching bolts from upper support assembly to inner panel ("2'; Figure 7-18 and

7- 19).

6. Remove attaching bolts from lower guide support

("6" Figure 7-18 and 7-1 9).

REAR QUARTER 7-15

Fig. 7-20-Quarter Glass and Guide Assembly

7. On "B and E-67" styles lower folding top.

8. Disengage regulator lift arm from sash channel cam and remove glass and guide as an assembly.

9. To install reverse removal procedure.

Adjustments

The rear quarter window guide is secured to the quarter inner panel at top and bottom by supports.

These supports provide in or out, fore or aft and up or down adjustment. One down-stop and two up-stops are provided for alignment operations.

Figure 7-21 illustrates typical "B-C and E" body style rear quarter window glass and hardware components that make up the window assembly.

NOTE: When reinstalling glass to sash channel bolts, or nylon roller nuts, torque to 72 inch pounds (6 foot pounds). The rear quarter window is constructed of solid tempered safety plate glass and cannot be drilled or ground.

Figure 7-22 illustrates usage of tool 5-22055 for removal of quarter window glass roller nuts (equiva- lent tool may be used).

REAR QUARTER WINDOW REGULATOR

(Manual or Electric)

-

"A-27-77" and

"X-

27" Styles

Removal and Installation

1. Remove necessary trim and water deflector or access hole cover.

2. On all electric styles, disconnect wire harness at motor.

3. While supporting window, disengage clip retainer securing regulator lift arm to glass and prop windo* in a full up position.

4. Remove regulator attaching bolts. Figure 7-23 is typical of closed style regulator attachment.

5. Remove regulator through large access hole.

6. To install, reverse removal procedure.

4

REAR QUARTER WINDOW REGULATOR

ASSEMBLY (Manual or Electric).

"A" Hardtop and Convertible Styles

Removal and lnstallation

1. Remove rear quarter trim assembly and inner panel access hole cover (or water deflector). On electric styles, disconnect feed wire at motor.

2. On

"A"

styles prop window up. Loosen and remove all window guide assembly attaching bolts.

3. Remove regulator to quarter inner panel attaching bolts, disengage lift arm roller from sash channel cam and remove through access hole.

NOTE: If necessary, loosen upper attaching points of front guide to gain additional clearance.

4. To install, reverse removal procedure.

REAR QUARTER WINDOW REGULATOR

(Manual or Electric). "8-C and EM Hardtop

(except Cadillac "E" Hardtop) and Convertible Styles

Removal and Installation'

1. Remove glass and guide assembly as outlined under Rear Quarter Window Assembly.

7-16 REAR QUARTER

I .

2.

3.

4.

Glass

Lower Sash Channel

Filler

Lower Sash Channel

Lower Sash Chamel

Cam

Fig. 7-21-Rear Quarter Window Assembly - "B-C and E Styles

5. Sash Channel to

Glass Bolts

6. Front and Rear

Guide Bearings

7. Center Guide Roller

8. Sash Channel to

Glass Nut

9. Sash Channel to

Glass Bushing

10.

12.

Front Vertical

Weatherstrip

1 1. Front Vertical

Channel

Front Vertical Filler

2. On styles with electric operated windows discon- nect wire at motor.

3. Remove quarter window rear up-stop.

NOTE: On styles with electric operated windows it may be necessary to remove quarter window down-stop.

4. Remove regulator attaching bolts. Remove regula- tor through access hole (see Figs. 7-18 and 7-19).

5. To install, reverse removal procedure.

REAR QUARTER 7-17

Fig. 7-22-Quarter Window Roller

REAR QUARTER WINDOW GUIDE

ASSEMBLY

-

"A''

Hardtop and Convertible Styles

Removal and Installation

1. Remove rear seat cushion, seat back, rear quarter trim and inner panel water deflector or loading hole cover.

2.

Remove rear up-travel stop bolt ("1" Figure 7-10) remove stop from inner panel.

3. Remove lower down-travel stop bolt ("6" Figure

7-10) and remove stop from inner panel.

REAR QUARTER WINDOW MOTOR

"A-27-37-57-77-87" Styles

-

Removal and Installation

1. Remove rear seat cushion, seat back, rear quarter trim, and inner panel water deflector or loading hole cover. Window should be in a full up position.

2. Remove wiring harness clips.

NOTE: Wiring harness and switch assembly should be placed in an out of the way area to prevent damage.

3.. Referring to Fig. 7-26 for "A" body styles, make a template for locating window motor to regulator attaching bolts.

4. Align regulator bolt locations on template with regulator lower attaching bolts on quarter panel.

Secure template in place with a piece of tape.

IMPORTANT: DO ing bolts.

NOT loosen regulator attach-

5. Using a center punch, dimple the quarter inner panel at the center of the 3/4" holes to be drilled as indicated on the template.

6. Using a 3/4" hole saw, drill three motor to regulator attaching bolt access holes as indicated.

These holes will align with motor to regulator attaching bolts, allowing access for removal of bolts ("F" Fig. 7-25).

7. Remove motor attaching bolts and remove motor through access hole.

NOTE: Although window regulator lift arm is under tension of counterbalance spring, weight of window assembly prevents lift arm from moving.

8. After replacing motor and prior to trim installa- tion, apply waterproof tape to seal any motor bolt access hole that is outdde of the sealing area of the water deflector.

NOTE: The procedure for removing the electric motor from the regulator as a bench operation is described in the "Door" section of this manual

-

Fig. 7-23-Rear Quarter Hardware Attachment

"A and Xu Closed Styles

-

7-18 REAR QUARTER

Figure 7-24-"A Rear Quarter Window Assembly

Fig. 7-25-quarter Window Hardware "Au Styles

(Electric)

REAR QUARTER 7-19 see index. On styles indicated, removal of motor can be accomplished without removal of regula- tor, as outlined in the preceding procedure.

4. Remove window guide lower attaching bolt.

5. Lower glass and remove guide through access hole.

6. To install, reverse removal procedure.

7-20 REAR QUARTER

I

DRILL THREE 3 1 4 " M O T O R

A T T A C H I N G BOLT ACCESS

H O L E S

Fig. 7-26-Window Regulator Lower Attaching Bolts (Reference Points for Locating Window

Motor to Regulator Attaching Bolts)

-

"A-27, 37, 57, 67, 77 87" Styles

REAR COMPARTMENT LID 8-1

SECTION 8

INDEX

SUBJECT PAGE

Rear Compartment Lid

.............................................

8-1

Pescription

..................................................................

8-1

Rear Compartment Lock Cylinder Emblem

.....

8-1

Rear Compartment Lid Lock Cylinder

Styles

..........................................................................

Rear Compartment Lid.Lock

-

-

All

All Styles

Rear Compartment Lid Lock Striker

-

.........

All Styles Except Cadillac with Mechanical

8-1

8-2

Pull Down Unit .....................................................

8-3

Rear Compartment Mechanical Pull-Down

Unit and Electric Lid Release Assembly

-

Cadillac Styles

........................................................

8-5

Rear Compartment Mechanical Pull-Down

Unit Cable

-

Cadillac Styles

...............................

8-6

SUBJECT PAGE

Rear Compartment Mechanical Pull-Down

Unit Hydraulic Cylinder

-

Cadillac Styles

......

8-6

Rear Compartment Lid

All Styles

Rear Compartment Weatherstrip

Rear Compartment Front Panel

Oldsmobile "E" Styles

Rear End Finishing Panel

Styles

.

-

All Styles

-

...................

Rear Compartment Torque Rod Adjustment

-

All Styles.. 8-9

"F" and

.............................................

8-10

-

Pontiac "F"

Rear Compartment Lid Drain Valves

-

..................................................................

........................ ............................................

................

8.7

8-7

8-10

8-1 1

REAR COMPARTMENT LID

INTRODUCTION

This section of the manual contains the service operations that are necessary for the removal, installation, adjustment and sealing of the rear compartment lid assembly and individual compart- ment lid hardware components.

REAR COMPARTMENT LOCK CYLINDER

EMBLEM

Rear compartment lock cylinder emblems are applied over the lock cylinder and retained by stud nuts or rivets. This

type

of installation necessitates removal of the emblem prior to lock cylinder removal.

Removal and Installation (Refer to Figure

Oldsmobile "Av Styles,

Figure 8-2 for Oldsmobile "6 and

Figure 8-3 for Buick

"Em

Styles

C" and Figure 8-4 For All Other Styles)

Styles,

I. On styles equipped with emblems retained by stud nuts, open rear compartment lid and remove attaching nuts and carefully remove (pry) emblem from lid assembly.

2. On styles equipped with emblems retained by rivets, drill out rivets with 5/32" diameter drill bit and remove emblem.

3. To install, align emblem and gasket with attaching holes in lid assembly and install stud nuts or new

1/8" "pop" rivets or equivalent. Seal base of attaching studs or rivet holes with suitable sealer.

REAR COMPARTMENT LID LOCK

CYLINDER

-

All Styles

On most styles, the rear compartment lid lock cylinder

VIEW I N

OF A R I

OUTER PANEL

SECTION 0 - 0

U P P E R

S N A P - I N STUDS

A T T A C H I N G N U T

3 5 9 9

Fig. 8-l-Rear Compartment Lock Cylinder

Emblem Oldsmobile "A" Styles

8-2 REAR COMPARTMENT LID

EMBLEM

GASKET

\\ .

A T T A C H I N G N U T S EMBLEM

\

LOCK CYLINDER EMBLEM

OCK CYLINDER

RETAINER

EMBLEM

Fig. 8-3-Rear Compartment Lock Cylinder

Emblem

-

Buick "E" Styles

4252

Fig. 8-2-Rear Compartment Lock Cylinder

Emblem-Oldsmobile "B and C" Styles is located on the lid assembly. On remaining styles, the cylinder is located on the rear end panel. The basic method of cylinder attachment is by means of a retainer which, in turn, is secured by a screw, rivet or stud nuts. On styles equipped with lock cylinder emblems, it is necessary to remove the emblem, as previously described, prior to cylinder removal.

Removal and Installation (Refer to Figures 8-5,

8-3, 84, 8-7 and 8-8)

1. Open rear compartment lid.

2. On styles so equipped, remove lock cylinder emblem as previously described.

I

Fia. 8-4-Rear Compartment Lock Cylinder

Emblem

-

Typical ~ u i c k

Styles and %adillac "E" Styles

3. Remove lock cylinder retainer attaching screw, stud nuts or, using a 5/32" drill bit, carefully drill out rivet securing lock cylinder retainer to lid or rear end panel. Use care to avoid enlarging rivet hole.

4. Pull retainer down or away from opening to release lock cylinder and remove cylinder from body.

0

5. To install, reverse removal procedure. Insure that lock cylinder shaft engages with lock and that gasket mates properly with outer panel to form a watertight seal. Check for proper operation of lock cylinder with key. Then, install retainer attaching screw, stud nuts or new 1/8" diameter

"pop"-rivet or equivalent where rivet is specified.

REAR COMPARTMENT LID LOCK

Styles

-

All

Two types of rear compartment lid locks are used on

1971 styles. Manual locks are standard equipment and electric release locks are optional. The electric lid release unit is designed to open a rear compartment lid from inside the car. Refer to Owner's Manual for operating instructions.

Removal and Installation

1. Open rear compartment lid and remove lock cylinder and shaft as previously described.

2. Remove attaching bolts securing lock (Figs. 8-9 and 8~10) to rear compartment lid or rear end panel.

3.

On all styles equipped with elkctric lid release units, disconnect electric feed wire at solenoid connector and remove lock.

4. To install, reverse removal operations. Close lid

REAR COMPARTMENT LID 8-3

Figure 8-5 Rear Compartment Lid Lock Cylinder - Typical

All Styles with Cylinder Located in Lid Assembly, Except Buick "E" Styles

1. Lqck Cylinder

2. Gasket

3.

4.

Shaft

Lock and check lock engagement with striker. Make necessary adjustments as outlined under adjustments.

5. Cylinder Retainer

6. Rivet or Screw

7. Lid Outer Panel

8. Lid Inner Panel

To determine if lock or striker adjustment is required, proceed as follows:

1. Make certain rear coqpartment lid is properly aligned. Adjustments

Rear compartment lid locks are adjustable laterally, regardless of location, to provide for proper lid operation and lock to striker engagement.

RETAINER FASTENER

/

2. With lid in an open position, apply a small quantity of modeling clay on lock frame at both sides of lock bolt (Figs. 8-9 and 8-10). Then, close lid with moderate force.

3. Open lid and check amount of engagement of striker with lock frame as indicated by indenta- tions in clay. Striker bar indentations in clay should be uniform on both sides of lock frame.

Where required, loosen striker or lock attaching screws and adjust lock to obtain proper engage- ment. Close lid and check for proper lid and key operation.

S E A L I N G G A S

B

Fig. 8-6-Rear Compartment Lid Lock Cylinder

-

Typical

All Styles with Cylinder Located in Rear End

Panel, Except "F" Styles

REAR COMPARTMENT LID LOCK STRIKER

All Styles, Except Cadillac Styles Equipped with Mechanical Pull-Down Unit

Removal and Installation

1. Open rear compartment lid. Mark vertical position of striker by scribing a line at top of striker support or at base of lid or rear end panel.

2. Remove striker attaching screws and remove striker (Figs. 8-9 and 8-10).

3. To install, reverse removal procedure. Close lid

8-4 REAR COMPARTMENT

LID

Fig. 8-7-Rear Compartment Lid Lock Cylinder

-

Chevrolet "F" Styles

I. Lock Cylinder Housing

2. Lock Cylinder Housing Attaching Bolts

3. Lock Cylinder Housing Gasket

4. Lamp Assembly Attaching Bolts

5. Lamp Assembly Rear License

6. Lock Cylinder Assembly

7. Lock Cylinder Assembly Housing Attaching Nuts

8. Lock Cylinder Shaft

9. Rear Compartment Lock Assembly

10. Rear End Panel and check lock to striker engagement. Make any necessary adjustments as outlined below.

Adjustments

Rear compartment lid lock strikers are adjustable vertically, regardless of location, to provide for proper lid operation and lock to striker engagement.

To determine if lock or striker adjustment are required, refer to rear compartment lock adjustments.

REAR COMPARTMENT LID 8-5

Panel

2. Rear Compartment

Lock Cylinder

Attaching Studs

Fig. 8-8-Rear Compartment Lock Cylinder

-

Pontiac "F" Styles

3. Rear Com~artment

Lock ~ s s & n b l ~

4. Lock Cylinder Gasket

5. Lock Cylinder

Assembly

6. Lock Cylinder Shaft

8. Lock Cylinder

Attaching Nuts

9. Rear End Panel

REAR COMPARTMENT MECHANICAL

PULL-DOWN UNIT and ELECTRIC LID

RELEASE ASSEMBLY

-

Cadillac Styles

The rear compgrtment lid mechanical pull-down unit is used in conjunction with the electric lid release (8-

11).

A hydraulic cylinder (Fig. 8-12) is incorporated in the mechanism to achieve a slow, uniform closing action.

The cylinder is attached to a bell crank at the right rear compartment lid hinge and to the closing unit by a cable (Figs. 8-13 and 8-11). When the rear compartment lid is lowered to a point where the lock engages with the striker (approximately 7/8" from a fully closed position), a piston forces the fluid through an orifice retarding the closing action of the spring in the hydraulic cylinder. Then, a mechanical closing unit pulls the lid the remaining distance (7/8") to a fully closed position.

Removal and Installation

,

1. Open rear compartment lid and remove mechani- cal pull-down unit cover panel. Depress striker slightly to relieve tension from cable and disengage clip securing cable to pull-down control arm (Fig. 8-1 1).

2. Disengage clip securing cable conduit to cable adjusting bracket and remove cable and cable conduit from pull-down unit.

8-6 REAR COMPARTMENT LID

Fig. 8-9-Typical Rear Compartment Lock

Mounted in Lid

3. Scribe position of pull-down unit on rear end panel to facilitate installation. Remove pull-down unit attaching bolts and disconnect electric feed wire (Figure 8-1 1). Remove unit from body.

4. To install, reverse removal procedure.

MECHANICAL PULL-DOWN UNIT

HYDRAULIC CYLINDER CABLES

Removal and Installation

1. Disengage cable and cable conduit retaining clips at both ends of cable (Figs. 8-1 1, 8-12 and 8-13).

Then, remove cable assemblies.

NOTE: To disengage cable from bell crank (Fig.

8-13), remove cable conduit support attaching bolts and rotate cable assembly to disengage eye on end of cable from bell crank.

2. To install, reverse removal procedure.

Fig. 8-11-Rear Compartment Mechanical Pull-

Down Unit and Electric Lid Release - Cadillac

Styles

MECHANICAL PULL-DOWN H I T

HYDRAULIC CYLINDER

Removal and Installation

1. Disengage cable to hydraulic cylinder retaining clips at both ends of cylinder (Figure 8-12) and remove cylinder.

2. To install, reverse removal procedure.

Adjustments

To actuate the mechanical pull-down unit, the rear

I

Fig. 8-10-Typical Rear Compartment Lock

Mounted in Rear End Panel

Fig. 8-12-Mechanical Pull-Down Unit Hydraulic

Cylinder - Cadillac Styles

REAR COMPARTMENT LID 8-7

Fig. 8- 13-Mechanical Pull-Down Unit

Hydraulic Cylinder Cable Attachment

-

Cadillac

Styles compartment lid lock must properly engage the striker arm and the detent lever on the mechanical pull-down unit (Fig. 8-11) fully depressed. Engagement can be checked by lowering the lid and visually checking lock and striker alignment. If adjustment is necessary, obtain "lateral" adjustment at lock attaching screw locations and "up or down" adjustments at pull-down unit attaching screw locations.

For proper operation of the pull-down unit, the pull- down unit cable must be adjusted to the proper tension. If the cable has too much tension it will not allow the pull-down unit to return to its full-up position and "cock". This is apparent when, as the lid begins to lower, so does the pull-down unit.

Too little tension in the cable results in a lessening of pull-down effort in the unit and consequently, a misaligned (high) rear compartment lid.

To increase cable tension or if finer adjustment is required, loosen cable adjusting bracket attaching screw (Fig. 8-1 1) and adjust bracket downward (to increase cable travel), then, tighten attaching screw.

IMPORTANT: A lack of lubrication between the toggle and the detent lever ("I", Figure 8-1 1) can greatly increase the effort required to trip (unlock) the pull- down unit. Therefore, make certain point of contact between these two levers is lubricated with 630 AAW

Lubriplate or equivalent.

REAR COMPARTMENT LID

-

All Styles

Removal and Installation

1. Open lid and place protective covering along edges of rear compartment compartment opening to prevent damage to painted surfaces.

2. Where necessary, disconnect wire harness from rear compartment lid.

3. Mark location of hinge straps on lid inner panel.

4. With aid of helper, remove attaching bolts securing hinges to lid and remove lid (Fig. 8-13 depicts hinges for all styles).

5. To install, reverse removal operations.

Adjustments

1. Fore And Aft and Laterial Adjustment of the lid assembly is controlled by the hinge strap to lid attaching bolts. To adjust lid, loosen hinge strap to lid attaching bolts (Figure 8-13) and shift lid to desired position. Then, tighten bolts.

2. Up And Down Adjustment of the lid assembly is accomplished by placing shims between the hinge strap and the lid assembly and by raising or lowering the rear compartment lid lock striker

(for adjustment of striker, refer to lid lock striker adjustment).

To raise the right and/or left sides of the lid assembly, mark location of hinge on lid and install suitable shim between hinge strap and lid at forward bolt location. To lower lid, install shims at rear bolt locations.

REAR COMPARTMENT TORQUE RODS

All Styles

-

Torque rods are used to control the amount of effort needed to operate the rear compartment lid and can be adjusted to increase or decrease operating effort.

Removal and Installation

1. For removal and/or adjustment of rear compart- ment lid torque rods, use tools outlined below: a. O n "A" styles, use tool 5-21412 or equivalent

(Figure 8- 14). b. O n Cadillac "C a n d

E

styles, use tool

5-23722 or equivalent (Figure 8-15). c. O n

" X

styles a n d Oldsmobile "E" styles, use tool BT-7102 or equivalent (Figure 8-16).

8-8 REAR COMPARTMENT LID

Fig. 8-14-Rear Compartment Torque Rod

Adjustment-"A" Styles d.

01-1

"F" styles, use a length of 1/4" inside diameter pipe (Figure 8- 17). e. On "B, C, E" styles, except Cadillac "C and E"

Fig. 8-15-Rear Compartment Torque Rod

Adjustment - Cadillac "C and E" Styles

Fig. 8- 16-Rear Compartment Torque Rod

Adjustment-"X" Styles and Oldsmobile and Oldsmobile "E" style* use a length of

3/8" inside diameter pipe.

To remove torque rods, disengage end of torque rod from adjusting notches on hinge strap, as shown in Figures 8-14, 8-18 and 8-19. Then, allow handle of removal tool to rotate forward to relieve tension on rod. In some cases, it may be necessary to install a pair of vise-grip pliers on rod, as shown in Figures 8-18 and 8-19, and lift upward on pliers to disengage removal tool from end of rod.

3. Disengage opposite end of torque rod from hinge strap and remove rod from body.

4. To install, revehe removal procedure.

Adjustments

Rear compartment torque rods are adjustable to increase or decrease operating effort.

1. To increase the amount of effort required to raise the rear compartment lid or to decrease the amount of effort required to close the lid, repaition the end of the rod to a lower torque rod adjusting notch (Figures 8-14, 8-15, 8-16 and

8-17).

2. To decrease the amount of effort required to raise the rear compartment lid or increase the amount of effort required to close the lid, reposition the end of the rod to a higher torque rod adjusting notch (Figures 8-14, 8- 15, 8-16 and 8-17).

REAR COMPARTMENT LID 8-9

Fig. 8-17-Rear Compartment Torque Rod Adjustment - "F" Styles

REAR COMPARTMENT WEATHERSTRI P

All Styles

-

4. Apply generous bead of black weatherstrip cement to bottom surface of gutter around opening (Fig.

8-20). With suitable brush, gently level applied

I cement.

Removal and Installation

1. Separate "butt" ends of weatherstrip at bottom rear of opening ("B" Fig. 8-20).

5. Starting at rear center of opening with one end of weatherstrip, insert weatherstrip into gutter while cement is still wet. Use flat bladed tool to aid installing weatherstrip. Avoid stretching weather- strip during installation.

2. Using flat bladed tool, such as sharp bladed putty knife, carefully cut cemented bond of weather- strip from outer surface of gutter (Fig. 8-20).

Then, with a narrower sharp tool, such as a wood chisel, cut cemented bond of weatherstrip from bottom of gutter around opening and remove weatherstrip.

6. If weatherstrip is new, cut end to form butt joint at rear center of opening. Apply cement to both ends of weatherstrip to form a neat joint. Secure weatherstrip unifornily in gutter.

3.

To install, clean out gutter around opening to provide clean cementing surface.

7. Using a pressure type applicator, apply weather- strip cement (neoprene type) between weatherstrip

8-10 REAR COMPARTMENT LID

SECTION A - A

A P P L Y C E M E N T

BEFORE

W/STRIP

INSTALLATION

AFJEF W/STRIP

INSTALLATION

Fig. 8- 18-Rear Compartment Torque Rod

Removal

-

Cadillac "C and E" Styles

Except Oldsmobile "EM Styles and outer surface of gutter completely around opening to assure a watertight seal (Fig. 8-20).

8. Roll or press weatherstrip to aid in obtaining good cement bond. Allow sufficient time for cement to set before closing rear compartment lid.

Fig. 8-19-Rear Compartment Torque Rod

Removal-"X" Styles and Oldsmobile

"E" Styles

Fig. 8-20-Rear Compartment Weatherstrip

REAR COMPARTMENT FRONT PANEL

"F"

Styles and Oldsmobile "E" Styles

-

Removal and Installation

1. With rear compartment lid raifled, remove screws from lower edge of panel (refer to Figure 8-21 for

"F" styles and Figure 8-22 for Olds "E" styles).

2. Remove back window lower reveal molding. (See

"Exterior Moldings" Section)

3. Remove screws from upper edge of panel and remove panel.

NOTE: It may be necessary to cut away a small amount of adhesive caulking material used to seal back glass in order to locate and remove screws.

Do not break adhesive caulk bond to rear window.

4. To install, reverse removal procedure.

REAR END FINISHING PANEL

"F" Styles

-

Pontiac

The rear end finishing panel is made of molded glass fiber plastic and retained by four attaching studs and nuts (Fig. 8-23).

Removal and Installation

1. Remove tail lamp assemblies, license plate bracket, and rear bumper.

2. Remove four rear end finishing panel retainer nuts, and remove panel from body (Fig. 8-23).

3. To install reverse removal procedure. Tighten finishing panel attaching nuts to a torque of 26-38 inch pounds.

REAR COMPARTMENT LID 8- 1 1

Fig. 8-21-Rear Compartment Front Panel

-

"F" Styles

Fig. 8-22-Rear Compartment Front Panel

Buick "E" Styles

-

I

Fig. 8-23-Rear End Finishing

-

Pontiac "F" Styles

1. Rear End Finishing Panel

2. Finishing Panel Studs

3. Washer

4.

5.

Rear End Panel

Attaching Nuts

Rear Compartment

.Lid

Drain Valves

Description

Deck lids on all "B-C-D-E" styles are louvered to accommodate the flo-thru ventilation system. Water entering these louvers is ,channeled rearward between the deck lid inner and outer panels and drains outside of the body through holes at the lower edge of the lid assembly. These holes are equipped with drain valves (Fig. 8-24).

8-12 REAR COMPARTMENT LID

These drain valves must form a complete and flat peripheral seal around the drain holes. If for any reason a drain valve is removed or missing, it must be reinstalled properly or replaced. Tom, mutilated or deformed valves must be replaced before the vehicle is returned to service.

Removal and Installation

1. With the deck lid in a raised position, remove the two screws securing the valve to the lid inner panel.

,2. To install, reverse the removal procedure.

LID INNER PANEL

SCREWS

Fig. 8-24-Rear Compartment Lid Drain Valves

TAIL GATE 9-1

SECTION 9

TAIL GATE

SUBJECT

INDEX

PAGE SUBJECT

Retractable Tail Gates

..............................................

9-1

Description

.................................................................

9-1

Back Body Opening Weatherstrip

........................

9-3

Tail Gate Belt Weatherstrip

..................................

9-4

Tail Gate Window Inner Weatherstrip

..............

9-4

Tail Gate Bottom Drain Hole Sealing Strips ... 9.4

Lower Housing Drain Sealing Strip

....................

9-6

Tail Gate Inner Finishirig Panel

..........................

9-6

Tail Gate Window

...................................................

Tail Gate Window Assembly

9-6

................................

9-6

Tail Gate Window Regulator Assembly

Tail Gate Window Motor Assembly

............

9-8

...................

9-8

Tail Gate Window Motor Cable Assembly ......

9-8

Tail Gate Window Cam Guide

.

.

..

9-8

.....

9-11 Tail Gate Window Cain Guide

Tail Gate Window Drive Cable Assembly

Window Stop Cable and Clip Assembly

Roller Assembly .

.......

9-1 1

...........

9-12

.

Right or Left

..........................................................

Roller Assembly

Right

.........................................................................

Roller Assembly

Left

............................................................................

Tail Gate Window Down-Travel Stops

..............

9-13

9-13

Tail Gate Window Assist Spring and Silencer 9-13

Heated Tail Gate Window Rear Wire

Harness

.....................................................................

Tail Gate Assembly

.................................................

Tail Gate Guide Channel

Tail Gate Roller Support

9-13

9-13

......................................

.......................................

5

Tail Gate Sychronizing Torque Tube

Assembly

...............................................................

9-1 5

Tail Gate Torque Rod

............................................

9-16

Tail Gate and Lift Arm Hinge Assembly

Manual and Electric

-

............................................

9-16

Tail Gate Lift Arm Hinge and Regulator

Assembly Motor

......................................................

Tail Gate Striker Assembly

9-18

..................................

9-18

Tail Gate Lock Assembly

......................................

9-1 8

Tail Gate Outer Panel Grip Handle

(Manual Tail Gate Only)

Tail Gate Adjustments

...................................

.

9-20

Tail Gate and Window Control Switch

.............

9-21

Handle

........................................................................

Tail Gate Window Regulator Outside Electric

Key Switch

............................................................

9-31

Tail Gate Window Assembly

Electric

-

Manual or

......................................................................

Tail Gate Remote Control Inside Handle

Gate Operation (Center)

-

9-31

.......................................

Tail Gate Inside Handle and Cable Assembly

Door Operation (Right Side)

..............................

9-32

Tail Gate Lock Remote Control Assembly

Gate Opeation (Center)

........................................

Tail Gate Right Upper Lock Assembly

-

9-33

.............

9-33

Tail Gate Right Lower Lock Assembly

.............

9-37

Tail Gate Left Upper Hinge and Lock

Assembly

-

Gate Side

...........................................

Tail Gate Left Lower Hinge Assembly

9-39

..............

9-39

Tail Gate Left Upper Hinge and Striker

Assembly

-

Body Side

.......................

.

Tail Gate Right Upper Striker Assembly

9-40

.........

9-41

Tail Gate Right Lower Striker and Support

Assembly

.................................................................

Tail Gate Torque Rod and Assist Link

9-41

............

9-41

Tail Gate Assembly

.................................................

9-42

Dual Acting Tail Gate Lock Synchronization

Check and Procedure

.............................................

9-45

TAIL GATES

PAGE

Tail Gate Window Control Switch Lock

Cylinder

.....................................................................

Retractable Tail Gate Lubrication

9-22

.......................

9-23

Dual Acting Tail Gates

............................................

Tail Gate Inner Panel Water Deflector

9-23

.............

9-23

Tail Gate Inner Panel Access Hole Covers

Tail Gate Body Hole Sealing Strips

......

9-24

...................

9-24

Tail Gate Opening Weatherstrip

.........................

9-25

Tail Gate Window Upper Glass Run

Channel

..................................................................

Tail Gate Window Lower Glass Run

Channel

Electric

....................................................................

Tail Gate Window Regulator

-

Manual and

.......................................................................

Tail Gate Window Electric Regulator Motor

Assembly

...................................................................

Tail Gate Cut-Out Switch

9-27

......................................

9-28

DESCRIPTION

The retractable tail gate is designed to lower into the underbody and in general follows the body contour during the opening and dosing cycles

.

Similarly. the back window. which is separate of the gate. raises upward and into the space between the roof inner and outer panels

.

9-2 TAIL .GATE

1. Window Lift Spring and Silencer

2. Window Guide Cam

Assembly - Right

3. Window Guide Roller

Assembly

-

Upper

Right

4. Window Drive Cable

Assembly

5. Window Stop Cable and Clip Assembly

-

(Manual Gate)

6. Window Guide Roller

Assembly

-

Lower

Right

7. Lock and Release

Switch Assembly -

(Manual Gate)

Fig. 9-1-Retractable Tail Gate and Window Hardware

8. Window Regulator

Assembly

9. Window a n d Gate

Switch Assembly

(Power Gate)

10. Tail Gate Lock

Assembly

1 1. Window Regulator

Storage Conduit

12. Tail Gate Roller

Support - Right

13. Window Motor

Assembly

14. Torque Roller and

Shaft Assembly

-

Right

The power operated window (standard equipment) can be operated by either of two control switches; one on the instrument panel and one (key operated) on the

IS. Tail Gate Guide

Channel Assembly

-

Right

16. Tail Gate Hinge

Torque Rod

17. Tail Gate

Synchronizing Torque

Tube Assembly

18. Tail Gate Roller

Support

-

Left

19. Torque .Roller and

Shaft Assembly -

Left

20. Tail Gate Guide

Channel Assembly

-

Left.

2 1. Torque Rod Block-

Out

22. Lift Arm Hinge and

Regulator Assembly

( ~ l e d c )

-

23. Lift Atm Hinge

Assembly

-

(Manual)

24. Window Guide Roller

Assembly

-

Lower

Left

25. Window Guide Roller

Assembly

-

Upper

LeR

26. Windm Guide Cam

Assembly - Left rear of the right hand quarter outer panel, adjacent to the gate. Both the manual and power operated tail gate may be oprated only by the rear switch on the

TAIL GATE 9-3 bod) exterior. The control switches actuate opening cycles when rotated clockwise and closing cycles when rotated counterclockwise.

For manual gate requirements the exterior control switch includes two positions right and left of center

(vertical) position. Movement of the key to the first position (clockwise) raises the tail gate window; further movement in the same direction mechanically releases the tail gate for manual lowering. For power operated tail gates, the exterior control switch incorporates detents for operation of window only, gate only and simultaneous operation of window and gate (in that order), depending upon the distance the switch is rotated. The front control switch on the instrument panel operates the window only.

The tail gate inner cover panel doubles as a finishing and a sealing 'panel. The panel is sealed around its periphery and is attached by screws. Vertical louvers in the inner cover serve to exhaust a ram air ventilation system.

I&

Fig. 9-1 identifies the component parts of the retractable tail gate and window and their relationship.

For the purpose of clarity, the following retractable tail gate information is divided into four major groups:

1. Weatherseal

2. Window system

3. Tail gate system

4. Window and tail gate control system

BACK BODY OPENING WEATHERSTRIP

The back body opening weatherstrip is of one-piece design with a butt joint located at the bottom of the opening (Fig. 9-2). The weatherstrip is cemented to the body opening below the beltline. The weatherstrip

Fig. 9-2-Back Body Opening Weatherstrip Retention

9-4 TAIL GATE

I

WINDOW INNER WEATHERSTRIP

I

WEATHERSTRIP GATE

BELT . WEATHERSTRIP

RETAINER mr

I

Fig. 9-3-Tail Gate Belt Weatherstrip and

Window Inner Weatherstrip retainer at the bottom of the opening is retained by screws. The weatherstrip includes sculptured detail areas at the beltline to seal the body opening off-set.

At this area, the weatherstrip is retained by cement and screws. Above the beltline, the weatherstrip is retained by cement and screw-attached retainers.

Removal and lnstallation

Raise tail gate window. Remove down travel bumper on tail gate hinge lift arm and lower tail gate.

Remove screws securing weatherstrip retainers above the beltline at the detail areas at beltline off-set and at lower corners of back body opening

(Fig. 9-2). Remove locating buttons at upper corners, if present.

With a flat-bladed tool, carefully remove weather- strip around entire back body-opening. Separate the weatherstrip at the butt joint to facilitate removal between hinge lift arm and tail gate.

To install original part, apply a bead of black weatherstrip cement to entire body opening and starting at the beltline details on both sides, reverse the removal procedure. When installing a new weatherstrip, begin the installation at the belt detail area, continue with the upper body installation and complete the operation at the bottom of the opening. Cut off excess weatherstrip to form a butt joint.

TAlL GATE BELT WEATHERSTRIP

Removal and lnstallation

1. Remove screws securing end of weatherstrip to tail

I gate and with a flat bladed tool, carefully remove the weatherstrip from its retainer (Fig. 9-3).

2. To install, reverse the removal procedure.

NbTE: The tail gate belt outer sealing strip is integral with the belt reveal molding and is removed as a unit.

TAlL GATE WINDOW INNER

WEATHERSTRIP

Removal and lnstallation

1. Remove back body pillar and/or upper body opening finishing molding (Fig. 9-4).

2. Remove screws securing inner weatherstrip section and remove weatherstrip.

3. To install reverse the removal procedure.

TAlL GATE BOTTOM DRAIN HOLE

SEALING STRIPS

Removal and Installation

6

1. With the tail gate in the closed position, remove back body lower housing access hole covers (Fig.

CAUTION: When conducting tail gate service operations through the access openin s in the body rear lower housing (Fig. 9-5) p f ace body tape over the tail gate opening key cylinder to prevent inadvertent operation of the tail gate.

2. Working through the lower housing access holes, detach the fastener at each end of the strip and remove the sealine s t r i ~ .

Fig. 9-4-Body Rear Finishing Moldings

TAIL GATE 9-5

Fig. 9-5-Tail Gate Rear Upper Housing Installation

1. Back Body Upper

Housing

,

2. Back Body Upper

3.

Housing Seals

Back Body Lower

Housing Drain

Sealing Strip (Right

Side Only)

4. Back Body Lower

Housing

5. Back Body Lower

Housing Access

6.

Covers

Back Body Lower

Housing Access Cover

Seal

9-6 TAIL GATE

/

INNER COVER PANEL v

Fig. 9-6-Tail Gate Inner Cover Panel Retention

3. To install, reverse the removal procedure. See illustration under (Front and Rear Door Bottom

Drain Hole Sealing Strips).

LOWER HOUSING DRAIN SEALING STRIP

Removal and Installation

1. On exterior of lower housing, (right side) remove screws securing housing sealing strip and remove strip.

2. To install, reverse the removal procedure.

TAlL GATE INNER FINISHING PANEL

The tail gate inner finishing panel is sealed and attached to the tail gate by screws; thus a separate paper water deflector is not required.

Removal

1. Remove screws securing inner panel to tail gate

(Fig. 9-6).

2. With a flat-bladed tool carefully break the bond sealing the inner panel to the tail gate and remove the panel.

TAlL GATE WINDOW

Description

The tail gate window is physically independent of the tail gate in the sense that all glass support and operating components are mounted in the body shell rather than in the tail gate.

The window motor, mounted to the rear of the spare tire well in the right quarter area, delivers torque to the window regulator assembly through a drive cable.

The window regulator, in turn drives another cable that is attached to the right upper glass roller support, thus moving the glass along the its cam guides (Fig.

9-1).

TAlL GATE WINDOW ASSEMBLY

-

(ALL)

The tail gate window assembly consists of a solid tempered safety plate glass of compound curvature with a pressed-on upper sash channel. Attached to the upper sash channel is a window lift spring and silencer. A roller support is bolted to each corner of the glass. With this design, the tail gate glass, upper sash channel with spring and roller supports are removed from the body opening as a unit and a replacement glass and roller suppo!ts are assembled as a bench operation.

Removal and Installation

Raise tail gate window and lower tail gate. On manual gates snap tail gate lock to closed position.

Remove back body opening weatherstrip across top and down sides to include belt detail areas

(previously described).

Remove right quarter window upper garnish molding and retainer, right rear body pillar finishing molding and back body opening upper finishing molding (Fig. 9-4).

Installation

Inspect sealer deposit in the depression of the tail gate. If required, apply a bead of body caulking compound in sufficient quantity to effect an adequate seal (Fig. 9-6).

Install tail gate inner panel to tail gate and press firmly around the periphery.

Apply body caulking to panel attaching screw threads and install screws. Fig. 9-7-Window Right Cam Guide Access - Front

TAIL GATE 9-7

4. Detach headlining over right quarter glass suffi- ciently to reveal access hole at forward attaching location of window right cam guide (Fig. 9-7).

5. Through access hole described in Step No. 4, transfe~ window assist spring from retainer on window cam guide to hook on window right upper roller support

(Fig. 9-8).

6. Through same access hole, loosen drive cable flag retainer bolt and move retainer inboard out of en- gagement with flag. Secure flag in full forward posi- tion with a metal screw.

7. Remove window down-travel s t o ~ of right and left window cam guides (Fig. 9-9).

1. Window Lift Spring

(Operating Position)

Fig. 9-8-Drive Cable Flag Retainer and Window Lift Spring Details

2. Drive Cable Flag

3. Window Guide Roller

Assembly

4. Window Lift Spring

(Position for Window

Removal)

.

5. Drive Cable Flag

Retainer

9-8 TAIL GATE

-- -

Fig. 9-9-Tail Gate Window Down-Travel Stop

8. Manually lower glass down and out of engagement with window guide cams.

NOTE: On styles equipped with tail gate window defogger, disengage defogger lead wire at clip on left upper roller assembly and from terminal on glass with window in down position. Secure defogger lead wire to body opening to prevent recoil of wire into body cavity.

9. To install, reverse the removal procedure.

Tail gate window components are illustrated in Fig.

9-10. Specified torque for the roller support-to-glass bolts is 72 inch Ibs.

Tail Gate Window Adjustment

Up and down adjustment of the window for proper weatherstrip contact is made by adjusting both right and left window guide cams vertically at the rear and midway attaching locations.

A cocked window adjustment is controlled by loosening and rotating the right upper roller support in the desired direction (Fig. 9-1 1).

Window down-travel is controlled by an adjustable stop in the lower end of the window right and left cam guides (Fig. 9-9).

TAlL GATE WINDOW REGULATOR

ASSEMBLY

Removal and lnstallation

1. Remove spare tire cover and spare tire.

2. Disengage motor drive cable at window regulator assembly (Fig. 9- 12).

3. Disengage window drive cable clip at upper end of regulator and remove cable storage conduit at lower end of regulator.

4. Remove regulator attaching screws and rotate regulator off lower end of drive cable.

5. To install, reverse the removal procedure.

TAlL GATE WINDOW MOTOR ASSEMBLY

Removal and lnstallation

1. Remove spare tire cover and spare tire.

2. Disconnect motor electrical lead and disengage drive cable at upper end of motor (Fig. 9-12).

3. Remove motor attaching screws and remove motor.

4. To install, reverse the removal procedure.

TAIL GATE WINDOW MOTOR CABLE

ASSEMBLY

Removal and lnstallation

1. Remove spare tire cover and spare tire.

2. Disengage cable at motor and window regulator assembly.

3. To install, reverse the removal procedure.

TAlL GATE WINDOW CAM GUIDE

RIGHT SIDE

-

Removal and lnstallation

1. Remove tail gate window as previously described.

2. Remove spare tire cover, spare tire and right pillar inner weatherstrip.

TAIL GATE 9-9

1. Window Guide Roller

Assembly

-

Upper

Left

2. Window Guide Roller

Assembly

-

Lower

Left

Fig. 9-10-Tail Gate Window Components

-

Exploded

3. Window Guide Roller

Assembly

-

Lower

Right (Manual Gate)

4. Window Guide Roller

Assembly

-

Lower

Right (Power Gate)

5. Window Guide Roller

Assembly

-

Upper

Right

6. Window Lift Spring and Silencer

Fig. 9-11-Window Guide Roller Assembly

Upper Right

-

3. Detach motor drive cable at bottom of window gear box and remove gear box attaching screws

(Fig. 9- 12).

4. Remove gear box as previously described.

NOTE: On styles equipped with manual tail gate, disengage upper end of tail gate window stop cable and clip assembly (Fig. 9-13).

5. kemove cam guide attaching bolts, move guide forward to clear pillar .access hole with drive cable and withdraw guide from body (Fig. 9-14).

6. To install reverse the removal procedure.

9-10 TAIL GATE

Fig. 9-12-Tail Gate Window Motor and Regulator Installation

TAIL GATE

9-

1 1

WINDOW GUIDE

. CAM ASSEMBLY

ATTACHING BOLTS

WINDOW STOP

CABLE & CLlP ASSEMBLY

\

WINDOW STOP

CABLE & CLlP ASSEMBLY

ATTACHING NUTS

Fig. 9-13-Window Stop Cable and Clip

Assembly Attachment

TAlL GATE WINDOW CAM GUIDE

SIDE

-

LEFT

Removal and Installation

1. Remove tail gate window as previously described.

2. Remove left quarter window upper garnish molding and retainer and left rear body pillar finishing molding.

ATTACHING B

Fig. 9-14-Tail Gate Window Right Cam Guide

Attachment

1108

Fig. 9-15-Tail Gate Window Left Cam Guide

Attachment

3. Remove cam guide attaching bolts and withdraw guide from body (Fig. 9-1 5).

4. To install, reverse the removal procedure.

TAlL GATE WINDOM DRIVE CABLE

ASSEMBLY

Removal and Installation

1. Remove spare tire cover and spare tire.

2. Remove right quarter window upper garnish molding and retainer, back body opening upper finishing molding right rear body pillar finishing molding and inner weatherstrip (Fig. 9-4).

3. Detach headlining over right quarter glass sufficiently to reveal access hole at forward attaching location of window right guide cam guide (Fig. 9-7).

4. Remove window gear box as previously described.

5. Loosen drive cable flag retainer and move retainer inboard out of engagement with flag.

6. Disengage drive cable at attaching bracket on cam guide (Fig. 9- 16).

7. Withdraw drive cable' t!lrough access hole in pillar.

8. To install, reverse the removal procedure.

9-12 TAIL GATE

VIEW C

Fig. 9-16-Window Right Cam Guide and Drive

Cable Details

A. Right Cam Guide

Center Attachment

B. Window Drive Cable- to-Cam Guide

Attaching Bracket

C. Window Stop Cable and Clip Assembly- to-Cam Guide

Attachment

WINDOW STOP CABLE AND CLIP

ASSEMBLY

Removal and lnstallation

1. Remove window as previously described.

2. Disengage upper end of tail gate window stop cable and clip assembly (Fig. 9-13).

3. Remove right cam guide as previously described.

4. Remove stop assembly as a bench operation.

5. Through access hole at gear box mounting area disengage window stop cable at lock lever and withdraw cable. (See Fig. 9-25 window and gate control section).

NOTE: Tie a suitable length of cord to lower end of cable to facilitate installation.

6. To replace cable and stop assembly, reverse the removal procedure.

Adjustment

1. Operate tail gate lock to unlatched position.

2. With window stop cable and clip assembly loosely assembled to cam guide, move stop assembly upward to remove slack from cable and position bell crank. Tighten stop attaching nuts (View "C"

Fig. 9- 16).

3. Operate glass with tail gate lock in both locked and unlocked positions to check operation of stop cable and clip assembly.

ROLLER ASSEMBLY

WINDOW

-

TAlL GATE

-

LOWER RIGHT OR LEFT

Removal and lnstallation

1. Raise window to full up position.

2. Remove back body opening upper finishing molding and inner weatherstrip (Fig. 9-3 and Fig.

9-4).

3. Remove rear pillar finishing molding and inner weatherstrip on affected side.

4. When right lower roller assembly is involved, remove glass down-travel stop in right cam guide.

5. Remove window roller assembly-to-glass nuts, disengage roller assembly from attaching bolts and pull roller assembly out of engagement with cam guide.

6. To install, reverse the removal procedure.

ROLLER ASSEMBLY

WINDOW

-

TAlL GATE

-

UPPER RIGHT

Removal and lnstallation

'1. Remove tail gate window as previously described.

2. Remove upper right roller assembly as a bench operation (Fig. 9- 10).

3. To install, reverse the removal procedure.

NOTE: Adjust right upper roller assembly, if necessary, to correct a cocked glass condition (Fig.

9-1 1).

ROLLER ASSEMBLY

WINDOW

-

TAlL GATE

-

UPPER LEFT

Removal and lnstallation

1. With window and gate in the open position, remove back body opening upper finishing molding and inner weatherstrip (Flgs. 9-3 and

9-4).

2. Remove left rear pillar finishing molding and inner weatherstip.

Lower tail gate window to full down position.

NOTE: On manual gates, snap the gate lock to closed position to allow full closing of the window.

Support window vertically at the top edge between the roof inner and outer panels with a wood wedge or equivalent.

Remove window lower left roller assembly as previously explained.

Remove attaching bolts securing window upper left roller assembly and slide assembly down and out of left cam guide.

To install reverse the removal procedure.

TAlL GATE WINDOW DOWN-TRAVEL

STOPS

Removal and Installation

1. Remove rear pillar finishing molding (Fig. 9-4).

2. Remove down-travel stop attaching screw in lower end of window cam guide and remove stop.

3. To install, reverse the removal procedure. Adjust stop as subsequently explained.

Adjustment

1. Loosen down-travel stop attaching screw and lower tail gate window for desired contact with tail gate belt weatherstrip.

2. From body interior, adjust down-travel stop upward for firm contact against glass lower roller and tighten stop attaching screw. Make minor adjustments if required (Fig. 9-9).

TAlL GATE WINDOW ASSIST SPRING

AND SILENCER

Removal and Installation

1. Remove tail gate window as previously explained.

2. Remove window assist spring and silencer as a bench operation (Fig. 9- 10).

3. To install, reverse the removal procedure.

Remove left rear pillar finishing molding and inner weatherstrip.

Remove left quarter window upper garnish molding and retainer.

Detach headlining over left quarter glass suffi- ciently to reveal access hole at forward end of tail gate window left cam guide.

Disengage heated window rear harness at front junction and secure a 4 ft. cord to harness to facilitate installation (Fig. 9-17).

Lower tail gate window to full down position for access to harness terminal on glass.

NOTE: On manual gates, snap tail gate lock to closed position in order to lower window fully.

Withdraw harness from body leaving installing cord in body cavity.

To install, reverse the removal procedure.

TAlL GATE ASSEMBLY

The tail gate lowers into a storage area beneath the load floor and is guided through the path of its travel by right and left lower guide channel assemblies and a regulator lift arm and hinge at the upper left corner.

Simultaneous movement of right and left sides is assured by a synchronizing torque tube assembly.

Operating effort is reduced by a torque rod assembly that acts upon the regulator lift arm and hinge (Fig.

9- 1).

Refer to Fig. 9-18 and prepare a 1 /4" 20 x 1" fixture bolt with two nuts to serve as a roller stop for the subsequent removal steps. In addition, prepare a prop of suitable length to support the tail gate in a horizontal position.

HEATED TAlL GATE WINDOW REAR

WIRE HARNESS ASSEMBLY

Removal and Installation

1. Remove back body opening upper trim finishing molding and inner weatherstrip (Fig. 9-4).

Fig.

Up

TAIL GATE 9-13

9-17-Heated Window Rear Wue Harness

-

Window

(Roof Outer Panel Removed for Illustrative Purposes)

9-'14 TAIL GATE

/ PREPARED FIXTURE

Removal and Installation

Fig. 9-18-Tail Gate Position For Reqoval

6. Carefully lower the gate to a horizontal position and support with above mentioned prop.

1. Remove rear bumper and body rear upper housing (Fig. 9-5).

2. Lower tail gate and with Tool 5-23719 or equivalent, relieve right (adjustable) end of tail gate torque r d . Allow torque rod rod to rotate fornard to fully relaxed position. (Refer to torque rod removal and installation

- step No. 2).

3. Raise tail gate to latched position and rernoye tail gate inner cover panel (Fig. 9-6).

4. Remove regulator hinge arm-to-tail gate attaching screws. On manual tail gates, secure lift arm hinge ip raised position with wire or cord.

5. Insert fixture bolt and nut assembly into key slot at upper end of right channel guide assembly below roller to hold synchronizing tube assembly in position during tail gate removal.

7. Scribe location of right lower roller support on tail gate and with the aid of a helper, remove bolts attaching right and left lower roller supports to tail gate. Remove tail gate.

8. To install, reverse the removal procedure.

NOTE: Remove fixture bolt from right channel assembly before raising tail gate to body position.

CAUTION: When conducting tail gate service opefations through the accessd openings in the body rear loiver housing (Fig. 9-5), place body tape over the tail'gate operating key cylinder to prevent inadvenent lowering of the tail gate.

TAIL GATE 9-15

Fig. 9-19-Tail Gate Guide Channel Assembly

Right

-

TAlL GATE GUIDE CHANNEL ASSEMBLY

RIGHT OR LEFT

Removal and Installation

With tail gate in a fully closed position, remove right or left access hole cover in body rear lower housing (Fig. 9-5).

Working through access hole in lower housing, remove synchronizing tube-to-guide channel link sholder bolt (Fig. 9-19 or 9-20).

Remove guide channel-to-body attaching bolts

(Fig. 9- 19 or 9-20).

Disengage guide channel from tail gate lower roller and withdraw guide channel through access hole in body rear lower housing.

To install, reverse the removal procedure. Adjust guide channel fore or aft as required.

TAlL GATE ROLLER SUPPORT

OR LEFT

-

RIGHT

Removal and Installation

1. With tail gate in a fully closed position, remove right or left access hole cover in body rear lower housing (Fig. 9-5).

2. Working through access hole in lower housing, remove (right side) roller support-to-tail gate attaching bolts and roller shaft-to-support attach- ing nut (Fig. 9-19) (left side)

- remove roller support-to-tail gate attaching bolts.

3. On either side disengage roller support from roller shaft and withdraw roller support through access hole.

4. To install, reverse the removal procedure. Right side roller only is adjustable laterally on tail gate and up-down on roller shaft.

TAlL GATE SYNCHRONIZING TORQUE

TUBE ASSEMBLY

Removal and Installation

1. Remove tail gate as previously explained.

2. Remove right and left roller supports as previously explained.

3.

Remove right and left synchronizing torque tube- to-guide channel link shoulder bolts.

4. Scribe location of guide channels on body and remove rearward attaching bolts and loosen forward attaching bolt# (Fig. 9- 19 and 9-20).

5. Rotate guide channels downward for clearance to allow disengagement of right and left torque rollers from upper end of guide channels (Fig.

9-2 1).

6. Remove synchronizing torque tube with torque rollers and shafts.

7. If necessary, torque rollers and shafts may now be removed

as

a bench operation.

Fig. 9-20-Tail Gate Guide Channel Assembly

Left

-

9-16 TAIL GATE

6

Fig. 9-21-Tail Gate Synchronizing Torque Tube and Guide Channels

8. To install, reverse the removal procedure. 4. Withdraw torque rod from lift arm link and remove torque rod from body.

TAIL GATE TORQUE ROD

5. To install reverse the removal procedure.

The retractable tail gate torque rod provides a counterbalance force for the operating cycles of the gate resulting in decreased opening and closing effort.

The adjustable end of the torque rod is located on the right side of the body under the rear load floor and is secured in one of three adjusting locations by a pin inserted above the rod and through a key slot in the torque rod retainer (Fig. 9-22).

Adjustment

Engage end of torque rod with tool 5-23719 or equivalent, apply downward pressure against rod and remove retaining pin (Fig. 9-23).

Place torque rod in desired location in torque rod retainer and insert retaining pin in key slot above torque rod.

Removal and Installation

Lower tail gate and prop rear load floor in full open position.

NOTE: Torque rod should be adjusted to achieve tail gate cycling action that requires only minimal manual assist.

Gain access to torque rod retainer (Fig. 9-23) and with tool 5-23719 or equivalent,apply downward pressure on torque rod. Carefully remove torque rod pin and allow torque rod to rotate forward to a fully relaxed position (Fig. 9-23).

On manual tail gates adjust torqbe rod block-out fore or aft (Fig. 9-22) if necessary, so that tail gate drops 3 to 6 inches after being released by the control switch.

CAUTION: Do not remove torque rod cover plate until torque rod is fully relieved.

TAIL

GATE

LIFT ARM

HINGE

ASSEMBLY

-

MANUAL AND ELECTRIC

' a

Remove torque rod cover plate screws and remove cover plate (Fig. 9-22).

Removal and Installation

1. Remove left quarter rear trim panel Fig. 9-4.

TAIL

GATE 9-17

1. Lift Arm Hinge-to-

Tail Gate Attaching

Screws

Fig! 9-22-Tail Gate Torque Rod and Hinge Arm Relationship

2. Lift Arm Hinge

3.

Assembly

-

Manual

Torque Rod Block-

Out

2.

Remove tail gate inner cover panel.

3.

Lower tail gate and remove tail gate torque rod as previously explained.

4.

Raise tail gate sufficiently to remove regulator lift arm hinge-to-tail gate attaching screws (Fig.

9-22).

- -

5.

Carefully lower tail gate and regulator lift arm to

.full down position. On power-operated units, d i w n n k t wire harness at motor terminal,

6. Mark location of lift arm hinbe assembly on body and"cemove attaching wrews (Fig.

9-22).

Remove regrilgtor a n d lift arm hinge assembly from body.

I .

)

4. Lift Arm Hinge and

Regulator Assembly

Electric

6. Torque Rod

-

7. Torque Rod Retainer

5. Torque Rod Retaining

8. Torque Rod Cover

.

Plate

'

.

Pip -

7.

TO

install, reverse the removal procedure.

Adjustments

The r'egulator and lift arm hinge assembly may be adjusted down-forward, aft-upward and rotated within the limitations of two over-size attaching holes to the body.-

NOTE:

Make adjustments with torque rod disengaged retainer on right side of body.

Assuming that all attaching bolts to body and tail gate are loose, proceed as follws:

1. Tighten regulator lift arm-to-tail gate attaching screws securely (Fig.

9-22).

9-18 TAIL GATE

2. Lower tail gate as far as possible without obscuring tail gate inner panel access hole.

3. Secure striker assembly on tail gate exterior with an extension magnet or looped cord.

4. Through access hole in tail gate inner panel, remove striker assembly bolt and striker pin jamb nut and washer (Fig. 9-24).

5. Withdraw striker assembly through gap between tail gate and body opening.

6. To install, reverse the removal procedure.

Fig. 9-23-Torque Rod Tool

-

Torque Rod

Release or Adjustment

With tail gate in full closed position, apply sufficient forward pressure on tail gate to achieve flush tail gate to body opening alignment. Secure regulator attaching bolts.

Secure torque rod in retainer, using tool J-23719 or equivalent and operate gate through several up- down cycles. Rotate regulator and hinge arm assembly at attaching location to body, if neces- sary, to maintain proper tail gate up-travel.

NOTE: On manual tail gates, if original location of regulator and hinge assembly is changed, the torque rod block-out should be readjusted. (Refer tail gate torque rod-adjustment).

TAlL GATE LIFT ARM HINGE AND

REGULATOR ASSEMBLY MOTOR

Removal and Installation

1. With tail gate fully lowered, remove left quarter rear trim panel.

2. Relieve tail gate torque rod at torque rod retainer with tool J-237 19 or equivalent(Fig. 9-23).

3. Detach wire harness at motor terminal and remove motor-to- regulator attaching bolts.

Remove motor (Fig. 9-22).

4. To install, reverse the removal procedure.

TAlL GATE STRIKER ASSEMBLY

Removal and Installation

1. Remove tail gate inner cover panel as previously described.

Adjustments

The tail gate striker is adjustable up-down and fore- aft. The striker pin is threaded into the striker plate and is adjustable cross-body. All striker adjustments are made through the access hole in the tail gate inner panel.

To adjust the striker cross-body for proper engage- ment with tail gate lock, proceed as follows:

1. Engage hex end of striker with a suitable wrench and loosen striker pin jamb nut &Fig. 9-24).

2. Rotate striker pin for desired relationship with lock.

NOTE: Striker pin head-to-lock bolt clearance

/ 16" minimum.

3. While holding hex end of striker in desired position, tighten striker pin jamb nut.

To adjust striker fore-aft or up-down, proceed as follows:

1. With tail gate fully closed loosen striker pin jamb nut as previously explained (Fig. 9-24).

2. Loosen striker assembly bolt.

3. Move tail gate fore-aft to position striker and/or move striker assembly up-down for proper influence on lock bolt.

4. Tighten striker pin jamb nut and striker assembly bolt.

TAlL GATE LOCK ASSEMBLY

Removal i n d Inctallatlon

1. Raise tail gate window and lower tail gate.

2. Remove spare tire cover and spare tire.

Released by: www.78ta.com

Serial Number: 71BDY-001-1026

4

VIEW I N DIRECTION

OF ARROW "A"

1

TAIL GATE 9-19

Fig. 9-24-Tail Gate Lock Striker and Grip Handle Assemblies

1.

2. Grip

3.

Lock Assembly

Grip

Handle

Handle Cover

4.

5.

6.

Striker Assembly Bolt

Striker Pin

Striker Pin Jamb Nut

3. Working around right pillar inner panel, disen- gage tail gate window stop cable and switch assembly link at lock lever (Fig. 9-25).

4. Remove lock attaching bolts at pillar facing, disengage lock lever from switch assembly link and remove lock (Fig. 9-26).

5. To install, reverse the removal procedure.

TAIL GATE OUTER PANEL GRIP HANDLE

-

(MANUAL TAIL GATE ONLY)

Removal and Installation

1. Remove screws securing tail gate outer panel grip handle and cover. Remove handle (Fig. 9-24).

9-20 TAIL GATE

1.

Fig. 9-25-Lock and Release Switch Assembly

Lock Cylinder

2. Window Stop Cable

3.

4.

5.

Window Stop Cable

Retaining Clip

Lock Lever

Switch-to-Lock Lever

Link and Swivel

6. Lock and Release

Switch Assembly

7. Switch-to-Cylinder

Retaining Clip

8. Lock Cylinder

Retaining Clip

TAIL GATE ADJUSTMENTS

The retractable tail gate is adjustable up-down, fore- aft and laterally within its body opening (Fig; 9-27).

All tail gate adjustments may be completed without removal of the rear bumper face bar and body rear upper housing. The covered openings in the body rear lower housing on each side (Fig. 9-5) provide access for adjustment provisions confined within the tail gate storage area.

CAUTION: When conducting tail gate service opera- tions through the access openings in the body rear lower housing (Fig. 9-5), place body tape over the tail gate operating key cylinder to prevent inadvertent lowering of the tail gate.

Up-down adjustment of the tail gate is controlled chiefly by the positioning of the tail gate striker assembly. To complete the up-down adjustment, proceed as follows:

1. With tail gate fully closed remove inner cover panel for access to striker attaching provisions

(Fig. 9-24).

Fig. 9-26-Lock and Lock Cylinder Attachment

1. Lock Cylinder

Retainer

2. Lock Cylinder Gasket

3.

4.

Lock Cylinder

Lock Assembly

Attaching Screws

2. Hold striker pin hex end and loosen striker jamb nut. Loosen striker assembly attaching bolt.

3. Position tail gate to desired height, move striker assembly to full engagement with lock bolt and tighten striker assembly.

To correct a cocked tail gate condition, close tail gate and loosen striker assembly. Through access hole in body. rear lower housing, loosen the right hand roller support-to-roller shaft nut (Fig. 9-19). Position tail gate and tighten subject nut. Complete striker assembly adjustment.

Fore-aft adjustment of the tail gate is attained by positioning the tail gate guide channel assemblies for correcting the bottom of the tail gate and/or positioning the striker assembly and regulator lift arm and hinge assembly for correcting the top of the tail gate.

To correct bottom of tail gate fore-aft proceed as follows:

1. With tail gate fully closed remove rear body lower housing access cover on affected side (Fig. 9-5).

2. Loosen tail gate guide channel attaching screws. channel attaching screws.

To correct top of tail gate fore-aft, proceed as follows:

1. Right side

TAIL GATE 9-21

4293

FORE-AFT

(BOTTOM OF GATE) COCKED GATE

Fig. 9-27-Location of Tail Gate Adjustment Provisions

A. Gain access to striker assembly and loosen striker pin jamb nut and striker assembly bolt

(Fig. 9-24).

TAIL GATE AND WINDOW CONTROL

SWITCH

B.

Position tail gate fore-aft and tighten striker assembly.

2. Left side

A. Gain access to lift arm and hinge assembly and loosen assembly attaching bolts (Fig.

9-22).

The tail gate and window control switch mounted on the rear of the right quarter outer panel adjacent to the tail gate is a combination of lock cylinder and control switch. Tivo control switches are used; one for the manual tail gate which includes a link to the lock lever, and one for the power operated tail gate

(without link). Figure 9-25 is typical of the clip method by which both manual and power operated tail gate switches are retained to the lock cylinder.

B. Position tail gate fore-aft and tighten lift arm and hinge assembly attaching bolts.

Removal and Installation (Control Switch Only)

Lateral adjustment of the tail gate is allowed by the elongated attaching bolt holes in the lower right roller support (Fig. 9-18). A corresponding lateral adjust- ment of the striker assembly is required.

1. Remove spare tire cover and spare tire.

2. Remove tail gate window regulator as previously explained.

1. With tail gate fully closed remove body rear lower housing access cover (right side) (Fig. 9-5). 3. Disengage wire harness terminal block off control switch

- manual or power (Fig. 9-25).

2. Loosen lower right roller support attaching screws

(Fig. 9-19).

3. Position tail gate laterally and tighten roller support attaching screws.

4. Gain access to striker assemblv and adiust striker pin to 1 / 16" striker head-to-l&k bolt cliarance.

4.

'

On

manual tail gate control switches, disengage control switch-to-lock lever link. On all switches remove wire clip securing control switch to lock cylinder and remove control switch (Fig. 9-25).

5. To install reverse the removal procedure.

9-22 TAIL GATE

VIEW "C"

4372

Fig. 9-28-Retractable Tail Gate Lubrication

Adjustment (Control Switch-to-Lock Lever Link)

(Manual Gates Only)

-

1. With key cylinder in centered (vertical) position, withdraw key sufficiently to render cylinder inoperative.

2. Assure that tail gate lock is in unlatched position

(lock lever down).

3. Move switch-to-lock lever link to full down position (against stop).

4. Adjust swivel on switch-to-lock lever link to align with clip hole on lock lever and engage swivel

(Fig. 9-25).

5. Reinsert key and check operation of lock release.

NOTE: Check operation of window stop cable and clip assembly. (Refer to "Adjustment" - window stop cable and clip assembly).

TAIL GATE WINDOW CONTROL SWITCH

LOCK CYLINDER

Removal and Installation

I

.'

Remove control switch as previously explained.

2. Remove key cylinder retaining'clip and remove cylinder (Fig. 9-26).

3. To install, reverse the removal procedure.

TAIL GATE 9-23

RETRACTABLE TAIL GATE LUBRICATION

Description

All mechanical components that have relative motion with other parts are lubricated during assembly. If additional lubrication is required the specified materials or their equivalents as stated here should be used.

The following tail gate and window components should be lubricated when required with a thin coat of white lithium soap grease (Fiske Bros. Lo-Temp

Lubriplate No.

9-28.

777 or equivalent) as shown in Fig.

1.

Tail gate lock fork bolt (View "A").

2. Torque roller shaft and synchronizing torque shaft-to-link shoulder bolt (View "B").

3. Torque rod and torque rod block-out (View "C").

4. Window guide cams and tail gate guide channels

(Section D-D).

DUAL ACTING TAlL GATES

DESCRIPTION

The dual-acting tail gate incorporates a unique hinge and locking arrangement that allows the tail gate to be operated in the conventional manner and, addition- ally, as a door. All wagons so equipped utilize either a mimually or electrically operated window that can be lowered into the gate or raised into the back body opening. The manual window is operated by a regulator control handle located in the tail gate outer panel. The power window can be operated by any one of three control switches; one on the instrument panel, one at the lock cylinder on tail gate outer panel (key operated) and one on the wheelhouse cover panel

(optional

- down only). All styles using a power tail gate window are equipped with an electrical switch that prevents movement of the window with gate in any position other than fully closed.

The tail gate is unlocked to "gate position" by means of a remote control inside handle located in the top center of gate inner panel. Unlocking to "door position" is accomplished with an inside handle located at top right side of inner panel. The tail gate cannot be opened in either direction, however, until the window has been fully lowered. All tail gates are counter-balanced by a torque rod that assists in reducing the effort required to open or close the tail gate.

IMPORT ANT: FOLLOWING ANY REPLACEMENT

OR REALIGNMENT OF THE TAIL GATE, OR

COMPONENT HARDWARE, ALL LOCKS MUST

BE

CHECmD FOR SYNCHRONIZATION (REFER

TO LOCK SYNCHRONIZATION CHECKS AND

PROCEDURE).

All dual-acting tail gates employ a "hang-on" type inner panel cover that attaches over the top of the tail gate inner panel and is further secured by a series of screws. This cover can be readily removed with gate in either the open or closed position.

Figure 9-29 identifies the component parts of a typical dual-acting tail gate and their relationship.

TAlL GATE INNER PANEL

WATER DEFLECTOR

A waterproof paper deflector is sealed against the tail gate h e r panel to deflect 5ater toward the bottom of the gate and out the drain holes.

IMPORTANT: When work is performed on the tail gate that requires any detachment of the water deflector, it must be properly resealed to the inner panel.

Removal

1. Remove tail gate inner panel cover.

2. Using a flat-bladed tool, carefully break bond securing water deflector to inner panel. Make sure string, located within sealer, is against water deflector and carefully slide tool between sealer and inner panel along both sides, top and bottom to disengage deflector from inner panel. If the entire deflector need not be removed, detach only that portion necessary.

Installation

1. Inspect deflector and repair any damage noted with waterproof body tape applied to both sides.

2. If a new deflector is to be installed, use old deflector as a template.

3. If needed, apply a bead of body caulking gate inner panel (See Fig. 9-30). The inner panel cover attaching screw holes should also be sealed with body caulking compound.

9-24 TAIL GATE

Fig. 9-29-Dual Acting Tail Gate Hardware (Typical)

1. Outside Handle

(Manual)

2. Gasket

3. Lock Cylinder

4. Electrical Feed Block

5. Gasket

6. Lock Cylinder

Retainer

7. Sash Channel Cam

8. Remote Control

Connecting Rod

9. Left Upper Lock and

Hinge Assembly

10. Torque Rod

11. Regulator

-

Manual

4. Position water deflector to tail gate with polyethyl- ene coated side (black) against inner panel.

Firmly press sealed areas to obtain a good bond between deflector and inner panel.

TAlL GATE INNER PANEL

ACCESS HOLE COVERS

Removal and Installation

1. Remove tail gate inner panel cover and water deflector.

12. Inside Remote Gate

Handle

13. Inside Door Handle and Cable Assembly

14. Right Upper Lock

15. Right Lower Lock and Cover Assembly

16. Glass Stabilizer

17. Lower Glass Run

Channels

18. Glass Block-Out Rod

19. Regulator Electrical

20. Sealing Strip

2 1. Remote Control

Assembly (Gate

Operation)

2. Remove upper screws securing right and left access hole covers to tail gate inner panel and remove covers by sliding upward (See

Fig.

9-3 1).

TAlL GATE BOTTOM DRAIN HOLE

SEALING STRIPS

Removal and Installation

1. With a flat-bladed tool carefully pry out snap-on fastener at each end of strip and remove sealing strip from tail gate.

TAIL GATE 9-25

Fig. 9-30-Tail Gate Sealing

2. To install sealing strips, reverse removal proce- dure. To prevent strip from adhering to the tail gate panel and blocking the drain holes, apply a sparing amount of silicone rubber lubricant on the center section of the sealing strip (See

Illustration under "Front and Rear Door Bottom

Drain Hole Sealing Strips").

TAlL GATE OPENING WEATHERSTRIP

1. Open tail gate and remove fasteners and/or screws securing upper corners of weatherstrip to right and left body pillars (Fig. 9-32).

Fig. 9-31-Tail Gate Inner Panel

Cover

Access Hole

TAlL GATE WINDOW

UPPER GLASS RUN 6HANNEL

Removal and Installation

1. Open tail gate and disengage clip at bottom of run channel on side to 'be removed. With finger pressure only, squeeze run channel at one end and pull channel out of retainer.

2. Once run channel has been removed, the retainer attaching screws are exposed (See Fig. 9-33). The retainer can be adjusted by loosening attaching screws, shifting retainer to desired position and tightening screws. If retainer is removed, seal retainer with medium bodied sealer prior to installation.

3. To install, reverse removal procedure.

2. With a flat-bladed tool, carefully remove weather- strip along entire tail gate opening.

3. To install original part, apply a bead of black weatherstrip cement into retainer along entire opening and reverse removal procedure. Replace- ment parts are serviced in two separate pieces, right and left. When installing a new weather- strip, begin at beltline (on both side) and work to bottom center. Cut off excess weatherstrip and form a butt joint.

TAlL GATE WINDOW LOWER

GLASS RUN CHANNELS

Removal and Installation

1. Remove tail gate window assembly as subse- quently described.

2. Remove upper attaching bolt pillar outer panel.

'

- accessible at lock

3. Remove lower attaching bolt

- accessible through inner panel access hole (Fig. 9-34).

9-26 TAIL GATE

Fig. 9-32-Tail Gate Weatherstrip Installation

V I E W I N C I R C L E B 3 2 8 6

'\

SECTION A - A

Fig. 9-33-Tail Gate Upper Glass Run Channel

Retention

Fig. 9-34-Tail Gate Lower Glass Run Channel

Attachment

TAIL GATE 9-27

4. Turn run channel 90 degrees and pull run channel(s) down into tail gate and remove through glass opening.

5. To install, reverse removal procedure.

TAlL GATE WINDOW REGULATOR

Manual

and

Electric

-

Removal and Installation

1. Remove tail gate window assembly as subse- quently described.

2. On styles equipped with a power operated tail gate window assembly, disconnect electric harness at regulator motor connector.

3. Remove bolts securing regulator to support and remove regulator, with motor attached, from tail gate (Refer to Fig. 9-29).

4. To install, reverse removal procedure.

Adjustment

The regulator attaching holes in the tail gate inner panel are oversize to permit movement of the regulator assembly to correct a "cocked" window (not parallel with the tail gate window upper run channel).

4. Drill a 1/8" hole through regulator sector gear and back plate (Fig. 9-35). Do NOT drill .hole closer than 1/2" to edge of sector gear or back plate. Install a pan head sheet metal .tapping screw (No. 10-12 x 5/8) in drilled hole to lock sector gears in position.

5. Remove regulator motor attaching screws and remove motor assembly from regulator and tail gate.

Installation

I. Lubricate the motor drive gear and regulator sector teeth.

NOTE: The lllbrication used must be cold weather approved to a minimum of minus 20 degrees fahrenheit

.

2. With tail gate in an open position, install regulator motor to regulator. Make sure the motor pinion gear teeth mesh properly with the sector gear teeth before installing the three motor attaching screws.

3. Remove screw locking sector gears i n - a fixed position.

#

4. Connect wire harness to motor and cycle tail gate window prior to installation of inner panel access hole cover, water deflector and cover panel.

TAlL GATE WINDOW ELECTRIC

REGULATOR MOTOR ASSEMBLY

Removal

I. Open tail gate and remove tail .gate inner cover panel. If necessary, cover can be removed with gate in the closed position.

2. Detach inner panel water deflector and remove left access hole cover.

3. Disconnect wire harness connector from motor.

NOTE: In the event a power operated window motor fails with tail gate closed and .glass in the closed (up) position, remove window sash channel cams and manually lower glass to bottom of gate.

CAUTION: Step 4 MUST be performed if the window is removed or disengaged from the regqlator lift arms. The regulator lift arms, are under tension from the counter-balance spring, and can cause serious injury if the motor is removed without locking the sector gears in position.

Fig. 9-35-Tail Gate Regulator Motor Assembly

9-28 TAIL GATE

Fig. 9-36-Dual Acting Tail Gate Right and Left Upper Lock Manual Locking

TAIL GATE CUT-OUT SWITCH

Description

All dual acting tail gates equipped with a power operated window utilize an electrical cut-out switch which prevents upward movement of the glass with tail gate in any position other than fully closed.

NOTE: In the event the tail gate cut-out switch fails with gate closed and glass in the fully lowered (open) position, refer to Daul Acting Tail Gate Diagnosis

Chart for procedures to raise glass.

Removal

1. With the tail gate open in a gate position, remove tail gate inner panel cover, water deflector and right access hole cover as previously described.

2. With glass supported in a full-up position, manually lock right upper lock as shown in Figure

9-36.

Fig. 9-37-Inside Handle (Door Operation)

Taped

TAIL GATE 9-29

1 / 1 6 " CLEARANCE BETWEEN

SWITCH

SCREWS

Fig. 9-38-Tail Gate Electrical Cut-Out Switch

9-30 TAIL GATE

/r

H A N D L E A C C E S S H O L E S

CAUTION:

Fig. 9-39-Tail Gate Window Outside Handle Removal

With tail gate open and right upper lock engaged, the tail gate has been placed in a vulnerable position and could drop from the right lower lock if inside door remote handle were actuated which could result in personal injury or damage to the tail gate assembly. As a safety precaution, prior to manually locking either right or left upper locks, apply body tape over inside door remote handle to render same inoperable

(Fig. 9-37). switch to achieve a 1/16" clearance between the cut-out switch plunger and the locking lever (See

Figure 9-38).

IMPORTANT: The adjustment specified in Step

No. 2 is absolutely necessary to insure proper operation of switch.

3. Following proper adjustment of cut-out switch, se- cure attaching screws and cycle tail gate window and gate to insure proper operation prior to installation of cover panel and water deflector. 3. Remove screws securing switch to right upper lock as shown in Figure 9-38. Disconnect electrical connector and remove switch through access hole.

Installation

1. Connect electrical connector and loosely attach switch to lock assembly.

2. With right upper lock in a locked position, adjust

TAIL GATE WINDOW REGULATOR

MANUAL OUTSIDE HANDLE

Removal and Installation

1. Open tail gate in door position.

2. Remove inner panel cover, water deflector and one access hole cover.

TAIL GATE 9-31

Fig. 9-40-Dual Gate Electric Key Switch and

Cylinder Removal

1.

2.

3.

Feed Block

Retainer

Gasket

4.

5.

Escutcheon

Key Switch and

Cylinder Assembly

3. Position tail gate window so that outside handle

(manual) attaching nuts are accessible through gate inner panel and window regulator access holes (Fig. 9-39).

4. Remove nuts securing handle to tail gate and remove handle and sealing gasket.

5. To install, reverse removal procedure.

TAlL GATE WINDOW REGULATOR

OUTSIDE ELECTRIC KEY SWITCH

Removal and Installation

1. Open tail gate in door position.

2. Remove inner panel cover, water deflector and access hole covers.

3. Remove tail gate window assembly and loosen tail gate window regulator so that key switch retainer is accessible through tail gate inner panel.

NOTE: To remove a power operated tail gate window, refer to "Tail Gate Window" in this section. Carefully read the CAUTION note.

4. Slide retainer free of key switch and remove switch (Fig. 9-40).

5. To install. reverse removal ~rocedure.

TAlL GATE WINDOW ASSEMBLY-MANUAL

OR ELECTRIC

The tail gate window assembly consists of a solid tempered safety plate window and a pressed-on lower sash channel which includes bolt-on lower sash channel cams at the right and left side. With this design, the tail gate glass and sash channel are removed from the gate as a unit and replacement glasses installed as a bench operation.

Removal and Installation

1. Open tail gate to gate position.

2. Remove tail gate inner panel cover, water deflector and both access hole covers as previously described.

3. Operate tail gate window to a point that sash channel cam attaching bolts are accessible through inner panel (Fig. 9-41).

NOTE: On manually operated tail gate windows, the glass can be raised by simply operating the outside handle. On electrically operated units, however, a switch mounted on the upper right lock assembly prevene window operation with

ANY lock in an open posiition. To operate window, with the gate in an open position, it is first necessary to manually lock both upper locks as follows:

A. The RIGHT upper lock is engaged by pivoting fork bolt to its full clockwise limits (Fig. 9-36).

B. The LEFT upper lock is engaged by depressing

(with a screwdriver, or other suitable tool) the locking lever to full-engagement (Fig. 9-36).

CAUTION: With tail gate open and locks engaged (as explained in preceding note), the tail gate has been placed in a vulnerable position and could drop from the right lower lock if inside door remote handle were actuated. As a safety precaution, prior to manually locking either right or left upper locks, firmly apply body tape over inside door remote handle to render same inoperable (Fig.

9-37).

4. Remove right and left cam attaching bolts (Fig.

9-41). Slide cams free of regulator lift arm rollers and remove cams from tail gate.

5. Pull window straight out to remove from tail gate.

6. To install, reverse removal procedure.

7. Right and left upper locks can be unlocked by actuating tail gate inside remote handle.

9-32 TAIL GATE

Fig. 9-41-Dual Acting Tail Gate Window Removal

Adjustments

The tail gate glass run channels can be adjusted to relieve a binding glass. To correct a rotated glass condition, loosen window regulator attaching screws and rotate regulator clockwise or counter clockwise as required.

TAlL GATE REMOTE CONTROL INSIDE

HANDLE-GATE OPERATION (CENTER)

Removal and Installation

1. Open tail gate to a gate position.

2. Raise inside handle and disengage remote push rod from spring clip (See Fig. 9-42).

3. Remove screws securing handle to inner panel and remove handle (Fig. 9-42).

4. To install, reverse removal procedure.

TAlL GATE INSIDE HANDLE AND

CABLE ASSEMBLY-DOOR OPERATION

(Right Side)

Removal and Installation

1. Open. tail gate in door position.

2. Remove inner panel cover, water deflector and left access hole cover.

3. Disengage handle cable at upper lock clip (Fig.

9-43).

TAIL GATE 9-33

R I G H T GLASS-

I

Fig. 9-42-Tail Gate Inside Handle Attachment-

Gate Operation

4. Raise inside handle and remove screws securing handle to inner panel and remove handle.

5. To install, reverse removal procedure.

NOTE: Prior to reinstalling inner panel cover, water deflector and access hole cover perform dual acting tail gate lock synchronization checks, as subsequently described.

TAlL GATE LOCK REMOTE CONTROL

ASSEMBLY-GATE OPERATION (CENTER)

Removal

1. open tail gate to gate position.

2. Remove inner panel cover, water deflector and access hole covers.

3. Disconnect remote control to lock connecting rods at remote control assembly by sliding clips out of engagement (Fig. 9-44).

4. Remove remote control to tail gate inner panel attaching bolts (Fig. 9-45).

5. Disengage remote control center handle from push rod and remove remote control and rod assembly

(Fig. 9-44).

Installation

1. With tail gate open in a gate position, manually lock upper right and left locks as shown in Figure

9-36.

CAUTION: With tail gate open in a gate position and upper locks engaged, the tail gate has been placed in a vulnerable position and could drop from the right lower lock if the inside DOOR remote handle was actuated. As a safety precaution, prior to manually locking either right or left upper locks, apply body tape over inside door remote handle to render same inoperable

(See Fig. 9-37).

2. Loosen gate remote control synchronization

(adjusting) screw (left hand thread, refer to

Figure 9-46). The adjusting screw is used to insure that right and left locks and gate control push rod are synchronized.

3. Install .a small nail or cotter pin in gate remote control synchronization (alignment) holes (Figure

9-46). This pin holds all levers in position until final adjustment has been achieved.

NOTE: Service repbcement remote control assemblies are supplied with the cotter pin installed in the alignment hole.

4. Engage remote control with remote control inside handle push rod and install remote control (two bolts) to inner panel.

5. Connect all remote rods and tighten remote synchronization (adjusting) bolt (See Figure 9-49).

6. Remove pin from remote control synchronization

(alignment) hole (See Figure 9-49) and actuate tail gate inside remote control handle (gate operation) to unlock upper right and left locks that were manually locked.

7. Remove tape applied over tail gate inside handle

(door operation) and perform dual acting tail gate lock synchronization checks, as subsequently described.

8. Reinstall access hole covers, water deflector and inner panel cover.

TAlL GATE RIGHT UPPER LOCK

'

ASSEMBLY-

Removal

1. Remove tail gate window and right lower glass run channels as previously described.

9-34 TAIL GATE

Fig. 9-43-Tail Gate Inside Handle and Cable Assembly-Door Operation

2. With tail gate open in a gate position, remove three screws securing lock to tail gate lock pillar panel (Figure 9-47).

3. Disengage tail gate inside handle cable assembly

(door operation) from lock (refer to View "A",

Figure 9-43).

4. Disengage clips securing right upper lock to lower lock connecting rod, remote control to upper lock connecting rod and tail gate window "block-out" rod (Figure 9-48).

5.

CAUTION: DO NOT pull reaxward on the right upper lock to lower lock connecting rod ("8",

Figure 9-48) when disengaging right upper lock from end of rod. Excessive movement of this rod could cause the gate to drop from the right lower lock which could result in personal injury or damage to the tail gate assembly.

On

electric styles, disconnect tail gate cut-out switch (Figure 9-38) and remove lock assembly through access hole.

TAIL GATE 9-35

L E F T LOCK

CONNECTING ROD RIGHT LOCK

CONNECTING ROD

VIEW A

Fig. 9-44-Dual Acting Tail Gate Lock Remote Control Assembly-Gate Operation (center)

Fig. 9-45-Dual Acting Tail Gate Torque Rod Retention

9-36 TAIL GATE

R E M O T E A D J U S T I N G S C R E W

LEFT

H A N D T H R E A D )

Fig. 9-&-Tail Gate Lock Remote Control-Gate

Operation

Installation

1. With tail gate open in a gate position, install screws (three) securing lock to tail gate lock pillar panel (Fig. 9-47).

2. Loosen lower lock to upper lock connecting rod synchronization (adjusting) bolt located on upper lock (Figure 9-49).

3. Engage inside handle and cable assembly, lower lock to upper lock connecting rod, remote control to upper lock connecting rod and block-out rod with right upper lock assembly (Figure 9-48).

4. Manually lock upper right and left locks as shown in Figure 9-36.

CAUTION: With tail gate open, in a gate position, and upper locks manually engaged, the tail gate has been placed in a vulnerable position and could drop from the right lower lock if the inside

DOOR remote handle was actuated, which could result in personal injury or damage to the tail gate assembly. As a safety precaution, prior to manually locking either right or left upper locks, apply body tape over inside door remote handle to render same inoperative (See Figure 9-37).

5.

~ i i h striker, reach through the access hole and hold the lower to upper lock connecting rod forward

(Figure 9-49), then tighten door lock, synchroniza- tion bolt (Figure 9-49).

NOTE: This adjustment is self seeking and should automatically synchronize the right upper and lower locks when the synchronizing (adjusting) bolt is loosened. However, to assure that the levers have automatically assumed their position, it is essential that the upper to lower lock connecting rod be held forward while tightening the synchronizing (adjusting) bolt.

CAUTION: DO NOT pull rearward on the right upper to lower connecting rod during this adjustment. Rearward movement of this rod could cause the tail gate to drop from the right lower lock, which could result in personal injury or damage to the tail gate assembly.

6. With right and left upper locks in a locked position, visually check gate remote synchroniza- tion holes in gate remote control levers (center of gate as shown in Figure 9-49). IF THE HOLES

DO NOT LINE UP, loosen gate remote synchronization bolt (Figure 9-49) by turning to the right (left hand thread), approximately three turns.

7. With gate synchronization bolt loose, check to make certain there is no bind in remote levers.

Align gate remote synchronization holes in remote assembly by inserting a cotter pin through alignment hole in both levers (Figure 9-49). Then, tighten synchronization bolt to27-87 inch pounds and REMOVE CO'ITER PIN.

RIGHT GLASS-

Fig. 9-47-Dual Acting Tail Gate Right Upperand Lowel

Lock Attachment

TAIL GATE 9-37

1. Left Upper Hinge and Lock Assembly

2. Tail Gate Remote to

Left Upper Lock

Connecting Rod

3. Inside Handle (Gate

Operation)

Fig. 9-48-Dual Acting Tail Gate Lock and Remote Control

Linkage

4. Remote to Inside

Handle Push Rod

5. Tail Gate Remote to

Right Upper Lock

Connecting Rod

6. Remote Control

Assembly (Gate

Operation)

7. Inside Handle and

Cable Assembly

(Door Operation)

8. Right Upper to Lower

Lock Connecting Rod

9. Right Upper Lock

Assembly

8. Actuate tail gate inside remote handle (gate operation) to unlock upper right and left locks that were manually locked and remove tape applied over tail gate inside handle (door operation). Perform Dual Acting Tail Gate Lock

Synchronization Checks as subsequently described.

9. Reinstall all previously removed components.

NOTE: Service shims are available for tail gate striker assemblies. These shims are the same parts

10. Right Upper and

Lower Lock

Synchronizing

(Adjusting) Screw

I I . Tail Gate Window

"Block-Out" Rod

12. Right Lower Lock used in body side doors. If installing new l&k, rubber dust seal must be transferred from removed lock.

TAIL GATE RIGHT LOWER LOCK

ASSEMBLY

Removal and Installation

I. 'open tail gate to a door position.

2. Remove inner panel cover, water deflector and access hole cover as previously described.

9-38 TAIL GATE

Fig. 9-49-Dual Acting Tail Gate Lock Synchronization Check

Loosen door lock synchronization (adjusting) bolt

(Figure 9-49).

Remove lower lock cover and disengage upper to lower lock connecting rod (Fig. 9-48).

Scribe (mark) position of lower lock position on tail gate. From underside of tail gate, remove lower lock attaching nuts and screws and remove assembly from tail gate (Fig. 9-47).

To install, engage lock with upper to lower lock connecting rod. Align lock to scribe marks on gate and install lock attaching nuts and bolts.

Close tail gate and open to a gate position.

Manually lock right and left upper locks as shown in Figure 9-36.

9.

CAUTION: With tail gate open and upper locks manually engaged, the tail gate has been placed in a vulnerable position and could drop from the right lower lock if the inside DOOR remote handle was activated, which could result in personal injury or damage the tail gate assembly.

As a safety precaution, prior to manually locking either right or left upper locks, apply body tape over inside door remote handle to render same inoperative (See Figure 9-37).

With the right lower lock fully engaged with the striker, reach through the access hole and hold the lower. to upper lock connecting rod forward

(Figure 9-49), then tighten door lock synchroniza- tion (adjusting) bolt (Figure 9-49).

NOTE: This adjustment is self seeking and should automatically synchronize the right upper and

TAIL GATE 9-39

Fig. 9-50-Dual Acting Tail Gate Left Upper Hinge and Lock Assembly (Typical) lower locks when the 'synchronizing (adjusting) bolt is loosened. However, to assure that the levers have automatically assumed their position, it is essential that the upper to lower lock connecting rod be held forward while tightening the synchronizing (adjusting) bolt.

CAUTION: DO NOT pull rearward on the right upper to lower connecting rod during this adjustment. Rearward movement of this rod could cause the tail gate to drop from the right lower lock, which could result in personal injury or damage to the tail gate assembly.

10. Actuate tail gate inside remote handle (gate operation) to unlock upper right and left locks that were manually locked and remove tape applied over tail gate inside handle (door operation). Perform dual acting tail gate lock synchronization checks, as subsequently described.

11. Reinstall all previously removed components.

TAlL GATE LEFT UPPER HINGE AND

LOCK ASSEMBLY-GATE SIDE

Removal and Installation

1. Open tail gate to a gate position and remove tail gate window as previously described. Scribe

(mark) a line around the outer perimeter of the hinge and lock assembly on the tail gate lock pillar.

2. Bolts "A" and "B" fit into a tapping plate and bolts "C" and "DM are retained by nuts. All bolts are pressed into the lock assembly and removed as a unit

- not separately.

3. Disengage clip securing remote control assembly rod and remove lock assembly (Fig. 9-48).

4. To install, align lock assembly within scribe marks and install attaching bolts and nuts.

NOTE: Torque all nuts to a minimum of forty foot pounds.

5. With tail gate open in a gate position, manually lock right and left upper locks as shown in Figure

9-36.

CAUTION: As a safety precaution, prior to manually locking either right or left upper locks, apply body tape over inside door remote handle to render same inoperative (See Figure 9-37).

With tail gate open and upper locks manually engaged, the tail gate has been placed in a vulnerable position and could drop from the right lower lock if the inside DOOR remote handle was actuated. A tail gate dropping from the right lower lock, when opened in a gate position, could result in personal injury or damage the tail gate assembly.

6. With right and left upper locks in a locked position, visually check gate remote synchroniza- tion holes in gate remote control levers (center of gate as shown in Figure 9-49). If the holes do not line up, loosen gate remote synchronization bolt

(Figure 9-49) by turning to the right (left hand thread) approximately three turns.

0

7. With gate synchronization bolt loose, check to make certain there is no bind in remote levers.

Align gate remote synchronization holes in remote assembly by inserting a cotter pin through alignment hole in both levers (Figure 9-49). Then, tighten synchronization bolt to 57-87 inch pounds and REMOVE COTTER PIN.

8. Actuate tail gate inside remote handle (gate operation) to unlock upper right and left locks that were manually locked and remove tape applied over tail gate inside handle (door operation). Perform Dual Acting Tail Gate Lock

Synchronization Checks, as subsequently described.

9. Reinstall all previously removed components.

Adjustments

The tail gate left upper hinge and lock assembly (gate side) is adjustable up or down and fore or aft.

TAlL GATE LEFT LOWER HINGE

ASSEMBLY

Removal and lnstallation

1. Open tail gate assembly to a gate position and remove tail gate window as previously described.

9-40 TAIL GATE

4. WITH THE AID OF A HELPER, remove left lower hinge to gate attaching bolts.

NOTE: Bolt "A", Figure 9-51, fits into a tapping plate. Bolts "B" and into the hinge assembly and retained to the tail gate by nuts. The pressed bolts are removed with the hinge assembly

- not separately.

5. Remove left lower hinge to body attaching bolts

(Figure 9-52), then, remove hinge from body.

6. To install, reverse removal procedure.

Fig. 9-51-Dual Acting Tail Gate Left Lower

Hinge-Removal (Typical)

2. Raise tail gate assembly to a partially closed position to achieve a neutral torque rod position or until tension on torque rod has been relieved.

Then, with torque rod in a neutral position, remove torque rod assist link retainer to body attaching bolts (Figure 9-47).

3. h e r tail gate and support in a full-open position. Remove support cable to left lower hinge to gate nut (Figure 9-5 1).

TAIL GATE LEFT UPPER HINGE AND

STRIKER ASSEMBLY-BODY SIDE

Removal and Installation

1. With the tail gate properly supported in an open

(gate position) position, remove hinge and striker attaching screws (Figure 9-52) and remove assembly from left body pillar.

NOTE: The support cable sprirg, shown in Figure

9-52, must be reinstalled in depicted position to insure proper movement of cable during gate operation.

2. To install, reverse removal procedure.

Fig. 9-52-Dual Acting Tail Gate Left Upper and Lower Hinge and Support Cable Attachment

Fig. 9-53-Dual Acting Tail Gate Right Upper and Lower Striker Assemblies

TAIL GATE 9-41

NOTE: Shims of 1/4" and 5/ 16" are available as service parts.

NOTE: THIS LOCK STRIKER IS AN IMPOR-

TANT ATTACHING PART IN THAT IT

COULD AFFECT THE PERFORMANCE OF

VITAL COMPONENTS AND SYSTEMS, AND/

OR COULD RESULT IN MAJOR REPAIR

EXPENSE. IT MUST BE REPLACED WITH

ONE OF THE SAME PART NUMBER OR

WITH AN EQUIVALENT PART IF REPLACE-

MENT BECOMES NECESSARY. DO NOT USE

A REPLACEMENT PART OF LESSER QUAL-

ITY OR SUBSTITUTE DESIGN. TORQUE

VALUES MUST BE USED AS SPECIFIED

DURING REASSEMBLY TO ASSURE PROPER

RETENTION OF THIS PART.

TAlL GATE RIGHT UPPER STRIKER

ASSEMBLY

The right upper striker assembly consists of a single metal bolt and washer assembly that is threaded into a tapped floating cage plate located in the back body lock pillar. With this design, the tail gate is secured in the closed position when the right upper tail gate lock fork bolt snaps-over and engages with the striker bolt.

Removal and Installation

1. Mark position of striker on back body pillar

(Figure 9-53).

2. Insert Tool 5-23457 or equivalent into the star shaped tool recess in the head of the striker bolt and remove striker.

To install, reverse removal procedure. Torque lock striker to 36-45 foot pounds.

NOTE: THIS LOCK STRIKER IS AN IMPOR-

TANT ATTACHING PART IN THAT IT

COULD AFFECT THE PERFORMANCE OF

VITAL COMPONENTS AND SYSTEMS, AND/

OR COULD RESULT IN MAJOR REPAIR

EXPENSE. IT MUST BE REPLACED WITH

ONE OF THE SAME PART NUMBER OR

WITH AN EQUIVALENT PART IF REPLACE-

MENT BECOMES NECESSARY. DO NOT USE

A REPLACEMENT PART OF LESSER QUAL-

ITY OR SUBSTITUTE DESIGN. TORQUE

VALUES MUST BE USED AS SPECIFIED

DURING REASSEMBLY TO ASSURE PROPER

RETENTION OF THIS PART.

Adjustments

Right upper striker assemblies are adjustable up or down, fore or aft and outboard by installing spacers beneath the striker washer. Spacers are available as service parts as follows:

A. 5/64" spacer

-

Part No. 4469196 or equivalent

B. 5/32" spacer

-

Part No. 4469197 or equivalent

C. 1/4" spacer

-

Part No. 4469194 or equivalent

D. 5/ 16" spacer

-

Part No. 4469195 or equivalent

TAlL GATE RIGHT LOWER STRIKER AND

SUPPORT ASSEMBLY

Removal and Installation

With tail gate open in a door position, remove step plate and filler panel to gain access to the striker and support assembly.

Scribe (mark) position of striker support on body and remove support (Figure 9-53).

To install, reverse removal procedure.

NOTE: THIS LOCK STRIKER IS AN IMPOR-

TANT ATTACHING PART IN THAT IT

COULD AFFECT THE PERFORMANCE OF

VITAL COMPONENTS AND SYSTEMS, AND/

OR COULD RESULT IN MAJOR REPAIR

EXPENSE. IT MUST BE REPLACED WITH

ONE OF THE SAME PART NUMBER OR

WITH AN EQUIVALENT PART IF REPLACE-

MENT BECOMES NECESSARY. DO NOT USE

A REPLACEMENT PART OF LESSER QUAL-

ITY OR SUBSTITUTE DESIGN. TORQUE

VALUES MUST BE USED AS SPECIFIED

DURING REASSEMBLY TO ASSURE PROPER

RETENTION OF THIS PART.

Adjustments

The striker support is adjustable up or down and laterally. In addition the striker bolt is adjustable laterally through the use of service shims.

TAlL GATE TORQUE ROD AND ASSIST

LlN K

Removal and Installation

Remove tail gate inner panel, water deflector and access hole cover as previously described.

With tail gate open in a door position, remove right lower lock cover, bumperette and step plate.

Remove rear bumper as'follows.

A. Remove the two rearward bumper to frame attaching bolts and loosen the forward two bolts (Figure 9-54).

.

9-42 TAIL GATE

F, R E A R W A R D BOLTS REMOVE) k-

F O R W A R D BOLTS (LOOSEN)

3 7 1 7

Fig. 9-54-Bumper Removal (Typical)

B. Remove the center bumper to frame bolt and lower bumper (Figure 9-54).

4. Close the tail gate and open sufficiently as a gate to achieve a neutral torque rod position or until tension on torque rod has been relieved. With torque rod in a neutral paition; remove torque rod assist link retainer attaching bolts (Figure

9-55) and disengage assist link from end of torque rod.

5. Lower tail gate to a full-open position and remove torque rod retainers along bottom of tail gate assembly (Figure 9-45).

6. Raise tail gate window sufficiently to gain access to the torque rod retainers located inside the tail gate on the right lock pillar. Using a suitable tool, pry the torque rod from the retainers and remove the rod.

NOTE: To raise electrically operated tail gate windows, with the gate open to the gate position, it is first necessary to manually lock both upper locks as shown in Figure 9-36.

CAUTION: As a safety precaution, prior to manually locking either right or left upper locks, apply body tape over inside door remote handle to render same inoperative (See Figure 9-37). A tail gate open, in a gate position, and upper locks manually engaged, the tail gate has been placed in a vulnerable position and could drop from the right lower lock if the inside DOOR remote handle was actuated. A tail gate dropping from the right lower lock could result in personal injury or damage to the tail gate assembly.

1

7. To install, reverse removal procedure.

TAIL GATE ASSEMBLY

Removal and Installation

1. Open tail gate sufficiently (partially open) as a gate to achieve a neutral torque rod position or' until tension on torque rod has been relieved.

With torque rod in a neutral position, remove torque rod assist link retainer to body attaching bolts (Figure 9-52).

2. Support tail gate in a full-open gate position and remove support cable to left upper hinge and striker assembly attaching bolt (Figure 9-52)

3. On styles equipped with electric options in the tail gate assembly, remove the tail gate inner panel water deflector and access hole cover. Then, disconnect wire harness at connectors and pull from tail gate.

4. WITH THE AID OF A HELPER, remove left lower hinge to body attaching bolts (Figure 9-52). in Figure 9-36. Then with the aid of a helper to support the tail gate, actuate the INSIDE DOOR

REMOTE HANDLE (right side) to unlock and free the right lower lock from the striker assembly.

.

Remove gate assembly by lifting upward, then rearward.

6. To install, reverse removal procedure.

Fig. 9-55-Dual Acting Tail Gate Assist Link

Fig. 9-56-Dual Acting Tail Gate Left Upper and Lower Hinge, Lock, and Torque Rod

Attachments

Adjustments

Proper evaluation of a misaligned condition can eliminate performing unnecessary adjustments. To properly evaluate a misaligned tail gate condition, the upper right lock striker should be removed. If the gate, when operated as a door, rides "up" or is pulled

"down" by the lower right lock striker the lower right lock striker and striker support should be loosened completely or the lower striker removed.

NOTE: Prior to performing any adjustments, the position of the hinge, lock or striker to be adjusted should be marked to facilitate realignment from original position.

The lower left hinge-to-body adjustment is the key adjustment for properly positioning the tail gate in the body opening. All other hinge and lock adjustments are for the purpose of providing flush alignment of the tail gate outer panel with adjacent panels and to provide proper operation of the locks.

NOTE: The upper left lock and striker adjustments and the right upper and lower lock striker adjustment are not provided for up or down adjustment of either side of the gate assembly. However, some adjustment at one or more of these locations is usually required when the left lower hinge is adjusted to raise, lower or move the gate sideways in the opening.

1. Lower Left Hinge Assembly at Body Attachment

Adjustable "up" or "down" and "laterally" ("l",

Figure 9-56).

-

TAIL GATE 9-43

To gain access to lower left hinge-to-body attaching bolts, remove rubber hinge cover at left end of step pad. Loosen the four hinge-to-body attaching bolts and adjust hinge "up"; "down",

"laterally" or rotate as required.

Rotating the hinge slightly will raise or lower the right side of the gate. This can be accomplished by loosening the three lower hinge-to-body attaching bolts. Then with the gate open as a door, support the right side of the gate in the desired raised or lowered position and tighten the attaching screws. If this adjustment is performed or if the gate is moved sideways, it may be necessary to also adjust the upper left hinge and lock striker, as described under adjustment "4".

If the lower left hinge is adjusted, "upward" or

"downward", clearance between the upper left lock frame on tail gate and the hinge and lock striker on body pillar should be checked (specified clearance 1/8"

-

7/32"; see Figure 9-57), and, where required, the upper left lock should be adjusted as described under adjusiment "3".

2. Lower Left Hinge Assembly

-

At gate attachment

- adjustable "forward" or "rearward" ("2", Figure

9-56).

0

"Forward" or "rearward" adjustment of lower left hinge at the gate attachment is primarily for flush alignment of tail gate outer panel with adjacent panels in the area of the lower left hinge.

Fig. 9-57-Dual Acting Tail Gate Upper Left

Lock Striker Clearance

9-44 TAIL GATE

The lower left hinge-to-tail gate attaching nuts are located inside the tail gate. To loosen nuts for adjustment of tail gate on hinge, remove tail gate inner cover panel and carefully peel back inner panel water deflector sufficiently to gain access to hinge-to-gate attaching nuts. Adjust gate on hinge as required, then, tighten attaching nuts and reseal water deflector.

3. Upper Left Hinge and Lock Assembly

-

Adjusta- ble "up", "down", "forward" and "rearward"

("3", Figure 9-56).

The "up" or "down" adjustment of the upper left lock is available to provide adequate clearance (1 /

8" to 7/32)') between the bottom of the lock frame and top of the hinge pin and striker plate.

(See Figure 9-57). To check clearance, open gate as a door and measure distance between the upper surface of the upper left hinge pin and striker plate and the lower surface of the upper left lock frame.

The "forward" and "rearward" adjustment of the upper left lock is available to provide a flush alignment of the tail gate outer panel with adjacent body panels in the area of the upper left lock.

Prior to adjusting upper left lock, mark position of lock on tail gate. The lock attaching nuts, are located inside the tail gate. To loosen nuts, remove tail gate inner cover panel and carefully peel back inner panel water deflector sufficiently to gain access to the inner panel left access hole cover. Then, remove cover and loosen hinge-to- gate attaching nuts. Adjust lock, as required, then replace all previously removed parts.

IMPORTANT: After any adjustment of the upper left lock, synchronization of the lock system should be checked and, where required, the lock system should be synchronized as subsequently described.

4. U p p r Left Hinge and Striker Assembly

Adjustable "in" or "out" from body pillar ("4",

-

Figure 9-56).

The upper left hinge and lock striker is not adjustable up, down, forward or rearward, however it is adjustable laterally from the body pillar by means of installing different thickness shims under the assembly.

This adjustment is available to provide proper engagement of the hinge pin and lock striker with the 1ot.k. This adjustment is not intended as a means of raising or lowering the left or right side of the gate.

The different thickness shims are available as service parts as follows:

A. 1/8" shims

-

Part No. 8776037 or equivalent

B. 3/ 16" shims

-

Part No. 8723094 or equivalent

C. 7/32" shims

-

Part No. 8723093 or equivalent

D. 1 /4" shims

-

Part No. 8723090 or equivalent

E. 9/32" shims

-

Part No. 8723091 or equivalent

F. 5/16" shims

-

Part No. 8723092 or equivalent

To determine the correct shim thickness required, open gate as a gate, then, while closing gate, carefully observe how the hinge pin and striker engages in the slot in the bottom surface of the lock. The pin should enter into the slot without any appreciable side pressure.

5. Right Upper Lock Striker Assembly ("5", Figure

9-58)

-

Adjustable "forward" or "rearward", "up" or "down" and "1aterall)l" by u h g spacers.

IMPORTANT: The upper right lock striker should be removed prior to performing any other hinge or lock adjustments.

/

Fig. 9-58-Dual Acting and

Tail Gate Right Upper

Lower Lock Striker

TAIL GATE 9-45

To properly adjust tne upper right lock striker, first open tail gate as a doo,r and remove striker with tool J-23457 or equivalent. Check alignment of gate in body opening. THE GATE SHOULD

BE PROPERLY ALIGNED IN BODY OPEN-

ING PRIOR TO ADJUSTMENT OF STRIKER.

Install striker slightly more than finger tight.

Then, carefully close gate to allow striker to self align. Then, carefully open gate and tighten striker. Operate gate both as a door and a gate and check flush alignment of outer panels in area of striker. If any further minor adjustment is required, mark position of striker on body pillar, loosen striker, make required adjustment from marked position and tighten striker. a. Lower Right Lock Striker

-

Adjustable

"Forward" and "Rearward" ("6", Figure

9-58). b. Lower Right Lock Striker Support

-

Adjustable

"Up", "Down" and "Sideways" ("7", Figure

9-58).

To gain access to lower right lock striker or striker support attaching bolts, open tail gate as a door and remove right step pad and step plate (Figure 9-58). To loosen lock striker attaching nut, use a 3/8" ratchet drive with a universal, 3" extension and 9/ 16" deep socket, as shown in Figure 9-58. To loosen striker support, loosen attaching bolts and move support up and down to make sure it is free.

To adjust lower right lock striker or striker support, loosen striker nut or support bolts.

Then, tighten nut or bolts finger tight and carefully close gate as a door allowing striker or support to self align. Carefully open tail gate as a door and tighten striker nut or support bolts.

Operate gate both as a door and a gate and check both ease of operation and flush alignment of outer panels. If any further minor adjustment is required, mark position of striker on support or support on body cross bars and make required adjustment from marked position as required.

IMPORTANT: Do not use upper right lock striker and/or lower lock striker support adjustments to align right side of gate "up" or

"down" in the body opening.

7. Bumperette

-

Adjustable "up" or "down",

"forward" or "rearward" and "laterally".

To adjust bumperette for proper alignment in the bumper opening, open tail gate as a door and remove bumperette support cover. To adjust bumperette "forward", "rearward" or "sideways" loosen nuts securing bumperette support to bottom of door. To adjust bumperette "up",

"down" or sideways loosen nuts securing bumper- ette to bumperette support. Adjust bumperette for proper Alignment in bumper opening and tighten attaching nuts.

DUAL ACTING TAIL GATE LOCK

SYNCHRONIZATION CHECK AND

PROCEDURE

The lock system on the dual acting tail gate is designed to perform the following two "block-out" functions.

1. Allow the tail gate to be opened as a door and at the same time prevent accidental operation of the upper left lock (which allows the gate to be opened as a gate).

2.

Allow the gate to be opened and closed as a tail gate and at the Sam5 time prevent accidental operation of the lower right lock (which allows gate to be o k n e d as a door).

The above "block-out" functions are accom- plished by levers in the upper right lock. Figure

9-59 shows the upper right lock (in closed door position) and identifies the levers which perform block-out functions.

To assure that the upper right lock levers perform the block-out functions properly, the upper right lock and gate remote control must be synchro- nized with the rest of the tail gate lock system

(lower right lock and upper left lock). This synchronization is required to prevent accidental operation of the upper left lock when the gate is opened as a door and to prevent accidental operation of the lower right lock when the gate is opened as a gate.

IMPORTANT: Whenever any of the locking system components inside the tail gate are serviced, the locking system MUST BE synchro- nized as described under "Lock Synchronization

Procedure".

Lock Synchronization Checks

1. Synchronization check for lower right lock.

A. Open tail gate as a gate (horizontal position).

Take precautions to prevent damage if tail gate should become disengaged from lower right lock by placing a protective support

9-46 TAIL GATE

GATE REMOTE LEVER ROD

WWDOW BMCK-OUT LEVER-

Blocks Out A l l Lock

Levers Unless Window

I s I n Down P o s i t i o n

LOCK DETENT RELEASE AND WINDOW

CUT-OUT SWITCH mVER

With Gate Opened As Door O r

Gate, Lever Depresses s w i t c h ,

I n t e r r u p t i n g Window Motor Up

Cycle C i r c u i t

W m O W CUT-OUT SWITCH

7

Upper Lock

SYNCHRONIZATION ADJUSTMENT BOLT

Lever With Upper Lock

CONNECTING ROD

UPPER-TO-LOWER MCK 1

-

Fig. 9-59-Dual Acting Tail Gate Lock Synchronization Check beneath the gate. Then grasp right inside lock release handle and pull upward until gate is in a vertical position .and close gate. Open gate as a door and close gate.

B. Repeat above procedure (Step 1-A) five times.

If tail gate lower right lock does not become disengaged, synchronization of the lower right lock is correct. If tail gate becomes disengaged at lower right lock, reinstall gate on lower right lock and proceed with "Synchronization

Procedure" as described and illustrated.

2. Synchronization check for upper right and left locks

A. Open tail gate as a door.

IMPORTANT: Place a protective support under

3650 right side of gate in the event gate becomes disengaged from upper left lock.

B. Operate center remote control handle (gate operation) with moderately heavy pressure, then operate the right inside lock release lever

(door operation) in the same manner. Operate both handles at the same time.

C. Close tail gate and repeat above operation

(Step 2-A and B) five times. If tail gate upper left lock does not become disengaged, the upper locks are in synchronization.

If tail gate becomes disengaged at the upper left lock, reinstall gate on upper left lock and proceed with "Synchronization Procedure" as described and illustrated.

TAIL GATE 9-47

Lock Synchronization Procedure

1. Open gate as a door then close gate securely. Open tail gate to "gate" (horizontal) position.

2. Remove tail gate inner cover panel; carefully remove inner panel water deflector or detach water deflector sufficiently to gain access to gate remote control and door lock synchronization bolts. Remove right inner panel access hole cover.

3. Place tape over door lock handle, as shown in

Figure 9-37, to prevent accidental opperation of lower right lock after upper locks have been manually locked as outlined below.

4. Manually lock both upper right and upper left locks as shown in Figure 9-36.

5. With all locks in locked position, visually check gate remote synchronization holes in gate remote control levers (center of gate as shown in Figure

9-49). If holes line up, proceed with step 7. If holes do not line up, loosen (turn to right approximately three turns) gate remote control synchronization bolt (this bolt has left hand threads). With synchronization bolt loose, check that there is no bind in remote levers. Align holes by inserting cotter pin through alignment hole in both levers (Figure 9-49). Then, tighten synchro- nization bolt to 57-87 INCH lbs. REMOVE

COTTER PIN.

6. With all locks in locked position and with the right lower lock securely engaged with the striker, loosen approximately three turns the door lock remote synchronization bolt at the right upper lock (See Fig. 9-49).

This adjustment is "self-seeking" and should automatically synchronize the right upper and lower locks when the synchronizing bolt is loosened. However, to assure that the levers automatically assumed their proper position, reach in through access hole and hold lower-to- upper lock connecting rod FORWARD (Figure

9-49) while tightening door lock synchronization bolt to 76-116 inch lbs. Make sure tab on door lock remote synchranization lever is properly engaged in hole (See Figure 9-49).

NOTE: The action of loosening the lock synchro- nization bolt can readily unlock the right lower lock causing the right side of the gate to disengage from the lock striker. To help prevent this from occuring, reach through access hole and hold the upper-to-lower lock connecting rod (See

Fig. 9-49) FORWARD while loosening synchroni- zation bolts.

If lower right lock should unlock and become disengaged from striker, lift right side of tail gate up and forward to re-engage lock with striker.

7. Unlock upper locks by actuating tail gate handle

(at center of gate).

8. Remove tape from door handle and close gate.

9. Perform lock synchronization checks, check window operation.

10. Reseal tail gate inner panel water deflector and install tail gate inner cover panel.

9-48 TAIL GATE

DUAL ACTING TAIL GATE DIAGNOSIS AND SERVICING PROCEDURES CHART

CONDITION APPARENT CAUSE CORRECTION

1. Gate does not open as a gate. I. Glass blockout lever of upper right hand lock not actuated.

NOTE: This condition pre- vents tail gate from operating

:ither way.

(A) Check to see if the glass blockout rod is installed and attached to the lever of the up- per right hand lock.

2. Lower right hand lock not locked.

3. Synchronization (adjusting) screw of the remote control . loose (located at center of tail gate).

(B) Check if the glass is in the fu down position.

(A) Check if the lower right hand lock is locked by visually in- specting the fork bolt of the lower lock. If the fork is vi- sible and approximately flush a with the rear of the lock hous- ing, the lock is locked. If the fork bolt is considerably for- ward or not visible, the lock is unlocked. (This check can be per- formed with bumper removed).

(B) Open as a door and slam it tc lock.

(C) If the lock still is unlocked, the lower striker should be adjusted aft.

NOTE: This condition can be determined by trying to unlock the upper locks. Only the up- per left hand hinge lock will unlock.

(A) With gate fully closed, remove the tail gate inner panel cover, water deflector and right hand access hole cover.

(B) After removing these parts, reach through the access hole and carefully, so as not to bend, pull the upper right hor- izontal lock rod towards the centerline of the body while simultaneously pulling gate handle. Open to gate position.

(C) Synchronize locks as outlined in lock synchronization pro- cedure.

(D) Make lock synchronization check.

TAIL GATE 9-49

DUAL ACTING TAIL GATE DIAGNOSIS AND SERVICING PROCEDURE CHART

CONDITION APPARENT CAUSE

4. Horizontal lock rods and/or vertical rod from center han- dle to remote control not in- stalled and/or attached.

CORRECTION

(A) This condition is charac- terized by the failure of the upper right hand lock and/or left hand lock to unlock. Check for unattached or missing rods. If either of the upper horizontal lock rods is unat- tached or missing, attach or replace and then follow the up- per lock synchronization pro- cedure as previously described.

NOTE: Rod attachment must be made with gate fully closed.

(A) Follow procedure outlined in

Condition 1, Solution "A and

"B".

!. Gate does not open as a door. Glass blockout lever of upper hand lock not actuated,

OTE: This condition pre- ents tail gate from operating ither way.

I .

Upper right hand striker too far rearward. (Gate out-of- flush and/or chucks at right upper corner).

3.

Upper locked. left hand hinge lock not

4. Cable from door handle to up-

per

right hand lock detached.

(A) This copdition can prevent the upper left hand hinge lock from locking. Readjustment of the right hand upper striker for- ward is necessary to allow both upper locks to lock.

(A) Check for unlocked upper left hand lock by pulling on corner of gate (gate will chuck if unlocked).

(B) Open gate and slam hard to lock.

(C) If the lock is still unlocked, the gate side upper left hinge and lock assembly will have to be adjusted forward as outlined under adjustment of left upper hinge and lock assembly.

(A) Check for loose cable by open- ing the gate and pulling on door handle. If the handle opens easily to approximately

90 degrees to the inner panel surface and by pulling on the cable it readily pulls out, the cable is loose and must be attached to the stud of the upper right hand lock. (Refer to inside- handle and cable assembly-door operation).

9-50 TAIL GATE

DUAL ACTING TAIL GATE DIAGNOSIS AND SERVICING PROCEDURE CHART

CONDITION

'

APPARENT, CAUSE i. Rod from upper right hand ock to lower right hand lock letached.

CORRECTION

(A) Determine if rod is detached by visual inspection. If unat- tached:

1. Open tail gate as a gate.

2. If rod is disconnected at upper lock, attach rod by moving the lever of the upper lock to the position of the rod.

NOTE: DO NOT PULL UP

ON THE LOCK ROD AS

THIS WILL UNLOCK THE

LOWER LOCK.

3. If rod is disconnected at lower lock, push rod forward to engage lock lever. Hold lock lever forward while engaging rod.

6

NOTE: DO NOT MOVE LOWER

LOCK LEVER REARWARD AS

THIS WILL UNLOCK LOWER

LOCK AND DROP GATE ON

BUMPER.

4. Be sure the lower lock is fully locked by pulling it against the striker.

5. Tighten the set screw in the upper lock (right hand thread).

6. Make lock synchronization check.

. With door open and center

~andle is pulled, gate unlocks upper left hand hinge and x k assembly).

1. Right hand lock synchronization screw loose.

1. Synchronize .both right hand locks as specified in lock synchronization procedure.

2. Improper synchronization of upper locks.

3. Bent upper horizontal lock rods (caused by using rods to unlock gate).

2. If loose, follow procedure outlined above in 2-5 (A).

(A) Refer to lock synchronization procedure.

(A) Replace rod and re-synchro- nize locks as outlined in lock synchronization procedure.

TAIL GATE 9-5 1

DUAL ACTING TAIL GATE DIAGNOSIS AND SERVICING PROCEDURE CHART

4. With gate open and door han- dle is pulled, lower right lock unlocks.

I .

Improper synchronization of lpper locks (loose set screw).

!. Bent vertical lock rod (caused

>y using rod to unlock door).

I. Improper synchronization of

.ight hand locks.

(A) Synchronize locks by following procedure outlined in lock synchronization procedure.

(A) Replace rod and re-synchro- nize locks by following lock synchronization procedure.

(A) Synchronize locks as outlined in lock synchronization pro- cedure.

I . Tail gate window cut-out switch noperative.

1. Open tail gate as a gate. Re- move inner cover panel and water deflector.

2. Insert bare end of a tape in- sulated welding rod through belt glass opening into BLUE

WIRE connjctor on regulator motor.

1. Window regulator motor noperative.

3. Ground negative pole of 12V battery to tail gate.

4. Raise glass by connecting oth- er end of welding rod to posi- tive pole of battery.

5. Replace cut-out switch as pre- viously described.

1. Refer to "Tail Gate Window

Electric Regulator Motor As- sembly Removal.

HEADLINING 10-1

SECTION 10

INDEX

SUBJECT PAGE

Headlining

-

Cloth and Vinyl Coated (Soft) -

All Styles Except 36-66'' Station Wagons ..... 10-1

Description

................................................................

Removal

.....................................................................

1 0-1

Installation

................................................................

10-4

Headlining "56-66" Station Wagon Styles ........ 1 0-7

Description ......................... ....................................... 1 0-7

Front Headlining Assembly

Removal

................................. 10-7

.................................................................. 1 0-7

SUBJECT PAGE

Installation .............................................................. 10-7

Rear Headlining Assembly

Removal

..................................

10-7

..................................................................

10-7

..............................................................

Installation

One Piece Formed Headlining

Description

.............................

10-9

10-9

..............................................................

1 0-9

Removal

....................................................................

10-9

Installation

................................................................

10-9

DESCRIPTION

HEADLINING-CLOTH AND VINYL COATED

(SOFT)

-AH

Styles Except 56-66 Vista

Cruiser Station Wagons

Quarter upper trim is covepd in "Door and Quarter

Trim" section.

The headlining assembly is contoured to the inner surface of the roof panel by listing wires. The listing wires are attached to the headlining by concealed listing wire pockets which are part of the headlining.

The ends of the listing wires are secured in holes at the side roof rail or by use of clips which are attached to the side rail with screws.

Removal

1. Place protective coverings over seat cushions and backs.

2. Prior to removing headlining, remove following hardware and trim assemblies if installed over headlining. On certain styles, the listing wires are further attached to the roof panel by snap-in type clips which are secured to the longitudinal roof bow (Fig. 10-1, View

"C").

Windshield side and upper garnish moldings or finishing lace.

When finishing lace is used at the windshield and back window or back body opening, the headlining is attached at those areas with non-staining adhesive.

Rear view mirror support.

Sun shade supports.

Where garnish moldings are utilized the headlining is tacked or stapled in addition to being cemented at the windshield and back window or back body openings

(See Fig. 10- 1, View "A").

Dome or rear quarter courtesy lamps.

Coat hooks.

The headlining is retained along the side roof rails by cement or the use of a pronged retainer. Depending upon style, garnish moldings or finishing lace is also used to assist in retaining the headlining. The side roof rail garnish moldings are secured to the headlining retainer by clips which are located in the molding (See Fig. 10-3).

At the roof extension area, the headlining is secured either by cement to a metal retainer or by tacks or staples to a trim stick.

Side roof rail moldings or finishing lace.

Back window garnish moldings or finishing lace. h. Center pillar upper, trim assembly. i. Rear quarter trim, where necessary. j. Quarter upper trim finishing panel.

HEADLINING 10-3

SLOT IN ROOF FOR

-/

WIRE SUPPORT /

-

ON

- -

I

LISTING WIRE SUPPORT

INSTALLED ROOF PANEL

VlEW "A"

-

TYPICAL OF ALL LISTING

WlRE SUPPORT LOCATIONS

VlEW "8"

Fig. 10-2-Typical Cloth or Vinyl Headlining Installation - "B, C, F and E" Body Styles

10-4 HEADLINING

Fig. 10-3-Side Roof Rail Garnish Moldings k. Back body opening garnish moldings or finishing lace.

1. Shoulder strap anchor plate and escutcheon.

3. Carefully remove tacks or staples securing headlining at windshield and back window opening or back body opening.

4. On styles using pronged retainer, use headlining inserting tool, 5-2272 or similar wide-bladed tool and carefully disengage headlining from pronged retainers where present.

5. Carefully detach cemented edge of headlining around entire perimeter.

6. On "A, X and D" Styles

- starting at front of body, carefully disengage No. 1 and No. 2 listing wires from side roof inner rails and from plastic supporting clips on roof bows on styles so equipped (See Fig. 10-1, View "C"). In like manner, working from rear of body, disengage listing wires from side roof rails and supporting clips on longitudinal bow. Exercise care to keep headlining material clean by gathering or folding headlining with listing wires on outside.

On "B, C, E and F" Styles

- starting at front of body, care- fully detach headlining and plastic supports from retaining slots in roof panel. (See

Fig. 10-2, View "A"). Exercise care to keep headlining material clean by gathering or folding headlining with listing wires on outside.

7. Depending on style, bend down tabs securing No.

3 listing wire or disengage No. 3 listing wire from plastic clips on structural bow and remove headlining assembly from body.

IMPORTANT: On "A, X and D" body styles note in which holes listing wires are installed in side roof rails. Listing wires should be placed in same hole when replacing headlining.

8. If replacing headlining, remove listing wires from pockets of old headlining.

IMPORTANT: Listing wires removed from old headlining must be installed in corresponding pockets of new headlining.

Installation

1. If previously removed, install listing wires into corres-ponding pockets of new headlining assem- bly. On "A, X and D" body styles check that plastic clips are installed in roof bow slots. On "B,

C, E and F" body styles install (slide on) plastic supports on headlining pockets after listing wires have been installed in pockets.

2. Apply an approved non-staining trim cement to headlining surface at windshield, side roof rail and back window or back body opening. On styles that utilize finishing lace be certain cement is applied to both sides of retainers (See Fig. 10-1,

View "A").

3. On "A, X and D" body styles proceed as follows:

A. Lift headlining assembly into body and install

No. 3 list- ing wire and listing wire pocket over metal tabs at roof bow and bend up tabs to secure wire to bow. On styles that incorporate plastic clips in place of metal tab, snap No. 3 listing wire into clips (See Fig. 10-

1, View "B" and "C").

B. Working rearward from No. 3 listing wire, install listing wires in side roof rails and snap listing wires into plastic clips on roof bows. In like manner, working forward, install remain- ing listing wires (See Fig. 10-1, View "C").

NOTE: Listing wires may be adjusted up or down by utilizing appro- priate holes in side roof rails. Listing wires should rest tight against roof panel after installation (See Fig.

10-1, View "D").

4. On "B, C, E and F" body styles proceed as follows:

A. Lift headlining assemby into body; then, starting at rear listing wire and working forward install plastic supports with headlin- ing attached into retaining slots in roof panel

(Fig. 10-2, View "A" and "B").

5. Stretch and secure headlining at windshield first; then, back window or back body opening. Stretch and secure headlining at rear quarters and side roof rails. Permanently attach material removing draws and wrinkles and replace all previously removed inside hardware and trim assemblies.

HEADLINING 10-5

VIEW "A"

E N G A G E MATERIAL UNDER

VlEW

"0"

VlEW

"C"

(LEFT SIDE)

VlEW

"C"

(RIGHT SIDE1

451 9

Fig. 10-4-Headlining Installation

-

"DM

10-6 HEADLINING

VIEW. "E"

Fig. 10-5-Headlining Installation

-

"DM

SLlT AND HOOK LISTING WlRE

OVER TAB ABOVE BACK WINDOW

SLlT AT AIR DUCT, CEMENT EDGES, FOLD

EDGES INTO OPENING AND SECURE

INSTALL LISTING WlRE

POSITION TO CEMENTED

TRIMSTICK AND STAPLE OR TACK

HEADLINING 10-7

HEADLININGS-56-66

Station Wagon Styles

DESCRIPTION

The 36-66'' station wagon styles use two separate headlining assemblies which may be removed and replaced separately. The front headlining is formed to the contour of the roof panel by concealed listing wires. The ends of the listing wires are installed into holes in the side roof inner rails, and may be adjusted up and down or fore and aft (View "B", Fig. 10-6).

The headlining material is cemented to metal retainers and side roof rail pinchweld flanges (View "A", Fig.

10-6. Escutcheons, moldings and finishing lace cover the edges and assist in holding the material in place.

The rear headlining is formed to the contour of the roof panel by concealed listing wires. The ends of the listing wires are installed into clips which are secured to the side roof inner rails by screws (View "EM, Fig.

10-6). The edges of the material are cemented to the retainer flanges. Finishing lace and moldings cover the edges and assist in holding the material in place.

IMPORTANT: Clean hands are essential when working with headlining material.

FRONT HEADLINING ASSEMBLY

Removal

1. Place protective covers over fronrseat cushion and back.

2. Prior to removal of the front headlining, remove the following items: a. Sunshade supports. b. Rear view mirror support. c. Windshield upper corner escutcheons. d. Center lock pillar upper finishing plates. e. Side skylight front upper garnish molding. f. Courtesy lamps. g. Front headlining finishing lace. h. Rear of headlining finishing lace. i. Finishing lace over front and rear doors. j. Shoulder strap anchor plate and escutcheon.

3. Starting at front, carefully detach all cemented edges of headlining material from retainers and flanges.

4. Disengage No. 2 listing wire from plastic clips on structural bow and remove No. 1 and 2 listing wires from inner rails. Gather or roll headlining with listing wires on outside to keep head- lining clean and remove old headlining assembly (See

Fig. 10-6, View "C").

IMPORTANT: Note into which holes ends of listing wires are installed in side roof rails. Listing wires should be placed in same holes when replacing headlining. If replacing headlining remove listing wires from pockets of old headlining.

Installation

1. If previously removed, install listing wires into pockets of headlining.

IMPORTANT: Listing wires removed from old headlining must be installed in corresponding pockets of replacement headlining.

2. Apply approved trim cement to headlining attaching surfaces.

3. Apply approved trim cement to metal retainers and flanges.

4. Lift headlining into body, install No. 1 and 2 listing wires into holes in side roof rails and snap

No. 2 listing wire into plastic clips on structural bow (See Fig. 10-6, View "B" and "C").

NOTE: Listing wires should rest tight against roof panel. Working from front to rear, attach headlining to retainers and flanges while stretch- ing and removing wrinkles. Reinstall all previ- ously removed parts.

REAR HEADLINING ASSEMBLY

Removal

1. Plav protective covering over seats and floor.

2.

Prior to removing headlining, remove the following items: a. Sunshade supports lbcated at the front skylight. b. Side skylight front upper garnish molding.

10-8 HEADLINING

Fig. 10-6-Headlining Installation "56 and 66" Styles

HEADLINING 10-9 c. Rear roof headlining trim finishing molding. d. All finishing lace around perimeter of headlining. e. Coat hooks.

Carefully detach headlining at cemented edges.

Starting at front remove listing wires from roof inner rails (See Fig. 10-6, View "E").

At rear listing wire, bend down tabs securing wire to bow (See Fig. 10-6, View "F").

Gather or roll headlining with listing wires on outside to keep headlining clean and remove headlining assembly from car.

Installation

1. If previously removed, install listing wires into pockets of new headlining assembly.

IMPORTANT: Listing wires removed from old headlining must be installed in corresponding pockets of new headlining.

2. Apply an approved trim cement to attaching surfaces of headlining material.

3. Apply an approved trim cement to retaining flanges of roof panel.

4. Lift headlining into body, install center of rear listing wire over metal tabs at rear bow and bend down tabs (See Fig. 10-6, View "F").

5. Working forward install remainder of listing wires into clips and secure clips to roof (See Fig. 10-6,

View "E").

6.

Listing wires must rest tight against the roof. If necessary adjust listing wires by moving clips at attaching screws.

7. Attach entire perimeter of headlining to retaining flanges, removing wrinkles by stretching the material as required.

8. Replace previously removed parts.

ONE-PIECE

DESCRIPTION

The one piece formed headliner consists of molded fiber glass covered with foam and nylon facing. The headliner is held in place by two (2) snap fasteners located on the longitudinal roof bow, and two (2) screws located in the quarter inner upper panel area.

The one piece construction requires the headliner be serviced as a complete assembly in all cases.

Removal

1. Remove the following items: a. Courtesy lamps. b. Rear view mirror support. c. Coat hooks. d. Upper quarter trim finishing panels. e. Side roof rail moldings. f. Windshield and back window garnish moldings. g. Shoulder strap anchor plate and escutcheon. h. Windshield side garnish molding. i. Sunshade support brackets.

Remove the screws located in the upper rear corner of the headlining (See Fig. 10-7, View

"D").

NOTE: These screws are exposed after upper quarter trim finishing panel is removed (see

"Door and Quarter" section).

Disengage the snap fasteners and carefully lower headliner from roof panel (See Fig. 10-7, View

"E" and "B").

Lower all windows on both sides of car to the full down position and remove headlining through window openings.

Installation

1. Load headliner into car through side window openings.

2. Raise one side of headliner to side roof rail, and then the other side.

NOTE: Headlining must be loaded from the side and positioned to rest on side roof rails.

10- 10 HEADLINING

3

V l E W D

0

9

VlEW E

3 4 2 5

1. Windshield

2. Sunshade Bracket

Holes

3.

4.

5.

Roof Bow

Snap Fastener

Headliner

Fig. 10-7-One Piece Headlining

6. Side Roof Rail

7. Coat Hook

3. Align holes in rear of headlining with piercing in rear quarter, and cut-outs for sunshade brackets at attaching location.

4. Install screws in the sail area and sunshade brackets (See Fig. 10-7, Views "A" and "D").

5. Install all previously removed hardware.

8. Quarter Inner Upper

9.

Panel

Retaining Screw

6. Engage snap fasteners (see Fig. 10-7, View "B" and "E") by placing flat of hand on back side of snap fastener and press upward until it engages.

IMPORTANT: TO AVOID DAMAGE OF CLIPS,

DO NOT ENGAGE BY EXSERTING HARD

STRIKING WITH ANY TYPE OF TOOL OR

HAND.

ROOF 11-1

SECTION 1 1

ROOF

SUBJECT PAGE

Fabric Roof Cover

...................................................

11-1

Description

..............................................................

11-1

Removal

....................................................................

1 1-1

Installation-Styles with Pad and/or Pad with

Roof Panel Moldings

.........................................

11-2

Installation-Styles without Pad-with or without

Roof Panel Moldings

..... .......................................

11-6

Fabric Roof Cover Discrepancy Repair

Description

.............

11-1 1

................................................................

Repair Utilizing Teflon Coated Graining

Tool

.......................................................................

11-12

INDEX

SUBJECT PAGE

Equipment and Material Requirements

...........

11-12

Repair Procedure

....................................................

1 1-1 3

Repair Utilizing Fabricated Plastic Graining

Die

..............................................................................

11-15

Equipment and Material Requirements

...........

11-1 5

Repair Procedure

....................................................

Repair of Cuts on Padded Roof Covers

1 1-1 5

.........

1 1-1 6

Repair

........................................................................

Luggage Carrier

1 1-16

........................................................

FABRIC ROOF COVER

DESCRIPTION

The roof panel cover is a vinyl coated fabric made in sections and is either dielectrically bonded or stitched together to form an assembly. The cover assembly is then applied to the roof panel with a. non-staining vinyl trim adhesive. On all styles, except Cadillac

68169 and Cadillac and Oldsmobile "E" styles, the cover assembly is cemented directly to the roof panel.

On Cadillac 68169 and 69347 and Oldsmobile "E" styles, a three piece pad is cemented to the roof panel and then the cover is applied over the pad and cemented along the outer perimeter only (Refer to

Figure 11-1).

The type of molding treatment determines whether the cover extends into the windshield opening and drip molding. All covers regardless of molding treatment extend into the back window openings.

On styles where the cover extends into the windshield and back window opening, the cover is retained in the opening by cement, clips installed over weld-on studs and drive nails. When the coyer extends into the drip molding or folds around the roof panel flange, it is retained by drip scalp moldings, weatherstrip retainers or finishing moldings.

On styles equipped with roof panel ("halo") moldings, the cover is retained under the moldings by cement and clips installed over weld-on studs. On styles utilizing a pad, a metal retaining strip is installed onto weld-on studs and held in place with slide-on retaining washers.

I

I

#

Removal

1. The following parts must be removed prior to removing the fabric roof cover. a. Upper and both side windshield and back window reveal moldings (except on styles where the cover does not extend into the windshield opening). b. Roof drip molding scalps, weatherstrip retain- ers or finishing moldings (when cover extends into drip molding or folds around the roof panel flange). c. Rear quarter belt reveal moldings and rear end belt reveal moldings.

FABRIC ROOF COVER PADS

(CONSIST OF THREE PIECES)

- - ---

Fig. 1 1-1-Tmical Fabric Roof Cover Pads

1 1-2 ROOF d. Roof cover retainer to rear body lock pillar (on styles so equipped). e. Roof extension panel emblem or nameplate assembly (if present). f. All roof panel moldings and molding retainers

(on styles so equipped). g. Quarter window lower belt reveal molding (on styles where fabric cover extends under molding). h. On "B" body station wagon styles, remove back body opening and quarter window reveal moldings.

2. Remove reveal molding clips across top and sides of windshield, quarter or back glass openings. On styles where fabric cover extends below back window remove reveal molding clips along bottom of back window opening. Clean off any excess adhesive caulking material adjacent to fabric roof cover material.

NOTE: In the event a repair type clip has been installed and retaining screw is not accessible, carefully trim roof cover around clip.

3. Remove all drive nails that are present in windshield and back window opening and at roof extension area.

IMPORTANT: When removing drive nails, the edge of glass must be protected.

-0 to three layers of cloth body tape should provide the necessary protection.

NOTE: Drive nails can best be removed by first driving a screwdriver or suitable tool under the nail heads to loosen them. Diagonal cutters or similar tool can then be used to grasp nails and twist them out. Unnecessary enlargement of holes in roof panel should be avoided.

4.

Prior to removing fabric cover, application of heat to cemented areas will permit easier loosening of cemented edges.

IMPORTANT: Heat may be applied by lamps held

18" (minimum) from fabric only until fabric is warm. If lamps are held too close or fabric cover is heated over 200 degrees fahrenheit, the fabric may lose its grain, blister, or become very shiny.

5. Loosen all cemented edges of fabric roof cover, then, carefully remove fabric cover from remain- ing cemented area of roof panel.

IMPORTANT: On styles where a pad is present, exercise care when removing fabric cover to avoid damage to the pad.

6. On styles equipped with pad, inspect padding and replace any damaged area. Padding may be removed by applying xylol solvent such as 3M

Adhesive Cleaner, or equivalent, to affected area.

Allow solvent to dissolve adhesive and remove padding. Exercise care to avoid softening of roof panel paint finish.

7. Replace pad by cementing pad to roof panel with nitrile vinyl trim adhesive:

Installation-Styles with Pad and/or Pad and Roof Panel Moldings

1. Completely mask off area of roof panel which is not covered by fabric cover. On Oldsmobile and

Cadillac "E" styles, extend tape over windshield upper reveal molding so cement will not contact paint or adhesive caulking material.

2. Where possible, install new cover at room temperature (approximately 72 degrees), to permit easier fitting and removing of wrinkles from new cover assembly.

NOTE: Where new cover is installed at tempera- tures below 72 degrees, fabricated pliers will aid in removing wrinkles (See Fig. 1 1-2).

3. Determine center line of roof panel by marking center points on windshield and back window opening with tape or equivalent.

4. Lay

cover on roof panel and fold cover lengthwise, precisely at center location. Mark center location at front and rear of cover. In addition, on 68169 styles, mark center location of right and left body center pillar.

5. Remove cover from roof panel and lay cover with lining side upward on a clean flat surface.

6. Apply nitrile type vinyl trim adhesive to that part of lining side of cover that will contact the metal portion of the roof panel. On styles with pads, cement should be applied so it will overlap the pad approximately

1

" (Figure 1 1-3). adhesive be applied with a spray gun. As an alternate method, a brush or roller may be used.

If spraying method is utilized, a spray gun with a pressure cup and specific Fluid Tip and air cap should be used as shown on chart below (or equivalent).

ROOF 1 1-3

Gun Model.

Devil biss Binks

. .

MBC-510 JGA-502 62 18

1 Qt. Pressure. KB-519 KB319 80-256 80-210

Air Cap.

. . . .

Fluid Tip..

.

.

. .

24

E

Fluid Needle.

.

E

24

E

E

66PG 66PG

66

365

66

65

The recommended air pressures are as follows:

A. Air Line Pressure

-

50 lbs.

B. Cup Pressure

-

2 to 4 lbs.

Permalastic, 3M Vinyl Trim Adhesive or equiva- lent purchased in the field is of spraying consistency. If rolling method is used, a mohair type roller should be utilized. Make certain cement is applied evenly and there are no highlights from excess cement build-up.

7. Allow cement on fabric roof cover to dry thoroughly.

8. Lay cover on roof panel and align to correspond with centerline(s) of roof panel. Determine proper material overhang at back window openings

(approximately 2" overhang at seam area at back window) and at center pillars on 68 169 styles.

9. Cut relief notches in cover at all weld-on studs and angle cuts as required in corners of window openings (Figure 11-4). Apply cement to window openings and cement cover in opening. In the event a reveal molding clip could not be removed, trim cover around clip and cement cover down behind clip (See Fig. 11-3).

10. protect the edge of back glass and install drive nails at seam locations, as low in opening as possible.

11. Apply cement to one side of exposed roof panel where cover is attached (on padded styles, make certain cement overlaps pad approximately 1 ") and cement cover to cemented areas. Relief notches must be cut in cover at weld-on studs on roof panel (View "A", Fig. 1 1-3).

12. Repeat step 11 on opposite half of roof panel.

13. Install drive nails, approximately 3" apart and two in each upper corners, across top and down sides of back window opening on Cadillac 68169 and

Oldsmobile and Cadillac "E" styles. In addition, install drive nails across top of windshield opening on 68169 styles (refer to View "D"

Figure 11-3 for Oldsmobile and Cadillac "E" styles and View "A" and "G", Figure 11-4 for

68 169 styles).

14. Carefully install drive nails as low as possible above each reveal molding clip that could not be removed.

NOTE: When installing drive nails it is best to first use an awl or similar tool to initiate a hole in metal. Strike drive nails only hard enough to seat them. Installation of drive nails should also be as low as possible in back window opening.

15. Apply cement to roof extension areas overlapping pad by 1" and below back window opening.

16. Cement cover below back window opening, and then in roof extension area (right and left side).

NOTE: Cement cover at roof extension areas by pulling cover down and rearward. When opera- tion is completed, fabric cover should be free of all wrinkles and draws in this area.

17. On styles equipped with roof panel moldings, position roof panel molding retainers over weld- on studs and install retaini clips.

18. Trim fabric cover in a line along retainers. DO

NOT DAMAGE PWNT

FINTSH.

~t front

Fig. 11-2-Fabric Roof cover Pliers

1 1-6 ROOF corners, raise cemented edge of cover and using scissors or sharp knife cut radius so roof panel moldings cover cut edge. Recement fabric cover to roof panel. Remove masking tape from roof panel (View "A", Fig. 11-3).

On 68169 styles, apply cement to the body center pillars and around the edge of the roof panel flange at the side rails and cement the cover into position.

Trim material along belt line at roof extension area and below back window, along rear end belt molding area. If it is necessary to trim material from outer edge of fabric cover around back window openings, raise cemented edge and cut as required.

Apply a "film" coat of silicone sealant such as

Dow Corning Automotive Sealant, General

Electric RVP Sealant, or equivalent over drive nails and to edges of cover in windshield and back window openings, at belt area and at edges under roof panel moldings. Make certain edge of material around all reveal molding clips that were

Remove all previously installed protective covering from glass and body.

Install all previously removed moldings and assemblies.

NOTE: Normally, minor creases of fold marks will gradually disappear after cover assembly has been in service.

Installation

-

Styles Without Pad (With or Without

Roof Panel Moldings)

1. Completely mask off areas of roof panel which are not covered by fabric cover. Mask upper windshield or reveal moldings, windshield glass, back window, all doors and flat painted surfaces

(hood, rear compartment lid, etc.).

2. Check all cementing surfaces on body to insure a smooth surface. Cementing surface must be smooth to prevent "highlighting" of excess cement through fabric cover after new cover has been installed. Clean off old cement as required.

In the event any metal finishing is performed on roof panel, repaired area must be painted.

NOTE: A xylol solvent such. as 3M Adhesive

Cleaner or equivalent should be used to remove or smooth out excess old cement. Apply solvent and allow to soak before rubbing.

IMPORTANT: Be certain to follow manufacturer's directions when using cleaner.

Where possible, install new cover at room temperature (approximately 72 degrees), to permit easier fitting and removing of wrinkles from new cover assembly.

NOTE: Where new cover is installed at' tempera- tures below 72 degrees, fabricated pliers will aid in removing wrinkles (See Fig. 11-2).

Determine centerline of roof panel by marking center points on windshield and back window opening with tape or equivalent.

Lay cover on roof panel and fold cover lengthwise, precisely at center location. Mark center location at front and rear of cover. On station wagon styles, mark center location on right and left rear body lock pillar.

Remove cover from roof panel and lay cover with lining side upward on a clean flat surface.

Apply an even application of nitrile non-staining vinyl trim adhesive (such as 3M Vinyl Trim

Adhesive, Permalastic Vinyl Trim Adhesive or equivalent) over entire lining side of fabric cover.

NOTE: It is recommended thtt the' vinyl trim adhesive be applied with a spray gun. As an alternate method, a brush or roller may be used.

If spraying method is utilized, a spray gun with a pressure cup and specific Fluid Tip and air cap should be used as shown on chart listed and previously described.

Permalastic. 3M Vinyl Trim Adhesive or equiva- lent purchased in the field is of spraying consistency. If rolling method is uqed, a mohair type roller should be utilized. Make certain cement is applied evenly and there are no highlights from excess cement build-up.

Allow cement on fabric roof cover to dry thoroughly.

Lay cover on roof panel and align to correspond with centerline of roof panel. Determine proper material overhang to windshield and back window openings (approximately 2" overhang at seam area at back window and windshield opening).

Fold one half of cover back at centerline and apply nitrile type vinyl trim adhesive to exposed half o f roof panel (Do not include drip molding or roof extension area). Starting in center at centerline and working toward drip molding, cement cover to area while cement is wet. As cover is being "unfolded" and cemented, it should be thoroughly "slicked" down to avoid wrinkles or air bubbles.

11-8 ROOF

11. Repeat Step 10 on opposite side of roof panel.

NOTE: Make certain that cover is free of wrinkles and seams are straight. Fabric cover pliers may be used in aiding removal of wrinkles.

12. On styles where the cover extends into window openings, perform the following (Fig. 11-5): a. Cut relief notches in cover at weld-on studs across top of back window or back body opening. Also, angle cut in comers as required.

b.

Apply cement across the top back window or back body opening and cement cover. In the event any reveal molding clips could not be removed, trim cover around clip and cement cover down behind clip. .

NOTE: Make certain a continuous and positive bond exists when cementing cover in the back window back body opening.

13. Apply cement to roof extension areas and below back window opening on styles where cover extends below back window.

14. On styles where cover extends below back window opening, cement cover in that area prior to performing Step 15.

,

15. Cement cover at roof extension areas by pulling cover down and rearward. When operation is completed, fabric cover should be free .of all wrinkles and draws in this area.

16. Cement cover into side of back window opening.

If weld-on studs are present, cut relief notches in cover.

17. On styles where roof panel cover extends down windshield pillar, cement fabric roof cover to windshield pillar.

18. On styles equipped with roof panel moldings, trim fabric cover in a line slightly outboard of weld-on studs on roof panel. DO NOT DAMAGE PAINT

FINISH. At front corners, raise cemented edge of cover and using scissors or sharp knife cut radius so roof panel moldings cover cut edge. Recement fabric cover to roof panel. Remove masking tape from roof panel (Fig. 11-8).

19. On all styles, trim material along belt line at roof extension area. On styles where fabric cover extends below back window, trim cover along rear end belt molding area. If it is necessary to trim material from outer edge of fabric cover around windshield or back wind06 opening, raise cemented edge and cut as required.

V I E W A

V I E W B

V I E W C V I E W C

Fig. lld-Typical Fabric Roof Cover Installation Without Pad or Roof Panel Moldings -

"A, B, C and F Styles

11-10 ROOF

ROOF 11-11

L

TRIM COVER ALONG BOTTOM

OF OUTBOARD SIDE OF DRIP MOLDING

Fig. 118-Trimming Fabric Roof Cover at Drip

Molding Area

20. On styles where roof cover extends into drip moldings or fold around roof panel pinchweld flange, at Side rail, perform the following: a. On "A and X" styles, cement cover into and around outboard side of drip molding and trim cover along outside bottom edge of molding (Fig. 1 1-9). b. On "B, C, E and F" styles, cement cover around and into pinchweld flange at side rail and trim cover as shown in Figure 11-6.

NOTE: When trimming cover, tool 5-21092 or equivalent may be used (Fig. 11-10).

2 1.

On

station wagon styles where the cover assembly extends down the rear body lock pillar, cement cover into the door and quarter window openings

(Figure 1 1-7).

Apply a "film" coat of silicone sealant such as

Dow Corning Automotive Sealant, General

Electric RVP Sealant, or equivalent, to the edge of cover in windshield and back window opening, quarter window, back body opening and at belt area; also, at edges on roof panel when roof panel moldings are used. Make certain edge of material around all reveal molding clips that were not removed is also sealed (Figs. 1 1-5, 1 1-6 and 1 1-8).

23. On styles outlined in Steps 20A or B, install drip scalp moldings or weatherstrip retainer and finishing moldings. These moldings aid in retaining the fabric roof cover.

FABRIC

DESCRIPTION

The fabric roof cover material is a vinyl coated fabric which exhibits a erain Dattern in the exterior vinvl

Fig. 1 1- 10-Fabric Cover Trimming Tool

24. Remove all previously installed protective covering from windshield, back glass and body.

25. Install all previously removed moldings and assemblies.

NOTE: Normally, minor creases or fold marks will gradually disappear after cover assembly has been in service. In the event slight bubbles or wrinkles exist in fabric cover, they can be repaired as follows: a. Pierce bubble with small needle. b. Apply a dampened shop towel over area. c. Using a low heat home-type flat iron, apply iron to dampened towel usin back and forth strokes until wrinkle or bubb

! certain shop towel docs not become dry as excess heat will permanently damage fabric roof cover.

DISCREPANCY REPAIR

surface. In the event the vinyl surface becomes damaged, (cut, scuffed, gouged or-torn) it is possible in most cases to make repairs without removing the cover assembly from the roof panel (See Figs. 1 1- 1 1 and 1 1

-

12).

11-12 ROOF

Fig. I I

- l l -Typical Fabric Roof Cover

Discrepancy

The repair procedures which follow describe two separate methods.

1. Repair utilizing a teflon coated metal graining tool, heating iron, and a variable heat control unit, Fig. 11-13.

Fig. I I - 12-Typical Fabric Roof Cover

Discrepancy

2. Repair utilizing a fabricated plastic body filler graining die and a heat gun, Fig. 1 1 - 14.

REPAIR PROCEDURE UlTlLlZlNG

TEFLON COATED GRAINING TOOL

All Styles Except Cadillac

-

Equipment and Material Requirements

1. Repair tool kits for graining and curing vinyl

Fig. I I-13-Fabric Roof Cover Repair Tool

repair patching compound are available as follows: a. Kit 5-23091 (or equivalent) includes graining tool 5-2309 1- 1 (or equivalent), heating iron and stand tool 5-2309 1-2 (or equivalent) and variable heat control tool 5-23091-3 (or equivalent) and is applicable for 1971 and prior model year fabric roof cover material

(Fig. 11-13).

NOTE: Each component part of Kit 5-23091 or equivalent is serviced individually.

2. Pallet knife

-

A small trowel used for applying vinyl repair patching compound (Fig. 1 1- 15).

3. Razor or sharp knife

-

To be used for removing frayed edges from damaged area prior to application of vinyl patching compound (Fig. 11-

15).

ROOF 11-13

4. Vinyl cleaner (detergent type)

-

All purpose cleaner for removal of surface dirt, grease dust, etc.'from extremely dirty roof covers.

5. Vinyl cleaner (solvent type)

-

For removal of wax, silicone, oil, etc. from repair area prior to paint application (Fig. 1 1

-

15).

6. Vinyl repair patching compound

-

A heat curing milky colored heavy bodied plastisol for repairing cut, tom, scuffed or gouged vinyl roof cover material (Fig. 1 1

-

15).

7. Vinyl repair paint

- an approved, durable, waterprof, weather resistent and pliable vinyl

1. Pre-heat graining tool at 60 setting, plus or minus

2, on variable heat control (5-23091-3 or

Fig. 1 l-14-Fabric Roof Cover Repair Die and Hot Air Gun

11-14 ROOF

Fig. I 1-1 5-Fabric Roof Cover Repair Materials and Tools equivalent) for a minimum of 15 minutes or until the temperature has reached 300 degrees.

2. Prepare surface as follows: a. If cover has an over-all soilage, clean repair area with detergent type all purpose vinyl cleaner. b. Mask-off areas adjacent to repair area (body panels, moldings, glass etc.). c. Using a razor knife, trim the damaged area to remove all frayed or damaged edges (Fig. 11-

16).

Fig. I 1 - 17-Vinyl Repair Patching Compound

Application

Fig. I l-18-Vinyl Repair Patching Compound

Application

Fig. I 1 - IdFabric Roof Cover Repair Trimming

Fig. ll-19-Vinyl Patching Compound Curing and Graining

ROOF 11-15

IMPORTANT: Trimming of vinyl at damaged area should be kept to a minimum. On cuts, scuffs or gouges with clean unfrayed edges, no trimming is necessary.

On damaged areas where no trimming was necessary, apply vinyl patching compound to edges of area as shown in Fig. 11-17). Where trimming was required, apply compound to area being repaired and trowel flush with adjacent surface as shown in Fig. 11-18. Remove any excess material (compound) with clean cloth.

Graining operation is performed by exerting light hand pressure and applying preheated graining iron over damaged compound filled area for approximately one and one half minutes (see

Figs. 11-19 and 11-20).

NOTE: Curing and graining time can be increased slightly depending on size of repair.

IMPORTANT: During graining operation, it is important that the iron be held in a stable, perpendicular position. The use

of

the tool must be compatible to the repair area surface (round edge in drip rail areas; tapered edge adjacent to reveal moldings; crown surface for flat areas). For large repairs, repeat curing and graining using an over-lapping technique.

NOTE: After graining operation is completed, clean the graining tool with solvent type vinyl cleaner and apply a small amount of silicone to prevent adhesion of vinyl paint during future usage of tool.

Apply vinyl paint (solid colors) as follows:

Using a soft lint-free cloth, wipe the repair area with solvent type vinyl cleaner to remove any wax, silicone, oil, etc. that may be present.

Thoroughly mix the vinyl color according to instructions on the container. If an aerosol type container is used, pre-test spray pattern on a piece of paper; then apply vinyl color to repair with two.or three light passes. Use a

"fanning" motion to create a feathering condition around the perimeter of the spot repair.

IMPORTANT: Heavy wet coats of paint must be avoided.

REPAIR PROCEDURE UTILIZING

FABRICATED PLASTIC GRAINING DIE

Equipment and Material Requirements

The following describes the materials and equipment required to repair minor cuts, scuffs, gouges or tears on vinyl coated fabric roof covers:

Plastic body filler and hardener

- a two-part material for fabricating a graining die with an impression of the grain present in the vinyl surface of the fabric roof cover (see Fig. 11-14).

Liquid Detergent Cleaner

- all-purpose cleaner for removal of surface dirt, grease, dust, etc.

Vinyl Cleaner (Solvent Type)

- for removal of wax, silicone, oil, etc. from repair area (see Fig. 11-15).

Vinyl Repair Patching Compound

- a heat curing milky colored heavy-bodied plastisol for repairing damaged area (see Fig. 1 1

-

15).

Vinyl Repair Paint

-

An approved, durable, water proof, weather resistant, pliable vinyl paint for final color refinishing (see Fig. 1 1

-

15).

Pallet Knife

- a small trowel for applying patching compound to repair area (see Fig. 1 1-1 5).

Heat Gun

- used to cure vinvl vatchiner com~ound. preferably 500 degrees to

706

degre& heai range

(Fig. 1 1-14).

Fig. I I-20-Vinyl Patching Compound Curing and Graining

1. To fabricate a graining die, select a scrap piece or roof cover fabric of the same grain design as area being repaired. Clean grain surface using a detergent type cleaner and allow the surface to dry completely while molding compound is being mixed.

11-16 ROOF

Using a non-porous mixing surface, mix the plastic body filler as instructed on container label as follows:

NOTE: A porous mixing surface, such as cardboard, will absorb the hardening agent. This will cause improper curing of hardener. a. With a thin-bladed tool, spread the mold compound on previously prepared grain surface. Maintain a 1/8 inch thick application, approximately 2 inches wide and 6 inches long. Spread material from the center toward outer edges. Immediately after application of mold material, place a scrap piece of vinyl material, cloth side down over mold and apply light finger pressure. The mold will cure in 10 to 15 minutes. Heat may be applied to accelerate curing process. b. After curing, the entire mold can be removed from vinyl cover. Trim excess vinyl backing and any area that is unsatisfactory in grain pattern (outer edges of mold etc).

Prepare surface as follows:

Using a soft lint-free cloth, wipe the repair area with solvent type vinyl cleaner. Allow area to dry completely.

IMPORTANT: Protect adjacent painted surfaces.

Utilizing a razor knife, scalpel or other suitable tool, trim any frayed edges from damaged area. The damaged area should be trimmed to a minimum of 1/8 inch in width.

This will permit easier filling process. A slight tapering angle of the repair surface walls provides greater surface for filler adhesion.

The vinyl patching compound is applied (using a pallet knife) in a succession of thin layers to the repair area. Cure material thoroughly after each layer with heat gun. Continue to apply patching compound until the top layer is flat to the surrounding surface level.

Thorough curing of patching compound is necessary for proper adhesion of each layer and can be accomplished with use of a heat gun. The filler is a milky substance which becomes almost transparent when properly cured. Heat should be directed to the repair area until the compound becomes transparent.

IMPORTANT: Too much heat can result in loss of grain texture. To avoid overheating, attention should be given to the vinyl being exposed to heat. As heat is applied, the adjacent vinyl areas will begin to show a glossy appearance. When this occurs, the vinyl has reached working tempera- ture. Further heating will result in loss of grain.

6. Perform graining operation as follows: a. After the last layer of filler material has been cured cured, the graining operation is per- formed. This operation must be performed prior to cooling of filler material. Using heat gun, apply heat directly on repair area.

Continue heat application until vinyl begins to become glossy. At this temperature, successful graining can be achieved. b. After heat was been applied, press the graining die into the soft vinyl. If possible, graining should be accomplished on the first attempt.

To minimize loss of pattern uniformity. Apply steady, even pressure to the back of graining die to provide an even impression.

7. When graining has been completed, the repair area is ready for application of vinyl paint (solid colors) as follows:

Using a soft lint-free cloth, wipe the repair area with solvent type vinyl cleaner to remove any wax, silicone, oil, etc. which may be present.

Thoroughly mix the vinyl color according to instructions on the container. If an aerosol type container is used, pre-test spray pattern on a piece of paper; then apply vinyl color to repair with two or three light passes. Use a

"fanning" motion to create a feathering condition around the perimeter of the spot repair.

IMPORTANT: Heavy wet coats of paint must be avoided.

REPAIR OF CUTS ON PADDED

ROOF COVERS

On certain styles which incorporate a pad between the roof cover and the roof panel, the basic repair procedures previously outlined are applicable at those areas where the fabric cover has direct contact to the roof panel; however, in the areas where padding is present, some modification is required.

Repair

When repairing covers equipped with a pad, patching compound applied to the damage area must not be allowed to contact the pad. To prevent this condition, either of the following methods can be used.

1. Without detaching the cover from the roof panel, working through the point of damage, insert a piece of waterproof tape udder the cut with the adhesive side out. he tape should be large enough to cover the opening, plus sufficient surface to adhere to the back side of the cover.

Press the cover against the tape to form a backing for the repair operation and prevent the filler from contacting the pad.

2. The method of pulling the cover loose and backing the repair area with a temporary metal panel can also be used. This method may be used when the daniaged area is adjacent to moldings or edge of fabric material. When using this method, the

ROOF 11-17 damage is prepared, filled, and grained as previously described, however, two additional steps must be observed: a. Because the cover is not in contact with metal, heat build-up is much quicker. b. The Cadillac cover has a high gloss finish; therefore, the glossy appearance which is normally used as an extreme heat indicator will react differently. The gloss appearance develops at a lower temperature than observed on covers having a dull finish. Closer attention is required to insure against excessive heat application of the roof cover assembly.

LUGGAGE CARRIER

DESCRIPTION

The luggage carrier is available as a factory or dealer installed option for "B" style station wagons. On factory option, skid strips and support mounting nuts are installed at the factory. During pre-delivery operations the dealer will complete installation as follows:

1. Assemble supports and top rails with ten 3/8 inch long screws (Figure 1 1-2 1).

2. Remove ten screws and washers from rubber support mounting nuts on roof (View "A", Figure

11-21). Leave rubber nuts in place. Keep screws, discard washers.

3. Place five gaskets over rubber well nuts (Gaskets are not required if vehicle is eqquipped with vinyl roof cover option).

4. Position luggage carrier on roof and install ten screws through supports into rubber nuts. Use light pressure on screws until threads engage in' the nut to avoid pushing nut through roof panel

(Figure 1 1-2 1 ).

5. Tighten all screws securely.

On dealer installed option, procedure is as follows:

1. Locate patterns as illustrated (Figure 11-22) and tape in place.

2. Center the skid strip in slots of front and rear patterns, five places each pattern.

NOTE: Close back window before drilling holes in roof. Do not let drill penetrate more than necessary.

3. Drill five 1/8 inch diameter holes in roof using skid strip holes as drill guide and fasten rear end of skid strips and gaskets to roof with 3/4 inch long screws (Gaskets are not required for vinyl covered roofs). Repeat this step for front of skid strips.

4. Assemble supports and top rails as shown (Figure

11-22) with ten 3/8 inch long screws and locate on roof as per pattern instructions at locations marked "S".

'

5. Drill two 3/16 inch diameter holes for left rear support using holes in support as drill guide and fasten this support and its gasket to roof with two one inch screws.

6; Repeat above step for remainixtg supports in the following order: right rear; front center; and front sides. Installation of supports in this sequence and screwing each support in place before holes are drilled for next support will result in the best installation.

11-18 ROOF

Fig. I l-21-Luggage Carrier Installation

-

Factory Installed Option

ALIGN FRONT EDGE OF FRONT PATTERN

WITH ROOF CONTOUR n

ROOF 11-19

Fig. 1 l-22-Luggage Carrier Installation

-

Dealer Installed Option

FOLDING TOP 12-1

SECTION 12

INDEX

SUBJECT PAGE

Folding Top Trim Assembly

Bodies

-

Complete

-

"A"

...........................................................................

Description

12-1

................................................................

.............

12-1 Folding Top Cover and Back Curtain

Removal

..................................................................

Installation

12-1

..............................................................

Folding Top Cover

Removal

- Less Back Curtain

1 2-5

.........

12-9

................................................................

12-9

Installation

..............................................................

Back Curtain Assembly

1 2 -9

.........................................

1 2-1 1

Removal

..................................................................

Installation

....................

1 2-1 1

..............................................................

Hydro-Lectric System

Description

-

"A" Bodies 12-1 3

................................................................

Motor and Pump Assembly

.................................

12-13

SUBJECT PAGE

Operation of Folding Top

...................................

1 2-1 5

Operation of Pump Assembly .............................

1 2- 1 5

Fluid Control Valve

...............................................

Mechanical Checking Procedure .........................

12-1 5

Electrical Checking Procedure

.............................

1 2

-

1 6

Hydraulic Checking Procedure

............................

12-1 7

Folding Top Lift Cylinder

...................................

Filling of Hydro-Lectric Reservoir

1 2- 1 9

....................

12-20

Folding Top Adjustments

-

"A" Bodies

Adjustment of Front Roof Rail Guide

............

............

.........................

12-2 1

12-21

Adjustment of Front Roof Rail

Front Roof Rail Lock Assembly

........................

12-21

....................

12-21

Front Roof Rail Lock Adjustment

Adjustment of Top Control Link

.......................

12-23

12-23

Trouble Shooting Chart

Lubrication

-

"A" Bodies

........................................

..................................

FOLDING TOP

DESCRIPTION

"A" body style convertible tops incorporate a one- piece rear belt rail trimstick assembly which mounts directly to the folding top male hinges. For trim repair and replacement purposes, the one-piece trimstick can be disconnected from the male hinges and raised above the rear belt rail. The trimstick, with due care in handling and removal, maintains its full shape and retains its stiffness for retacking or stapling operations.

Convertible top cover assemblies incorporate a spring loaded hold-down cable along the sides. The cables are retained in a pocket sewn to the top cover and are secured at the front and rear ends by screws. Under tension, the cables are designed to form a tight fit of the top cover to the side rails to minimize air leakage along the side roof rails.

Convertible style back curtains utilize an integral solid

- tempered back window glass.

FOLDING TOP COVER AND

BACK CURTAIN ASSEMBLY

Removal

1. Apply masking tape to rear quarter pinchweld

ASSEMBLY

finishing moldings, and apply cover protection on rear deck and other adjacent painted surfaces.

2. Mark position of top cover vertical edges on back curtain valance at rear belt line. u s e sharpened grease pencil (Item "C", Fig. 12-1).

3. Remove rear seat cushion. Disconnect rear seat speaker if present, and remove rear seat back.

I

4. Remove right and left folding top compartment side trim panels.

5. Lower top part-way, and remove side roof rail rear and center weatherstrips. Then, lower top to stacked position and remove weatherstrips from front roof rail and side roof front rails.

6. Detach top cover from front roof rail. Then raise top and detach top cover flaps from side roof rear rails. Remove escutcheons and wire-on binding from rear bow. Also, detach top cover at rear bow.

Note location and spacing of staples before removal.

7. With front roof rail, raised several inches off windshield header, remove attaching screws from front and rear of each hold-down cable and remove cables (Views "A" and "B" in Fig. 12-2).

12-2 FOLDING TOP

A.

Fig. 12-1-Reference Marks on Top Cover and Back Curtain,

One Piece Trimstick B. Top Cover Vertical

Edge Reference

C. Back Curtain Center

Reference during back curtain and/or side stay pad removal and installation.

8.

At underside of front bow, remove screws secur- ing listing pocket retainer to front bow. Disengage retainer from bow and remove retainer from listing pocket. Note location of screws before removal (See Fig. 12-3).

9. Detach folding top compartment bag from rear seat back panel.

10. Lock top to windshield header and install spacer stick along inboard edge of each side stay pad

(Fig. 12-4).

Spacer sticks can be fabricated as shown in Figure

12-5. Fit spacer sticks snugly between center bow and rear bow, then tighten wing nuts. Spacer sticks are adjustable. Fasten rear bow securely to side roof rear rails.

NOTE: The purpose of spacer sticks is to hold the rear bow in a stationary (car installed) position

MATERIAL PER STICK

B. Steel

C. Steel

-

1/32 x 1 /2 x 2-1/2

-

1/32 x 1-1/2 x 7

D. 2 Screw No. 6 x 1/2"

E.

Bolt 1/4

-

20 UNC.- 2A x 1"

F. Wingnut

1

/4 x 20 UNC

-

2B

G. 2 Washers 1/4" 1.D

FOLDING TOP 12-3

VlEW A

VlEW B

Fig. 12-2-Hold Down Cable Attachment

11. Raise front roof rail several inches off windshield header and disconnect rear trimstick removing attaching bolts using a suitable box-socket type wrench to remove each bolt from "outside" surface of male hinge (Fig. 12-6 and 12-7).

12. Remove rear trimstick from body and position above quarter pinchweld finishing moldings.

With top two to four inches off header, move one end of trimstick inward for clearance. Then pry it upward between hinge and body to clear rear side roof rail. Raise removed end of trimstick upward and forward. Then continue by removing remaining part of trimstick above body belt line (Figs. 12-8,

12-9 and 12-10).

IMPORTANT: Avoid contact with or damage to top lift cylinder piston rod.

13. Perform the following operation on car, or later on bench:

A. Using a suitably sharp penci1,ACCURATELY mark location of complete rear trimstick

(UPPER AND LOWER edges and ends) on outer surface of top cover and on back curtain.

Re-check, and mark right and left inner vertical edge of top cover on back curtain at trimstick. Make center mark on curtain at notch on trimstick (See Fig. 12-1).

"V"

4. Detach and remove top cover from rear trimstick.

Accurately mark location of balance of trimstick on back curtain. Note spacing of staples before removal.

5. Detach back curtain from rear bow and, with the aid of a helper, remove rear trimstick with attached back curtain and top compartment bag from body. Place on clean, protected surface.

Note location and 'spacing of staples before removal.

16, Re-check accuracy of trimstick location markings on back curtain, and remove curtain from

12-4 FOLDING TOP

CENTER B O W

SECTION A - A

Fig. 12-3-Listing Pocket Retainer

1516

I

CORD OR TAPE

Fig. 12-4-Spacer Stick Installation

J

Fig. 12-5-Spacer Stick Fabrication

V I E W A

Fig. 12-6-Trimstick Attachment "A" Styles

3 2 5 4

FOLDING TOP 12-5

Fig. 12-7-Trimstick Removal "A" Styles

Fig. 12-9-Raising Balance of Trimstick

Fig. 12-8-Raising End of Trimstick trimst'ick. Note location and spacing of staples before removal.

17. Rimove polyurethane and side stay pads. Stay pads are secured with tacks or staples to front roof rail, front roof bow and rear roof bow, and with screws to center bow (Fig. 12-1 1).

FOLDING TOP COVER AND BACK

CURTAIN ASSEMBLY

-

"A" BODIES

Installation

1. With front roof rail locked at windshield header, Fig. 12-10-Trimstick Removed

12-6 FOLDING TOP

I

TACKS SCREWS

,lo*

Fig. 12-1 1-Side Stay Pad Attachment and with rear bow spacer sticks firmly in place, install side stay pads. Align stay pads with depression in rear bow and tack to secure. Pull stay pads forward for snug fit and tack to front roof rail. Tack stay pads to front bow. Secure stay pads to center bow with screws. Check alignment of polyurethane padding on stay pads to determine cementing area, and remove. Apply an approved trim cement to stay pads uniformly and install polyurethane padding. Trim off selvage end (excess material) of stay pads just forward of rear rolled edge of rear bow. Also, trim at front roof rail as required (Fig. 12-1 1).

Transfer reference marks from removed back curtain to new one as follows: Place new back curtain on clean covered bench with inner sur- face down. Position removed back curtain correspondingly over new one. Carefully align upper window over lower one. While holding both windows together securely, carefully lay out trim material of both curtains and transfer reference marks along bottom location of trimstick (UPPER

AND LOWER edges, as well as the ends), and the inner vertical edges of top cover.

Then reverse back curtains by positioning new curtain over removed one as described above. Re- check location of reference marks.

F R O N T R O O F RAIL

F R O N T WEATHERSTRIP

P MATERIAL

Fig. 12-12-Top Cover at Front Roof Rail

Fig. 12- 13-Back Curtain Installation

A. Top Cover Rear

Vertical Edge

References

B. Trimstick Lower Edge

Reference

C. Trimstick Upper Edge

Reference

D. Back Curtain Center

Reference

FOLDING TOP 12-7

A.

Fig. 12-14-Cross Section at Rear Trimstick

Back Curtain

B. Rear Belt Rail

Trimstick Assembly

C. Folding Top

Compartment Bag

D. 1/2 inch over-hang

E. Lower Edge Reference

Mark

F. Staples

G. Upper Edge Reference

Mark

NOTE: If any difference is noted, the average between the two is the correct reference to use.

Mark corrected references clearly. Trim off excess material beyond the 1/2 inch allowance along the bottom and transfer center mark from bottom center of removed curtain to new one.

IMPORTANT: Transfer of reference marks must be done in a highly exacting manner for best results and minimum rework.

3. As a bench operation, position and center new back curtain to trimstick according to reference marks and tack curtain to trimstick. Tack from center to ends. Avoid stretching, but keep material flat during tacking operations.

4.

Transfer reference marks from removed top cover t o new one as follows: Place new top cover o n a suitable clean surface, such as on clean roof of a car t o provide proper contour and fullness, with inner surface of cover down. Position removed top cover over new one. Carefully align back window opening upper corners and rear quarter upper corners of both covers. Secure both covers together at these locations. Carefully lay out trim material of sail. area of both covers and proceed as follows:

A. Transfer location marks for trimstick (UPPER

AND LOWER trimstick edges, as well as ends,

Fig. 12-1).

B. Then reverse position of covers by positioning new cover over removed one, as described above. Re-check location of reference marks.

NOTE: If any difference is noted, the average between the two is the correct reference to use.

Mark corrected references clearly.

IMPORTANT: Transfer of reference marks must be done in a highly exacting manner for best results and minimum rework.

5. As a bench operation, position and locate top cover to trimstick according to reference marks and tack top cover to trimstick. Tack from top cover inner vertical edge reference on back curtain toward front (Item "B", Fig. 12-1). Avoid excessive stretching, but keep material flat during tacking operations.

6. With aid of a helper, position rear trimstick with attached bag, cover and back curtain, on rear deck of body. Use care in protecting trim material and back window during this operation. With front roof rail slightly off header, position bag in folding top well and stay-tack edge of back e trimstick installation. Also, lay top cover on folding top framework.

7. Position rear trimstick into body in reverse of removal operations (See Step 12 of Removal of

Folding Top and Back Curtain Trim Assembly,

Fig. 12-6).

8. Secure rear trimstick to body assembled position and install attaching bolts (Flg. 12-6).

9. With front roof rail locked to windshield header, and with top cover laying on rear deck, tack back curtain to rear bow as follows: Remove all stay tacks except two at. outer ends supporting back curtain. Then pull curtain fonvard to remove all fullness and tack curtain to rear bow. Tack from center toward each end of curtain. Remove stay tacks. Apply fonvard tension to curtain at each point of tack installation (Fig. 12-15).

IMPORTANT: Make certain trimstick is flush to quarter pinchweld finishing molding during all tacking operations. This will require assistank of a helper or a support.

10. Insert hold-down cables into top cover listing

, pockets and secure as follows:

A. Position front roof rail slightly above wind- shield header. A length of welding rod or equivalent wire can be used to facilitate cable insertion by pulling cable through listing

12-8 FOLDING TOP

TACKING BACK CURTAI

TO REAR B O W

-

FRONT EDGE OF

Fig. 12-15-Tacking Back Curtain pocket. Install attaching screw at rear of cable.

Then, apply forward pull on cable and install front attaching screw (Fig. 12-2).

11. Insert and center retainer in top cover listing pocket at front roof bow. Position retainer on front bow and install attaching screws (Fig. 12-3).

12. Apply nitrile cement or neoprene type weather- strip adhesive to cementing surfaces of side roof rear rails and to quarter flaps. Center top cover over rear bow and align quarter flap seams with edges of side roof rear rails to remove all fullness from rear of top cover. A forward draw on cover outer sides will aid this operation. With quarter flap seams aligned with each rear rail, cement quarter flaps securely in place.

NOTE: Top cover may require some lateral stretching along rear bow to achieve proper fit of quarter flaps to rear rails, and to remove fullness from top cover valance over rear window.

13. Using an awl or equivalent tool, pierce flaps for side roof rear rail weather- strip attaching screws.

Install weatherstrips to help maintain position of quarter flaps while adhesive is drying.

14. While pulling top cover rearward slightly to straighten material over rear window, install tacks. to secure cover to rear bow.

IMPORTANT: Tacks must be installed in a straight line in center of rear bow. Tacks outboard of deck seams should not exceed 6 inches. Also, tacking distance outboard of deck seams on each side should be uniform. Pierce hole into top material and tacking strip at each outboard end of rear bow for wire-on binding clip escutcheons.

15. Lock front roof rail to windshield header. Pull top

Fig. 12-16-Marking Top Cover at

Front Roof Rail cover straight forward at seams to desired top fullness. While maintaining tenskn on cover over front roof rail, make pencil mark on cover outer surface along forward edge of front. front roof rail(Fig. 12- 16).

16. Lower top to stacked position. Carefully, apply nitrile cement or neoprene weatherstrip adhesive to cementing area of front roof rail, to corres- ponding surface of top cover, and to front comer flaps.

17. Raise top within four inches of windshield header and support roof rail on header with suitable wood block. Secure cover to front roof rail by pulling top cover reference marks slightly beyond target so that pencil marks will be slightly under front edge of roof rail. With doors open, align sides of top cover with forward pull, and secure comer flaps to cemented surfaces. Remove wood block and complete cementing top cover to front roof rail. Lower top and install several stay tacks.

18. Raise top and lock to windshield header. Check appearance of top trim, top operation and locking action of top. If additional tension is needed in top cover, repeat Step 17 and pull top cover further forward. Stay tack and re-check top for proper appearance and operation.

19. Lower top and complete tacking of top cover to front roof rail. Trim off excess material (Fig. 12-

12).

20. Carefully align, seal and install front roof rail and side roof rail weatherstrips.

FOLDING TOP 12-9

Raise top, and using due caution, apply a bead of neoprene-type weatherstrip adhesive around each rear bow tack head and into two holes pierced into top material for wire-on binding clip escutcheon screws. Applied adhesive must be within area covered by wire-on binding.

Install rear bow wire-on binding and escutcheons.

Tack from center outward to maintain a snug and straight fit. Length of binding outside of deck seams should not exceed 6 inches and should be of uniform length on each side.

When completed, folding top should be free from wrinkles and draws. Install all previously removed trim and hardware. Clean up top material and car as required.

FOLDING TOP COVER

LESS BACK CURTAIN

-

"A" BODIES

Removal

Apply masking tape to rear quarter pinchweld finishing moldings, and apply cover protection on rear deck and other adjacent painted surfaces.

Mark position of top cover vertical edges on back curtain valance at rear belt line. Use sharpened grease pencil (Fig. 12-1).

Remove rear seat cushion. Disconnect rear seat speaker, if present, and remove rear seat back.

Remove right and left folding top compartment side trim panels.

Lower top part-way, and remove side roof rail rear and center weatherstrips. Then lower top to stacked position and remove weatherstrips from front roof rail, and side roof front rails.

Detach top cover from front roof rail. Then raise top and detach top cover flaps from side roof rear rails. Remove escutcheons and wire-on binding from rear bow. Also, detach top cover at rear bow.

Note location and spacing of staples before removal.

With front roof rail several inches off windshield header, remove attach- ing screws from front and rear of each hold-down cable and remove cables

(Views "A" and "B" in Fig. 12-2.

At underside of front bow, remove screws securing listing pocket retainer to front bow. Disengage retainer from bow and remove retainer from listing pocket. Note location of screws before removal (Fig. 12-3).

Detach folding top compartment bag from rear seat back panel.

With front roof rail several inches off windshield header, disconnect rear trimstick as rzquired by removing attaching bolts using a suitable box- socket type wrench to remove each bolt from

"outside;; surface of male hinge (Fig. 12-6 and

12-7).

Raise rear trimstick from body and position above> quarter pinchweld finishing moldings.

With top two to four inches off header, move one end of trimstick inward for clearance. Then pry it upward between hinge and body to clear rear roof rail. Raise removed end of trimstick upward and forward. Then continue by removing balance of trimstick above body belt line (Fig. 12-8, 12-9 and

12-10).

IMPORTANT: Avoid contact with or damage to top lift cylinder piston rod.

Using a suitably sharp pencil, accurately mark location of complete rear trimstick (UPPER and

LOWER edges, and ends) on outer surface of top cover. Re-check, and Ihark right and left inner vertical edge of top cover on back curtain at trim stick (Fig. 12-1).

Detach top cover from rear trimstick and remove.

Note spacing of staples before removal.

Installation

1. Transfer reference marks from removed top cover to new one as follows:

Place new top cover on a suitable clean surface, such as on clean roof of a car to provide proper contour and fullness, with inner surface of cover down.

Position removed top cover over new one.

Carefully align back window opening upper corners and rear quarter upper corners of both covers. Secure both covers together at these locations. Carefully lay out trim material of sail area of, both covers.

Transfer location marks for trimstick (upper and lower trimstick edges, as well as ends) as shown in Fig. 12-1.

Then reverse position of covers by positioning new wver over removed one, as described above. Re-check location of reference marks.

NOTE: If any difference is noted, the average between the two is the correct reference to use.

Mark corrected references clearly.

12-10 FOLDING TOP

IMPORTANT: Transfer of reference marks must be done in a highly exacting manner for best results and minimum rework.

2. Place folding top cover on folding top framework.

Then, position and locate top cover to trimstick according to reference marks, and tack top cover to trimstick. Tack from top cover inner vertical edge reference on back curtain toward front.

Avoid excessive stretching, but keep material flat during tacking operations (Fig. 12- 1).

3. Position rear trimstick into body in reverse of removal operation (See Steps 10 11 of Removal of

Folding Top Cover Less Back Curtain) as shown in Fig. 12-9).

4. Secure rear trimstick to body assembled position and tighten attaching bolts (Fig. 12-6).

5; Insert hold-down cables into top cover listing pockets and secure as follows:

A. Raise front roof rail slightly above windshield header. A length of welding rod or equivalent wire can be used to facilitate cable insertion by pulling cable through listing pocket. Install attaching screw at rear of cable. Then, apply forward pull on cable and install front attaching screw (Fig. 12-2).

6. Insert and center retainer in top cover listing pocket at front roof bow. Position retainer on front bow and install attaching screws (Fig. 12-3).

Apply nitrile cement or neoprene-type weather- strip adhesive to cementing surfaces of side roof rear rails and to quarter flaps. Center top cover over rear bow and align quarter flap seams with edges of side roof rear rails to remove all fullness from top cover. A forward draw on cover outer sides will aid this operation. With quarter flap seams aligned with each rear rail, cement quarter flaps securely in place.

NOTE: Top cover may require some lateral stretching along rear bow to achieve proper fit of quarter flaps to rear rails, and to remove fullness from top cover valance over rear window.

8. Using an awl or equivalent tool, pierce flaps for side roof rail rear weatherstrip attaching screws.

Install weatherstrips to help maintain position of quarter flaps while'adhesive is drying.

9. While pulling top cover rearward slightly to straighten material over rear window, install tacks to secure cover to rear bow.

IMPORTANT: Tacks must be installed in a straight line in center of rear bow. Tacks ourboard of deck seams should not exceed 6 inches. Also, tacking distance outboard of deck seams on each side should be uniform. Pierce hole into top material and tacking strip at each outboard end of rear bow for wire-on binding clip escutcheons (Fig. 12- 1).

10. Lock front roof rail to windshield header. Pull top cover straight forward at seams to desired top fullness. While maintaining tension on cover over front roof rail, make pencil mark on cover outer surface along forward kdge of front roof rail (Fig.

12-16).

11. Lower top to stacked position. Carefully, apply nitrile cement or neoprene weatherstrip adhesive to cementing area of front rail, to corresponding surface of top cover, and to front corner flaps.

12. Raise top within four inches of windshield header and support roof rail on header with suitable wood block. Secure cover to front roof rail by pulling top cover reference mark slightly beyond target so that pencil marks will be slightly under front edge of roof rail. With doors open, align sides of top cover with forward pull, and secure corner flaps to cemented surfaces. Remove wood block and complete cementing top cover to front roof rail. Lower top and install several stay tacks.

13. Raise top and lock to windshield header. Check appearance of top trim, top operation and locking action of top. If additional tension is needed in top cover, repeat Step 12 and pull top cover further forward. Stay tack and re-check top for proper appearance and operation.

14. Lower top and complete tacking of top cover to front roof rail. Trim off excess material (Fig. 12-

12).

15. Carefully align, seal and install front roof rail and side roof rail weatherstrips.

16. Raise top and carefully, apply a bead of neoprene- type weatherstrip adhesive around each rear bow tack head and into two holes pierced into top material for wire-on binding clip escutcheons screws. Applied adhesive must be within area covered by wire-on binding.

17. Install rear bow wire-on binding and escutcheons.

Tack from center outward to maintain a snug and straight fit. Length of bindin outside of deck

f

of uniform length on each side.

18. When completed, folding top should be free from wrinkles and draws. Install all previously removed

FOLDING TOP 12-1 1 trim and hardware. Clean up top material and car as required.

BACK CURTAIN ASSEMBLY

BODIES

-

"A"

Removal

1. Apply masking tape to rear quarter pinchweld finishing moldings, and apply cover protection on rear deck and other adjacent painted surfaces.

2. Mark position of top cover vertical edges on back curtain valance at rear belt line. Use sharpened grease pencil (Fig. 12-1).

3. Remove rear seat cushion. Disconnect rear seat speaker, if present, and remove rear seat back.

4. Remove right and left folding top compartment side trim panels.

5. Lower top part-way, and remove side roof rail rear weatherstrips.

6. Raise and lock top. Mark exact location of following: rear roof bow (front and rear edges); wire-on binding escutcheons; and quarter flaps.

Note location and spacing of staples before removal. Then, remove escutcheons and wire-on binding. Detach quarter flaps and remove staples from top cover at rear roof bow.

7. With top several inches off header, remove rear attaching screw from hold-down cables (View "B"

Fig. 12-2).

8. Detach folding top compartment bag from rear seat back panel.

9. Lock top to windshield header and install spacer stick along inboard edge of each side stay pad

(Fig. 12-4). Spacer sticks can be fabricated as shown in Figure 12-5. Fit spacer sticks snugly between center bow and rear bow, then tighten wing nuts. Spacer sticks are adjustable. Fasten rear bow securely to side roof rear rails.

IMPORTANT: The purpose of spacer sticks is to hold the rear bow in a stationary (car installed) position curing back curtain and/or side stay pad removal and installation.

Material Per Stick

B. Steel

-

1 /32 x 1 /2 x 2-1 /2

C. Steel

-

1/32 x 1-1/2 x 7

D. 2 Screw No. 6 x 1/2"

E. Bolt l/4

-

20 UNC

-

2A x 1"

F. Wingnut 1/4 x 20 UNC

-

2B

G. 2 Washers 1 /4" I.D.

10. Raise front roof rail several inches off windshield header and disconnect rear trimstick by removing attaching bolts using a suitable box-socket type wrench to remove each bolt from "outside" surface of male hinge (Fig. 12-6 and 12-7).

11. Remove rear trimstick .from body and position above quarter pinchweld finishing moldings as follows:

A. With top two to four inches off header, move one end of trimstick inward for clearance.

Then pry it upward between hinge and body to clear rear roof rail (Fig. 12-8).

B. Raise removed end of trimstick upward and forward. Then continue by removing balance of trimstick above iody beltline (Fig. 12-9 and

12-10).

IMPORTANT: Avoid contact with or damage to top lift cylinder piston rod.

12. Using a sharp pencil, accurately mark location of complete rear trimstick UPPER and LOWER edges and ends on outer surface of top cover and on back curtain. Re-check, and mark right and left inner vertical edge of top cover on back curtain at trim stick. (Fig. 12-1). Make center mark on curtain at

'Y"

notch on trimstick.

13. Detach top cover from rear trimstick and raise cover for access to back curtain. Accurately mark location of balance of trimstick on back curtain.

14. Detach back curtain from rear bow. With aid of a helper, remove rear trimstick with attached back curtain and top compartment bag from body.

Place on clean, protected surface. Note location and spacing of staples before removal.

15. Re-check accuracy of trimstick location markings on back curtain, and remove curtain from trimstick. Note location and spacing of staples before removal.

Installation

1. With front roof rail iocked at windshield header, and with rear bow spacer sticks firmly in place

(Fig. 12-4), check side stay pads. If necessary, align and secure side stay pads. See Step 1 of

12-12 FOLDING TOP

"Folding Top Cover and Back Curtain Assembly

Installation" (Fig. 12- 1 1).

2. Transfer reference marks from removed back curtain to new one as follows:

A. Place new back curtain on clean covered bench with inner surface down and position removed back curtain correspondingly over new one.

B. Carefully align upper window over lower one.

While holding both windows together securely, carefully lay out trim material of both curtains and transfer following reference marks along bottom location of trimstick (upper and lower edges), as well as ends, and the inner vertical edges of top cover. Allow ' l / 2 inch of back curtain material to extend below trimstick

(Fig. 12-13 and 12-14).

C. Then reverse back curtains by positioning new curtain over removed one, as described above.

Re-check location of reference marks.

NOTE: If any difference is noted, the average between the two is the correct reference to use.

Mark corrected references clearly.

D. Along bottom, trim off excess material beyond the 1/2 inch allowance. Transfer center mark from bottom center of removed curtain to new one.

IMPORTANT: Transfer of reference marks must be done in a highly exacting manner for best results and minimum rework.

As a bench operation, position and center new back curtain to trimstick according to reference marks and tack from center to ends. Avoid stretching, but keep material flat during tacking operations.

With aid of a helper, position rear trimstick, with attached bag and back curtain, on rear deck of body. Use care in protecting trim material and back window during this operation. Position bag in folding top well. Stay tack edge of back curtain to rear bow to protect back window during following operations.

Position rear trimstick into body in reverse of removal operations. (See Step 10 11 of Back

Curtain Removal (Fig. 12-9).

Secure rear trimstick to body assembled position and tighten all attaching bolts (Fig. 12-6).

With front roof rail locked to windshield header and with spacer sticks firmly in place, tack back curtain to rear bow by removing all stay tacks except two at outer ends supporting back curtain.

Then pull curtain forward to remove ALL

FULLNESS and tack curtain to rear bow. Tack from center toward each end of curtain. Remove stay tacks. Apply forward tension to curtain at each point of tack installation (Fig. 12-1 5).

IMPORTANT: Make certain one-piece trimstick is flush to quarter pinchweld finishing molding during tacking operations. This will require assistance of a helper or a support. Trim excess back curtain material at rear bow. Also remove spacer sticks (Fig. 12-4).

8. Disconnect rear trimstick as described in Step 10 of "Removal of Back Curtain" Procedure.

9. Remove rear trimstick from body and position above quarter pinchweld finishing moldings as described in Step 11 of "Removal of Back

Curtain" Procedure.

10. Position and locate top cover to trimstick according to reference marks and tack top cover to trimstick. Tack from top cover inner vertical edge reference on back curtain toward front.

Avoid excessive stretching, but keep material flat during tacking operations (Fig. 12-1).

11. Position rear trimstick into body in reverse of removal operations as described in Step 11 of

"Removal of Back Curtain" Procedure.

12. With front roof rail several inches off windshield header, secure rear trimstick to body assembled position and tighten all attaching bolts. This is the reverse of Step 10 of "Removal of Back Curtain"

Procedure.

13. Align and secure hold down cables at rear with attaching screw (Fig. 12-2).

14. Position front roof rail several inches off windshield header and proceed as follows:

A. Apply nitrile cement or neoprene-type weatherstrip adhesive to cementing surfaces of side roof rear rails and to quarter flaps.

B. Position and center top cover reference marks over rear bow. Align quarter flaps and seams with previously scribed marks and edges of side roof rear rails to remove all fullness from top cover. A forward draw on the cover outer sides will aid in this operation.

C. With quarter flap seams aligned with each rear rail, cement quarter flaps securely in place.

FOLDING TOP 12-13

NOTE: Top cover may require some lateral stretching along rear bow to achieve proper fit of quarter flaps to rear .rails, and to remove fullness from top cover valance over rear window.

17. Carefully, apply a bead of neoprene-type weather- strip adhesive around each rear bow tack head, over unused staple holes, and over screw holes for escutcheons.

15. Using an awl or equivalent tool, pierce flaps for side roof rail rear weather- strip attaching screws.

Install weatherstrips to help maintain position of quarter flaps while adhesive is drying.

18. Install rear bow wire-on binding and escutcheons.

Tack from center outward to maintain a snug and straight fit. Length of binding outside of deck seams should not exceed 6 inches and must be uniform length on each side.

16. With front roof rail resting on windshield header, and with top cover reference marks aligned with rear bow, tack top cover securely to rear bow.

Location and spacing of tacks should be similar to that of removed staples.

19. When completed, folding top should be free from wrinkles and draws. Install all previously removed trim and hardware. Clean up top material and car as required.

HYDRO-LECTRIC SYSTEM

-

A

BODIES

DESCRIPTION

The high pressure hydro-lectric unit used in the convertible bodies, consists of a 12 volt reversible type motor, a rotor-type pump, two hydraulic lift cylinders, and an upper and lower hydraulic hose assembly. Tbe unit is installed in the body directly behind rear seat back support (Fig. 12- 17).

Figure 12-18 illustrates and identifies the individual parts of the motor and pump assembly.

NOTE: When servicing the motor assembly or pump end plate assembly, it is extremely important that the small motor shaft "0" ring seal is properly installed over the motor armature shaft and into the pump end plate assembly prior to installing the pump rotors or the motor shaft drive ball.

MOTOR AND PUMP ASSEMBLY

7. To facilitate removal, apply a rubber lubricant to pump attaching grommets; then carefully disen- gage grommets from rear seat back support (Fig.

12-17).

8. Place absorbent rags below hose connections and end of reservoir.

9. Vent reservoir by removing filler plug; then install plug.

NOTE: Venting reservoir is necessary in this

"sealed-in" unit to equalize air pressure in reservoir to that of the atmosphere. This operation prevents the possibility of hydraulic fluid being forced under pressure from discon- nected lines and causing damage to trim or body finish.

10. Disconnect hydraulic lines and cap open fittings to prevent leakage of fluid. Use a cloth to absorb

I

y

G R O U N D WIRE Removal

1. Operate folding top to full "up" position.

2. Disconnect positive battery cable.

3. Place protective covering over rear seat cushion and back.

4. Working inside body, detach front edge of folding top compartment bag from rear seat back panel. ,

5. Remove clips securing wire harness and hydraulic hose to rear seat back panel and support.

6. Disconnect motor leads from wire harness and ground attaching screws.

MOTOR A N D

PUMP ASSEMBLY

-- -

Fie. 12- 17-Motor and P u m ~

2066

12-14 FOLDING TOP

A. Motor Assembly

B. Motor Shaft "0" Ring

Seal

C. Reservoir Seal

D. Outer Pump Rotor

E. Inner Pump Rotor

Fig. 12- 18-Motor and Pump Components

F. Fluid Control Valve

G.

H.

Balls

Pump Cover Plate

Assembly

Pump Cover Attaching any leaking fluid, then remove unit from rear compartment (Fig. 12-17).

Installation

1. If a replacement unit is being installed, fill reservoir unit with Type "A" transmission fluid,

Dextron or equivalent. See "Filling of Hydro-

Lcctric Reservoir".

2. Connect hydraulic hoses, engage attaching grom- mets in panel and connect wiring.

3. Connect battery and operate top through its up and down cycles until all air has been "bled"

Screws

I. Reservoir Tube and

Bracket Assembly

J. Reservoir Filler Plug

K. Reservoir End Plate

Attaching Bolt

L. Reservoir End Plate

Attaching Bolt

Washer

M. Reservoir End Plate

Attaching Bolt

Fig. 12-20-Operation of Pump to Raise Top

L

Fig. 12-19-Motor and Pump Assembly

1 7 1 1

FROM BOTTOM

OF CYLINDER

1716

Fig. 12-21-Operation of Pump to Lower Top

FOLDING TOP 12-15 from hydraulic circuit. See "Filling of Hydro-

Lectric Reservoir".

4. Check connections for leaks and recheck fluid level in reservoir.

5. Install all previously removed parts.

RESERVOIR TUBE

,Disassembly From Motor and Pump Assembly

Remove motor and pump assembly from body.

Scribe a line across pump end plate and reservoir tube to insure a correct assembly of parts. See

Figure 12-19.

Using needle nose pliers, remove reservoir filler plug.

Drain fluid from reservoir into a clean container.

With suitable tool, remove bolt from end of assembly and remove reservoir tube. Note sealing rings around bolt and between end of reservoir tube and pump cover plate assembly.

Assembly To Motor and Pump Assembly

1. Position sealing ring on pump and assemble reservoir tube to pump according to scribe marks.

2. Install and tighten attaching bolt.

3. Place unit in horizontal position and fill with fluid until fluid level is within 1/4" of lower edge of filler plug hole.

OPERATION OF FOLDING TOP

When the control switch is actuated to the "up" position, the battery feed wire is connected to the red motor lead and the motor and pump assembly operate to force the hydraulic fluid through the hoses to the lower end of the double-acting cylinders. The fluid forces the piston rods in the cylinders upward, thus raising the top. The fluid in the top of the cylinders returns to the pump for recirculation to the bottom of the cylinders. When the control switch knob is actuated to the "down" position, the feed wire is connected to the dark green motor lead and the motor and pump assembly operate in a reversed direction to force the dydraulic fluid through the hoses to the top of the cylinders. The fluid forces the piston rods in the cylinders downward, thus lowering the top. The fluid

in

the bottom of the cylinders returns to the pump for recirculation to the top of the cylinders.

OPERATION OF PUMP ASSEMBLY

The rotor

type

pump assembly is designed to deliver a

m ~ m u m

to 380 psi.

The operation of the pump assembly when raising the top is as follows:

1. Raising the top. When the red motor lead is energized the motor drive shaft turns the rotors clockwise as indicated by the large arrow in

Figure 12-20. The action of the pump rotors forces the fluid under pressure to the bottom of each cylinder forcing -the piston upward. This action causes the fluid above the piston in each cylinder to be forced into the pump, which recirculates the fluid to the bottom of the cylinders. The additional fluid required to fill the cylinder due to piston rod displacement is drawn from the reservoir.

Lowering the Top. When the green motor lead is energized the motor drive shaft turns the rotors counterclockwise as indicated by the large arrow in Figure 12-21. The action of the pump rotors forces the fluid under pressure to the top of each cylinder. This action causes the fluid below the piston in each cylinder to be forced into the pump which recirculates t h e q u i d to the top of each cylinder. The surplus hydraulic fluid d& to piston rod displacement flows into the reservoir.

FLUID CONTROL VALVE

The fluid control valve consists of a rocker arm installed in the pump cover plate, and two steel balls.

Figure 12-22 shows the top surface of the pump cover plate. The dotted lines indicate the cavities on the bottom side of the cover plate. The cavities are designed to permit fluid flow between pump rotors and the reservoir. Figures 12-23 and 12-24 illustrate the operation of the fluid control valve.

MECHANICAL CHECKING PROCEDURE

If there is a failure in the hydro-lectric system and the cause is not evident, the mechanical operation of the top should first be checked. If the folding top assembly appears to have a binding action, disconnect the top lift cylinder piston rods from the top linkage and then manually raise and lower the top. The top should travel through its up and down cycle without any

.evidence of bind- ing action. If a binding action is noted when the top is being locked at the header, check the alignment of the door windows and rear quarter windows with relation to the side roof rail weatherstrips. Make all necessary adjustments for correct top alignment. See "Folding Top Adjust- ments". If a failure continues to exist after a check for

12-16 FOLDING TOP

SURPLUS FLUlD

(DUE T O PISTON R O D DISPLACEMENT)

ENTERS RESERVOIR

THROUGH,VALVE

FLUlD CONTROL

V A L V E ROCKER

ARM

L

PRESSURIZED FLUlD SEATS BALL

PREVENTING FLUlD F R O M

ENTERING RESERVOIR

Fig. 12-22-Pump Cover Plate mechanical failure has been completed, the hydro- lectric system should then be checked for electrical or hydraulic failures.

ELECTRICAL CHECKING PROCEDURE

If a failure in the hydro-lectric system continues to exist after the mechanical operation has been checked, the electrical system should then be checked. A failure in the electrical system may be caused by a low battery, breaks in wiring, faulty connections, mechani- cal failure of an electrical component, or wires or components shorting to one another or to body metal.

Before beginning checking procedures, check battery according to recommended procedure.

Check for Current at Folding Top

Control Switch

1. Disconnect green motor lead wire from switch to motor feed wire in rear compartment.

EXCESS FLUlD REQUIREMENTS

D R A W N IN FROM RESERVOIR

/

RVOlR SIDE

Fig. 12-24-Fluid Control Valve

2. Connect light tester to central feed terminal of

3. switch terminal block.

#

Ground light tester ground lead to body metal.

4. If light tester does not light, there is an open or short circuit between power source and switch.

NOTE: Check light tester to insure proper operation prior to electrical checking.

Checking the Folding Top Control Switch

If there is current at the feed wire terminal of the

M P SIDE

L PRESSURIZED FLUlD

SEATS BALL

PREVENTING FLUlD FROM

ENTERING RESERVOIR

1730

Fig. 12-23-Fluid Control Valve Fig. 12-25-Checking Wire Leads to Motor

FOLDING TOP 12-17 terminal block, operation of switch can be checked as follows:

1. Place a 12 gauge jumper wire on switch terminal block between center terminal (feed) and one motor wire terminal. If motor operates with jumper wire, but did not operate with switch, switch is defective.

2. Connect jumper wire between center terminal and other motor wire terminal on switch terminal block. If motor operates with jumper wire, but did not operate with switch, switch is defective.

Checking Switch to Motor Lead Wires

If switch is found to be operating properly, the switch to motor lead wires can be checked as follows (See

Figure 12-25).

1. Disconnect green motor lead switch-to-motor wire - from motor in rear compartment.

2. Connect a light tester to switch-to-motor wire terminal.

3. Ground light tester ground lead to body metal.

4. Actuate switch to "down" position. If tester does not light, there is an open or short circuit in wire.

5. Disconnect red switch-to-motor wire from motor lead. .

6. Connect light tester to switch-to-motor wire feed terminal.

7. Actuate switch to "up" position. If tester does not light, there is an open or short circuit in wire.

Checking the Motor Unit

If a light tester indicates current at the motor lead terminals of the switch-to-motor wires, but motor unit does not operate from switch, a final check of the motor unit can be made as follows:

1. Check connection of motor ground wire to body metal (See Fig. 12-17).

2. Connect a 12 gauge jumper wire from battery positive pole to motor lead terminal that connects to green motor lead wire. The motor should operate to lower top.

3. Connect jumper wire to motor lead terminal that connects to red motor lead wire. The motor should operate to raise top.

4. If motor fails to operate on either or both of these checks, it should be repaired or replaced.

5. If motor operates with jumper wire but will not operate from switch-to-motor wires, the trouble may be caused by reduced current resulting from damaged wiring or poor connections.

HYDRAULIC

CHECKING PROCEDURE

Failures in the hydraulic system can be caused by lack of hydraulic fluid, leaks in hydraulic system, obstructions or kinks in hydraulic hoses or faulty operation of a cylinder or pump.

Checking Hydraulic Fluid Lever in Reservoir

1. Operate top to raised position.

2. Perform the following operations: a. Detach front edge of folding top compartment bag from rear seat back panel. b. Remove clips securing hydraulic hose to rear seat back panel. c. Disengage pump attaching grommets from compartment pan brace.

3. Place absorbent rags below reservoir at filler plug.

4. With needle nose pliers, remove filler plug. Fluid level should be within 1/4 inch of lower edge of filler plug hole.

5. If fluid is low, add Type A transmission fluid,

Dexron or equivalent to bring to specified level.

See "Filling of Hydro-Lectric Reservoir".

6. Install filler plug.

Fig. 12-26-Checking Pump Pressure

12-18 FOLDING TOP

Fig. 12-27-Folding Top Linkage Attachment

7. Install motor and pump assembly and all previously removed parts.

Checking Operation of Lift Cylinders

1. Remove rear seat cushion and back and folding top compartment side panel assemblies.

2. Operate folding top control switch and observe lift cylinders during "up" and "down" cycles for these conditions: a. If movement of cylinder is uncoordinated or sluggish when the motor is actuated, check hydraulic hoses from motor and pump to cylinder for kinds. b. If one cylinder rod moves slower than the other, cylinder having slower moving rod is defective and should be replaced. c. If both cylinder rods move slowly or do not move at all, check the pressure of the pump.

See "Checking the Pressure of the Pump".

NOTE: To insure proper operation of the lift cylinders, the top lift cylinder rods should be cleaned and lubricated at least twice a year. To perform these operations, raise top to "up" position and wipe exposed portion of each top lift cylinder piston rod with a cloth dampened with Type A transmission fluid or equivalent to remove any oxidation and/or accumulated grime.

FOLDING TOP 12-19

EXISTING HOLE IN PLUG

11 l I

V I E W " A "

7

-

Fig. 12-29-Reservoir Filler Plug Adapter

3 3 4 8

Fig. 12-28-Folding Top Lift Cylinder Attachment

IMPORTANT: Exercise care so that transmis- sion fluid does not come in contact with any painted or trimmed parts of the body.

Checking Pressure at the Pump

1. Remove motor and pump assembly from rear compartment.

2. Install plug in one port, and pressure gauge in port to be checked (Figure 12-26).

'

3. Actuate motor with applied terminal voltage within range of 9.5 volts to 11.0 volts. Pressure gauge should show a pressure between 340 psi and

380 psi.

4. Check pressure in other port.

NOTE: A difference in pressure readings may exist between the pressure port for top of cylinders and pressure port for bottom of cylinders. This condition is acceptable if both readings are within the limit of 340 psi and 380 psi.

5. If the pressure is not within specified limits, unit is defective and should be repaired or replaced, as required.

Removal and Installation

1. Lock top to windshield header.

2. Disconnect positive battery cable to prevent accidental operation ,of motor and pump, particularly when hydraulic hoses are discon- nected from cylinder.

3. Remove rear seat cushion and seat back.

4. Remove folding top compartment side trim panel assembly on side affected.

5. Remove clips securing hydraulic hose to rear seat back panel.

6. Remove attaching nut, bolt, bushing and washer from upper end of cylinder rod (Figures 12-27 and 12-28).

7. Remove inner and outer bolt securing cylinder to male hinge (Fig. 12-28).

8. Carefully move cylinder to inboard side of top compartment brace, exposing upper and lower hydraulic hose to cylinder connections.

9. Prior to disconnecting hydraulic connections, place suitable wiping rags under connections to absorb any drippage of hydraulic fluid.

10. Disconnect hydraulic connections from old cylin-

. der and transfer to new cylinder assembly, if replacement is required.

11. Install cylinder to male hinge.

12. Connect positive battery cable to battery terminal.

12-20 FOLDING TOP

CONTAINER

AOTOR AND 1

Fig. 12-30-Filling Reservoir with Hydraulic

Fluid

13. Using power, raise cylinder piston rod to extended position.

14. Attach upper end of cylinder rod to folding top linkage using previously removed nut, bolt, bushing and washer.

15. Operate folding top assembly down and up several times; then check and correct level of hydraulic fluid in reservoir. See "Filling of Hydro-Lectric

Reservoir".

16. Install hydraulic hose to rear seat back panel with clips and install all previously removed trim and hardware.

FILLING OF HYDRO-LECTRIC

RESERVOIR

This procedure virtually eliminates discharge or spillage of hydraulic fluid and possible trim damage while filling and bleeding system.

FABRICATION OF RUBBER FILLER PLUG

ADAPTER

1. Obtain a spare rubber filler plug, Part No.

7596442 or equivalent.

2. Cut approximately 1/2" off male end of plug (end inserted into reservoir) to permit insertion of tubing as shown in sketch.

3. Obtain a 2" length of metal tubing 7/32 O.D. x

5/32 I.D.

4. Insert reworked plug into filler hole in reservoir.

5. Insert metal tubing through hole in reworked filler plug.

NOTE: Figure 12-29 illustrates fabricated filler plug adapter.

FILLING AND BLEEDING RESERVOIR

1. With top in raised position, remove folding top compartment bag material from rear seat back panel.

2. Place absorbent rags below reservoir at filler plug.

Using pliers, slowly pull filler plug from reservoir.

IMPORTANT: When installing new or overhauled motor and pump assembly as a bench operation, fill reservoir with proper fluid.

This priming operation is necessary prior to performing the following steps in order to avoid drawing excessive amount of air into hydraulic system.

3. Install filler plug adapter to refervoir and attach four or five foot length 5/32 inch I.D. rubber tubing or hose to filler plug tubing.

4. Install opposite end of hose into a container of proper fluid

NOTE: Container should be placed in rear compartment area below level of fluid in the reservoir. In addition, sufficient fluid must be available in container to avoid drawing air into hydraulic system (Fig. 12-30).

5. Operate top to down or stacked position. After top is fully lowered continue motor and pump assembly (approximately 15 to 20 seconds), or until noise level of pump is noticeably reduced.

Reduction in pump noise level indicates that hydraulic system is filled with fluid.

6. Operate top up and down several times or until operation of top is consistently smooth in both up and down cycles and no further air bubbles are exhausted in container or fluid.

7. WITH TOP IN DOWN POSITION, remove 'filler plug tubing and remove filler plug adapter from reservoir.

NOTE: Fluid level should be within 1/4 inch of lower edge of filler plug with top in down position.

IMPORTANT: DO NOT OVER-FILL

FOLDING TOP 12-21

FOLDING TOP ADJUSTMENTS "A" BODIES

Description

The folding top linkage consists of three sections of side roof rails, a front roof rail, hinges, connecting links and bows. The top linkage is attached to the body at the rear quarter area by a stationary, side- mounted male hinge. The front roof rail locks at the windshield header by hook type locks which are integral with the locking handles.

The following information outlines and illustrates procedures which may bZ used to correct misaligned folding top linkage. To correct some top variations, only a single adjustment is required; other top variations require a combination of adjustments. In conjunction with adjustments of the folding top, it may be necessary to adjust ,the door, door glass, rear quarter glass, or side roof rail weatherstrips.

ADJUSTMENT OF FRONT

ROOF RAlL GUIDE

If the front roof rail guide does not properly engage with the striker when the top is raised, the guide may be adjusted laterally as followc.

1. Unlatch top and raise it above windshield header.

2. Loosen guide and adjust to desired position; then tighten guide (Fig. 12-3 1).

NOTE: The sunshade support and striker assembly is not adjustable. If additional fore and aft adjustment is required, it must be obtained by adjusting the front roof rail.

ADJUSTMENT OF FRONT ROOF RAlL

If the top, when raised, is too far forward or does not move forward enough to allow the guide pin to enter the striker, proceed as follows:

1. Unlatch top and raise it above windshield header.

Remove side roof rail weatherstrip front attach- ing screws.

2. Loosen side roof rail lock attaching screws and adjust front roof rail fore or aft as required (Fig.

12-32).

3. Tighten lock attaching screws and install weather- strip screws.

#

FRONT ROOF RAlL LOCK ASSEMBLY

Removal and Installation

1. Lower top to halfilowered position, remove lock attaching screws; and remove lock assembly from front roof rail (Fig. 12-32).

2. To install, reverse removal procedure and adjust front roof rail as required.

Fig. 12-31-Front Roof Rail Guide and Lock

Hook

Fig. 12-32-Front Roof Rail and Lock

Attachment

12-22 FOLDING TOP

I

FRONT ROOF RAIL

VIEW A

ATTACHING SCREWS

VIEW C

FRONT B O W 7

VlEW B

Fig. 12-33-Folding Top Adjustments

FOLDING TOP 12-23

FRONT ROOF RAIL LOCK ADJUSTMENT

If locking action of top is unsatisfactory, the hook on the lock assembly may be adjusted as follows:

1. To tighten or increase locking action, turn lock hook clockwise.

2. To reduce or decrease locking action, turn lock hook counterclockwise (Fig. 12-32).

ADJUSTMENT OF TOP CONTROL LINK

If side roof rails are too high or too low over side windows, proceed as follows:

IMPORTANT: When making top control link adjust- ments, be sure side roof rail hinge adjusting screw

(Fig. 12-33 View "B") is backed off.

1. Operate top to half-lowered position.

2. Loosen bolt securing control link sufficiently to permit adjustment (pig. 12-27).

3. Adjust top control link as required bolt. and tighten

Raise and lock top. Check alignment.

TROUBLE SHOOTING CHART "A" STYLES

I A. Difficult locking action at front

APPARENT CAUSE CONDITION 0

1. Lock hook to short.

CORRECTION

Adjust lock hook counterclock-

2. Misaligned front roof rail wise

6

Loosen, realign and retack front front weatherstrip.--- roof rail front weatherstrip.

3. Front roof rail misaligned. Adjust front roof rail.

B. Top does not lock tight enough to windshield header.

1. Lock hook too long.

2. Misaligned front roof rail weatherstrips.

3. Front roof rail misaligned.

Adjust lock hook clockwise.

Loosen and realign front roof rail weatherstrips.

Adjust front roof rail.

D. Top does not travel forward far enough.

1. Front roof rail misaligned.

E. Side roof rails low. 1. Center side roof rail hinge adjusting screw protrudes.

2. control. link misaligned.

Adjust front roof rail forward.

Back off adjusting screw (View

"B" Fig. 12-33).

Adjust control link downward.

12-24 FOLDING TOP

CONDITION APPARENT CAUSE

G. Top material is too low over windows or side roof rails.

I. Front roof bow insufficiently shimmed.

1. Excessive width in top ma- terial.

CORRECTION

Install one or two 1/8" shims between front roof bow and slat iron (See View "B" in Fig.

12-33).

If top is too large, detach binding along affected area; trim off ex- cessive material along side bind- ing as required; then hand sew binding to top material.

H. Top material is too high over windows or side roof rails.

I . Front roof bow shimmed too high.

Remove one or two 1/8" shims between front roof bow and slat iron (See View "B" in Fig.

12-33).

I. Top material has wrinkles or draws.

1. Top material improperly installed.

J. Top material binds at side quarters.

1. Insufficient clearance.

Reposition and retack top ma- terial as required.

0

Install shim of necessary thick- ness between hinge and body.

K.

One side staggers upon raisin1 top from folding top compart- ment.

1. Bind condition in folding top linkage

With top lowered, remove trim on affected side. Loosen male hinge attaching bolts. Do not loosen top control link. Raise top

3 to 4 feet. Tighten bolts and re- check operation of top. Reinstall trim.

When no shims are required or when installing only one shim, use attaching screw part No. 4412844 (1/4

When two shims are required, use attaching screw part

-

No. 4412619 (1/4

-

20 x 3/4" oval head with external

20 x 5/8" oval head with external tooth lock washer, tooth lock washer, type "T-T" tapping screw, chrome type "T-T" tapping screw, chrome finish or equivalent). finish or equivalent).

1. On annual basis apply a limited amount of low temperature lubricant-(a good grade machine oil or equivalent) to all friction surfaces.

2.

The friction surfaces lubricated should include all washer$, bushings and other contact surfaces.

3. T o prevent soiling trim, wipe 'off e x e s s lubricant.

DOOR AND QUARTER TRIM 13-1

SECTION 13

SUBJECT PAGE

Door and Quarter Trim ......................................... 13-1

Introduction

..............................................................

13-1

Door Pull Handles

..................................................

13-1

Door Arm Rests

.....................................................

13-1

Door Outside Mirror Remote Controls and

Escutcheon

..............................................................

13-1

Door and Quarter Inside Handles

Door Trim Assemblies

'Door Trim Panel Moldings

.

.....................

..........................................

13-2

Door Belt Finishing Molding

. with', Standard Trim

- 12487 Style

............................................

....

13-2

13-5

13-7

Rear Quarter Arm Rest

2-Door Closed Styles

-

"A and X"

..........................................

Rear Quarter Arm Rest

-

"A, B, C and E"

13-8

2-Door Hardtop Styles and

"B and E" Convertible Styles

........................... 13-8

Rear Quarter Arm Rest styles

-

"A" Convertible

.......................................................................

13-9

Rear Quarter Trim Assembly

,-

All 2-Door

Styles Except "P" Styles

Rear Quarter Trim Panel

....................................

-

"F" Styles

-

...........

All

13-1 1

13-11

Rear Quarter Trim Finishing Panel

4-Door and "A-80'' Styles

................................ 13-1 1

INDEX

SUBJECT PAGE

Rear Quarter Upper Trim (Above Belt)

Styles

Center Pillar Trim

Center Pillar Upper and Lower Trim

68169 Style

-

-

All

.......................................................................

...........................................................

13-11

-

All Styles Except 68169 13-14

13-14

Body Lock Pillar Windlace Assembly and C" Coupe Styles

-

"A, B

...........................................

13-15

Rear Quarter Trim Front Finishing Panel

"A and B" Station Wagon Styles

-

...................

13-15

Rear Quarter Wheelhouse Trim Cover Panel

(Right Side)

-

"A and B"

Station Wagon Styles

..........................................

-

"A and B" Station

13-16

Spare Tire Cover Panel

Wagon Styles

.........................................................

Rear Quarter Wheelhouse Trim Cover Panel

(Left Side)

-

"A and B"

Station Wagon Styles

..........................................

Back Window Panel Trim

......................................

13-17

13-20

Rear Seat to Back Window Panel Trim

Assembly

-

All Styles

............................................

INTRODUCTION

This section of the manual contains the service operations that are necessary for the removal and installation of door and rear quarter trim assemblies.

Body series or styles references in the procedures are explained under "General Information", Section I of this manual.

DOOR PULL HANDLES

Door pull handles are secured to the trim pad with screws or stud nuts on the outboard (reverse) side of the trim assembly prior to trim installation. In addition, on some styles, the handles are secured to the door inner panel with screws installed from the inboard side after trim installation. With this method of installation, the pull handle and trim pad are removed from the door as an assembly (Figs. 13-1 and

13-2).

NOTE: To remove the door trim assembly on any style equipped with a door pull handle requires removal of the screws inserted through the handle hinges or handle base into the door inner panel. On styles with snap-on escutcheons .covering the handle screws, carefully disengage the escutcheons from the retainers using a flat-bladed tool (Figs. 13- 1 and 13-2). On styles with stud retained escutcheons (Figure 13-2), pry alternately from both ends of the escutcheon to prevent siud breakage during removal operation.

DOOR ARM RESTS

There are three basic types of door arm rests: those applied after door trim installation, those assembled to the door trim prior to trim installation and arm rests which are an integral part of the door trim assembly.

For removal of the first or second type arm rests, refer to Figures 13-3 and 13-4.

DOOR OUTSIDE MIRROR REMOTE

CONTROLS AND ESCUTCHEON

On ,styles with remote control door outside mirrors, the remote control mirror cable must be disengaged from the door trim assembly or arm rest (Cadillac styles only) to permit trim assembly removal. To disengage the remote cable from the door trim assembly, refer to

Figures 13-5 and 13-6.

13-2 DOOR AND QUARTER TRIM

- -

Fig. 13- 1 -Typical Door Pull Handle Attachment

DOOR AND QUARTER INSIDE HANDLES

Door and quarter inside handles are retained by either screws or spring clips (Figures 13-7, 13-8 and 13-9). On styles equipped with screw retained handles, the screws are either exposed or covered by a remote control cover plate that can be removed as shown in Figures

13-8 and 13-10).

Removal and Installation

1. On styles with clip retained handles, clip is either exposed when arm rest is removed, or else is hidden by handle (Figs. 13-7 and 13-9). Exposed clips can be disengaged from remote control spindle with a screwdriver.

Clips hidden by window regulator or remote control handles can be disengaged by depressing door trim assembly sufficiently to permit inserting tool 5-9886 or equivalent between handle and plastic bearing plate (Figure 13-11). Then, with tool in same plane as inside handle, push tool as indicated to disengage clip. Pull handle inboard to remove from spindle.

2. To install ventilator and window regulator handles, engage retaining clip on handle. Position handle at same angle as opposite side handle and press handle outboard until clip engages regulator spindle. On remote control spindles, install handle in a horizontal position.

DOOR TRIM ASSEMBLIES

There are two basic types of door trim assemblies, a one piece trim assembly that is used on all "A, F and

X" styles and a two piece trim that is used on "B, C and E" styles.

On all "A, F and

Xu

styles, except 12487 styles, the one piece trim hangs over the door inner panel across the top and is secured by clips or nails down the sides,

DOOR AND QUARTER TRIM 13-3

I

Fig. 13-2-Typical Door Pull Handle Attachment and by screws across the bottom (Fig. 13-12 is a composite illustration of the various types of door trim panel fasteners). 12487 styles with standard trim utilize a belt finishing molding across the top of the trim assembly (Figure 13-4). For removai of this molding refer to "Door Belt Finishing Molding (12487 Style with Standard Trim)".

1

On "B, C and

E"

styles with the two piece trim, the upper portion hangs over the door inner panel across the top and is secured by trim nails and screws across the bottom. The lower portion is retained by screws across the top and by clips down the sides .and across the bottom.

Fig. 13-3-Typical Door Arm Rest Applied After

Trim Installation

Removal and Installation

1. Remove all door inside handles as previously described.

2. Remove door inside locking rod knob.

13-4 DOOR AND QUARTER TRIM

1

Fig. 13-4-Typical Door Arm Rest Assembled to Door Trim Assembly Prior to Trim Installation

3. On styles equipped with door pull handles, remove screws inserted through handle into door inner panel (For location of screws, refer to Figures 13-

1 and 13-2).

13-13) and disconnect wire harness at switch assembly.

4. On styles with remote control mirror assemblies, remove remote mirror escutcheon and disengage end of mirror control cable from escutcheon as previously described (Figures 13-5 and 13-6).

9. On

"B,

C and

E"

styles, with two piece trim assemblies, remove attaching screws located at outer lower corners of upper trim assembly. Then, using tool 5-9886 or equivalent disengage retaining nails from plastic cups inserted in door inner panel along lower edge of upper trim.

Remove upper trim from door by lifting upward and sliding it slightly rearward to disengage it from door inner panel at beltline.

5. On styles equipped with switch cover plate in door arm rest, remove screws securing cover plate and disconnect switches and cigar lighter (if equipped) from wire harness connectors (Fig. 13-6).

6. On styles with remote control cover plates (Figures

13-8 and 13-10), remove exposed screws securing cover plate to door inner panel.

7. On styles with arm rest applied to door trim assembly prior to trim installation (Figure 13-4) or styles with integral arm rest, remove screws inserted throhgh pull cup into arm rest hanger support. On styles with arm rest applied after door trim installation (Figure 13-3), remove arm rest to door inner panel attaching screws.

8. On Cadillac styles, remove windshield wiper control switch to "pod" attaching screw (Figure

NOTE: On styles with electric switches located in door trim assembly, disconnect wire harness at switch assembly.

To remove lower trim, on

"B,

C and

E"

styles remove attaching screws along upper edge of lower trim assembly. Then, starting at a lower corner, insert tool 5-9886 or equivalent between door .inner panel and trim assembly and disengage, retaining clips from plastic cups down both sides and across the bottom.

NOTE: On styles with courtesy lamps located in lower trim assembly, disconnect wire harness at lamp assembly (Figure 13-14).

DOOR AND QUARTER TRIM 13-5

Fig. 13-5-Typical Remote Mirror Cable and Escutcheon Attachment, All Except Cadillac Styles

10. On "A,

F

and

X"

styles remove all screws down both sides and across bottom of door trim pad.

Then, starting at a lower corner, insert tool J-9886 or equivalent between door inner panel and trim assembly and, carefully disengage retaining nails or clips from plastic cups inserted in door inner panel (Fig. 13-12).

To remove trim assembly, lift trim assembly upward and slide it slightly rearward to disengage it from door inner panel at the belt line. On styles with electric switches located in the door trim assembly, disconnect wire harness and remove trim assembly from door.

11. To install door trim assemblies, reverse removal procedure.

'

NOTE: On styles with adjustable trim supports at belt line, the door trim assembly can be adjusted in or out so as not to restrict door window operation.

DOOR BELT FINISHING MOLDING

-

(12487 STYLE WITH STANDARD TRIM)

Fig. 13-6-Door Armrest. Switch Cover Plate and

Remote Mirror Cable Attachment (Cadillac Styles)

The door belt trim molding is retained by trim supports at top of the door inner panel, and by screws

13-6 DOOR AND QUARTER TRIM

VIEW "A"

Fig. 13-7-Typical Door Lock Remote Control

Handle Installations

-

(Figure 13-4).

-

SPRING CLIP

4304

0

Fig. 13-9-Typical Window Regulator Handle

Assembly Installation

Removal and Installation

1. Remove door inside locking rod knob.

2. Loosen upper portion of door trim panel sufficiently, as previously described, to gain access to and remove molding attaching screws.

Fig. 13-8-Typical Door Lock Remote Control and Handle Assembly Installation

Fig. 13-10-Typical Remote Control Cover Plate

Installations

DOOR AND QUARTER TRIM 13-7

TOOL J-7797 RETAINING SPRING

\

DISENGAGED\

DIRECTION OF ARROW 'NS'DE HANDLE

Fig. 13-1 1-Clip Retained Door Inside Handle

Removal

3. Lift molding upward to disengage from trim supports on top of door inner panel.

4. To install, reverse removal procedure.

DOOR TRIM PANEL MOLDINGS AND

APPLIQUES

Door trim moldings and appliques are secured from

Fig. 13-13-Windshield Wiper Control Switch

Removal and Installation (Cadillac Styles)

the outboard side of the door trim panel with several types of metal fasteners (Figure 13-15) or bend-over tabs.

Removal and Installation

1.

Remove door trim p e m b l y as previously described.

2. For removal of type "A" fasteners, Figure 13- 15, use tool J-23554 or equivalent.

3. To remove type

"B"

fasteners, Figure 13-15, carefully pry-up on fastener until there is sufficient working space to insert wire cutter; then, cut fastener and discard.

4. For removal of type use a cross head type screwdriver.

5. To install, reverse removal procedure.

Fig. 13-12-Typical Types of Door Trim

Retention r ~ " A

OUTBOARD )

~ ~

Fig. 13-14-Courtesy Lamp Removal and

Installation

13-8 DOOR A N D QUARTER TRIM

TYPE

'

A" TYPE "0

'

TYPE "C"

Fig. 13-IS-Door Trim Pad Molding and

Applique Removal

REAR QUARTER ARM REST

-

"A and X" Two-Door Closed Styles

Removal and Installation

Certain two door closed styles are equipped with

"applied-type" arm rests. Each arm rest is secured to quarter inner panel by two attaching screws. Removal is simply a matter of removing two attaching screws

(Fig. 13-16). To install, reverse the removal operations.

REAR QUARTER ARM REST

-

"A,

B, C and E" Two-Door Hardtop Styles and

"B and E" Convertible Styles

Certain two-door hardtop and convertible styles are equipped with "Floor-Mounted Type" arm rests. The arm rests extend from the arm position to the floor, and from the body lock pillar to the rear seat back panel (Fig. 13-17).

V I E W B

Fig. 13-16-Quarter Trim Assembly Attachment Two-Door Sedan Styles

3 8 4 2

DOOR AND QUARTER TRIM 13-9

VIEW "A" VIEW "C"

VlEW "D"

VlEW "B"

Fig. 13-17-Quarter Trim Assembly Attachment Two-Door Hardtop Styles ("B" Style Shown)

Removal and installation

REAR QUARTER ARM REST

-

"A"

1. Remove rear seat cushion and back assemblies.

2. Remove arm rest front and lower attaching screws.

Arm rests on convertible styles are a "Floor-Mounted

Type" and include an integral folding top compart- ment side trim panel (Fig. 13-20).

Removal and Installation

3. On "B", "C" and "E" styles, remove attaching screw at upper rear of arm rest (Fig. 13-17).

1. Remove rear seat cushion and back assemblies.

On "A" styles, remove attaching screws from side filler panel (Fig. 13-18). Quarter arm rest and filler panel are connected together and are removed as assembly at this time.

4. Where present, detach electrical wiring and remove arm rest (View "B" Fig. 13- 19).

2. Remove attaching screws at front of arm rest.

.

3. Remove attaching screws from folding top compartment side trim panel as

she*

(Fig. 13-

.20).

4. Where present, detach electrical wiring and remove arm rest (View "A" Fig. 13-2 1).

5. To install, connect electrical wiring and reverse removal operations.

5. To install, connect electrical wiring and reverse removal operations.

13-10 DOOR AND QUARTER TRIM

SEAT BACK

FILLER PANEL

VlEW A

QUARTER TRI

V l E W C

3 8 3 6

Fig. 13-18-Quarter Trim Assembly Attachment Two-Door Hardtop Styles ("A" Style Shown)

FOLDING TOP COMPARTMENT

SIDE TRlM PANEL

A R M REST

/ u m

W I N D O W S E C T I O N A - A

ASH TRAY

C I G A R LIGHTER

V l E W B

Fig. 13-19-Quarter Arm Rest Ash Tray and

Electric Switch Plate (Hardtop Styles)

116

QUARTER TRIM

3 8 37

Fig. 13-20-Quarter Trim Assembly Attachment

Convertible Styles

DOOR AND QUARTER TRIM 13- 1 1

OCKET

RETAINING SCREWS

VIEW A

Fig. 13-21-Quarter Arm Rest Courtesy Lamp

Convertible Styles

REAR QUARTER TRlM ASSEMBLY

-

All Two-Door Styles, Except "F" Styles

Removal and lnstallation

1. Remove rear seat cushion and back assemblies.

2. Where present, remove quarter window regulator handle.

3. Remove quarter arm rest and, where present, quarter filler panel.

4. Where present, remove attaching screw(s) from front and/or rear of quarter trim assembly (Fig.

13-16 and View "C" Fig. 13- 17).

5. Where present, detach fasteners securing quarter trim along body lock pillar (View "B" Fig. 13-16) with tool 5-9886 or equivalent.

6. Detach quarter trim by lifting assembly off hangar retention.

7. Where present, detach electrical wiring and remove trim assembly.

8. To install, connect electrical wiring and reverse removal operations.

REAR QUARTER TRlM PANEL

Styles

-

"F"

The rear quarter trim panel consist of a one-piece plastic panel with an integral arm rest (Fig. 13-22).

Removal and lnstallation

1. Remove rear seat back and applicable rear seat cushion.

2. Remove rear quarter upper trim.

3. Remove attaching screws from lower front (View

"C", Figure 13-22) and upper rear (View "D",

Figure 13-22) of trim panel.

4. Remove door opening sill plate. Then, slide trim panel forward and rkmove quarter trim panel.

5. To install, reverse removal operations.

REAR QUARTER TRlM FINISHING PANEL

All Four-Door and "A-80" Styles

Removal and lnstallation

1. Remove rear seat cushion and back assemblies.

2. On "A, B and X" styles, remove attaching screws from trim panel (Fig. 13-23) and remove trim panel.

3. On "C" styles, insert tool 5-9886 or equivalent at each clip location and pry retaining clip from plastic retaining plugs (View "B" Fig. 13-24) and remove trim panel.

4. To install, reverse removal operations.

REAR QUARTER UPPER TRlM

(Above Belt)

-

All Styles

Removal and lnstallation

1. On styles so equipped, detach molding or finishing lace from side of back window opening and along side roof rail adjacent to quarter upper trim assembly.

2. Remove attaching screw(s) or, if cemented, carefully break cement bond between upper trim and retainer along back window (Figs. 13-25 and

13-26).

3. On styles equipped with optional rear seat shoulder harness, remove anchor bolts securing harness at quarter upper trim. On styles equipped with courtesy lamps in quarter upper trim, disconnect and remove lamp before proceeding with next removal operation.

4. With long flat bladed tool, carefully locate and unfasten quarter upper trim two-part multiple-peg

13-12 DOOR AND QUARTER TRIM

SECTION A - A

SECTION 0 - B

Fig. 13-22-hear Quarter Trim Attachment

- "F" Styles

REAR QUARTER

LOWER TRIM

SECTION A - A

SECTION 0 - 0

3277

Fig. 13-23-Quarter Trim Assembly Attachment

"A, B and X" Four-Door and "A-80" Styles

Fig. 13-24-Quarter Trim Assembly Attachment

"C" Four-Door Styles

DOOR AND QUARTER TRIM 13-13

Fig. 13:25-Quarter TJpper Trim Attachment

-

Typical Installation

13-14 DOOR AND QUARTER TRIM fasteners (View "A" Fig. 13-25). Then remove trim.

2. On hardtop styles, remove attaching screws securing trim finishing cap (Fig. 13-27). Then,

NOTE: Part 1 of fastener, as shown in Figure 13-

25, secures to quarter inner panel. Part 2 of fastener (Figure 13-25) is stapled to foundation of quarter upper trim. For best results during removal, confine prying operations between the fasteners. remove trim from pillar by lifting straight-up to clear retaining flanges.

3. On closed styles, remove attaching screws securing upper trim to center pillar. To remove lower trim after upper trim has been removed, lift trim straight-up to clear retaining flanges on center pillar.

5. To install trim assembly, feed courtesy lamp wire through trim panel. Also, position trim assembly at lower retaining clip ("DM Fig. 13-25) and along front and rear edges. Then, secure fasteners with a moderate hand pressure. Reverse balance of removal operations. When necessary, use non- staining vinyl trim adhesive t o cement trim at back window retainer.

CENTER PILLAR TRIM

68169 Style

4. To install reverse removal operations.

CENTER PILLAR UPPER AND LOWER

TRIM

-

68169 Style

Removal and Installation

-

All Styles, Except

1. Remove center pillar upper trim by gently prying serrated attaching nails from center pillar (Fig.

13-28).

Removal and Installation

2. Remove front and rear door sill plates.

1. Remove front and rear door sill plates.

P A R T I F A S T E N E R

A T T A C H I N G H O L E S

#

QUARTER

UPPER-TRIM

1 ;

-'

" ' I QUARTER UPPER T R I M

QUARTER UPPER T R l M

( B A C K - S I D E )

Fig. 13-26-Quarter Upper Trim Attachment - Typical Installation

3 9 4 3

DOOR AND QUARTER TRIM 13-15

VIEW A

C E N T E R P I L L A R T R l M P A N E L

.

. . .

-- -

Fig. 13-27-Center Pillar Trim Attachment "A, B and C" Hardtop Styles

3. Remove attaching screws from center pillar lower trim.

4. With flat bladed tool, such as 5-9886 or equivalent, carefully pry attaching clips from center pillar and remove lower trim.

5. To install, reverse removal procedure.

BODY LOCK PILLAR WINDLACE

ASSEMBLY

-

"A, 6 and C" Coupe Styles

Removal and Installation

1. Remove rear quarter trim assembly and detach door sill plate.

Fig. 13-29-Body Lock Pillar Windlace

-

"A" Styles

2. On "A" styles, remove windlace attaching screws

(Fig. 13-29) and remove windlace. The windlace is sewn to a foundation board and is installed as a separate assembly.

3. On "B and C" styles, pull inboard on the windlace to disengage from the lock pillar (Figure 13-30).

4. To install, reverse removal operations.

CENTER PILLAR

UPPER TRlM

Fig. 13-28-Center Pillar Trim Attachment

Typical Installation

REAR QUARTER TRlM FRONT FINISHING

PANEL

-

"A and B" Station Wagon Styles

Removal and Installation

1. Detach quarter window lower garnish molding.

2.

Detach side roof rail finishing molding and remove rear body lock pillar upper finishing panel.

3. Detach door sill plate.

4. On all "B" styles with split second seat, remove seat back lock striker and bumper assembly from wheelhouse.

5. Remove attaching screws from finishing panel and remove panel (Fig. 13-3 1).

13-16 DOOR AND QUARTER TRIM

VlEW "A"

4356

VlEW "8"

Fig. 13-30-Body Lock Pillar Windlace

-

"B and C" Styles

6. TO install, position finishing panel to rear lock pillar and reverse removal operations.

5 . Remove attaching screws from perimeter of trim cover panel and remove panel.

6. To install, reverse removal operations.

REAR QUARTER WHEELHOUSE TRIM

COVER PANEL

(Right Side)

Styles

-

-

"A and

B"

Station Wagon

SPARE TIRE COVER PANEL

"A and

-

Bw

Station Wagon Styles

Removal and Installation

1. Remove quarter window lower and front garnish moldings.

2. Remove rear quarter trim front finishing panel.

3. Remove spare tire cover panel.

4. Remove second folding seat back lock striker and bumper assembly from wheelhouse (Fig. 13-32).

Removal and Installation

The spare tire cover panel is retained at the beltline by an overlapping quarter window garnish molding. The cover panel is secured at the bottorp by a striker and folding

1

(catch-type) lock handle (Fig. 13-32). To remove cover, open lock handle, swing bottom of cover outward to release at belt line and remove. To install, reverse removal procedure.

DOOR AND QUARTER TRIM 13-17

S E C T I O N A - A

I

V I E W I N C I R C L E ' 8

Fig. 13-31-Quaner Front Trim Finishing Panel

"A and B Station Wagon Styles

31 6

NOTE:

On styles with tail gate window defogger, disconnect hose from defogger outlet grille to complete removal.

REAR QUARTER WHEELHOUSE TRIM

COVER PANEL

(Left Side)

Styles

-

-

*'A and 6" Station Wagon

Removal and Installation

6

1. Remove quarter window lower and front garnish molqing

.

2. Remove seat back bumper or seat back lock striker

(on all

"B"

styles and "A" styles with optional split seat) Fig. 13-33.

3. Remove rear quarter trim front finishing panel.

4. Remove attaching screws from perimeter of trim cover panel as shown in Figure 13-33.

5. Detacb electrical wiring from cover panel components and remove cover panel.

6. To install, connect electrical wiring and reverse removal operations.

13-18 DOOR A N D QUARTER TRIM

-

V l E W I N C I R C L E ' B '

V l E W I N CIRCLE ' A '

Fig. 13-32-Wheelhouse Trim Cover Panels (Right Side) "A and B" Station Wagon Styles

T A I L G A T E W I N D O W SW1TC.H

C O U R T E S

R E T A l

DOOR A N D QUARTER TRIM 13-19

S E A T BACK

L O C K STRICKER

( s t y l e s w i t h o p t i o n a l s p l i t s e a t )

V I E W I N C I R C L E C

Fig. 13-33-Wheelhouse Trim Cover Panel (Left Side) "A and B" Station Wagon Styles

3 1 9 4

13-20 DOOR AND QUARTER TRIM

BACK WINDOW PANEL TRlM

REAR SEAT TO BACK WINDOW PANEL

TRlM ASSEMBLY

-

All

Styles

Rembval and Installation

1. Remove rear seat cushion and back assemblies.

2. Detach shoulder straps if so equipped. Also, whert present, detach optional equipment grilles.

3. Remove rear quarter lower and upper trim assemblies.

4. Carefully break cement bond securing trim assembly at seat back panel (Fig. 13-34).

5. Remove trim assembly by lifting up front edge and by pulling assembly forward.

6. To install, position trim assembly to back window panel by inserting rear edge of assembly under garnish molding or feature strip. Center and align front edge of trim assembly with front edge of seat back panel as shown in Figure 13-34. With non-staining vinyl trim adhesive, cement valance of trim assembly to seat back panel as shown.

Then reverse balance of removal procedure.

BACK W I N D O W PANEL TRlM 7

SECTION A-A

Fig. 13-34-Back Window Panel Trim Attachment

All Styles

SEATS 14-1

SECTION

14

SEATS

INDEX

SUBJECT PAGE

Introduction ...............................................................

14-3

Front Seat Dealer Relocation Provisions

...........

14-3

Seat Adjuster Spacer Usage

..................................

14-3

Seat Torque Specifications

..................................

14-3

Manually Operated Seat Adjuster Control Arm

Knob

..........................................................................

Front Seat Assembly

-

Conventional Full Width

Strato and 60-40 Seats

..........................................

14-5

Description

...............................................................

Seat Assembly

Seat Assembly or Six-Way

-

Manually Operated

................

.............................................................

Adjuster Assembly

Four or Six-Way

-

Power Operated Two,

..................................................

14-1 2

Two-way Seat Adjuster Major Components

-

146

Adjuster Assembly

-

Manually Operated

.........

14-7

-

Power Operated Two, Four

'IC" Body Full Width Seats and 60-40

Drivers Seat

Electric Motor

.......................................................... 14-12

.......................................................

Horizontal Gearnut Assembly

Horizontal Jackscrew

Plastic Slides

Plastic Slides

Drive Cables

Transmission

.........................................

............................................................

.............................................................

Disassembly and Assembly of Transmission

Six-Way Seat Adjuster Major Components -

60-40

..

14-22

Seats ................................................................ 14-22

Electric Motor

..........................................................

Rear Vertical Drive Cable

14-22

...................................

14-23

Horizontal or Front Vertical Drive Cables

.....

14-23

Transmission Assembly

........................................

Disassembly and .Assembly

14-14

............................................................

Four-Way Seat Adjuster Major Components

"A" Body Full Width Seats

-

................................

14-17

Electric Motor

..........................

........................................

. ..........

14-1 7

Vertical Gearnut .....................................................

14-17

Horizontal Actuator

................................................

14-18

Jackscrew

...................................................................

Horizontal and Vertical Drive Cables

Transmission

.............................................................

Disassembly and Assembly of Transmission

Six-Way Seat Adjuster Major Components

"B-C and E" Full Width Seats

-

..

14-18

..........................

14-19

Electric Motor

..........................................................

Horizontal Actuator

...............................................

Horizontal Actuator Adjustment

14-19

.........................

14-20

Front and Rear Vertical Gearnut

......................

14-20

..

..............

.................

14-1 8

14-18

14-21

- Transmission

.....

14-24

Front Seat Back Assembly

-

"A-X and B"

Four-Door Styles With Full Width Seat

.......

14-25

Front Seat Back Assembly

-

Four-Door Style

Full Width Seat With Notch Down Center

Arm Rest and 60-40 Seat

Front Seat Back Assembly

................................

-

Two-Door Style

14-25

Full Width Seat With Notch Down Center

Arm Rest and 60-40 Seat

.................................

Front Seat Back Manually or Electrically

14-26

Operated Lock

-

Two-Door Styles With

Conventional Full Width Seats

.........................

14-28

Front Seat Back Manually Operated Lock

Lock Control and Lock Rod

-

Two-Door

Styles With Conventional Full Width Seats or 60-40 Seats

. ........ .

14-28

Seat Back Electric Lock Solenoid and

Support Assembly

.................................................

14-30

Front Seat Back Head Restraint

-

"B and C"

Bod)' Conventional Full Width or 60-40 Seat 14-32

Head Restraint Lock and Escutcheon

Assembly

...............................................................

Head Restraint Guide Tube

14-33

................................

14-33

Center Arm Rest and Curtain Assembly

Full Width Seat Back

-

.........................................

14-34

Center Arm Rest and Support Assembly

Full Width Seat Back

-

.........................................

14-35

Center Arm Rest and Curtain Assembly

Notch Down Seat Back and Strato Seat

-

.......

14-35

-

Notch Down Center Arm Rest Assembly

Seat Back and Strato Seat

.................................

14-35

Foot Rest Assembly

-

Cadillac 68169

Style

.........................................................................

Strato-Front Seats

Description

............................................................

14-36

Strato Full Width Front Seat Assembly

..........

14-37

Manually Operated Bucket Seat Assembly

......

14-37

Power Operated Four-Way Bucket Seat

Assembly

............................................................

14-37

Manually Operated Bucket Seat Adjuster

..........

1440

Power Operated Four-Way Bucket Seat

Adjuster

.....................................................................

Major Components

.................................................

1440

Motor and Transmission Drive Belts and

Pulleys

... . . ....... ... . . ........... . . . .. . . ..... . . . . . . . . . . .

,

............ .

14-40

Motor Assembly

........................................................

1441

.Transmission Assembly and Horizontal and

Vertical Drive Cables

............................................

1442

Disassembly and Assembly of Transmission

....

1442

......................................

1442

Adjuster Jackscrew

................................................

14-42

Adjuster Horizontal Actuator Assembly

.............

14-42

Torque Tube Assembly

.........................................

14-2 SEATS

SUBJECT PAGE

Adjustable Front Seat Back Assembly

Chevrolet "F" Styles

Description

.............................

.

:

..............

14-43

................................................................

Handle. Cams. Cam Rod. Detent Plate and

Spring ...........................................................................

Seat Back Lock Striker and Seat Back

Side Inner Bar Stop

Description

...............................................

................................................................

Removal and Installation .....................................

Strato-Front Seat Back Panel

14-44

................................

Seat Back Head Restraints .....................................

Seat Back Head Restraint Retainer and Guide

Tube

...........................................................................

Seat Back Manually Operated Lock Assembly and Electrically Operated Lock Assembly

Bucket Seat Back Assembly .:

.......

.......................

14-46

14-47

Rear Seats

..........

.............................................................

14-48

..........................

14-48

Rear Seat Assembly .

Station Wagons

.....................................................

Rear Seat Back Center Arm Rest and

Curtain

...................................................................

Rear Seat Back Center Arm Rest Hanger

Plate and Linkage

Styles

................................................

14-5 1

Auxiliary Seat Assembly

.

........................................................................

14-52

Auxiliary Seat Adjustments

Limousine Styles

...................................................

14-52

Auxiliary Seat Lower Support Assembly-

Cadillac Limousine Styles

..................................

14-53

Seat Trim Buttons

................................................

14-53

Station Wagon Folding Rear Seats and Floor

Panels

.

Rear Floor Side Filler Panel

..............................

14-55

Luggage Compartment Panel and Hinge

Assembly

.....................................................................

14-55

Folding Third Seat Cushion

Styles

. ................................................

14-55 and Support

-

.................

"A" Body Three Seat Styles

.

14-53

14-56

Folding Third Seat Back Trim Assembly

'I

A

'I

Body Three Seat Styles

.

.............................

14-57

Folding Third Seat Back Panel Assembly

"A" Body Three Seat Styles

.

.............................

14-57

Folding Third Seat Back Lock

Three Seat Styles

..................................................

14-59

Compartment Floor Panel Assembly (At Kick

Up) All Styles

........................................................

14-59

Second Seat Back Filler Panel

Second Seat Cushion

.

....

14-60

....................

14-60

Folding Second Seat Back Trim and Spring

Assembly . ........................................

14-60

Folding Second Seat Back Trim. Panel and

Linkage Assembly .

.......................

14-60

Folding Second Seat Back Linkage Assembly

(Right or Left Side) . ...................

14-61

SUBJECT PAGE

Luggage Compartment Lock Cylinder-

Two Seat Styles

.....................................................

1461

Luggage Compartment Lock

...............................

14-62

Folding Second Seat Back Lock

All "A and B" Styles (Except

"A.56. 66" Styles)

..................................................

Folding Second Seat Cushion Assembly

.

1462

Folding Seats and Floor Panels

"56. 66" Styles

.

........................................................

1462

Folding Second Seat Assembly

"66" Styles

.............................................................

14-64

Folding Second Seat Back Trim and Spring

Assembly

Folding Second Seat Front Floor Pan

Linkage

.

.

..................................

........................................

Folding Second Seat Rear Floor Pan Linkage

14-64

14-64

"66" Styles

.............................................................

1465

Folding Second Seat Side Inner Linkage

"66" Styles

.

.............................................................

1466

Folding Second Seat Side Outer Linkage

"66" Styles

.

.............................................................

1466

Folding Second Seat Back Lock

Styles

....................................................................

1466

Folding Second Seat Back Panel and Filler

Panel

. ................................... .........

1467

Folding Third Seat and Floor Pant1

Assembly

. ..................................

Folding Third Seat Cushion Trim Assembly

"66" Styles

14-67

.

.............................................................

14-67

Folding Third Seat Back Trim Assembly or

Seat Back Panel Assembly

.

Folding Third Seat Back Lack

Panel

. ff66f'Styles

.

..............................................

Folding Seats and Load Floor Panels

Third Seat Cushion and Back

.

.........

.

Luggage Compartment Cover Panel and Fille~

1468

"Bff Station Wagon

.............................................

1469

............................

Third Seat Back Lock and Striker

....................

Third Seat Back Trim Foam Pad and

Foundation Board Assembly

Second Seat' Cushion

..............................

.............................................

1467

1468

1469

1469

14-72

14-72

Second Seat Back Trim Foam Pad and

Wire Mat Assembly

.............................................

14-73

Second Seat Back and Filler Panel Assembly 14-73

Second Full Width Seat Back Linkage and

Two-Thirds Seat Back Outer Linkage

............

14-73

Second Two-Thirds Seat Back Assembly and

Inner Linkage Assembly

.....................................

14-73

Second One-Third Seat Assembly

......................

14-74

Second One-Third Seat Back Outer

Linkage Assembly

.................................................

Lap Belts and Shoulder Belts

...............................

General' Information

..............................................

14-75

14-76

14-76

Standard Front Lap Belt Retractor

(Plastic Buckle Cover)

.........................................

14-77

SEATS 14-3

SUBJECT PAGE

Front Lap Belt Retractor

Coupes

-

" X u Body

.......................................... ........................ 14-77

Standard Front Lap Belt Retractor

(With Vinyl Cover)

..............................................

Deluxe Front Lap Belt Self-Locking

Retractor

.................................................................

Rear Seat Bail Type Retractor

...........................

14-77

14-78

F R O N T '

AND

REAR SEATS

INTRODUCTION

All front seats incorporate a front seat back head restraint on the drivers and passengers seat back. On the "B, C and E" body styles as an anit-theft feature the head restraints are designed so they cannot be removed from the seat back without first removing the bar escutcheon and depressing a lock clip. However, the head restraints can be raised or lowered for proper positioning.

All two-door style front seats and station wagon folding second and third seats are equipped with positive acting seat back locks. Onn all two-door front seats (except strato seats and "F" body seats) the seat back lock is actuated by a control lever at the outboard side of the seat back. On two-door styles with straro seats the seat back lock is actuated by a control button located at the upper center of the seat back. On "F" body bucket seats the seat back lock is actuated by a control lever located at the lower, rear oqtboard corner of the seat back.

Some Pontiac, Oldsmobile, Buick and Cadillac styles feature 60/40 seats consisting of an individually controlled drivers seat (40 percent of front seat width) and an individually controlled pass- enger seat (60 percent of front seat width).

All front and rear seat backs have formed polyure- thane foam pads in place of springs and cotton padding. The formed foam seat back pads are formed to fit the contours of the full panel seat back frame assembly and also to the designed contour of the seat.

FRONT SEAT DEALER RELOCATION

PROVISIONS

All front seat adjusters except Buick "E" Body Style do not have dealer relocation provision. The "B, C, E and

D" body seat adjusters have increased horizontal travel (5 1/2 inches or 1 inch more than previous models). The Buick "E" style full width seats can be relocated approximately one inch forward by remov- ing the adjuster-to-floor pan bolts moving the seat assembly forward sufficiently to reinstall bolts through adjuster rear set of attaching holes.

SEAT ADJUSTER SPACER USAGE

Seat adjuster-to-floor pan spacers (1/2 inch thick) are used on only the Buick "E" Body Style full width front seat between both the adjuster front and rear pedistals and the floor pan.

SEAT TORQUE SPECIFICATIONS

The following torque specifications should be used when servicing seat assemblies:

BOLT OR NUT LOCATION AND TORQUE

FT. LBS.

-

Bolts or Nuts

...........................................

2. Seat Adjuster-to-Seat Frame Bolts

.......

12-18 ft. lbs.

3. Seat Back to Cushion Frame Bolts

.........

7-1 1 ft. Ibs.

4. Seat Back Hinge Bolts

...........................

7-1 1 ft. lbs.

5. Seat sack Lock Attaching Screws

..........

7-1 1 ft. Ibs.

6. Seat Back Lock Striker and Inner

Side Bar Stop 12-18 ft. lbs.

IMPORTANT: SEAT ATTACHING PARTS

SUCH AS SEAT ADJUSTER-TO-FLOOR PAN

BOLTS OR NUTS, SEAT ADJUSTER-TO SEAT

FRAME BOLTS, SEAT CUSHION FRAME- TO-

SEAT BACK FRAME BOLTS, SEAT BACK

LOCK BOLTS, SEAT BACK LOCK STRIKER,

ETC. ARE IMPORTANT ATTACHING PARTS

IN THAT THEY COULD AFFECT THE

PERFORMANCE OF VITAL COMPONENTS

AND SYSTEMS. THEY MUST BE REPLACED

WITH ONE OF THE SAME PART NUMBER

OR WITH AN EQUIVALENT PART IF RE-

PLACEMENT BECOMES NECESSARY. DO

NOT USE A REPLACEMENT PART OF

LESSER QUALITY OR SUBSTITUTE DESIGN.

TORQUE VALUES MUST BE USED AS

SPECIFIED DURING REASSEMBLY TO AS-

SURE PROPER RETENTION OF THESE

PARTS.

14-4 SEATS

O D Y S P O O N

C O N T R O L K N O B P R O T E C T S E A T T R I M

H O L E IN C O N T R

M F O R D R I F T

O R D A M A G E S I L L P L A T E

W I T H n a l F T P I N

Fig. 141-Front Seat Adjuster Control Knob

Side Control Knob Shown

- Removal

-

-

Front Control Knob Typical

MANUALLY OPERATED SEAT

ADJUSTER CONTROL ARM KNOB-

All Styles with Manually

Operated Seat Adjusters

Manually operated seat adjuster control arm knobs are a press fit on the adjuster control arm. When replacing a manually operated seat adjuster with the control arm knob it will be necessary to remove the knob from the old adjuster and install it on the new adjuster or install a new knob.

NOTE: Control arm knobs can general\y be rep6ved and reinstalled several times without losing. adequate retention. If removing or installing a control knob on a trimmed seat assembly, place a protective cover over trim material in area of knob (see Figs. 14-1 and 14-

2).

Removal

Using a heavy body spoon, a long drift pin and a piece of wood as a fulcrum, as shown in Figure 14-1, carefully remove knob from adjuster control arm.

NOTE: On seats with the control arm at the side of the seat, use caution not to push drift. pin down onto rocker panel sill plate. On seats with the control arm at the front of the seat, place a support under control arm to prevent bending arm.

Installation Equipment

The following equipment is required to install seat adjuster control knob.

1. One four inch "C" clamp.

NOTE: Swivel pad of "C" clamp should rotate freely.

Where necessary add a drop or two of oil in swivel pad.

2. o n e round rubber plug- (Part No. 4802102 or equivalent) to fit over "C" clamp swivel pad to knob or damaging control knob.

3. One 1/8 inch diameter sheet metal screw approximately one inch long.

NOTE: Round off sharp point of screw to prevent possible damage to seat trim.

Installation Procedure

1. Place pencil mark on seat adjuster control arm,

4 \

SEATS 14-5

/3

PROTECT SEAT TRIM

L U G ( # 4 8

O V E R ' C '

1 1 8 " D I A M E T E R M E T A L S C R E W

TH RO U G H E X I S T I N G H O L \ P \ \ ~ \ \ \ \

FOR ' C ' C L A M P G R I P

Fig. 14-2-Front Seat Adjuster Control Knob

Side Control Knob Shown

-

Installation

- Front Control Knob Typical r one inch from top edge of arm as a guide for determining when knob is fully installed.

2. Place seat adjuster control knob in position on control arm and start knob on by hand pressure making certain knob is started on straight.

NOTE: All electrically operated seats and seats equipped with cigarette lighter, courtesy lamps etc. have a ground wire secured to the seat frame and under the seat adjuster rear attaching bolt or nut.

NOTE: Install knob so that "gate" mark (on one face of knob) is facing seat and is not visible.

R E A R B O L T S

,

3. Insert sheet metal screw in hole provided in adjuster control arm and place "C" clamp in position as shown in Figure 14-2. Use round rubber plug (Part No. 4802102 or equivalent) over swivel pad. of "C" clamp to prevent damage to knob and to prevent "C" clamp swivel pad from slipping off knob.

4. Carefully press knob on control arm with "C" clamp until bottom edge of knob is down to mark

(one inch below edge of arm).

FULL WIDTH CONVENTIONAL AND

STRATO SEATS AND 60-40 SEATS

Description

All seat assemblies are secured to the floor pan by either nuts installed on floor pan anchor plate studs or bolts installed into anchor nuts in the floor pan.

S E A T A D J U S T E R F R O N T B O L T

Fig. 14-3-Front Seat Adjuster-to-Floor Pan

Attachment

"A and

-

Manually Operated

X" Body Full Width Seats

14-6 SEATS

The 60-40 seat, available on Pontiac, Buick, Oldsmo- bile and Cadillac styles, consists of an individual passenger seat (60 percent of front seat width) and an individual driver seat (40 percent of front seat width).

NOTE: Power operated two-way seat adjusters are standard equipment on the drivers seat on most styles and manual seat adjusters are standard on the passengers side. Six-way power operated seat adjusters are available as optional equipment.

FRONT SEAT ASSEMBLY-

Manually Operated-Full Width and

60-40 Seats

The full width manually operated seat assembly and

60-40 seat incorporate manuaily operated seat adjusters to provide fore and aft movement of the seat. When the control lever is moved forward the seat adjusters unlock, permitting horizontal travel of the seat. When the seat is in the desired position and the locking lever is released the seat is locked.

SEAT ASSEMBLY- Manually Operated

Full Width and 60-40 Seats

Removal and Installation

1. Where the front inner seat belts go through the seat assembly, remove seat belt floor pan inner anchor plate attaching bolt.

2. Remove door sill plates and turn back floor mat or carpeting, where necessary, to expose seat adjuster-to-floor pan attaching nuts or bolts.

3. Operate seat to full forward position.

4. At rear of adjusters, remove adjuster-to-floor pan rear attaching nuts or bolts. (Fig. 14-4, 14-6 or 14-

5).

5. Operate seat to full rearward position. Remove adjuster- to-floor pan front attaching bolts. On seats incorporating any electrical equipment, tilt

Fig. 14-4-Front Seat Adjuster - Manually Operated Full Width Conventional Seats

C and E" Body

.

-

"B,

1 . Adjuster-to-Floor Pan

2. Adjuster-to-Floor Pan

Spacer ("E" Buick

Only)

3. Adiuster-to-Seat

me

Attaching

Bolts

4. Adjuster Assist Spring

5. Adjuster Lock Bar

Spring

6.

7. wire

Locking Wire Tension

Hooks

8.

,

Tension Hook

Adjusting Holes In

9.

Seat Frame

Seat Frame-to-

Adjuster Ground

Strap

SEATS 14-7 seat assembly rearward sufficiently to disconnect feed wires at connectors under seat. With aid of a helper, remove seat assembly from body.

6. To install seat assembly, reverse removal proce- dure. Where seat adjuster-to-floor pan spacers were present, reinstall spacers in same position.

On seats with electrical equipment, connect feed wire connectors under seat, also make sure ground wire is secured under seat adjuster rear attaching bolt or nut.

NOTE: Tighten seat adjuster to floor pan attaching bolts or nuts 12 to 18 ft. lbs. Check operation of seat assembly to full limits of travel.

On two-door styles equipped with electric seat back locks check operation of both seat back locks.

FRONT SEAT ADJUSTER ASSEMBLY-

Manually Operated ~ ~ Width and

60-40

seats

Removal and Installation

1. Remove front seat assembly with adjusters attached, as previously described, and place upside-down on a clean protected surface.

1. Adjuster Assembly

2. Adjuster Rear

3.

Pedistal Covers

Outer Adjuster-to-

Floor Pan Bolts

Fig. 14-5-Front Seat and Adjuster

(Passenger Side Shown

-

Manually Operated 60/40 Seats

- Driver Side Typical)

4. Inner Adjuster-to-

Floor Pan Nuts

5 . Adjuster-to-Seat

Frame Bolts

6. Adjuster Assist Spring a

7. Adjuster Lock Bar spring

8.

9.

Adjuster Locking

Wire

Ground Strap

14-8 SEATS

Fig. 14-6-Front Seat Adjusters - Manual Operated Full Width Strato Seat

Body

-

Buick '3"

1.

2.

3.

Adjuster Assembly

Adjuster Locking

Wire

Locking Wire Tension

Hook

4.

5.

Locking Wire Tension

Adjustment Holes In

Seat Frame

Adjuster-to-Floor Pan

Attaching Bolts

6.

7.

8.

Adjuster-to-Floor Pan

Attaching Nuts

Adjuster-to-Seat

Frame Attaching

Bolts

Adjuster Assist Spring

9. Adjuster Lock Bar spring

10. Adjuster Anchor

Plate-to-Floor Pan

1 1.

Attaching Bolts

Ground Strap

2. Remove seat adjuster assist spring from adjuster to be removed (See Fig. 14-4, 14-6 or 14-5).

3. Squeeze hooked end of seat adjuster locking wire together and slide retaining spring back over hump in locking wire and remove locking wire from adjuster.

4. Remove adjuster-to-seat bottom frame front and rear attaching bolts and remove seat adjuster from seat (Figs. 14-4 and 14-6).

5. To install, reverse removal procedure. If adjuster with control arm is being replaced, install new adjuster control knob as describkd under "Manu- ally Operated Seat Adjuster Coliirol Arm Knob".

NOTE: The right and left seat adjuster sliding mechanism should be in same relative position when attaching adjuster to seat bottom frame tighten seat adjuster-to-seat frame attaching bolts

12 to 18 ft. lbs.

After installing adjuster to seat frame, check operation of adjusters. If on full width seats the adjusters do not lock or unlock satisfactorily when control handle is operated, disengage locking wire retainer from hole in seat bottom frame and engage retainer in one of adjacent holes to obtain proper tension in wire (Fig.

14-4, Item "8", Fig. 14-6, Item "4").

FRONT SEAT ASSEMBLY- Power

Operated Two, Four or Six-Way

Full Width and 60-40 Two or Six-Way

Seats

Description

The seat adjusters are actuated by a 12 volt, reversible, shunt wound motor with a built-in circuit breaker. The motor is energized by a toggle-type control switch installed in the left seat side panel or in the left door arm rest.

SEATS 14-9

Fig. 14-7-Four-Way Power Operated Full Width Seat, Seat Adjusters, Motor and

Transmission "A" Body Styles

1. Motor and

Transmission Support

2. Motor Control Relay

3. Adjuster-to-Floor Pan

Front Attaching Bolt

4. Ground Strap

5. Adjuster-to-Floor Pan

Rear Attaching Nuts

6. Adjuster Rear Carpet

Retainer

7. Adjuster-to-Seat

Frame Attaching Bolt

8. Adjuster Track Rear

Lower Cover

9. Adjuster Track Upper

Cover

'

10. Four-Way Switch

Assembly

1 I . . Motor and

Transmission Support

Attaching Screws

12. Adjuster Track Cover

Retainers

13. Horizontal Drive

Cable-Black

14. Vertical Drive Cable-

Blue

1 5. Transmission

Assembly

16. Motor-to-Transmission

Coupling

17. Motor Assembly

14-10 SEATS

I

Fig. 14-8-Front Seat Adjusters

-

Power Operated Horizontal - Oldsmobile and Cadillac

1.

2.

Seat Adjuster-to-Floor

Pan Attaching Bolts

Horizontal Drive

Cables

3.

4.

5.

Adjuster Horizontal

Gear Nut and

Shoulder Screws

Adjuster Jack Screw

Jack Screw Support

Pin

6.

7.

8.

Electric Motor

Motor-to-Seat Frame

Attaching Screws

Horizontal Drive

Cable Straps

9. Seat Frame-to-

10.

Adjuster Ground

Strap

Adjuster-to-Seat

Frame Attaching

Bolts

J a

On four-way and six-way power operated seats the seat operating mechanism has a transmission assembly which incorporates solenoids and drive cable to the seat adjusters. On the four-way seat one solenoid controls the horizontal movement of the seat while the second solenoid controls the vertiacal movement of the seat. On the six-way seat one solenoid controls the vertical movement of the front of the seat, the second solenoid controls the horizontal movement of the seat and the third solenoid controls the vertical movement of the rear of the seat. When the control switch is actuated, the motor and one of the solenoids are energized simultaneously. Then the solenoid plunger engages with the driving gear dog. The driving gear rotates the drive cables and operates both adjusters.

When the adjusters reach their limit of travel, the drive cables stop their rotating action and torque is absorbed by the rubber coupler connecting the motor and transmission. When the control switch is released, a return spring returns the solenoid plunger to its original position disengaging if from the driving gear dog.

Removal and Installation

1. Operate seat to full forward position. On four-way or six-way power seats, operate seats to full up position.

2. Wher.e front inner seat belts go through the seat assembly, remove seat belt floor pan inner anchor plate attaching bolt.

3.

Where necessary, remove sill plates and turn back floor mat or carpeting to expose seat adjuster-to- floor pan attaching nuts or bolts.

SEATS 14- 1 1

Fig. 14-9 Power Operated Horizontal Seat

Adjusters

-

60/40 Drivers Seat

1. Adjuster Assembly

2. Adjuster-to-Floor Pan

Attaching Bolts

3. Adjuster-to-Floor Pan

Attaching Nuts

4. Adjuster-to-Seat

Frame Attaching

Bolts

5. Adjuster Horizontal

Gear Nut and

Attaching Screw

6. Adjuster Jack Screw

7. Jack Screw Support

Pin

8. Electric Motor and

Suppo*

9. Motor Support-to-Seat

Frame Attaching

Screws

10. Seat Frame-to-

Adjuster Ground

Strap

4. Remove seat adjuster-to-floor pan rear attaching bolts (Figs. 14-8 through 14-14).

5.

Operate seat to full rearward position. Remove adjuster-to- floor pan front attaching bolts. Tilt seat assembly rearward sufficiently to disconnect seat harness feed connector and detach harness from clip on floor pan; on two-door styles with electric seat back locks, disconnect both right and left seat back lock actuator feed wires at connectors under seat. On styles with seat back cigar lighter, seat back courtesy lamps or seat back vanity lamp, disconnect electrical feed wire

Fig. 14-10-Front Seat Adjusters

-

Power 6-Way

60/40 Drivers Seat

1. Seat Adjuster

Assembly

2. Adjuster-to-Floor Pan

Attaching Bolts

3. Adjuster-to-Floor Pan

Attaching Nuts

4. Front Vertical

Actuator

5. Front Vertical

Actuator Drive

6.

Cable-Yellow

Horizontal Actuator

7. Horizontal Actuator

Drive Cable-Black

8. Rear Vertical

Actuator

9. Rear Vertical

Actuator Drive Cable

(Inboard-Green. outboard-~lue)

10. Electric Motor

Assembly

1 1. Motor Control Relay

Assembly

13. Motor and

Transmission Support

Attaching Nuts

14. Carpet Retainers

15. ~ d f i s t e r Track Upper

Rear Cover

16. Adjuster Track Lower

Cover

17. Rear Vertical Cable

Route When Cover is

Installed

18. Seat Frame-to-

Adjuster Ground

Strap

19. Inner Adjuster Floor

Pan Anchor Plate and Studs or wires. With aid of a helper remove seat assembly from body.

'

6. To install seat assembly, reverse removal 'proce- dure. Where seat adjuster-to-floor pan spacers were present reinstall spacers in same position.

14-12 SEATS

Make sure ground wire is securely attached under seat adjuster-to-floor pan rear attaching bolt.

Check for proper operation of seat adjusters to limits of travel. On two-door styles equipped with electric seat back locks, check operation of both seat back locks (see Figs. 14-8 through 14-14).

IMPORTANT: When installing seat assembly in body, seat adjusters should be parallel and "in phase" with each other. In the event the adjusters are "out of phase" (this is, one adjuster reaches its maximum horizontal or vertical travel in a given direction before the 'other adjuster), proceed as follows: a. Horizontal Travel

-

Operate seat control switch until one adjuster reaches full forward position. Detach horizontal.drive cable from adjuster which

. has reached full forward position. Operate seat forward until other adjuster reaches full forward position; then, connect horizontal drive cable and check horizontal travel of seat. b. Front or Rear Vertical Travel

-

Operate seat control switch until one adjuster has reached fully raised position at both front and rear vertical travel limits. Disconnect both front and rear vertical drive cables from adjuster which has reached the fully raised position. reaches the fully raised position at both front and rear vertical travel limits; then, connect previously removed front and rear vertical drive cables. Check vertical travel by operating adjusters through one or two complete cycles.

The above operation may be repeated on an

"as required" basis if adjusters do not appear to be "in phase" after test cycle.

ADJUSTER ASSEMBLY- Power Operated

Two, Four or Six-Way Full Width Seat

And 60-40 Drivers Seat

Removal and Installation

Operate seat to a midway horizontal position; on four-way and six-way seats also operate seat to fully raised position.

Remove front seat assembly with adjusters attached, as previously described, and place upside-down on a clean protected surface.

Detach power drive cables from gear nuts of adjuster to be removed (Figs. 14-5 through 14-14).

Remove adjuster-to-seat bottom frame front and rear attaching bolts and remove adjuster from seat assembly (Figs. 14-5 through 14- 14).

5. To install seat adjuster assembly, reverse removal procedure. On seats with adjuster upper track covers, make sure track cover supports are installed between adjuster and seat frame. (Figs.

14-5 through 14-14). Check operation of seat adjusters and make sure adjusters are "in phase" before installing assembly into body. (See Step 6 under "Front Seat Assembly

-

Removal and

Installation").

IMPORTANT: THE SEAT ADJUSTER-TO-SEAT

FRAME ATTACHING BOLTS ARE IMPOR-

TANT ATTACHING PARTS IN THAT IT/

THEY COULD AFFECT THE PERFORMANCE

OF VITAL COMPONENTS AND SYSTEMS.

THEY MUST BE REPLACED WITH ONE OF

THE SAME PART NUMBER OR WITH AN

EQUIVALENT PART IF REPLACEMENT BE-

COMES NECESSARY. DO NOT USE A

REPLACEMENT PART OF LESSER QUALITY

OR SUBSTITUTE DESIGN. TORQUE VALUES

MUST BE USED AS SPECIFIED DURING

REASSEMBLY TO ASSURE PROPER RETEN-

TION OF THIS PART.

TWO-WAY SEAT ADJUSTER MAJOR

COMPONENTS- "C" Body

Full Width Seat And 60-40 Dlivers Seat

The following service procedures cover replacement of the major component parts of the power operated two- way seat adjusters used on "C" body full width seats or the drivers 60-40 seat.

ELECTRIC MOTOR-

Power Two-way Full Width Seat

And 60-40 Drivers Seat

Removal and Installation

Remove front seat assembly as previously described and place upside-down on a clean, protected surface. On 60-40 drivers seat remove one seat adjuster (see Fig. 14-9).

Disconnect both power drive cables from motor

(Fig. 14-8).

Disconnect feed wire harness from actuator motor.

Remove screws that secure actuator motor support bracket to seat bottom frame and remove actuator motor with attached support bracket from seat assembly (Figs. 14-8 and 14-9).

Remove

' screws securing motor to motor support bracket and remove motor assembly.

To install, reverse removal procedure. Check for proper seat operation to extreme limits of travel.

SEATS 14-13

1. Seat Adjuster

Assembly

2. Adjuster-to-Floor Pan

Attaching Bolts

3. Adjuster-to-Floor Pan

Attaching Nuts

4. Front Vertical

Actuator

5. Front Vertical

Actuator Drive

Cable-Yellow

Fig. 14-1 1-Front Seat Adjusters

-

Power 6-Way 60/40 Passenger Seat

6. Horizontal Actuator

7. Horizontal Actuator

Drive Cable-Blue

8. Rear Vertical

Actuator

9. Rear Vertical

Actuator Drive Cable

(Inboard-Green,

Outboard-Blue)

10. Electric Motor

Assembly

1 1. Motor Control Relay

12. Transmission

Assembly

13: Motor and

Transmission Support

Attaching Nuts

14. Carpet Retainers a

15. Adjuster Track Upper

Rear Cover

16. Adjuster Track Lower

Cover

17. Seat Frame-to-

Adjuster

'

Ground

Strap

18. Inner Adjuster Floor

,

Pan Anchor Plate and Studs

14-14 SEATS

Fig. 14-12-Front Seat Adjusters

-

Power 6-Way

-

Conventional and Strato Full Width

Seats

1. Seat Assembly

2. Seat ~djuste&Floor

Pan Bolts

3. Seat Adjuster-to-Floor

Pan Spacers-Buick

Conventional Seat

Only

4. Seat Adjuster-to-Seat

Frame Bolts

5. Front Vertical

Actuator

6. Front Vertical Drive

Cable

-

Conventional

Seat-Red

-

Strato

Seat-Yellow

7. Horizontal Actuator

8. Horizontal Drive

9.

Cable-Black

Rear Vertical

Actuator

HORIZONTAL GEARNUT ASSEMBLY-

Power Two-way Full Width Seat

And 60-40 Drivers Seat

Removal and Installation

1.

Remove front seat assembly with adjusters

10. Rear Vertical Drive

Cable

-

Conventional

Seat-Blue

-

Strato

Seat-Orange

1 1. Electric Motor

Assembly

12. Motor Control Relay

13. Transmission

Assembly

14. Motor and

Transmission Support

15. Adjuster Track Upper

Rear Cover

16. Adjuster Track Lower

Cover

17. Carpet Retainers

18. Seat Frame-to-

Adjuster Ground

Strap attached and place protected surfack. upside-down on

a

clean,

2. Detach .power drive cable from gearnut to be removed.

3. Using a "clutch" type screwdriver or others suitable tool, remove two shoulder bolts securing

SEATS 14-15

Fig. 14-13-Front Seat Adjusters - Power 6-Way - Buick "E" Body Strato Full Width Seat

1. Seat Adjuster

Assembly

2. Seat Adjuster-to-Floor

Pan Bolts and Nuts

3. Seat Adjuster-to-Floor

Pan Anchor Plates and Attaching Bolts

4. Seat Adjuster-to-Seat

Frame Bolts

5. Front Vertical

Actuator

6. Front Vertical Drive

Cable-Yellow

7. Horizontal Actuator

8. Horizontal Drive

Ca ble-Black

9. Rear Vertical

Actuator gearnut to upper slide portion of seat adjusters

(Figs. 14-8 and 14-9).

10. Rear Vertical Drive

Ca ble-Orange

1 1. Electric Motor

Assembly

12. Motor Control Relay

13. Transmission

Assem bly

14. Motor and

Transmission

15. Adjuster Track Upper

Cover Supports

16. Adjuster Track Upper

Cover

17. Adjuster Track Lower

Cover

18. Carpet Retainers

19. Seat Frame-to-

Adjuster Ground

Strap from rear end of jackscrew; then, remove gearnut from jackscrew.

4. Rotate jackscrew assembly upward sufficiently to gain access to cotter pin at rear of jackscrew assembly.

5. Remove cotter pin, washer and rubber bumper

6. To install, reverse removal procedure. Prior to installing seat assembly in body, be sure adjusters are "in phase". See Step 6 under "Front Seat

Assembly - Removal and Installation".

14-16 SEATS

1. Motor and

Transmission Support

2. Motor Control Relay

3. Adjuster-to-Floor Pan

Front Attaching Bolt

4. Seat Frame-to-

Adjuster Ground

Strap

5. Adjuster-to-Floor Pan

Rear Attaching Nuts

6. Adjuster Rear Carpet

Retainer

7. Adjuster-to-Seat

Frame Attaching Bolt

8. Adjuster-to-Seat

Frame Spacers

(13857-67 Styles

Only)

HORIZONTAL JACKSCREW-

Power Two-way Full Width Seat

And 60-40 Drivers Seat

em oval

and Instal.lation

1. Remove from seat assembly with adjusters attached and place upside-down on a clean, protected surface.

2. Detach power drive cable from gearnut and jackscrew assembly to be removed.

3. Using a suitable tool (preferably a "clutch" type screwdriver or equivalent), remove two shoulder

9. Adjuster Track Rear

Lower Cover

10. Adjuster Track Upper

Cover

1 1. Four-Way Switch

Assembly

12. Motor and

Transmission Support

Attaching Screws

1 3. Horizontal Drive

Cable-Black

14. Vertical Drive Cable-

Yellow

15. Transmission

Assembly

16. Motor-to-Transmission

Coupling

17. Motor Assembly bolts securing gearnut to upper slide portion of seat adjuster assembly (Figs. 14-8 and 14-9).

4. Remove retainer that secures stop bracket crosspin to adjuster front pedestal and remove crosspin

(Figs. 14-8 and 14-9).

5. Remove jackscrew assembly from seat adjuster.

6. To install, reverse removal procedure.

NOTE: When replacing jacksctew assembly with new part, remove nut, washers, rubber bumper and stop bracket with inserted rubber grommet from front end of jackscrew, as well as gearnut

SEATS 14-17 and washers, rubber bumper and cotter pin from rear end of jackscrew and transfer to new jackscrew assembly.

PLASTIC SLIDES-

Power Two-way Full Width Seat

And 60-40 Drivers Seat

Removal and Installation

1. Remove front seat adjuster to be serviced from front seat assembly. (See "Front Seat Adjuster

Two-way Electric

-

Removal and Installation"

- procedures).

2. Using a suitable tool (preferably a "clutch" type screwdriver or equivalent), remove two shoulder bolts securing gearnut to upper channel to seat adjuster assembly (Figs. 14-8 and 14-9).

3. Slide lower track and support base portion of seat adjuster, with attached jackscrew and gearnut, forward until it disengages from upper channel assembly. The four plastic slides may now be disengaged from positioning slots on lower track.

4. To install, reverse removal procedure making sure that groove in plastic slide slips onto lower track with thinner section of slide protruding above surface of track.

FOUR-WAY SEAT ADJUSTER MAJOR

COMPONENTS- "A" Body Full

Width Seats

The following service procedures cover replacement of the major component parts of the power operated four-way seat adjusters used on the "A" body full width seats.

ELECTRIC MOTOR- "A" Body

Four-Way Full Width Seat

Removal and Installation

1. Remove front seat assembly as previously described and place upside-down on a clean, protected surface.

2. Disconnect wire harness from motor relay assembly.

3. Remove screws securing motor and transmission support to seat seat bottom (see Fig. 14-14).

4. Remove motor-to-motor support attaching screws and remove motor assembly from support.

5. To install, reverse removal procedure making sure rubber coupler is properly engaged at both motor and transmission ends. Check operation of seat to full limits of travel.

VERTICAL GEARNUT- "A" Body

Four-Way Full Width Seat

Removal and Installation

1. Operate seat assembly to fully raised and midway horizontal p0sitio.n.

2. Remove front seat assembly from body as previously described and place upside-down on a clean, protected surface.

3. Detach vertical gearnut drive cable from other adjuster.

4. Using a clutch type screwdriver or other suitable tool, remove shoulder screws securing linkage to vertical gearnut being replaced (Fig. 14-15).

5. If right adjuster gearnut is being replaced, at front of jack- screw, remove double nut that acts as a jackscrew "down" stop.

6.

6

Using a portable power source to energize the motor, actuate vertical gearnut until gearnut is disengaged from jackscrew.

NOTE: It may be necessary to manually raise or lower upper rear portion of adjuster to gain clearance for removal of gearnut.

7. Disconnect drive cable from gearnut.

8. To install, reverse removal procedure.

NOTE: Check operation of seat adjusters and make sure adjusters are "in phase". See Step 6 under "Front Seat Assemblv

-

Removal and

Installation".

1

VERTICAL G E A R N U T 7 r

JACKSCREW I

JACKSCREW RIVET IIORIZONTAL

Fig. 14-15-Four-Way Seat Adjuster

-

"A" Styles

14-18 SEATS

HORIZONTAL ACTUATOR- "A" Body

Four.Way Full Width Seat

Removal and lnstallation

Remove adjuster vertical gearnut as previously described.

Disconnect drive cable from horizontal actuator.

Remove screws securing horizontal actuator assembly to adjuster lower track; then remove actuator from adjuster assembly (Fig. 14-15).

To install, reverse removal procedure.

NOTE: When installing horizontal actuator, adjust actuator so that drive gear is fully engaged with teeth on lower channel. When horizontal actuator attaching screws are tightened, there should be no free motion between upper and lower channels.

Re-adjust actuator ''as required" until all free motion between channels has been removed.

Check operation of seat adjusters and make sure adjusters are "in phase". See Step 6 under "Front

Seat Assembly

-

Removal and Installation".

JACKSCREW- "A" Body

Four-Way Full Width Seat

Removal and lnstallation

1. Remove adjuster vertical gearnut as previously described.

2. Remove seat adjuster-to-seat bottom frame front and rear attaching bolts on side affected (Fig. 14-

14).

3. As a bench operation, remove jackscrew-to- adjuster linkage attaching rivet and remove jackscrew from adjuster assembly (Fig. 14- 15).

4. To install, reverse removal procedure. Check operation of seat adjusters and make sure adjusters are "in phase". See Step 6 under "Front

Seat Assembly

-

Removal and Installation".

HORIZONTAL AND VERTICAL DRIVE

CABLES- "A" Body Four-Way

Full Width Seat

Removal and lnstallation

1. Remove front seat assembly from body with attached adjusters, motor and transmission and place upside-down on a clean, protected surface.

2. Detach both horizontal and vertical cables from seat adjuster.

3. Remove screws securing horizontal and vertical cable end plate on side of transmission from which cables are being removed and remove cables from seat assembly (Fig. 14-14).

4. Disengage cable to be replaced from end plate.

5. To install cables, reverse removal procedure. Black cable attaches from front of transmission to horizontal actuator; blue cable attaches from rear of transmission to rear vertical gearnut. Check operation of seat to full limits of travel.

TRANSMISSION- "A" Body

Four-Way Full Width Seat

Removal and lnstallation

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.

3. Remove screws securing horizontal and vertical cable end plate on both sides of transmission and detach cables from transmission.

4. Remove transmission-to-support attaching bolts; then, disengage transmission from rubber coupler and remove transmission from seat assembly.

5. To install, reverse removal procedure. Black cable attaches from front of transmission to horizontal actuator; blue cable attaches from rear of transmission to rear vertical gearnut.

DISASSEMBLY AND ASSEMBLY

OF TRANSMISSION

1. Remove front seat adjuster transmission from seat assembly.

2. Remove screws securing gear and solenoid housings together; then, carefully separate hous- ings and remove component parts of transmission assembly (Fig. 14-16).

3. To assemble transmission, reverse removal procedure.

IMPORTANT: Prior to or during installation, lubricate frictional surfaces of driving gear thrust washer, gears, dog washers, shaft and solenoid plungers with "Lubriplate" (630AAW) or equivalent.

GEAR H O U S I N G DRIVING GEAR

\

GEAR

/

\

SEATS 14-19

HARNESS SOLENOID

CONNECTOR PLUNGER

I /

I

\

RUBBER COUPLER DOG

/

SPRING

\ I

SOLENOIDS A N D SOLENOID

D O G SHAFT COVER PLATE H O U S I N G , 6 9 3

Fig. 14- 16-Four-Way Seat Adjuster Transmission

SIX-WAY SEAT ADJUSTER MAJOR

COMPONENTS- "B-C and E" Body

Full

Width Seats

The following service procedures cover replacement of the major component parts of the power operated six- way seat adjusters used on the

"B,

C and

EM

body full width seats.

ELECTRIC MOTOR- "B-C and E"

Body Six-Way

Full

Width Seats

Removal and Installation

1. Remove front seat assembly, as previously described, and place upside-down on a clean, protected surface.

2. Disconnect motor feed wires from motor contol relay (Figs. 14-12 and 14- 13).

3. Remove motor and transmission support-to-seat frame attaching bolts (Figs. 14- 12 and 14- 13).

4. Remove motor-to-support attaching bolts; then, move motor assembly outboard (away from transmission) sufficiently to disengage motor from rubber coupling.

5. To install, reverse removal procedure making sure rubber coupling is properly engaged at both motor and transmission. Check that seat harness is properly secured to seat. Check operation of seat to full limits of travel.

HORIZONTAL ACTUATOR-

"B-C and EM Body Six-Way

Full

Width

Seats

0

Removal and Install.ation

1. Remove seat assembly from body, as ,previously described and place upside-down on a clean, protected surface.

2. Detach three power drive cables from adjuster to be removed (Figs. 14- 12 and 14- 13).

3. Remove screws securing seat adjuster to seat bottom frame (Figs. 14-12 and 14-13) and remove adjuster from skarassembly.

APPLY PRESSURE SUFFICIENT

HORIZONTAY~$F

ACTUATOR

H O R I Z O N T A L ACTUATOR

ATTACHINO SCREWS

L

\POSITION ADJUSTER WITH UPPER TRACK S L l o n r r r

REARWARD O F LOW^ TRACK A N D CHECK (OBSERVE)

FOR H O R I Z O N T A L CHUCK 3 7 ~

Fig. 14-17-Horizontal Actuator Adjustment-"B and C" Power Operated Six-way Seat Adjusters

14-20 SEATS

4. At top of adjuster remove front and rear vertical gearnut attaching nuts and tension springs (Figs.

14-18 and 14-19).

5. Lift front of adjuster upper channelsupward; then remove screws securing horizontal actuator to adjuster upper channel assembly and remove actuator from adjuster (Figs. 14-18 and 14-19).

6.

To

install, reverse removal procedure. When installing horizontal actuator, be sure actuator drive gear is fully engaged with teeth on lower channel. With actuator attaching screws tight, there should be no free motion between upper and lower adjusting channels. Re-adjust actuator

"as required" until all free motion between channels has been removed. Be sure seat adjusters are "in phase", before installing seat assembly into body. See Step 6 under "Front Seat Assembly

- Removal and Installation".

HORIZONTAL ACTUATOR ADJUSTMENT-

With Adjusters on Seat or With Seat In

Body

With seat adjuster assembly installed on seat or seat assembly installed in body horizontal movement

(checking) can be corrected by adjusting the horizontal actuator and pinion gear in tight to the adjuster lower track rack gear as follows:

1. Operate seat to full "up" position and approxi- mately 3/4 full forward position.

2. Loosen horizontal actuator attaching screws (see

Fig. 14-17). Using a large screw drivgr, inserted as shown in Figure 14-17 apply outward pressure on horizontal actuator (sufficient to equal 15 to 25 lbs. on horizontal actuator) and at the same time

GEARNUT ATTACHING NUTS

GEARNUT TENSION SPRINGS

1 1

UPPER CHANNEL -z

I I energize horizontal switch to move seat fore and aft slightly; this helps seat the horizontal actuator pinion gear teeth tight to the lower track rack gear teeth and eliminate any free play between gear teeth. While maintaining outward pressure against horizontal actuator, tighten actuator atttaching screws.

FRONT AND REAR VERTICAL GEARNUT-

"B-C and E" Body Six-Way Full Width

Seat

Removal and Installation

1. Operate seat to full forward position.

2. Remove front seat assembly from body as previously described and place upside-down on a clean, protected surface.

3. Detach three power drive cables from adjuster to be removed.

4. Remove screws securing seat adjuster to seat bottom frame and remove adjuster from seat assembly.

Fig. 14-18-Six-Way Seat Adjuster

E" Styles

- "B, C and

Fig. 14-19-Six-Way Seat Adjuster Components

-

"B, C and E" Styles

I .

2.

Upper Channel

Assembly

Upper Channel to

3.

Gearnut Attaching

Bolts

Gearnut Tension

Springs

4. Gearnut Shoulder

Nuts .

5. Rear Vertical Gearnut and Attaching Screws

6.

7.

Horizontal Actuator and Attaching Screws

Front Vertical

Gearnut and

Attaching Screws

8. Plastic Shoes

9. Lower Channel

SEATS 14-2 1

5. At top of adjuster, remove both vertical gearnut attaching nuts and tension springs (Figs. 14-18 and 14- 19).

6. Lay adjuster on its side and remove front vertical gearnut attaching screws; then, remove gearnut from adjuster (Fig. 14- 19).

NOTE: If seat was not in fonvard position when removed from car, it may be necessary to manually operate the horizontal actuator to gain access to vertical gearnut attaching screws on bottom of lower channel.

7. If front vertical gearnut is being replaced with a new part, transfer gearnut shoulder nut and tension spring to new, gearnut assembly (Fig. 14-

19).

8. To install, reverse removal procedure. Be sure adjusters are "in phase" before installing seat assembly into body. See Step 6 under "Front Seat

Assembly

-

Removal and Installation".

LOWER OR UPPER CHANNEL AND

PLASTIC SLIDES- "B-C and E" Body Six-

Way Full Width Seats

Removal and Installation

1. Remove seat assembly from body and place upside-down on a clean, protected surface.

2. Detach three power drive cables from adjuster to be removed.

3. Remove screws securing seat adjuster to seat bottom frame and repove adjuster from seat assembly.

4. At top of adjuster, remove both vertical gearnut attaching nuts and tension springs (Figs. 14-18 and 14-19). Lift front of adjuster upper channel upward; then, remove horizontal actuator attach- ing screws and remove horizontal actuator from adjuster (Fig. 14- 19).

5. Slide lower channel until it is completely disengaged from upper channel. Plastic slides may be removed from lower channel.

6. To install upper and lower channel, reverse removal procedure. a. If replacing lower channel, transfer vertical slides to new lower channel. b. If replacing upper channel, transfer vertical gearnuts to new upper channel.

NOTE: Make sure horizontal gear of lower channel and sliding surface of upper channel are properly lubricated with "Lubriplate"

(630AAW) or equivalent.

Make sure adjusters are "in phase" prior to installing seat assembly into body. See Step 6 under "Front Seat Assemby

-

Removal and

Installation".

Check operation of seat to limits of both horizontal and vertical travel.

HORIZONTAL AND VERTICAL DRIVE

CABLES- "B-C and EM Body Six-Way Full

Width Seats

Removal and lnstallation

1. Remove front seat assembly from body with attached adjusters, motor apd transmission and place upside-down on a clean, protected surface.

2. Detach both horizontal and vertical cables from seat adjuster.

3. Remove screws securi~g horizontal and vertical a b l e end plate on side of transmission from which cables are being removed and remove cables from seat assembly; then, disengage cables from end plate.

4. To install horizontal and vertical cables, reverse removal procedure. Install colored drive cables as shown in Figure 14-12 for conventional and strato full wideth seats (except Buick and Figure 14-13 for Buick strato seat.

"EM

strato seat)

"EM

body full width

TRANSMISSION- "B-C and Ew Body

Six-Way Full Width Seats

Removal and lnstallation

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.

3.

.

Remove screws securing horizontal and vertical cable end plate on both sides of transmission and detach cables from transmission.

4. Remove transmission to support attaching bolts; then, disengage transmission from motor drive coupling and remove transmission from seat assembly (Figs. 14-12 and 14-13).

14-22 SEATS

C

SOLENOID HOUSING

'"""

\

7

\

","H\I.IIER

,

I

HARNESS

CONNECTOR

RUBBER

COUPLING

DRIVING GEAR

GEAR HOUSlNG

J

.

4276

Fig. 14-20-Six-Way Seat Adjuster Transmission - "B and C" Full Width Seat

5. To install, reverse removal procedure. "Horizontal and Vertical Drive Cables" or as shown in Figure

14-12 or 14-13. Make sure seat wiring harness is properly secured to seat.

DISASSEMBLY AND ASSEMBLY

OF TRANSMISSION

1. Remove front seat adjuster transmission from seat assembly.

2. Remove screws securing rear gear housing to the solenoid housing; then, carefully separate hous- ings and remove component parts of transmission assembly (Fig. 14-20).

3. To assemble transmission, reverse removal procedure.

IMPORTANT: Prior to or during installation, lubricate frictional surfaces of driving gear; thrust washer, large gears, dog washers, gear shafts and solenoid plungers with "Lubriplate" (630AAW) or equivalent.

SIX-WAY SEAT ADJUSTER MAJOR

COMPONENTS- Pontiac, Buick, Oldsmobile and Cadillac 60-40 Seats

The following service procedures cover replacement of the major component parts of the power operated six- way seat adjusters used on the 60-40 seats.

SIX-WAY ADJUSTER MOTOR- Pontiac,

Buick, Oldsmobile and Cadillac 60-40 Seats

Removal and Installation

1. If seat is operable, raise seat assembly to the full

"up" position.

2. Detach motor wire harness connectors from motor relay.

3. From underside of motor and transmission support, remove two motor attaching screws; then, disengage motor from drive coupling and remove motor. If seat is inoperative in "down" position remove motor from under rear of seat.

SEATS 14-23

Fig. 14-21-Six-Way Seat Adjuster Motor, Transmission, Cable and Support

- Pontiac, Buick,

Oldsmobile and Cadillac 60-40 Seats

- Disassembled

1 . Electric Motor

2. Motor-to-Transmission

3.

Coupling

Transmission

Assembly

4. Transmission End

Plate and Attaching

5.

Screws

Front Vertical Drive

Cable - Yellow

4. To install, reverse removal procedure. Check operation of seat assembly to limits of horizontal and vertical travel.

6. Rear Vertical Drive

Cable - Inboard -

Green; Outboard -

Blue

7. Horizontal Drive

Cable

-

Black

8.

9.

Motor Relay and

Attaching Screw

Motor and

Transmission Support

10. Transmission

Attaching Screws

SIX-WAY SEAT ADJUSTER ASSEMBLY

AND HORIZONTAL OR FRONT VERTICAL

DRIVE CABLES- Pontiac, Buick, Oldsmobile and Cadillac 60-40 Seats

SIX-WAY SEAT ADJUSTER REAR

VERTICAL DRIVE CABLE- Pontiac, Buick,

Oldsmobile and Cadillac 60-40 Seats

Removal and Installation

Removal and Installation

. 1. If seat is operable, raise seat assembly to the full

"up" position.

1. Remove seat assembly from body, as described under "Front Seat Assembly

-

Power Operated

Two, Four or Six-Way Full Width and 60-40 Six-

Way Seats

-

Removal and Installation". Place seat assembly upside-down on a clean, protected surface.

2. Detach rear vertical cable from rear vertical gearnut at rear of adjuster. 2. Detach drive cables from adjuster being removed.

3. From under front of seat, remove transmission cable end plate attaching screws; then, slide end plate up cables sufficiently to disengage rear vertical cable from end plate (Fig. 14-2 1).

3. At adjuster being removed, remove nut securing

. motor and transmission support at front of adjuster (Figs. 14-10, 14-1 1). Remove seat adjuster to seat frame front and rear attaching bolts; then, remove adjuster froni seat assembly.

4. To install rear vertical cable(s), reverse removal procedure. Check operation of seat assembly to limits of horizontal and vertical travel.

4. To remove horizontal and/or front vertical cable(s), remove seat adjuster on side from which

14-24 SEATS cable@) is being removed. Remove transmission end plate attaching screws (Fig. 14-21); then, slide end plate up cables sufficiently to disengage cable(s) from end plate.

5. To install seat adjuster assembly or horizontal and/or front vertical drive cable@) reverse removal procedure. Make sure cables are properly engaged with transmission and adjuster before installing transmission end plate and seat adjuster. Orange cable attaches from front of transmission to adjuster front vertical gear nut.

Blue cable attaches from center of transmission to adjuster rear vertical gear nut. Black cable attaches from rear of transmission to adjuster horizontal actuator.

Check operation of seat assembly to limits of horizontal and vertical travel.

SIX-WAY SEAT ADJUSTER

TRANSMISSION ASSEMBLY- Pontiac,

Buick, Oldsmobile and Cadillac 60-40 Seats

Removal and Installation

1. Remove seat assembly from car, place upside- down on a clean, protected surface and remove one seat adjuster assembly; as previously described.

2. At opposite adjuster, detach drive cables from adjuster and remove nut securing motor and transmission support at front of adjuster (Fig. 14-

? 1 \

3. Disengage and remove motor and transmission support from adjuster. As a bench operation, remove screws securing transmission assembly to support; then, disengage transmission from motor drive coupling and remove transmission. Where required, remove .transmission end plates and drive cables.

4. To install transmission assembly, reverse removal procedure. Install drive cables (color coded) as shown in Figure 14-21. Check operation of seat assembly to limits of horizontal and vertical travel.

SIX-WAY SEAT ADJUSTER

TRANSMISSION ASSEMBLY- Pontiac,

Buick, Oldsmobile and Cadillac 60-40 Seats

Disassembly and Assembly

1. Remove seat adjuster transmission assembly, as previously described.

0

2. Remove screws securing solenoid housing to gear housing; then, carefully separate housings and remove component parts of transmission assembly

(Fig. 14-22).

GEAR HOUSING

' I

DPG SPRING

GEAR SHAFT

SOLENOIDS AND

COVER P L A T E

SOLENOID

PLUNGER

I

SOLENOID

HOUSING

/

DRIVING GEAR

I

THRUST WASHERS

I

HARNESS CONNECTOR

Fig. 14-22-Six-Way Seat Adjuster Transmission - Disassembled

Oldsmobile and Cadillac 60-40 Seats

- Pontiac, Buick,

SEATS 14-25

3. To assembly transmission, reverse removal procedure.

IMPORTANT: Prior to or during installation, lubricate frictional surfaces of driving gear thrust washer, gears, dog washers, shaft and solenoid plungers with "Lubriplate" (630AAW) or equivalent.

FRONT SEAT BACK ASSEMBLY- "A", "X" and "B" Body Four Door Styles with

Conventional Full Width Seat

Removal and lnstallation

1. Remove front seat assembly from body and place it upside- down on a clean, protected surface.

Remove seat side panels, where present.

2. Remove hog rings securing lower edge of seat back trim to seat cushion springs (see Fig. 14-23).

3. Raise lower edge of seat back trim, detach fiberboard breakover foundation and bend out tabs on seat back frame securing seat cushion springs. Disengage springs from tabs (Fig. 14-23).

4. At each end of seat, remove hog rings securing lower edge of seat back trim to seat bottom

\

SEAT BACK

ATTACHING BOLTS

VlEW "A"

VlEW "B"

4271

Fig. 14-23-Front Seat Back Attachment

-

Typical Four Door Attachment-"A" Style Full

Width Conventional Seat frame. Raise or turn back seat back trim to expose bolts securing seat back frame to seat cushion frame (Fig. 14-23). Where seat back lighter or courtesy light is present, disconnect wire from seat cushion frame.

5. Place seat assembly in upright position. Then with a helper holding seat back assembly, remove seat back attaching bolts on each side of seat and remove seat back assembly.

6. To install seat back assembly, reverse removal procedure.

FRONT SEAT BACK ASSEMBLY (Right or Left)- Four-Door Style Full Width

Conventional Seat with Notch-Down

Center Arm Rest or 60- 40 Seats

Removal and lnstallation

1. Remove front seat assembly from body and place upside-down on a tlean, protected surface.

Remove seat cushion side panels. On 60-40 seats remove seat cushion and seat back side panels.

2. Remove hog rings securing lower edge of seat cushion trim bottom facing to seat cushion springs and frame (Fig. 14-24 or 14-25).

3. Remove seat side panel where present or outer hinge arm cover (Fig. 14-24 or 14-25); then, using a flat-bladed tool carefully remove retainer

, securing seat back outer arm to hinge pin (Fig.

14-24 or 14-25).

4. On notch back seats detach trim sufficiently to expose seat back attaching bolt access holes (Fig.

14-24); then, through access holes remove seat back lock-up screws (Fig. 14-24). On 60- 40 seats detach trim at outer hinge arm sufficiently to remove outer hinge arm lock-up screw (Fig. 14-

25).

5. Turn seat assembly right side up. Carefully disengage seat back outer arm from hinge pin; then, tilt seat back forward and upward to disengage seat back inner arm from hinge pin

. and remove seat back from body (Fig. 14-24 or

14-25).

6. To install seat back assembly, reverse removal procedure. If seat back outer arm retainer is damaged, install new retainer.

14-26 SEATS

V I E W "8"

4270:

Fig. 14-24-Front Seat Back Attachment (Right or Left)

Seat

-

Four-Door Style Notch Back

FRONT SEAT BACK ASSEMBLY (Right or

Left)- Two-Door Style Conventional Full

Width Seat, Seat with Notch Down

Center Arm Rest and 60/40 Seat, Seat

Removal and Installation

1. On seat with seat cushion side panel, remove side panel and detach seat cushion trim sufficiently to expose outer hinge pin and retainer (Fig. 14-26 or

14-27).

On seats where seat back side panel covers outer hinge pin and retainer, remove seat back side panel.

' On seats with outer hinge arm cover or inner hinge pin cover, remove screw or detach fastener securing cover and remove cover (Fig. 14-26 or

14-27).

2. Using a flat-bladed tool carefully remove retainer, securing seat back outer arm to hinge pin (Fig.

14-26 or 14-27).

3. Carefully disengage seat back outer arm from hinge pin; then, tilt seat back fonvard and upward to disengage seat back inner arm from hinge pin and detach seat back from seat cushion.

On seats with manually operated seat back locks the seat back can be removed from the body.

SEATS 14-27

1

, '

INNER HINGE

PIN COVER

VlEW "B"

OUTER ARM

RETAINER

VIEW

"A"

VIEW

"C"

Fig. 14-25-Front Seat Back Attachment (Right or Left) - Four-Door Style 60-40 Seat

4274

I

14-28 SEATS

NOTE: On seats equipped with electric seat back locks, lay seat back on seat cushion and carefully disengage seat belt webbing plastic protector (set

Fig. 14-26 or 14-28) from seat cushion. From under front of seat, disconnect lock actuator feed wire from relay jumper wire; from under rear of seat detach feed wire clip from strap securing wire to seat spring (see Fig. 14-28); then, carefully pull feed wire up through seat cushion and remove seat back from body.

4. To install seat back assembly, reverse removal procedure making sure washers are installed over hinge pins prior to installing seat back. If outer retainer is damaged, install new, retainer.

IMPORTANT: Check operation of seat back locks.

On seats equipped with manually operated locks the seat back should lock with no more than 10 lbs. rearward effort applied at the top outboard corner of the seat back. On seats equipped with electric seat back locks both seat back locks should lock in the upright position when the doors are closed. If either seat back does not lock refer to

"Electric Seat Back Lock"

I

C U S H I O N TRIM

SlDE F A C I N G

H I N G E ARM COVER

FRONT SEAT BACK MANUALLY OR

ELECTRICALLY OPERATED LOCK- (Right or Left) All Two-Door Styles with Conventional Full Width Seats

Removal and Installation

1. On seats with full seat back panel or detachable seat back trim panel, remove hog rings securing trim along bottom and sides of trim. On seats with one piece (envelope type) trim cover.

2. Remove front seat back assembly from front seat cushion assembly, as previously described.

3. Remove front seat back outer side panel and side panel lower support, where present.

4. On seats with electrically operated locks, remove manual override handle and escutcheon.

5. Remove hog rings securing seat back front and rear trim facings and foam pad facing along bottom of seat back; then, turn up trim and carefully pull out foam pad sufficiently to gain access to lock attaching bolts ( F e . 14-29 or 14-30).

6. On manually operated seat back lock, disengage lock connecting rod clip (Fig. 14-29) and detach rod from lock. On electrically operated seat back lock, disconnect feed connector from lock solenoid.

NOTE: To disengage clip it is usually necessary to damage or break clip.

7. Remove seat back lock attaching bolts (Fig. 14-29 for manual lock, Fig. 14-30 for electric lock); then, remove lock assembly from seat back.

8. To install, reverse removal procedure. If rod to lock retaining clip is damaged, install new clip.

Check for proper operation of seat back lock.

TRIM WASHER

SEATS WITHOUT C U S H I O N SlDE PANELS 3235

Fig. 14-26-Seat Back Attachment

-

Two-Door

Style Conventional Seat

FRONT SEAT BACK MANUALLY

OPERATED LOCK

CONTROL AND LOCK ROD.

Two-Door Styles With Conventional

Full Width Seats or 60-40 Seats With

Manually Operated Seat Back Locks

Removal and Installation

1. On styles with one piece (envelope type) seat back trim cover remove front seat back assembly, as previously described. Remove seat back side panel where present. Remove hog rings securing trim

SEATS 14-29

STANDARD SEAT

VlEW

X

-

.

_

Fig. 14-27-Seat Back Attachment

7

-

Two-Door Style Notch Down Center Arm Rest

Seat and 60-40 Skat

14-30 SEATS

SEAT BACK DETACHED

FROM CUSHION FOR:,.

ILLUSTRATIVE PURPOSES

0-NLY ---

--

Fig. 14-28-Electric Seat Back Lock Wire Route

Through Seat Cushion-Two-Door

Style Full Width Conventional Seat cover at bottom of seat back and pull trim up sufficiently to gain access to lock and lock control.

2. On styles with full seat back panel, remove lock control handle; then, remove seat back panel.

3. On styles with seat back panel or detachable rear trim facing, remove hog rings securing seat back panel or trim facing along bottom and sides of seat. If removing lock, control-to-lock rod on any style or lock control on Cadillac styles turn back seat trim sufficiently to gain access to lock control.

If removing lock control on any style except

Cadillac remove seat back trim cover and foam pad assemblies.

4. To remove seat back lock rod from lock control carefully squeeze prongs of clip (Fig. 14-29, View

"C") sufficiently to disengage clip and detach rod from lock. Remove lock attaching bolts and rod from control (Fig. 14-29).

5. To remove seat back lock control on Cadillac styles, remove control attaching screws and remove control. To remove lock control on all styles except Cadillac, scribe position of control assembly on seat back side bar. Using a spot weld cutter tool J- 8943-01 or equivalent, drill out three control.

6. ~ o ' i n s t a l l lock control on Cadillac styles, reverse removal procedure. To install lock control on all styles except Cadillac, position and clamp new control assembly to seat back frame side bar in

SAME position as original control assembly.

Braze new control assembly to seat back frame side bar at the three original weld locations.

7. To install control-to-lock rod position rod (with attached clip) up through seat back frame bar; then, carefully install clip into slot in control lever making sure both prongs of clip are engaged through slot.

NOTE: If clip is damaged o f does not retain properly, break off old clip and install new clip.

8. After assembly, check for proper operation of seat back lock, the seat backs should lock with no more than 10 lbs. of rearward effort applied at the top outboard corner of the seat back.

SEAT BACK ELECTRIC LOCK SOLENOID

AND SUPPORT ASSEMBLY- Two-Door

Styles with Conventional Full Width Seat

Removal and Installation

1. Remove front seat back electric lock assembly with attached solenoid and support from seat, as previously described.

2. Remove small position lock screw and two solenoid support-to- lock attaching screws; then, disengage solenoid plunger bar from lock link

(Fig. 14-3 1) and remove assembly from lock.

3. To install solenoid and support assembly, engage solenoid plunger bar to lock link; then, install loosely two solenoid support-to-lock attaching screws (Fig. 14-31). With lock hook tight against stop tab (see Fig. 14-31) extend solenoid plunger bar all the way out of solenoid; then, adjust solenoid support until the lack link rivet just contacts bottom of slot in solenoid plunger bar

(see Fig. 14-31) and tighten securely solenoid support attaching screws.

SEATS 14-3 1

VIEW "B"

Fig. 14-29-Front Seat Back Manually Operated

Lock

-

"A, B, C and X" Two-Door Styles,

Standard Full Width Seat

Styles, Standard Full Width Seat

IMPORTANT: Carefully drill a new position lock screw hole (9/64") through both solenoid support and lock frame in area where previous lock screw was located and install securely position lock up screw.

IMPORTANT: Check operation of both electric actuated seat back locks. If either lock does not lock or unlock properly refer to "Electric Seat

Back Lock Trouble Diagnosis Chart-Conventional

.

Seats".

NOTE: When seat back is returned to locked position with both doors closed the locking effort, applied rearward at upper outboard corner of seat back, must not exceed 10 lbs.

14-32 SEATS

ELECTRIC SEAT BACK LOCK TROUBLE DIAGNOSIS CHART

STYLE CONVENTIONAL SEATS

-

TWO-DOOR

1. Seat back lock does not lock when doors are closed.

APPARENT CAUSE CONDITION 0

1. Current at actuator solenoid does not cut off

-

CORRECTION

1. Refer to Electrical Checking

Procedure

- where required, install new jamb switch.

, jamb switch remains open.

2. Seat back relay contacts sticking.

2. Refer to Electrical Checking

Procedure

- where required, install new relay.

3. Seat back does not return to upright position far enough to trip lock into locked position. Check for excessive trim build-up; also check inboard bumper clearance.

3. Specified inboard bumper

. clearance 1/16"

- where required install thinner bumper. Locking effort applied rearward at upper outboard corner of seat back is

0-10 lbs. maximum.

I 2. Seat back lock will not unlock when door@) are

1. No current at actuator solenoid - blown fuse,

.defective jamb switch or seat back realy, or short in wiring.

2. Bind in lock or lock linkage.

1. Refer to Electrical Checking

Procedure.

2. Locate and eliminate bind or, where required, install new lock assembly.

3. Seat back lock unlocks but solenoid flutters or solenoid circuit breaker

1. Bind in lock or linkage which does not allow solenoid plunger to completely deactivate pull in coil.

2. Actuator solenoid plunger is not c o q letely deact- ivating pul f in coil with no bind present in lock or linkage. Lock operates okay manually.

1. Locate bind or interference and eliminate, or where required install new lock.

2. Check solenoid as described under "Electrical Checking

Procedure"

-

Check if solenoid is adjusted properly on lock see "Seat Back Electric Lock

-

Solenoid and Support Assembly"

-

Step 3 and 4. Where required replace solenoid assembly.

FRONT SEAT BACK HEAD RESTRAINT-

Conventional Full Width or

60-40

Seat

(Drivers or Passengers Side)

Head restraints for the standard full width or 60-40 seat are single post type, which can be adjusted to two positions (low or high). On "A and head restraint can be removed from the seat back by actuating (push in) the lock lever located at the head restraint post escutcheon and lifting the head restraint out of the seat back. To remove head restraints on "B and C" body styles it is necessary to follow the procedure described below:

SEATS 14-33

MANUAL OVERIDE LEVER

Fig. 14-30-Front Seat Back Electrically Operated

Lock

- "A, B and C" Two-Door Styles,

Standard Full Width Seat

FRONT SEAT BACK HEAD RESTRAINT-

All "B and C" Body

Conventional Full Width or 60-40 Seats

Removal and Installation

1. Raise head restraint to full "up" position.

2. Remove head restraint post escutcheon attaching screws.

3. Lift escutcheon upward; then insert a narrow screwdriver down the left side of head restraint post sufficiently to depress lock spring and remove head restraint.

4. To install head restraint, insert post into guide and push down to full down position. Check that lock spring engages and prevents head restraint from being removed.

Fig. 14-31-Front Seat Back Electric Lock

Solenoid and Support Assembly

-

"A, B and C Two-Door Styles with Standard

Full Width or 60/40 Seats

FRONT SEAT BACK HEAD RESTRAINT

LOCK AND ESCUTCHEON ASSEMBLY-

Conventional and 60-40 Seats

Removal and Installation

1. b n "B and C" bodies remove head restraint, as previously described. On "A and Xu bodies remove head restraint by actuating (push in) the lock lever at the post escutcheon and lifting the head restraint out of the seat back.

2. Remove lock and escutcheon assembly attaching screws and remove lock and escutcheon (Fig. 14-

32).

3. To install, reverse removal procedure. Check operation of head restraint.

FRONT SEAT BACK HEAD RESTRAINT

GUIDE TUBE- Conventional and

60-40 Seats

The front seat back head restraint guide tube is a plastic tube inserted through slots in a guide tube support assembly. The guide tube support assembly,

14-34 SEATS

H E A D R E S T R A I N T E S C U T C H E O N

A N D L O C K A S S L M I L I

RETAINER LOCK NUT 7

GUIDE TUBE

SEAT BACK

HEAD R~STRAINT

Fig. 14-33-Head Restraint Guide Tube Typical of All Conventional Seats

Fig. 14-32-Front Seat Back Head Restraint

Retainer, Lock and Escutcheon

-

Conventional and 60-40 Seats which incorporates a riveted-on tension spring, is welded to the seat back frame.

Removal and lnstallation

1. Remove front seat back and head restraint lock and escutcheon assembly, as previously described.

Remove trim retainer (see Fig. 14-32).

On seat backs with one piece (envelope type) seat back trim assembly, remove seat back assembly, as previously described; then, as a bench operation remove hog rings securing trim at bottom of seat back and pull up trim sufficiently to gain access to head restraint support or guide tube. On seat backs with seat back panel or detachable rear trim facing, remove seat back panel and detach back trim sufficiently to gain access to head restraint support or guide tube.

3. Remove screw securing guide tube and slide guide tube out of support (Fig. 14-33).

4. To install head restraing, guide tube reverse removal procedure.

FRONT SEAT CENTER ARM REST AND

CURTAIN ASSEMBLY- Front Seat with

Standard Full Width Seat Back

Removal and lnstallation

1. Place center arm rest in dawn position.

2. At top of arm rest curtain, remove hog rings securing curtain to flange of support plate and pull curtain forward to expose screws securing arm rest to support linkage (Fig. 14-34).

3. Remove arm rest-to-support linkage screws and remove arm rest and curtain .from seat (Fig. 14-

34).

4. To install, reverse removal procedure.

SEATS 14-35

H O G R I N G C U R T A I N

A R M R E S T f

HOOK SLOT

Fig. 14-34-Front Seat Back Center Arm Rest

CENTER ARM REST AND SUPPORT

ASSEMBLY- Front Seat with

Standard Full Width Seat Back

Removal and Installation

1. Place center arm rest in down position.

2. At top of arm rest curtain, remove hog rings securing curtain to flange of support plate (Fig.

14-34).

3. Remove two screws security arm rest to supports on seat back (Fig. 14-34); then, carefully lift arm rest and linkage upward to disengage hooks of. arm rest from slots in supports and remove assembly from seat.

4. To install, reverse removal procedure. Prior to installing curtain screws check alignment and operation of arm rest.

FRONT SEAT CENTER ARM REST AND

CURTAIN ASSEMBLY- Front Seat with

Notch Down Seat Back and Strato

Front Seat

Removal and Installation

1. Lower arm rest to within approximately 2 inches of full down position.

2. Carefully pull curtain back sufficiently to remove screws securing center arm rest to linkage and loosen outer screws securing curtain lower retainer to arm rest (Fig. 14-35).

3. Disengage arm rest from support linkage and turn arm rest upside-side down on trim panel finishing cover. Remove arm rest curtain upper retainer screws (Fig. 14-35); then, remove arm rest and curtain from seat.

4. To install, reverse removd procedure.

FRONT SEAT CENTER ARM REST

ASSEMBLY- Front Seat with Notch Down

Seat Back and Strato Front Seat

Removal and Installation

1. Place arm rest in up position.

2. Working between arm rest and seat back, remove fastener at both sides of arm rest securing front end of screw finishing covers (Fig. 14-35).

3. On two-door styles, push one seat back to full forward position. Cardully pull up front of screw finishing cover sufficiently to expose arm rest linkage and linkage cover attaching screws; then, remove screws (Fig. 14-35). Repeat this operation on opposite side of arm rest; then, carefully remove arm rest linkage cover and linkage assembly from seat.

NOTE: If washers are present between arm rest linkage and linkage supports on seat (Fig. 14-35), note location and number of washers used to

COVER

A

Fig. 14-35-Front Seat Center Arm Rest (Full

Width Seat with Notch Down Seat Back)

14-36 SEATS

I N N E R SUPPORT

SPRING WASHER

I N N E R COVER

-

T O

-

PANEL

A T T A C H I N G SCREWS

COVER ASSEMBLY

VlEW B COVER - T O

-

PANEL

H l N G SCREWS

OUTER END F I N I S H I N G

COVER ASSEMBLY V l E W A

SHEET M

SCREWS

Fig. 14-36-Foot Rest Assembly

-

Cadillac 68169 Styles facilitate installation in same position. Washer@)

4. To proadure'

Prior

to bending down screw finishing

covers'

and 'peration of arm rest' check

where arm

washer(s), as required, with seat back(s) support and support on seat (Fig. 14-35).

arm

rest

36, are secured to the seat back by hinges. To remove foot rest assemblv. remove hinee-to-seat back attaching screws f r o k both sides of fGot rest (Fig. 14-

36) and remove foot rest assembly from seat back. To remove trimmed foot rest board remove hinge-to- board attaching screws (Fig. 14-36) and remove hinges from foot rest board. To install, reverse removal prmdure. When installing foot rest hinge-to-seat back attaching screws, install machine thread screws in upper attaching hole at each hinge.

FOOT REST ASSEMBLY-

Cadillac

68169 Styles

The folding foot rest assemblies shown in Figure 14-

BUCKET SEATS

STRATO F R O N T SEATS

Description

The Chevrolet and Pontiac "F" body styles are equipped with high back bucket seats which do not require head restraints. Strato bucket seats are available on Chevrolet, Pontiac, Oldsmobile and Buick

"A" body styles and Buick "E" body styles.

AU

two- door style bucket seats incorporate seat back locks on both the driver's and passenger's seat back. The strato seat (two -door styles) seat back lock is actuated by a

SEATS 14-37 control button located at the rear upper center center of the seat back. The "F" body style seat back lock is actuated by a control lever located on the lower portion of the seat back outer hinge arm.

Head restraints for the strato seats are a dual post type, which can be adjusted to two positions (low or high) or removed from the seat back by actuating

(push in) the lock levers located at the head restraint post escutcheons and lifting the head restraint from the seat back.

IMPORTANT: SEAT ATTACHING PARTS SUCH AS

SEAT ADJUSTER-TO-FLOOR PAN BOLTS OR

NUTS, SEAT ADJUSTER-TO-SEAT FRAME

BOLTS, SEAT BACK LOCK BOLTS, SEAT BACK

LOCK STRIKER, ETC. .ARE IMPORTANT AT-

TACHING PARTS IN THAT THEY COULD

AFFECT THE PERFORMANCE OF VITAL COM-

PONENTS AND SYSTEMS. THEY MUST BE

REPLACED WITH ONE OF THE SAME PART

NUMBER OR WITH AN EQUIVALENT PART IF

REPLACEMENT BECOMES NECESSARY. DO

NOT USE A REPLACEMENT PART OF LESSER

QUALITY OR SUBSTITUTE DESIGN. TORQUE

VALUES MUST BE USED AS SPECIFIED DURING

REASSEMBLY TO ASSURE PROPER RETENTION

OF THESE PARTS.

STRATO FULL-WIDTH FRONT SEAT

ASSEMBLY

Removal and Installation

The removal and installation procedures for the strato

ADJUSTER-TO-FLOOR P A N

ATTACHING NUTS full width seat assembly, seat adjuster and seat adjuster components are the same as for the conventional full width front seat assembly

-

Refer to the appropriate section under "Front Seat Assembly -

Full Width".

MANUALLY OPERATED BUCKET

SEAT ASSEMBLY

Removal and Installation

1. Operate seat to full rearwa'rd position.

2. Turn back floor carpeting sufficiently to expose seat adjuster -to-floor pan attaching nuts or bolts

(Figs. 14-37 and 14-14).

3. Operate seat to full rearward position. Remove adjuster-to- floor pan front attaching bolts or nuts

(Figs. 14-37,14-38 and 14-39). Operate seat to full forward position. Remove adjuster- to-floor pan rear attaching bolts or nuts. On seats with electric seat back locks disconnect lock solenoid wire from feed wire connector under rear of seat. Remove seat assembly from body.

4. To install, reverse removal procedure. Check operation of seat adjuders to full limits of travel.

On seats with electric seat back locks, check operation of both seat back locks. If either seat back does not lock or unlock properly see

"Trouble Diagnosis Chart

-

Strato Seats".

POWER OPERATED

FOUR-WAY BUCKET SEAT ASSEMBLY

The four-way seat adjusters are actuated by a 12 volt,

\

G R O U N D WIRE

(POWER SEAT O N L Y )

2

Fig. 14-37-Bucket Seat Floor Pan Attachment

"A and X" Styles

-

Fig. 14-38-Bucket Seat Floor Pan Attachment

"F" Styles

-

14-38 SEATS

Fig. 14-39-Front Seat Adjusters

-

Manually Operated Strato Bucket

-

Buick "E" Body

1. Adjuster Floor Pan

Anchor Plates and

2.

Studs

Adjuster-to-Anchor

Plate Attaching Bolts and Nuts

3.

4.

Ad~uster-to-Anchor

Plate Attaching Bolts

Adjuster-to-Seat

Frame Attaching

Bolts

5.

6.

Adjuster Assist Spring

Adjuster Lock Bar spring

7. Seat Frame-to-

duster

Ground

Wire With Electric

Locks) reversible shunt wound motor with a built-in circuit breaker.

2. Where necessary, remove sill plates and turn back floor carpeting to expose seat adjuster-to-floor pan attaching nuts and bolts.

The four-way seat adjuster operating mechanism incorporates a transmission assembly which includes two solenoids and two drive cables leading to the seat adjusters. One solenoid controls the vertical movement of the seat while the other solenoid controls the horizontal movement of the seat. When the control switch is actuated, the motor drives the transmission by means of a belt and one of the transmission solenoids is energized simultaneously. The solenoid plunger then engages with the drive cables and operates both adjusters. When the adjusters reach their limit of travel, the drive cables stop their rotating action and torque is absorbed by the rubber belt connecting the motor and transmission. When the switch contacts are opened, a return spring returns the solenoid plunger to its original positibn disengaging it from the driver gear dog.

Removal and Installation

1. Operate seat to full forward and up position.

Remove seat cushion side panels, where present.

Where seat adjuster track covers are present, carefully pry out track cover snap-on retainers with a flat-bladed tool and remove track covers.

3. Remove seat adjuster-to-floor pan rear attaching bolts (Figs. 14-40 and 14-41).

4. Operate seat to full rearward position. Remove seat adjuster- to-floor attaching bolts (Figs. 14-40 and 14-41). Tilt seat rearward sufficiently to disconnect seat harness feed connector and detach harness from clip on floor pan. On seats with electric seat back locks disconnect lock solenoid wire from feed wire connector. Remove seat assembly from body.

5. To install, reverse removal procedure. Make sure ground wire is secured under adjuster inboard rear attaching nut or bolt. Check operation of seat adjusters to full limits of travel. On "A" Body

Styles make sure floor carpet is properly positioned around rear supports of adjuster prior to installing carpet retainer on adjuster stud and adjuster rear attaching nuts. On seats with electric seat back locks check operation of both seat back locks. If either seat back does not lock or unlock properly see "Trouble Diagnosis Chart

-

Strato

Seats".

SEATS 14-39

Fig. 14-40-Power Operated Four-Way Bucket Seat Adjusters

-

"A" Body Styles

1. Adjuster Floor Pan

Achor Plates and

Studs

2. Adjuster Assembly

3. Adjuster-to-Floor Pan

Anchor Plate

Attaching Nuts

4. Motor Assembly

5. Motor and

Transmission Drive

Belt Cover

6. Transmission

Assembly

7. Motor and

Transmission Support

Attaching Nuts

8. Adjuster Track Cover

Retainers

9. Adjuster Track Upper

Cover Front Support

10: Adjuster Track Upper

Cover

11. Adjuster Track Upper

Cover Rear Support

12. Adjuster Track Lower

Rear Cover

13. Adjuster-to-Seat

Frame Attaching

Bolts

14. Adjuster Rear Carpet

Retainer

15. Ground Strap

16. Adjuster Horizontal

Actuator

14-40 SEATS

Fig. 14-4 1 -Four-Way Power Operated Bucket

Seat Adjusters

-

Buick "E" Body

1. Adjuster Floor Pan

Anchor Plates and

Studs

2. Adjuster Floor Pan

Outer Anchor Plate

Attaching Bolts

3. Adjuster-to-Anchor

Plate Attaching Bolts and Nuts

4. Adjuster-to-Seat

Frame Attaching

Bolts

$;. Motor Assembly

6. Transmission

Assembly

7. Motor and

Transmission Drive

Belt Cover

8. Motor and

Transmission Support

9.

Attaching Nuts

Adjuster Upper Track

Cover

10. Adjuster Lower Track

Cover

1 1 . Adjuster Lower Rear

Track Cover

12. Seat Frame-to-

Adjuster Ground

Wire

MANUALLY OPERATED BUCKET

SEAT ADJUSTER

Removal and Installation

1. Remove bucket seat assembly, as previously described, and place seat upside-down on a clean, protected surface.

2. If replacing inboard adjuster, remove assist spring.

3. Operate adjuster so that both front and rear adjuster-to-seat frame attaching bolts are accessi- ble; then, remove attaching bolts and remove adjuster from seat assembly.

4. To install, reverse removal procedure. If adjuster with control arm and knob is being replaced, install new adjuster control knob. Refer to

"Manually Operated Seat Adjuster Control Arm

Knob".

POWER OPERATED FOUR-WAY

BUCKET SEAT ADJUSTER

Removal and Installation

1. Operate seat assembly to fully raised and midway horizontal positions.

2. Remove front seat assembly from body with attached adjusters, motor and transmission, as previously described, and place upside-down on a clean, protected surface.

3. If outbbard adjuster is being removed, disconnect both, horizontal and vertical, drive cables from vertical gearnut and horizontalractuator (Figs. 14-

40, 14-41 and 14-42).

4. Remove nuts securing motor and transmission support to adjuster being removed (Figs. 14-40,

14-41 and 14-42).

5. Remove adjuster-to-seat bottom frame front and rear attaching bolts securing adjuster to be removed (Figs. 14-40, 14-39 and 14-42).

6. Carefully disengage adjuster from support, and torque tube; then, remove adjuster from seat.

7. To install power operated four-way bucket seat adjuster assembly, reverse removal procedure.

Check for proper operation of seat adjusters to limits of travel.

POWER OPERATED FOUR-WAY BUCKET

SEAT ADJUSTER MAJOR COMPONENTS

The following service p&edures cover replacement of the major component parts of the power operated four-way seat adjuster used on bucket seats.

MOTOR .AND TRANSMISSION

DRIVE BELT AND PULLEYS

Removal and Installation

1. At front of seat remove motor and transmission

I

L E F T A D J U S T E R .

SEATS 14-41

1. Motor and

Transmission Drive

Belt Cover and

Attaching Screws

2. Transmission Drive

Pulley

3. ~ransmission and

Motor Drive Belt

4. Motor Drive Pulley

5. Transmission

Assembly

Fig. 14-42-Power Operated Four-Way Bucket Seat Adjusters

6. Electric Motor

Assembly

7. Electric Motor Relay

8. Motor and

Transmission Support

9. Motor and

T~ansmission Support- to-Right Adjuster

Attaching Nut

10. Motor and

Transmission Support- to-Left Adjuster

Attaching Nut

1 1. Adjuster Horizontal

Drive Cable

12. Adjuster Vertical

Drive Cable

13. Adjuster Torque Tube

14. Adjuster Vertical

Gearnut Shoulder

Screw

15. Adjuster Vertical

Gearnut Assembly

16. Adjuster Vertical

Jackscrew

17. Adjuster Vertical

Jackscrew Stop Nuts

18. Adjuster Horizontal

Actuator Assembly

19. Adjuster Horizontal

Actuator Attaching

Screws

20. Seat Side Panel support full "up" position. Disconnect wire harness connector from motor relay. drive belt cover attaching screws and remove cover (Fig. 14-42).

2. Remove drive belt from both motor and transmission drive pulleys. Pulleys may be removed from either motor or transmission by pulling off their respective shafts (Fig. 14-42).

3. To install drive belt, reverse removal procedure.

Check for proper operation of seats to full limits of travel.

MOTOR ASSEMBLY

Removal and Installation

1. If motor can be operated, operate seat assembly to

2. Remove motor-to-transmission drive belt cover and drive belt, as previously described.

3.

'

From under motor and transmission support remove two cap screws securing motor to motor- and-transmission support and remove motor assembly from under se.at.

4. To install, reverse removal procedure. Check for proper operation of seat to full limits of travel.

14-42 SEATS

TRANSMISSION ASSEMBLY AND

HORIZONTAL AND VERTICAL

DRIVE CABLES

.

Removal and Installation

Remove front seat assembly from body with attached adjusters, motor and transmission, as previously described, and place upside-down on a clean, protected surface.

Disconnect wire harness connector from transmission.

Remove motor and transmission drive belt cover and remove drive belt (Fig. 14-32).

Remove two screws securing transmission assem- bly to motor and transmission support; then, move transmission forward to disengage from drive cables and remove transmission from seat.

NOTE: To remove horizontal or vertical drive cables, detach drive cable from adjuster and remove cable.

Disassembly and Assembly of Transmission

Remove front seat adjuster transmissiom from seat assembly.

Remove screws securing rear and solenoid housings together; then, carefully separate hous- ings and remove component parts of transmission assembly.

To assemble transmission, reverse removal procedure.

IMPORTANT: Prior to or during installation, lubricate frictional surfaces of driving gear thrust washer, gears, dog washers, shaft and solenoid plungers with "Lubriplate" (630AAW) or equivalent.

To install transmission assembly, reverse removal procedure. Make certain drive cables are properly engaged in transmission and properly retained in cut out notches of motor and transmission support prior to installing transmission attaching screws.

Check for proper operation of seat to full limits of travel.

ADJUSTER VERTICAL GEARNUT

Removal and lnstallatlon

1. Operate seat assembly to full raised and midway horizontal position.

Remove front seat assembly from body and place upside-down on a clean, protected surface.

Using a clutch type screwdriver or other suitable tool, remove shoulder screws securing linkage to vertical gearnut (Fig. 14-42).

Remove jackscrew "down" stop from jackscrew

(Fig. 14-42).

,

Using a portable power source to energize the motor, actuate vertical gearnut until gearnut is disengaged from jackscrew.

NOTE: It may be necessary to manually raise or lower upper rear portion of adjuster to gain clearance for removal of gearnut.

Disconnect drive cable from gearnut.

To install, reverse removal procedure. Check seat adjusters for proper operation.

ADJUSTER JACKSCREW

Removal and Installation

#

Remove adjuster gearnut as previously described.

Remove seat adjuster-to-seat bottom frame front and rear attaching bolts.

As a bench operation, remove jackscrew-to- adjuster linkage attaching rivet and remove jackscrew from adjuster assembly (Fig. 14-42).

NOTE: It may be necessary to manually raise or lower upper rear portion of adjuster to gain access to jackscrew attaching rivet.

To install, reverse removal procedure. Use new rivet to attach jackscrew-to-adjuster linkage.

Check seat adjusters for proper operation.

ADJUSTER HORIZONTAL

ACTUATOR ASSEMBLY

Removal and Installation

Remove front seat assembly from body as previously described and place upside-down on a clean, protected surface.

Using

a:

clutch type screwdriver or other suitable tool, remove shoulder screws pecuring linkage to vertical gearnut (Fig. 14-42).

Using a portable power source, actuate vertical gearnut until gearnut is againt "down" stop on jackscrew assembly.

SEATS 14-43

4. Disconnect drive cable from horizontal actuator assembly.

5. Remove screws securing horizontal actuator assembly to adjuster lower track; then, remove actuator from adjuster assembly (Fig. 14-42).

6. To install, reverse removal procedure.

NOTE: When installing horizontal actuator, adjust actuator so that drive gear is fully engaged with teeth on lower channel. When horizontal actuator attaching screws are tightened, there should be no free motion between upper and lower channels.

Re-adjust actuator. "as required" until all free motion between channels has been removed.

Check seat adjusters for proper operation.

TORQUE. TUBE ASSEMBLY

Removal and Installation

1. Remove inboard seat adjuster assembly, as previously described.

2. Disengage torque tube from outboard adjuster and remove torque tube assembly (Fig. 14-42).

3. To install torque tube assembly, reverse removal procedure. Check for proper operation of seat to full limits of travel.

ADJUSTABLE FRONT SEAT BACK

ASSEMBLY (Drivers Side Only)-Chevrolet

"F" Body Style

Descrlptlon

The optional adjustable front seat back (drivers side) can be adjusted to three positions by means of a control handle located at the right rear of the drivers seat cushion. With the control handle in the full rearward position the seat back is adjusted to the full rearward position; when the control handle is actuated

(rotated) forward the seat back is adjusted forward to a normal or full position.

Removal and Installatlon~Handle, Cams, Cam Rod,

Detent Plate and Spring

The handle, outer cam, cam rod, detent plate, inner cam and spring are removed in the order stated.

1. At inner side of seat remove handle screws (see

Figs. 14-43 and 14-45) and remove handle.

2. At left side of seat, remove nut securing outer cam to cam rod (see Figs. 14-44 and 14-45) and remove cam from rod.

Fig. 14-43-Adjustable Drivers Seat Back

Side

-

Chevrolet "F" Styles

-

Inner

3. At outer side of seat remove nut securing outer cam to cam rod (Fig. 14-44) and remove handle and cam (see Figs. 14-44 and 14-45).

#

4. To remove cam rod, pull rod out of seat cushion from inner side of seat (see Fig. 14-45).

NOTE: It may be necessary to turn cam rod until keyed end of rod can be pulled through key way in hole of seat frame. Where required, remove inner cam and spring from cam rod.

5. Remove screw securing inner detent plate and remove detent plate (see Figs. 14-43 and-14-45).

Fig. 14-44-Adjustable Drivers Seat Back

Side

-

Chevrolet "F" Styles

- Outer

14-44 SEATS

6.

Fig. 14-45-Adjustable Drivers Seat Back Handle, Cams, Cam Rod, Detent Plate and

Spring Removal and Installation from Seat Cushion - Chevrolet "F" Styles

To install adjustable seat back cam rod, detent operation. Tighten cam rod nut 18-24 in. lbs.

SEAT BACK LOCK STRIKER AND SEAT

BACK SIDE INNER BAR STOP-"F" Body

Styles

Description

Both the seat back lock striker located on the outboard side of the seat cushion and seat back side inner bar stop located on the inboard side of the seat cushion of a single metal bolt and washer assembly threaded into a tapped plate located in the seat cushion frame assembly.

Removal and Installation

1. Using door and tail gate striker removal tool

5-23457 or equivalent remove striker or stop from seat back side arm.

2. To install striker or stop, start thread engagement by hand to assure that bolts is threaded straight then tighten striker or stop 22 to 34 ft. lbs.

IMPORTANT: On the DRIVERS seat ONLY two threaded holes are provided in the outboard anchor plate for instailation of the seat back lock striker. -The striker must be installed in the

FRONT threaded hole on a drivers seat

WITHOUT adiustable seat back. On a drivers seat WITH adiustable seat back the striker must be installed in the REAR threaded hole (see Fig.

14-45).

IMPORTANT: THE SEAT BACK LOCK

STRIKER AND SEAT BACK SIDE INNER BAR

STOP ARE IMPORTANT ATTACHING PARTS

IN THAT THEY COULD AFFECT THE

PERFORMANCE OF VITAL COMPONENTS

AND SYSTEMS. THEY MUST BE REPLACED

WITH ONE OF THE SAME PART NUMBER

OR-WITH AN EQUIVALENT PART IF RE-

PLACE'MENT BECOMES NECESSARY. DO

NOT USE A REPLACEMENT PART OF

LESSER QUALITY OR SUBSTITUTE DESIGN.

TORQUE VALUES MUST BE USED AS

SPECIFIED DURING REASSEMBLY TO AS-

SURE PROPER RETENTION OF THIS PART.

SEATS 14-45

STRATO FRONT SEAT BACK PANEL

Removal and Installation

1. Remove head restraint from seat back.

2. Using a flat-bladed tool, carefully snap off seat back lock push button and escutcheon assembly and remove two screws securing seat back panel to lock assembly (Fig. 14-46).

3. Tilt seat back forward and remove three screws securing bottom of seat back panel to seat back frame (Fig. 14-46).

4. Pull bottom of seat back panel outward and lift panel upward to disengage panel from upper retainers; then, remove panel from seat back.

5. To install seat back panel, reverse removal procedure. When snapping on seat back lock push button and escutcheon assembly, make sure assembly is installed right side up with contour of side flanges matching contour of seat back panel.

STRATO FRONT SEAT BACK HEAD

RESTRAINTS

Operation and Removal

Front seat back head restraints are standard factory installed equipment for the driver and right front

LOCK PUSH B U T T O N A N D

ESCUTCHE?N ASSEMBLY passenger. They can be adjusted to two heights (low or high) or removed by pushing the lopking lever "in" at the head restraint post escutcheons, foward and adjusting the head restraint "up" or "down" or removing the head restraint from the seat.

STRATO SEAT BACK HEAD RESTRAINT

RETAINER AND GUIDE TUBE

Removal and Installation ,

1. Remove head restraint from seat back. Remove escutcheon and lock assembly attaching screws and remove assembly (Fig. 14-47).

2. Remove two screws securing retainer to seat back

(Fig. 14-47).

3. Remove seat back panel, as previously described.

4. Detach seat back trim cover sufficiently to expose upper end of guide tube.

5. Remove screw securing upper flange of guide tube to seat back frame; then, pull tube out of supports

(Fig. 14-47).

6. To install guide tube and retainer, reverse removal procedure.

1

' r H E A D R E S T R A I N T

E S C U T C H E O N A N D

L O C I

AssEMBL1Es

7

Fig. 14-46-Strato Back Panel Removal Fig. 14-47-Head Restraint

-

Strato Seats

14-46 SEATS

STRATQ FRONT SEAT BACK MANUALLY

OPERATED LOCK ASSEMBLY AND

ELECTRICALLY OPERATED ACTUATOR

ASSEMBLY

Removal and Installation

Remove front seat back panel, as previously described. On seats with electric seat back locks, disconnect solenoid feed wire at connector (Fig.

14-49).

IMPORTANT: If removing and reinstalling same lock or actuator assembly, install lock-up screw (8-

32 x 1/2" screw) at location shown in Figure 14-

48.

Remove lock strap-to-cushion' frame attaching screws (Fig. 14-48).

Remove lock or actuator assembly attaching screws and remove assembly from seat back (Fig. 14-48).

4. To install seat back lock or actuator assembly, reverse removal procedure.

IMPORTANT: After all lock or actuator assembly attaching screws, including lock strap-to-cushion frame screws, have been tightened: REMOVE lock-up screw at location shown in Figure 14-48.

NOTE: If any service operations have been performed on the seat back where the lock solenoid wire has been disturbqd, make certain solenoid wire is routed and secured to the seat back frame, as shown in Figure 14-49.

Check for proper operation of seat back lock.

When seat back is returned to upright (normal) position the locking effort applied rearward at upper outboard corner of seat back is 0-10 lbs. maximum. If seat back does not lock or unlock properly refer to "Electric Seat Back Lock

Trouble Diagnosis Chart

-

Strato Seats".

ELECTRIC SEAT BACK LOCK TROUBLE DIAGNOSIS CHART

-

TWO-DOOR

STYLE STRATO SEATS

CONDITION APPARENT CAUSE CORRECTION

1 .

Seat back lock does not ock when doors are closed.

1. Current at actuator sol- enoid does not cut off

- jamb switch remains open.

2. Seat back relay contacts sticking.

3. Seat back does not return to upright position far enough to allow lock to engage into locked position.

Check for excessive trim build-up; also check bumper thickness (specified bumper is

1/2" thick).

Procedure

- where required, install new jamb switch.

2. Refer to Electrical Checking

Procedure

- where required, install new relay.

3. Check thickness of both seat back bumpers

- where required, install correct thickness bumpers or, if necessary, slightly thinner bumpers. Lock- ing effort applied rearward at upper outboard corner of seat back is 0-10 lbs. maximum.

!. Seat back lock will not inlock when door(s) are

)pen.

1. No current at actuator solenoid

- blown fuse, de- fective jamb switch or seat back relay, or short in wiring.

.

2. Bind in l&k or lock linkage.

1. Refer to Electrical Checking

Procedure.

2. Locate and eliminate bind or where required, install new lock and solenoid assembly

(actuator assembly).

Released by: www.78ta.com

Serial Number: 71BDY-001-1026

SEATS 14-47

CONDITION

ELECTRIC SEAT BACK LOCK TROUBLE DIAGNOSIS

.CHART TWO-DOOR STYLE STRATO SEATS

APPARENT

CAUSE

CORRECTION

3. Seat back .lock unlocks but solenoid flutters or solenoid circuit breaker cuts in and out.

1. Bind in lock or linkage which does not allow sol- enoid to completely deact- ivate pull in coil.

2.

Actuator solenoid plunger is not completely deact- ivating pull in coil with no bind present in lock or linkage

- lock operates okay manually.

1. Locate bind or interference and eliminate or, where required, install new lock and solenoid assembly (actuator assembly).

2.

Check solenoid as described under "Electrical Checking

Procedure"

- where required, install new lock and solenoid assembly (actuator assembly).

STRATO BUCKET SEAT BACK ASSEMLY

Removal and Installation

1. Remove seat assembly from body, as previously described, and place on a clean, protected surface.

2.

On styles with electric actuated seat back locks remove hog rings securing seat cushion trim rear bar facing under seat (see Fig. 14-50) turn back cushion trim rear bar facing sufficiently to feed the seat back lock wire up through the grommet in the top of the cushion trim rear bar facing (see

Fig. 14-50).

3. With seat side panels romoved, remove hog rings securing seat cushion trim side trim at rear and bottom of seat and turn back trim sufficiently to expose seat back hinge-to-seat cushion frame attaching bolts (Fig. 14-5 1).

4. Remove seat back hinge-to-seat cushion frame attaching bolts from both sides of seat and remove seat back assembly from seat cushion

(Fig. 14-51).

5. To install seat back assembly, reverse removal back locks.

I

Fig. 14-48-Strato Seat Back Lock Assembly

I

Fig. 14-49-Electric Seat Back Wire Routing through Seat Back-Strato Seats

14-48 SEATS

Fig. 14-50-Electric Seat Back Wire Routing through Seat Cushion-Strato Seats

NOTE: If any service operations have been performed on the seat back where the lock solenoid wire has been disturbed, make certain

Fig. 14-5 1-Bucket Seat Back Removal solenoid wire is routed and secured to the seat back frame, as shown in Figure 14-49.

5. To install, reverse removal pr&edure. Prior to installing seat assembly in body, check for proper operation of seat back -lock.

REAR SEAT CUSHION- All Styles

Removal

1. Push lower forward edge of seat cushion rearward; then, lift upward and pull forward on seat cushion frame to disengage cushion frame wires from retainers on rear seat pan (Figs. 14-53, 14-52 and

14-54).

NOTE: If difficulty is experienced in disengaging the front edge of the rear seat cushion from retainers on rear seat pan it may be necessary to kneel (on four-door styles) or stoop (on two-door styles) on the rear floor pan. Grasp lower edge of seat cushion at location of retainer on one side of seat; then, lean forward (towards seat cushion) using leg pressure against hands or arms, exert sufficient rearward pressure to disengage seat from retainers.

Installation

1. Carefully lift cushion into body using caution not to damage adjacent trim.

REAR SEATS

2. Position rear edge of cushion under rear seat back assembly. On "A" Body four-door styles make certain rear portion of seat cushion frame is engaged with retainer on rear seat pan.

3. Align wire protrusions on front of seat cushion frame with retainers on floor pan. Push seat cushion assembly rearward until protrusions engage in retainers; then, press down and pull cushion forward to fully engage in retainers.

NOTE: If difficulty is expedenced in engaging front of cushion in retainers, use the same method described under step 1 of "Removal", to engage cushion in retainers.

IMPORTANT: If seat cushion frame protrusions are not properly centered in relation to retainers on seat pan, proper engagement and placement of cushion will be extremely difficult.

REAR SEAT BACK ASSEMBLY-

All Styles Except Station Wagons

Removal and Installation

1. Remove rear seat cushion assembly.

C U S H I O N FRAME

WIRE

SEAT BACK F R A M E

L F

EL

V I E W " A "

SEAT BACK

#

V l E W " D "

FRAME

V l E W " 0 " V I E W " C "

" A " BODY FOUR D O O R O N L Y

Fig. 14-52-Rear Seat Cushion and Back Installation

-

"A" Body Styles Except Three Seat

Station Wagons

2. At bottom of seat back bend out tabs and where present, remove screws securing the lower portion of the seat back to floor panel. On convertible styles, remove screw from rear side of seat back panel support securing upper corners of seat back to panel (see Figs. 14-53, 14-52 and 14-54).

NOTE: If screws are used to secure center of rear side to seat back panel it will be necessary to work from inside rear compartment to remove screws.

.

3. Pull seat back assembly out at the bottom until seat back clears body tabs; then, on all styles except "E" styles, raise seat back upward until disengaged from hangers on the seat back panel support. On "E" styles push seat back downward until wire protrusions at top of seat back are disengaged from slots in seat back panel support.

4. Remove seat back assembly from body.

14-50 SEATS

V I E W " A "

Fig. 14-53-Rear Seat Cushion and Back Installation

-

"F" Body Styles

5. To install, reverse removal procedure, making certain that all attaching body tabs and hangers have industrial body tape applied to them to act as an anti-squeak.

SEATS

14-5

1

Fig. 14-54-Rear Seat Cushion and Back Installation

-

"B-C" Body Styles

IMPORTANT: On

"B"

and "C" body styles make sure rear seat outer lap straps are properly secured under seat back lower attaching bolts (see

Fig. 14-54)

- tighten bolts 24 to 45 ft. Ibs.

REAR SEAT BACK CENTER ARM REST

AND CURTAIN

Removal and Installation

I.

Lower rear seat back arm rest. On all styles except

68169 carefully pull upper portion of arm rest curtain out of slot in hanger plate and fold curtain forward. On 68169 styles, fold arm rest flipper forward.

2. Remove four screws securing arm rest to hanger plate linkage then, remove arm rest from seat back.

'

3.

To install, reverse removal procedure.

REAR SEAT BACK CENTER ARM

REST HANGER PLATE

AND

LINKAGE

Removal and Installation

1. Remove rear seat back center arm rest; then, remove two screws securing arm rest hanger plate to body seat back support brace. Remove rear seat back.

'

2. On back side of rear seat back, remove four screws securing arm rest hanger plate to seat back

. supports; then, carefully remove arm rest and hanger plate assembly from seat back (Fig. 14-

55).

3. To install, reverse iemoval procedure. Prior to tightening hanger plate screws move arm rest assembly upward until top is snug against top of opening in seat back.

14-52 SEATS carpet flap. Move foot rest forward and carefully pull carpet flap from under foot rest, as shown in

Figure 14-56.

3. Remove foot rest hinge attaching screws and remove foot rest assembly (Fig. 14-56).

4. Remove auxiliary seat hinge pin cap screws; then, remove cap and auxiliary seat assembly (Fig. 14-

56).

5. To install auxiliary seat assembly, reverse removal procedure.

C U R T A I N

1953

Fig. 14-55-Rear Seat Back Arm Rest and

Hanger Plate

AUXILIARY SEAT ASSEMBLY-

Cadillac Limousine Styles

Removal and Installation

1. Place auxiliary seat in the folded forward position.

2. Move rear seat foot rest rearward; then, unsnap

AUXILIARY SEAT ADJUSTMENT-

Cadillac Limousine Styles

The auxiliary seats in Cadillac Limousine Styles can be adjusted to provide additional leg room for auxiliary seat passengers.

The following procedure describes and illustrates how to adjust the auxiliary seat.

1. Place auxiliary seat in the uprighs sitting position.

BOARD

AUXILIARY SEAT LOWER

SUPPORT ASSEMBLY

Fig. 14-56-Auxiliary Seat Assembly

-

Removal and Installation - Cadillac Limousine Styles

LDJUSTING 'SCREW

LOCK NUT

,

J

1 TURN SCREW TO TILT

SEAT FORWARD

2 TURN SCREW TO TILl

SEAT REARWARD

3 4 2 8

Fig. 14-57-Auxiliary Seat Adjustment

Limousine Styles

-

Cadillac

SEATS 14-53

2. On the front side of the auxiliary seat heel board, turn back foot well carpet flap to expose the auxiliary seat lower outboard and inboard support assemblies (Fig. 14-57).

3. Loosen the allen adjusting screw lock nut at both inboard and outboard support (see Fig. 14-57).

4. Carefully turn the adjusting screw (see Fig. 14-57) at both supports the SAME AMOUNT to allow the seat to pivot rearward further; thereby,

~roviding additional leg room for the auxiliary seat passenger. Tighten the adjusting screw lock nut at both supports.

When making this adjustment maintain a minimum distance of at least 6 1/4 inches from rear' seat cushion to auxiliary seat.

AUXILIARY SEAT LOWER SUPPORT

ASSEMBLY- Cadillac Limousine Styles

Removal and Installation

1. Remove auxiliary seat assembly, as previously described.

2. Remove lower support assembly attaching screws, shown in Figure 14-58, and remove support assembly.

Fig. 14-58-Auxiliary Seat Lower Support

Cadillac Limousine Styles

-

3. To install auxiliary seat lower support assembly, reverse removal procedure.

SEAT TRIM BUTTONS

Figure 14-59 illustrates the basic types of seat trim buttons used on 1971 styles and their method of retention.

STATION WAGON FOLDING REAR SEATS

AND FLOOR PANELS

All Station Wagon Styles Except Oldsmobile 34856 and

34866 Styles

All station wagon second seat backs incorporate seat back locks lpcated on the upper right side of the seat backs. On split second seats, a seat back lock is located at the upper outer side of each seat back.

On "B" body three seat station wagons, the third seat back incorporates a lock located at the right lower side of the third seat back.

IMPORTANT: STATION WAGON SECOND AND

THIRD SEAT ATTACHING PARTS SUCH AS SEAT

LINKAGE-TO-FLOOR PAN AND SEAT LINKAGE-

TO-SEAT CUSHION OR BACK BOLTS ON NUTS,

SEAT BACK LOCK BOLTS ETC. ARE IMPORTANT

ATTACHING PARTS IN THAT THEY COULD

AFFECT THE PERFORMANCE OF VITAL COM-

PONENTS AND SYSTEMS. THEY MUST BE

REPLACED WITH ONE OF THE SAME PART

NUMBER OR 7$'ITfI AN EQUIVALENT PART IF

REPLACEVENT BECOMES NECESSARY. DO

NOT USE A REPLACEMENT PART OF LESSER

QUALITY OR SUBSTITUTE DESIGN. TORQUE

VALUES MUST BE USED AS SPECIFIED DURING

REASSEMBLY TO ASSURE PROPER RETENTION

OF THESE PARTS.

The following views are typical of the station wagon folding seats and rear compartment floor panels.

These illustrations identify the component panels of the rear compartment area and their relationship to adjacent panels.

Figure 14-60 is typical of the "A" Body Series Two-

Seat Station Wagons.

Figure 14-6 1 is typical of. Chevrolet "A" Body Series

Three-Seat.

Figure 14-62 is typical of Chevrolet, Pontiac, Buick

14-54 SEATS

SINGLE AND DOUBLE LONG PRONG BUTTONS WITH

SPRING RETAINERS OR FULL DOUBLE RETAINER

I

SINGLE AND DOUBLE STUD BUTTONS WITH SHELL RETAINER

EYELET JIFFY LOOP BUTTON

WITH BOARD RETAINER

STUD 'JIFFY LOOP BUTTON

WITH BOARD RETAINER

3438

-

Fig. 14-59-Typical Seat Trim Buttons and Retainers

SEATS 14-55

Fig. 14-60-Folding Seats and Load FloorPanels

-

"A" Body Two-Seat Styles

1 . Folding Second Seat

Back and Seat Back

Panel

2. Second Seat Back

Filler Panel

3. Rear Compartment

Floor Panel (At

Kick-Up) and Oldsmobile "B" Body Series Two-Seat Station

Wagons.

Figure 14-63 is typical of Chevrolet, Pontiac,

Oldsmobile and Buick "B" Body Series Three-Seat

Station Wagon.

4. Luggage

Compartment Cover

Panel

5. Rear Floor Side

Filler Panels and Right

- Left tape over screw attaching holes prior to installation.

REAR FLOOR SIDE FILLER PANEL

(Right or Left Side)- "B" Body Two-Seat and Three-Seat Styles

LUGGAGE COMPARTMENT

PANEL(S)

AND

PANEL HINGE ASSEMBLY-

Two and Three-Seat Styles

Removal and Installation

1. Raise luggage compartment panel (both rear and front on "B" body styles) sufficiently to gain access to panel piano hinge attaching screws; then, support panel(s) in this position. Removal and Installation

1. Remove attaching screws from top of panel. If removing right side filler panel, remove spare tire cover panel and remove two screws securing filler panel, then remove panel.

2. To install filler panel, reverse removal procedure.

If installing a new filler panel, apply cloth body

FOLDING THIRD SEAT CUSHION-

"Av Body Three-Seat Styles

Removal and Installation

1. Lift third seat cushion to half raised position or approximately vertical to floor pan (Fig. 14-64).

14-56 SEATS

Fig. 14-61-Folding Seats and Load Floor Panels -

"A" Body Three-Seat Styles

1 . Folding Second Seat

Back and Back Panel

2. Second Seat Back

Filler Panels

3. Rear Compartment

Floor Panel (At

Kick-Up)

4. Folding Third Seat

Back and Panel

5. Folding Third Seat

Cushion and Panel

2. Remove four seat cushion screws from rearward edge of cushion (Fig. 14-64).

3. Pull rear edge of cushion away from flange of cushion panel then lift cushion upward to disengage cushion border wire from four tabs on panel. Remove cushion from body and place on a clean, protected surface.

4. To install, reverse removal procedure. Make sure cushion border wire is engaged with all four panel tabs prior to installing cushion attaching screws.

FOLDING THIRD SEAT CUSHION

PANEL ASSEMBLY AND SUPPORT- "A"

Body Three-Seat Styles

Removal and Installation

1. Lift third seat cushion to a half raised position or approximately vertical to floor pan (Fig. 14-64).

2. Remove two bolts at each side of seat securing supports to body, then, remove seat cushion, panel assembly' and supports from body and place on a clean, protected surface (Fig. 14-64).

To remove support, remove cushion from panel assembly; then, remove bolt securing support to cushion (Fig. 14-65).

SEATS 14-57

I. Folding Second Seat

Back

2. Folding Second Seat

Back Filler Panel

3. Rear Compartment

Floor Panel (At

Kick-Up)

3. To install, reverse removal procedure. If support was removed from seat cushion Banel, make sure bushing and s ring washer are properly installed

(see Fig. 14-657.

FOLDING THIRD SEAT BACK TRIM

ASSEMBLY- "Aw Body Three-Seat Styles

Removal and Installation

1. Raise third seat back assembly assembly in down position.

- leave cushion

2. Remove four screws securing lower edge of seat back trim to seat back panel (see Fig. 14-66).

3. Pull lower edge of seat back trim slightly rearward; then, lift trim assembly upward to disengage trim border wire from four tabs on

-

"B" Body Two-Seat Styles

4. Luggage

Compartment Front

Panel

5. Luggage

Compartment Rear

Panel

,

6. Rear Floor Side

Filler Panels upper portion of panel. Remove trim assembly from body and place on a clean, protected surface.

4. To install, reverse removal procedure. Make sure seat back trim border wire is engaged with all four panel tabs at upper portion of panel prior to installing seat back trim attaching screws.

FOLDING THIRD SEAT BACK PANEL

.ASSEMBLY- "A" Body Three-Seat Styles

1. Remove third seat back trim assembly.

2. At both sides of third seat back panel remove seat back linkage bolt and bolt securing seat back

14-58 SEATS

Fig. 14-63-Folding Seats and Load Floor Panels - "B" Body Three-Seat Styles

1. Folding Second Seat

Backs (1/3 and 2/3

Seats)

2. Second Seat Back

Filler Panels (1 /3 and 2/3 Seats)

3. Folding Third Seat

Back

4. Third Seat Back

Filler Panel

5. Luggage

Compartment Filler

Panel

6. Luggage

7.

Compartment Panel

Itear-i lo or Side

Filler Panels

Fig. 14-64-Folding Third Seat Cushion

Body Three-Seat Styles

-

"A" Fig. 14-65-Third Seat Cushion Panel and

Support -

"A" Body Three-Seat Styles

SEATS 14-59

Fig. 14-66-Folding Third Seat Back

Three-Seat Styles

-

"A" Body panel to support, then, remove seat back panel assembly from body (Fig. 14-67).

3. To install, reverse removal procedure.

FOLDING THIRD SEAT BACK LOCK-

"A" Body Three-Seat Styles

Removal and Installation

1. Raise third seat back. At seat back right linkage carefully snap off lock bolt plastic cover.

2. Remove shoulder bolt securing lock latch and spring to seat back frame and remove latch, spring and washer (Fig. 14-68).

3. To install seat back lock, reverse removal procedure. Check operation of third seat back to assure proper operation of lock.

COMPARTMENT FLOOR PANEL

ASSEMBLY (At Kick-Up)-All Styles

(See Figs. 14-60, 14-61, 14-62 and 14-63)

Removal and Installation

1. On three-seat styles, remove folding 3rd seat back assembly as previously described.

I

2. On two-seat styles, remove luggage compartment front and rear panel assemblies (complete) as previously described.

3. Directly under rear edge of compartment floor panel remove four screws securing panel to floor pan.

4. At front of compartment floor panel remove five screws securing panel to floor pan; then, remove compartment floor panel from body.

5. To install, reverse removal procedure.

L O C K L A T C H A S S E M B L E D

T O S E A T B A C K F R A M E

I N G W A S H E R

-

L O C K L A T C H ,

L O C K S P R I N G

S P R I N G A R B 0

L O C K W A S H E R

I

S P R I N G W A S H E R

B O L T

Fig. 14-67-Third Seat Back Panel and Linkage

- "A" Body Three-Seat Styles

V I E W " A "

Fig. 14-68-Third Seat Back Lock -

"A" Body

Two-Seat and Three-Seat Station wagons

14-60 SEATS

SECOND SEAT BACK FILLER PANEL-All

Styles

(See Figs. 14-60, 14-61, 14-62 and 14-63)

Removal and lnstallation

1. Remove compartment floor panel assembly (at kick-up) as previously described.

2. Along rear edge of filler panel, remove screws which secure panel to floor pan.

3. Fold filler panel forward sufficiently to remove screws which secure panel to folding 2nd seat back assembly and remove filler panel from body.

4. To install, reverse removal procedure.

SECOND SEAT CUSHION

-

"A" Body

Two-Seat and Three-Seat Styles

Removal and lnstallation

1. Push lower forward edge of seat cushion rearward; then, lift upward and pull forward on seat cushion to disengage cushion frame wires from retainers on floor pan. (See Figs. 14-52 and 14-54 under

"Rear Seats

-

Removal and Installation", which are typical of station wagon two-seat styles).

2. To install, reverse removal procedure. Make certain wires on seat bottom frame are fully engaged in retainers on floor pan.

Fig. 14-69-Second Seat Back Trim and Spring

Assembly - "A" Body

Two-Seat and Three-Seat Styles

FOLDING SECOND SEAT BACK TRlM

AND SPRING ASSEMBLY

-

"A" Body

Two-Seat and Three Seat Styles

Removal and lnstallation

1. Raise folding second seat back and remove .second seat cushion.

2. On underside of second seat back, panel, remove screws securing seat back trim assembly to seat back panel (see Fig. 14-69).

NOTE: Do not remove screws securing rear floor filler panel hinge to second seat back panel.

3. Pull lower edge of seat back trim slightly forward; then, lift trim assembly upward to disengage trim border wire from tabs on upper portion of panel.

Remove trim assembly from body and place on a clean, protected surface.

4. To install, reverse removal procedure. Make sure seat back trim border wire is engaged with panel tabs at upper portion of seat back panel prior to installing seat back trim attachi4 screws.

FOLDING SECOND SEAT BACK TRlM

PANEL AND LINKAGE ASSEMBLY-

"Au Body Two-Seat and Three-Seat Styles

Removal and lnstallation

1. Raise folding second seat back and remove second seat cushion.

2. On underside of folding second seat back remove screws securing rear floor filler panel hinge to seat back panel.

NOTE: Do not remove screws securing seat back trim assembly to seat back panel.

3. Mark position of folding second seat back linkage supports on floor pan. Remove nuts from both sides of seat back securing linkage supports to floor pan. See Figure 14-70 for full width seat,

Figure 14-71 for split seat.

Lift seat back assembly with attached linkage from body and place on a clean, protected surface.

4. To remove linkage from folding second seat back remove linkage-to-seat back panel attaching bolts and remove linkage

- see Figure 14-70 for full width seat, Figure 14-71 for split seat.

5. To install, reverse removal procedure.

SEATS 14-6 1

1

FILLER P A N E L

Fig. 14-70-Folding Second Seat Back Linkage and Filler Panel

-

"A" Body Two-Seat and

Three-Seat Styles

FOLDING SECOND SEAT BACK

LINKAGE ASSEMBLY-(Right or Left Side)

-

"Au Body Two-Seat and Three-Seat Styles

If both right and left linkage assemblies are to be removed on full width second seat, remove second seat back trim, back panel and linkage assembly and remove linkage from seat back panel as described under "Folding Second Seat Back Trim, Panel and

Linkage Assembly

-

Removal and Installation".

If one linkage assembly (right or left side) is t o be

,,,, removed proceed as follows:

.

I Removal and Installation

1. Remove second seat cushion.

2. Move folding second seat back forward just sufficiently to remove two lower linkage-to-seat back panel attaching screws (see Fig. 14-70).

3. Carefully return seat back to full up position; then, place a support under seat back assembly to support seat back in this pasition.

4. Remove two upper linkage-to-seat back panel attaching screws (see Fig. 14-70).

5. Remove nuts securing linkage support to floor pan, then, carefully remove linkage assembly from seat back and floor pan (see Fig. 14-70).

6. To install, reverse removal procedure.

LUGGAGE COMPARTMENT LOCK

CYLINDER-Two-Seat Styles

Removal and Installation

1. Open luggage compartment rear panel.

2. On underside of luggage compartment rear panel

.remove catch retainer and catch from lock cylinder case, then, turn lock cylinder with key

E S C U T C H E O N

BUSHING

SPRING WASHER

LINKAGE-TO-SEAT

BACK SCREW

CAGE SUPPORT

SCREWS OR NUTS

Fig. 14-71-Split Second Seat Inner Linkage

" A Body Styles

-

E S C U T C H E O N

REAR P A N E L

C Y L I N D E R CASE

Fig. 14-72-Luggage Compartment Lock

Body Styles

-

"A"

14-62 SEATS until cylinder can be removed from case (Fig. 14-

72).

3. To install, reverse removal procedure.

LUGGAGE COMPARTMENT LOCK

Removal and Installation

1. Open luggage compartment rear panel.

2. On underside of luggage compartment rear panel, remove catch retainer and catch (Fig. 14-72).

3. Remove lock cylinder case retainer screw and retainer; then, remove lock cylinder and case, gasket and escutcheon from panel (Fig. 14-72).

4. To install, reverse removal procedure.

FOLDING SECOND SEAT BACK LOCK

(Full Width or Split Seat)-All "A and B"

Styles (Except "A-56 and 66" Styles)

Description

'

The station wagon full width folding second seat incorporates a seat back lock located on the upper right side of the seat back. On styles with split second seat a seat back lock is located at the upper outer side of each seat back. The folding second seats can be folded down by actuating the lock handle forward and pulling the seat back down.

FOLDING SECOND SEAT BACK LOCK

(Full Width or Split Seat-All "A and B"

Styles (Except "A-56 and 66" Styles).

'Removal and Installation

1. Remove folding second seat back trim and spring assembly, as previously described.

2. Remove seat back lock handle attaching screw and remove lock handle (Fig. 14-73).

3. Remove seat back lock retainer attaching screws

(Fig. 14-89) and remove seat back lock retainer and lock from seat back panel (Fig. 14-73).

4. To install seat back lock assembly, reverse removal procedure. A small amount of lock adjustment is available to obtain proper engagement of lock bolt with lock striker on wheelhouse as shown in

Figure 14-74.

STATION WAGON FOLDING SEATS AND

FLOOR PANELS Vista Cruiser 36-66''

Styles

Description

The Vista Cruiser "56" style Skylight station wagon has a full width folding second seat on which the seat back folds flush with the floor panels. A luggage

R U B B E R B U M P E R

L O C K S T R I K E

LOCK HANDLE SCREW

1

Fig. 14-73-Folding Sewnd Seat Back Lock

Installation - All "A and B" Station Wagons (Except Vista Cruiser and Sport Wagon Styles)

L O C K S C R E W S

2 5 4 1

Fig. 14-74-Folding Sewnd Seat Back Lock and

Striker - All "A and B" Station Wagons (Except Vista Cruiser and Sport Wagon Styles)

SEATS 14-63

Fig. 14-75-Folding Seats and Load Floor Panels -

"A"

Wagon Three-Seat Styles

Body Vista Cruiser and Sport

1. Folding Second Seat

Back and Panel -

Left and Right

2. Rear Floor Filler

Panel

Left

-

Right and compartment is provided under the luggage compart- ment floor panel. Refer to Figure 14-60 for identification of folding seat and load floor panels.

3. Folding Third Seat

Cushion, Back and

Back Panel

4. Luggage

Compartment Cover

Panel

5. Rear Floor Filler

Panel

The service procedures for the "56" style station wagon full width folding second seat are the same as for the '!A-36" style station wagon folding second seat.

The jock handle is depressed to lock the seat in the up position and pulled upward to release the lock and allow the seat to be folded.

The "66" style station wagon has a folding split second seat

-

1 /3 (right side), 2/3 (left side).

Figure 14-75 identifies the major folding seats and load floor panels on the "56 and 66" style Skylight station wagon.

FOLDING SECOND SEAT ASSEMBLY-

Right or Left Seat-"66" Styles

Both sections of the folding second seat are hinged to the floor pan and can be folded forward to provide entrance room into the third seat area. Also both sections of the folding second seat back can be folded flush with the floor panels. A seat back lock located at the outer linkage of both right and left folding second seat backs, locks the seat backs in the up position and must be released to fold the seats.

The full 3/4 width folding third seat is provided with a positive acting lock at the right side linkage.

Removal and Installation

1.. Remove rear door sill plate and turn back floor carpeting sufficiently to gain access to nuts securing folding seat. front and rear linkage to floor pan (Figs. 14-76 and 14-77).

2. Mark position of seat front and rear linkage

14-64 SEATS

1214

Fig. 14-76-Folding Second Seat Rear Linkage

(Vista Cruiser "66" Style) supports on floor pan to facilitate installation of seat in same position.

Remove nut and washer assemblies securing front and rear linkage to floor pan; then, remove seat assembly from body (Figs. 14-76 and 14-77).

To install seat assembly, reverse removal proce- dure. Align linkage floor pan supports with previously made marks prior to tightening nuts.

FOLDING SECOND SEAT CUSHION

ASSEMBLY (Right or Left Seat)-

Vista Cruiser %6"~tyle

Removal and Installation

Remove folding second seat assembly from car, as previously described and place on a clean surface.

Remove hog rings and detach outboard rear portion of trim sufficiently to remove three screws securing seat outer link to cushion frame (Fig. 14-

78).

Remove three screws securing inner link to cushion frame; then, remove seat cushion and frame assembly from linkage (Fig. 14-79). If required, remove cushion front and rear floor pan linkage.

To install, reverse removal procedure.

Fig. 14-77-Folding Second Seat Fr'ont Linkage

Nista Cruiser "66" Style)

FOLDING SECOND SEAT BACK

TRIM

AND SPRING ASSEMBLY (Right ;Lift

Seat)-Vista Cruiser "66" Style

Removal and Installation

1. Fold second seat back forward.

2. Remove seat back trim assembly attaching screws

(see Fig. 14-76).

3. Raise seat back; ihen, pull seat back trim assembly upward to disengage wire loops at top of seat back trim from slots in seat back panel.

NOTE: If seat back trim does not readily disengage from seat back panel, fold rear floor filler panel down and remove upper inboard screw remove stat back trim assembly.

4. To install seat back trim assembly, reverse removal procedure.

FOLDING SECOND SEAT FRONT FLOOR

PAN LINKAGE (Right or Left Seat)-

Vista Cruiser "66" Style

Removal and Installation

1. Place seat in an up position. Turn back floor carpet sufficiently to gain access to front linkage floor pan attaching nuts.

2. Mark lokation of front linkage support on floor pan to facilitate installation .in same position.

Support front of seat. Remove bolts securing linkage to seat and nuts securing linkage to floor pan studs; the, remove front linkage (See Fig. 14-

77).

REAR F L O O R FILLER

P A N E L R E T A I N E R

A U T O r -

M A T O R CARPET v u

I c n

L I I Y R A V C

REAR F L O O R T O SEAT BACK

F I L L E R P A N E L

,

P A N E L

S C R E W S V

SEATS 14-65

S E A T O U T E R LINK T O S E A T ~ -

C U S H I O N F R A M E S C R E W S

Fig. 14-78-Folding Second Seat Cushion Assembly (Right or Left Side)

"66" Style

-

Vista Cruiser

3. To install, reverse removal procedure making sure linkage support on floor pan is aligned with previously made alignment mark.

A R F L O O R F I L L E R

A N E L R E T A I N E R

FOLDING SECOND SEAT REAR FLOOR

PAN LINKAGE (Right or Left Seat)-

Vista Cruiser "66" Style

Removal and Installation

1. Remove folding second seat assembly from car as previously described and place on a clean surface.

2. Remove screws securing rear floor pan linkage to each side of seat cushion frame; then, remove linkage assembly from seat (Fig. 14-80).

3. To install, reverse removal procedure. Inserts in

Figure 14-80 show relationship of linkage, bushings and attaching screws.

Fig. 14-79-Folding Second Seat Cushion

Assembly (Right or Left Side) - Vista Cruiser

"66" Style

14-66 SEATS

SPRING W A S H E R S

R E A R LINKAGE_

-TO S E A T I N N E R

SCREWS

REAR L I N K A G E TO

SEAT O U T E R SCREW

Fig. 14-80-Floor Pan Rear Linkage (Vista

Cruiser "66" Style)

FOLDING SECOND SEAT SlDE INNER

LINKAGE (Right or Left Seat)-

Vista Cruiser "66" Style

Removal and Installation

1. Remove folding second seat assembly from car as previously described and place on a clean surface.

2. Remove floor pan rear linkage-to-seat inner linkage attaching screws (Fig. 14-80).

3. Remove seat inner linkage-to-seat back panel and seat cushion frame attaching screws; then, disengage and remove side linkage from seat (see

Fig. 14-79).

4. To install, reverse removal procedure. Make sure rear floor filler panel retainer is inserted through slot in seat back panel prior to installing inner linkage-to-seat back panel attaching screws.

FOLDING SECOND SEAT SlDE OUTER

LINKAGE (Right and Left Seat)-

Vista Cruiser "66" STYLE

Removal and Installation

1. Remove folding second seat assembly from car as previously described and place on a clean surface.

2. Remove outer linkage cover. Remove rear floor pan linkage to seat outer attaching screw (Fig. 14-

80).

3. Remove hog rings and detach rear portion of trim sufficiently to remove three screws securing outer linkage to seat cushion frame (see Fig. 14-78).

4. Remove outer linkage-to-seat back panel attaching screws; then, remove linkage and seat back catch from seat (see Fig. 14-78).

5. To install, reverse removal procedure. Install seat back lock and spring as described under "Folding

Second Seat Back Lock

Installation".

- Removal and

FOLDING SECOND SEAT BACK LOCK-

(Right or Left Seat)- Vista Cruiser "66"

Style

Removal

1. Remove seat back trim assembly, as previously described. Remove outer linkage cover.

2. Remove outer linkage-to-seat back panel attaching screws (see Fig. 14-78).

3. Remove lock handle, spring and bushing from linkage.

4

Installation

1. Position bushing and spring on lock handle.

2. Install lock handle, bushing and spring into

' position between seat back panel and outer linkage making sure end of spring is engaged in hole in outer link (Fig. 14-81).

3. Install lock handle attaching screw; then, install outer linkage to seat back panel attaching screws

(Fig. 14-78).

+,%SEAT BACK

LOCK

-

SEAT BACK LOCK

H A N D L E KNOB

Fig. 14-8 1-Seat Back Lock (Vista Cruiser "66"

Style)

SEATS 14-67

4. Install seat back trim assembly and outer linkage cover.

FOLDING SECOND SEAT BACK PANEL

AND FILLER PANEL (Right or Left Seat).

Vista Cruiser "66" Style

Removal and lnstallation

Remove seat baqk trim assembly, as previously described. Remove outer linkage cover.

Remove outer and inner linkage to seat back attaching screws. Remove seat back lock handle, spring and bushing from between outer linkage and seat back panel; then, remove seat back panel and rear floor filler panel from linkage.

To install, reverse removal procedure. To install seat back lock refer to "Folding Second Seat Back

Lock

-

Installation".

FOLDING THIRD SEAT AND FLOOR

PANEL ASSEMBLY-Vista Cruiser "66"

Style

Removal and lnstallation

Raise folding third seat. Remove rear compart- ment left side panel (see Fig. 14-75).

Remove seat back linkage-to-compartment side pan attaching bolt at both right and left sides of seat (Fig. 14-83).

At left side of seat remove seat back hinge pin retainer (Fig. 14-83).

Carefully move seat back assembly to the left sufficiently to disengage right seat back hinge pin from hinge pin retainer; then, remove folding third seat assembly from body and place on a clean surface.

To install folding third seat and floor panel assembly, reverse removal procedure. Make sure a seat back hinge pin bushing is installed over both hinge pins. Also install flat washer between seat back linkage and compartment side pan and spring washer between linkage and bolt head

(Fig. 14-83).

FOLDING THIRD SEAT CUSHION TRlM

ASSEMBLY-Vista Cruiser "66" Style

Removal and lnstallation

1. Raise folding third seat. Raise front of third seat cushion and prop in up position.

2. Remove hog rings securing seat back trim flap to bottom of seat cushion (Fig. 14-84).

3. Remove seat cushion frame-to-seat back panel attaching bolt from both sides of seat; then, remove seat cushion assembly and place on a clean surface (Fig. 14-83).

4. As a bench operation remove hex-head screws securing seat cushion trim to seat cushion frame and three screws securing rear edge of seat cushion trim to seat cushion frame; then, remove cushion trim assembly from cushion frame (Fig.

14-84).

5. To install, reverse .removal procedures. When iostalling seat cushion frame-to-seat back frame attaching bolts install bolt bushing and spring washer, as shown in insert on Figure 14-83.

FOLDING THIRD SEAT BACK TRlM

ASSEMBLY OR SEAT BACK PANEL

ASSEM BLY-Vista Cruiser "66" Style

Removal and lnstallation

6

Remove folding third seat and floor panel assembly, as previously described, and place on a clean surface.

Remove hog rings securing seat back trim flap to bottom of seat cushion (Fig. 14-84).

To remove seat back trim assembly remove seat back trim-to-seat back panel attaching screws; then, lift trim assembly upward to disengage wire

I N N E R L I N K A G E T O

SEAT B A C K SCREWS

OUTER L I N K A G E T O

SEAT BACK SCREWS

-

N

Fig. 14-82-Seat Inner and Outer Linkage

Vista Cruiser "66" Style

-

14-68 SEATS

Fig. 14-83-Folding Third Seat

-

Vista Cruiser "66" Style loops on seat back trim from slots in seat back

ane el and remove trim assemblv (Fin. 14-84). d .

"

4. To remove seat back panel assembly, remove seat cushion frame-to-seat back panel attaching bolt; then, remove seat back panel with attached rear floor filler (at kick-up) panel from seat cushion

(Fig. 14-83).

5. To install, reverse removal procedure. Refer to inserts in Figure 14-83 for correct installtion of linkage bolts, bushings and spring washers.

FOLDING THIRD SEAT BACK LOCK-

Vista Cruiser "66" Style

Removal and Installation

1. Raise folding third seat back sufficiently to gain access to seat back lock at right side of seat.

2. ~ e m o v e

3. Remove shoulder bolt securing lock to rear seat compartment side and "remove lock latch, spring and washer.

4. To install seat back l&k latch, spring and washer, reverse removal piocedure. Check operation of third seat back to assure proper operation of lock.

LUGGAGE COMPARTMENf COVER

PANEL AND FILLER PANEL-

Vista Cruiser "66" Style

Removal and Installation

1. Raise luggage compartment b v e r panel and support cover panel in up position.

2. Remove five hex-head screws securing cover panel

SEATS 14-69 to cross bar; then, remove luggage compartment cover panel and filler panel.

3. To iristall, reverse removal procedure.

FOLDING SEATS AND LOAD FLOOR

PANELS

-

Chevrolet, Pontiac, Oldsmobile and Buick

"B" Body Two-Seat and Three-Seat Station

Wagons

The "B" body "35" style two-seat station wagon second seat and load floor panels are very similar to the past model (see Fig. 14-62). The "B" body "45" style three-seat station wagon incorporates new folding second and third seats and load floor panels (see Fig.

14-86).

The three-seat station wagon has a split second seat

(2/3 left side and 1/3 right side). The 1/3 right side second seat has a dual action linkage which allows the seat to be moved either forward for access or entrance into the third seat area or allows the seat back to be lowered into load floor position. The dual action linkage incorporates two separate locks which lock the seat and the seat back when the seat is in the up

(sitting) position and also locks out either action of the linkage while the other linkage action is in operation.

The 2/3 left side second seat linkage allows the seat back to be placed in load floor position only. The seat back incorporates a positive acting seat back lock which locks the seat back in the up (sitting) position.

The forward facing third seat can also be folded into load floor position and incorporates a lock at the lower right side of the seat which locks the seat in the up

(sitting) position.

FOLDING THIRD SEAT CUSHION AND

BACK ASSEMBLIES

-

"B" Body Three-Seat Styles

Removal and Installaion

1. Lift third seat to raised (sitting) position.

2. To remove third seat cushion assembly, remove linkage to cushion attaching bolt (Fig. 14-87) at both sides of seat cushion and remove cushion assembly from body.

3. To remove thrid seat back assembly perform step

2; then, remove both right and left rear floor side filler panels and remove seat back hinge pin retainer (Fig. 14-87) from both sides of seat back.

Remove seat back assembly including filler panel from body.

Fig. 14-84-Folding Third Seat Assembly - Vista

Cruiser "66" Style

A. Third Seat Back

B. Third Seat Cushion

C. Seat Back Trim to

Seat Back Panel

Attaching

D. Cushion Trim to

Cushion Frame

Attaching Scrcws

E. Hog Rings Securing

Seat Back Trim Flap

F. Location of Cushion

Trim to Cushion

Frame Attaching

Screws (Under Trim

Flap)

4. To remove third seat cushion and back as an assembly, remove cushion linkage-to-flobr pan support attaching bolt (Fig. 14-87); then, perform step 3 and with aid of a helper lift seat cushion and back assembly, including linkage and back filler panel, from body.

5. To install seat cushion, seat back or seat cushion and back assembly, reverse removal procedure.

Make sure hinge pin bushing (see Fig. 14-87) is installed over hinge pin at both sides of seat back prior to installing retainers.

FOLDING THIRD SEAT BACK LOCK AND

LOCK STRIKER-

"B" Body Three-Seat Station Wagons

Removal and Installation

1. Partially lower seat back to a point where seat back lock'is accessible for removal.

2. Using an internal drive hex-head wrench, remove

14-70 SEATS

Fig. 14-85-Folding Second Seat and Load Floor Panels

Wagon

-

"B" Body Two-Seat Station

Fig. 14-86-Folding Second and Third Seat and Load Floor Panels

Station Wagons

-

"B" Body Three-Seat

SEATS 14-71

14-72 SEATS

HINGE PIN BUSHIN

SPRING WASHER

VlEW "A"

SPRING W y p

BUSHING

SUPPORT

VlEW "0"

4483

Fig. 14-87-Third Seat Cushion, Back and Linkage - "B" Body Three-Seat Station Wagon seat back lock assembly from lower right corner of seat back panel.

3. To remove lock striker use an internal star-drive wrench.

4. To install seat back lock or lock striker reverse removal procedure, engage lock spring under tab on seat back panel. Tighten lock assembly 14-22 ft. lbs. Tighten lock striker 22-34 ft. lbs.

FOLDING THIRD SEAT BACK TRIM,

FOAM PAD AND FOUNDATION BOARD

ASSEMBLY- "B" Body Three-Seat

Station Wagons

Removal and Installation

1. Raise luggage compartment panel and prop in

"up" position. Lower third seat back sufficiently to attaching screws along bottom of seat back.

2. Working through luggage compartment remove three screws along bottom of seat back panel securing foundation board to seat back panel.

3. Raise third seat back sufficiently to pull lower edge of trim, foam pad and foundation board forward; then, lift assembly upward to disengage upper edge of assembly from hanger tabs on seat back panel and remove assembly.

4. To install assembly, reverse removal procedure.

SECOND, SEAT CUSHION- "B" Body TWO-

Seat and Three Seat-Station Wagons

The second seat cushion on the two-seat station wagons and the second seat left side cushion (2/3 side) on the three-seat station wagons are removed and

SEATS 14-73

THIRD SEAT BACK

C

SPRGJG TAB

V I E W "A"

Fig. 14-88-Folding Third Seat Back Lock

Body Three-Seat Station Wagon

- "B" installed in the same manner as the regular sedan styles

- refer to "Rear Seat Cushion

-

Removal and

Installation".

To remove the right side second seat cushion (113 seat) on three? seat station wagon styles, place the seat assembly in the forward position. From under both rear and front of seat cushion remove bolts securing cushion assembly to inner and outer rear linkage (see

Fig. 14-90) and to front linkage; then, remove cushion assembly.

FOLDING SECOND SEAT BACK TRIM,

FOAM PAD AND WIRE MAT ASSEMBLY-

"B" Body Two- Seat and Three-Seat

Station Wagons

Removal and lnstallation

I.

Lower folding second seat back to load floor position, leave filler panel against seat back.

2. At bottom of seat back and at cut-outs in filler panel piano hinge, remove trim and foam pad wire mat attaching screws.

3. Raise seat back sufficiently to pull lower edge of trim, foam pad and wire mat forward; then, lift assembly upward to disengage upper edge of assembly from hanger tabs on seat back panel and remove assembly.

4. To install, reverse removal procedure

- use awl or suitable tool to locate wire mat attaching holes through bottom of seat back panel.

FOLDING SECOND SEAT BACK AND

FILLER PANEL ASSEMBLY (Less Linkage).

"B" Body Two- Seat and Three-Seat

Station Wagons

Removal and lnstallation

1. Lower seat back to load floor position, leave filler panel against seat back.

2. At both right and left side of seat back, remove linkage to seat back panel attaching screws (Figs.

14-91, 14-89 and 14-90) and remove seat back assembly with filler panel from linkage.

3. To install second seat back and filler panel assembly, reverse removd procedure.

FULL WIDTH FOLDING SECOND SEAT

BACK LINKAGE ASSEMBLY AND

FOLDING SECOND (2/3) SEAT BACK

OUTER LINKAGE ASSEMBLY-

"B" Body Two-Seat and Three-Seat

Station Wagon

Removal and lnstallation

I. Lower folding second seat back to load floor position, leave filler panel against seat back.

2. Remove linkage-to-seat back panel attaching screws (Fig. 14-89); then, remove linkage-to-floor pan attaching screws (Fig. 14-89) and remove linkage assembly.

3. To install linkage assembly, reverse removal procedure.

FOLDiNG SECOND (2/3) SEAT BACK

ASSEMBLY AND/OR (2/3) SEAT BACK

INNER LINKAGE ASSEMBLY- "B" Body

Three-Seat Station Wagon

Removal and lnstallation

1. Remove 2/3 seat cushion assembly.

2. Loosen 1 /3 seat torque rod-to-floor pan attaching nut (see Fig. 14-90). Move 1 /3 seat forward to a

14-74 SEATS

Fig. 14-89-Folding Second 2 / 3 Seat Back and Linkage

Wagon

-

"B" Body Three-Seat Station position where torque is relieved from rod; then, remove torque rod nut. bushing and spring washer are installed at 1/3 seat back inner link-to-2/3 seat back inner linkaue

Y attachment (Fig. 14-91).

3. Remove 1/3 seat back inner link-to-2/3 seat back inner link attaching bolt (Fig. 14-91).

4. Remove 2/3 seat back inner linkage-to-floor pan attaching nuts (Fig. 14-91).

FOLDING SECOND

(1/3)

SEAT ASSEMBLY

(Including Inner, Outer and Front Linkage

Assemblies). "B" Body Three-Seat

Station Wagon

5. Remove 2/3 seat back outer linkage-to-floor pan attaching bolts (Fig. 14-89); then, remove second

2/3 seat assembly, including linkages from body.

Removal and Installation

6. If removeing inner linkage assembly, remove inner linkage to seat back panel attaching screws as a bench operation and remove linkage assembly from seat back.

1. Loosen torque rod-to-floor pan attaching nut (Fig.

14-90). Move 1/3 seat forward to a position where torque is releived from rod; then, remove torque rod nut.

7. To install second 2/3 seat back or inner linkage assembly, reverse removal procedure. Make sure

2. Move 1/3 seat to full forward position, and remove bolt securing 1/3 seat back inner link to,

2/3 seat back inner link (See Fig. 14-90).

SEATS 14-75

Fig. 14-90-Folding Sewnd 213 Seat Back Inner Linkage and 1/3 Seat Back Outer

Linkage

-

"B" Body Three-Seat Station Wagon

3. Remove 113 seat cushion front linkage-to-floor stud caps and attaching nuts.

4. Remove 113 seat back outer linkage-to-floor pan stud caps and attaching nuts (Fig. 14-90); then, remove seat assembly, including all attached linkages, from body.

Linkage assemblies may be removed from 1/3 seat, as required. Refer to Figure 14-90 and 14-91 for 113 seat linkage attachments.

5. To install 1/3 seat assembly, reverse removal procedure. Make sure that bushing and spring washer is installed at 1/3 seat back inner link-to-

2/3 seat back inner link base plate attachement.

FOLDING SECOND

(1/3)

SEAT BACK

OUTER LINKAGE ASSEMBLY-

"6" Body Three-Seat Station Wagon

Removal and Installation l.:Fold right 113 seat back to a position where seat back outer linkage-to-seat back screws, indicated in Figure 14-90, are accessible; then, remove screws.

2. Remove seat back outer linkage-to-seat cushion screws (Fig. 14-90).

3. Remove seat back outer linkage-to-floor pan attaching stud caps and nuts at locations indicated in Figure 4486; then, rgmove outer linkage from seat.

4. To install 113 seat back outer linkage assembly, reverse removal procedure.

14-76 SEATS

2/3 SEAT BACK INNER

.INK-TO-FLOOR PAN

ATTACHING NUTS

113 SEAT BACK INNER

LINK-TO-213 SEAT BACK

INNER LINK ATTACHING BOLT

4484

Fig. 14-91-Folding Sewnd 213 Seat Back Inner Linkage and 1/3 Seat Back Inner Link

"B" Body Three-Seat Station Wagon

-

LAP BELT$ AND SHOULDER BELTS

General Information-All Styles

-

Front and rear lap belts and front seat shoulder belts, except convertible shoulder belts, are installed on all cars as standard equipment. Convertible style front seat shoulder belts and rear seat shoulder belts on all styles are available as factory optional equipment or as a dealer installed accessory.

Before servicing or replacing lap belts and shoulder belts, refer to the following precautionary items:

1. Lap belts must be serviced in matched sets. a. DO NOT replace one-half of lap belt or shoulder belt set. b. DO NOT intermix standard and deluxe lap belts or shoulder belts on front or rear seats.

2. Keep sharp edges and damaging objects away from lap belts or shoulder belts.

3. Exercise caution to avoid bending or damaging any portion of the belt buckle or latch.

4. Do not bleach or re-dye belt or strap webbing

(clean with a mild soap solution and water).

5. When installing lap belt or shoulder belt anchor bolt, start bolt by hand to assure that bolt is threaded straight.

6. DO NOT attempt repairs on lap belt retractor mechanisms. Replace defective part with NEW service replacement parts.

SEATS 14-77

IMPORTANT: LAP BELT TO FLOOR PAN

ANCHOR FASTENERS *AND SHOULDER

BELT TO ROOF RAIL, REAR QUARTER, OR

REAR SEAT TO BACK WINDOW PANEL

FASTENERS ARE IMPORTANT A'ITACHING

PARTS IN THAT THEY COULD AFFECT THE

PERFORMANCE OF VITAL COMPONENTS

AND SYSTEMS, AND/OR COULD RESULT

IN MAJOR REPAIR EXPENSE. THEY MUST

BE REPLACED WITH ONE OF THE SAME

PART NUMBER OR WITH AN EQUIVALENT

PART IF REPLACEMENT BECOMES NECES-

SARY. DO NOT USE A REPLACEMENT PART

OF LESSER QUALITY OR SUBSTITUTE

DESIGN. TORQUE VALUES MUST BE USED

AS SPECIFIED DURING REASSEMBLY TO

ASSURE PROPER RETENTION OF THESE

PARTS.

7. Tighten lap belt or shoulder belt floor pan anchor bolts to specified torque

-

24 to 45 ft. lbs. Tighten shoulder belt roof rail, quarter panel or rear seat- to-back window panel anchor bolts

-

12 to 18 ft. lbs.

IMPORTANT: Specified 1/2 inch

-

13 UNC

-

2A bolts must be used for all lap belt and shoulder belt floor pan anchorages. Shoulder belt roof rail, quarter panel or rear seat-to-back window panel anchorages use specified 5/16 inch

-

18 UNC bolts.

-

2A

STANDARD FRONT LAP BELT

RETRACTOR-

(Belts With Plastic Buckle Cover)

RETRACTOR-(BELTS WITH PLASTIC

BUCKLE COVER)

To disengage standard lap belt retractor cover, carefully exert pressure in direction of arrows, Figure

14-92, to disengage the cover from tabs on the retractor. Lift cover to expose seat belt retractor anchor bolt and remove bolt.

FRONT LAP BELT

RETRACTOR (Swivel and Non-Swivel

Type)- "X" Body Coupes

To disengage lap belt retractor cover, place finger under outboard rear corner of cover and pull outward while pulling cover "up" with other hand. Lift up cover to expose retractor anchor bolt and remove bolt.

STANDARD FRONT LAP BELT

RETRACTOR-

(Belts With Vinyl Covered Metal Buckle)

With belt fully extended, insert screwdriver through belt opening in cover, as shown in Figure 14-93, apply just enough outward pressure to inside of cover adjacent to metal tabs to disengage cover from tabs.

Lift up cover to expose seat belt retractor anchor bolt.

DELUXE SELF LOCKING FRONT LAP

BELT RETRACTORS

Removal

1. Position front seat assembly to full forward and up positions.

2. Insert the blade of a 2-1/2" or 4" flat-bladed screw driver up under the retractor cover and engage blade of screw driver over top of retaining spring, as shown in Figure 14-94. Press retaining spring downward; then, pull retractor and cover assembly rearward and upward to disengage retractor and cover from anchor plate assembly.

EXERT PRESSURE IN

DIRECTION OF ARRWS

Fig. 14-92-Standard Front Lap Belt Retractor

(Belts with Plastic Buckle Cover)

Fig. 14-93-Standard Front Lap Belt Retractor

(Belts with Vinyl Covered Metal Buckle)

14-78 SEATS

FIRST

-

PRESS S P R I N G

D O W N F R O M U N D E R

EDGE O F C O V E R

A N C H O R PLATE

-

'IRST

-

A L I G N RETRACTOR BAR

R E A R W A R D T O D I S E N G A G

SUPPORT BAR

Fig. 14-94-Deluxe Front Lap Belt Self-Locking

Retractor - Removal

3. Remove anchor plate attaching bolt and remove anchor plate assembly.

Installation

1. Properly position anchor plate assembly on floor pan and start attaching bolt by hand. Tighten anchor plate attaching bolt to specified torque (24 to 45 ft. lbs.).

2. Position retractor and cover assembly over anchor plate assembly so that bar in retractor is aligned with slots in anchor plate. Push rear of retractor assembly down and then forward to lock retractor to anchor plate (see Fig. 14-95).

NOTE: An AUDIBLE SNAP will be heard when retaining spring on anchor plate locks retractor bar into position.

3. Check operation of lap belt retractor several times to assure proper operation.

IMPORTANT: DO NOT attempt any repairs on either the retractor and cover mechanism or the anchor plate assembly. In addition lap belts

MUST BE serviced in matched sets (retractor and cover assembly, anchor plate assembly and buckle end of belt). DO NOT replace only one part of lap belt set.

S E C O N D

-

PUSH REAR O F RETRACTOR

C O V E R D O W N ; T H E N , F O R W A R D U N T I L

A U D I B L E S N A P I S H E A R D 3 8 9 3

Fig. 14-95-Deluxe Front Lap Belt Self-Locking

Retractor - Installation

6

REAR SEAT BAIL TYPE RETRACTOR

As an option, rear lap belts are available with bail type seat belt retractors on the outboard rear lap belt only.

Removal

1. Extend outboard lap belt to full lenght.

2. Insert a piece of stiff wire such as a paper clip in slot in roller drum to maintain spring tension of retractor (see Fig. 14-96).

IMPORTANT: Keep wire in slot until retractor is reinstalled. In the event that spring tension is lost, drum on retractor can be turned 8 revolutions by hand to regain spring tension.

3. Using a flat-bladed tool pry open tabs that secure belt webbing on drum and remove retractor from belt (see Fig. 14-96). lnstallation

1. With lap belt fully extended, insert belt under tabs on retractor (tabs of retractor should be on inboard side of belt webbing and bail pointing forward) and position retractor at center of belt webbing.

2. Using pliers, bend down tabs to secure retractor in correct position on belt webbing.

SEATS 14-79

3. Remove wire from slot in drum (when installing a new retractor, remove retaining clip on retractor drum to release spring tension) and allow belt to roll up on retractor.

LAP BELTS AND SHOULDER BELTS

Removal and Installation

Refer to illustrations on following pages and select the appropriate illustration for removing and installing seat belts and shoulder belts.

IMPORTANT: LAP BELT TO FLOOR PAN AN-

CHOR FASTENERS AND SHOULDER BELT TO

ROOF RAIL, REAR QUARTER, OR REAR SEAT

TO BACK WINDOW PANEL FASTENERS ARE

IMPORTANT ATTACHING PARTS IN THAT

THEY COULD AFFECT THE PERFORMANCE OF

VITAL COMPONENTS AND SYSTEMS, AND/OR

COULD RESULT IN MAJOR REPAIR EXPENSE.

THEY MUST BE REPLACED WITH ONE OF THE

SAME PART NUMBER OR WITH AN EQUNA-

LENT PART IF REPLACEMENT BECOMES NEC-

ESSARY. DO NOT USE A REPLACEMENT PART

O F LESSER QUALITY OR SUBSTITUTE DESIGN.

TORQUE VALUES MUST BE USED AS SPECIFIED

DURING REASSEMBLY TO ASSURE PROPER

RETENTION OF THESE PARTS.

Check position of factory installed lap belt and shoulder belt anchors and reinstall anchor plates in same position. Care must be exercised when making

Fig. 14-96-Removal of Bail Type Retractor

From Lap Belt installation that all anchor plates inter-lock, as shown in illustrations.

To remove full width seat igner lap belt(s) from seat, remove anchor bolts at floor pan and carefully pull floor anchor end of belt through lap belt protector.

When installing belts

24 TO 45 LBS.

TIGHTEN ANCHOR BOLTS

On two-door styles, it is important that seat belt webbing is routed over seat back outer hinge arm and NOT under arm.

14-80 SEATS

LOCKING RETRACTOR

INSTRUCTIONS

-ATE PROPER B U T POR BPEQIIC LAP BELT REPLAC-

MOVE TO N L L mRIYARD -ION

VIEWE

AND RElER M

FOR RNOVAL AND MALLATIDW 01 B U ' N .

OAM A C C m TO FLOOR ANCHORAGE M MPCATB) AND

ANCHORAGE VIEWS ?'OR REMOVAL AND MALLATIOW OF BELTS. p--

CAUTION

&

NON-LOCKING RETRACTOR

' 13 THREAD

REMOVAL

I nrSERTTOOLUNDERCWERAT

O R E A R 01 BEAT BIDE AND DC-

BPRIWO.

TROY RETRACTQR ANCHOR BAIE.

VIEW A

FRONT SEATS -ALL EXCEPT NOVA, CAMARO AND FIREBIRD

4524

- - -

Fig. 14-97-Front Seat Lap Belts

-

All Styles Except Nova, Camaro and Firebird

SEATS 14-81

FRONT SEATS

1/2" 13 THREAD

PL*.IT cwm

A

C ~ X W S ~ I O N O P P A C T O R Y M ~ A L L E D B E L T A N C R O R A O E A h D

==ALL REPLACEMENT BELT AhD ANCHOR PLATE M E POWION.

CAUE MUST BE EXERCIEED WHEN M A l W G REPLACEMEW THAT ALL

BELT ANCHOR PLATES INTER-UXX All EIIOWW.

0

P L m I C COVER. REMOVE ANCHOR BOLT AND

G

ANCHOR BOLT IS EHOWN AT RIGHT) THMUOH BELT

ANCHOR PLATESANDPIASTICCQVER IECURSTO

FLOOR ANCHORAGE (BEE CAUTION NOTE)

VlEW

B .

CAMARO

AND FIREBIRD

ALL STYLES

NOVA

STANDARD

VlEW A

2 DOOR STYLES 4 DOOR STYLES

NOVA DELUXE

Fig. 14-98-Front Seat Lap Belts - Nova, Camaro and Firebird

14-82 SEATS

M C E P T REGULAR

SIZE STATION

WAGONS

(EILY RgOULAR SIZE

STATION WAGON8

M C E P T REGULAR SIZE

STATION WAGONS

F

ONLY REGULAR SIZE

STATION WAMNS

REAR SEAT

C A M A R O & FIREBIRD

I

SIZE

BELTS SHOWN M

STOWAGE POBrrION

THIRD SEAT FACING FRONT

ST AT I O N W A G O N S

THIRD SEAT FACING REARWARD

INTERMEDIATE SIZE STATION W A G O N S

C R E C K ~ I O N O P F A C T O R Y M A L L E D B E L T . A N C H O R A G E A N D

M m A L L REPLACEMEM BELT AhW ANCHOR PLATE M

CARE BE EXERCISED WEEN MAKING REPLACEMENT TRAT ALL

BELT ANCHOR PLATES INTER-LOCK AS SHOWN.

N O T E

-

S E E N E X T P A G E FOR V I E W S

Fig. 14-99-Rear, Second and Third Seat Lap Belts

-

All Styles

(SEE PREVIOUS PAGE FOR V l E W L O C A T I O N S )

1/2" 13 THRE

NO SHOULD

ANCHOR BOLT

BELT ANCHOR PLATE

1/2" 13 THREAD

NO SHOULD

ANCBOR BO

NO CENTER BELTS

USED ON "F" BOD

STYLES

BELTANCHOR PLATES

VIEW C VIEW

D

a

REMOVE ANCHOR BOLT AND OLD BELT (SEE CAUTION NOTE)

1 PROTECTOR MUST BE REMOVED FROM FACTORY MSTALLED BELT W E R E VSED AND ASSEMBLED TO REPLACEMENT

O B E L T PRIOR T O INSTALLATION (SEE CAUTION NOTE)

8 INSERT ANCHOR BOLT (PROPER ANCHOR BOLT B

O P L A T E S AND PROTECTOR WHERE USED. SECURE T O PLOOR ANCHORAGE (BEE CAUTION NOTE)

NOTE. bi VlEW F ANCHOR BOLT MUST PASS THROUGH SEAT SUPPORT PRIOR TO BELT ANCHOR PLATE.

I i

CHECKPOSI7IONOFFACTORYMBTALLEDBELTANCRORAGEAND

INSTALL REPLACEMEhT EEL-

~

CARE MUBT BE EXERCISED

AND

WREN

ANCHOR PLATE

~

BELT ANCHOR PLATES INTER-LOCK M SHOWN.

IN SAME P M O N .

REPLACEUENI. 'w?LL

I

1/2" 13 THREAD

SEATS 14-83

SEATSUPPORT

V I E W

E

BELT ANCHOR

PLATE

- -

PROTECTOR

VIEW G

- - -

Fig. 14-100-Rear, Second and Third Seat Lap Belt Views (Refer to Fig. 14-99)

-

All Styles

14-84 SEATS

HOIRSER BELT

SHOULDERBELT

P W I C CAP

SHOULDER BELT

CAUTION

-1

I CHECK -ION 01 ?ACIORI M A L L I D

BELTANCHORAGEANDTW.rALL

REPLACEMEWBELTANDAWCHORPIATE

IN SAME P08ITION.

I

ROD? ANCHOMOE 7

1/2" 13 THREAD

13/16" SHOULDER

CHOR PLATE

ArnACW(G K R E W

5/16" 1% THREAD

NO SHOULDER

VIEW A

LRT REWYL ANCHOR KRRn AJ4D OLD BELT (ICE CAVaOW m a .

ASIXBLE NEW

AWCUOR KREW

CAVRON NOTE).

BELT TO P L M K T

Y

R04 CAP AND MSERT ANCHOR KRIIYI (PROPER

CAP V I E

SECURE TO AWCHORAGE AND W P-IC TRIM CAP

BELT ANCHOR PLATE

Urn P-IC

VIEW 6

COVER, REMOVE AWCH011 BOLT *I(D m a .

C W L R CLOBED.

Fig. 14- 101 -Front Seat Shoulder Belts-All Styles Except

Convertibles, Limousines And El Carnino

SEATS 14-85

P W D C T W I CAP

1/2" 13 THREAD

13/16" SHOULDER

-

VlEW B

@MOVE #EAT TO NLL -

AND O W BELT (BEE CAUTWN NOTE).

I Atm NEW BELT AND m E R T ANCHOR BOLT (PADPER ANCHOR BOLT I

' 8 - TarPouOa BELT ANCHOR PLAT=. 8EcURE TO FWOR ANCHORAOE

@EL CAWION

Norm.

@ g E b M D C

ANCHOR PLATE

ANCH -3

/5/l6" 18 THREAD

NO SHOULDER

VlEW A

T I M CAP, REMOVE ANCHOR ECRRYB AND OLD BELT (BEE CAUTION

CAWWN m E ) .

@ECURE TO ANCWORAOE AND WAP P M C M

CAUTION

,-i

Fig. 14-102-Front Seat Shoulder Belts-Chevrolet El Camino Styles

14-86 SEATS

WITHOUT CENTER

PLASTIC COVER

13/16" SHOULDER

ANCHOR BOLT

SHOULDER BELT

VlEW A

WITHOUT CENTER PARTITION

LIFT PLASTIC COVER. REMOVE ANCHOR BOLT. BPACER AWD OLD BELT

(SEE CAWION NOTE).

ADDNEWBELTAND~5ERTANCHORBOLTlPROPERANCHORBOLTBSHOYlWI

THROUGHBELT ANCHORPLATE. SPACERANDPLABTICCOVERM(RIOURI

SECURE TO PILLAR ANCHORAGE.

CHECKPOSrrlONOFFACTORYMBTALLkDBELT

ANCHORAGE AND INSTALL REPLACEMENT BELT

AND ANCHOR PLATE IN SAME POBITION.

VlEW 5

WITH CENTER PARTITION a

REMOVE PILLAR TRM. ANCHOR BOLT AND OLD BELT (SEE CAUTION NOTE).

2 D(BEFl? ANCHOR BOLT lPROPER ANCHOR BOLT IS S H O W TIWDVOH ANCHOR

P W E SECURE TO ANCHORACE (SEE CAUTION N m E L

SHOULDER

BELT ANCHOR PLATES

VlEW C

a

MOVE FRONT SEAT TO FULL FORWARD WOTlOW

8 ADD NEW BELT AND M E R T ANCHOR DOLT ( P R W U

O A N C H O R BOLT

=

S H O W AT RlCRT) TIlROUOR BELT

ANCHOR PLATES AND PLABTlC COVER IECVRI

FLOOR ANCHORAGE (BEE CAUTION NOTE).

TO

Fig. 14-103-Front Seat Shoulder Belts-Cadillac Limousine Styles

SEATS 14-87

BELT

ANCH

PLAT

1/2" 13 THREAD

HOULDER BOLT

5116" 18 THREAD

CENTER ANCHOR BCRFAr

SHOULDER BELT

MOUNTMO PLATE

PLASTIC TRUd CAP

SHOULDER BELT

VlEW A

VlEW

CAUTION

CHECK PWlTION O F FACTORY INSTALLED BELT

AWCBORB AND

U M E PO@n'ION. CARE

AND ANCHOR PLATES IN

MUST BE EXERCISED WHEN MAKING

EdSrALLATION TRAT ALL BELT ANCHOR PLATES INTER-LOCK

M mom.

B

REAR BEAT T O BACK w l m m

PANEL

U ) C A r n O COLLAR

ANCHOR PLATE

Fig. 14-104-Rear Seat Shoulder Belts-All Styles Except

Convertibles And Station Wagons

14-88 SEATS

ALL DIMENSIONS ARE

TO O F PART AM)

A m % c n m G HOLES.

CHECK POSITION O F FACTORY

INSTALLED BELT ANCHORAGE AND

INSTALL NEW BELT AND ANCHOR

BUCKLE RETAINER

1 LOCATE POBITION O F RETAINER

O U S M O DIMENSIONS SHOWN

VIEW

B

IN

LOWER TRIM PANEL-

BUCKLE

MOUNTING PLATE

5/16" 18 THREAD

NO SHOULDER

VlEW

B

1/2" 13 THREAD

9/16" SHOULDER

ANCHOR BOLT

VlEW A

INSTALLATION O F ALL SEAT CUSHIONS, SEAT

BACKS AND TRIM PANELS NECESSARY TO

PERFORY OPERATIONS DESCRIBED ON THIS

SHEET. REFER T O 1971 COPY O F THE

FISHER BODY SERVICE MANUAL AVAILABLE

AT YOUR G M DEALER

BELTANCHOR PLATES

PLASTIC COVER

VISTA-CRUISER ONLY

VlEW

C

SECOND SEAT

4529

Fig. 14-105-Second And .Third Seat Shoulder Belts-"A" Body

Station Wagon Styles

SEATS 14-89

SPARE TIRE

LATCH

VlEW D RIGHT SIDE

INSTALLATION OF ALL SEAT CUSHIONS, SEAT

BACKS AND TRIM PANELS NECESSARY TO

PERFORM OPERATIONS DESCRIBED ON THIS

SHEET, REFER TO 1071 COPY OF THE

FISHER BODY SERVICE W U A L AVAILABLE

AT YOUR G.

CHECK POSITION O F FACTORY

VlEW

E

LEFT SIDE

CAUTION

ON LEFT SIDE OF BODY, WHEN MAKING HOLES FOR

RETAINER, DRILL OR PUNCH NO DEEPER THAN 1/2

INCH TO AVOID PIERCING GAS TANK (FIRE OR EXPLOSION

MAY RESULT WHEN GASOLINE FUMES CONTACT SPARKS

FROM DRILLING OR PUNCHING, LIGHTED CIGARETTES,

ETC., IN PASSENGER COMPARTMEEFP).

1/2" 13 THREAD

ANCHOR BOLT

NO SHOULDER

LOWER SKYLIGHT MOLDING

SHOULDER BELT

VIEW F

T H I R D

SEAT

Fig. 14-106-Second And Third Seat Shoulder Belt Views (Refer

To Figs. 14-105)-"A" Body Station Wagon Styles

14-90 SEATS

( S E E NEXT PAGE FOR V l EMS 1, M & N ) N

BUCKLE RETAINER

CHECK POBITION O F FACTORY INSTALLED BELT ANCHORAGE AND I

INSTALL NEW BELT AND ANCHOR PLATE IN SAME PCSITION.

I

NOTE:

FOR INSTRUCTIONS ON REMOVAL AND INSTALLATION O F ALL SEAT

CUSHIONS. SEAT BACKS AND TRIM PANELS NECESSARY T O PERFORM OPERATIONS

DESCRIBED ON THIS SHEET, R E F E R T O 1071 COPY O F THE FISHER BODY SERVICE

MANUAL AVAILABLE AT YOUR G. M. DEALER.

UPPER TRIM PANEL

LOWER TRlM PANEL

SHOULDER BELT ASSEMBLY

VIEW J

5 POSITION BUCKLE RETAINER ON THE LOWER O

DRILLED 1/4" HOLES AS SHOWN IN VIEW.

RETAINER AS A TEMPLATE. SECURE BUCKLE

RETAINER T O BODY. r B E L T RETAINER

VlEW

H

5/16" 18 THREAD

NO SHOULDER VlEW K

POSITION BELT RETAINER ON THE LOWER O

DRILLED 1/4" HOLES AS SHOWN IN VIEW.

O 1/8" DIAMETER HOLES INTO BODY

RETAINER AS A TEMPLATE. SECURE BELT

RETAINER T O BODY.

4 5 3 3

Fig. 14-107-Second And Third Seat Shoulder Belts-"B"

Body Station Wagon Styles

SEATS 14-91

1/2" 13 THREAD

9/16" SHOULDER

(SEE P R E V I O U S PAGE FOR V l EW L O C A T I O N S )

BOLT1

SHOULDER B E L T 7

I

ANCHORAGE AND INSTALL REPLACE-

AND ANCHOR PLATE IN SAME POBmION.

B E L T

I

1/2" 13 THREAD

NO SHOULDER r

ANCHOR BOLT

1 MAKE FLOORANCHOPAGE ACCESSIBLE AND O

2 INSTALL SHOULDER BELT AS SHOWN IN VIEW. O

EXISTS AT THE INBOARD RIGHT HAND LOCATION

O F SECOND SEAT AND MUST NOT BE REMOVED.

3 INSERTANCHORBOLT(PROPERANCHORB0LT O

PLAT S (AND BELT PROTECTOR WHERE USED).

SEC& T O FLOOR ANCHORAGE.

(SEE NOTE BELOW)

;ECOND SEAT FLOOR ANCHORAGE

VIEW L

BELT ANCHOR-'

PLATES

$

THIRD SEAT FLOOR ANCHORAGE

Y l E W M

PILLAR TRIM PANEL

FRONT BELT RETAME

BUCKLE RETAINER

SHOULDER BELT ASSEMBLY

5/16" 18 THREAD

NO SHOULDER

V I E W N

T O BODY AS SHOWN IN VIEW WITH ANCHOR

2 POSITION BUCKLE RETAINER AS SHOWN IN VIEW. USING THE BUCKLE RETAIN= A8 O

AND

SECURE T O BODY.

CAUTION

CARE MUST BE TAKEN T O AVOID PIERCING

R o o F w H m D R i L L m G

POSITION FRONT BELT RETAINER O

A

SECURE TO BODY.

AS SHOWN IN VIEW. USING THE BELT RETAINER

TEMPLATE AND THE DIMENSION SHOWN,DRILL TWO 1/8" DIAMETER HOLES ANI

C A U T I 0

CARE MUST BE TAKEN T O AVOID PIERCING

ROOF WHEN DRILLING

Fig. 14-108-Second And Third Seat Shoulder Belt Views

(Refer To Fig. 14- 107)-"B" Body Station Wagon Styles

ELECTRICAL 15- 1

SECTION 15

ELECTRICAL

SUBJECT PAGE

Introduction

................................................................

General Checking Procedures

15-2

.............................

15-2

Power Windows

.....................................................

Cross Over Harness

15-5

.............................................

15-5

Front Door Window Harness

............................

15-5

Front Door Window Control Harness-"F"

Styles

...................

Rear Door or Quarter Window Harness

15-6

.......

15-6

Rear Door Window Harness-"A!

.

Styles

Motor Description

........

15-6

................................................

1 5 4