Pontiac Bonneville 1972 Workshop Manual

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Serial Number: 72BDY-001-1009

1972

FISHER

BODY

SERVICE

MANUAL

FOR ALL BODY STYLES

(Except "H" Body)

This publication contains the essential removal, installation, adjustment and maintenance procedures for servicing all US. and Canadian built 1972 Fisher

Body Styles. All information, illustrations, and specifi- cafions contained in this publication are based on the latest product information avnilable at the time of publication approval. The right i s reserved to make changes at any time without notice.

Arrangement of the material i s 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. r l s m

MX)Y DIVISION

PART NO. 8705501

Reprinted wlth Permission of

General Motors Corporatlon

TABLE O F CONTENTS

TITLE

GENERAL INFORMATION

WINDSHIELD WIPER SYSTEM

UNDERBODY

STATIONARY GLASS

FRONT END

DOORS

REAR QUARTERS

REAR COMPARTMENT LID

TAIL GATE

HEADLINING

ROOF

FOLDING TOP

DOOR AND QUARTER TRIM

SEATS

ELECTRICAL

EXTERIOR MOLDiNGS

INDEX

O 971 GENERAL MOTORS CORPORATION

LlTHO IN U.S.A.

AUGUST 1971

GENERAL INFORMATION

1-1

SECTION 1 GENERAL INFORMATION AND

MAINTENANCE

SUBJECT PAGE

Manual Description

Introduction

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

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

Index

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

Page and Figure Numbers

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

Reference Tabs

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

Text

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

Illustrations

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

Model Identification Chart

Model Identification

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

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

Introduction

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

Body Series Number

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

Body Style Identification

Body Style Name

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

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

Body Number Plate

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

Vehicle Identification Number

Lock Cylinder Coding

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

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

SUBJECT PAGE

Five Bitting Level Lock Cylinder and Key

Cutting Keys

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

Replacement Lock Cylinders ........................

Assembly and Coding Lock Cylinders

........

Assembly and Coding Glove and Console

Compartment Lock Cylinders

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

Glass Polishing ................................................

Description

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

Glass Polishing Procedure

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

Wood Grain Transfer

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

Description

Removal

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

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

Installation

Lubrication

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

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

Gas Tank Fuel Emission Separator

Special Tools

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

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

MANUAL DESCRIPTION

INTRODUCTION

This publication contains essential removal, installation, adjustment and maintenance procedures for servicing all 1972 Fisher Body Styles. This information is current as of time of publication approval.

INDEX

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 idgRtify 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 prox- imity to accompanying text and should be used as part of the text.

1-2 GENERAL INFORMATION

Division

Chevrolet

MODEL IDENTIFICATION CHART

Body Type Series Sales Name

Chevelle Nomad

Chevelle " 300" Deluxe

Chevelle Malibu

Concours Estate

Monte Carlo

Biscayne

Be1 Air

Impala

Caprice

Camaro

Nova

Styles

Pontiac LeMans

LeMans Sport

LeMans Luxury

Grand Prix

Catalina

Brougham

Bonneville

Grand Ville

Firebird

Ventura I1

Oldsmobile

F-85

Cutlass

Cutlass Supreme

Vista-Cruiser

Delta 88

Delta Royale 88

Delta Cruiser 88

Ninety Eight

Ninety Eight Luxury

Toronado

Toronado Deluxe

GENERAL INFORMATION 1-3

Division

Buick

MODEL IDENTIFICATION CHART (Cont'd.)

Sales Name

Skylark

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

39-57-69

39-57-67-69

35-45

39-47-67

37-39

8 7

Cadillac Fleetwood Brougham Sedan

Calais

DeVille

Fleetwood Seventy-Five

Eldorado

G M of

Canada

Pontiac

Laurentian

Parisienne Brougham

MODEL IDENTIFICATION

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:

1. Division

- first digit and four zeros (ex. 10000

Chevrolet; 20000 Pontiac).

2. Division, Car Line and Style Group - first three digits and two zeros (ex. 25200 Catalina; 25800

Brougham).

BODY SERIES NUMBER

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

BODY STYLE IDENTIFICATION

The last two digits of the body series number indicate body style type as follows:

14 GENERAL INFORMATION

STYLE DESCRIPTION

Limousine with Auxiliary Seat

Notch Back

Pillar Coupe

Limousine with Auxiliary Seat and Center Partition Window

Station Wagon - 2 Seat

Station Wagon

2 Seat

Dual

Acting Tail Gate

Notch Back

- Hardtop Coupe

Hardtop (4 Win- dow) Sedan

Station Wagon

3 Seat

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

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)

BODY NUMBER PLATE

The body number plate identifies the model year, car division, series, style, body assembly plant, body number, trim combination, modular seat code, paint code and date build code (Figs. 1- 1 and 1-2). O n all

"B", "C", "D" and "E" 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.

D I V I S I O N S E R I E S 1 ,-BODY STYLE U N I T N U M I E e

MODEL YEAR7

1 I r A S S E M I L I PLANT

TIME BUILT CODE

TRIM C O M B I N A T I O N

NUMBER

SEAT CODE

LOWER BODY

COLOR

U P P E R 0 0 9 ~

COLOR OR

FABRIC COLOR

4 5 8 3

Fig. 1-1-Body Number Plate

U.S. c o

ES TO THE

Dr4.a

MS TO ALL FEDERAL

AT TlME OF MANUFACTURE

U W I

BODY

COLOI

WWIR loDY

COLOR

1 onwm

Fig. 1-2-Body Number Plate

Canadian Models

GENERAL INFORMATION 1-5

VEHICLE IDENTIFICATION NUMBER

The Vehicle Identification Number (serial number) is located on left front horizontal surface of instrument panel which is visible from outside the car.

LOCK CYLINDER CODING

FIVE BITTING LEVEL LOCK CYLINDER A N D

KEY

All models 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.

Two non-interchangeable keys are used. One key, known as type "C" is identified by a square head, and the letter "C" stamped on the shank and is used in all ignition, front door and station wagon tail gate lock cylinders.

The second key, known as type a round head, and the letter

"D"

"D" is identified by stamped on the shank and is used in instrument panel compartment, console compartment, rear compartment and station wagon rear floor compartment lock cylinders. Spe- cific key identification is obtained from the four character key code stamped on the knock-out portion of the key head. o n t y p e "C" keys codes range from OONO to 99N9 and OOPO to 99P9. On type "D" keys, codes range from OOSO to 9939 and OOUO to

99U9. This number identifies the lock combination and is used when ordering or making new keys.

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 "k- nock-outH plug, lock combination (tumbler numbers ing key on diagram in Figure 1-3.

POSITION LEVELS

Fig. 1-3-Key Code Diagram

1-6 GENERAL INFORMATION

CUTTING KEYS

After the special code has been determined, either from code list or Key Code Diagram (Figure 1-3) 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 kombinations 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 1-3) with key outlined by diagram as accurately as possible. b. Starting at head of key blade, determine and record lowest level (tumbler number) that is visible in position No. 1 and subsequent position numbers 2 through 6. After tumbler numbers and arrangement have been determined, 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 1-4.

3. Pull out side bar with fingers so that tumblers will drop completely into place (Fig. 1-4). Insert one tumbler spring in space provided above each tumbler.

CAUTION: 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 1-5).

TUMBLER SPRING RETAINER

(

LOCK CYLINDER HEAD

Fig. 1-5-Installing Spring Retainer Fig. 1-4-Installing Tumblers

GENERAL INFORMATION 1-7

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

4 TUMBLER

C Y L I N D E R

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

-RETAINER

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

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

Fig. 1-6-Glove Compartment Lock Cylinder

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.

CAUTION: 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. is assembled properly, remove keg'and secure cylinder in a vise with spring retainer exposed.

CAUTION: 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 1-5.

ASSEMBLING AND CODING GLOVE AND

CONSOLE COMPARTMENT LOCK

CYLINDERS

Only one type of tumbler is used to make various lock tumbler combinations for glove and console

Fig. 1-7-Coded Glove Compartment Cylinder compartment 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 lock 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 1-6.

1. Insert properly coded key in cylinder.

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

CAUTION: D o 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 1-7.

1-8 GENERAL INFORMATION

GLASS POLISHING

REMOVAL OF MINOR SCRATCHES AND

ABRASIONS

Description

Minor glass scratches and abrasions can be effec- tively removed or substantially reduced by utilizing procedure 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 reason, 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.

CAUTION: 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, approximately three inches in diameter and two inches thick.

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

4. A wide mouth container to hold the pollsh.

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 oxide 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 in locating scratch during polishing (Fig.

1-8).

4. Use masking paper where needed to catch drip- pings or spattered polish.

5. 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.

6. Using moderate, but steady, pressure, hold pad flat against scratched area of glass, and with a feathering-out motion, polish affected area as shown i n - ~ i ~ u r e -

FEATHERING-OUT

GUIDELINES

3077

H O L D P A D FLAT A G A I N S T GLASS

Glass Polishing Procedure

1. Mix at least three heaping tablespoons of cerium oxide (Glass-Nu or equivalent) with sufficient water to obtain a creamy consistency. Fig. 1-8-Minor Glass Scratch Removal

GENERAL INFORMATION 1-9

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

7. Cover sufficient area around scratch with a feathering-out motion as shown in Figure 1-8, to eliminate any possibility of a "bulls-eye".

CAUTION: 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 1972 model station wagons. The transfers incorporate a pressure sesitive 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 "Division", "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.

Prepare a supply of wetting solution, as called out in the procedure, by adding 1/4 ounce of detergent

("Joy", " Vel", or equivalent) to one gallon of clean water.

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

Transfer replacement involving collision damage, or damage to underlying acrylic paint finish requires that metal repair and/or refinish operations be car- ried 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 progres- sive, overlapping strokes and work from center out- wardly. 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 removes dirt nibs and high spots.

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

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

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

Kleano", " Acryli- Clean" or equivalent.

3. 3-M Vinyl Trim Adhesive or equivalent; brush or spray-can.

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

5. Water bucket and sponge.

6. Sandpaper, No. 360 or No. 400, Wet-or-Dry

Type.

7. Infra-red heat bulb and extension cord

8. Clean wiping rags or paper towels.

9. Sharp knife.

10. Scissors.

1 1. Fine pin or needle.

1-10 GENERAL INFORMATION

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 parts.

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.

CAUTION: Avoid using pointed or sharp instru- ments 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 and 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

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

NOTE: If wrinkle is trapped during squeegee operations, stop immediately. Carefully 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 in steps "a", "b" and "c", 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 ir- regularities 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.

14. Install previously removed parts and clean up car as required.

GENERAL INFORMATION 1-1 1

LUBRICATION

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 w , Part No. 1050110, or Spray-

Lube " A w , 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 (compartment lid and "B" style tail gate) are to be lubricated every six (6) months with Auto-Lube

"A", Part No. 1050110, 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). The compartment 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 manual.

SPECIAL BODY TOOLS

Figs. 1-9 and 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 3, 4 and 5 shown in Fig. 1-9 are new type tools for 1972.

1-12 GENERAL 1NFORMATION

J-2309 1

Fabric Roof

Cover Repair Tool

Chevrolet, Pontiac,

Oldsrnobile and Buick

Styles

J-23497 - Door Hinge

Spring Corr.pressing

Tool - "X" Styles

J-23302, J-23457 and BT-7 107 - Seat

Belt Anchor Bolt

Removing Tool

Fig. 1 -9-Special Body Tools

BT-7 1 1 1

Folding

Top Tension

Checking Gauge

"B and E" Styles

J - 2 3 7 9 0

Folding

Top Tension

Checking Gauge

"B and E" Styles

J-228 10

Door Hinge

Wrench

"A, B, C, E and F" Styles

J-21412

Rear

Compartment Lid

Torque Rod Removal and Adjusting Tool

"A and X" Styles

BT-7 102

Rear

Compartment Lid

Torque Rod Removal and Adjusting Tool

"A" and Oldsmobile

"E" Styles

9. J-23722

Rear

Compartment Lid

Torque Rod Removal and Adjusting Tool

Cadillac "C and E"

Styles

10. J - 2 3 7 1 9 -

Retractable Tail Gate

Torque Rod Adjusting

Tool

"B" Styles

GENERAL INFORMATION 1-13

1. J-2 1549-10

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. J-21549-5

Reveal

Molding Remover

(Left Hand

Operations)

"A and

X" Styles

4. J-2 1549-6

Reveal

Molding Remover

(Right Hand

Operations)

"A and

X" Styles

J-21214

Molding

Clip Pliers (Bath-Tub

Type Clips)

All

Styles

J-9886

Door Handle

Clip and Trim Pad

Remover

J-23394

All Styles

Glass

Alignment Gauge

Block Set

"A and F"

Hardtop Styles

J-23457 or BT-7 107

Door Lock, Tail Gate and Seat Back Lock

Striker Remover and

Adjusting Tool

All

Styles

J-22055

Window

Nut Remover

All

Styles

Fig. 1 -10-Special Body Tools

10. J-22 128

Windshield Wiper

Arm Removing Tool

"A, F and X" Styles

1 1. J-8966

Windshield

Wiper Arm Removing

Tool

"A, F and X"

Styles

12. J-2 1092

Fabric

Roof Cover Trim

Knife

All Styles

13. J - 2 1 1 0 4 -

Weatherstrip

Removing Tool

All

Styles

14. J-2772

Headlining

Installer

All Styles

15. J-237 1 1-5

Glass

Alignment Gauge

lock -

68 169 style

Rear Doors

16. J-237 1 1

Glass

Alignment Gauge

Block Set

"B, C and

Ed' Hardtop Styles

17. J-8074

Hydraulic

Pressure Gauge

(0-600 Ibs.)

"A"

Convertible Styles

18. J-23554

Door Trim

Pad Applique

WINDSHIELD WIPER SYSTEM 2-1

SECTION 2

INDEX

PAGE SUBJECT SUBJECT

Windshield Wiper System

Description

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

2-1

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

2-1

Control Switches

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

2-1

Two Speed Rectangular Motor

Description

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

2-2

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

2-2

Diagnosis Wiper on Car

Diagnosis Chart

Wiper Arm Adjustment

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

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

Wiper Motor Removal and Installation

Wiper Arm Removal and Installation

2-3

2 4

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

2-5

....

2-6

........ 2 6

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

2-8

Wiper Blade Removal and Installation

......

2-8

Wiper Transmission Removal and

Installation

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

2.8

Disassembly and Assembly Procedure

Two Speed Round Motor

Description

Diagnosis

......

2-9

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

2-13

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

2-13

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

2-16

Diagnosis Chart .

Diagnosis Chart

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

2-17

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

2-18

Wiper Motor Removal and Installation

Wiper Arm Removal and Installation

....

2-22

........

2-22

Wiper Arm Adjustment

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

2-24

Wiper Blade Removal and Installation

......

2-25

Wiper Transmission Removal and

Installation

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

2-26

Motor Disassembly and Assembly

Procedure .................................................... 2-27

Gear Box Disassembly and Assembly

Procedure ....................................................

Wiper Motor Adjustments ..........................

Demand Wiper System

Description

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

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

Diagnosis Chart ..........................................

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

2-28

2-31

2-32

2-33

Washer Systems

Description

2-35

.................................................... 2-35

Rectangular Motor Washer System

Description

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

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

2-36

Diagnosis Chart

2-36

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

Washer Disassembly

2-38

.................................... 2-39

Round Motor Washer System

Description

Diagnosis Chart

..................... 240

.................................................... 240

.......................................... 242

Removal of Washer Pump from

Wiper Motor ................................................ 243

Washer Disassembly .................................... 243

Programmed Washer System ........................ 244

Description ................................................. 244

Diagnosis-Wiper Motor on Car

Diagnosis Chart

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

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

248

2-50

Removal of Washer Pump from Wiper

Motor .......................................................... 2-55

Washer Disassembly ....................................

Washer Assembly

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

2-55

2-56

DESCRlPTlON

WINDSHIELD WIPER SYSTEM

tor and wiper blades that park below the hood line .

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 mo-

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

CONTROL SWITCHES

For service information on control switches. refer to

Car Division Service Manuals .

2-2 WINDSHIELD WIPER SYSTEM

T W O SPEED-RECTANGULAR MOTOR

DESCRIPTION

The system consists of a compound wound rectangular-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 and pinion drives an output gear and shaft assembly

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

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

RECTANGULAR MOTOR A P P L I C A T I O N

CAR D V I S O N S E R I E S

GEAR R A T I O

CRANKARM LETTER

36: 1

3 6 : 1

CHEVROLET

A A

PONT l AC

OLDSMOBlLE

B U l C K

36: I

36: 1

36: I

36: 1

4638

Fig. 2-1-Rectangular Motor Application Chart 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.

Moving the wiper switch to the " H I " speed position 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).

The parking 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 wiper output gear is turned to a position where it's cam opens the park switch. Referring to Figure 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 through the parking switch to ground. The series field and armature circuit is also completed from terminal No. 1 through the parking switch to ground.

TERMINAL

D A S H

SVV I T C H

SHUNT F - N A T . W I R E

S W I T C H

Fig. 2-2-"Lo" Speed Circuit

3992

WINDSHIELD WIPER SYSTEM

2-3

DASH

SWITCH

Fig. 2-3-"Hi" Speed Circuit

NOTE: The shunt field is connected direct to ground by-passing the resistor. This results in "LO" speed operation during the parking operation. c. Wiper switch is securely mounted and grounded. d. Check fuse.

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

DIAGNOSIS-WIPER ON CAR

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

1. Inspect for the following items: 3. Disconnect wiring harness from wiper and try operating wiper as shown in Figure 2-5. a. Wiring harness is securely connected to wiper and switch. a. If wiper operates correctly independently of switch and car wirina, refer to the DIAG- b. Wiper motor is securely grounded to body.

DASH

SWITCH

OFF LO

H I

I

Fig. 2-CParking Circuit

SWITCH

2-4 WINDSHIELD WIPER SYSTEM b. If wiper still fails to operate correctly in Step

3, disconnect wiper linkage from motor crankarm 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 independently of linkage, remove wiper motor from car and refer to DIAGNOSIS CHART-

WIPER O F F CAR.

DIAGNOSIS CHART

WIPER ON CAR

CONDITION

1. Wiper Inoperative or intermittent

NOTE: Ignition switch must be "on" for all electrical tests.

APPARENT CAUSE CORRECTION

A. Blown fuse

B. Open circuit in feed wire

(No. 2 terminal on wiper motor)

C. Loose mounting of wiper switch

D. Defective wiper switch

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

A. Locate short circuit and repair. Replace fuse.

B. Locate broken wire and repair

C. Tighten switch mounting

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

C. Wiper has "Hi" speed only

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

A. Defective wiper switch

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

A. Defective wiper switch

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

A. Locate short circuit and repair

A. Replace wiper switch

B. Locate and repair short circuit

A. Replace wiper switch

B. Locate and repair broken wire

A. Locate broken wire and repair wiper switch

WINDSHIELD WIPER SYSTEM 2-5

CONDITION

DIAGNOSIS CHART

WIPER ON CAR (CONT'D)

APPARENT CAUSE

4. Wiper has "Lo" speed only

5. Blades do not return to full park position

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

I B. Defective wiper switch

A. Loose wiper ground strap connection

CORRECTION

A. Locate short circuit and repair

B. Replace wiper switch

A. Tighten strap connection

CONDITION

1. Wiper Inoperative or

Intermittent

DIAGNOSIS CHART

WlPER OFF CAR

(FIGURES 2-5, 2-8 and 2-9)

APPARENT CAUSE CORRECTION

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

E. Open circuit in armature

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

2. Wiper will not shut-off:

A. Wiper has normal "Hi" and "Lo" speed

B. Wiper has "Lo" speed or

A. Defective park switch

B. Grounded red lead wire

A. Grounded shunt field coil

(Fig. 2-9)

B. Grounded black wire

A. Replace terminal board assembly

B. Repair short circuit in red wire

A. Replace frame and field assembly

B. Repair short circuit in black wire

2-6 WINDSHIELD WIPER SYSTEM

CONDITION

DIAGNOSIS CHART WIPER OFF CAR (CONT'D)

APPARENT CAUSE CORRECTION

C. Wiper has "Hi" speed only A. Open circuit in shunt field coil (Fig. 2-9)

B. Open circuit in black wire

A. Replace frame and field assembly

B. Repair broken wire or poor solder connection

3. Wiper shuts off - but not in park position

A. Park switch defective or contacts dirty

A. Replace terminal board assembly or clean contacts

4. "Hi" speed to fast A. Resistor defective A. Replace terminal board assembly

WIPER MOTOR

Removal and Installation

1. Raise hood and remove cowl screen or grille.

2. Disconnect wiring.

3. Reaching through cowl opening, loosen the transmission drive link attaching nuts to motor crankarm (Fig. 2-6).

LO SPEED - AS S H W N

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 I PER SHOULD

STOP WITH GEAR SHAFT FLATS AS SHOWN.

I WI PER

GROUND STRAP

Fig. 2-5-Jumper Wire Connections

4. Disconnect transmission drive link from motor crankarm.

5. Disconnect washer hoses.

6. Remove three motor attaching screws.

7. Remove motor while guiding crankarm through hole.

8. T o install, reverse the removal procedure.

WIPER ARM

Removal and Installation

1. T o remove the wiper arm and blade assemblies use tool J- 22128 or 5-8966, 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-X" 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

WINDSHIELD WIPER SYSTEM 2-7

DRIVE LINK

CRANKARM

VIEW "A"

Fig. 2-6-Wiper Installation and Wipe Pattern

"F" Styles

2-8 WINDSHIELD WIPER SYSTEM

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

A. All "A" styles

.oOv.

1.54" plus 1.50" or minus

B. All "F" styles - .5" minimum to 2.25" maximum.

C. "X" styles - 7/8".

NOTE The correct park position and outwipe dimension is determined with the wipers operating at "Lo" speed on a wet glass.

WIPER ARM

Adjustment

The only adjustment of the wiper arm(s) is to remove 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 release tab. When the release tab is depressed the blade assembly can be separated from the arm.

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

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 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.

Fig. 2-7-Wiper Blade Assemblies

NOTE: 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 Installation

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. Disconnect wiring from wiper motor.

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

5. Remove right and left transmission to body attaching screws and guide transmission and linkage assembly out through cowl plenum chamber opening.

WINDSHIELD WIPER SYSTEM 2-9

6. To install, place transmission and linkage assembly in plenum chamber and install transmission to body attaching screws loosely.

7. Connect transmission drive link to motor crankarm and tighten attaching nuts (19-29 .inch pounds torque).

NOTE: Wiper motor must be in park position.

8. Align transmission assemblies and tighten transmission to body attaching screws.

9. Connect wiring to wiper motor.

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

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

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 screwdriver or similar tool. c. Remove the felt washer from the wiper gearshaft.

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

CAUTION: Failure to clamp crankarm may result in stripping of wiper gears.

3. Remove crankarm, seal cap, Tru-Arc retaining ring and end play washers (Fig. 2-10).

CAUTION: Seal cap should be cleaned and re- packed with a waterproof type grease before reassembly.

COMMUTATOR HOOK

CHECK FOR TEST LIGHT PROBES,

POOR WELD

JOINTS

BAR TO BAR CHECK

FOR OPENS

LAMP

SHOULD LlGHT BETWEEN

ADJACENT BARS

4068

Fig. 2-&Checking Armature

4. Drill out staking that secures gear box cover

(Fig. 2-11). Use a 9/32" drill.

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

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

SERIES F mum

USING TEST LAMP.

"A". IF LAMP

LIGHT FIELD COIL I S OPEN.

TEST LIGHT PROBES FOR

GROUND CHECK. I F LAMP

LIGHTS, ARMATURE I S

GROUNDED,

( R E C ~ C K ) \

SHUNT F

TOUCH "A" AND "3". IF LAMP \

DOES NOTLIGHT, FIELD COIL I S OPEN.

(CHECK SPLICE AND SOLDER JOINTS. I

TESTING FOR GROUNDED COIL:

TOUCH TEST LIGHT TO "A" AND

FRAMC I F LAMP LIGHTS, FIELD

M I L S ARE GROUNDED.

Fig. 2-9-Testing Field Coils

TEST

LIGHT

2-10 WINDSHIELD WIPER SYSTEM

GEAR aOX COVER

O U T P U T G E

S H A F T A S S E M B L Y

A N D ' T F R M I N A L

B O A R D A S S E M B L Y C R A N K A R M

3991

Fig. 2-10-Gear Box

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

NOTE: Screws, nuts and washers for attaching a replacement terminal board park switch assembly are included with a replacement assembly. a. Note position of motor leads on terminals, then unsolder. b. Drill out rivets that secure terminal board and park switch ground strap to plate. Use a

7/64" drill.

Gear Box Reassembly

CAUTION: Lubricate all gear teeth with lubricant noted on specifications chart Figure 2-1 7.

1. If park switch and terminal board assembly were 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.

INSTALLING CRANKARM

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

2- 13).

Fig. 2-1 1-Staking Locations

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

WINDSHIELD WIPER SYSTEM 2-1

I

Fig. 2-12-Parking Switch and Terminal Board

5. Secure cover to gear mounting plate over dowels. Be sure to reinstall ground strap.

NOTE: Screws, nuts and lockwashers for reassembling cover to wiper are contained in a Ser- vice 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-

1 1) and install crankarm so tha; index marks on crankarm line up with those on the gear box cover (Fig. 2-1 1).

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

INSTALL G E A R SO

Fig. 2- 14-Cam Positioning

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

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).

Fig. 2- 13-Gear Installation

4009

W A S H E R A R R A N G E M E N T

Fig. 2- 15-Wiper Motor-Exploded View

2-12 WINDSHIELD WIPER SYSTEM

REMOVE BRUSH SPRING FROM SLOT AND

PLACE IT IN GROOVE AS SHOWN

Fig. 2-16-Removing Brush Spring Tension

SPECIFICATION CHART

O p e r a t i n g V o l t a g e

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

12 V o l t s D . C .

C u r r e n t Draw (No Load)

"Lo" Speed

" H i " Speed

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

WAX.

S t a l l ( c o l d M o t o r )

Crankarm Speed ( R P M s )

12 V "Lo" Speed

"Hi" Speed 12 V

Torque Inch Pounds

Washer Pump Mounting Screws

M o t o r T i e B o l t s

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

Motor Crankarm A t t a c h i n g Nut

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

I 8

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

130

Motor Crankarm To T r a n s m i s s i o n D r i v e L i n k

H o t o r TO ~ o d y

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

T r a n s m i s s i o n To Body A t t a c h i n g B o l t s

. . . . . . . .

. . . . . . . . . .

L u b r i c a t i o n

Armature S h a f t

Bearings

Gear T e e t h P r e s t l g e No. 42

4636

Fig. 2- 17-Specification Chart-Rectangular Motor

2. Position four lobe cam as shown in Figure 2-14.

It may be necessary to manually rotate crankarm.

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.

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

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

15.

8. To replace brushes, cut brush pigtail approximately 1/4" from splicing clip. Splice the new brush pigtail to the 1/4" of pigtail left from the original brush.

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

Motor Reassembly

Reverse disassembly Steps 1 through 7 and reassemble gear. Lubricate the motor assembly as indicated in Specification Chart, Figure 2-17.

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

WINDSHIELD WIPER SYSTEM 2-13

T W O SPEED-ROUND MOTOR

A, F - STYLES

ROUND I O T O R A P P L I C A T I O N C H A R T

CAR D I V I S I O Y S E R l L S W T O R L E N G T H GEAR COLOR GEAR R A T I O CRANKARM L E T T E R

Fig. 2-1 8-Wiper Assembly

B U l C K

C A O I L L I C

5062

0 - C - E

C - 0 - E

4 "

4 4 "

4 t"

G r e e n

L t . G r q

L I G r q

4 5 . 1

5 1 : l

5 1 : 1

A 0

A L

Fig. 2- 19-Round Motor Application Chart

DESCRIPTION

The round motor used on the "B", "C", "D" 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 .

7mmmnnmmnm

12V FEED V I A R U Y SWITCH TO MOTOR

SERIES

F

l E l D

ARMATURE CIRCUIT

Fig. 2-20-'Lo' Speed Circuit

2-14

WINDSHIELD WIPER SYSTEM

The round motor used on "A" and "F" styles is approximately 4" in length (Fig. 2-18). The motor uses a green colored drive gear with a gear ratio of

45:l.

The service procedures for both motors are the same.

A round motor application chart is shown in Figure

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. 2-35).

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.

The 12 volt circuit to the center terminal of the wiper terminal board is completed through the ignition switch and fuse.

Moving the wiper switch to the "LO" speed position

(Fig. 2-20) 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 to ground at the wiper switch, the other through the armature to ground via the internal circuit breaker.

Moving the wiper switch to the "HI" speed position

(Fig. 2- 2 1) 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.

Moving the wiper switch to the "Med" speed position (Cadillac Only) connects a 13 ohm resistor, located in the switch, in parallel with the 20 ohm resistor from the shunt field circuit. These two resis- tors, connected in parallel, provide slightly less than

8 ohms resistance in the shunt field. The difference in resistance results in medium speed.

OFF LO H I

SPLICE

,BLAWKW,l

COIL

I

1 I / -

RELAY COIL ClRUClT FROM 12V FEED

SHUNT FIELD CIRCUIT

SERIES FIELD

ARMATURE CIRCUIT

Fig. 2-2 1 -'Hi" Speed Circuit

WINDSHIELD WIPER SYSTEM 2-15

S P L I C E BLACK W l P l N K

STR I

I G N I T I O N

S W I T C H

SHUNT FIELD C I R C U I T

SERIES FIELD - ARMATURE C I R C U I T

'OR

Fig. 2-22-Parking Circuit

Turning the wiper switch off (Fig. 2-22) 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. 2-23).

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.

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

Since the wiper motor continues to run when the switch is first turned off, the continuing rotation of

RELAY LATCH A R M I S HELD

OUT OF PATH OF GEAR BY

RELAY MAGNET.

5032

Fig. 2-23-Gear in Normal Run Position

2-16 WINDSHIELD WlPER SYSTEM 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. 2-25).

LATCH A R M

5009 i

Fig. 2-24-Wiper Shutting "Off" the gear causes the drive pawl to engage the relay latch arm (Fig. 2-24). This action unlocks the gear from the drive pawl, lock pawl and the drive plate and output shaft assembly. With the drive plate and

Fig. 2-25-Wiper Shut "Off" in Park Position

DIAGNOSIS

WIPER ON CAR

1. Make a preliminary check of the following items:

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

B. Wiper motor to dash mounting screws tight.

C. Wiper switch securely mounted.

D. Fuse.

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 Figure 2-29. Check wiper operation in "OFF", "LO" and "HI" positions.

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. If wiper motor operates correctly in Step 2, check linkage for severe binding condition or breakage.

2. If wiper fails to operate correctly in Step 2, remove wiper motor from car and check

DIAGNOSIS CHART

WIPER OFF

CAR.

WINDSHIELD WIPER SYSTEM 2.17

DIAGNOSIS CHART

WIPER ON CAR

LESS DEMAND WIPER SYSTEM

NOTE: For Demand Wiper System see preliminary inspection and diagnosis chart in the Programmed

Washer System section.

NOTE: Ignition switch must be "on" for all electrical tests.

APPARENT CAUSE CONDITION 0

A. Open lead wire from wiper

CORRECTION

A. Repair broken wire. terminal No. 1 to wiper switch.

B. Tighten switch mounting. B. Wiper switch not securely mounted.

C. Wiper switch defective. w

2. Will not shut off A. Grounded lead wire from wiper terminal No. 1 to wiper switch.

B. Corroded wiper terminals.

C. Defective wiper switch.

C. Replace wiper switch.

A. Tape uninsulated portion of wire.

B. Clean terminals.

C. Replace wiper switch.

3. Will not shut off

(Blades move up and down about 15 degrees from park position.

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

B. Wiper switch mounting loose.

C. Wiper switch defective.

A. Repair broken wire.

B. Tighten switch mounting.

C. Replace wiper switch.

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

B. Wiper switch defective.

A. Repair broken wire.

B. Replace wiper switch.

A. Grounded lead from wiper terminal No. 3 t o wiper switch.

B. Defective wiper switch.

A. Tape uninsulated portion of wire.

B. Replace wiper switch.

2-18 WINDSHIELD WIPER SYSTEM

DIAGNOSIS CHART

WIPER ON CAR

LESS DEMAND WIPER SYSTEM (CONT'D)

CONDITION APPARENT CAUSE CORRECTION

6. "Hi" speed in "Med" position (Cadillac only)

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

DIAGNOSIS CHART

WIPER OFF CAR

LESS DEMAND WlPER SYSTEM

NOTE: For Demand Wiper System see Preliminary

Inspection and Diagnosis Chart in the Programmed

Washer System section.

NOTE: Before using chart, try operating wiper as

CONDITION shown in Figure 2- 29. Check if wiper has "LO" and

"HI" speeds and shuts off correctly. Match the trouble found with the trouble shown in the chart. Use checking procedure following this chart by letter as indicated t o . locate cause of trouble.

APPARENT CAUSE CORRECTION

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

2. Wiper will not shut off

(Crankarm rotates through

360 degrees)

1. Relay coil grounded

2. Relay latch spring disconnected or broken

3. Latch arm binding

3. Wiper will not shut off

(Crankarm moves back and forth in a horizontal plane accompanied by a loud

"knock")

1. Relay switch contacts shorting together

2. Drive pawl spring disconnected

3. Wiper has one speed, "HI", caused by open shunt field

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

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

WINDSHIELD WIPER SYSTEM 2-19

DIAGNOSIS CHART

WIPER OFF CAR

LESS DEMAND WIPER SYSTEM (CONT'D)

CONDITION APPARENT CAUSE CORRECTION

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

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

3. Shorted armature

6. Wiper has excessive speed in "Hi"; "Lo" speed normal

1. Open speed resistor

2. Poor resistor ground connection

7. Wiper stops at random

(Crankarm stops rotating immediately and does not return to full park position.)

1. Relay switch contacts dirty or broken

9. No apparent trouble on bench test but fails occasionally on car.

Clean or replace relay switch assembly as required

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 joints

See Wiper Motor

Adjustments

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. 2-29). Do not connect jumper to terminal

1 and 3.

3. T o 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 Figure 2-26. 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.

2-20

WINDSHIELD WIPER SYSTEM

DRIVE PLATE

SHAFT ASSEMBLY

DRIVE PAWL I N

PARK POSITION I N

RELAY SWITCH SLOl

4 0 1 1

Fig. 2-26-Testing Relay Switch 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. 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. 2-28).

PROCEDURE "B" (WIPER WILL NOT SHUT

OFF-CRANKARM ROTATES 360 DEGREES)

1. Observe if relay latch arm spring is connected properly (Fig. 2-27).

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

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. D O NOT make any connections from terminal No. 1. Manually

RELAY S

Fig. 2-27-Latch Mechanism Fig. 2-28-Brush Plate Assembly

WINDSHIELD WIPER SYSTEM 2-21 actuate latch arm in direction of arrow (Fig.

2-27) 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 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-RECY CLES)

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. 2-27). fi

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

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

- field coil cross-over splice

(Fig.

2-35). 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

~ d .

POWER SOURCE

GROUND CONNECTOR

NAL

CON-

NECTED TO GROUND)

PARK OR RECONNECT JUMPER TO TERMINAL NO. 3

SHUT OFF BUT D I SCONNECT I T FROM TERM I NAL

NO. 1. (W I PER GEAR MECHAN I S M SHOULC

STOP I N POSITION SHOWN

4057

Fig. 2-29-Bench Checking Wiper Motor

2-22 WINDSHIELD WIPER SYSTEM

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,

" L O )

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

3. Refer to Figure 2-29 for terminal No. 3 location.

2. Disassemble motor section of wiper and check for grounded shunt field coil (Fig. 2-34).

WIPER MOTOR

Removal and Installation

1. Raise hood and remove cowl screen.

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

2-30).

3. Remove transmission drive link(s) from motor crankarm.

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).

PROCEDURE "E" (WIPER HAS EXCESSIVE

SPEED IN "HI" BUT "LO" SPEED IS NORMAL)

1. Check for open 20 ohm resistor and the resistor ground connection (Fig. 2-38).

PROCEDURE "F" (INTERMITTENT

OPERATION)

Check solder connections at wiper terminal board.

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

2-29). 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. 2-45). 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.

Adjust armature end play as required and recheck current draw.

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

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.

WIPER ARM

Removal and Installation

1. Raise hood to gain access to wiper arms.

2. On "A" and "F" styles, use tool 5-22128 or J-

8966, or equivalent, and lift arms off transmission shaft.-on left arm slide articulating arm lock clip (Fig. 2-30) away from transmission pivot pin and lift arm off pin.

3. On "B", "C", "D" and "E" styles, lift wiper arm and slide latch clip (Fig. 2-3 1) out from under wiper arm.

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

5. On left arm, slide articulating arm lock clip away from transmission pivot pin (Fig. 2-30) and lift arm off pin.

6. To install left wiper arm assembly, on all styles, position the articulating arm over the transmission 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.

7. On "A" and "F" styles align the right wiper arm assembly in the proper park position and install wiper arm to transmission shaft.

8. On "B", "C", "D" and "E" styles, align keyway

WINDSHIELD WIPER SYSTEM 2-23

Fig. 2-30-Round Motor Installation

"B-C-D-E" Styles

2-24 WINDSHIELD WIPER SYSTEM

Fig. 2-3 1-Wiper A m Latch Clips in right wiper arm assembly to transmission shaft and install arm assembly to shaft.

9. On "B", "C", " D M arm assemblies and slide latch clips (Fig. 2-31) 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 t o wiper arm removal, adjustment should not be required. However, if adjustment is required, it can be performed as follows:

1. Raise the hood and remove cowl vent screen.

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

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

30). On "B", "C", "D" and "En styles, if only

N "A"

Fig. 2-32-Wipe Pattern

WINDSHIELD WIPER SYSTEM 2-25 one arm and blade assembly requires adjustment, loosen only the drive link to crankarm attaching nuts for the unit requiring adjustment.

4. 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.

CAUTION: 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.

5. Tighten the attaching nuts on the transmission drive link(s) to motor crankarm (19-29 inch pounds torque).

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

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

8. Check wipe pattern (Fig. 2-32) and park position. Dimension "A" shown in Figure 2-32 for various body styles is as follows: a. All "A" styles

1.61" plus 1.10" or minus .5" b. "B-35-45-49-69" and 26847 styles plus 1.50" or minus .00"

2.00" c. "B-39-47-57-67" (less 26847) styles plus 1.50" or minus .00"

1.50" d. "C-39-49-69-37-47" styles

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

2.00" plus 1.50" or minus

.00" f. "E-47-57-67-87" styles

1.50" plus 1.50" or minus .00" g. All "F" styles - 1.25" plus 1.10" or minus .5"

NOTE: The correct park position and outwipe dimension is determined with the wipers operating at "Lo" speed on a wet glass.

9. Install cowl vent screen.

WIPER BLADE

Removal and Installation

Two methods are used to retain wiper blades to wiper arms (Fig. 2-33).

1. One method uses a press type release tab. When the release tab is depressed the blade assembly can be slid off 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.

2-33). 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. 2-33).

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 c a n be slih out of the blade assembly.

Fig. 2-33-Wiper Blade Assemblies

E L E M E N T

RELEASE

B U T T O N

. R L A D E

RELEASE

T A B

4641

2-26 WINDSHIELD WIPER SYSTEM

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.

NOTE: When properly installed, the 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",

"D", 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. 2-30).

N0TE: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 m styles, remove the attaching screws securing the transmission(s), to be removed, to the body.

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

7. T o 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 19-29 inch pounds pounds torque (Fig. 2-30).

NOTE: Wiper motor must be in park position.

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

1 1. Install wiper arm and blade assemblies and adjust as described under WIPER ARM AD-

JUSTMENT.

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

13. Install cowl vent screen.

BRUSH

ND ClRCUl

Fig. 2-34-Testing Field Coils

Fig. 2-35-Field and End Cap Assembly

WINDSHIELD WIPER SYSTEM 2-27

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. 2-35).

NOTE: I t 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. 2-28).

CAUTION: 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. 2-28).

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.

2. The end case and field assembly is serviced as a unit. T o 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. 2-28).

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 of the wiper.

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

3. Lubricate end of armature shaft that fits in case bearing with recommended type grease (Fig. 2-

45). 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. 2-36) over the armature shaft far enough to allow reassembly of the remaining brush in its brush holder; then position the brush plate assembly on the mounting tabs in the position shown in Figure 2-28.

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.

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

BRUSH SPRING

Case and Field Assembly Removal

1. Remove brush plate and armature. Fig. 2-36-Brush Plate Assembly

Removed

2-28 WINDSHIELD WIPER SYSTEM

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.

1 1. 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.

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

(Fig. 2-26), remove gear assembly. (See drive gear disassembly).

If wiper gear mechanism is not in park position

(drive pawl away from latch arm Fig. 2-27, 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 Figure 2-37 when resolder- ing leads.

RELAY COIL LEADS

.,.-a

T A

~ CONNECT

RELAY SWITCH TERMINAL

WlTH RED

BLACK WlTH

PlNK STRIPE

INAL

BOARD

U 1,

Fig. 2-38-Positioning Resistor Lead Fig. 2-37-Terminal Board and Latch Relay

RETAINING NUT

RUBBER SEAL

I r WIPER HOUSING.

SHIM WASHERS

SPACER WASHER iTAlNlNG RING

Fig. 2-39-Crank Arm Components-Exploded View

4. T o 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

Latch and Terminal

Board

1. Resolder red coil lead to w i ~ e r required (Fig. 2-37). as

WINDSHIELD WIPER SYSTEM 2-29

2. Slide terminal board into wiper housing being careful to position the terminal board resistor lead as shown in Figure 2-38.

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 t o the wiper housing.

3. Resolder leads t o relay switch assembly as required.

4. Position relay switch assembly in housing.

CAUTION: 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 t o wiper motor. r - N O T E : VIEW SHOWS RELAY SWITCH AND

TERMINAL BOARD REMOVED. GEAR CAN[

RE LA^

SWITCH OR-TERMINAL BOARD

SO1 6

Fig. 2-40-Removing Gear

LOCK PAWL

SHAFT AND

ASSEMBLY

4639

Fig. 2-41-Gear Removed

2-30 WINDSHIELD WIPER SYSTEM

DRI

SHAFT AND

ASSEMBLY

.OCK PAWL

Fig. 2-42-Lock Pawl

Drive Gear Disassembly

1. Remove crankarm retaining nut, crankarm, rubber 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. 2-40).

3. Slide drive plate and shaft out of gear and remove the drive pawl, lock pawl and coil spring as required (Fig. 2-41).

NOTE: A drive plate and shaft assembly with two grooves machined in the shaft can be used to service all 1968 through current model depressed park wiper systems. Service instructions included in any replacement package call out which groove to use.

Drive Gear Reassembly

1. Position drive pawl on drive plate.

2. Assemble lock pawl over drive pawl as shown in

Figure 2-42.

Fig. 2-43-Lock Pawl and Drive Pin Positioning

WINDSHIELD WIPER SYSTEM 2-31

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. 2-43).

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 the housing in the approximate location shown in Figure 2-40.

7. Reassemble the outer spacer

* washer, shield, shim washers, as required t o obtain .WW or minus .002") end play, snap ring and rubber seal cap in the order indicated. Refer to Figure

2-39.

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

Figure 2-44.

9. Reassemble washer pump to gear.

NOTE: Refer to "washer system"

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

WIPER MOTOR ADJUSTMENTS

Armature End Play

1. Loosen adjusting screw locknut (Fig. 2-44) and tighten or loosen the adjusting screw as required until end of screw barely touches end of armature.

2. Back off adjusting screw 1/4 turn and tighten locknut.

Gear Assembly End Play

1. Add o r remove shim washers as required t o obtain . W " (plus o r minus .002") end play (Fig.

2-39).

ADJUSTING SCREW

Fig. 2-44-Wiper Motor and Crank Arm in Park Position

SPECIFICATION CHART

Operating V o l t a g e

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

I 2 V o l t s D.C.

Bench Check (No Load) C u r r e n t Drrnr (AMPS) Crankarm Spee

"Lo" Speed

. . . . . .

5.0 Max.

"HI" Speed

. . . . . .

4.0 Max.

6.0 Max.

4.5 Max.

S t a l l (Cold Motor) nnLom

Speed

. . . . . .

18.0 Max. 29.0 Max 0

Torque

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

Inch Pounds

Washer Pump Mounting Screws

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

Armature A d j u s t i n g Screw Jam Nut

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

Motor T i e B o l t s

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

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

Motor Crankarm A t t a c h i n g Nut

Motor Crankarm To Transrnisslon D r i v e L i n k

Motor To Body A t t a c h i n g B o l t s

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

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

. . . . . . . .

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

Transmlsslon To Body A t t a c h i n g B o l t s

. . . . . . . . . . .

130

29 -

L u b r l c a t l o n

Gear Teeth

Gear S h a f t

Gear Camtrack

Seal Cap ( I n s i d e )

Armature S h a f t

Armature Worm 4637

Fig. 2-45-Specification Chart-Round Motor

2-32

WINDSHIELD WIPER SYSTEM

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. 2-46) 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 continuous 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.

1. With the switch in the first detent position the coil circuits of the wiper gear box relay and the

Fig. 2-46-Demand Wiper Assembly demand relay are completed to ground simultaneously at the shift lever switch. Figure 2-47 shows wiper circuits in "off" position. Figure

2-48 shows the shift lever switch in the first detent position and the completed relay coil circuits.

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.

2-48).

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.

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 "off" position.

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. 2-49).

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 released and moves out into the path of the gear drive pawl (Fig. 2-50). At this stage of operation the gear box relay switch is still closed and the wiper motor continues to run.

WINDSHIELD WIPER SYSTEM 2-33 c. T h e continuing rotation of the wiper gear and Clobe cam moves the fin away from the holding switch contacts "A" allowing them t o 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 t o engage the relay latch arm

(Fig. 2-51). 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.

T h e 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. 2-52) shutting off the wiper.

DIAGNOSIS CHART

Refer t o preliminary inspection procedure and diagnosis chart in Programmed Washer System Section.

RATCHET

RELAY

BLACK W/ 'PINK I

STRIF 'E ! r

WHEEL

DEMAND

RELAY

ORANGE

HOLD SW. F I N ON

"A"

4 LOBE CAM

------I

SHIFT LEVER SWITCH

WIPER CONTROL SWITCH

WASH BUTTON

5028

Fig. 2-47-Demand Wiper Circuits

Off Position

2-34 WINDSHIELD WIPER SYSTEM

MOTOR WINDINGS

- - - - - - - -

WIPER CONTROL SWITCH

GEAR BOX RELAY

IGN

I rL

25 AMP

FUSE tc iREEN

DEMAND

RELAY

- -

ORANGE

RATCHET

RE LAY

HET WHEEL

HOLD

SW. F I N ON 4 LOBE CAM

SHIFT LEVER SWITCH d , t R S T DETENT

WIPER CONTROL SWITCH

WASH BUTTON

4634

Fig. 2-48-Switch in First Detent Position

WINDSHIELD WIPER SYSTEM 2-35

FOUR LOBE C A M

Fig. 2-49-Demand Washer 4-Lobe Cam

LATCH ARM

Fig. 2-51-Gear Drive Pawl Engaged

RELAY LATCH A R M l S HELD

OUT OF PATH OF GEAR B Y

RELAY MAGNET.

5032

Fig. 2-50-Gear in Normal Run Position

Fig. 2-52-Wiper Shut Off In Park Position

DESCRIPTION

WASHER SYSTEMS

The washer pump used on both the rectangular and

- - . - employing a small-piston, s p r k g and valve arrangement. 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.

2-36 WINDSHIELD WIPER SYSTEM

FOLLOWER

WASHER PUMP

ASSEMBLY

_ a h

FOUR LOBE CAM

Fig. 2-53-Four Lobe Cam

RECTANGULAR MOTOR WASHER SYSTEM

Description

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

When the pump is attached to the wiper motor, the four lobe cam actuates a spring loaded cam follower arm and pin assembly. Figure 2-53 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- 54).

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.

Referring to Figure 2-54, 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 actuator plate elongated opening and no pumping action occurs.

The ratchet pawl is held away from the ratchet wheel by a spring loaded solenoid plunger.

Depressing the control switch washer button completes the pump solenoid circuit to ground at the control switch and mechanically actuates the wiper switch to turn the wiper motor on (Fig. 2-55).

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 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.

RATCHET PAWL VALVE ,ASSEMBLY

CAM FOLLO

U P P E R Z I N

SOLENOID

Fig. 2-54-Actuator Plate

BATTERY

- -

Fig. 2-55-Pump Wiring Circuit

5069

WINDSHIELD WIPER SYSTEM 2-37

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. 2-56).

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 u p tight agaihst 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.

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. 2-56).

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

FROM

WASHER

JAR

CLOSED

-w

DIRECTION OF TRAVEL

I N T A K E S T R O K E

NOZZLES

Fig. 2-56-Intake and Exhaust Stroke

2-38 WINDSHIELD WIPER SYSTEM

1

SOLENOID COIL

SOLENOID PLUNGER

Fig. 2-57-Washer Assembly Internal Gear

1

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

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. 2-57).

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

(Fig. 2-54).

DIAGNOSIS CHART RECTANGULAR MOTOR WASHER SYSTEM

APPARENT CAUSE CORRECTION

A. Inadequate quantity of washer solution

B. Hoses damaged or loose

C. Plugged screen at end of jar cover hose

D. Loose electrical connection to washer pump or wiper switch

E. Open circuit in feed wire to pump solenoid coil

F. Wiper switch defective

G. Pump solenoid coil defective

H. Washer nozzles plugged

I. Ratchet wheel tooth missing

J. Ratchet pawl spring missing

A. Add washer solution

8. Cut short length to insure air tight connection or replace hose

C. Clean screen

D. Check electrical connection and repair if necessary

E. Locate open circuit and repair

F. Replace wiper switch

G. Replace solenoid

H. Clean washer nozzles

I. Replace ratchet wheel

J. Replace ratchet pawl spring

WINDSHIELD WIPER SYSTEM 2-39

DIAGNOSIS CHART

RECTANGULAR MOTOR WASHER SYSTEM (CONT'D)

A P P A R E N T CAUSE CONDITION 0

K. Defective pump valve assembly

CORRECTION

K. Replace pump valve assembly

2. Washer pumps continuously when wipers are operating

A. Grounded wire from pump solenoid to switch

B. Wiper Switch Defective

C. Ratchet wheel tooth missing

D . Ratchet wheel dog broken. o r not contacting ratchet wheel teeth

E. Lock-out tang broken o r bent on piston actuating plate

A. Locate grounded wire and repair

B. Replace wiper switch

C. Replace ratchet wheel

D. Replace o r repair ratchet wheel dog

E. Replace piston actuating plate

WASHER DISASSEMBLY

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. 2-59).

Ratchet Pawl

1. Disconnect ratchet pawl spring (see Fig. 2-58 for proper location of spring).

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

RETAINER

RAT

RETAIN

RATCHET D O G

RATCHET P A W L SPRING

S O L E N O I D PLUNGER

A N D S P R I N G

RATCHET WHEEL

SPRING

Fig. 2-58-Ratchet Pawl Spring Location

Fig. 2-59-Pump Assembly

Exploded View

2-40 WINDSHIELD WIPER SYSTEM

RATCHET

WHEEL

SPRING in the housing clear the frame. Then remove the actuator plate from the ratchet wheel and cam follower shafts.

Fig. 2-60-Pump Ratchet Wheel

Ratchet Wheel

1. Follow step 1 under solenoid sembly.

- ratchet dog as-

2. Move ratchet wheel spring out of shaft groove and slide ratchet wheel off its shaft (Fig. 2-60).

Pump and Actuator Plate Assembly

1. Remove solenoid assembly - ratchet dog, ratchet pawl and ratchet wheel as outlined in their respective procedures.

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

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 installed between valve body and pipe assembly.

ROUND MOTOR WASHER SYSTEM

Description

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 Figure 2-62, 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.

When the cam-follower moves in the direction indicated by the arrow in Figure 2-62, the cam-follower pin, which extends thru the piston actuating plate, pulls the actuator plate away from the valve

C A M FOLLOWER PIN--,

V A L V E PLATE

TRIPLE

Fig. 2-61 -Valve Assembly

5072

Fig. 2-62-Pump Intake Stroke

WINDSHIELD WIPER SYSTEM 2-41 assembly compressing the piston spring. A s 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. 2-56).

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. 2-56).

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

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

The programming section of the pump mechanism consists of a relay, ratchet pawl, ratchet wheel, and ratchet wheel dog (Fig. 2-63).

Refer t o Figure 2-64 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 l'ock-out position.

With actuator plate in this position and the wiper running, the cam-follower pin merely moves back

\RELAY ARMATURE

ARMATURE LEG

ARMATURE

PRlNG

PAWL

OF RATCHET WHEEL

Fig. 2-63-Pump Mechanism 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.

Actuating the washer button t o obtain windshield washer pump operation starts the wiper motor and energizes the pump relay. When relay is energized, the 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 t o 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. 2-64), 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.

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. 2-63 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. 2-64).

2 4 2

WINDSHIELD WIPER SYSTEM

DIAGNOSIS CHART

ROUND MOTOR WASHER SYSTEM

APPARENT CAUSE CORRECTION

A. Inadequate quantity of washer solution

B. Hoses damaged or loose

C. Plugged screen at end of jar cover hose

D. Loose electrical connection to washer pump or wiper switch

E. Open circuit in feed wire to ratchet relay coil

F. Wiper switch defective

G. Ratchet relay coil defective

H. Washer nozzles plugged

I. Ratchet wheel tooth missing

J. Ratchet pawl spring missing

K. Defective pump valve assembly

A. Add washer solution

B. Cut short length off end of hose to insure air tight connection or replace hose

C. Clean screen

D. Check electrical connections and repair if necessary

E. Locate open circuit and repair

F. Replace wiper switch

G. Replace ratchet relay

H. Clean washer nozzles

I. Replace ratchet wheel

J. Replace ratchet pawl spring

K. Replace pump valve assembly

A. Grounded wire from ratchet relay to switch

B. Wiper switch defective

C. Ratchet wheel tooth missing

D. Ratchet wheel dog broken or not contacting ratchet wheel teeth

E. Lock-out tang broken or bent on piston actuating plate

A. Locate grounded wire and repair

B. Replace wiper switch

C. Replace ratchet wheel

D. Replace of repair ratchet wheel dog

E. Replace piston actuating plate

WINDSHIELD WIPER SYSTEM 243

REMOVAL OF WASHER PUMP FROM WIPER

MOTOR

1. Remove washer hoses from pump.

2. Disconnect wires from pump relay.

3. Remove plastic pump cover.

4. Remove attaching screws securing pump frame to motor gear box and remove pump and frame.

WASHER DISASSEMBLY

Ratchet Dog

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

Fig. 2-65-Removing Four Lobe Cam

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

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.

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

Four-Lobe Cam

shaft (Fig. 2-65).

Fig. 2-64-Ratchet Wheel-Ramp Fig. 2-66-Installing Washer to Pump

2-44 WINDSHIELD WIPER SYSTEM

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. 2-65).

Remove relay coil and terminal board assembly.

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

CAUTION: Be careful not to damage coil winding or terminals.

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.

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. 2-62).

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

Valve Assembly

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

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

Fig. 2-67-Cam Alignment Pin Installation

Assembly of Washer Pump to Wiper Motor

NOTE: Wiper motor gear must be in P A R K position

(Fig. 2-66) to assemble pump to wiper motor.

1. Remove plastic pump cover.

2. Rotate the 4-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. 2-67).

3. Position pump on wiper so that slot in 4-lobe cam fits over the gear drive pin (Fig. 2-66). Se- cure pump to gear housing and remove locator pin, temporarily connect wiring connector.

4. Turn on wiper and washer pump t o 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.

DESCRIPTION

PROGRAMMED WASHER SYSTEM

detent position t o start the cycle of operation and is immediately released.

The programmed washer system (Fig. 2-68) is used in conjunction with the demand wiper system and provides a fully automatic windshield washer cycle of operation as follows:

2. Wiper motor and washer pump start to operate.

1. The shift lever switch is depressed t o the second

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

WINDSHIELD WlPER SYSTEM 2-45 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 " o f f position to shut off the wipers after the wash cycle is completed.

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. 2-69).

2. With the three relay coils energized, the following completed circuits result almost simultaneously. a. The gear box relay switch contacts close

RATCHET RELAY 7

DEMAND RELAY

HOLDING

HOLDING hr SWITCH

HOLDING

CONTACTS "A"

LEAD

Fig. 2-68-Washer Assembly completing the feed circuit to the wiper motor windings and the motor starts operating.

SHUNT F I E L D , , , , , , , , , L

GEAR BOX RELAY

-----

#YELLOW L nTHE

T WHEEL

1 I

DEMAND

RELAY

ORANGE

1

HOLD

SW,

F I N ON 4 LOBE CAM

I

WIPER CONTROL SWITCH

SWITCH

RATCHET

RE LAY

WIPER CONTROL SWITCH

WASH BUTTON

4 6 3 5

- -- - - -

Fig. 2-69-Shift Lever Switch in Second Detent Position

2-46 WINDSHIELD WIPER SYSTEM

HOLDING

CONTACTS

OPENING HOLDIN

Fig. 2-70-Pump in Idling Position 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. 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.

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. 2-70). However, when the pump starts and the ratchet wheel is rotated one tooth, holding switch contacts "B" close providing an alternate ground for both the gear box relay coil and the washer pump demand relay coil (Fig. 2-71). The alternate ground circuit through switch contacts "B" is required'because contacts "A" are opened once

-- ---------

---

GEAR BOX RELAY

RATCHET

RE LAY

CONTACTS F I N ON

"A"

4 LOBE CAM

-i-

.PI

C - f r"?-

SHIFT LEVER SWITCH

WIPER CONTROL SWITCH

WASH BUTTON

5037

Fig. 2-71-Holding Circuit for Washer

for every revolution of the washer pump 4-lobe cam (Fig. 2-74). 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. 2-72).

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, 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. when the washer pump ratche; wheel ha; been rotated 360 follows: as a. The pump ratchet relay armature moves into a position that prevents the ratchet pawl

DEMAND RELAY7

DEMAND

WINDSHIELD WIPER SYSTEM 247 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. 2-73).

However, contacts "A" are still closed at this stage of operation. With contacts "A" still closed, the gear box relay coil is still energized completing the feed circuit to the motor windings, and 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.

NOTE: DEMAND RELAY AND HOLDING SWITCH ASSEMBLY

REMOVED I N ORDER TO SEE EXTENDED RATCHET

WHEEL RAMP

5038

Fig. 2-72-Ratchet Wheel Ramp Fig. 2-73-Ratchet Wheel Cam

2-48 WINDSHIELD WIPER SYSTEM 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.

Fig. 2-74-Four Lobe Cam e. The output shaft extends through the gear tube off center and the continuing rotation of

DIAGNOSIS

WIPER MOTOR ON CAR

NOTE: T o duplicate the various types of operation independently of the car wiring and wiper control and shift lever switches refer to Figures 2-75 and

2-76.

Preliminary Inspection

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

2. Wiper motor securely grounded.

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

DISCONNECT THESE LEADS FROM RELAY .

0- As shown , Terminals 1 & 3 connected to ground

HI SPEED- Disconnect jumper connector from No. 3 terminal.

SHUT OFF & PARK- Reconnect jumper to terminal No. 3 & disconnect it from No. 1.

4642

REGULAR WIPER OPERATION- (DEMAND RELAY DISCONNECTED - AND/OR WASHER PUMP REMOVED FROM WIPER

Fig. 2-75-Wiper Operation

WINDSHIELD WIPER SYSTEM

2 4 9

NOTE: WIPER

WASHER SHOULD START,

COMPLETE A WASH CYCLE AND AUTOMATICALLY SHUT OFF.

(WIPER SHOULD OPERATE I N "LO" SPEED)

AND GROUND

I ' ] n

TOUCH THESE

PUMP COVER. D O N O T ALLOW

OTHER.

Fig. 2-76-Wiper

Washer Operational Check

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 control switch. Check operation in all speeds and determine if wipers shut off correctly.

If wipers operate correctly

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

- proceed to step

2. Demand Wiper Operation: a. To check Demand Wiper operation, momentarily depress the shift lever switch to the first detent position. The wiper should operate,

ZOIL SOLDER CONIECTIMIS

- -- -

Fig. 2-77-Checking Procedure

SO45

2-50 WINDSHIELD WIPER SYSTEM

LAMP SHOULD LIGHT

IF HOT,

CHECK SMITCJI C W A C T S

Fig. 2-78-Checking Procedure making one complete wiping stroke and then automatically shut off. m b

I &-

LEAD T E R l r l U L

(IGN SY ON)

CHECKING I F HOLD SWITCH

CONTACTS 'A. ARE CLOSED

L A M SHOULD LIGHT

J W E R MIRE

TO G R W I D

Fig. 2-79-Checking Procedure b. If the wipers operate correctly step 3.

- proceed to c. If the wipers do not operate correctly ceed to step 4.

Rro-

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 - i: touch wiper metal. 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 Figures 2-77, 2-78 and 2-79.

If the wipers and/or washer 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

CONDITION

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

APPARENT CAUSE

CORRECTION

- -

1. Wiper motor operates correctly with wiper control switch but will not start when shift lever switch is used in either detent position.

A. Shift lever switch ground connection loose.

B. Light blue wire to shift lever switch open.

A. Check shift lever switch ground connection.

B. Check harness connectors-

Shift lever switch to wiper control switch.

WINDSHIELD WIPER SYSTEM

2-51

DIAGNOSIS CHART

DEMAND WIPER AND PROGRAMMED WASHER (CONT'D)

CONDITION APPARENT CAUSE CORRECTION

C. Shift lever switch defective.

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.

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

A. Fuse blown.

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

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. 2-76)

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

If wiper motor is still inoperative, remove motor and refer to Diagnosis Chart

Wiper

Off Car (round motor)

3. Wiper operates correctly with wiper control switch but when shift lever switch is lepressed to the first detent and released quickly, the wiper blades start out of

:he park position but pickly return to park without making a complete wiping stroke.

A. Demand relay coil open

B. Demand relay switch contacts dirty or not closing.

C. Holding contacts "A" not closing.

D. Yellow and/or orange leads not connected to demand relay or poor solder connections. checking procedure.

B. Refer to Figure 2-77 for checking procedure.

C. Refer to Figure 2-78 for checking procedure.

D. Refer to Figure 2-79 for checking procedure.

2-62 WINDSHIELD WIPER SYSTEM

DIAGNOSIS CHART

DEMAND WIPER AND PROGRAMMED WASHER (CONT'D)

CONDITION APPARENT CAUSE CORRECTION

4. Wipers will not shut off.

Blades operate through normal wipe pattern.

A. Holding switch contacts

"A" or "B" (Fig. 2-68) not opening.

B. Wire between wiper terminal

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

C. Defective wiper control or shift lever switch.

D. Wiper gear box relay coil grounded.

A. Turn ignition switch "off" 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 car wiring to washer pump and using wiper control switch re-check wiper operation through all speeds and park.

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

If the wipers d o 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 blue 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.

5. Wipers won't shut off.

Blades move up and down approximately in and out of park position and wipers have

"Hi" speed only

A. Wiper motor defective.

Shunt field open.

A. T o eliminate wiper motor leave harness connector on wiper terminals and connect terminal No. 3 to ground.

WINDSHIELD WIPER SYSTEM

2-63

DIAGNOSIS CHART

DEMAND WIPER AND PROGRAMMED WASHER (CONT'D)

A P P A R E N T CAUSE CORRECTION

If the wiper motor then has

"Lo" speed and shuts " o f f , the trouble is in the car wiring o r wiper control switch. Proceed to steps B and C.

B. Wire between wiper terminal No. 3 and wiper control switch open.

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. Wiper control switch defective.

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.

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

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

B. Defective wiper control switch.

A. Disconnect harness connector from washer pump terminals. If the washer stops pumping, the trouble is in the wiring o r 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 " o f f , trouble is in wiper control switch.

2-54 WINDSHIELD WIPER SYSTEM

DIAGNOSIS CHART

DEMAND WIPER AND PROGRAMMED WASHER (CONT'D)

CONDITION

-- -

CORRECTION

C. Washer pump defective.

Washer pump ratchet wheel not being rotated by ratchet pawl.

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 o r dog not engaging ratchet wheel teeth. Repair or replace parts as required.

7. Wipers have "Hi" speed only.

8. Wipers have "Lo" speed only and shut off correctly.

9. Intermittent operation with wiper control switch "on".

A. See item 5

A. Defective wiper control switch.

B. Black wire from wiper terminal No. 3 to wiper control switch is grounded.

C. Wiper motor defective.

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.

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. Loose wiper ground strap.

B. Wiper control switch loose

C. Loose wiring connection

A. Check ground strap for secure ground.

B. Check switch mounting for looseness and secure ground.

C. Check all wiring connections for proper engagement.

WINDSHIELD WIPER SYSTEM 2-66

DIAGNOSIS CHART

DEMAND WIPER AND PROGRAMMED WASHER (CONT'D)

CONDITION APPARENT CAUSE CORRECTION

D. Defective wiper motor. D. Remove motor and refer to

Diagnosis Chart-Wiper Off

Car (round motor).

REMOVAL OF WASHER PUMP FROM WIPER

MOTOR

1. Remove washer hoses from pump.

2. Disconnect wiring from pump relay.

3. Remove plastic pump cover.

4. Disconnect yellow wire from holding switch and green wire from demand relay.

5. Remove attaching screws securing pump frame to motor gear box and remove pump and frame.

WASHER DISASSEMBLY

1. Remove retaining ring and slide 4-lobe cam off shaft (Fig. 2-74).

2. Remove holding switch retaining screw and lift the holding switch assembly and demand relay assembly off the pump mounting surface (Fig.

2-73). Separate relay assembly from holding switch.

RATCHET WHEEL DOG-

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

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

(Fig. 2-80).

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

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

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. 2-81).

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

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.

Note position of valve assembly relative to the pump housing for reassembly purposes, then

RATCHET WHEEL CAM FOLLOWER

ARMATURE SPRING

SO40

Fig. 2-80-Pump Assembly Fig. 2-8 1-Pump Assembly

2-56

WINDSHIELD WIPER SYSTEM

Fig. 2-82-Aligning Pump to Motor remove the 4 screws that secure the valve ports to the pump housing.

NOTE: Save housing to valve body gasket reassembly.

WASHER ASSE,MBLY

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

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.

10. Install ratchet wheel dog and screw.

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

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

12. Connect wire connector to outboard connector

(one nearest to pump outlets).

13. Position 4-lobe cam over shaft and install retainer 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 .12OW to . l X " diameter pin through both holes so the drive slot in the cam will be in the proper position for the drive pin

(Fig. 2-82).

NOTE: Make sure the pump is in the free whee- ling 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.

UNDERBODY 3-1

SECTION

UNDERBODY

SUBJECT PAGE

Underbody Alignment

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

3-1

General Body Construction

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

3-1

Alignment Checking

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

3-1

Reference Point Dimensions

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

3- 1

SUBJECT

Horizontal Dimensions

Vertical Dimensions

- "F" Bodies

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

3-2

"F" Bodies

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

3-3

Horizontal Dimensions

Vertical Dimensions

- "X" Bodies ............ 3 4

"X" Bodies ................ 3 4

UNDERBODY ALIGNMENT

"F and

X"

Bodies

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 demands 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 or equivalent material). It is not advisable to use combination type primer-surfac- ers.

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 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 indicated in the upper portion of

Figure 3-1 and 3-3 are calculated on a horizontal plane parallel to the plane of the underbody. Preci- sion 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.

T o 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 DimensionsdFig. 3-1 and 3-3)

Dimensions to gage holes are measured to dead center of the holes and flush to adjacen! 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.

Fig. 3-1 Horizontal and Vertical Checking Dimensions

"F" Bodies

Horizontal Dimensions

"F" Bodies (Fig. 3-1)

Fig.

Ref. Dimension Location

Fig.

Ref. Dimension Location

A 37- 1 1 16

B 28-13/16

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 location.

(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

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

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.

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

Center of 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.

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" master 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.

OF BODY

REFERENCE POINT

FRONT OF BODY

Fig. 3-2 Side Rail at Rear Spring Shackle Bushing

Bodies

"Fa

Fig.

Ref. Dimension Location f 17-1/16 g 13-1/4

Lower horizontal surface of compartment side rail above rear axle housing.

Lower surface of compartment side rail at centerline of shackle bolt hole (see Fig. 3-2).

Vertical Dimensions " F Bodies (Fig. 3-1)

Rear edge at centerline of

1-5/16" 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 cage nut.

Compartment side rail adjacent to 11/16" master gage hole.

Horizontal Dimensions- " X Bodies (Fig. 3-3)

A 38-1/4

B

35-1/4

C 54-3/16

D 44-9/16

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 adjacent to No.

1

body mount on same side of body.

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 masters gage hole adjacent to No. . l body mount on opposite side of body.

Center of master gage hole adjacent to No. 1 body mount.

3-4 UNDERBODY

Fig.

Ref. Dimension

E 33-3/4

Fig. 3-3-Horizontal and Vertical Checking Dimensions

"X' Bodies

Location

Rear edge at centerline of No. 2 body mount bolt hole.

Center of master gage hole adjacent to No. 1 body mount and center of master gage hole in side rail on opposite side of body.

Center of master gage hole adjacent to No. 1 body mount and center of master gage hole in side rail on same side of body.

Fig.

Ref. Dimension Location

J 66-3/8 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).

K 42-5/8

L 41-15/16

Between inboard lower edges of compartment side rails on centerline of shackle bolt hole (see Fig. 3-4).

Center of rear bumper lower attaching bolts.

Between centers of master gage holes in compartment side rails.

Center of master gage hole in side rail and a point at inboard edge of same side rail at centerline of shackle bolt hole

(see Fig. 3-4).

Vertical Dimensions- " X Bodies (Fig. 3-3)

a 10-1/8 7/8" hole in lower surface of rail approximately 2" rearward of lower front edge of rail.

UNDERBODY

3-6

Fig.

Ref. Dimension Location b 10-15/16

11-13/16

d

6-21/32 e 6-7/16 f 12-7/32 g

10-5/16

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.

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

(see Fig. 3-4).

Q OF BODY

FRONT OF BODY

Fig. 3-4-Side Rail at Rear Spring Rear Shackle Bushing

("X' Bodies)

STATIONARY GLASS 4-1

SECTION 4

INDEX

SUBJECT PAGE

Adhesive Caulked Glass

Description

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

4-1

.................................................... 4-1

Identification of Stationary

Glass Adhesive Material .......................... 4-1

Adhesive Service Kits

Removal

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

4-2

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

4-2

Installation (Short Method)

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

4 4

Installation (Extended Method)

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

4-6

SUBJECT PAGE

Back Window and Rear Quarter

Window Installed with Butyl

Rubber Tape Adhesive ................................ 4-1 0

Waterleak Correction .................................... 4-1 0

Bonded Rear View Mirror Support

Description

.............. 4-1 1

.................................................... 4-1 1

Installation .................................................... 4-1 1

Removal ........................................................ 4-1 2

ADHESIVE CAULKED GLASS

DESCRIPTION

The windshield and back window on all styles are bonded to body opening with one of two synthetic, self-curing, rubber adhesive material - (1) Polysulfide

Adhesive or (2) Urethane Adhesive.

To replace a window installed with either of these materials requires either partial or complete replacement of adhesive material. 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 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. materials will be available through service parts systems for service glass replacements.

1. Glass Adhesive Kit - Part No. 4226000 (Sili- cone) or equivalent to be used only for replacement of a glass installed with production polysulfide adhesive or silicone adhesive. Do not use a Silicone Adhesive Kit for replacement of a glass installed with Urethane adhesive material.

2. Glass Adhesive Kit

Part No. 8707000 (Ure- thane) or equivalent can be used for replacement of a glass installed with production polysulfide adhesive or urethane adhesive

DO NOT use

Urethane Adhesive kit for replacement of a glass installed with service silicone adhesive unless all silicone adhesive is removed from body glass opening and body glass sealing surface is primed.

NOTE: Since each service glass adhesive kit has a specific application depending on the type of adhesive material previously installed, it is necessary that the original adhesive material in the body be identified as polysulfide, urethane or silicone.

The "extended method" is required when the original adhesive material 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 adhesive material and body metal. In these cases, original material is removed and replaced with fresh material during window installation.

Two different production adhesives are used, Poly- sulfide (also used in prior model years) and Urethane

(a one-part material). Two different service adhesive

IDENTIFICATION OF STATIONARY GLASS

ADHESIVE MATERIAL

The following method should be used to identily stationary glass adhesive.

1. Cut a small piece of excess adhesive from glass or opening.

4-2 STATIONARY GLASS

2. Stick small piece of sealant on end of knife or wire; then, hold sealant over match or lighter flame until it ignites.

Polysulfide

- burns with a clear flame with very small amount of white smoke or no smoke

- odor is very objectionable (heavy sulfur dioxide).

Urethane

- burns with a dirty flame and emits a black smoke

- very little odor.

Silicone

- glows with little or no flame; emits white smoke and very little odor - bum resi- due is ash white.

ADHESIVE SERVICE KITS

Adhesive Kit No. 4226000 (Silicone Adhesive) or equivalent and Kit No. 8707000 (Urethane Adhe- sive) or equivalent contain some of the materials needed to remove and replace an adhesive installed glass. These kits can be obtained through service parts systems as well as other materials that may be required.

The components of glass adhesive kit (Urethane) No.

8707000 or equivalent are as follows:

1. One tube of adhesive Urethane material.

2. One dispensing nozzle (cut for "short method" but can be notched-out for "extended method").

3. One cap for sealing partially used tube of adhesive material.

4. Steel music wire.

5. Adhesive primer for priming glass sealing surface.

Additional material required for installing glass with

Adhesive Kit (Urethane) No. 8707000 or equivalent:

Caulking gun

- standard household cartridge type. Plunger disc should be no wider than 1-3/4 inches.

Two pieces of wood for wire handles.

Black weatherstrip adhesive.

Two rubber glass side spacers.

Lower support spacers - for back window and quarter glass "short and extended method" installations.

The components of glass adhesive kit (Silicone) No.

4226000 or equivalent are as follows:

One tube of adhesive Silicone material.

One dispensing nozzle (cut for "short method" but can be notched-out for "extended method").

Steel music wire (.020 diameter).

Adhesive Primer (for priming original adhesive material in window opening).

Additional material required to install glass with

Adhesive Kit (Silicone) No. 4226000 or equivalent:

1. Caulking gun - standard household cartridge type reworked as follows:

A. Widen end-slot to accept dispensing end of adhesive material tube.

B. Reduce diameter of plunger disc on rod so that disc can enter large end of adhesive material 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. Two rubber glass side spacers.

6. Lower support spacers

- for "short and extended method" installations.

NOTE: When glass is originally installed, a rubber sealing strip "dam" is used around edges of window to prevent excessive squeeze-out of adhesive 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.

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 material remains on window opening to serve as a base for replacement glass. Also, make certain that glass lower support spacers are not disturbed.

STATIONARY GLASS 4 3

Place protective coverings around area where glass is being removed.

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 Ex- terior Molding Section 16.

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 adhesive material at edge of glass; then, secure that end of wire to another wood handle (Fig. 4-1).

Fig. 4-2-Electric Hot-Knife Removal Method

6. With aid of helper, carefully cut (pull wire) through adhesive material around entire perimeter 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 material 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

(not recommended on some styles due to inac- cessibility at lower corners of windshield glass), and (2) pulling cutting wire through upper and

Fig. 4-1-Cutting Adhesive Material Fig. 4-3-One Man Wire Removal Method

4-4 STATIONARY GLASS lower edges of glass simultaneously. For latter optional method, insert one end of wire through adhesive material at inner upper edge of glass and other end of wire through adhesive material ends outside of body (Figs. 4-2 and 4-3).

7. If original glass is to be reinstalled, place it on a protected bench or holding fixture; remove old material using a razor blade or sharp scraper.

Any remaining traces of adhesive material can be removed with denatured alcohol or lacquer thinner dampened cloth.

CAUTION: 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. DO NOT use a petroleum base solvent such as kerosene or gaso- line. The presence of oil will prevent adhesion of new material.

NOTE: Prior to installation of glass with either

"short" or "extended" method DETERMINE if original adhesive material is SILICONE, PO-

LYSULFIDE or URETHANE, as previously described; then, proceed with the installation procedure and Glass Adhesive Kit specified for use with that original adhesive material.

INSTALLATION-"Short" Method

The "short" method of glass installation can be used if original adhesive material remaining on window opening flanges after glass is removed can serve as a base for replacement glass. If there is substantial loss of adhesion between adhesive material and body metal, or window opening must be reworked or refin- ished, "extended" method of replacement will be required.

"Short" Method URETHANE Adhesive Glass

Installation

NOTE: For use with Urethane Adhesive Kit No.

8707000 or equivalent, use ONLY where

ORIGINAL adhesive material is POLYSUL-

FIDE or URETHANE.

1. Position glass in the window opening. If new glass is being installed, check relationship of glass to adhesive material on pinchweld flange.

Gaps in excess of 1/8" must be corrected by shimming or by applying more adhesive material than specified in Step 6. For further alignment of glass refer to Step 5 of "extended" method using urethane adhesive.

Cement a rubber spacer between both right and left side of glass and body pillar to assure that glass will remain centered in opening while

2. 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 with tape on body to guide window into desired position.

3. Remove glass from opening and place on a protected bench or holding fixture. Masking tape may be applied

to

inside of windshield glass 114" inboard from edge of glass, along

top

and sides of glass,

to

facilitate clean-up after installation.

4. Using a clean lint free cloth dampened with denatured alcohol or lacquer thinner, thoroughly clean inside edge surface of glass

to

remove any oil film or foreign material from glass.

5. Using applicator apply adhesive glass primer

(furnished in Kit No.

114" wide around inside edge surface of glass and around edge of glass. Allow primer

to

dry a minimum of

6. While glass primer is drying, inspect reveal molding retaining clips. Replace or reshape clips which are bent away from body metal 1/32" or

N O Z Z L E I N KIT

A D H E S I V E

C A U L K I N G M A T E R I A L

T A P E x

F R O M E D G E

Fig. 4-4-Adhesive Material Application-Short Method

STATIONARY GLASS 4 5

Fig. 4-5-Glass Installation more. Inspect original adhesive material, if any dirt or foreign material is on cut surface of adhesive material wipe off with a damp or wet cloth.

7. Apply smooth continuous bead of adhesive material (urethane) around entire inside edge of glass. Material should be 1/8" to 3/16" in diameter (Fig. 4-4).

NOTE: Due to curing characteristics of urethane adhesive material, glass installation should be completed within 30 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 carrying devices. As shown in

Figure 4-5, carry 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 2, carefully position glass in window opening. When installing windshield glass, 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" adhesive material. Use care

to

avoid excessive squeeze-out which would cause an appearance problem If clean-up masking tape was applied t o inside of glass, carefully remove tape.

11.

Watertest car immediately using warm

or

hot water spray. Do not direct hard stream of water a t fresh adhesive material. If any leaks are encountered, paddle-in extra adhesive material a t leak point using a stick

or

flat- blade tool.

12. Install window reveal moldings and install remaining parts.

"Short" Method SILICONE Adhesive Glass

Installation

NOTE: For use with Silicone Adhesive Kit 4226000 or equivalent, use ONLY where ORIGINAL adhesive material is SILICONE or POLYSULFIDE.

1. Inspect reveal molding retaining clips. Replace or reshape 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 material on pinchweld flange.

Gaps in excess of 1/8" must be corrected by shimming or by applying more adhesive material than specified in Step 7. For further alignment of glass refer to Step 8 of "extended" method using silicone adhesive.

Cement a rubber spacer between both right and left side of glass and windshield pillar to assure that glass will remain centered in opening while adhesive material in curing.

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 with tape on body to guide window into desired position.

4. Using clean lint-free cloth liberally dampened with Adhesive Primer (furnished in Kit No.

4226000 or equivalent) and 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.

CAUTION: Use care so as not to spill or drip primer on painted or trimmed surfaces.

5.

Masking tape may be applied

to

inside of windshield glass 114" inboard from edge of glass, across top and down each side,

to

facilitate clean-up after installation.

4-6 STATIONARY GLASS

Wipe surface of glass to which adhesive material will be applied (around edge of inside surface) with a clean, water- dampened cloth. Dry glass with clean cloth.

Apply smooth continuous bead of adhesive material (silicone) around entire inside edge of glass. Material should be 1/8" to 3/16" in diameter (Fig. 4-4).

NOTE: Due to fast curing characteristics of silicone adhesive material, glass installation should be completed within 15 minutes from start of application of material to glass.

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 carrying devices. As shown in

Using tape guides applied in Step 3, carefully position glass in window opening. When installing windshield glass, guide outer lower surface of glass along rear edge of front fenders, making certain glass is properly centered and positioned on lower metal supports.

Press glass firmly t o "wet-out" and "set" adhesive material. Use care t o avoid excessive squeeze-out which would cause

an

appearance problem. If clean-up masking tape was applied to inside of glass carefully remove tape.

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 and install remaining parts.

INSTALLATlON-"Extended" Method

If adhesive 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.

"Extended" Method URETHANE Adhesive Glass

Installation

NOTE: For use with Urethane Adhesive Kit No.

870700 or equivalent, use ONLY where ORIGI-

NAL adhesive material is POLYSULFIDE or

URETHANE.

1. Using sharp scraper or chisel, remove MAJOR portion of old adhesive 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.

2. Using black weatherstrip adhesive or urethane adhesive material, cement flat rubber spacers

No. 4459429 or equivalent to window opening pinchweld flanges. As shown in Figure 4-6, location "B", spacers should be positioned to provide equal support around entire perimeter of glass. Figure 4-6, location "A", illustrates rectangular spacers positioned in typical back window installation.

The following rubber spacers are available as service parts.

A. Part No. 4459429 or equivalent (.20 x -63 x

1.0) stand off spacers for maintaining glass

3/16" from body opening

- see location "B",

Figure 4-6.

B. Part No. 7694478 or equivalent (.34 x .44

.75) lower and side support spacers - see locations "A" and "C", Figure 4-6.

C. Part No. 9848544 or equivalent (.52 x .44 x

.75) lower and side support spacers

- see locations "A" and "C", Figure 4-6.

D. Part No. 9842329 or equivalent (.75 x .44 x

.75) lower and side support spacers

- see locations "A" and "C", Figure 4-6.

CAUTION: If weatherstrip adhesive is used, apply sufficient material to obtain watertight seal beneath spacer, however, DO NOT allow excessive squeeze-out. Weatherstrip adhesive is not comvatible with revlacement adhesive material and waterleaks may develop at locations where these two materials are used together to form seal.

3. With aid of helper, lift replacement glass into window opening. On back window installations

-- --

' A ' LOCATION

WINDSHIELD

' A ' L O C A T I O N

BACK W I N D O W

'B' L O C A T I O N

A762

Fig. 4-6-Glass Spacer Installation 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 4.

4. 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 (see Fig. 4-5).

Quarter window glass can be installed in same manner.

5. With glass positioned in opening, check relationship of glass to pinchweld flange around entire perimeter. Overlap of pinchweld flange should be equal with minimum overlap of 3/16". Over- lap 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.

6. 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 stay- ing between these limits, correction can be made by any one of the following methods: a. Reposition flat spacers. b. Apply more adhesive material than is speci-

STATIONARY GLASS 4 7 fied at excessive gap areas. Material can be applied to pinchweld flange or by allowing bead on glass to exceed 3/8" height at gap areas. c. Change glasses

- another glass may fit opening better. d. Rework pinchweld flange.

7. 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.

Cement a rubber spacer between both right and left side of glass and windshield pillar (see location "C", Fig. 4-6) to assure that glass will remain centered in opening while adhesive material is curing.

8. Remove glass from opening and place on a protected bench or holding fixture. Masking tape may be applied to inside of windshield glass 114" inboard from edge of glass, along top and sides of glass, to facilitate clean-up after installation.

Using a clean lint free cloth dampened with denatured alcohol or lacquer thinner, thoroughly clean inside edge surface of glass to remove any oil film or foreign material from glass.

FOR EXTENDED M E T H O D , ENLARGE

N O Z Z L E BY C U T T I N G - O U T MATERIAL

W I T H I N SCORE LINES

M A S K I N G TAPE

. "

f

3 / 8 " -

3 / 1 6 "

MATERIAL

2761

Fig. 4-7-Adhesive Material Application

Extended Method

4 8 STATIONARY GLASS

Using applicator apply adhesive glass primer

(furnished in Kit No.

114" wide around inside edge surface of glass and around edge of glass. Allow primer to dry a minimum of

While glass primer is drying, inspect reveal molding retaining clips. If upper end of clip is bent away from body metal more than 1/32", replace or reform clip.

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 4-7. Do not notch nozzle beyond score lines.

With caulking gun and nozzle positioned as illustrated in Figure 4-7, carefully apply smooth continuous bead of adhesive material 3/8" high by 3/16" wide at base completely around inside edge of glass.

NOTE: Urethane adhesive material begins to cure after thirty minute exposure to air; therefore, install glass in opening as quickly as possible.

Using tape guides applied in Step 7, carefully position glass in window opening. When installing windshield glass, guide lower outer surface of glass along rear edge of front fenders to avoid smearing fresh adhesive material on instrument panel (Fig. 4-5). Make certain glass is properly aligned to tape guides on pillars, and positioned on lower metal supports.

Press glass firmly to "wet-out" and "set" adhesive material. Use care to avoid excessive squeeze-out which would cause an appearance problem. If clean-up masking tape was applied t o inside of glass, carefully remove tape.

Watertest car immediately using warm or hot water spray. Do not direct hard stream of water a t fresh adhesive material. If any leaks are encountered, paddle-in extra adhesive material at leak point usilig a stick or flat- blade tool.

Install window reveal moldings and install remaining parts.

NOTE: The curing time of urethane adhesive material can be accelerated by applying moderately hot water over adhesive material.

"Extended Method SILICONE Adhesive

Installation

NOTE: For use with Silicone Adhesive Kit

4226000 or equivalent, use ONLY where

ORIGINAL adhesive material is SILICONE or

POLYSULFIDE.

1. Remove screw-retained lower glass supports

(windshield only).

2. Using sharp scraper or chisel, remove MAJOR portion of old adhesive 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 material, cement flat rubber spacers No.

4459429 or equivalent to window opening pinchweld flanges. As shown in Figure 4-6, location "B", spacers should be positioned to prov- eide equal support around entire perimeter of glass.

CAUTION: If weatherstrip adhesive is used, apply sufficient material to obtain watertight seal beneath spacer, however, DO NOT allow excessive squeeze-out. Weatherstrip adhesive is not compatible with replacement adhesive 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 sukion cups to position glass in opening. The windshield glass can be positioned without aid of carrying devices as described in

Step 7 (Fig. 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.

STATIONARY GLASS 4 9

8. With glass positioned in opening, check relationship of glass to pinchweld flange around entire perimeter. Overlap of pinchweld flange should be equal with minimum overlap of 3/16". Over- lap 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.

The following rubber spacers are available as service parts.

A. Part No. 4459429 or equivalent (.20 x .63 x

1.0) stand off spacers for maintaining glass

3/16" from body opening - see location "B",

Figure 4-6.

B. Part No. 7694478 or equivalent (.34 x .44 x

.75) lower and side support spacers

- see locations "A" and "C", Figure 4-6.

C. Part No. 9848544 or equivalent (.52 x .44 x

.75) lower and side support spacers - see locations "A" and "C", Figure 4-6.

D. Part No. 9842329 or equivalent (.75 x .44 x

.75) lower and side support spacers - see locations "A" and "C", Figure 4-6.

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 stay- ing 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 3/8" height at gap areas. c. Change glasses

- another glass may fit opening better. 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 installations, 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.

4-7).

12. Using clean lint-free cloth liberally dampened with Adhesive Primer or equivalent (supplied 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.

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.

CAUTION: Use extreme care to avoid spilling ei-. ther 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 designkd for "short" method. For "extended" method, enlarge nozzle opening by removing material within score lines as indicated in Figure 4-7. Do not notch nozzle beyond score lines.

14. Wipe surface of glass to which bead of adhesive 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 4-7, carefully apply smooth continuous bead of adhesive material 3/8" high by 3/16" wide at base completely around inside edge of glass.

NOTE: Adhesive 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 material on instrument panel (Fig. 4-5). Make certain glass is properly aligned to 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 frksh adhesive material. Allow water to spill over edges of glass.

If waterleak is encountered, use flat-bladed tool to work-in additional adhesive material at leak point.

4.10 STATIONARY GLASS

18. Install window reveal moldings. Then, carefully remove masking tape from around inner periphery of window. Pull tape toward center of glass to give a clean-cut edge to adhesive material, and to prevent excess squeeze-out material on tape from creating an aqditiorial clean-up problem.

19. Install all other previously removed parts and clean-up.

BACK WINDOW AND REAR QUARTER

WINDOW INSTALLED WITH BUTYL RUBBER

TAPE ADHESIVE

Back window and rear and rear quarter windows installed with butyl rubber adhesive should not be replaced with ordinary butyl adhesive currently available for service replacement. Butyl rubber adhesive can be identified in that it remains soft and does not cure to a rubber type material. Replacement of a back window, or rear quarter window, installed with butyl rubber adhesive, requires removal of all butyl material from the body opening; then, installing new glass by the "extended" method installation with one of the following glass adhesive service kits:

1. Glass Adhesive Kit (Urethane) Part No.

8707000 or equivalent.

2. Glass Adhesive Kit (Silicone) Part No. 4226000 or equivalent.

Refer to installation procedure specified for the glass adhesive kit being used, "Urethane" or "Silicone".

WATERLEAK CORRECTION

Description

Adhesive glass installation waterleaks can be corrected without removing and reinstalling glass.

NOTE: First determine the type of adhesive securing the glass, see "Identification of Stationary Glass Ad- hesive" in the first part of this Section (Stationary

Glass). After adhesive has been identified use the proper service adhesive to correct waterleak.

A. Glass Adhesive Kit

8707000 or equivalent)

Urethane (Part No.

- use to correct waterleaks on glass installed with Polysulfide or Ure- thane Adhesive.

B. Glass Adhesive Kit - Silicone (Part No. 4226000 or equivalent)

- use to correct waterleaks on glass installed with Silicone or Polysulfide

Adhesive.

PRIME

O P E R A T I O N A O P E R A T I O N B

FLAT STICK

WORK

INTO

JOINTS

OPERATION D

, 2 9 4

OPERATION C

Fig. 4-8-Adhesive Glass Waterleak Correction

Procedure

1. Remove reveal moldings in area of leak. In some cases, it may become necessary to remove garnish moldings or finishing.lace to locate source of leak.

2. Mark location of leak(s).

NOTE: If leak is between adhesive 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 material (see Operation "A", Fig. 4-8) at leak point and 3 to 4 inches on both sides of leak point or beyond limits of leak area.

5. If using silicone glass adhesive, use small brush to apply adhesive material primer (furnished in

Kit No. 4226000 or equivalent) over trimmed edge of adhesive material and over adjacent painted surface (see Operation "B", Fig. 4-8).

6. Apply adhesive material, as shown in Operation

"C" (Fig. 4-8), 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 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. 4-8).

8. Spray watertest to assure that leak has been corrected. DO NOT run heavy stream of water directly on freshly applied adhesive material.

STATIONARY GLASS 4-1 1

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 re-

, placement 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.

BONDED REAR VlEVV MIRROR SUPPORT

DESCRIPTION

The rear view mirror support on "B, C, D, E and F" styles is bonded to windshield glass with a poly vinyl- butyral patch, through heat induction process, at assembly plant.

Service replacement windshield glass may have rear view mirror support bonded to windshield glass as an 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 perfo;med with use of Loctite Minute-Bond Adhesive 312, 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:

Loctite Minute-Bond Adhesive 3 12 two component pack, Catalog No. 33-33, or equivalent.

Replacement rear view mirror support, Service

Part No. 983 1062, (or equivalent) or original mirror support, prepared per Steps 4 and 5 of installation procedure.

Wax marking pencil, or crayon.

Heat gun (air blower type), 250 to 350 degree range (required only if rear view mirror support must be removed).

Domestic scouring cleanser, glass cleaning solution, or glass polishing compound.

Rubbing alcohol.

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" Fig. 4-9):

A. 20 1/4" - "BV-39-47-57 and 67 styles (less

B. 20 3/4"

"BU-35-45-49-69 and "C"-37 and 47 styles.

C. 20 7/8'( - "F" styles.

D. 21 1/4" - "CV-39-49

- 23 and 33 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

Fig. 4-9).

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.

4-1 2 STATIONARY GLASS

GLASS SURFACE

WATER D A M P F N E D ASBESTO

AFTER H E A T I N G

. D I S E N G A G E M E N T

R O M G L A S S

Fig. 4-9-Locating Bonded Rear View Mirror Support on

Glass

CAUTION: If original rear view mirror support is to be re-used, 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.

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 performed 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.

8. Properly position support to its pre-marked location, with rounded end pointed upward; press support against glass for to 60 ing steady pressure against glass. After five minutes, any excess adhesive may be removed with

Fig. 4-lo-Removal of Bonded Rear View Mirror Support

From Glass 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 4-10.

CAUTION: 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 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 support may now b e prepared and installed per installation Steps 1 through 7.

FRONT END 5-1

SECTION 5

SUBJECT PAGE

Body Ventilation

Description - Non-Air Conditioned Styles .. 5-1

Shroud Center Duct High Level Air

Outlet and Door - "B-C-E" Styles

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

5-2

Low-Level Air Duct Outlet, Door and

Grille - "B-C-E" Styles

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

5-2

Shroud Center Duct High-Level Air

Outlet Door

"A" Styles

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

5-2

Shroud Center Duct High-Level Air

Outlet and Door - "F" Styles

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

5-2

High-Level Ventilation Blowers

Buick "A" Styles

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

5-3

SUBJECT PAGE

Shroud Side Finishing Panel

" A-B-C-E-F-X" Styles

................................ 5-4

Pressure Relief Valve

Description

"A-F" Styles

Hood Latch Release Cable

..........

5-6

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

5-7

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

5-7

Removal and Installation

Instrument Panel

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

5-7

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

5-8

Instrument Panel Compartment Door

Buick Styles

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

5-8

Instrument Panel Compartment Door Lock and Cylinder - Buick Styles

Instrument Panel Cover

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

- "X" Styles

5-8

..........

-5-9

BODY VENTILATION

DESCR (NON- AIR CO INDlTlON 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 equipment 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"

High-level ventilation systems include the following components:

1. High-level air outlet(s) on the instrument panel.

2. Pressure relief valves (air exhaust outlets) on rear body lock pillars.

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

Ventilating air enters the front plenum chamber through an air intake grille and/or screen. Air is

CENTER

Fig. 5- 1 -Air Duct Outlet Locations

5-2 FRONT END 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. 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 (Figs. 5- 13, 5- 14 and 5- 15). 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 flat deflection type drain valves.

SHROUD CENTER DUCT HIGH-LEVEL AIR

OUTLET AND DOOR

"B-C-E" Styles

The outlet and door are shown in Figures 5-1 and

5-2.

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.

NOTE: If the gasket becomes damaged, the duct outlet can be. sealed to the center duct panel with medium bodied sealer.

LOW-LEVEL AIR DUCT OUTLET, DOOR AND

GRILLE

"B-C-E" Styles

To remove grille from air duct outlet, remove grille to air outlet attaching screw(s). The left grille is re-

Fig. 5-3-Low-Level Air Outlet Grilles tained by one screw and the right grille by two screws

(Fig. 5-3). Disengage grille from retaining tabs on outlet and remove grille. To install, reverse removal procedure.

To remove air outlet door, remove grille as previously described, remove control cable to door crank retainer and disengage control cable from crank (Fig.

5-4). Disengage crank end of door from snap-in slot of air outlet and remove door. To install, reverse removal procedure.

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 outlet to duct opening with medium bodied sealer.

LEFT"

(LO W-LEVEL)

CENTER .

(HIGH-LEVEL)

Fig. 5-2-High-Level and Low-Level Air Outlets and Doors

"B-C-En Styles

SHROUD CENTER DUCT HIGH-LEVEL AIR

OUTLET DOOR

"A" Styles

The door and control cable attachment is illustrated in Figure 5-5.

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.

SHROUD CENTER DUCT HIGH-LEVEL AIR

OUTLET AND DOOR

"F" Styles

The air duct outlet, door and control cable attachment is illustrated in Figure 5-6.

- ---

FRONT END 5-3

Fig. 5-4-Low-Level Air Outlet Control Cables

The door can be removed by removing retaining clip

(Fig. 5-6) removing control cable from retaining clip 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.

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.

(

L O W E R V E N ~

HIGH-LEVEL VENTILATION BLOWERS

Buick

"A" Styles

The power ventilation option, available on some

Fig. 5-5-Shroud Center Duct High-Level Air Outlet Door

"A" Styles

5-4 FRONT END

Fig. 5-6-Shroud Center Duct High-Level Air Outlet and Door

"F" Styles

Buick "A" styles, consists of blower assemblies on each side of the body which provide upper-level ventilation at low 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.

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.

Removal and Installation

1. Remove shroud side finishing panel.

2. Unplug electrical wiring, disengage wiring grommet, and remove screw securing ground wire (Fig. 5-7).

3. Remove sheet metal screw securing lower support of blower housing.

SHROUD SIDE FINISHING PANEL

"A-F-B-C-E and

X

Styles

On "A-F-X" styles, the shroud side finishing panel is designed with an integral air duct outlet and hinge pillar pinchweld finishing lace. The following are added to the finishing panel before installation: air outlet door and upper and/or lower vent control cables. The attaching flanges of the panel must be sealed to the contacting panel. If the original seal is damaged or disturbed, apply medium bodied sealer around the attaching flanges (Fig. 5- 12). The finishing panel is secured by screws at the side panel. A

FRONT END

5-5

Fig. 5-7-High-Level Ventilation Blowers

Buick "A" Styles

1 . Left Blower Location

2. Right Blower

Location

3. Blowers Before

Installation

4 . Upper Support

Attaching Studs

5 . Lower Support

6. Grommet

7. Motor Ground

8. Electrical Connector

9. Front Plenum

Chamber

U P P E R 6 LOWER L E V E L

VENT S Y S T E M CONTROL

3211

Fig. 5-8-Shroud Side Finishing Panel

"A" Styles

RELEASE CABLE

SECTION A - A

Fig. 5-9-Shroud Side Finishing Panel

"B-C-E" Styles

5-6 FRONT

END

INTEGRAL-

FINISHING

LACE

ATTACHING

SCREWS

Fig. 5-10-Shroud Side Finishing Panel

"F" Styles snap-in type grille completes the installation on the

"A-X" styles. The grille on the gral part of the finishing panel.

"F" style is an inte-

Removal of the low-level air duct door and/or upper and lower vent control cable requires removal of the finishing panel. (Figures 5-8, 5-9, 5-10 and 5- 1 1 de- pict 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. 5-9).

PRESSURE RELIEF VALVE- "A-B-C-E-F" Styles

On all styles with high-level ventilation systems, pressure relief valves are attached to rear lock pillars with screws. Figures 5-13, 5-14 and 5-15 show the pressure relief valve installations.

G R I L L E

Fig. 5-1 1-Shroud Side Finishing Panel

"X" Styles

3 2 1 4

FRONT END 5-7

N T R O L C A B L E

T O R E M O V E

DOOR

Pusn "DOWN-

Fig. 5-12-Shroud Side Finishing Panel Sealing

"A-F-X'

Styles

- - -

Fig. 5-1CPressure Relief Valve

"F' Styles

2 DOOR STYLES 4 DOOR STYLES GASKET

4 DOOR STYLES

0 2 STYLES 4673

#///

Fig. 5-15-Pressure Relief Valve

"B-C-En Styles Fig. 5-13-Pressure Relief Valve

"A" Styles

HOOD LATCH RELEASE CABLE (REAR SECTION) "6-C-E"

STYLES

DESCRIPTION

The rear section of the hood latch release cable 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.

5-8 FRONT END

Fig. 5-16-Hood Latch Release Cable

2. Remove sealing grommet from dash panel and remove grommet from cable.

3. Remove left shroud side finishing panel, including cable assembly, sliding control cable through hole in dash panel.

4. Disengage control assembly housing from s n a p 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 Syles

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 lnstallation

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- Buick 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 (Fig. 5-17). Alternate retainer position, 3 o'clock position, may be obtained by rotating lock cylinder (key inserted) to locked position (Fig. 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 screwdriver or other suitable tool into lock escutcheon, unscrew and remove lock case assembly.

lnstallation

1. 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. T o install lock cylinder, depress cylinder retainer and insert key.

4. Push lock fork bolt to latched position. Align

FRONT END

6-9

SECTION A - A

Fig. 5-17-Instrument Panel Compartment Door Lock and

Cylinder

Buick Styles

1. Door

2. Fork Bolt

3. Lock Case View Slots

4. Washer

5. Escutcheon

6. Retainer

7. Lock Cylinder

8. Unlocked Position

Q. Locked Position

10. Locating Tang cylinder tumblers with lock case view slot. Push cylinder assembly, key installed, into lock case.

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.

CAUTION: Failure to unlatch fork bolt could result in damage to striker and/or lock if door is closed.

SECTION B - B

Fig. 5-18-Instrument Panel Cover

'X' Styles

2 9 4 0

INSTRUMENT PANEL COVERS

" X 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 assemblies. 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.

DOORS 6-1

SECTION 6 DOORS

SUBJECT PAGE

FRONT A N D REAR DOORS

Introduction

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

Weatherstrips

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

Door Bottom Drain Hole Sealing Strip

Inner Panel Water Deflectors

......

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

Door Window Belt Sealing Strips

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

Side Roof Rail Weatherstrip Adjustment

....

Side Roof Rail Weatherstrip and Retainer

Specified Body Opening Clearance

Tolerances

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

Spring Clips

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

Outside Handles

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

Lock Strikers All Styles

Electric Lock Solenoid

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

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

Window Regulator Electric Motor-All

Styles

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

Hardware Lubrication

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

FRONT DOORS

Description-All Styles

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

Door Hinges-All Except "X" Styles

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

Door Removal and Installation-All Except

"X" Styles

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

Hinge-Removal

Option- Except "X" Styles

Hinge-Removal .

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

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

Power Option

Door Hinges .

Door-Removal

Hinge-Removal

Door-Installation .

Hinge-Installation .

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

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

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

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

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

Inside Locking Rod .

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

Lock Remote Control and Connecting Rod

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

Lock Assembly .

Lock Cylinder Assembly

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

All Styles

..........

Mirror, Door Outside Remote Control

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

Mirror, Door Outside-Standard Mirror

Inner Panel Cam .

......

"A, B, C and E" Two Door Hardtop and

Convertible Styles

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

Ventilator Regulator

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

Ventilator Assembly .

....

Ventilator Assembly

Window Assembly

Styles

....... .-

..........

"X" Styles

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

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

SUBJECT PAGE

Window Assembly

Styles

.............. 6-53

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

6-54

Window Assembly

Hardtop and Convertible Styles

Window Assembly .

......

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

6-57

6-58

Styles

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

Window Assembly .

6-61

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

6-64

Window Regulator-Manual-"A and X"

Closed Styles

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

6-67

Window Regulator-Electric-"A" Closed

. Styles

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

Window Regulator-Manual and

6-67

Electric-"A-39" Styles

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

6-67

Window Regulator-Manual and

Electric."A. B. C and E" Two Door

Hardtop and Convertible Styles

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

6-68

Window Regulator-Manual-All "B and C"

Four Door Styles

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

6-68

Window Regulator-Electric-A11 "B and C"

Four Door Styles

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

6-68

Window Regulator-Manual and Electric-"F"

Styles

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

6-68

Window Rear Guide-"A-39" Styles

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

Window Guide Tube.I1A. B. C and E" Two

6-68

Door Hardtop and Convertible Styles

........

Hardtop Styles

6-69

Window Front Guide-"B and C" Four Door

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

6-69

Window Rear Guide-"B and C" Four Door

Hardtop Styles

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

6-69

Window Rear Guide-"B" Closed Styles.

......

Window Upper and Lower Sash Guide

6-69

Assembly .

Hardtop and Convertible Styles

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

6-69

Window Front Guide-"F" Styles

Window Rear Guide-" F" Styles

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

6-69

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

6-70

Styles

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

6-70

Door Wedge Plates-"67" Styles

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

6-70

REAR DOORS

Description-All Styles

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

Rear Door Hinges-All Styles

6-71

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

6-71

Lock Remote Control-All Styles

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

6-84

Lock Assembly-All Styles

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

6-84

Inner Panel Cam-"A-39" and "B-35-45 and 69" Styles

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

6-86

Window Assembly-" A" Closed Styles

..........

6-86

Window Assembly-"A-39" Styles

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

6-87

6-2 DOORS

SUBJECT PAGE

Window Assembly-"B" Closed Styles

..........

Window Assembly-"B and C" Four Door

Hardtop Styles-Except 68169 Style

Window Assembly-68169 Style

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

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

Window Stationary Ventilator Division

Channel-"X-69" Styles

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

Window Stationary Ventilator Assembly

-"X-69" Styles

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

Window Assembly-" X-69" Styles

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

Window Regulator-Manual-"A" Styles

........

Window Regulator-Electric-"A" Styles

........

Window Regulator-Manual and Electric

"B" Closed Styles

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

Window Regulator

Manual and Electric

-"B-C" Four Door Hardtop

Styles-Except 68169 Style

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

SUBJECT PAGE

Window Regulator-68 169 Style

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

6-98

Window Regulator-Electric Motor Removal

- All Styles

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

Window Regulator-"X-69" Styles

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

6-98

Window Front Guide and Bracket Assembly

"A-39" Styles

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

Window Rear Guide

"A-39" Styles

..........

6-98

Window Center Guide Cam-"B-C"

Four Door Hardtop Styles-Except

68 169 Style

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

6-99

Window Guide Tube-68 169 Style

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

6-99

Window Lower Sash Upper and/or Lower

Guide Assembly-68 169 Style

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

6-99

Window Glass Run Channel-"A-B and X"

Closed Styles

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

6-99

FRONT AND 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". beltline and down the front door hinge pillar.

To disengage nylon fasteners from door panel piercings use tool J- 21 104 equivalent (Fig. 6-1). This tool

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 weatherstrips. Items which are peculiar to front or rear doors are 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.

R E T A I N E R

\ A

FRONT AND REAR DOOR WEATHERSTRIPS

Description

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 openings from water entry (Fig. 6-1). On closed styles, nylon fasteners are used below the beltline only. Weather- strip adhesive retains the weatherstrip around the door upper frame (Fig. 6-2). On all styles, in addition to the fastener, weatherstrip adhesive is used a t the Fig& l-Door Weathentrip Removal

DOORS 6-3

A =BLACK WEATHERSTRIP ADHESIVE

SECTION 8 - 8

Fig. 6-2-Door Weatherstrip

All Styles permits removal of the weatherstrip without damaging the serrations on the fasteners so that the weatherstrip can be reinstalled if desired. Although a replacement door weatherstrip will include nylon fasteners, individual fasteners are also available as service parts.

Removal

1. 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).

2. Use a flat-bladed tool to break cement bond between door and weatherstrip. A tool applicable to this usage can be fabricated from tool 5-21 104 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 adhesive completely around door upper frame

(Fig. 6-2).

3. On all styles, use tool 5-21 104 or equivalent to disengage weatherstrip from door where weatherstrip 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.

Fig. 6-3-Door Weatherstrip - Hardtop Styles

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: 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 styles, apply weatherstrip adhesive between door and weatherstrip outboard surface at the follow-

. - ing locations:

LOCK C O N N E C T I N G R O D

CLIP ENGAGED CLIP'DISENGAGED

Fig. 6-4-Weatherstrip Removal Tool

6 4 DOORS 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.

CAUTION: 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

STRIPS

Description

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).

Removal and Installation

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.

Description

Waterproof deflectors are 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 comers. Whenever work is performed on 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

(refer to Fig. 6-6). For service sealing, body caulking compound or stip 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.

V I E W I N CIRCLE " A "

3102

Fig. 6-5-Door Bottom Drain Hole Sealing Strips

Released by: www.78ta.com

Serial Number: 72BDY-001-1009

Fig. 6-6-Door Inner Panel Sealing

DOORS

6-5

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)

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. 6-9, carefully break sealer bond between water deflector and door inner panel down both sides of deflector. Make certain tool blade 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 comers of water deflector. Disen- gage 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.

5. On styles with door inner panel hardware 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. 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.

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 Fig- ure 6-7.

NOTE: To fabricate strip assembly removal tool, make a 1/4" wide by 3/8" deep slot in a flat-bladed headlining inserting tool (tool J-

2772 or equivalent). 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 downward. Prior to installation, re-form

6-6 DOORS

Fig. 6-7-Clip Retained Belt Sealing Strip Assembly Removal tangs on clip to assure positive retention when installed.

3. On

"F"

styles equipped with rivet retained strip assemblies, drill-out rivets. When installing new strip assemblies, use 1/8" diameter by 5/16" reach aluminum "pop" rivets or equivalent.

SlDE ROOF RAlL WEATHERSTRIP AND

RETAINER

Description

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 plastic fasteners or screws at the rear edges, except on two door hardtop styles. The sealer that retains the weatherstrip also protects against air noise and water entry between the retainer and weatherstrip.

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, Fig. 6-8).

Side Roof Rail Weatherstrip (Retainer) Adjustment

The side roof rail weatherstrip can be adjusted either

\\ \

SIDE R O O F RAIL W / S T R I P RETAINER

F R O N T A N D REAR

R O O F RAlL W / S T R I P

I E A L I N G STRIP

S E C T I O N A - A

Fig. 6-8-Side Roof Rail Weatherstrip and Weatherstrip Retainer

"Fa Styles Shown, Other Styles Similar

S E C T I O N B - 8

3 9 2 7

DOORS

8-7 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 subsequently described and loosen retainer attaching screws.

2. Adjust retainer inboard or outboard as required and replace screws. Reinstall weatherstrip qnd seal with a "pumpable" sealer.

For proper relationship of weatherstrip to door window, refer to "Front Door ,Window Adjust- ments''.

NOTE:

Major retainer adjustments will require resealing retain& to body at front upper corner of retainer as described in Step 2 of weatherstrip installation procedure (" Fig. 6-8).

If additional inboard or outboard adjustment of the retainer is required, it can be accomplished by either elongating the adjusting slots in the retainer or repositioning the retainer and drilling new attaching holes in the rail or pillar assembly.

Removal-All Styles

1. Remove plastic fasteners at front of side roof rail weatherstrip (Fig. 6-8 is typical of all styles at front hinge pillar) with tool J-21104 or equivalent.

2. On all "39,49 and 69" styles, open rear door and remove plastic fastener securing rear end of side roof rail weatherstrip to rear door lock pillar. On

"F" styles, remove screw retaining weatherstrip to rear body lock pillar (Fig. 6-8).

3. Beginning at the front body hinge pillar, carefully pull weitherstrip out of retainer while breaking sealer bond between 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 6-9 illustrates fabrication of this tool.

CAUTION: This operation must be performed carefully to prevent damaging side roof rail weatherstrip.

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 (Fig. 6-8).

Installation (All Styles)

1. Scrape off any excess sealer from weatherstrip retainer.

LOCK CONNECTING ROD

Fig. 6-9-Weatherstrip Removal Tool

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". Fig. 6-8). 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",

Fig. 6-8). 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", Fig. 6-8).

NOTE:

Replacement plastic fasteners are available as a service part.

6. After weatherstrip has been installed along length of retainer, install screw or plastic fastener at rear end of weatherstrip on styles so equipped. b

SPECIFIED BODY OPENING CLEARANCE

TOLERANCES-All Styles

Figures 6-10 through 6-14 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 1972 body styles.

6-8 DOORS

FENDER

DOOR

--I P - -

)--

FRONT 0001

AT POINT " W " IS:

SECTION THRU POINT " W "

C h e v .

5 / 4 4 " PLUS OR MINUS 1/16"

P e n t . - 3 / 3 2 " PLUS OR MINUS 1/16"

Old1. - 5 / 6 4 " PLUS OR MINUS 1/16"

0 u i c k - 5 / 6 4 " PLUS OR MINUS 1/16-

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

DOORS 6-9

FLUSH T O PLUS OR M I N U S

1 / 1 6 " RELATIONSHIP

FRO

FRONT T O REAR D O O R GAP 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

3 1 5 7

Body Opening Clearance Tolmces

'A' Body Four Door Styles

6-10

DOORS

VlEW A

FLUSH f

7/32"

Fig. 612-Specified Body O p i n g Clearance Tolerances

"B, C and E" Styles

VlEW B

DOORS 6-1 1

VlEW A

V l E W C

VIEW 0

3907

6-12

DOORS

SPECIFIED BODY OPENING CLEARANCE TOLERANCES

C h e v II Four-Omr S t y k

PEAK

2 3 / 1 6 " w l T n FENDER AND FRONT DOOR

FLUSH AT P O I N T S "C 6 D " F R O N l

D O O R S W I N G CLEARANCE

A L L O W A N C E AT PEAK IS 3 / 3 2 "

W I T H FRONT A N D REAR D O O R S FLUSH

AT P O I N T S "Y 6 W", REAR D O O R S W I N G FRONT D O O R FLUSH T O 1/16"

O U T B O A R D O F REAR D O O R AT

P O I N T S "Y 6 W "

CLEARANCE A L L O W A N C E AT PEAK I S 7 [

3 / 3 2 ' ' A N D 1/16" AT P O I N T " X "

SECTION S H O W I N G CLEARANCE

BETWEEN FENDER A N D FRONT D O O R

FRONT T O REAR D O O R G A P

S P A C I N G IS 3/16" PLUS 1 / 3 1 "

S E C I I O N S H O W I N G CLEARANCE

BETWEEN FRONT A N D REAR D O O R

Fig. 6-14-Specified Body Opening Clearance Tolerances

'X' Styles

LOCK CONNECTING ROD

----

DOORS

8-1

DOOR OUTSIDE HANDLE

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

2 7 0 8

Fig. 6- 1 5-Door Lock Spring Clip

SPRING CLIPS

Description

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.

Removal and Installation

To disengage a spring clip, use a screwdriver, or other suitable thin bladed tool, to slide clip out of engagement as shown in Figure 6-1 5. To install, reverse removal procedure.

SCREWS

2081

Fig. 6-16-Door Outside Handle Removal (Push-Button Type)

Fig. 6- 17-Door Outside Handle Removal (Lift Bar Type)

FRONT A N D REAR DOOR OUTSIDE HANDLE

ASSEMBLY-All Styles

Description

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.

Removal and Installation (Refer to Figures 6-1 6,

6-1 7 and 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", Fig. 6-42) and remove guide bracket from door. Then, working through access hole, disconnect door outside handle to lock push rod at handle assembly (Fig.

6- 173.

2. On all other styles, remove handle attaching

6-14 DOORS

Fig. 6-18-Door Outside Handle Removal

(Pull-Out Type) 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 previously described.

2. Depress retainer slightly and rotate 1/4 turn in either direction. Reinove retainer, spring. push button and shaft and sealing washer from handle

(refer to Fig. 6-19).

NOTE: "B and C" style rear door handle push buttons, springs and retainers are serviced as an assembly. The die case handle is serviced separately. Front door handle components are serviced separately as shown in Figure 6-19.

Lift-bar, "bail" pull-out and "flush" pull-out handles are serviced as an assembly.

3. To assemble, reverse disassembly procedure.

Fig. 6-19-Front Door Outside Handle

Push-Button Handles

("A and X" Styles Shown, Other Styles Similar)

FRONT AND REAR DOOR LOCK

STRIKERS-All Styles

Description

The front and rear door lock striker consists of a single metal bolt and washer 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.

Diagnosis of Alignment and Adjustments

1. To adjust striker up or down, or in or out, loosen striker bolt and shift striker as required, then tighten striker.

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 Fig- ure 6-20. c. Close door only as far as necessary for striker bolt to form an impression in clay or caulking compound as shown in Figure 6-20.

NOTE: Do not close door completely. Com- plete door closing will make clay removal v,ery 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

6-20 be strictly maintained. The following

DOORS

6-1 5 spacers are available as service parts and can be used individually or in combination to achieve the desired alignment.

1.5/64" spacer

Part 44691 96 or equivalent

("A,

F

and

X'

styles)

2.5/64" spacer - Part 98271 54 or equivalent

("0,

C

and E' styles)

3.5/32" spacer

('A, F and

Part 4469197 or equivalent

X'

styles)

4.5/32" spacer

Part 98271 55 or equivalent

("0,

C

and En styles)

5.1/4" spacer

Part 44691 94 or equivalent ('A,

F and

X"

styles)

6.5/16" spacer

("A, F and

Part 4469195 or equivalent

X"

styles)

Removal and Installation

1. Mark position of striker on body lock pillar using a pencil.

2. Insert tool 5-23457, BT-7107 or equivalent into the star shaped tool recess in the head of the

Fig. 6-20-Lock to Striker Engagement

TAPPED C A G E

PLATE

Fig. 6-21-Door Lock Striker Installation striker bolt and remove striker (refer to Fig. 6-

2 1). tain striker is positioned within pencil mark. If striker is positioned outside of pencil marks, touch-up any exposed unpainted surface on lock

~ i l l a r adiacent to striker assembly. Torque striker bolt 34-46 foot pounds.

WARNING: THE DOOR LOCI(

AN IMPORTANT ATTACHING PART IN

THAT IT COULD AFFECT THE PER-

FORMANCE O F VITAL COMPONENTS

AND SYSTEMS, AND/OR COULD RE-

SULT IN MAJOR REPAIR EXPENSE. IT

MUST BE REPLACED WITH ONE O F THE

SAME PART NUMBER OR WITH AN

EQUIVALENT PART I F REPLACEMENT

BECOMES NECESSARY. DO NOT USE A

REPLACEMENT PART O F LESSER QUAL-

ITY OR SUBSTITUTE DESIGN. TORQUE

VALUES MUST BE USED AS SPECIFIED

DURING REASSEMBLY TO ASSURE

PROPER RETENTION O F THIS PART.

CAUTION: Whenever a door has been removed and reinstalled or realigned, the door should not be closed completely until a visual check is made to determine if lock fork-bolt will correctly engage with striker.

ELECTRIC DOOR LOCK SOLENOID

Theory of Operation

The optional electric door lock system incorporates

6-16 DOORS

a solenoid for each door and a control switch for each front door, except "F" styles, which is operated by a switch located on the instrument panel. All doors lock and unlock simultaneously from the control switch(s) or manually from each door in the conventional manner. Each solenoid has an internal circuit breaker which (under extreme conditions) may require up to three minutes to reset. The door harness is routed in the power window harness conduit.

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. 6-22).

4. On rear doors, remove electric solenoid to door inner panel attaching screws and connecting rod to door inside locking rod connecting link attaching clip. Remove through access hole (Fig.

6-23).

5. To install, reverse removal procedure.

DOOR WINDOW REGULATOR ELECTRIC

MOTOR

Theory of Operation

RIC S O L E N O I D

A T T A C H I N G

Fig. 6-22-Front Door Lock Electric Solenoid Installation

Fig. 6-23-Rear Door Lock Electric Solenoid Installation

The optional power operated window system incorporates an electric motor and an independent control switch for each door and quarter window, except drivers door. The drivers door incorporates an electric motor and a master window control switch (four button) permitting window operation of all windows from drivers position. Cadillac styles incorporate a window blockout (cut out) switch which permits normal operation of power windows from all switch locations when the blockout switch located on the left front door armrest is in the normal (on) position.

When the blockout switch is in the lock position, the windows will operate only from the master control switch.

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 secured to the regulator assembly with bolts. is

Removal and Inatallation-All Styles

1. Remove door trim assembly and inner panel water deflector. Disconnect harness connector at motor.

2. Refer to Figures 6-24, 6-25,626, 6 2 7 and 6-28 and select the appropriate teinplate for locating window motor to regulator attaching bolts by using window regulator to door inner panel attaching bolts as reference points.

A L I G N T E M P L A T E W I T H A P P R O P R I A T E UPPER A N D L O W E R

LEFT R E G U L A T O R A T T A C H I N G B O L T S O N D O O R

' I O N

DOORS 6-17

4 " M O T O R

LT A C C E S S

Fig. 6-24-Window Regulator Upper and Lower Left Attaching Bolt

Reference Points for Locating Window Motor to Regulator Attaching

Bolts

"A-27 and 77" Styles

&I8 DOORS

A L I G N TEMPLATE W I T H UPPER A N D LOWER L E F T

REGULATOR 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

HOLES

L-

REGULATOR B C L T L O C A T I O N

Fig. 6-25-Window Regulator Upper and Lower Left Attaching Bolt

Reference Points for Locating Window Motor to Regulator Attaching

Bolts

'A-35, 39, 45, 55, 69" Style Front Doors

DOORS 6-18 i L I G N TEMPLATE U S I N G REFERENCE P O I N T S

"I

O R

IL"

VITH APPROPRIATE 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 1 4 " M O T O R

LT ACCESS

H O L E S

Fig. 6-26-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 Doon; "I1 for "A-37, 57, 67 and 87" Style Front Doors

6-20 DOORS

ALIGN TEMPLATE USING REFERENCE POINTS

"I,lI,

OR

IJI"

WITH REGULATOR LOWER ATTACHING BOLTS O N DOOR

OTOR

ATTACHING BOLT ACCESS

HOLES

Fig. 6-27-Window Regulator Lower Attaching Bolts Reference

Points for Locating Window Motor to Regulator Attaching Bolts: "I" for "B, C and E-1 I, 37, 47, 57 and 67" Style Front Doors; "11" for

"C-69" Style Rear Doors; "111" for "B-36, 39, 46 and 69" and "(2-49 and 69" Style Front and Rear Doors

DOORS 6-21

A L I G N TEMPLATE W I T H 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

1-11/16"-

DRILL THREE 3 / 4 "

M O T O R A T T A C H I N G

B O L T A C C E S S H O L E S

3 2 2 5

R E G U L A T O R B O L T L O C A T I O N

Fig. 6-28-Window Regulator Lower Attaching Bolt Reference

Points for Locating Window Motor to Regulator Attaching Bolts

"F* Styles

6-22

DOORS

Align regulator bolt locations specified on template with appropriate regulator attaching bolts on door. Secure template in place with a piece of tape.

Using a center punch, dimple the door inner panel at the center of each of the 3/4" holes to be drilled as indicated on the template.

Using a 3/4" hole saw, drill three 3/4" motor to regulator attaching bolt access holes as indicated.

Remove motor attaching bolts and remove motor through access hole.

NOTE:

Although ,window regulator lift arm is utlder tension of counterbalance spring, weight of window assembly prevents lift arm from moving. If necessary, window can be moved manually to clear access holes.

After replacing motor and prior to trim installation, 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 Lubri- plate 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 6-29 through 6-44 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.

FRONT DOOR HINGES All Except

" X

Styles

Description

All hinges are constructed of steel and incorporate a two stage hold-open feature in the lower hinge on "A and X" 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 6-45 illustrates typical front door bolt-on hinge installation, except for "X" 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.

Front Door Hinge Adjustment

Styles

All Except " X

Door adjustments are provided through use of floating anchor plates in door and front body hinge pillars. When checking door for alignment, and prior to 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

- up and down and fore and aft on all body styles.

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

- in and out on all body styles.

DOORS

6-23

1. Front Door Window

Assembly

2. Ventilator Regulator

Fig. 6-29-Front Door Hardware

"A' Closed Styles

3. Window Regulator

4. Ventilator Division

Channel

5. Door Lock Remote

Control

8. Window Down Stop

Support

7. Inner Panel Cam

8. Door Lock

8. Lower Sash Channel

Cam

8 2 4

DOORS

1. Window Regulator

Attaching Bolts

2. Ventilator Division

Channel Lower

Adjusting Stud

Fig. 6-30-Front Door Hardware

" A Closed Styles

3. Ventilator Regulator

Attaching Bolts

4. Ventilator Frame to

Outer Panel

Attaching Bolt

5 . Door Lock Remote

Control Attacbing

Bblts

6. Door Lock Attaching

Screws

7. Down Stop Support

Attaching Bolt

8. Ventilator to Door

Upper Frame

Attaching Screws

DOORS

6-26

1. Ventilator Regulator

2. Window ~e&lator

3. Ventilator Division

Channel

Fig. 631-Front Door Hardware

"A-39" Styles

4. Front Door Window

Assembly

6. Rear Guide

6. Inner Panel Cam

. 7. Door Lock

8. Door Outside Handle

9. Lower Sash Channel

Cam

6-26 DOORS

1. Door Lock Attaching

Screws

2. Rear Guide Lower

Attaching Bolt

3. Window Rear Upper

Stop Bolt

4. Ventilator Division

Channel Lower

Adjusting Stud and

Nut

Fig. 6-32-Front Door Hardware

"A-39" Styles

5. Rear Guide Upper

Attaching Bolts

6. Inner Panel Cam

Attaching Bolts

7. Lower Sash Channel

Cam Attaching

Screws Access Holes

8. Door Lock Remote

Control Attaching

Bolts

9. Window Regulator

Attaching Bolts

10. wind'ow Front Upper

Stop Access Hole

1 1. Ventilator Frame t o

Door Outer Panel

Attaching Bolts -

12. Ventilator Regulator

Attaching Bolts

13. Ventilator Lower

Frame Adjusting Stud and Nut

14. Ventilator "T" Shaft t o Regulator Screw

Access Hole

DOORS

6-27

1. Window Assembly

2. Stabilizer Strips

3. Trim Pad Adjusting

Plates

4. Tube Assembly,

Window Guide

5. Guide Assembly,

Lower Sash Lower

Fig. 6-33-Front Door Hardware

"A-37, 57, 67 and 87" Styles

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

Bumper

14. Handle, Door Outside

(Pull Type)

15. Retainer, Door

Outside Handle

16. Door Lock

17. Rod, Inside Locking

b28 DOORS

1. Tube Assembly,

Window Guide

Attaching Bolts

2. Guide Assembly,

Lower Sash Lower

Attaching Bolts

3. Plate Assembly,

Lower Sash Guide

Attaching Bolts

Fig. 6-34Front 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

@. Support, Front

Window Bumper

Attaching Bolt

10. Support, Rear

Window Bumper'

Attaching Bolt

1 1. 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 and

Stabilizer Strips

3. Lower Sash Channel

Cam

Fig. 6-35-Front Door Hardware

"B-69" Styles

4. Window Regulator

Handle

5. Window Regulator

6 . Remote Control and

Handle Assembly

7.' Window Down-Travel

Support and Bumper

8. Inner Panel Cam

9. Remove Control to

Lock Connecting Rod

10. Rear Guide Assembly

11. 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 t o lnner Panel

Attaching Bolts

3. Rear Guide Lower

Attaching Bolt

Fig. 6-36-Front Door Hardware

"B': Four Door Closed Styles

4. lnner 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 Attachjng

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

(RIGHT SIDE

REAR

"E" STYLES ONLY)

Fig. 6-37-Front Door Hardware

"B, C and E" Two-Door" Hardtop and Convertible Styles

1. Front Door Window

Assembly

2. Strip, Stabilizer and

Support, Trim Hanger

3. Stop, Window Front

Upper

4. Stop, Window Rear

Upper

5. Window Regulator

Electric

6. Door Lock Remote

Control and Handle

Assembly

7. Glass Bearing Plate

8. Tube Assembly,

Window Guide

Q. Door Lock

10.. Door Lock Cylinder

11. Door Outside Handle

12. Guide Assembly,

Lower Sash Lower

13. Guide Assembly.

Lower Sash Upper

14. Plate Assembly,

Lower Sash Guide

16. Support, Window

Bumper

16. Rod, Inside Locking

17. Rod, Remote Control to Lock

6-32 DOORS

Fig. 6-38-Front Door Hardware

"B, C and E 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

Anaching Bolts

4. Regulator Assembly,

Attaching Bolts

5. Guide Assembly,

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 Bolt

9. Support, Rear

Window Bumper

Anaching Bolt

10. Strip, stabilizer ~ r o n t and Trim Support

Hanger Attaching

Bolt

1 1. Strip, Stabilizer Rear and Trim Support

Hanger Attaching

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. Stabilizer Strips and

Trim Support

Hangers

3. Lower Sash Channel

Cam

4. Front Guide

Fig. 6-39-Front Door Hardware - "B and C;39 and 49" Styles and "C-69" Styles

5. Window Regulator

6. Door Lock Remote

Control

7. Inner Panel Cam

8. Rear Guide

9. Door Lock

10. Door Outisde Handle

1 1. Window Down-Travel

Support Bracket and

Bumper

12. Window Regulator

Handle

13. Inside Locking Rod

15. Remote Control to

Lock Connecting Rod

16. Window Up-Travel

Stops

6-34 DOORS

Window Rear Upper

Stop Attaching Bolt

2. Rear Guide Upper

Bracket Attaching

Bolts

3. Rear Guide to Upper

Bracket Attaching

Bolt

- -

Fig. 6-40-Front Door Hardware

"B and C-39 and 49" Styles and "C-69" Styles

4. Rear Guide Lower

Attaching Bolt

5. Window Stabilizer

Strip Attaching Bolts

6. Window Front Upper

Stop Attaching Eklt

7. Front Guide Upper

Attaching Bolts

8. Window Regulator

Attaching Bolts

9. lnnet Panel Cam

Attaching Bolts

10. Door Lock Remote

Control Attaching

Bolts

1 1. Front Guide Lower

Attaching Bolt

1 2 . Door Lock Attaching

Screws

13. Window Lower Sash

Channel Cam Stud

Nuts Access Holes

14. Door Lock Solenoid

Attaching Screws

15. Window Down-Travel

Bumper Support

Attaching Bolt

DOORS 6-36

1. Window Assembly

2. Trim Pad Hanger

Plates

3. Trim Pad Hanger

Plate and Stabilizer

Strip

Fig. 6-41-Door Hardware

"F" Styles

4. Door Outside Handle

5. Lock Cylinder

6. Lock Assembly

7. Inside Locking Rod

8. Rear Guide

9. Inner Panel Cam

10. Window Down Travel

Bumper Support

1 1. Remote Control t o

Lock Rod

12. Window Regulator

(Manual)

13. Lower Sash Channel

Cam

14. Remote Control

Handle Assembly and

Escutcheon

15. Window Regulator

Handle

18. 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. 6-42-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

9. Reir Guide Lower

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. 6-43-Front Door Hardware

- "X-27

3. Door Lock Remote

Control

4. Window Down-Travel

Stop Support

Assembly

6. Lower Sash Channel

Cam

7. Door Outside Handle

8. Door Lock

6-38 DOORS

Fig. 6-44-Front Door Hardware

"X-27 69" Styles

1. Door Lock Remote .

Control Attaching

Bolts

2. Ventilator Division

Channel Lower

Adjusting Stud

4. Door Lock Attaching

Screws

5. Door Upper Frame

Attaching Screws to

Ventilator Frame

6. Ventilator Frame to

Door Outer Panel

Attaching Bolt

7.. Window Down Stop

Support Attaching

Bolt

DOORS

6-39

Hinge Removal

All Except " X 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 (Fig. 6-45).

2. To install door, reverse removal procedure.

Prior to installation, apply coat uf 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 accomplished with the door removed and without loosening front fender.

Fig. 6-45-Typical Front Door Hinge Attachment

All Except

3. For removal or adjustment of all front door hinge to body attaching bolts, use tool J-22810

1/2" wrench (or equivalent) (Fig. 6-46).

Door Removal and Installation

All Except " X

Styles

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 SUE- ciently 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 (Fig. 6-45).

4. To install, reverse removal procedure. Adjust door as outlined in subsequent adjustment procedure.

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 (Fig. 6-45). Then, remove hinge from body.

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 subsequentyly described.

Fig. 6-46zFront Door Hinge Tool J-22810

"A, B, C, E and

F" Styles

8-40 DOORS

FRONT DOOR HINGES

"X" Styles

Description

Front door hinges on "X" 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, door side and body side hinge straps, hinge pins, bushings and

"E" rings are available as separate service parts. Ser- vice replacement hinge assemblies 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 Fig. 6-47).

DETENT IHOLD-OPEN)

LINK A_ND RIVET

DOOR REMOVAL

" X Styles

1. Remove "E" ring (snap retainer) from lower end of both upper and lower hinge pins (Fig. 6-47).

2. Disengage door hold-open spring from lower hinge assembly by prying upward against spring with a suitable prying tool (Fig. 6-48). Use care not to damage hold-open link.

WARNING: COVER SPRING WITH SHOP

TOWEL TO PREVENT SPRING FROM

"FLYING" AND POSSIBLY CAUSING

PERSONAL INJURY OR DAMAGE.

Fig. 6-48-Front Door Hinge " Hold-Open Spring" Removal

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. r

DOOR INSTALLATION

"Xu Styles

1. With aid of a helper, place door into position

IGHT SPRING LOADING POSITION

Fig. 6-47-Front Door Hinge "E" Ring Removal

LEFT SPRING

OADING POSITION

OPEN SPRING

4089

Fig. 6-49-Hold-Open Spring, Loading Positions Using Tool

(J. 23497 or equivalent)

DOORS

641

., y

\ LEFT DOOR

SCRIBE LOCATION

'OF HlNGE ON

DOOR HlNGE

PILLAR

CENTER PUNCH

UPPER AND LOWE

INBOARD CORNER

Fig. 6-50-Front Door Hinge Hold-Open Spring Installation

Using Tool (J-23497 or equivalent)

2. Using spring compressing tool (J-23497 or equivalent), install hold-open spring in lower hinge (Figs. 6-49 and 6-50).

NOTE:

When installing hold-open spring on tool

J-23497 or equivalent, position spring so that the cut end of the spring is in line with the center of the blade on the straight jaw. Figure 6-49 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.

WARNING:

BE SURE SPRING IS SEATED

PROPERLY BEFORE COMPRESSING TO

PREVENT T H E SPRING FROM SLIPPING

OUT O F THE TOOL AND POSSIBLY

CAUSING DAMAGE OR PERSONAL IN-

JURY.

DOOR SIDE HlNGE 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.

Fig. 6-51-Locating Hinge on Hinge Pillar

2. Remove door from body as previously described.

3. Center punch and scribe location of hinge on hinge pillar (refer to Figure 6-5 1).

4. Center punch visible weld marks on hinge base as shown in Figure 6-47 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.

NOTE:

When drilling out welds, drill only deep enough to penetrate hinge base to release hinge from panel as shown in Figure 6-52.

HlNGE PILLAR

REINFORCEMENT

GUIDE HOLE

HINGE BASE

DRILL THROUGH

HlNGE BASE TO

REINFORCEMENT

1/2" DRILL BIT

Fig. 6-52-Typical Weld

6-42 DOORS

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.

lnatallation

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 in and out 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.

BODY SIDE HlNGE STRAP

1. Remove door assembly from body as previously described.

2. Locate hinge position on body hinge pillar (refer to Fig. 6-53). a. Scribe location of upper and lower hinge tabs on hinge pillar. b. Measure exactly 1 -3/4" rearward from upper and lower forward flange of hinge. Center punch and drill indentation at this location into (not through) hinge pillar facing with

1/8" drill bit.

NOTE:

Drill indentation will serve as a loca-

USING CUTTING

.........

HINGE FROM UPPER

AND LOWER TAB A N

REMOVE

FTER REMOVING

M A I N PORTION,

SEPARATE WELDED

VERTICALLY CUTTIN

TABS WlTH TORCH

AS INDICATED

Fig. 6-54Body Side Hinge Strap Removal

"X" Styles tor for the replacement hinge and will not be lost during torching operation. c. Drill additional 1/8" locator at the upper and lower hinge tab immediately forward of the measured locator.

3. Protect the carpet and door sill plate area adjacent to the front body hinge pillar with asbestos sheeting.

4. Using a cutting torch, separate main portion of hinge from upper and lower tabs. After main portion has been removed, vertically cut upper and lower hinge tabs with cutting torch, as shown in Figure 6-54.

5. Mig welds holding separated hinge tabs can be broken by twisting or rotating the individual hinge tab segments with suitable tool, such as, grip type pliers, pipe wrench, etc. (refer to Fig.

6-55).

6. Dress and prepare hinge pillar facing as required for replacement hinge.

lnatallation

1. Measure 1 -3/4" rearward from upper and lower

DRILL I /

INTO HI

AT SCRl

NOT DR

4575

RIGHT FRONT

BODY HlNGE PILLAR

IBE HlNGE LOCATION

UPPER AND LOWER TAB)

SCRIBE MARK 1.314"

REARWARD FROM

UPPER AND LOWER

FORWARD HlNGE

RILL ADDITIONAL 1/8"

EPRESSlON TO LOCATE

HlNGE TO PILLAR

Fig. 6-%Locating Hinge Position on Body Hinge Pillar

"X' Styles

EPARATED HlNGE

TABS MAY BE

REMOVED BY

TWISTING TABS WITH

WRENCH OR HAMMER

AND CAULKING IRON.

Fig. 6-55-Body Side Hinge Strap Removal

"X" Styles

DOORS

6-43 weld tab forward flange of replacement hinge, and mark dimension on hinge as shown in Fig- ure 6-56.

2. Locate replacement hinge to scribe marks and drill depressions identifying 1-3/4" dimension

(Fig. 6-57). Tack in place with arc weld at upper and lower hinge tabs.

3. Re-hang door and install hinge pins to insure proper alignment of door to opening.

4. Remove door and complete arc welding of hinge. Arc weld completely around upper and lower hinge tab as shown in Figure 6-58.

5. Wire brush and clean welds as required. Seal around perimeter of hinge with a paintable sealer.

6. Refinish hinge pillar and replacement hinge as required.

7. Install door assembly as previously described.

INSIDE LOCKING ROD

All Coupe Styles

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. 6-38). On "B, C and E" styles, remove upper and lower portion of door trim assembly.

2, Slide inside locking rod to door inner panel plas- ure 6-38.

CATE NEW HINGE

TO PILLAR AT SCRIBE

MARK AND DRILLED

DEPRESSIONS. TACK

WELD I N PLACE WHEN

PROPERLY LOCATED.

Fig. 6-57-Body Side Hinge Strap Installation

"X"

3. Disengage rod from lock and lower locking rod through beltline to remove.

4. To install, reverse removal procedure.

FRONT DOOR LOCK REMOTE CONTROL

AND CONNECTING ROD

Description

There are two basic types of door lock 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.

MEASURE 1-314" FROM

FORWARD FLANGE OF

UPPER AND LOWER HINGE

TAB ON SERVICE

REPLACEMENT HINGE, AND

SCRIBE LOCATION O N

HINGE

Fig. 6-56-Body Side Hinge Strap Installation

'X" Styles

Fig. 6-58-Body Side Hinge Strap Installation

'X" Styles

6-44 DOORS

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 En 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 6-38 for pull-in type and Figure 6-32 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

Description

All styles use the fork bolt lock design which includes a safety interlock feature. The door is secured in a closed position when the door lock fork bolt snaps over and engages the striker bolt. Front and rear doors can be locked from the inside by depressing the passenger guard door lock button located on the upper door panel. All doors can be locked from the outside by simply depressing the interior door lock button and closing the door. The front doors can also be locked by using the square headed key.

WARNING: FIGURES 6-59 AND 6-60 DEPICTS

TYPICAL "A, F AND X" AND "B, C AND En

STYLES, RESPECTIVELY, FRONT DOOR

LOCK ASSEMBLIES WHICH CAN BE USED

FOR IDENTIFYING LOCKING PROBLEMS.

DO NOT ATTEMPT REPAIRS TO CORRECT

LOCK DISCREPANCIES. MAKE CORREC-

TIONS THROUGH REPLACEMENT O F LOCK

ASSEMBLY.

Removal and lnstallation

1. On "B, C and E n 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 assembly and then remove the lock and connecting rod as 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 6-40) 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

Disassembly and Assembly

1. Remove lock cylinder from door as subsequently described.

2. With a pointed tool, disengage pawl retaining clip and remove pawl (Fig. 6-61).

3. With a flat-bladed tool, straighten out crimped- over edges of lock cylinder housing scalp and remoye scalp and lock cylinder from housing.

NOTE: Refer to General Information Index (Sec- tion 1 of this manual) for lock cylinder coding.

4. To install, reverse removal procedure.

DOORS 6-45 r

PUSH BUTTON L E V E R

Fig. 6-59-Front Door Lock Assembly

"A, F and X" Styles

3066

6-46 DOORS

1. Lock Back Plate

2. Sliding Shoe

3. Push Button Lever

4. Transfer Lever

5. Remote Control Lever

Fig. 6-60-Front Door Lock Assembly

"B, C and E" Styles

7. Detent Lever

8. Fork Bolt

9. Push Button Return

Spring

NOTE: Lock cylinder housing scalp is usually damaged in removal procedure and, therefore, must be replaced. Replacement scalps are available as service parts.

Removal and Installation

1. On "B, C and E" styles, remove upper and lower

10. Detent Spring

1 1. Spring Tension

Washer (Replace'

Fork Bolt Return

Spring) .

12. Intermittent Lever

13. Lock Frame

14. Lock Silencer

15. Sliding Shoe Pin and

Spring portion of door trim assembly, then raise door window. On "A, F X" styles, remove door trim assembly and peel back inner panel water deflector.

2. With a screwdriver or other comparable tool, slide lock cylinder retaining clip (on door outer

DOORS

6-47

SEALING

GASKET

LOCK CYLINDER

( REMOVED )

Fig. 6-6 1 -Door Lock Cylinder Assembly panel) out of engagement and remove lock cylinder from door (Fig. 6-62).

3. To install, reverse removal procedure.

DOOR OUTSIDE REMOTE CONTROL MIRROR

Description

The optional remote control mirror can be adjusted from the interior of the car by moving the remote control lever located on the left front door trim assembly in the directian desired.

Remote Mirror Face Replacement

All Styles

1. To remove a scratched, broken, stained, etc. mirror face from the mirror frame, break the mirror glass and remove the broken glass and fiber pad from the mirror frame.

CAUTION: Protect painted surface on door assembly when breaking mirror face to remove from mirror frame.

2. Wipe inside of mirror frame clean.

3. To install replacement mirror faces, remove paper backing from mirror face and center mirror in mirror frame. Then press firmly to ensure adhesion of the mirror face to the mirror frame.

''L ..."

V I E W A

3087

Fig. 6-62-Front Door Lock Cylinder Removal

All Styles remote cable escutcheon access hole in door trim assembly and/or through the beltline, detach remote cable from retaining tab on door hinge pillar (Fig. 6-64).

3. On Buick styles, remove remote control mirror

ARM

' Y LES

Removal and Installation

Buick and Oldsmobile

" A Styles

1. Lower window to a full-down position. Remove remote cable escutcheon to door trim assembly attaching screws and disconnect cable to escutcheon attaching clip (Fig. 6-63).

2. On Oldsmobile ventless styles, remove cable support arm from end of cable (Fig. 6-63). On

Buick ventless styles working through the

ESCUT

Fig. 6-63-Door Outside Remote Mirror Trim Pad Escutcheon

Removal

Buick and Oldsmobile "A" Styles

648 DOORS

OLDSMOBILE STYLES BUlCK S T Y L E S

CLOCKWISE WITH A

OLDSMOBILE STYLE

FOR

Oldsmobile "A" Styles

3616

Buick and to mounting bracket attaching screw, in base of mirror, and mounting bracket to door outer panel attaching screws (Fig. 6-64). 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 (Fig. 6-64).

Then slide mirror rearward, then upward to remove.

5. To install, reverse removal procedure.

Removal and Installation

Chevrolet and Pontiac

"A and F" Styles

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 6-65 for

"A" styles and Figure 6-66 for "F" styles).

2. On Chevrolet and Pontiac "A" styles, remove mirror base to door outer panel stud nuts (Fig.

6-65) and remove mirror and cable assembly trom door.

TAB

INSTALLATION

Fig. 6-65-Door Outside Remote Mirror Removal - Chevrolet and Pontiac "A" Styles

REMOTE MIRROR INSTALLATION

391 2

Fig. 6-66-Door Outside Remote Mirror Removal and F" Styles, Except Cadillac

"B, C, E

"F" Styles Shown,

"B. C and En Similar

- --

DOORS 6-49

Fig. 6-67-Door Outside Mirror -

Typical All Styles

3. On Chevrolet and Pontiac "F" styles, remove attaching screw in base of mirror and mounting bracket to door outer panel attaching screws

(Fig. 6-66). Then, remove mirror and cable assembly from door.

4. To install, reverse removal procedure.

Removal and lnstallation

"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 (Fig. 6-66).

2. Remove attaching screw in base of mirror and mounting bracket to door outer panel attaching screws (Fig. 6-66) 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 (Fig. 6-65). Remove mirror and cable assembly from door.

3. To, install reverse removal procedure.

DOOR OUTSIDE MIRROR

STANDARD

MIRROR

Removal and lnstallation All Styles

1. Remove attaching screw in base of mirror and remove mirror (Fig. 6-67).

2. T o 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 lnstallation

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.

On "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", Fig. 6-40) 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 lnstallation

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 ("6", Fig. 6-68) and ventilator regulator to inner panel attaching bolts ("4", Fig. 6-68).

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

Adjustments

Some in-and-out, or fore-and-aft adjus;tment of the ventilator division channel is available at the lower adjusting stud ( " I " , Fig. 6-68). Adjustment at this location is required only to eliminate any misalignment between the ventilator division channel and window glass run channel.

6-50 DOORS

Fig. 6-68-Front Door Ventilator and Window Removal and Adjustments

" A " Closed Styles

1. Ventilator Division

Channel Lower

2. Window Down Stop

Support Attaching

Bolt

3. Ventilator to Door

Upper Frame

Attaching Screws

4 . Ventilator Frame to

Door Outer Panel

5 . Ventilator Regulator

Attaching Bolts

6. Ventilator Regulator to "T-Shaft"

Attaching Bolt

Access Hole

Disassembly and Assembly

The ventilator front frame is attached to the division channel with rivets at the bottom and a screw at the top (Fig. 6-69).

The parts that can be replaced are the division channel strip assembly, ventilator weatherstrip (on division channel) and the vent glass.

Removal and Installation

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", Fig. 6-68).

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", Fig. 6-68).

5. Remove division channel lower adjusting stud nut (" ", Fig. 6-68).

6. Remove ventilator to door upper frame attaching screws ("3", Fig. 6-68). 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 ru,n channel removal procedure).

7. Tilt vent assembly rearward and remove vent inboard of door upper frame.

8. To install, reverse removal procedure.

FRONT DOOR VENTILATOR ASSEMBLY

"A-39" Styles

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", Fig. 6-70).

D I V I S I O N C H A N N E L TO.-N

F R A M E S C R E W

D I V I S I O N C H A N N E L

STRIP A S S E M B L Y

Fig. 6-69-Front Door Ventilator Assembly

" A " Closed

Styles

DOORS

6 6 1

Fig. 6-70-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

Ventilator Regulator

Attaching Bolts

To adjust the top of the ventilator in or out, loosen only the adjusting stud nuts ("2" and "3", Fig. 6-70) and adjust the studs in or out as required.

It is not necessary to loosen the vent to outer panel bolts (" 3", Fig. 6-70).

Ventilator Disassembly and Assembly

The "hardtop" style ventilator permits more disassembly 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 6-7 1, 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 (refer to following removal procedure). With the regulator out, open the vent window to align the bosses on 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.

The division channel to casting screw (Fig. 6-71), 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.

Removal and Installation

1. Remove door window and ventilator regulator

(see index for removal procedures).

2. Remove ventilator frame to door panel bolts

(" 1 ", Fig. 6-70) and trim pad hanger plate retained by rear bolt.

3. Remove ventilator lower frame adjusting stud

("2", Fig. 6-70).

4. Remove division channel lower adjusting stud

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

- described below.

U P P E

R U N

R U N C H A N N E L

N T F ~ A M E

S T I N G SCREWS

Fig. 6-71-Front Door Ventilator Assembly

'A-39' Styles

6-52 DOORS

V E N T

F R A M E

U P P E R

S C R E W S

V E N T T O DOOR

OUTER P A N E L SCREW

VENT D I V I S I O N C H A N N E L

A D J U S T I N G STUD A N D N U T

V I E W A V I E W B

3088

V I E W C

Fig. 6-72-Fropt Door Ventilator Removal

FRONT DOOR VENTILATOR ASSEMBLY

" X

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.

Removal and lnstallation

1. Remove door trim assembly and inner panel water deflector.

2. With window in "full-up" position loosen down stop support attaching bolt and remove support

("7", Fig. 6-44).

3. Lower door window and remove ventilator division channel lower adjusting stuQ nut and ventilator to door outer panel attaching screw (View

"A" in Fig. 6-72).

4. Remove ventilator to door upper frame attaching screws (View " A", in Fig. 6-72).

5. Lift ventilator rearward and upward until lower forward comer of assembly is free of door upper frame (View "B" in Fig. 6-72).

6. Rotate ventilator assembly in an outboard movement and remove unit outboard of door upper frame (View "C" in Fig. 6-72).

7. To install, reverse removal procedure.

FRONT DOOR WINDOW ASSEMBLY

"A

and

X

Closed Styles

Description

The front door window assembly consists of a frame- less 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.

Adjustments

1. To adjust lower portion of ventilator division channel for proper alignment with door window assembly, lower door window and loosen ventilator adjusting stud nut (Fig. 6-73). 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).

Removal and lnstallation

1. Remove front door ventilator assembly as previously described.

2. Slide window lower sash channel cam off window regulator lift arm and balance arm rollers

Fig. 6-73-Front Dodr Window Removal and Adjustment

"A and X" Closed Styles

DOORS 6-53 on two door styles and off lift arm roller on four door styles. Remove window inboard of door upper frame.

3. To install, reverse removal procedure. Adjust window for proper alignment as subsequently described.

FRONT DOOR WINDOW ASSEMBLY

"A-39"

.Styles

Description

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 door glass and sash channel are removed from the door as a unit and replacement glasses installed in bench operations.

Figure 6-74 is an exploded view of the front door window assembly and identifies the various components and their assembly sequence.

NOTE: When installing the glass to sash channel bolts, torque nuts to 72 inch pounds (6 foot pounds).

Fig. 6-74-Front Door Window Assembly

"A-39" Styles

1. Front Door Window

2. Glass to Sash

Channel Bolt Nut

3. Glass to Sash

Channel Bolt Spacers

4. Glass to Sash

Channel Bolt

5. Glass to Sash

Channel Filler

6. Glass Lower Sash

Channel

Fig. 6-75-Front Door Window Removal and Adjustments

"A-39" Styles

Stop Access Hole

2. Window Rear Upper

Stop Bolt

3. Rear Guide Upper

Attaching Bolts

4. Lower Sash Channel

Cam Attaching

Screws Access Holes

5. Ventilator Lower

Frame Adjusting Stud and Nut

6. Ventilator Division

Channel Lower

Adjusting Stud and

Nut

7. Inner Panel Cam

Attaching Bolts

Also, when replacing door glass, replace glass spacers.

Diagnosis and Adjustments

1. WINDOW NOT PARALLEL WITH SIDE

ROOF RAIL WEATHERSTRIP-A rotated window condition (glass cocked in opening) can be corrected by loosening the front and rear up- travel stops (" 1 " and "2", Fig. 6-75) and inner panel cam,attaching bolts ("7", Fig. 6-75) and raising or lowering front edge of glass inrelation to rear edge of glass, as required, to parallel upper edge of glass with side roof rail weatherstrip. Then, tighten inner panel cam attaching bolts and raise glass to desired height to establish proper contact with the side roof rail weatherstrip. Tighten up-travel stop bolts.

' 2. WINDOW TOO FAR INBOARD OR OUT-

BOARD ALONG REAR UPPER EDGE OF

GLASS IN RELATION TO SIDE ROOF

RAIL WEATHERSTRIP-To adjust upper rear come? of window in or out in relation to side roof rail weatherstrip, loosen rear guide upper attaching bolts ("3", Fig. 6-75) and position

6-64 DOORS guide further inboard or outboard as required.

Outboard adjustment at this location tends to move the door window upper rear comer 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 ("S", Fig. 6-75).

3. WINDOW TOO HIGH OR LOW I N RELA-

TION T O SIDE ROOF RAIL WEATHER-

STRIP-To adjust window up-travel, loosen front and rear upper stops (" " and "2", Fig.

6-75) and operate window to desired up position to establish proper contact with the side roof rail weatherstrip. Tighten stop bolts.

4. WINDOW MECHANISM BINDS WHEN

OPERATING WINDOW ASSEMBLY-

Adjustment has been provided to relieve a binding door glass due to a misaligned ventilator division channel ("6", Fig. 6-75).

Removal and Installation

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" and "2", Fig. 6-75).

Fig. 6-76-Front Door Window Assembly "A-37, 57, 67 and

87" Styles ("B, C and E" Coupe Styles Shown,

"A" Styles Similar)

1. Stop, Up-Travel (On

Glass)

2. Nut

3. Bolt

4. Spacer

5. Washer

6. Fastener, Glass

Bearing ("B, C and E"

Styles Only)

3. Loosen rear guide to door inner panel attaching bolts ("3", Fig. 6-75).

4. With window in a three quarter down position, remove screws securing lower sash channel cam to lower sash channel ("4", Fig. 6-75).

5. Support window and disengage lower sash channel cam from regulator lift and balance arm rollers.

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 desczbed in the subsequent procedure.

FRONT DOOR WINDOW ASSEMBLY

"A-37,

57,67,87" Styles

Description

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 6-76 is an exploded view of the window assembly and identifies the -various components and their assembly sequence.

NOTE: When installing glass attachments, torque nuts to 72 inch pounds (6 foot pounds). Also, when replacing door glass, replace glass spacers.

Diagnosis and Adjustments

1. WINDOW NOT PARALLEL WITH SIDE

ROOF RAIL WEATHERSTRIP

A rotated window condition (glass cocked in opening) can be corrected by loosening front and rear up- travel stops (" " and "2", Fig. 6 77) and lower sash upper guide bolts ("8", Fig. 6-77) and raising or lowering front edge of glass in relation to rear edge of glass, as required, to parallel upper edge of glass with side roof rail weatherstrip.

Then, tighten lower sash upper guide attaching bolts and raise glass to desired height to establish proper contact with side roof rail weatherstrip.

Tighten up-travel stop bolts.

2. WINDOW TOO FAR INBOARD OR OUT-

BOARD ALONG UPPER EDGE I N RELA-

.TION T O SIDE ROOF RAIL

WEATHERSTRIP

To adjust upper edge of

DOORS 6-55 window in or out in relation to side roof rail weatherstrip, loosen lower sash lower guide bolts ("9", Fig. 6-77) and front and rear stabil-

, izer strip bolts ("6", Fig. 6-77) and position guide inboard or outboard as required. Out- board adjustment of the guide assembly tends to move upper edge of glass inboard. Conversely, inboard adjustment moves the upper edge of glass outboard. With glass in a full-up position, position stabilizer strip against inner surface of glass and tighten attaching bolts.

3. WINDOW TOO H I G H O R LOW I N RELA-

TION T O SIDE ROOF RAIL WEATHER-

STRIP

To adjust window up-travel, loosen front and rear up-travel stops (" 1 " and " 2". Fig.

6-77) and operate window to desired position to establish proper glass to side roof rail weatherstrip contact. Tighten up-travel stop bolts.

4. WINDOW TOO H I G H OR LOW WHEN I N

A DOWN POSITION

T H E .BELTLINE

I N RELATION TO

- T o adjust window down- travel, loosen front and rear window down- travel bumper supports ("3" and "4", Fig. 6-77) and lower or raise window to desired full-down glass height. Then, position front and rear

Fig. 6-77-Front Door Window Removal and Adjustment

"A-37, 57.67 and 87" Styles

Stop. Front Up-Travel

Bolt

Stop, Rear Up-Travel

Bolt

Support, Front

Window Bumper Bolt

Support, Rear

Window Bumper Bolt

Plate, Trim Pad

Adjusting

6. Strip Stabilizer

7. Plate Assembly,

Lower Sash ~ & d e

Bolts

8. Guide Assembly,

Lower Sash Upper

~ o l t s

9. Guide Assembly,

Lower Sash Lower

Bolts

Fig. 6-78-Front Door Window Adjustment Two-Door

Hardtop Styles bumper against lower edge of glass and tighten bumper support attaching bolts.

5. WINDOW TOO FAR FORWARD OR

REARWARD I N RELATION T O PILLAR

WEATHERSTRIP O R ADJACENT BODY

GLASS

To adjust window forward or rearward, loosen lower sash guide plate bolts ("7",

Fig. 6-77) and reposition glass as necessary. The guide plate to glass attaching locations are slotted to permit fore and aft adjustment of the glass. Tighten lower sash guide plate attaching bolts.

6. WINDOW MECHANISM BINDS WHEN

OPERATING WINDOW ASSEMBLY - Ease of window operation and window stability de- pend to a great extent on the adjustment of the window stabilizer strip assemblies at the beltline

("6", Fig. 6-77). 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 elass halfway through the cycle.

This is permissibie provided i t does i o t resilt in loose giass. contact should be sufficient to stabilize glass, but not restrict ease of window operation.

GLASS ALIGNMENT GAUGE BLOCKS

"A-37,

57, and 87" Styles

With theilimination of front and rear guides and the incorporation of a single vertical guide tube in the

6-56 DOORS

TOOL J 23394-2

( B L U E )

Fig. 6-79-Glass Alignment Gauge Blocks

Tool J23394

(Consists of a set of three blocks) center of the door, most window adjustments will be made from a guide plate attached to the lower edge of the glass (Fig. 6-78). 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. 6-79).

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 rail weatherstrip at lower front corner and carefully remove from retainer over

Fig. 6-80-Front Door Window Alignment (Fore and Aft and

Rotated "Cocked Glassnin Body Opening Adjustment)

I front door window as shown in Figure 6-80.

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 corners of glass as shown in Figure 6-80. Then, install gauge block, tool J-23394-1 (red) or equivalent into windshield pillar retainer slightly above beltline.

NOTE: 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", Fig. 6-77) and stabilizer strips

("6", Fig. 6-77).

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

Fig. 6080), 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 (" assembly (" by hand until upper and brward ed e of glass contacts all three gauge blocks in fu f

1-up position (as shown in Fig. 6-77). Tighten guide plate and upper guide assembly attaching bolts.

6. Loosen lower sash lower guide assembly ("9",

Fig. 6-77). 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 6-81. Then, tighten lower guide assembly attaching bolts.

NOTE: 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.

7. With glass in full-up position against the upper gauge blocks as shown in Figure 6-81, tighten adjustable up-travel stops on glass (Fig. 6-77) against inner panel. Adjust stabilizer strips

("6",

Fig. 6-77) for proper tension against glass.

8. Lower window and remove gauge blocks from weatherstrip retainer. Reinstall and reseal weatherstrip as previously described.

DOORS

6-57

Removal and Installation'

1. Remove door trim assembly and inner panel water deflector.

2. Remove front and rear up-travel stops (" 1" and

"2", Fig. 6-77) and front and rear stabilizer strips ("6", Fig. 6-77).

NOTE: Removal of rear stabilizer strip necessitates removal of trim pad adjusting plate ( " 5 " ,

Fig. 6-77).

3. Remove lower sash guide plate assembly to glass attaching bolts ("7", Fig. 6-77). 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.

FRONT DOOR WINDOW ASSEMBLY

"B"

Closed Styles

Description

The front door window assembly consists of a solid tempered safety plate glass window and an individually 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.

NOTE: When installing glass attachments, torque nuts to 72 inch pounds (6 foot pounds). Also, when replacing door glass, replace glass spacers.

GAUGE BLOCKS

TOOL J 23394-2

Fig. 6-81-Front Door Window Alignment (In and Out and

Up-Travel Adjustment)

Fig. 6-82-Window Removal and Adjustment

Styles

- "B" Closed

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 lnner

Panel Bolts

5 . Window Rear Guide

Lower Bolt

6. lnner Panel Cam

Bolts

7 . Window Down-Travel

Support Bracket Bolt

Diagnosis and Adjustment

1. WINDOW NOT PARALLEL ALONG UP-

PER EDGE WITH DOOR UPPER FRAME -

A rotated window condition (glass cocked in opening) can be corrected by loosening door window inner panel cam attaching bolts ("6",

Fig. 6-82) and raising or lowering front edge of glass in relation to rear edge of glass, as required, to parallel upper edge of glass with door upper frame. .Tighten inner panel cam attaching bolts.

2. WINDOW TOO HIGH OR TOO LOW,

WHEN I N A DOWN POSITION, I N RELA-

TION TO THE BELTLINE

To adjust window down-travel, loosen window down- travel bumper support ("7", Fig. 6-82) and raise or lower window to desired full-down glass height.

Then, position bumper support against lower edge of glass and tighten attaching bolts.

6-68 DOORS

3. WINDOW MECHANISM BINDS WHEN

OPERATING

The rear guide is adjustable in and out ("3", Fig. 6-82) and fore and aft ("4",

Fig. 6-82) to relieve a binding door window assembly.

Removal and Installation

1. Remove upper and lower portion of door trim assembly and inner panel water deflector.

2. Loosen window stabilizer strips (" 1 ",

3. Operate window to a three-quarter-down position and remove window lower sash channel cam to glass attaching stud nuts ("2", Fig. 6-82).

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 performing the subsequent procedure.

FRONT DOOR W I N D O W ASSEMBLY

"0, C and E Two-Door Hardtop and Convertible

Styles

Description

The front door window assembly consists of a solid tempered safety plate glass window, with a bolted-on

Fig. 6-83-Front Door Window Assembly

"B, C and E n

Two-Door Hardtop and Convertible Styles

1. Stop, Up-Travel (On

Glass)

2. Nut

3. Bolt

4. Spacer

5. Washer

6. Fastener, Glass

Bearing lower sash guide plate assembly, which operates on a single vertical guide tube located in the center of the door.

Figure 6-83 is an exploded view of the window assembly and identifies the various components and their assembly sequence.

NOTE:

When installing glass attachments, torque nuts to 72 inch pounds (6 foot pounds). Also, when replacing door glass, replace glass spacers.

Diagnosis and Adjustments

1. WINDOW NOT PARALLEL WITH SIDE

ROOF RAIL WEATHERSTRIP

A rotated window condition (glass cocked in opening) can be corrected by loosening front and rear up- travel stops ("3" and "4", Fig. 6- 84) and lower sash upper guide bolts ("7", Fig. 6-84) and raising or lowering front edge of glass in relation to rear edge of glass, as required, to parallel upper edge of glass with side roof rail weatherstrip.

Then, tighten lower sash upper guide attaching bolts and raise glass to desired height to establish proper contact with side roof rail weatherstrip.

Tighten up-travel stop bolts.

2. WINDOW TOO FAR INBOARD OR OUT-

BOARD ALONG UPPER EDGE IN RELA-

TION TO SIDE ROOF RAIL

WEATHERSTRIP

To adjust upper edge of window in or out in relation to side roof rail weatherstrip, loosen lower sash lower guide bolts (" izer strip bolts ( " 5 " , Fig. 6-84) and position guide inboard or outboard as required. Out- board adjustment of the guide assembly tends to move upper edge of glass inboard. Conversely, inboard adjustment moves the upper edge of glass outboard. With glass in a full-up position, position stabilizer strip against inner surface of glass and tighten attaching bolts.

3. WINDOW TOO HIGH OR LOW IN RELA-

'TION TO SIDE ROOF RAIL WEATHER-

STRIP

To adjust window up-travel, loosen front and rear up-travel stops (" 3" and "4", Fig.

6-84) and operate window to desired position to establish proper glass to side roof rail weatherstrip contact. Tighten up-travel stop bolts.

4. WINDOW TOO HIGH OR LOW WHEN IN

A DOWN POSITION IN RELATION TO

TH,E BELTLINE

To adjust window down- travel, loosen front and rear window down- travel bumper supports (" 1 " and "2", Fig. 6-84) and lower or raise window to desired full-down glass height, Then, position front and rear bumper against lower edge of glass and tighten bumper support attaching bolts.

DOORS

6-69

5. WINDOW TOO FAR FORWARD OR

REARWARD IN RELATION TO PILLAR

WEATHERSTRIP OR ADJACENT BODY

GLASS

To adjust window forward or rearward, loosen lower sash guide plate bolts ("6",

Fig. 6-84) and reposition glass as necessary. The guide plate to glass attaching locations are slotted to permit fore and aft adjustment of the glass. Tighten lower sash guide plate attaching bolts.

6. WINDOW MECHANISM BINDS WHEN

OPERATING WINDOW ASSEMBLY

Ease of window operation and window stability de- pend to a great extent on the adjustment of the window stabilizer strip assemblies at the beltline

(" 5", Fig. 6-84) and glass bearing plate ("9" and

"lo",

Fig. 6-84). 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

Fig. 6-84-Front Door Window Removal and Adjustment

"B, C and E n Two-Door Hardtop and Convertible Styles

1. Support, Front

Window Bumper Bolt

2. Support Rear

Window Bumper Bolt

3. Stop, Front Up-Travel

Bolt Location ("B, C and E" Styles)

4. Stop, Rear Up-Travel

Bolt Location ("B, C and E" Stylee)

6. Trim Pad Adjusting

Plates and Stabilizer

Strip8

6. Plate Assembly,

Lower Sash Guide

Bolts

7. Guide Assembly,

Lower Saeh Upper

Bolts

8. Guide Assembly,

Lower Sash Lower

Bolts

9. Glass Bearing Plate to 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 Aft

Adjustment)

Fig. 6-85-Front Door Window Adjustment ("A" Styles

Shown, "B, C and E" Styles Similar) not result in loose glass. Contact should be sufficient to stabilize glass, but not restrict ease of window operation. The 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.

GLASS ALIGNMENT GAUGE BLOCKS

("0, C and E" 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 (Fig. 6-78). Fine adjustment of this glass

TOOL J 23711.5 (BEIGE)

68169 S TYLE ONLY

Fig. 6-86-Glass Alignment Gauge Blocks

Tool J-23394

(Consists of a Set o f Four Blocks)

6-60 DOORS

G A U G E B L O C K S

TOOL. J 23711-2

(BLACK)

Fig. 6-87-Front Door Window Alignment (Rotated

Glass in Body Opening Adjustment)

"Cocked" 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.

6-86). 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 comer and carefully remove from retainer over the door window, as shown in Figure 6-88.

Fig. 6-88-Front Door Window Alignment (Fore and Aft

Adjustment)

Fig. 6-89-Front Door Window Alignment (In and Out and

Up-Travel Adjustment)

Lower front and rear quarter windows and install gauge blocks, tool 5-23711-2 (black) or equivalent into side roof rail weatherstrip retainer above upper front and rear comers of the glass as shown in Figure 6-88. Then, install gauge block, tool J- 2371 1-1 (grey), or equivalent into windshield pillar retainer slightly above beltline.

NOTE:

The grooves on sides of the gauge blocks must be fully engaged with side roof rail weatherstrip retainer.

Working from inside body, with door in the closed position loosen front and rear up-travel stops ("3" and "4", Fig. 6-84, stabilizer strips

5", Figure 6-84) and glass bearing plate (" lo",

Fig. 6-84). 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", Fig.

6-83). Then, raise door window assembly to approximately 1" from the full-up position, as illustrated in Figure 6-87. If distance (space) between the upper edge of glass and the front and rear gauge blocks is equal (as shown in Fig.

6-87), 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", Fig.

6-84) through access holes (" 1 1 ", adjust and adjust glass as necessary.

Raise front door window assembly until contact is established between the upper and forward

DOORS 8-81 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

Fig. 6-88), proceed with step number seven (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" Fig. 6-84) through access holes rearward until the edge of glass contacts all three gauge blocks in the full-up position.

Completely loosen lower sash lower guide assembly ("7", Fig. 6-84). Apply firm outboard pressure against upper end of front guide to remove slack in system and to hold upper inner edge of glass inboard against the outer edge of the gauge blocks, as shown in Figure 6-89. Then, tighten lower sash lower guide assembly attaching bolts.

NOTE: 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 (" " and

"4", Fig. 6-84) and adjust stabilizer strips ("5",

Fig. 6-84) for proper tension against glass. Then turn glass bearing plate adjusting stud counterclockwise until the plate assembly contacts the bearing button or glass.

Lower window and remove gauge blocks from weatherstrip retainer. Then, tighten rear stationary up-travel stop on glass (" 1 ", Fig. 6-83) and reinstall and seal weatherstrip as previously described.

Removal and Installation

1. Remove upper portion of door trim assembly.

2. Remove front and rear up-travel stops ("3" and

"4", Fig. 6-84) and stabilizer strips ("5", Fig.

6-84).

3. Remove glass bearing plate adjusting stud nut wise until bearing plate is out of contact with bearing button on glass.

4. Remove lower sash guide plate assembly to glass attaching bolts ("6", Fig. 6-84). Tilt upper edge of glass inboard to disengage glass from guide plate, then remove the window from the door by lifting straight-up.

5. To install, reverse removal procedure. Adjust window for proper alignment and operation as described in the subsequent adjustment procedure.

FRONT DOOR WINDOW ASSEMBLY

"B and

C-39 and 49" and "C-69" Styles

Description

The front door window assembly consists of a solid tempered safety plate glass window and an individually 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 6-70 is an exploded view of the window assembly and identifies the various components and their assembly sequence.

NOTE: When installing glass attachments, torque nuts to 72 inch pounds (6 foot pounds). Also, when replacing door glass, replace glass spacers.

Diagnosis and Adjustment

1. WINDOW NOT PARALLEL WITH SIDE

ROOF RAIL WEATHERSTRIP

A rotated window condition (glass cocked in opening) can be corrected by loosening front and rear up- travel stops ("1" and "2", Fig. 6-91) and inner panel cam bolts ("8", Fig. 6-91) and raising or

VlEW "B"

VlEW "A" A1 87

Fig. 6-90-Front Door Window Assembly

"B and C-39, 49" and "C-69" Styles

1. W i n d o w Assembly

2. Window Assembly

(Bell Crank)

3. space;

4. Bolt, Inner Panel Cam

5. Washer (Plastic)

6. Nut

7. Window Roller

8. Washer (Metal)

6-02 DOORS lowering front edge of glass ,in relation to rear edge of glass, as required, to parallel upper edge of glass with side roof rail weatherstrip. Then, tighten inner panel cam attaching bolts and raise glass to desired height to establish proper contact with side roof rail weatherstrip. Tighten up- travel stop bolts.

2. WINDOW TOO FAR INBOARD OR OUT-

BOARD ALONG UPPER EDGE I N RELA-

TION TO SIDE ROOF RAIL

WEATHERSTRIP

To adjust upper edge of window in or out in relation to side roof rail weatherstrip, loosen upper ends of front and rear guides ("6" and izer strip assemblies ("3", Fig. 6-9 1) and position guide inboard or outboard as required.

Outboard adjustment of the guide assembly tends to move the upper edge of the glass inboard. Conversely, inboard adjustment moves the upper edge of the glass outboard. With glass in a full-up position, position stabilizer strips against inner surface of glass and tighten attaching bolts.

3. WINDOW TOO HIGH OR LOW I N RELA-

TION TO SIDE ROOF RAIL WEATHER-

STRIP

T o adjust window up-travel, loosen front and rear up-travel stops (" 1" and "2", Fig.

6-9 1) and operate window to desired position to establish proper glass to side roof rail weatherstrip contact. Tighten up-travel stop bolts.

4. WINDOW TOO HIGH OR LOW WHEN IN

A DOWN POSITION I N RELATION TO

THE BELTLINE

To adjust window down- travel, loosen window down- travel bumper support ("9", Fig. 6-9 1) and lower or raise window to desired full-down glass height. Then, position bumper support against lower edge of glass and tighten attaching bolts.

5. WINDOW TOO FAR FORWARD OR

REARWARD I N RELATION TO PILLAR

WEATHERSTRIP OR ADJACENT BODY

GLASS

To adjust window forward or rearward, loosen upper end of rear guide ("S", Fig.

6-91) and reposition glass as necessary. Upper attaching locations in the inner panel 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.

6. WINDOW MECHANISM BINDS WHEN

OPERATING WINDOW ASSEMBLY

Ease of window operation and window stability de- pends a great extent on adjustment of window stabilizer strip assemblies at beltline ("3", Fig.

6-91). The stabilizing strips "3" should contact

Fig. 6-91-Window Removal and Adjustment

49" and "C-69" Styles

"B and C-39,

1. Window Front

Up-Travel Stop Bolt

2. Window Rear

Up-Travel Stop Bolt

3. Window

rim

Support Hanger and

Stabilizer Strip Bolts

4. Window Lower Sash

Channel Cam Nuts

Access Holes

5. Rear Guide Upper

Bracket Bolts

6. Front Guide Upper

Bolt

7. Rear Guide to Guide

Upper Bracket Bolt

8. Inner Panel Cam

Bolts

9. Window Down-Travel

Support Bracket Bolt glass throughout full cycle of window. However, in some cases due to slight variations in glass contour, the strip may lose contact with glass halfway through the cycle. This is permissible provided it does not result in loose glass or re-

Htrict ease of window operation.

TOOL J 23711-5 (BEIGE]

68\69 STYLE ONLY

I / TOOLS J 23711-2 (BLACK)

TOO1 J 23711-1 [GREY)

5088

Fig. 6-92-Glass Alignment Gauge Blocks

Tool J-23711 or equivalent for "B-and C" styles (Consists of a set of four blocks)

DOORS 6-63

Fig. 6-93-Front Door Window Alignment (Rotated "Cocked'

Glass in Body Opening Adjustment)

GLASS ALIGNMENT GAUGE BLOCKS

("0

AND C" FOUR-DOOR HARDTOP

VENTLESS STYLES)

To facilitate adjustment of this glass, use glass alignment gauge blocks tool J-23711 or equivalent (Fig.

6-92). For proper use of gauge blocks, refer to the following procedure:

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).

Detach side roof rail weatherstrip at lower front corner and carefully remove from retainer over door window, as shown in Figure 6-94.

Lower front and rear door or quarter windows and install gauge blocks, tool J-23711-2 (black) or equivalent into side roof rail weatherstrip retainer above upper front and rear comers of glass as shown in Figure 6-94. Then, install gauge block, tool J-23394-1 (red), or equivalent into the windshield pillar retainer slightly above beltline.

NOTE: Grooves on sides of gauge blocks must be fully engaged with side roof rail weatherstrip retainer.

Working from inside body, with door in the closed position, loosen front and rear up-travel stops ("1" and "2", Fig. 6-91) and stabilizer strips ("3", Fig: 6-91).

Raise front door window assembly to approxi-

" from full- up position, as illustrated in

Fig. 6-94-Front Door Window Alignment (Fore and Aft

Adjustment)

Figure 6-93. If distance (space) between upper edge of glass and front and rear gauge blocks is equal (as shown in Fig. 6-93), 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

1) 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 forward edge of glass contacts all three gauge blocks simultaneously (as shown in

Fig. 6-94), proceed with step number seven (7).

GAUGE BLOCKS

TOOL J 23711-2

(BLACK)

8-64 DOORS

If upper and forward edge of glass does not contact all three gauge blocks simultaneously, itiosen fore and aft adjustment on rear guide

("5" Figure 6-91) 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 6-95. Then, tighten, upper guide attaching bolts. Repeat operation with rear guide. Guides will now be coordinated to the plane of the glass.

NOTE: Inner surface of glass must contact outer surface of both upper blocks during this adjustment.

8. With glass in full-up position against upper gauge blocks, tighten up-travel stops (" " and

"2", Fig. 6-9 1) and adjust stabilizer strips ("3",

Fig. 6-91) for proper tension against glass.

9. Lower window and remove gauge blocks from weatherstrip retainer. Reinstall and seal weatherstrip as previously described.

Removal and Installation

1. Remove upper and lower portion of door trim assembly and inner panel water deflector.

Fig. 6-96 Dmr Window Assembly

1. Window Assembly

2. Window Roller

3. Washer (Plastic)

4. Bolt Inner Panel Cam

5. Nut

6. Glass Bearing

Fastener

7. Glass Bearing

Fastener Cap

8. Spacers

9. Roller Assembly (Bell

Crank)

10. Washer (Metal)

2. Remove front and rear window up-travel stops

("1" and "2", Fig. 6-91).

3. Loosen front and rear window stabilizer strips

("3", Fig. 6-91).

4. With window in three-quarter-down position, remove lower sash channel cam to glass attaching nuts ("4", Fig. 6-91). 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 subsequent adjustment procedure.

DOOR WINDOW

ASSEMBLY

"F" Styles

Description

The door window assembly consists of a solid tempered safety plate glass window and an individually 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 6-96 is an exploded view of the window assembly and identifies the various components and their assembly sequence.

NOTE: When installing glass attachments, torque attaching nuts to 72 inch pounds (6 foot pounds). Also, when replacing door glass, replace door glass spacers

("8", Fig.' 6-96).

Diagnosis and Adjustment

1. WINDOW NOT PARALLEL WITH SIDE

ROOF RAIL WEATHERSTRIP

A rotated window condition (glass cocked in opening) can be corrected by loosening front and rear up- travel stops (" 1" and "2", Fig. 6-97) and inner panel cam bolts ("8", Fig. 6-97) and raising or lowering front edge of glass in relation to rear edge of glass as required, to parallel upper edge of glass with side roof rail weatherstrip. Then, tighten inner panel cam attaching bolts and raise glass to desired height to establish proper contact with side roof rail weatherstrip. Tighten up- travkl stop bolts.

2. WINDOW TOO FAR INBOARD OR OUT-

BOARD ALONG UPPER EDGE I N RELA-

TION TO SIDE ROOF RAIL

WEATHERSTRIP

To adjust upper edge of window in or out in relation to side roof rail

DOORS 6-65 weatherstrip, loosen upper ends of front and rear guides (" and "6", Fig. 6-97) and glass stabilizer strip assemblies (" ", Fig. 6-97) and position guide inboard or outboard as required.

3. WINDOW TOO HIGH OR LOW IN RELA-

TION TO SIDE ROOF RAIL WEATHER-

STRIP

To adjust window up-travel, loosen front and rear up- travel stops (" " and " 2", Fig.

6-97) and operate window to desired position to establish proper glass to side roof rail weatherstrip contact. Tighten up-travel stop bolts.

4. WINDOW TOO HIGH OR LOW WHEN IN

A DOWN POSITION IN RELATION TO

T H E BELTLINE - To adjust window down- travel, loosen window down- travel bumper support ("9", Fig. 6-97) and lower or raise window to desired full-down glass height. Then, position bumper support against lower edge of glass and tighten attaching bolts.

5. WINDOW TOO FAR FORWARD OR

REARWARD I N RELATION TO PILLAR

WEATHERSTRIP OR ADJACENT BODY

GLASS

To adjust window forward or rearward, loosen upper end of rear guide ("7", Fig.

6-97) and reposition glass as necessary. Upper attaching locations in the inner panel 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.

6. WINDOW MECHANISM BINDS WHEN

OPERATING WINDOW ASSEMBLY

Ease of window operation and window stability de- pends a great extent on the adjustment of the window stabilizer strip assembly at the beltline

("3 ", Fig. 6-97). 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 strip may lose 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.

GLASS ALIGNMENT GAUGE BLOCKS

"F"

Styles

To facilitate adjustment of this glass, use glass alignment gauge block tool 5-23394 (or equivalent) (Fig.

6-98). 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.

I

2. Detach side roof rail weatherstrip at lower front and rear corners and carefully remove from retainer.

T O O L J 23394-2

( B L U E )

-- -

Fig. 6-97-Window Removal and Adjustment

"F" Styles

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. Inner Panel Cam

Bolts

0. Window Down Travel

Bumper Support

Fig. 6-98-Glass Alignment Gauge Blocks

Equivalent (Consists of a Set of

Tool J-23394 or

Three Blocks)

6-66 DOORS

GAUGE BLOCKS TOOL

J 2339 4-2 (BLUE, A

Fig. 6-99-"F" Style Door Window Alignment (Rotated

"Cocked" Glass in Body Opening Adjustment)

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 in Figure 6-99. Then, install glass suction cups on interior surface of glass (Fig. 6-99) to enable adjuster to shift glass when making adjustments with door in a closed position.

NOTE: When installing gauge blocks (blue) or equivalent into upper retainer on "F" styles, handle portion of blocks must protrude outboard (Fig. 6-99). Also, grooves on sides of blocks must be fully engaged with side roof rail weatherstrip retainer.

Working from inside body, with door in a closed position, loosen front and rear up-travel stops

(" 1" and "2", Fig. 6-97) and stabilizer strips

("3", Fig. 6-97).

Raise door window to approximately 1" from full-up position as illustrated in Figure 6-99. If

GAUGE BLOCK TOOL

1 23394-1 (RED)

*-2

GAUGE BLOCKS TOOL

(BLUE]

Fig. 6-100-"F" Style Door Window Alignment (Fore and Aft

Adjustment) distance (space) between upper edge of glass and front and rear gauge blocks is equal (as shown in Fig. 6-99), proceed with step number six. If distance (space) between upper edge of glass and both upper gauge blocks i$ not equal loosen inner pannel cam attaching bolts ("8", Fig. 6-97) and adjust as necessary.

Lower glass. and install gauge block, tool J-

23394- 1 (red), or equivalent into the windshield pillar retainer slightly above the beltline (Fig.

6- 100).

NOTE: When installing gauge block (red) or dle 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

Fig. 6-100), proceed with step number seven. If upper and forward edge does not contact all three gauge blocks simultaneously, loosen fore and aft adjustment on rear guide (" ", and move glass forward or rearward until edge of glass contacts all three gauge blocks in full-up position.

Completely loosen upper and lower ends of front and rear guides (" 5" and "6", Fig. 6-97). 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.

With glass in full-up position against gauge blocks, tighten up- travel stops ("1" and "2",

Fig. 6-97) and adjust stabilizer strips ("3", Fig.

6-97) for proper tension against glass.

Lower window and remove gauge blocks from weatherstrip retainer. Reinstall and seal weatherstrip with a pumpable sealer.

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", Fig. 6-97).

DOORS 6-67

3. Loosen window front 'and rear stabilizer strip

("3", Fig. 6-97).

4. With window in three-quarter-down position, remove lower sash channel cam to glass attaching nuts ("4". Fig. 6-97). 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 subsequent adjustment procedure.

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 adjusting stud and nut and window regulator attaching bolts (Fig. 6- 10 1).

5. Press ventilator division channel outboard to permit disengagement of regulator spindle from 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 REGULATOR-

Electric-"AW Closed Styles

Removal and Installation

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 (" 1 ",

Fig. 6-30) and remove regulator through access hole.

4. To install, reverse removal procedure.

Fig. 6-101-Door Ventilator and Regulator Attachment

Styles

"A'

FRONT DOOR WINDOW REGULATOR-

Manual and Electric

"A-39" Styles

Removal and Installation

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", Fig. 6-32). Remove regulator attaching bolts ("9", Fig. 6-32) and remove regulator through large access hole.

3. On electrically operated regulators, remove door window as previously described and disconnect wire harness connector at window regulator motor. Remove the regulator attaching bolts ("9",

Fig. 6-32). 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.

6-66 DOORS

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 EN styles, remove upper and lower portion of door trim assembly) and detach inner panel water deflector.

2. Remove inside locking rod as previously described.

3. Lower window to half-down position and remove regulator attaching bolts ("4", Fig. 6-

38). 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.

4. To install, reverse removal procedure.

FRONT DOOR WINDOW REGULATOR

Manual

All

"B

and C" Four Door Styles

Removal and lnstallation (Refer to Figure 6-40)

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 "Bw 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 6-40)

1. Remove upper and lower portion of door trim assembly and detach inner panel water deflector.

2. Remove door window and inner panel cam as previously described.

3. Disconnect wire harness connector at regulator motor.

4. Remove window regulator attaching bolts (" ",

Fig. 6-40), 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 6-42)

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 (Fig.

6-42), remove regulator through large access hole.

5. To install, reverse removal procedure.

FRONT DOOR WINDOW REAR GUIDE

"A-39" Styles

Removal and lnstallation

1. Remove front door trim assembly and inner panel water deflector.

2. With window in full-up position, loosen rear guide window up- travel stop attaching bolt

("3", Fig. 6-32), remove stop from guide.

3. Remove rear guide lower attaching bracket to door inner panel attaching bolt ("2", Fig. 6-32).

4. Remove rear guide upper attaching bolts ("5",

Fig. 6-32).

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 adjustment, refer to door window adjustments.

FRONT DOOR WINDOW GUlDE TUBE

"A, B,

C and E Two-Door Hardtop and Convertible

Styles

Removal and lnstallation

1. Remove door trim assembly and inner panel water deflector as previously described.

2. With window in a full down position, remove guide tube upper and lower attaching bolts (" 1 ",

Fig. 6-34 for "A" styles and " l", Fig. 6-38 for

"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

C

Four-door Hardtop Styles

Removal and lnstallation (Refer to Figure 6-40)

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 GUIDE

"B and

C

Four-Door Hardtop Styles

Removal and Installation (Refer to Figure 6 4 0 )

Remove upper and lower portion of door trim assetnbly 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.

DOORS 6-69

FRONT DOOR WINDOW REAR GUlDE

"8"

Closed Styles

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 rear guide upper and lower attaching bolts ("2" and

"3" Fig. 6-36).

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", Fig. 6-38).

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

"F" Styles

Removal and Installation (Refer to Figure 6-42)

1. Remove front door trim assembly and inner panel water deflector.

2. With window in full-up position, remove front up-stop from guide.

3. Remove front guide upper and lower attaching bolts.

4. Pull guide down and rearward to disepgage from window front roller. Remove guide through large access hole.

5. To install, reverse removal procedure. For adjustment, refer to door window adjustments.

670 DOORS

DOOR WINDOW REAR GUIDE

"F" Styles

Removal and Installation (Refer to Figure 6-42)

1. Remove door trim assembly and inner panel water deflector.

2. Remove rear guide upper and lower attaching bolts.

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 X Closed Styles

Removal and Installation

1. On "A and X" styles, remove front door window as previously described. On "B" styles, lower glass to a full-down position.

2. Starting at the upper front comer 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

Description and Installation

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 (Fig.

6-102). 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.

VlEW "8"'

VlEW "A"

INTERFERENCE BETWEEN WEDGE PLATES

SHOULD \BE 1 / 3 2 OF AN INCH

SECTION "C-C"

51 04

DOORS 6-71

REAR DOORS

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 Sdction 13 - see index.

Illustrations 6-103 through 6-1 14 are typical of rear doors with the trim assembly and inner panel water deflector removed. These figures identify the component parts of the rear door assembly (by style), their relationship and various attaching points. 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- 1 15 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.

REAR DOOR HINGES

All Styles

Description

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.

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.

Install all previously removed parts and check door for proper alignment.

CAUTION: When replacing or adjusting door hinges, torque bolts to 14 to 22 foot pounds.

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.

Hinge Removalqand Installation

Door Removal and Installation

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.

1. Prior to loosening any hinge bolts, mark location of hinges on door or center pillar, depending on removal method being used.

2. On styles equipped with electric window regulators or power operated locks, proceed as follows:

Remove door trim assembly and inner panel water deflector.

Disconnect wire harness connector from regulator motor and/or wire harness connector from electric lock solenoid.

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.

With door properly supported, remove upper or lower hinge to door and center pillar attaching bolts and remove hinge from door.

T o 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.

CAUTION: When replacing or adjusting door hinges, torque bolts to 14 to 22 foot pounds.

6-72 DOORS

1. Inside Locking Rod

2. Window Regulator

Manual

Fig. 6-103-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 6-73

1. Inside Locking Rod to

Lock Connecting Link

Attaching Bolts

2. Window Regulator

Attaching Bolts

Fig. 6-104-Rear Door

"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

8-74

DOORS

1. Front Guide

2. Inside Locking Rod

3. Rear Door Window

Fig. 6-105-Rear Door Hardware

"A-39" Styles

4. Window Regulator

Manual

5. Door Lock Remote

Control

6. Inner Panel Cam

7. Rear Guide

8. Door Lock

P. Door Outside Handle

10. Lower Sash Channel

Cam

DOORS 6-76

1. Door Lock Remote

Control Attaching

Bolts

2, Inner Panel Cam

Anaching Bolts

3. Window Stabilizer

Strip

Fig. 6-106-Rear Door Hardware

"A-39" Styles

4. Window Rear

Up-Travel Stop

5. Window Front

Up-Travel Stop

6. Rear Guide Upper

Attaching Bolts

7. Rear Guide Lower

Attaching Bolts

.8. Front Guide Upper

Bolt

0. Front Guide Lower

Anaching Bolt

10. Window Regulator

Attaching Bolts

1 1. Front Guide to Upper

Support Attaching

Bolts

12. Window Lower Saoh

Channel Cam Stud

Nuts

6-76

DOORS

1. Window Assembly

2. Lower Sash Channel

Cam

3. Outside Handle and

Sealing Gaskets

Fig. Door Hardware

"B" Clped Styles

4. Door Lock

5. Remote Control

Connecting Rod

6. Inner Panel Cam

7. Remote Control

8. Glass Run Channel

9. Inside Locking Rod

10. Window Regulator

1 1. Window Regulator

Handle

DOORS 6-77

1. Lower Rear Glass

Run Channel Lower

Attaching Bolt

2. Inside Locking Rod

Connecting Link Bolt

Fig. 6-108-Rear Door Hardware

"B" Closed Styles

3. Lower Rear Glass

Run Channel Upper

Attaching Bolt

4. Door Lock Remote

Control Attaching

Bolts

5. Inner Panel Cam

Attaching Bolts

6. Window Lower Sash

Chan'nel Cam Stud

Nuts Access Hole

7. Door Lock Attaching

Screws

8. Window Regulator

Attaching Bolts

6-78 DOORS

- - - - -

1. Window Assembly

2. Trim Support

Hangers and

Stabilizer Strips

3. Window Front

Up-Travel Stop

Fig. 6-109-Rear Door Hardware

"B and C-39 and 49" and "C-69"

Styles, Except 68169 Styles ,

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 Regulatcw

1 1. Door Lock Remote

Control and Handle

Assembly

12. Remote Control to

Lock Connecting Rod

13. Lock Assembly

14. Door Outside Handle

DOORS 6-79

1 . Trim Support Hanger and Stabilizer Strip

Attaching Bolts

2. Window Front

Up-Travel Stop Bolt

3. Window Rear

Up-Travel Stop

Attaching Bolt

Fig. 6-1 10-Rear Door Hardware

"B and C-39 and 49" and "C-69"

Styles, Except 68169 Style

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

6-80

DOORS

1. Window Assembly

2. Trim Support

Hangers and

Stabilizer Strips

3. Window Front

Up-Travel Stop

Fig. 6-1 l 1-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 t o

Lock Connecting Rod

10. Window Down-Travel

Support and Bumper

11. Inside Locking Rod

12. Door Outside Handle

13. Door Lock

14. Window Regulator

DOORS 6-81

Fig. 6-1 12-Rear D o o r Hardware

68169 Styles

1. Tube Assembly,

W i n d o w Guide Tube

Attaching Bolts

2. Guide Assembly,

Lower Sash Lower

Attaching Bolts

3. Plate Assembly,

Lower Sash Guide

Attaching Bolts

4. Guide Assembly,

Lower Sash Upper

Attaching Bolts

5. Regulator Assembly

Anaching 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

6-82 DOORS

1. Rear Door Window

2. Inside Locking Rod

3. Window Regulator

Fig. 6-1 13-Rear Door Hardware

"X" Style

4. Lower Sash Channel

Cam

5. Door Lock

6. Door Lock Remote

Control

7. Ventilator Division

Channel

DOORS 6-83

1. Ventilator Division

Channel Lower

Adjusting Stud

2. Door Lock Attaching

Screws

Fig. 6-1 14-Rear Door Hardware

" X Style

3. Door Lock

emote

Control Attaching

Bolts

4. Ventilator Division

Channel Upper

Attaching Screw

5 . Window Regulator

Attaching Bolts

6. Inside Locking Rod to

Lock Connecting Link

Attaching Bolt

6-84

DOORS

2. Remove remote control attaching bolts ("3",

Fig. 6- 104).

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 REMOTE CONTROL

Description

There are two basic types of door lock remote controls; the " spindle" type (Figure 6- 104) which rotates upward when actuated and the "pull-in" type (Fig.

6-1 10) 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 portion on "B and C" styles) and inner panel water deflector.

REAR DOOR LOCK ASSEMBLY

All Styles

Description

All styles use the fork bolt lock design which includes a safety interlock feature. Where necessary striker spacers should be used to insure satisfactory

1,ock striker engagement. Refer to "Front and Rear

Door" section for spacer usage.

Front and rear doors can be locked from the inside by depressing the passenger guard door lock buttpn located on the upper door panel. All doors can be locked from the outside by simply depressing the interior door lock button and closing the door. The front doors can also be locked by using the square headed key.

WARNING: FIGURES 6-1 16 AND 6-1 17 DEPICTS

TYPICAL "A AND X u AND "B AND C"

STYLES, RESPECTIVELY, REAR DOOR LOCK

ASSEMBLIES WHICH CAN BE USED FOR

IDENTIFYING LOCKING PROBLEMS. DO

NOT ATTEMPT REPAIRS TO CORRECT

LOCK DISCREPANCIES. MAKE CORREC-

TJONS THROUGH REPLACEMENT OF LOCK

ASSEMBLY.

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

6-104) and remove lock from door.

4. To install, reverse removal procedure.

SECONDARY

DETENT LEVER

RETURN SPRING

REAR D O O R L O C K

/ r

PRIMARY DETENT LEVER

T R I P LEVER

LOCKING LEVER7

DOORS 6-85

- - -

STRIKER SHOE

FORK BOLT RETURN SPRING

REMOTE LEVER

Fig. 6-1 16-Rear Door Lock Assembly

"A and X" Styles

6-88

DOORS

1. Locking Lever

2. Sliding Shoe

3. Intermittent Guide Pin

4. Lock Back Plate

5. Detent Lever

Fig. 6-117-Rear Door Lock Assembly

"B and C" Styles

6. Fork Bolt

7. Intermittent Lever

8. Push Button Lever

9. Transfer Lever

10. Remote Control Lever

1 1. Spring Tension

Washer (Replace

Fork Bolt Return

Spring)

12. Push Button Pin

13. Lock Frame

REAR DOOR INNER PANEL CAM

"A-39" and "8-35,45 and 6 9 Styles

Removal and Installation

1. Remove door trim assembly (on "B" and "C" styles, remove upper and lower trim assembly) inner panel cam attaching bolts ("4", Fig. 6-

104). 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.

14. Detent Return Spring

15. Push Button Return

Spring

16. Lock Silencer

17. Sliding Shoe Pin and

Spring

18. Overcenter Spring

Correct adjustment of cam will prevent a rotated

(cocked) door window.

REAR DOOR WINDOW ASSEMBLY

" A

Closed Styles

Description

The rear door window assembly consists of a frame- less 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.

DOORS 687

Adjustments

Adjustments have been provided to relieve a binding door glass due to misalignment of the glass run channel (" Fig. 6- 1 18). In addition, the door window inner panel cam (" 3", Fig. 6- 1 18) is adjustable which can correct a rotated (cocked) rear door window.

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 (" ", Fig. 6- 1 18).

3. Loosen rear glass run channel upper and lower attaching screws (" 2", Fig. 6- 1 18).

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

Fig. 6-1 18-Rear Door Window Removal and Adjustments

" A " Closed Styles

1. Lower Sash Channel

Cam Attaching Screw

Access Holes

2. Rear Glass Run

Channel Upper and

Lower Attaching

Bolts

3. lnner Panel Cam

Anaching Bolts

Fig. 6-1 19-Rear Door Window Assembly

"A-39" Styles

1 . Roller Assembly

2. Glass Bearing

Fastener Cao

3. Glass Bearing

Fastener

4. Stud Inner Panel Cam

5. Washer (Metal)

6. Washer

7. Glass Bearing

Fastener Cap

8. Spacer

NU^

10. Rear Guide Cam

Assembly

1 1. Glass Bearing

Fastener window for proper operation and alignment as described in the following adjustment procedure.

REAR DOOR WINDOW ASSEMBLY

" A - 3 9

Styles

Description

The rear door window assembly consists of a solid tempered safety plate glass window and an individually 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.

Figure 6-1 19 is an exploded view of the window assembly and identifies the various components and their assembly sequence.

NOTE: When replacing window assembly, install new door glass spacers ("

,component attaching nuts to 72 inch pounds (6 foot pounds).

Diagnosis and Adjustment

1. WINDOW NOT PARALLEL WITH SIDE

ROOF RAIL WEATHERSTRIP

A rotated

6-88 DOORS window condition (glass cocked in opening) can be corrected by loosening front and rear up- travel stops (" 1 " and " 2", Fig. 6- 120) and inner panel cam bolts (" 8", lowering front edge of glass in relation to rear edge of glass, as required, to parallel upper edge of glass with side roof rail weatherstrip. Then, tighten inner panel cam attaching bolts and raise glass to desired height to establish proper contact with side roof rail weatherstrip. Tighten up- travel stop bolts.

WINDOW TOO FAR INBOARD OR OUT-

BOARD ALONG UPPER EDGE I N RELA-

TION TO SIDE ROOF RAIL

WEATHERSTRIP - To adjust upper edge of glass in or out in relation to side 'roof rail weatherstrip, loosen upper ends of front and rear guides (" " and " 6", Fig. 6- 120) and glass stabilizer strips (" inboard or outboard as required. Outboard adjustment of the guide assemblies tends to move the upper edge of the glass inboard. Conversely, inboard adjustment moves the upper edge of the

Fig. 6-120-Rear Door Window Removal and Adjustments -

"A-39" Styles

Window Front

Up-Travel Stop

Window Rear

Up-Travel Stop

Window Front and

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

Anaching Bolts glass outboard. With glass in a full-up position, position stabilizer strips against inner surface of glass sufficiently to stabilize glass, but not restrict operation. Then tighten attaching bolts.

3. WINDOW TOO HIGH OR LOW I N RELA-

TION TO SIDE ROOF RAIL WEATHER-

STRIP

To adjust window up-travel, loosen front and rear up-travel stops (" 1 and "2", Fig.

6- 120) and operate window to desired position to establish proper glass to side roof rail weatherstrip contact. Then tighten up-travel stop bolts.

4. WINDOW TOO FAR FORWARD OR

REARWARD I N BODY OPENING - To adjust window forward or rearward, loosen upper end of front guide (" Fig. 6- 120) and reposition glass as necessary. Upper attaching locations are slotted to permit fore and aft adjustment of the guide. Because of the free floating roller in the window rear sash channel cam (Fig. 6-1 19), rear guide does not have to be adjusted during fore or aft window alignment.

5. WINDOW MECHANISM BINDS WHEN

OPERATING WINDOW ASSEMBLY - Ease of window operation and window stability de- pend to a great extent on the adjustment of the window stabilizer strip assemblies at the beltline

("3", Fig. 6- 120).

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.

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 (Fig. 6-121).

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 6-122.

CAUTION: 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

DOORS 6-89

TOOL J 23394-2

(BLUE)

Fig. 6-121-Glass Alignment Gauge Blocks

Tool J-23394 or equivalent (Consists of a set of Three Blocks). the weatherstrip and the retainer. A tool applicable to this usage may be fabricated from tool

5-2 1 104 or equivalent (Fig. 6- 125).

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 comers of the glass, as shown in Figure 6-122.

NOTE: The grooves on the sides of the gauge blocks must be fully engaged with the side roof rail weatherstrip retainer.-

4. Working from inside the body, with the door in the ciosed position, loosen front and rear up-

Fig. 6-123-Rear Door Window Alignment

(Fore and Aft Adjustment) travel stops (" 1 and "2", Fig. 6-1 20) and stabilizer strips ("3", Fig. 6-120);

5. Raise the rear door window assembly to approximately 1" from the full-up position, as illustrated in Fig. 6-122. If the distance (space) between the upper edge of the glass and the front and rear gauge blocks is equal (as shown in Fig.

6-122), 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 panel cam attaching bolts ("8", Fig.

6- 120) and adjust glass as necessary.

6. Raise rear door window assembly until contact is established between upper edge of glass and

GAUGE BLOCKS

TOOL J 23394-2

Fig. 6-122-Rear Door Window Alignment (Rotated "Cocked"

Glass in Body Opening)

Fig. 6-124-Rear Door Window Alignment

(In and Out and Up-Travel Adjustment)

6-90 DOORS

Fig. 6-125-Weatherstrip Removing Tool 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 front guide ("7", Fig. 6- 120) and move glass forward or rearward as necessary.

Completely loosen upper ends of front and rear guides ("5" and "6", Fig. 6-120). 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 6-122. Then, tighten upper guide attaching bolts. Repeat operation with rear guide. The guides will now be coordinated to the plane of the glass.

NOTE: Inner surface of glass must contact outer surface of the upper blocks during this adjustment.

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.

Lower window and remove gauge blocks from weatherstrip retainer. Reinstall and seal weatherstrip as previously described.

Removal and Installation

1. Remove door trim pad and inner panel water deflector.

2. Remove window front up-stop from guide (" 1 ",

Fig. 6-120) and rear up-stop from door inner panel ("2", Fig. 6- 120).

3. Loosen front and rear window stabilizer strip assembly bolts (" " bilizer strips.

4. With window in full-up position, remove lower sash channel cam to glass attaching stud nuts

("4", Fig. 6-120).

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.

7. To install, reverse removal procedure. Adjust window for proper alignment and operation as described in the subsequent adjustment procedure.

REAR DOOR WINDOW ASSEMBLY

"B"

Closed Styles

Description

The rear door window assembly consists of a frame- less 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.

Adjustments

Adjustments have been provided to relieve a binding door glass due to misalignment of the glass run channel (" 1 " and "2". Fig. 6- 126). In addition. the door window inner panel cam is adjustable which can correct a rotated (cocked) front door window ("4",

Fig. 6- 126).

Removal and Installation

1. Remove upper and lower portion of door trim assembly 'and inner panel water deflector.

2. Remove rear glass run channel upper and lower attaching bolts (" 1" and "2", Fig. 6-126) and remove run channel from door.

3. Partially lower rear door window, remove lower sash channel cam to glass attaching stud nuts

("3", Fig. 6-126). Press lower sash channel cam

DOORS

6-81

inboard to disengage from attaching studs and lower window regulator to full-down position.

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 subsequent procedure.

REAR DOOR WINDOW ASSEMBLY

"B and

C" Four-Door Hardtop Sty)es8 'Except 681

69

Style

Description

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.

Fig. 6-126-Rear Door Window Removal and Adjustments

'B' Closed Styles

1. 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

Fig. 6-127-Rear Door Window Assembly

"B and C' Four

Door Hardtop Styles, Except 68169 Styles

1. Tee-Nut

2. Spacers

3. Washer (Plastic)

4. Washer (Metal)

5. Stop, Up-Travel

6. Bolt

Figure 6-127 is an exploded view of the window assembly and identifies the various components and their assembly sequence.

NOTE: When replacing window assembly, install new glass spacers (" ponent attaching nuts to 72 inch pounds (6 foot pounds).

Diagnosis end Adjustment

1. WINDOW NOT PARALLEL WITH SIDE

ROOF RAIL WEATHERSTRIP

A rotated window condition (glass cocked in opening) can be corrected by loosening front and rear up- travel stops ("2" and "3", Fig. 6- 128) and lower sash guide plate bolts ("7", Fig. 6-128) and raising or lowering front edge of glass in relation to rear edge of glass, as required, to parallel upper edge of glass with side roof rail weatherstrip.

Then, tighten lower sash guide plate bolts and raise glass to desired height to establish proper contact with side roof rail weatherstrip. Tighten up-travel stop bolts.

2. WINDOW TOO FAR INBOARD OR OUT-

BOARD ALONG UPPER EDGE IN RELA-

TION TO SIDE ROOF RAIL

WEATHERSTRIP

To adjust upper edge of window in or out in relation to side roof rail

. weatherstrip, loosen upper end of center guide

5 " , blies (" 1 ", Fig. 6- 128) and position guide inboard or outboard as required. Outboard adjustment of guide assembly tends to move upper edge of glass inboard. Conversely, inboard

6-92 DOORS adjustment moves upper edge of glass outboard.

With glass in a full-up position, position stabilizer strips against inner surface of glass and tighten attaching bolts.

3. WINDOW TOO HIGH OR LOW I N RELA-

TION TO SIDE ROOF RAIL WEATHER-

STRIP

To adjust window up-travel, loosen front and rear up-travel stops (" and " 3", Fig.

6-128) and operating window to desired position to establish proper contact with side roof rail weatherstrip. Tighten up-travel stop bolts.

4. WINDOW TOO FAR FORWARD OR

REARWARD I N BODY OPENING I N RE-

LATION T O WEATHERSTRIPS

To adjust window forward or rearward, loosen upper center guide support ("4", Fig. 6-128) and reposition glass as necessary. Upper attaching locations are slotted to permit fore and aft adjustment of the guide.

5. WINDOW MECHANISM BINDS WHEN

OPERATING WINDOW ASSEMBLY

Ease of window operation and window stability de- pends to a great extent on the adjustment of the window stabilizer strip assemblies " , Fig. 6-

TOOL J 23711-5 (BEIGE)

'LACK]

TOOL J 23711-1 (GREY) h

5088

Fig. 6-129-Glass Alignment Gauge Blocks, Tool J-23711

01 equivalent

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.

GLASS ALIGNMENT GAUGE BLOCKS

"B:C

Four-Door Hardtop Styles, Except 681 69

Styles

To facilitate adjustment of this glass, use glass alignment gauge blocks tool 5-2371 1 or equivalent (Fig.

6-129). For proper use gauge blocks, refer to the following procedure:

1. Remove upper portion of door trim assembly as described in Section 13 of this manual.

Fig. 6-128-Rear Door Window Removal and Adjustments

"B and C-39-49" and "C-69", Except 68169 Styles

1. Trim Support

Hangers and Window

Stabilizer Strip Bolts

2. Window Front

Up-Travel Stop Bolt

3. Window Rear

Up-Travel Stop Bolt

4. Center Guide Cam

Support Bolts

5. Center Guide Cam to

Upper Cam Support

Bolts

6. Center Guide Cam

Lower Bolt

7. Lower Sash Guide

Plate Stud Nuts Fig. 6-130-Rear Door Window Alignment

DOORS

6-93

Detach the side roof 'rail weatherstrip at the lower rear comer (screw retained at rear edge) and carefully remove from the retainer over the door window, as shown in Figure 6-130.

Lower front and rear door windows 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- 130.

NOTE: The grooves on the sides of the gauge blocks must be fully engaged with the side roof rail weatherstrip retainer.

Working from inside the body, with the door in the closed position, loosen front and rear up- travel stops ("2" and "3" Fig. 6- 128) and stabilizer strips (" 1 ", Fig. 6- 128).

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 Fig. 6-130), proceed with step number six (6).

If upper edge of glass does not contact both blocks simultaneously, completely loosen lower sash guide plate stud nuts ("7", Fig. 6- 128) and manipulate the glass until the upper edge of glass contacts both blocks in the full-up position.

Tighten guide plate stud nuts.

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 6-130, 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 support ("4", Figure 6-

128) and move glass forward or rearward as necessary.

Completely loosen upper end of (center) guide cam support 5 ", Fig. 6- 128). 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 6-130. Then, tighten (center) guide cam support attaching bolts.

NOTE: 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 weatherstrip with a pumpable sealer.

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 (" ",

6-128) and up-travel stops ("2" and "3", Fig.

6-128). 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", Fig. 6-128), 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 subsequently described.

REAR DOOR WINDOW ASSEMBLY

68169

Style

Description

The rear 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 6-131 is an exploded view of the window assembly and identifies the various components and their assembly sequence.

NOTE: When replacing window assembly, install new glass spacers (" ponents attaching nuts to 72 inch pounds (6 foot pounds).

Diagnosis and Adjustments

1. WINDOW NOT PARALLEL WITH SIDE

ROOF RAIL WEATHERSTRIP

A rotated

6-94 DOORS

VIEW "A"

Fig. 6- 13 1 -Rear Door Window Assembly

68 169 Styles

1. Tee-Nut

2. Spacer

3. Washer (Plastic)

4 . Washer (Metal)

5. Stop, Up-Travel

6. Bolt window condition (glass cocked in opening) can be corrected by loosening front and rear u p travel stops ("2" and "3", Figure 6- 132) and lower sash upper guide assembly ( " 5 " , Fig. 6-

132) and raising or lowering front edge of glass in relation to rear edge of glass, as required, to parallel upper edge of glass with side roof rail weatherstrip. Then, tighten lower sash upper guide attaching bolts and raise glass to establish proper contact with side roof rail weatherstrip.

Tighten up-travel stop bolts.

2. WINDOW TOO FAR INBOARD OR OUT-

BOARD ALONG UPPER EDGE I N RELA-

TION TO SIDE ROOF RAIL

WEATHERSTRIP

To adjust upper edge of window in or out in relation to side roof rail weatherstrip, loosen glass stabilizer strip assemblies ("I", Fig. 6-132) and lower sash lower guide assembly ("6", Fig. 6-132) and position glass inboard or outboard as required. Outboard adjustment of lower guide tends to move upper edge of glass inboard. Conversely, inboard adjustment moves upper edge of glass outboard.

With glass in a full-up position, position stabilizer strips against inner surface of glass and tighten attaching bolts.

3. WINDOW TOO HIGH OR LOW IN RELA-

TION TO SIDE ROOF RAIL WEATHER-

STRIP

To adjust window up-travel, loosen front and rear up-travel stops (" " 3", Fig.

6-132) and operate window to desired position to establish proper contact with side roof rail weatherstrip. Tighten up-travel stop bolts.

4. WINDOW TOO FAR FORWARD OR

REARWARD I N BODY OPENING IN RE-

LATION TO WEATHERSTRIPS

To adjust window forward or rearward loosen lower sash channel guide plate attaching bolts ("4". Fig.

6-132) and reposition glass as necessary. The attaching locations in the guide plate are slotted to permit fore and aft adjustment of the glass.

5. WINDOW MECHANISM BINDS WHEN

OPERATING WINDOW ASSEMBLY

Ease of window operation and window stability de- pend to a great extent on the adjustment of the window stabilizer strip assemblies at the beltline

", Fig. 6- 132). 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 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.

GLASS ALIGNMENT 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

- -

Fig. 6-132-Rear Door Window Removal and Adjustment

68169 Styles

1. Trim Support

Hangers and

Stabilizer Strip Bolts

2. Front Up-Travel Stop

Bolt

3. Rear U p l r a v e l Stop

Bolt

4. Lower Sash Guide

Plate Assembly Bolts

5. Lower Sash Upper

Guide Assembly Bolts

6. Lower Sash Lower

Guide Assembly Bolts

DOORS 8-96

Fig. 6-133-Glass Alignment Gauge Blocks 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 J-23711-2 and 5 or equivalent (Fig. 6-133). For proper use of gauge blocks refer to the following adjustment 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 comers and remove from retainer.

3. Lower front door window and install gauge blocks, tool J-237 1 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 6-134. Then, install gauge block, tool J-23711-5 (Beige), or equivalent into the center pillar retainer above the beltline.

NOTE: 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 u p travel stops ("2" and " 3", Fig. 6- 132) and stabilizer strips (" 1 ", Fig. 6- 132).

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 contact all three gauge blocks simultaneously (as shown in

Fig. 6-134), 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" Fig. 6-132) and lower sash upper guide assembly " 5 " Fig. 6- 132) 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 Fig. 6-134).

Tighten guide plate and upper guide assembly attaching bolts.

6. Loosen lower sash lower guide assembly "6",

Fig. 6-132). Apply firm outboard pressure against the bottom of the lower sash guide plate assembly to remove slack in the system and to hold the upper inner edge of glass inboard against outer edge of gauge blocks. Then, tighten lower guide assembly attaching bolts.

NOTE: 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 F'igure 6-134, tighten adjustable up-travel stops. Adjust stabilizer strips for proper tension against glass.

8. Lower window and remove gauge blocks from weatherstrip retainer. Reinstall and reseal weatherstrip with a pumpable sealer.

Removal and Installation

1. Remove upper portion of door trim assembly as subsequently described.

GAUGE BLOCKS

5001

Fig. 6-134Rear Door Window Alignment (Fore and Aft and

RotatedaCocked" Glass in Body Opening Adjustment)

8-98 DOORS

2. Loosen stabilizer strip bolts. (" 1 ", Fig. 6- 132) and remove front and rear up-travel stops ("2" and "3", Fig. 6-132).

3. Remove lower sash guide plate assembly to glass attaching stud nuts ("4", Fig. 6- 132). 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 subsequently described.

REAR DOOR WINDOW STATIONARY

VENTILATOR DIVISION CHANNEL

"X-69"

Style

Description

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. This assembly acts as a rear door window rear glass run channel and alsa holds the stationary ventilator window in proper position.

Removal and Inatallation

1. RCmove door trim assembly and detach inner panel water deflector sufficiently to gain access to the lower adjusting stud and nut (" ", Fig.

6-135).

2. Remove door window lower stop (rubber bumper) from down stop support bracket on door inner panel.

3. Remove ventilator division channel lower adjusting stud and nut. ( " l a , Fig. 6-135).

4. Carefully lower door window and remove division channel to door upper frame attaching screw. ("2", Fig. 6-135).

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

"X-69" Style

Description

The rear door stationary ventilator assembly is set sure of the ventilator division channel.

Fig. 6-135-Rear Door Window Removal and Adjustments

"X-69' Styles

1. Ventilator Division

Channel Lower

Adjusting Stud

2. Ventilator Division

Channel Upper

Attaching Screw

Romoval and Inatallation

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.

DOORS 6-97

REAR DOOR WINDOW. ASSEMBLY

"X-69"

Style

Description

The rear door window assembly consists of a frame- less solid tempered safety plate glass window and a pressed-on lower sash channel assembly.

Adjustments

Adjustment has been provided to relieve a binding door glass due to misalignment of the ventilator division channel. (" ", Fig. 6- 135).

Removal and lnstallation

Remove door trim assembly and inner panel water deflector.

Remove rear door window stationary ventilator assembly as previously described.

Slide window regulator lift arm roller out of window lower sash channel cam and remove glass inboard of door upper frame.

T o install, reverse removal procedure. Adjust window for proper operation as subsequently described.

REAR DOOR WINDOW REGULATOR

Manual

All " A Styles

Removal and Installation.Refer to Figure 6-104 for

"Closed" Styles and Figure 6-106 for " A - 3 9 Styles

1. Remove door trim assembly and inner panel water deflector.

2. Lower 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 " A Styles

Removal and Installation-Refer to Fig. 6-1 06

1. Remove door window as previously described.

2. Remove inner panel cam attaching bolts.

3. Disconnect body wire harness from window regulator at regulator motor.

4. On "A-39" styles, remove the window rear guide as subsequently described.

5. Remove window renulator attaching bolts and remove regulator thTough large access hole.

6. To install, reverse removal procedure.

REAR DOOR WINDOW REGULATOR

Manual and Electric

"8" Closed Styles

Removal and Installation-Refer to Figure 6-1 0 8

1. Remove upper and lower portion of door trim assembly and inner panel water deflector.

2. Lower window to a three-quarter-down position. remove lower sash channel cam to nlass attaching stud nuts. While supporting aass, 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.

3. Remove inner panel cam attaching bolts.

4. Loosen window regulator attaching bolts and remove window regulator through access hole.

5. To install, reverse removal procedure.

REAR DOOR WINDOW REGULATOR

Manual and Electric

"B and C" Four-Door

.Hardtop Styles, Except 68169 Style

Removal and Installation (Refer to Fig. 6-1 10)

1. Remove upper and lower portion of door trim assembly and inner panel water deflector (refer

6-98 DOORS 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",

Fig. 6-1 lo), then slide regulator lift arm rollef out of lower sash channel cam and remove regulator through large access hole.

4. To install, reverse removal procedure.

Operate window to full-up position and secure in place with pieces of cloth-backed body tape applied over door frame.

Remove regulator attaching bolts ("5", Fig. 6-

114). Slide regulator lift arm roller out of lower sash channel cam and remove regulator through large access hole.

To install, reverse removal procedure.

REAR DOOR WINDOW REGULATOR

68169

Style

Removal and lnstallation

Refer to Figure 6-1 12

Remove upper and lower portion of door trim assembly and inner panel water deflector.

Remove window regulator attaching bolts.

Disengage 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.

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 and Rear Door" section for the proper procedure. The tension otl the lift arm assist spring can cause serious injury if the motor is removed without use of the cautionary meas- ures described in the procedure.

REAR DOOR WINDOW REGULATOR

"X-69"

Style

Removal and lnstallation

1. Remove door trim assembly and inner panel water deflector.

2. Remove inside locking rod to lock connecting link bolt (" ing rod at lock.

REAR DOOR WINDOW FRONT GUIDE AND

BRACKET ASSEMBLY

"A-39" Styles

Removal and lnstallation

Remove door trim assembly and inner panel water deflector.

Remove window front up-travel stop from guide

( " 5 " , Fig. 6-106).

Remove inside locking rod to lock connecting link bolt. Pull locking rod assembly downward through guide bracket.

With window in full-up position, loosen front guide upper and lower attaching bolts ("8" and cess hole..

To install, reverse removal procedure. Adjust guide for proper window operation as described in door window adjustment procedure.

REAR DOOR WINDOW REAR GUIDE

"A-39"

Styles

Removal ahd lnstallation

1. Remove door tfim assembly and inner panel water deflector.

2. With window in full-up position, remove rear guide upper and lower attaching bolts ("6" and

"7", Fig. 6-106). Remove guide through access hole.

3. To install, reverse removal procedure. Adjust guide for proper window operation as described in door window adjustment procedure.

DOORS 6-98

REAR DOOR WINDOW CENTER GUIDE C A M

"B and C Four-Door Hardtop Styles, Except

681 6 9 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 atid Fig. 6- 1 10).

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. Adjust guide for proper window operation as described in door window adjustment procedure.

REAR DOOR WINDOW GUIDE TUBE

68169

Style

Removal and lnstallation

1. Remove upper and lower portion of door trim assembly and inner panel water deflector.

2. Remove upper and lower sash guide assembly

as

subsequently described, then remove tube assembly through access hole.

TO install, reverse removal procedure.

REAR DOOR WINDOW LOWER SASH UPPER

AND/OR LOWER GUIDE ASSEMBLY

68169

Style

Removal and Installation

1. Remove upper portion of door trim assembly

(refer to Index for door trim assembly removal).

2. For removal of lower sash upper and/or lower guide assembly, remove attaching bolts ("2" and/or "4', Fig. 6-112). 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

SUBJECT PAGE

Introduction

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

Rear Quarter Inner Panel Sealing

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

Rear Quarter Rear Vertical Inner Sealing

Strip-"A-57" Styles ......................................

Rear Quarter Window Rear Vertical Outer

Sealing Strip-"A-57" Styles

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

Rear Quarter Window Inner and Outer

Strip Assemblies-All " B-C-E"

Coupe and Convertible Styles

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

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 Assembly-

"A-37-57-67-87" Styles

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

Rear Quarter Window Assembly-"B-C-E"

Hardtop and Convertible Styles, Except

69347 Style

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

INDEX

SUBJECT PAGE

Rear Quarter Window Regulator (Manual or Electric)-"A-27-77" and "X-27" Styles 7-1 2

Rear Quarter Window Regulator Assembly

(Manual or Electric)- " A " Hardtop and

Convertible Styles

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

7-1 2

Rear Quarter Window Regulator (Manual or Electric)-" B-C-E" Hardtop and

Convertible Styles, Except 69347 Style

.......

7-1 5

Rear Quarter Window Motor-"A-27-

37-57-77-87" Styles

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

7-1 6

Rear Quarter Window Regulator Motor

All Styles

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

7-1 9

Rear Quarter Window Guide Assembly-"A"

Hardtop and Convertible

Styles

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

7-1 9 index). Figure 7-1 is typical of all quarter water deflector installation.

INTRODUCTION

This section of the manaul contains the service operations that are necessary for the removal, installation, adjustment and sealing of quarter assemblies and individual quarter hardware components. The procedures are arranged in the sequence that they would be performed when servicing a quarter.

To locate specific procedures, refer to "Quarter In- dex". Quarter trim service procedures are covered in

Section 13 of this manual (see Index). Also, body series or style references in the. procedures are explained under "General Information" in Section 1 of this manual.

WATER DEFLECTOR

REAR QUARTER INNER PANEL SEALING

Description and Installation

All rear quarter inner panels' are either sealed with a water deflector, access hole cover, sealing plug (or grommet) or a combination of all three to prevent entry of water into the body. Service procedures for inner panel water deflectors are outlined in the

"Front and Rear Door"' section of this manual (see

SEALING TAPE

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

Inner panel access hole covers are retained by screws to the quarter inner panel and sealed with a medium bodied body sealer. Whenever any seal has been disturbed, the area must be carefully resealed to prevent waterleaks. Body caulking compound or strip caulking is recommended if additional sealing is required.

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

"A-57" Styles

Removal and Installation

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 (Fig. 7-3).

To remove the strip assembly, lower quarter window and disengage side roof rail finishing molding adjacent to sealing strip. Then, slide strip assembly forward to disengage clips and remove sealing strip from window opening.

REAR QUARTER WINDOW REAR VERTICAL

OUTER SEALING STRIP

"A-57" Styles

Removal and Installation

Remove the quarter upper trim assembly (above belt) and quarter window rear vertical inner strip

REAR

INNER

STRIP

Fig. 7-3-Rear Quarter Window Rear Vertical Inner Sealing

Strip Assembly

ROOF DRIP MOLDING

R E A R S C A L P ASSEMBLY w i t h i n t e g r a l s e a l i n g s t r i p )

OF ARROW " A " !

Fig. 7-4-Quarter Window Rear Vertical Outer Sealing

Strip

Typical of "A-57" Styles

REAR QUARTER 7-3 assembly to gain access to the attaching screws (Fig.

7-4). On Chevrolet, Pontiac apd Oldsmobile "A-57" styles, the roof drip rear scalp molding and sealing strip are removed as an assembly.

REAR QUARTER WINDOW INNER AND

OUTER STRIP ASSEMBLIES

All "B-C-E

Coupe and Convertible Styleg

Removal and Installation (Inner Sealing Strip)

Inner sealing strips are attached to a support and are removed as an assembly. The support and strip assembly can be removed from the body by removing a bolt at the front of the window guide upper support, and, depending on the style, two or three attaching screws at the rear.

Removal and Installation (Outer Sealing Strip)

1. Remove rear seat, quarter trim panel and water deflector.

2. Scribe bolt locations at upper and lower support to guide bolts.

3. Remove upper support t'o guide bolts (" 1 Fig.

7-20 and 7121) and iower support guide bolt

("6"

Fig. 7-20 and 7-21). Lower glass and guide assembly into quarter panel to gain access to outer sealing strip attaching rivets.

I \ L I F T A R M

1113

Fig. 7-6-Rear Quarter Window Attachment

Typical

"A" Closed Styles

4. Attaching rivets can be removed by drilling out the rivet with a 1/8 inch drill bit.

CAUTION: Using larger than 1/8 inch drill bit, would enlarge the attaching 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 new rivets (Fig. 7-5).

Fig. 7-5-Quarter Window Outer Sealing Strip Rivet

Installation ("E-57" Style Shown, "B-C-E" Styles Similar)

REAR QUARTER WINDOW

"A-27 and 77" and "X-27" Styles

Adjustments

1. To obtain proper seating of glass in 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 hard operating window assemblies due to binding glass run channels 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.

7-4

REAR QUARTER

Removal and Installation

1. Remove rear quarter trim assembly and inner panel water deflector.

2. Operate quarter window to the position illustrated in Figure 7-6.

NOTE: Figures quarters and 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 front and rear lower edges of glass are sufficiently free of their respective run channels. Then, rotate front edge of glass downward between rear quarter inner and outer panels and remove window, rear edge first, inboard of side roof rail.

5. T o install, reverse removal procedure.

REAR QUARTER WINDOW REAR RUN

CHANNEL

All Closed Styles

Removal and Installation

1. Remove rear quarter window as previously described.

1. Rear Glass Run

Channel

2. Rear Window Glass

Fig. 7-7-Rear Quarter Hardware

'X-27" Styles

3. Retainer and Pivot

Pin

4. Regulator Lift Arm

5. Regulator Assembly

8. Front Glass Run

Channel

7. Front Run Channel

Retaining Screws

Fig. 7-8-Rear Glass Run Channels

Typical of All Closed Styles

REAR QUARTER

7-6

7-6 REAR QUARTER

SECTION B - B

3 2 9 7

Fig. 7-9-Rear Quarter Window Front Glass Run Channel

Typical of All Closed Styles

2. Remove run channel to inner panel attaching bolt (Fig. 7-8).

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 could result in waterleaks, and replace as necessary.

6. To install, reverse removal procedure.

REAR QUARTER WINDOW FRONT RUN

CHANNEL

All Closed Styles

Removal and Installation

1. Remove rear quarter window as previously described.

2. Remove screws along length of run channel securing channel to body (Fig. 7-9).

3. To remove run channel, carefully pry run channel from body pillar with a flat bladed tool.

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.

REAR QUARTER WINDOW ASSEMBLY

"A-37-57-67-87" Styles

Description

The rear quarter window assembly consists of a solid tempered safety plate glass window with a bolted-on lower sash guide plate and roller assembly that operates within a center guide assembly (Fig. 7-10).

Figures 7-1 1,7-12 and 7-13 are typical of "A-37, 57,

67 and 87" style quarters with trim assembly and inner panel water deflector removed. These illustrations identify the component parts of the rear quarter

P E R SUPPORT

BRACKET

UlDE ROLLERS

GUIDE

Fig. 7-10-Rear Quarter Window and Guide Assembly

"A-37, 67, 87" Styles

REAR QUARTER

7-7

1. Rear Up-Stop

2. Regulator Lift Arm

Roller

3. Regulator Lift Arm

4. Front Up-Stop

Fig. 7-1 1-Rear Quarter Hardware

'A-37 and 87" Styles

5. Window Guide

6. Down Stop

7. Lower Guide Support

Bracket

8. Electric Motor

9. Regulator Assembly

10. Fron! 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. 7-12-Quarter Hardware

"A-57"

3. Regulator

4. Lower Stop

5. Lower Guide Support

6. Guide

7. Regulator Lift Arm

8. Stop Assembly

9. Sash Channel Cam

10. Rear Up-Stop

REAR QUARTER

7 8

1. Window Glass

2. Regulator

3. Lower Stop

Fig. 7-13-Quarter Hardware

"A-57"

4. Support Guide Lower

5. Support Guide Upper

6. Front Upper Stop

7. Sash Channel Cam

8. Rear Upper Stop

0. Roguletor Lift Arm

10. Front Roller

11. Guide

7-10

REAR QUARTER

2 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 disengagement 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.

Then, remove glass, bottom side first, through the belt line opening outboard of side roof rail.

To install, reverse removal procedure.

S E C T I O N B - B

" I E w A 3 2 9 6

Fig. 7-14-Rear Quarter Window

"A-37, 57, 87" Stylea

1. Quarter Window

Glass

2. Filler

3. Channel

4. Sealer hardware by style, their relationship and various attaching points.

Figures 7- 14 and 7- 15 are typical exploded views of window assemblies and identifies the various components and their assembly sequence.

NOTE:

When installing glass to sash channel bolts, or nylon roller nuts, torque to 72 inch pounds (6 foot pounds). When replacing window assembly, install new glass spacers (" ", Fig. 7- 15).

Adjustments

The rear quarter window guide is secured to the quarter inner panel at the bottom and top with support brackets. 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.

Removal and Installation

1. Remove rear seat cushion, seat back, rear quarter trim and inner panel water deflector and/or

Fig. 7-15-Rear Quarter Window Assembly

Styles

"A-37, 87"

Shown, "A-51" Style Typical

1. Glass

2. Lower Sash Channel

Filler

3. Lower Sash Channel

4. Lower Sash Channel

Cam

6. Glass to Sash Bolt

6. Guide Front Roller

7. Guide Roller Spring

8. Guide Lower Roller

9. Guide Roller Washer

Rubber

10. Washer

Rubber

1 1. Glass to Sash

Bushing (Spacer)

12. Glass to Saah Nut

13. Front Vertical

Weatherstrip

REAR QUARTER

1. Glass

2. Lower Sash Channel

Filler

3. Lower Sash Channel

4. Lower Sash Channel

Cam

Fig. 7-16-Rear Quarter Window Assembly

"B-C and E n 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

(Spacers)

REAR QUARTER WINDOW ASSEMBLY

"B,

C and E Hardtop and Convertible Styles,

Except 69347 Style

Description

"B, and E" Hardtop and Convertible Style rear quarter window

assemblies

consist of a solid tem-

10. Front Vertical

Weatherstrip

1 1. Front Vertical

Channel

12. Front Vertical Filler pered safety plate glass window with bolted-on

, lower sash guide plate and roller assembly that operates within a center guide assembly.. 69347 Styles utilize a stationary quarter window assembly. For

69347 Style quarter window assembly removal, refer to stationary glass removal procedures in Section 4 of this manual.

Figures 7-1 8 and 7-19 are typical of E"

7-12

REAR QUARTER

Fig. 7- 17-Quarter Window Roller Removal hardtop and convertible styles, except Cadillac

69347 Styles. These illustrations identify the component parts of the rear quarter hardware by style, their relationship and various attaching points.

Figure 7-16 is a typical exploded view of "B, C and components and their assembly sequence.

NOTE: When installing glass to sash channel bolts, or nylon roller nuts, torque to 72 inch pounds (6 foot pounds). When replacing window assembly, install new glass spacers ("9", Fig. 7- 16).

Figure 7-17 illustrates usage of tool 5-22055 or equivalent for removal of quarter window glass roller nuts.

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.

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" Fig. 7-20 for "B and C" Styles and 7-21 for "EN Styles) and remove stop from inner panel.

4. Remove lower down-travel stop bolt ("5" Fig.

7-20 for "B and C" Styles and 7-21 for "E"

Styles) and remove stop from inner panel.

5. Remove attaching bolts from upper support assembly to inner panel ("2" Fig. 7-20 for "B and

6. Remove attaching bolts from lower guide support ("6" Fig. 7-20 for "B and C" Styles and

7-21 for "E" Styles).

7. On "B and E-67" styles lower folding top.

8. Disengage regulator lift arm from sash channel came and remove glass and guide as an assembly

(Fig. 7-22).

9. To install reverse removal procedure.

REAR QUARTER WINDOW REGULATOR

(MANUAL OR ELECTRIC)-"A-27 AND

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 window 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.

REAR QUARTER WINDOW REGULATOR

ASSEMBLY (Manual or Electric)- " A Hardtop and Convertible Styles

Removal and Installation

1. Remove rear quarter trim assembly and inner

REAR QUARTER 7-13

1. Quarter Window

Glaes

2. Vertical Sash

Channel and

Weatherstrip

Fig. 7-18-Quarter Window Hardware - "B, C and E Hardtop

Convertible Styles, Except Cadillac 69347 Styles

3. Upper Support

Assembly

4. Regulator Assembly

5. Guide

6. Lower Guide Support

Assembly

7 . Lower Down Stop

Assembly

8. Upper Front Stop

Assembly

9. Upper Rear Stop

Assembly

7-14 REAR QUARTER

1. Quarter Window

Glass

2. Vertical Sash

Channel and

Weatherstrip

Fig. 7-19-Quarter Window Hardware

"B-C and E Styles (Power Window)

3. Upper Support

Assembly

4 . Regulator Assembly

5. 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

7-15

Fig. 7-20-Rear Quarter Hardware

'B and C-47, 57 and 67" Styles

1. Upper Support to

Window Guide

Attaching Bolts

2. Upper Support to

Inner Panel Attaching

Bolts

3. Front Up-Travel Stop panel access hole cover or water deflector. On electric styles, disconnect feed wire at motor.

4. Window Regulator

Attaching Bolts

5. Down-Travel Stop

6. Window Guide Lower

Support to Inner

Panel Attaching Bolt

7 . Rear Up-Travel Stop

4. To install, reverse removal procedure.

2. On "A" Styles, prop window in up position 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 n,-essary, loosen upper attaching points of front guide to gain additional clearance.

REAR QUARTER WINDOW REGULATOR

(MANUAL OR ELECTRIC)-"B, C AND

.E" HARDTOP AND CONVERTIBLE

STYLES, EXCEPT 69347 STYLE

Removal and Installation

1. Remove glass and guide assembly as outlined under Rear Quarter Window Assembly.

7-16

REAR QUARTER

Fig. 7-21-Rear Quarter Hardware

"E-47, and 67" Styles shown, "E-87"

1. Upper Support to

Window Guide

Attaching Bolts

2. Upper Support to

Inner Panel Attaching

Bolts

3. Front Up-Travel Stop

On styles with electric operated windows disconnect wire at motor.

Remove quarter window rear up-stop.

NOTE: On styles with electric operated windows it may be necessary to remove quarter window down-stop.

Remove regulator attaching bolts. Remove regulator through access hole (see Figs. 7-20 for

"B and C" Styles and 7-2 1 for

To install, reverse removal procedure.

4. Window Regulator

Attaching Bolts

5. Down-Travel Stop

6. Window Guide Lower

Support to Inner

Panel Attaching Bolt

7. Rear Up-Travel Stop

REAR QUARTER WINDOW MOTOR

"A-27,37,57,77 and 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 posi'tion.

2. Remove wiring harness clips.

CAUTION: Wiiing harness and switch assembly should be placed in an out of the way area to prevent damage.

REAR QUARTER 7-17

3. Referring to Fig. 7-25 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.

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. 7-24).

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 mov- i'ng.

Fig. 7-23-Rear Quarter Hardware Attachment - " A and X"

Closed Styles

8. After replacing motor and prior to trim installation, apply waterproof tape to seal any motor

- of the water deflector.

Fig. 7-22-Quarter Glass and Guide Assembly Fig. 7-24-Quarter Window Hardware "A" Styles (Electric)

7-18 REAR QUARTER

H O L E S

Points for Locating Window Motor to Regulator Attaching Bolts)

"A-27, 37, 57, 67, 77 and 87" Style

3 4 7 4

REAR QUARTER 7-19

REAR QUARTER WINDOW REGULATOR

MOTOR

All Styles

Description

BALANCE ARM

LIFT ARM

INDICATES

MOTOR HOUSING EXTENSION

Removal and Installation

1. Remove front quarter window electric regulator and clamp assembly in a vise (Fig. 7-26).

NOTE: The position of regulator assembly in vise will vary with type of regulator and position of lift arm.

2. Drill a 1/4" hole through regulator back plate and sector gear. The exact point of this hole will be dependent on the position of the regulator lift arm.

CAUTION: DO NOT drill into the motor housing, part of which is indicated by the dotted line illustrated in Figure 7-26. In addition, locate hole sufficient distance from edge of sector gear to insure proper retention of sector gear to back plate.

3. Install a 3/16" bolt through hole in regulator back plate and sector gear and install a nut on the bolt. D O NOT tighten nut.

WARNING: BE SURE T O PERFORM STEPS 2

A N D 3 BEFORE ATTEMPTING TO

REMOVE MOTOR FROM REGULATOR

ASSEMBLY. THE REGULATOR LIFT

ARM IS UNDER TENSION FROM THE

REGULATOR COUNTER-BALANCE

SPRING A N D CAN CAUSE SERIOUS IN-

JURY I F MOTOR IS REMOVED FROM

REGULATOR WITHOUT LOCKING THE

SECTOR GEAR I N POSITION WITH A

NUT A N D BOLT.

4. Remove regulator motor attaching bolts and remove motor from regulator assembly (Fig. 7-

26).

CAUTION: Clean off any steel chips from regulator sector gear and motor pinion gear.

5. To install, reverse removal procedure. If difficulty is encountered in lining up motor attaching holes with regulator assembly, the regulator

-~ - - - - -~

- = -

Fig. 7-26-Quarter Window Regulator Removal

Door

Window Regulator Shown,

Quarter Window Regulator Similar that motor pinion gear will mesh with teeth on regulator sector gear. After installation of front door window assembly, cycle electric regulator several times before installing inner panel water deflector and door trim pad.

CAUTION: Be sure to remove temporary nut and bolt securing regulator back plate to. regulator sector gear before installing assembly into door.

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 " Fig. 7-27) and remove stop from inner panel.

3. R e m ~ v e

Fig.

("6"

7-27)

and remove stop from inner panel.

# .

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

Figure 7-27-"A" Rear Quarter Window Assembly

REAR COMPARTMENT

LID 8-1

SECTION

SUBJECT PAGE

Rear Compartment Lid

Introduction

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

8- 1

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

8- 1

Rear Compartment Lock Cylinder Emblem 8-1

Rear Compartment Lid Lock Cylinder

All Styles

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

8-2

Rear Compartment Lid Lock

All Styles

8-2

Rear Compartment Lid Lock Striker

All Styles Except Cadillac with Mechanical

Pull Down Unit

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

8-4

Rear Compartment Mechanical Pull-Down

Unit and Electric Lid Release Assembly

Cadillac Styles

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

8-5

INDEX

SUBJECT PAGE

Rear Compartment Mechanical Pull-Down

Unit Hydraulic Cylinder Cables

Styles

Cadillac

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

8-8

Rear Compartment Mechanical Pull-Down

Unit Hydraulic Cylinder

Rear Compartment Lid

Cadillac Styles. 8-8

All Styles

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

8-8

Rear Compartment Torque Rod Adjustment

All Styles

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

Rear Compartment Weatherstrip

All

8-8

Styles

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

Rear Compartment Front Panel

"F" and

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

8 -9

8-1 1

Rear End Finishing-panel

Styles

Pontiac "F"

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

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 compartment lid hardware components.

REAR COMPARTMENT LOCK CYLINDER

EMBLEM

Description

Rear compartment lock cylinder emblems are applied over the lock cylinder and retained by stud nuts

EMBLEM

SECTION B-B

OUTER P A N

VIEW I N I

O F ARRC

Fig. 8-1-Rear Compartment Lock Cylinder Emblem

Oldsmobile "A" Styles

L O C K c ~ L ~ ~ D ~ E R -

RETAINER

Fig. 8-2-Rear Compartment Lock Cylinder Emblem

Oldsmobile "B and C" Styles

8-2 REAR COMPARTMENT LID

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

J

ing holes in lid assembly and install stud nuts or new 5/32" x 1/8" "pop" rivets or equivalent.

Seal base of attaching studs or rivet holes with suitable sealer.

RETAINER

Gg. 8-3-Rear Compartment Lock Cylinder Emblem

"E" Styles

Buick or rivets. This type of installation necessitates removal of the emblem prior to lock cylinder removal.

Removal and Installation

NOTE: Refer to Figure 8-1 for Oldsmobile "A"

Styles, Figure 8-2 for Oldsmobile "B and C" Styles,

Figure 8-3 for Buick

All Other Styles.

"E" Styles and Figure 8-4 For

. .

1. o h 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 attach-

REAR COMPARTMENT LID LOCK CYLINDER

All Styles

Description

On most styles, the rear compartment lid lock cylinder 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 nut. On styles equipped with lock cylinder emblems, it is necessary to remove the emblem, as previously described, prior to cylinder removal.

Removal and Installation

NOTE: Refer to Figures 8-5, 8-3, 8-6, 8-7 and 8-8.

1. Open rear compartment lid.

2. On styles so equipped, remove lock cylinder emblem as previously described.

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.

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. .

Fig. 8-4-Rear Compartment Lock Cylinder Emblem

Typical

Buick and Cadillac "C" Styles and Cadillac "E" Styles

REAR

COMPARTMENT

LID LOCK.

AN styles

Description

Two types of rear compartment lid locks are used on

1972 styles. Manual locks are standard equipment and electric release locks are optional. The electric

REAR COMPARTMENT LID 8-3

Fig. 8-5-Rear Compartment Lid Lock Cylinder

Typical All

Styles with Cylinder Located in Lid Assembly, Except Buick 'E" Styles

1. Lock Cylinder

2. Gasket

3. Shaft

4. Lock lid release unit is designed to unlock and open a rear compartment lid from inside the

car.

The specific operating instructions are covered in detail in the

Owner's Manual.

Adjurtmentr

Rear compartment lid locks are adjustable laterally, regardless of location, to provide for proper lid operation and lock to striker engagement.

To determine if lock or striker adjustment is required, proceed as follows:

1. Make certain rear compartment lid is properly aligned.

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 indentations 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 tngage- ment. Close lid and check for proper lid and key operation.

6. Cylinder Retainer 7. Lid Outer Panel

8. Lid Inher Panel cylinder and shaft as previously described.

2. Remove attaching bolts sectlring lock (Figs. 8-9 and 8-10) to rear compartment lid or rear end panel.

3. On all styles equipped with electric lid release units, disconnect electric feed wire at solenoid connector and remove lock.

RETAINER FASTENER

LOCK CYLINDER

RETAINER

SEALING GASKET

LOCK CYLINDER

Removal and lnrtallation

1. Open rear compartment lid and remove lock

Fig. 8-6-Rear Compartment Lid Lock Cylinder

Typical All

Styla with Cylinder Located in Rear End Panel, Except "F'

Style9

8 4 REAR COMPARTMENT LID

4. T o install, reverse removal operations. Close lid and check lock engagement with striker. Make necessary adjustments as outlined under adjustments.

REAR COMPARTMENT LID LOCK STRIKER

All Styles, Except Cadillac Styles Equipped

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.

1. Lock Cylinder

Housing

2. Lock Cylinder

Housing Attaching

Bolts

Fig. 8-7-Rear Compartment Lid Lock Cylinder

Chevrolet "F'

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

REAR COMPARTMENT LID 8-6

Fig. 8-&Rear Compartment Lock Cylinder

Pontiac "F" Styles

1. Rear End Finishing

Panel

2. Rear Compartment

Lock Cylinder

Attaching Studs

Removal and Installation

3. Rear Compartment

Lock Assembly

4. Lock Cylinder Gasket

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 and check lock to striker engagement. Make any necessary adjustments as outlined below.

6. Lock Cylinder

~ s s e m b l y

6. Lock Cylinder Shaft

7. Lock Cylinder Guard

8. Lock Cylinder

Attaching Nuts

9. Rear End Panel unit is used in conjunction with the electric lid release (Fig. 8-1 1).

A hydraulic cylinder (Fig. 8-12 for "C" styles and

Fig. 8- 13 for anism to achieve a slow, uniform closing action. On

REAR COMPARTMENT MECHANICAL

PULL-DOWN UNIT and ELECTRIC LID

RELEASE ASSEMBLY

Cadillac Styles

Description

The rear compartment lid mechanical pull-down Fig. 8-9-Typical Rear Compartment Lock Mounted i n Lid

8-6 REAR COMPARTMENT LID

Fig. 8-10-Typical Rear Compartment Lock Mounted in Rear

End Panel

"C" styles the cylinder (Fig. 8-12) is attached to a bell crank at the right rear compartment lid hinge and to the closing unit by a cable (Figs. 8-14 and

8-1 1). On "E" styles, one end of the cylinder is attached to the bell crank at the right rear compartment lid hinge and to the closing unit by a cable

(Figs. 8-13 and 8-1 1). 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.

Adjustments

To actuate the mechanical pull-down unit, the rear

Fig. 8-1 1-Rear Compartment Mechanical Pull-Down Unit and Electric Lid Release - Cadillac Styles

REAR COMPARTMENT LID 8-7 compartment lid lock must properly engage the striker arm and the detent lever on the mechanical pull-down unit (Fig. 8-1 1) fully depressed. Engage- ment 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.

CAUTION: A lack of lubrication between the toggle and the detent lever (" ", Fig. 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.

Removal and Installation

1. Open rear compartment lid and remove mechanical pull-down unit cover panel. Depress striker slightly to relieve tension from cable and

Fig. 8-13-Mechanical Pull-Down Unit Hydraulic Cylinder

Cadillac "E" Styles 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.

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 (Fig. 8-1 1). Remove unit from body.

4. To install, reverse removal procedure.

HINGE STRAP

ATTACH IN^,

ATTACHING BOLT

Fig. 8-12-Mechanical Pull-Down Unit Hydraulic Cylinder

Fig. 8-1CMechanical Pull-Down Unit Hydraulic Cylinder

Cable Attachment

Cadillac Styles

8-8 REAR COMPARTMENT LID

REAR COMPARTMENT MECHANICAL

PULL-DOWN UNlT HYDRAULIC CYLINDER

CABLES-Cadillac Styles

Removal and Installation

1. Disengage cable and cable conduit retaining clips at both ends of cable (Figs. 8- 1 1, 8- 12 and

8- 14). Then, remove cable assemblies.

NOTE: On "C" styles, to disengage cable from bell crank (Fig, 8- 14), 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.

REAR COMPARTMENT MECHANICAL

PULL-DOWN UNlT HYDRAULIC

CYLINDER-Cadillac Styles

Removal and Installation

On " C" styles, disengage cable to hydraulic cylinder retaining clips at both ends of cylinder

(Fig. 8- 12) and remove cylinder.

On "E" styles, disengage cable from lower end of hydraulic cylinder as previously described.

Then, lift cylinder to disengage upper end from shoulder to shaft on linkage portion of hinge assembly to remove cylinder.

To install, reverse removal procedure.

REAR COMPARTMENT LID

All Styles

Adjustments

Fore And Aft and Lateral 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 (Fig. 8-14) and shift lid to desired position. Then, tighten bolts.

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

Fig. 8-15-Rear Compartment Torque Rod Adjustment and X" Styles

"A forward bolt location. To lower lid, install shims at rear bolt locations.

Removal and Installation

Open lid and place protective covering along edges of rear compartment opening to prevent damage to painted surfaces.

Where necessary, disconnect wire harness from rear compartment lid.

Mark location of hinge straps on lid inner panel.

With aid of helper, remove attaching bolts securing hinges to lid and remove lid (Fig. 8-14 depicts hinges for all styles).

To install, reverse removal operations.

REAR COMPARTMENT TORQUE RODS

All

Styles

Description

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.

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

REAR COMPARTMENT LID 8-9 amount of effort required to close the lid, reposition the end of the rod to a lower torque rod adjusting notch (Figs. 8- 15, 8- 16, 8- 17 and 8- 18).

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 (Figs. 8-1 5, 8- 16, 8- 17 and 8-1 8).

1. For removal and/or adjustment of rear compartment lid torque rods, use tools outlined below: a. On "A and X" styles, use tool 5-21412 or equivalent (Fig. 8- 15). b. On Cadillac "C and E" styles, use tool J-

23722 or equivalent (Fig. 8-16). c. On Oldsmobile "En styles, use tool BT-7102 or equivalent (Fig. 8-17). d. On "F" styles, use a length of 1/4" inside diameter pipe (Fig. 8-1 8). e. On "B, C, E" styles, except Cadillac "C and

E" and Oldsmobile "E" styles, use a length of 1/2" inside diameter pipe (refer to Fig.

8- 18).

2. To remove torque rods, disengage end of torque rod from adjusting notches on hinge strap, as shown in Figures 8-15, 8-19 and 8-20. 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 19 and 8-20, 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, reverse removal procedure.

REAR COMPARTMENT WEATHERSTRIP All

Styles

Removal and Installation

1. Separate "butt" ends of weatherstrip at bottom rear of opening ("B", Fig. 8-21).

Fig. 8-16-Rear Compartment Torque Rod Adjustment

Cadillac "C and

2. Using flat-bladed tool, such as sharp bladed putty knife, carefully cut cemented bond of weatherstrip from outer surface of gutter (Fig. 8-21).

Then, with a narrower sharp tool, such as a

Fig. 8-17-Rear Compartment Torque Rod Adjustment

Oldsmobile "E" Styles

8-10 REAR COMPARTMENT LID

Fig. 8-18-Rear Compartment Torque Rod Adjustment

Shown, "B, C and E" Styles, except Cadillac " C and

"F" Styles wood chisel, cut cemented bond of weatherstrip from bottom of gutter around opening and remove weatherstrip.

3. To install, clean out gutter around opening to provide clean cementing surface.

4. Apply generous bead of black weatherstrip cement to bottom surface of gutter around opening

(Fig. 8-21). With suitable brush, gently level applied cement.

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 linstalling weatherstrip. Avoid stretching weatherstrip during installation.

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 uniformly in gutter.

REAR COMPARTMENT LID 8-1 1

7. Using a pressure type applicator, apply weatherstrip cement (neoprene type) between weatherstrip and outer surface of gutter completely around opening to assure a watertight seal (Fig.

8-21).

8. Roll or press weatherstrip to aid in obtaining good cement bond. Allow sufficient time for cement to set before closing r&r compartment lid.

REAR COMPARTMENT FRONT PANEL

"F"

Styles and Oldsmobile " E Styles

Removal and Installation

1. With rear compartment lid raised, remove screws from lower edge of panel as shown in

Figure 8-22 ("F" styles shown, Oldsmobile "EW styles similar).

2. Remove back window lower reveal molding.

(See "Exterior Moldingsw Section).

3. Remove screws from upper edge of panel and remove panel.

Fig. 8-20-Rear Compartment Torque Rod Removal -

Oldsmobile "En Styles

CAUTION: 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. T o install, reverse removal procedure.

REAR END FINISHING PANEL

Pontiac "F"

Styles

The rear end finishing panel is made of molded glass nuts (Fig. 8-23).

I b .

SECTION A - A

A P P L Y C E M E N T

T R l l

' I N S T A L ~ A T ~ O N

~ 2 - b l N T

I N S T A L L A T I O N

Fig. 8-19-Rear Compartment Torque Rod Removal

Cadillac

"C and E" Styles Except Oldsmobile "En Styles Fig. 8-21-Rear Compartment Weatherstrip

8-12 REAR COMPARTMENT LID

Fig. 8-22-Rear Compartment Front Panel

"F" Styles Shown, Oldsmobile "E" Styles Similar

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.

Fig. 8-23-Rear End Finishing

Pontiac "F" Styles

1 . Rear End Finishing

Panel

2. Finishing Panel Studs

3. Washer

4 . Rear End Panel

5 . Attaching Nuts

TAlL GATE 9-1

SECTION 9 TAlL GATE

INDEX

SUBJECT PAGE

Retractable Tail Gates

Description

.................................... 9-2

.................................................... 9 -2

Back Body Opening Weatherstrip ................ 9-2

Tail Gate Belt Weatherstrip

........................ 9-4

Tail Gate Window Inner Weatherstrip ........ 9-5

Tail Gate Bottom Drain Hole Sealing

Strips ............................................................ 9-5

............ 9-5 Lower Housing Drain Sealing Strip

Tail Gate Inner Finishing Panel

Tail Gate Window

.................. 9-6

........................................ 9-7

Tail Gate Window Assembly ........................ 9-7

Tail Gate Window Regulator

Assembly

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

Tail Gate Window Motor Assembly

9-8

............ 9-8

Tail Gate Window Motor Cable

Assembly ...................................................... 9 -9

Tail Gate Window Cam Guide

.................................... 9-1 0

Tail Gate Window Drive Cable Assembly .. 9-10

Window Stop Cable and Clip Assembly

Roller Assembly .

......

Tail Gate Window Down-Travel Stops

........

9-1 3

9-1 4

Tail Gate Window Assist Spring and

Silencer ........................................................

Heated Tail Gate Window Rear Wire

Harness

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

9- 1 5

9 - 1 6

Retractable Tail Gate Window

Diagnosis Chart

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

9 - 1 6

Tail Gate System ........................................ 9-1 8

Tail Gate Assembly ...................................... 9-1 8

Tail Gate Guide Channel .............................. 9-1 9

Tail Gate Roller Support .............................. 9-20

Assembly ......................................................

Tail Gate Torque Rod

9-2 1

.................................. 9-22

Retractable Tail Gate Diagnosis

Chart ............................................................ 9-23

Tail Gate and Lift Arm Hinge Assembly

................................ 9-24

Tail Gate Lift Arm Hinge and Regulator

Assembly Motor

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

Tail Gate Striker Assembly

Tail Gate Lock Assembly

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

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

9-24

9-26

Tail Gate Outer Panel Grip Handle (Manual

Tail Gate Only)

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

Tail Gate Adjustments .................................. 9-26

Window and Tail Gate Control System

......

9-26

9-28

Tail Gate Lock and Release Switch Assembly

(Manual Tail Gate) .................................... 9-28

Tail Gate Window Control Switch

(Power Tail Gate Only)

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

9-29

SUBJECT PAGE

Tail Gate Window Control Switch Lock

Cylinder (Manual Tail Gate Only)

Retractable Tail Gate Lubrication

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

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

Retractable Tail Gate Control System

Diagnosis Chart ..........................................

Dual Acting Tail Gates ..................................

Tail Gate Inner Panel Water Deflector

......

Tail Gate Inner Panel Access Hole

Covers ..........................................................

Tail Gate Body Hole Sealing Strips

Tail Gate Opening Weatherstrip

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

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

Tail Gate Window Upper Glass Run

Channel

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

Tail Gate Window Lower Glass Run

Channel ........................................................

Tail Gate Window Regulator . and Electric ..................................................

Tail Gate Window Electric Regulator

Motor Assembly

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

Tail Gate Cut-Out Switch ............................

Tail Gate Window Regulator Manual

Outside Handle

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

Tail Gate Window Regulator Outside

Electric Key Switch ....................................

Tail Gate Window Assembly . or Electric ....................................................

Tail Gate Remote Control Inside Handle

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

Tail Gate Inside Handle and Cable

Assembly .

Side) ............................................................

Tail Gate Lock Remote Control

Assembly . ..........

Tail Gate Right Upper Lock Assembly

Tail Gate Right Lower Lock Assembly

......

Tail Gate Left Upper Hinge and Lock

Assembly Gate Side ..................................

Tail Gate Left Lower Hinge Assembly ........

Tail Gate Left Upper Hinge and Striker

Assembly Body Side ................................

Tail Gate Right Upper Striker

Assembly ......................................................

Tail Gate Right Lower Striker and

Support Assembly

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

Tail Gate Torque Rod and Assist

Link ..............................................................

Tail Gate Assembly ......................................

Dual Acting Tail Gate Lock Synchro- nization Check and Procedure

Single Acting Tail Gate

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

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

9-2

TAlL GATE

SUBJECT PAGE

Tail Gate Inner Cover Panel

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

9-60

Tail Gate Inner Panel Access Hole

Covers

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

9-60

Tail Gate Hinge Assembly

Tail Gate Support Cables

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

9-6 1

SUBJECT PAGE

Tail Gate Assembly ...................................... 9 -6 1

Tail Gate Remote Control Assembly

..........

9-62

Tail Gate Lock Assembly - Right or

Left

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

9-6 3

Tail Gate Lock Striker

Right or Left ........ 9-63

RETRACTABLE TAlL GATES

DESCRIPTION

The retractable tail gate is designed to lower into the underbody and in general follows the body contour during the opening and closing cycles. Similarly, the back window, which is separate from the gate, raises upward and into the space between the roof inner and outer panels.

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 rear of the right hand quarter outer panel, adjacent to the gate.

The power operated tail gate (optional equipment) may be operated by the exterior key switch, but remote operation by an instrument panel switch is limited to the following car divisions and specific conditions:

1. On Chevrolet styles, the power tail gate can be operated only by the key switch on the rear quarter panel.

2. On Pontiac and Buick styles, the power tail gate can be operated by the instrument panel switch, provided ignition switch is in "Run" position and transmission is in "Park" or "Neutral".

3. On Oldsmobile styles, the tail gate can be operated by the instrument panel switch, provided ignition switch is in "Run" position with the engine off.

For power operated tail gates, the exterior control switch incorporates three detents each to the right and left of center (vertical) position. Rotation of the switch to the first detent operates the window, second detent the tail gate and third detent is for simultaneous operation of window and tail gate. The exterior switches actuate opening cycles when rotated clockwise and closing cycles when rotated counterclockwise.

The manual tail gate may be released from the fully closed (latched) position only by the exterior control switch. Rotation of the key to the first position

(clockwise) opens the tail gate window; then, clockwise rotation of the knob mechanically releases the tail gate for manual lowering. A grip handle at top center of the manual tail gate is provided for manual raising and latching of the gate. Rotation of the key counterclockwise closes the tail gate window.

A design feature prevents counterclockwise rotation of the exterior key switch for lowering (closing) the window until the manual tail gate is fully closed.

Another safety feature prevents lowering the window from the instrument panel switch (beyond a point approximately 8 inches above the beltline) until the manual tail gate is fully closed.

Control of the window and power operated tail gate from the instrument panel is accomplished with individual switches. The safety features provided with the manual tail gate with relation to the window, are not required with the power operated tail gate option.

Figure 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

Description

The back body opening weatherstrip is of two-piece design with a butt joint located at the bottom and top of the opening (Fig. 9-2). Below the belt, the weatherstrip is cemented into screw applied channel-

9-4 TAlL GATE

SECTION A - A

Fig. 9-2-Back Body Opening Weatherstrip Retention

2. Remove right and left pillar finishing moldings. operation at bottom of the opening. Cut off excess weatherstrip to form a butt joint at top and-

/or bottom of body opening.

3. Remove screws securing weatherstrip retainers above beltline, at detail-areas at beltiine off-set and at lower corners of back body opening (Fig.

9-2). Remove locating buttons at upper corners, if present.

4. With a flat-bladed tool, carefully remove weatherstrip around entire back body opening.

Separate the weatherstrip at either or both butt joint to facilitate removal between hinge lift arm and tail gate.

5. T o install original part, apply bead of black weatherstrip cement to entire body opening and starting at beltline details on both sides, reverse removal procedure. When installing new weatherstrip, begin installation at belt detail area, continue to the upper butt joint and complete

TAIL GATE BELT WEATHERSTRIP

Description

The tail gate belt weatherstrip is cemented to an adjustable (fore-aft) metal retainer which is fastened to the top of the tail gate by screws (Fig. 9-3). Ap- proximately 2 inches of belt weatherstrip extends beyond each end of the metal retainer. This section of weatherstrip (each end) is secured directly to the tail gate by cement and a single screw.

Removal and Installation

1. Remove screws securing end of weatherstrip to

9-6 TAlL GATE

FRONT OF CAR

Fig. 9-5-Body Rear Upper and Lower Housing Components

1. Back Body Upper

Housing

2. Back Body Upper

Housing Seals

3. Back Body Lower

Housing Drain

Sealing Strip (Right

Side Only)

2. To install, reverse removal procedure.

TAlL GATE INNER FINISHING PANEL

Description

The tail gate inner finishing panel is sealed around its periphery and is attached by screws; thus a separate water deflector is not required (Fig. 9-6). applied to the finishing panel provides the seal. A 3 inch gap in the tape at each upper outer comer, channels water that may by-pass the gate belt weatherstrip into the tail gate.

Removal

1. Remove screws securing inner panel to tail gate.

4. Back Body Lower

Housing

5. Back Body Lower

Housing Access

Covers

6. Back Body Lower

Housing Access

Cover Seal

2. With a flat-bladed tool carefully break bond sealing inner panel to tail gate and remove panel.

Installation

1. Inspect finishing panel sealing strip and repair if necessary, with equivalent material or strip caulk (Fig. 9-6).

2. Install tail gate inner panel to tail gate and press firmly around periphery.

3. Apply body caulking to panel attaching screw threads and install screws.

VIEW " A "

Fig. 9-6-Tail Gate Finishing Panel Sealing

4647

TAlL GATE WINDOW SYSTEM

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 guide cams

(Fig. 9- 1).

TAlL GATE WINDOW ASSEMBLY

Description

The tail gate window assembly consists of a solid tempered safety plate glass 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, roller supports and upper sash channel (with or without lift spring) are removed from the body opening as a unit. Replacement glass and roller supports are assembled as a bench operation.

Removal and Installation

1. Remove finishing moldings from right and left pillars, from upper section of back body opening

TAlL GATE 9-7 and remove upper and right side inner filler strips (Figs. 9-4 and 9-3).

2. Carefully detach back body opening weatherstrip sculptured belt detail sections.to approximately 5" below beltline. Rotate detached weatherstrip areas outboard to allow window clearance. Tape weatherstrip sections to body exterior (Fig. 9-7).

3. Lower tail gate on power tail gate styles, then lower window fully. On manual tail gate styles, lower gate and manually snap lock bolt into locked position. Then lower window fully.

NOTE: On electrically heated back windows, on left side at upper left roller assembly, detach connector at bus bar and detach harness fastener from roller assembly (Fig. 9-18).

CAUTION: Maintain control of spiral electrical harness at rear of roof with body tape, or other suitable means to prevent the extended harness from recoiling into the roof inner construction.

4. Using adjustable pliers, detach spring from window upper sash channel (at center) and move spring to right side of body to relax spring tension. Avoid detachment of spring.from window guide cam at front (Fig. 9-8).

5. Loosen drive cable flag retainer screw and move flag retainer inboard out of engagement with flag (Fig. 9- 1 1).

6. While supporting glass, remove tail gate window down-travel stop(s) (Fig. 9-9) and carefully remove window.

NOTE: If additional clearance is required, adjust rear of guide cams down.

7. To install, reverse removal procedure.

Tail gate window components are illustrated in Fig- ure 9- 10. Specified torque for the roller support-to- glass bolts is 72 inch lbs.

Adjustment

Up and down adjustment of window for proper weatherstrip contact is made by adjusting both right and left window guide cams vertically at rear and midway attaching locations.

A cocked window adjustment is controlled by loosening and rotating the right upper roller support in desired direction (Fig. 9- 1 1).

9-8 TAlL GATE

Fig.

Window down-travel is controlled by an adjustable stop in lower end of window right guide cam for manual tail gates and both guide cams for power operated tail gates (Fig. 9-9).

TAlL GATE WINDOW REGULATOR

ASSEMBLY

Description

The tail gate window regulator assembly is mounted on the inner surface of the right hand back body pillar and is concealed by the spare tire cover (Fig.

9-12). A rubber-coupled gear drive within the regulator transfers torque delivered by the window motor to the window drive cable. When the window is lowered the drive cable is drawn through the regulator and into a storage conduit connected to the lower end of the regulator. Reverse direction of the drive cable raises the window.

Removal and Installation

Remove spare tire-cover and spare tire.

Disengage window motor cable at window regulator assembly (Fig. 9- 12).

Disengage window drive cable clip at upper end of regulator and remove cable storage conduit at lower end of regulator.

Remove regulator attaching screws and rotate regulator counter -clockwise off lower end of drive cable.

To install, reverse removal procedure.

TAlL GATE WINDOW MOTOR ASSEMBLY

Description

The tail gate window motor is secured to a mounting

TAlL GATE 9-9

Fig. 9-8-Window Detachment plate and in turn, the plate is bolted to the inner surface of the right hand back body pillar behind the spare tire cover (Fig. 9- 12). Rubber cushions insulate the plate from body metal, thereby requiring a separate ground strap to complete the motor circuit. Re- fer to the Electrical Section of this manual for details concerning the window motor and circuit.

TAlL GATE WINDOW MOTOR CABLE

ASSEMBLY

Description

Torque is delivered from the motor to the window regulator by a cable approximately 13 inches long.

The cable is routed behind the back body inner panel; however, access to each end of the cable for disconnect purposes is provided at the motor and regulator mounting locations (Fig. 9-12).

Removal and Installation

1. Remove spare tire cover and spare tire.

2. Disconnect motor electrical lead and disengage cable at upper end of motor (Fig. 9-12).

3. Remove motor mounting plate attaching screws and remove plate and motor assembly.

4. Disassemble motor from mounting plate as a bench operation.

5. To install, reverse removal procedure.

Removal and Installation

1. Remove spare tire cover and spare tire.

2. Disengage cable at motor and at window regulator assembly and remove cable.

3. To install, reverse removal procedure.

9-10 TAlL GATE

Fig. 9-9-Tail Gate Window Down-Travel Stop

TAlL GATE WINDOW GUIDE CAM

RIGHT

OR LEFT SIDE

Description

The window operates within a cam type guide on each side of the body (Fig. 9-1). The left hand guide consists of a cam and attaching provisions. The right hand guide includes a cam, attaching provisions, an additional channel adjacent to the cam for the window drive cable and safety provisions specific to the manual tail gate. Each guide is concealed at the pillar locations by pjllar finishing moldings and inner filler strips. The forward end of each guide extends into the space between the roof inner and outer panels.

Removal and Installation

1. Raise tail gate window and lower tail gate. On manual gates, snap tail gate lock to closed position.

2. Remove rear body pillar finishing moldings, right pillar inner filler strip, right quarter window upper garnish molding (left side also if left guide cam is to be removed) and body opening upper finishing molding and filler strip.

3. Detach back body opening weatherstrip sculptured belt detail sections and tape to body exterior as previously described (Fig. 9-7).

4. Detach headlining over quarter glass on right side (left side also if left guide cam is to be removed) sufficiently to reveal access hole at forward attaching location of window guide cam

(Fig. 9-14).

5. Through access hole described in Step No. 4, transfer window assist spring from retainer on window guide cam to hook on window right upper roller support (Fig. 9-14).

6. Through same access hole, remove drive cable flag retainer bolt and move flag retainer inboard out of engagement with flag. Secure flag in full forward position with a metal screw.

7. Lower window to point where glass right upper roller detent lever engages either of two notches in right guide cam (Figs. 9- 1 1 and 9- 17).

NOTE: Roller detent lever is released when drive cable flag is detached from glass.

8. 'Disengage roller detent lever at guide cam notches and lower glass to down-travel stop(s).

9. While supporting glass, remove down-travel stop(s) and remove glass.

10. For removal of right guide cam, detach and remove window regulator as previously described. Remove guide cam attaching bolts, move guide assembly forward to clear pillar access hole with drive cable and withdraw guide from body (Fig. 9- 15).

NOTE: On styles equipped with a manual tail gate disengage upper end of window stop cable and clip assembly prior to removing guide attaching bolts (Fig. 9-1 3).

11. For removal of left guide cam, remove guide attaching screws and withdraw guide from body

(Fig. 9- 16).

12. To install either guide, reverse removal procedure.

TAlL GATE WINDOW DRIVE CABLE

Description

The window drive cable consists of a stranded wire core with an integral spiral wire exterior. The spi- ralled character of the cable surface meshes with the rubber-coupled gear drive of the window regulator

TAIL GATE 9-1 1

1. Window Guide Roller

Assembly

Upper

Left

2. Window Guide Roller

Assembly

Lower

Left

DRIVE CABLE

FLAG RETAINER

DETENT LEVER

ADJUSTMENT

LOCK BOLT

Fig. 9-10-Tail Gate Window Components

3. Window Guide Roller

Assembly

Lower

Right (Manual Gate)

4. Window Guide Roller

Assembly

Lower

Right (Power Gate)

5. Window Guide Roller

Assembly

Right

Upper

6. Window Lift Spring and Silencer resulting in fore-aft motion of the drive cable. The cable is confined within a channel of the right guide cam from the guide forward end to the cable-to- guide cam attaching bracket (View " B , Fig. 9- 17).

From this point rearward to the regulator the cable passes through a conduit for routing under the guide cam and into the back body pillar. The forward end of the drive cable includes a metal tab (or flag) by which attachment to the glass hardware is made.

Fig. 9-1 1-Window Guide Roller Assembly

Upper Right

Removal and Installation

1. Remove tail gate window as previously described.

2. Remove window regulator as previously described.

9-1 2 TAIL GATE

Fig. 9-12-Tail Gate Window Motor and Regulator Installation

Remove screws securing drive cable conduit to guide cam (View "B", Fig. 9- 17).

Lower cable conduit suffkiently to allow drive cable to be lowered and cleared of guide cam channel.

5. Withdraw cable from conduit.

TAlL GATE 9-13

WINDOW STOP

CABLE 8 CLlP ASSEMBLY

WINDOW GUIDE

CAM ASSEMBLY

WINDOW STOP

BLE 8 CLlP ASSEMBLY

ATTACHING NUTS

Fig. 9-13-Window Stop Cable and Clip Assembly Attachment

6. T o install, reverse removal procedure.

NOTE: Drive cable conduit removal requires removal of the right guide cam from the body. The conduit is then removed as a bench operation.

WINDOW STOP CABLE AND CLlP

ASSEMBLY- (MANUAL TAlL GATE ONLY)

Description

The window stop cable and clip assembly is designed to prevent full lowering of the tail gate window (approximately 8" above the beltline) until the tail gate is fully closed (View "C", Fig. 9-17). In addition, this assembly prevents mechanical release of the tail gate until the window is raised approximately 8 inches above the beltline. This feature is not required with the power tail gate option.

Removal and Installation

1. Remove window right guide cam as previously described.

2. Remove stop assembly as a bench operation.

3. Through access hole at window regulator mounting area disengage window stop cable at lock lever and withdraw cable. (See Fig. 9-27 window and gate control section).

NOTE: Tie a suitable length of cord to lower end of cable to facilitate installation.

4. T O 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 guide cam, move stop assembly upward to remove slack from cable and position bell crank. Tighten stop attaching nuts

(View "C", Fig. 9-17).

3. Operate glass with tail gate lock in both locked and unlocked positions to check operation of stop cable and clip assembly. Window stop cable and clip assembly should be adjusted to function as follows:

A. Control knob on body exterior should not release tail gate until window raises sufficiently to clear bell crank on stop cable and clip assembly (approximately 8" above beltline).

B. With tail gate open, window should contact bell crank pin on stop cable and clip assembly approximately 8" above beltline when lowered with instrument panel switch.

ROLLER ASSEMBLY

TAlL GATE WINDOW

Description

A roller assembly is used at each corner of the glass to control the path of travel along the window guide cams (Fig. 9-10). The left side rollers are staked to pivots and follows the path established by the right side roller assemblies which are non-pivoting. Two right hand lower roller assemblies are required, one for the manual tail gate and another for power tail gates. The right hand upper roller also assumes a fixed position, but includes an adjustable roller plate for a cocked glass correction.

Removal and Installation

1. Remove tail gate window as previously described.

2. Remove roller assembly as a bench operation

(Fig. 9-10).

9-14

TAlL GATE

Fig. 9-14-Drive Cable Flag Retainer and Window Lift Spring Details

1 . Window Lift Spring

Retainer on Guide

Cam (Operating

Position)

2. Drive Cable Flag

3. Window Guide Roller

Assembly

3. To install, reverse removal procedure.

NOTE:

Torque roller assemblv to glass attaching bolts to 72 in. lbs.

4 . Window Lift Spring

Hook on Roller

Assembly (Position for Window Removal)

5 . Drive Cable Flag

Retainer (Not

Removable) tive limits for glass contact to the tail gate belt weatherstrip (Fig. 9-9). One stop only is required on the right side for units equipped with the manual tail gate. Two stops (right and left) are required for power tail gate application.

TAlL GATE WINDOW DOWN-TRAVEL

STOP(S)

Description

The tail gate window down-travel stops provide posi-

Removal and Installation

1. Remove rear pillar finishing molding (both sides for power gate; right side only for manual gate).

TAlL GATE 9-1 5

D E T E N T LEVER N O T C H E S

ATTACHING 8 0

Fig. 9-15-Tail Gate Window Right Guide Cam Attachment

2. Remove down-travel stop attaching screw in lower end of window cam guide and remove stop(s) (Fig. 9-9).

3. To install, reverse removal procedure. Adjust stop(s) as subsequently explained.

Fig. 9-17-Window Right Guide Cam and Drive Cable Details

A. Right Guide Cam

Center Attachment

B. Window Drive

Cable-to-Guide Cam

Attaching Bracket

C. Window Stop Cable and Clip

Assembly-to-Guide

Cam Attachment

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).

Fig. 9-16-Tail Gate Window Left Guide Cam Attachment

TAlL BATE WINDOW ASSIST SPRING AND

SILENCER

Removal and Installation

1. Remove back body opening upper finishing molding and filler strip (Fig. 9-4).

2. Remove right quarter glass upper garnish molding.

3. Detach headlining over quarter glass on right side sufficiently to reveal access hole at forward attaching location of window guide cam (Fig.

9-14).

4. With glass in down position detach spring from window upper sash channel and move spring to right side of body to relax spring tension (Fig.

9-8).

5. Through access hole in roof inner panel detach spring from retainer on guide cam (Item " l",

Fig. 9-14) and withdraw spring rearward from body.

6. T o install, reverse removal procedure.

9-16 TAlL GATE

HEATED TAlL GATE WINDOW REAR WIRE

HARNESS ASSEMBLY

Description

A coiled harness serves the heated window circuit requirements. This allows the harness to extend when the window is closed and recoil when the window is raised (Fig. 9- 18). A plastic tube integral with the harness guides the harness during recoil.

Removal and Installation

1. Remove back body opening upper trim finishing molding and inner filler strip (Fig. 9-4).

2. Remove left rear pillar finishing molding and inner filler strip.

3. Remove left quarter window upper garnish molding and detach headlining over left quarter glass sufficiently to reveal access hole at forward end of tail gate window left guide cam.

4. Disengage heated window rear harness at front junction and secure a 4 ft. cord to harness to facilitate installation (Fig. 9- 18).

Fig. 9-18-Heated Window Rear Wire Harness

Window Up

(Roof Outer Panel Removed for Illustrative Purposes)

5. 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.

6. Withdraw harness from body leaving installing cord in body cavity.

8. To install, reverse removal procedure.

RETRACTABLE TAlL GATE WINDOW DIAGNOSIS CHART

CONDITION

1. Window cannot be raised. Window motor operative.

APPARENT CAUSE

1. Window motor cable disconnected or broken.

2. Possible inoperative window regulator or disconnected or broken window drive cable.

CORRECTION

(A) Check window motor drive cable. Re- connect or replace.

(A) Detach window drive cable storage conduit from regulator to expose drive cable.

With helper actuating window switch for

"up" cycle, observe exposed drive cable for movement. If no movement occurs, remove regulator and disassemble for inspection.

(B) If cable movement occurs in above test at regulator, repeat test while observing

TAlL GATE

9.1 7

RETRACTABLE TAlL GATE WINDOW DIAGNOSIS CHART (Continued)

CONDITION

2. Window cannot be lowered. Window motor operative.

1. Window motor cable disconnected or broken.

2. Possible inoperative window regulator, disconnected or broken window drive cable.

CORRECTION upper (flag) end of drive cable at glass right upper roller assembly. This will determine whether drive cable is disconnected or broken.

(A) Check window motor cable. Re-connect or replace.

(A) Detach window drive cable storage conduit from regulator. With helper actuating window switch for

"down" cycle, observe if drive cable exits lower end of regulator.

If drive cable appears, drive cable is disconnected at window upper roller or cable is broken. Re-connect or replace cable.

(B)

If drive cable does not appear, grasp window and attempt manual lowering. If window lowers and cable exits at lower end of regulator, remove regulator and disassemble for inspection.

3. Window cannot be lowered. Window motor operative.

Window regulator noisy.

1. Window drive cable out of engagement with regulator drive gear.

(A) Attempt manual lowering of window sufficiently to cause engagement of window drive cable in regulator. If engagement occurs, check window up-travel stop on window right guide cam or check length of drive cable.

(B)

If engagement of cable does not occur check cable flag to window upper right roller attachment or remove

9-18 TAlL GATE

RETRACTABLE T A l L GATE WINDOW DIAGNOSIS CHART (Continued)

CONDITION APPARENT CAUSE CORRECTION and disassemble regulator for inspection.

4. Window cannot be raised or lowered.

Window motor inoperative.

1. Possible lock and release switch malfunction.

2. Possible window electrical circuit problem.

(A) Refer Window and Tail

Gate Control System

Diagnosis Chart.

(A) Refer Electrical

Section for Tail

Gate Window Circuit

Diagnosis.

5. Window lowers fully with tail gate open or tail gate releases before window raises beyond 8" above belt. (Manual tail gate)

1. Stop cable and clip assembly

, out of adjustment on right guide cam.

2. Cable of above assembly disconnected at either end.

(A) Align stop cable and clip assembly.

(A) Re-connect cable.

TAlL GATE SYSTEM

Description

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 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. 9-23).

TAlL GATE ASSEMBLY

Description

The tail gate assembly is fabricated primarily of an inner and an outer panel with reinforcements provided at critical attachment locations. Since the tail gate window is independent of the gate, no hardware is required within the assembly. A single opening is provided at the right upper area of the tail gate inner panel for access to the striker attachment provisions

(Fig. 9-19). A grip handle is provided at center of the beltline on manual tail gates only.

Removal and Installation

NOTE: Refer to Figure 9- 19 and prepare a 1 20 x

1 fixture bolt to serve as a roller stop for subsequent removal steps. In addition, tape a doubled fender cover or equivalent to upper surface of bumper face bar to protect gate.

1. Raise tail gate to latched position and remove tail gate inner cover panel.

WARNING: MAINTAIN A FIRM GRIP ON

TAIL GATE FOR SUBSEQUENT STEPS.

2. Remove regulator hinge arm-to-tail gate attaching screws. On manual tail gates, actuate control knob to unlock gate. Lower gate sufficiently to clear lock assembly and allow gate to pivot rearward approximately 45 degrees.

3. Insert fixture bolt and nut assembly into key slot at upper end of right channel guide assembly below roller to hold synchronizing tube assembly m position during tail gate removal (Fig.

9- 19).

4. Scribe location of right lower roller support on tail gate and remove attaching bolts.

5. Move right side of tail gate rearward sufficiently to clear body opening. Then slide tail gate to right and out of engagement with left torque roller shaft to remove tail gate.

6. T o install, reverse removal procedure.

NOTE: Remove fixture bolt from right channel assembly before raising tail gate to body position.

TAlL GATE GUIDE CHANNEL ASSEMBLY

RIGHT OR LEFT

Description

The tail gate guide channels, right and left, are mounted in the back body lower housing and establish path of travel for the tail gate (Fig. 9-22). Each guide channel assembly consists of a curved channel and mounting brackets. A pivot link is used at the

TAlL GATE

9-18

rear of each assembly to accommodate the synchronizing torque tube. The guide channel bracket attaching holes are elongated to provide fore-aft adjustment for the lower portion of the gate (Figs.

9-1 and 9-22).

Removal and Installation

1. Remove tail gate as previously described.

2. Working through opening between body and rear bumper, remove synchronizing tube-to- guide channel link sholder bolt (Fig. 9-20 or

9-2 1).

3. Remove guide channel-to-body attaching bolts

(Fig. 9-20 or 9-21).

4. Disengage guide channel from tail gate lower roller and withdraw guide channel through opening between body and rear bumper.

Fig. 9-19-Tail Gate Position For Removal

9-20 TAlL GATE

Fig. 9-20-Tail Gate Guide Channel Assembly - Right

5. To install, reverse removal procedure. Adjust guide channel fore or aft as required.

TAlL GATE ROLLER SUPPORT

RIGHT OR

LEFT

Description

A torque roller and shaft assembly engages the guide

Fig. 9-21-Tail Gate Guide Channel Assembly

Left channel on each side of the body. The torque rollers and shafts in turn are connected to the bottom of the tail gate by torque roller supports. The left torque roller support is mounted to a fixed location on the bottom of the tail gate. The right torque roller support is adjustable laterally with respect to the gate in order to allow cross-body adjustment of the gate.

Additionally, the right torque roller support-to- roller shaft attaching hole is elongated vertically to provide a cocked tail gate adjustment (Fig. 9-20).

Fig. 9-22-Tail Gate Synchronizing Torque Tube and Guide Channels

TAlL GATE 9-21

1. Lift Arm Hinge-to-Tail

Gate Attaching

Screws

2. Tail Gate Drop

Adjusting Screw

Fig. 9-23-Tail Gate Torque R o d and Hinge Arm Relationship

3. Lift Arm Hinge

Assembly - Manual

4 . Lift Arm Hinge and

Regulator Assembly

Electric

Removal and Installation

1. Remove tail gate as previously described.

2. Remove left roller support as a bench operation.

- - removing roller shaft-to-support attaching nut

(Fig. 9-20).

3. To install, reverse the removal procedure. Right side roller only is adjustable laterally on tail gate and up-down on roller shaft.

5 . Torque Rod Retaining

Pin

6. Torque Rod

7. Torque Rod Retainer

8. Torque Rod Cover

Plate

TAlL GATE SYNCHRONIZING TORQUE TUBE

ASSEMBLY

Description

A synchronizing torque tube assembly assures level operation of the tail gate through opening and closing cycles. An arm on each end of the tube connects to a torque roller at the bottom of the tail gate (each side). The opposite end of the arm is connected to the guide channel link by a shoulder bolt (Figs. 9-1 and

9-22).

9-22 TAlL GATE

Removal and Installation

1. Remove tail gate as previously explained.

2. Remove right and left synchronizing torque tube-to-guide channel link shoulder bolts (Fig.

9-22).

3. Scribe location of guide channels on body and remove rearward attaching bolts and loosen forward attaching bolts (Figs. 9-20 and 9-21).

4. Rotate guide channels downward at rear for clearance to allow disengagement of right and left torque rollers from upper end of guide channels (Fig. 9-22).

5. Remove synchronizing torque tube with torque rollers and shafts and right roller support intact.

6. If necessary, torque rollers and shafts and right roller support may be removed as a bench operation.

7. To install, reverse removal procedure.

TAlL GATE TORQUE ROD

Description

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 supports 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. 9-23).

Removal and Installation

1. Lower tail gate and prop rear load floor in full open position.

2. Remove load floor supports to gain access to torque rod retainer 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. 9-24).

Fig. 9-24-Torque Rod Tool

Torque Rod Release or

Adjustment

WARNING: D O NOT REMOVE TORQUE

ROD COVER PLATE UNTIL TORQUE

ROD TENSION IS FULLY RELIEVED.

3 . . Remove torque rod cover plate screws and remove cover plate (Fig. 9-23).

4. Withdraw torque rod from lift arm link and remove torque rod from body.

5. To install, reverse removal procedure.

Adjustment

1. Engage end of torque rod with tool 5-23719 or equivalent, apply downward pressure against rod and remove retaining pin (Fig. 9-24).

2. Place torque rod in desired location in torque rod retainer and insert retaining pin in key slot

' above torque rod.

NOTE: Torque rod should be adjusted to achieve tail gate cycling action that requires only mini- mal manual assist.

3. On manual tail gates adjust tail gate drop adjusting screw (Fig. 9-23) if necessary, so that tail gate drops 3 to 6 inches after being released by the control knob.

TAlL GATE 9-23

CONDITION

1. With window open, manual tail gate will not release from closed position.

RETRACTABLE TAlL GATE DIAGNOSIS CHART

APPARENT CAUSE

1. Swivel on switch pawl-to-lock lever rod positioned too high on link.

2. Swivel on switch pawl-to-lock lever rod disconnected at lock lever.

CORRECTION

(A) Adjust swivel down on rod sufficiently to trip lock lever.

(A) Check swivel adjustment and condition of retaining clip on lock lever.

Re-connect swivel.

2. With window open, manual tail gate releases but will not drop sufficiently to clear lock.

1. Tail gate drop adjusting screw positioned improperly.

(A) Position tail gate drop adjusting screw so that tail gate drops 3 to 6 inches when released.

3. Manual tail gate requires excessive effort to raise.

1. Torque rod improper] y adjusted.

4. Power tail gate operates from only one of two control switches.

1. Possible defective switch.

2. Possible tail gate circuit problem to affected switch.

(A) Adjust torque rod down in retainer to reduce manual effort.

(A) Check switch. Refer to checking procedures in tail gate portion of Electrical Section.

(A) Check circuit. Refer

Electrical Section as above.

5. Power tail gate will not operate from either of two control switches.

1. Possible defective motor.

2. Possible tail gate electrical circuit problem.

(A) Check motor and/or tail gate electrical circuit. Refer

Electrical Section.

9-24 TAlL GATE

TAlL GATE LlFT ARM HINGE ASSEMBLY

MANUAL AND ELECTRIC

Deacriptlon

A lift arm and hinge assembly is mounted to the left quarter ixiner construction and to the left upper inner corner of the gate to provide raising and lowering effort. For power operated tail gates a motor and sector are added to the assembly. The assembly mounting holes are elongated to allow down-forward and aft-upward adjustment to the left side of the gate

(Fig. 9-23).

Removal and lnstallation

Remove left quarter rear trim panel Figure 9-4.

Remove tail gate inner cover panel.

Remove regulator lift arm hinge-to-tail gate attaching screws and carefully lower tail gate. On power-operated units, disconnect wire harness at motor terminal (Fig. 9-23).

Remove tail gate torque rod as previously explained.

Mark location of lift arm hinge assembly on body and remove attaching screws (Fig. 9-23).

Remove regulator and lift arm hinge assembly from body.

To install, reverse removal procedure.

Adjustments

The regulator and lift arm hinge assembly may be adjusted down-forward, aft-upward and rotated within the limitations of over-size attaching holes to the body.

NOTE:

Make adjustments with torque rod disengaged at retainer on right side of body.

Assuming that all attaching bolts to body and tail gate are loose, proceed as follows:

Tighten regulator lift arm-to-tail gate attaching screws securely (Fig. 9-23).

With tail gate in full closed position, move tail gate fore or aft to achieve flush tail gate to body opening alignment. Secure regulator attaching bolts.

Secure torque rod in retainer, using tool 5-23719 or equivalent, and operate gate through several

NOTE:

On manual tail gates, if original location of regulator and hinge assembly is changed, the tail gate drop adjusting screw should be read- justed. (Refer tail gate torque rod-adjustment).

TAlL GATE LlFT ARM HINGE AND

REGULATOR ASSEMBLY MOTOR

Removal and Inatallation

1. With tail gate fully lowered, remove left quarter rear trim panel.

2. Detach wire harness at motor terminal and remove motor-to- regulator attaching bolts.

Remove motor (Fig. 9-23).

3. T o install, reverse removal procedure.

TAlL GATE STRIKER ASSEMBLY

Description

The tail gate striker assembly mounted on the right side of the gate provides fore-aft, up-down and cross- body adjustments. The assembly is designed to pivot from the lower attaching point so that fore-aft adjustment can be made without disturbing the height setting. Cross-body adjustment is made by loosening the striker pin jamb nut and turning the striker pin in the desired direction (Fig. 9-25).

Removal and lnstallation

1. Remove tail gate inner cover panel as previously described.

2. Lower tail gate as far as possible without obscur- ing 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 nut and striker pin jamb nut and washer (Fig. 9-25).

5. Withdraw striker assembly through gap between tail gate and body opening.

6. To install, reverse removal procedure.

Adjustments

The tail gate striker is adjustable up-down and fore- aft. The striker pin is threaded into the striker plate

TAIL GATE 9-26

1. Lock Assembly

2. Grip Handle and is adjustable cross-body. All striker adjustments are made through the access hole in the tail gate inner panel.

T o adjust the striker cross-body for proper engagement with tail gate lock, proceed as follows:

1. Engage hex end of striker with a suitable wrench and loosen striker pin jamb nut (Fig. 9-25).

2. Rotate striker pin for desired relationship with lock.

Fig. 9-25-Tail Gate Lock Striker and Grip Handle Assemblies

3. G r i ~

4. Striker Assembly Nut

5. Striker Pin

6. Striker Pin Jamb Nut

3. While holding hex end of striker in desired position, tighten striker pin jamb nut.

T o adjust striker fore-aft or up-down, proceed as follows:

1. T o achieve fore-aft adjustment only, loosen striker pin jamb nut while holding striker pin.

Position striker and secure jamb nut.

2. For up-down adjustment loosen striker pin jamb nut and striker assembly nut. Position striker and tighten jamb nut and striker assembly nut.

9-20 TAlL GATE

TAlL GATE LOCK ASSEMBLY

Removal and Installation

1. Raise tail gate window and lower tail gate.

2. For manual tail gates remove spare tire cover and spare tire.

3. Working around right pillar inner panel, disengage tail gate window stop cable and switch pawl rod at lock lever (Fig. 9-28).

4. For either manual or electric tail gates, remove lock attaching bolts at pillar facing and remove lock and lock lower guide (Fig. 9-27).

5. To install, reverse removal procedure.

TAlL GATE OUTER PANEL GRIP HANDLE-

(Manual Tail Gate Only)

Removal and Installation

LOCK

/ \

LOCK LOWER

Ibbb

Fig. 9-27-Lock and Lock Lower Guide Attachment

1. Remove screws securing tail gate outer panel grip handle and cover. Remove handle (Fig. 9-

25).

2 . To install, reverse removal procedure.

TAlL GATE ADJUSTMENTS

The retractable tail gate is adjustable up-down, fore- aft and laterally within its body opening (Fig. 9-29).

Fig. 9-26-Electric Window and Gate Switch Assembly

1. Lock Cylinder

2. Electric Window and

Gate Switch

3. Switch-to-Cylinder

Retaining Clip

4. Lock Cylinder

Retaining Clip

Fig. 9-28-Lock and Release Switch Assembly

Manual Gate

1. Lock and Release

Assembly Retaining

Clip

2. Switch Pawl

3. Pawl-to-Lock Lever

Rod

4. Swivel

5. Lock Lever Pilot Hole

6. Lock Lever

7. Cable

Stop Cable and Clip Assembly

8. Swivel

Installed

Position

TAIL GATE 9-27

FORE-AFT

4293

FORE-AFT

(BOTTOM O F GATE) COCKED- GATE

Fig. 9-29-Location of Tail Gate Adjustment Provisions

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.

WARNING: WHEN PERFORMING TAIL GATE

SERVICE OPERATIONS THROUGH THE AC-

CESS OPENINGS I N T H E BODY REAR

LOWER HOUSING (Fig. 9 - 9 , PLACE BODY

TAPE OVER THE TAIL GATE OPERATING

KEY CYLINDER OR RELEASE KNOBS TO

PREVENT INADVERTENT LOWERING O F

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. 9-25).

2. Hold striker pin hex end and loosen striker jamb nut. Loosen striker assembly attaching nut.

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. 9-20). 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.

3. Reposition tail gate fore-aft and tighten guide channel attaching screws.

T o correct top of tail gate fore-aft, proceed as follows:

1. Right side

A. Gain access to striker assembly and loosen

8-28 TAlL GATE

striker pin jamb nut and striker assembly nut

(Fig. 9-25).

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-

23).

B. Position tail gate fore-aft and tighten lift arm and hinge assembly attaching bolts.

Lateral adjustment of the tail gate is allowed by the elongated attaching bolt holes in the lower right roller support (Fig. 9-19). A corresponding lateral adjustment of the striker assembly is required.

With tail gate fully closed remove right access cover from body rear lower housing (Fig. 9-5).

Loosen lower right roller support attaching screws (Fig. 9-20).

Adjust striker pin t o position tail gate laterally and tighten roller support attaching screws.

WINDOW AND TAlL GATE CONTROL

SYSTEM

Description

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. Two control switches are used; one for the manual tail gate which includes a link t o the lock lever, and one for the power operated tail gate without link.

TAlL GATE LOCK AND RELEASE SWITCH

ASSEMBLY- (Manual Tail Gate)

Description

The exterior control switch and release assembly for manual tail gates combines the lock cylinder and switch assembly into one integral unit and is held in place by a flat spring retainer (Fig. 9-28). The key cylinder operates the glass electrically through the opening cycle (first position clockwise) and closing cycle (first position couterclockwise). The winged knob rotates only in a clockwise direction for mechanical release of the tail gate, however, the window must be raised approximately 8 inches before the tail gate may be released with the knob. The key is not required for operation of the knob, provided the window is opened by the instrument panel control switch.

The control knob is connected to the lock lever by a pawl, connecting rod and swivel (Fig. 9-28). The swivel is adjustable on the connecting rod in order to provide correct switch-to-lock lever relationship.

Removal and Installation

1. Remove spare tire cover and spare tire.

2. Remove tail gate window regulator as previously explained.

3. Disengage wire harness terminal block off control switch - manual o r power (Fig. 9-26

- typical).

4. On manual tail gate control switches, disengage control switch- to-lock lever link. Remove control switch retaining clip and withdraw switch and cylinder unit outward through piercing in quarter panel (Fig. 9-28).

5. O n power tail gates pull control switch toward front of car to separate switch from cylinder and remove switch (Fig. 9-26). D o not disengage switch-to-cylinder retaining clip.

6. T o install, reverse removal procedure.

Manual Gates Only)

1. With key cylinder in centered (vertical) position, withdraw key sufficiently to render cylinder inoperative (Fig. 9-28).

2. Assure that tail gate lock is in unlatched position

(lock lever down).

3. Rotate switch pawl t o full down position and hold in place.

4. Adjust swivel on pawl-to-lock lever rod t o align with pilot hole on lock lever (Item "5", Fig.

9-28).

5. Rotate pawl upward and engage swivel in clip on lock lever (Item "8", Fig. 9-28).

6. Insert 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).

TAlL GATE WINDOW CONTROL SWITCH-

(Power Tail Gate Only)

Description

The tail gate and window control switch for power operated tail gates in comprised of a key cylinder and a switch assembly held together by a wire-type clip

(Fig. 9-26). The switch includes three positions, each to the right and left of center (vertical) position, of the key cylinder. The total of six switch positions allows opening or closing of window only, tail gate only or both window and tail gate simultaneously.

TAlL GATE 9-29

Removal and Installation

1. Remove control switch as previously explained.

2. Remove key cylinder retaining clip and remove cylinder (Fig. 9-26).

3. T o install, reverse removal procedure.

TAlL GATE WINDOW CONTROL SWITCH

LOCK CYLINDER- (Manual Tail Gate Only)

Removal and Installation

1. Remove control switch as previously explained.

2. Remove cylinder from control switch as a bench operation.

1..

... LUBRICATE

G m ,

V I E W " A "

' ) ' / /

LUBRICATE-

SECTIONS D-D

V I E W " C "

LUBR

V l E W " 0 "

Fig. 9-30-Retractable Tail Gate Lubrication

4675

9-30 TAlL GATE

3. To install, reverse removal procedure.

RETRACTABLE TAlL 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. 777 o r equivalent) as shown in Figure

9-30.

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).

RETRACTABLE TAlL GATE CONTROL SYSTEM DIAGNOSIS CHART

CONDITION APPARENT CAUSE CORRECTION

1. Exterior key switch cannot be rotated sufficiently counterclockwise to lower window. (Manual tail gate)

1. Swivel on switch pawl-to-lock lever rod positioned too high.

(A) Adjust swivel downward.

2. Exterior key switch cannot be rotated sufficiently clockwise to raise window.

(Manual tail gate)

1. Swivel on switch pawl-to-lock lever positioned too low.

(A) Adjust swivel upward.

3. Window cannot be raised or lowered with exterior key switch

- cylinder . rotational travel correct. (Manual tail gate)

4. Tail gate or window inoperative from exterior switch.

(Power tail gate)

1. Possible open window electrical circuit.

1. Possible open tail gate or window electrical circuit.

2. Possible defective switch contacts or cam.

(A) Check window circuit (refer tail gate coverage in Electrical

Section).

(A) Check tail gate or window circuit.

Refer tail gate coverage in

Electrical Section.

(A) Remove and inspect switch.

TAlL GATE 9-31

DUAL ACTING TAIL 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, additionally, as a door. All wagons so equipped utilize either a manually 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.

WARNING: FOLLOWING ANY REPLACEMENT

OR REALIGNMENT OF THE TAIL GATE, OR

COMPONENT HARDWARE, ALL LOCKS

MUST BE CHECKED FOR SYNCHRONIZA-

TION (REFER TO LOCK SYNCHRONIZA-

TION 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 9-3 1 identifies the component parts of a typical dual- tail gate and their relationship.

TAlL GATE INNER PANEL WATER

DEFLECTOR

A waterproof paper deflector is sealed against the tail gate inner panel to deflect water toward the bottom of the gate and out the drain holes.

CAUTION: 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 compound (approximately 3/16" diameter) to tail gate inner panel (See Fig. 9-32). The inner panel cover attaching screw holes should also be sealed with body caulking compound.

4. Position water deflector to tail gate with po- lyethylene 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.

2. Remove upper screws securing right and left access hole covers to tail gate inner panel and remove covers by sliding upward (See Fig. 9-33).

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.

9-32 TAlL GATE

Fig. 9-31-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

2. To install sealing strips, reverse removal procedure. 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

Removal and Installation

1. Open tail gate and remove fasteners and/or

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

21. Remote Control

Assembly (Gate

Operation) screws securing upper corners of weatherstrip to right and left body pillars (Fig. 9-34).

2. With a flat-bladed tool, carefully remove weatherstrip along entire tail gate opening.

3. T o install original part, apply a bead of black weatherstrip cement into retainer along entire opening and reverse removal procedure. When installing a new weatherstrip, (two separate pieces, right and left) begin at beltline (on both sides) and work to bottom center. Cut off excess weatherstrip and form a butt joint.

TAlL GATE 9-33

CAULKING COMPOUND,

I l N N l COVlR

PANfil ATTACHIN0

scrm

~ o u s

VIEW "6"

3 7 2 c

Fig. 9-32-Tail Gate Sealing

TAlL GATE WINDOW UPPER GLASS RUN

CHANNEL

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.

9-35). 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.

TAlL GATE WINDOW LOWER GLASS RUN

CHANNELS

Removal and Installation

1. Remove tail gate window assembly as subsequently described.

Fig. 9-33-Tail Gate Inner Panel Access Hole Cover

2. Remove upper attaching bolt pillar outer panel.

- accessible at lock

3. Remove lower attaching bolt - accessible through inner panel access hole (Fig. 9-36).

4. Turn run channel 90 degrees and pull run chan- glass opening.

5. T o install, reverse removal procedure.

TAlL GATE WINDOW REGULATOR

Manual and Electric

Removal and lnstallation

1. Remove tail gate window assembly as subsequently 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. 9-3 1).

4. T o install, reverse removal procedure.

Adjustment

The regulator attaching holes in the tail gate inner panel are oversize to permit movement of the regula-

9-34 TAIL GATE

Fig. 9-34-Tail Gate Weatherstrip Installation

Fig. 9-35-Tail Gate Upper Glass Run Channel Retention Fig. 9-36-Tail Gate Lower Glass Run Channel Attachment

TAlL GATE 9-36 tor assembly to correct a "cockedN window (not parallel with the tail gate window upper run channel).

TAlL GATE WINDOW ELECTRIC REGULATOR

MOTOR ASSEMBLY

Removal

1. 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.

WARNING: STEP 4 MUST BE PERFORMED

I F THE WINDOW IS REMOVED OR

DISENGAGED FROM THE REGULATOR

LIFT ARMS. THE REGULATOR LIFT

ARMS, ARE UNDER TENSION FROM

THE COUNTER-BALANCE SPRING, AND

CAN CAUSE SERIOUS INJURY I F THE

MOTOR IS REMOVED WITHOUT LOCK-

ING THE SECTOR GEARS IN POSITION.

4. Drill a 1/8" hole through regulator sector gear and back plate (Fig. 9-37). 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

1. Lubricate the motor drive gear and regulator sector teeth.

NOTE: The lubrication 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

Fig. 9-37-Tail Gate Regulator Motor Assembly gear teeth before installing the three motor attaching screws.

3. Remove screw locking sector gears in 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 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 Dual 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 deTlector and right access hole cover as previously described.

WARNING: WITH TAIL GATE OPEN AND

RIGHT UPPER LOCK ENGAGED, THE

9-36

T AIL GATE

Fig. 9-38-Dual Acting Tail Gate Right and Left Upper Lock Manual Locking

TAIL GATE HAS BEEN PLACED IN A

VULNERABLE POSITION AND COULD

DROP FROM THE RIGHT LOWER LOCK

I F INSIDE DOOR REMOTE HANDLE

WERE ACTUATED WHICH COULD RE-

SULT IN PERSONAL INJURY OR DAM-

AGE 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 INOPERA-

BLE (Fig. 9-39).

2. With glass supported in a full-up position, manually lock right upper lock as shown in Fig- ure 9-38.

3. Remove screws securing switch t o right upper lock as shown in Figure 9-40. Disconnect electrical connector and remove switch through access hole. Fig. 9-39-Inside Handle (Door Operation) Taped

TAIL GATE

9-37

1 / 1 6 " C L E A R A N C E BETWEE

C U T - O U T S W I T C H PLUNGER

A N D L O C K I N G LEVER

S W I T C H

SCREWS

L O C K ASSEMBLY

JUMPER HARNESS

Fig. 9-40-Tail Gate Electrical Cut-Out Switch

9-38 TAlL GATE

Installation

1. Connect electrical connector and loosely attach switch to lock assembly.

2. With right upper lock in a locked position, adjust switch to achieve a 1/16" clearance between the cut-out switch plunger and the locking lever

(See Fig. 9-40).

NOTE: The adjustment specified in Step No. 2 is absolutely necessary to insure proper operation of switch.

3. Following proper adjustment of cut-out switch, secure attaching screws and cycle tail gate window and gate to insure proper operation prior to installation of cover panel and water deflector.

TAlL 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.

3. Position tail gate window so that outside handle

(manual) attaching nuts are accessible through gate inner panel and window regulator access holes (Fig. 9-41).

4. Remove nuts securing handle to tail gate and remove handle and sealing gasket.

5. T o install, reverse removal procedure.

[HANDLE ACCESS H O L E S

Fig. 9-4 1 -Tail Gate Window Outside Handle Removal

TAlL GATE

9-39.

TAlL GATE WINDOW REGULATOR OUTSIDE

ELECTRIC KEY SWITCH

Removal and lnstallation

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 WARNING note.

4. Slide retainer free of key switch and remove switch (Fig. 9-42).

5. To install, reverse removal procedure.

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. 9-43).

WARNING: 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 I F INSIDE

DOOR REMOTE HANDLE WERE AC-

TUATED. AS A SAFETY PRECAUTION,

PRIOR TO MANUALLY LOCKING EI-

Fig. 9-42-Dual

Removal

1. Feed Block

2. .Retainer

3. Gasket

Escutcheon

Key Switch and

Cylinder Assembly

THER RIGHT OR L E m UPPER LOCKS,

FIRMLY APPLY BODY TAPE OVER IN-

SIDE DOOR REMOTE HANDLE TO

RENDER SAME INOPERABLE (Fig. 9-39).

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 prevents 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.

9-38).

B. The L E m upper lock is engaged by depressing (with a screwdriver, or other suitable tool) the locking lever to full engagement

(Fig. 9-38).

4. Remove right and left cam attaching bolts (Fig.

9-43). 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.

940 TAlL GATE

S A S H C H A N N E L C A M BOLTS A

Fig. 9-43-Dual Acting Tail Gate Window Removal

Adjustments

The tail gate glass run channels can be adjusted to relieve a binding glass. T o correct a rotated glass condition, loosen window regulator attaching screws and rotate regulator clockwise or counterclockwise as required.

3. Remove screws securing handle to inner panel and remove handle (Fig. 9-44).

4. T o install, reverse removal procedure.

TAlL GATE INSIDE HANDLE AND CABLE

ASSEMBLY-DOOR OPERATION

(Right Side)

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. 9-44).

Removal and Installation

1. Open tail gate in door position.

2. Remove inner panel cover, water deflector and left access hole cover.

RIGHT GLASS-

TAlL GATE 9-41

5. Disengage remote control center handle from push rod and remove remote control and rod assembly (Fig. 9-46).

Fig. 9-44-Tail Gate Inside Handle Attachment-Gate

Operation

3. Disengage handle cable at upper lock clip (Fig.

9-45).

4. Raise inside handle and remove screws securing handle to inner panel and remove handle.

5. T o 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. 9-46).

4. Remove remote control to tail gate inner panel attaching bolts (Fig. 9-47).

Installation

WARNING: WITH TAIL GATE OPEN IN A

GATE POSITION A N D UPPER LOCKS EN-

GAGED, THE TAIL GATE HAS BEEN

PLACED I N A VULNERABLE POSITION

A N D COULD DROP FROM THE RIGHT

LOWER LOCK I F T H E 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 T O RENDER SAME INOPERA-

BLE (See Fig. 9-39).

1. With tail gate open in a gate position, manually lock upper right and left locks as shown in Fig- ure 9-38.

2. Loosen gate remote control synchronization

(adjusting) screw (left hand thread, refer to Fig.

9-48). 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 (Fig.

9-48). This pin holds all levers in position until final adjustment has been achieved.

NOTE: Service replacement 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 Fig. 9-5 1).

6. Remove pin from remote control synchronization (alignment) hole (See Fig. 9-5 1) 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.

9-42 TAlL GATE

Fig. 9-45-Tail Gate Inside Handle and Cable Assembly-Door Operation

TAIL GATE RIGHT UPPER LOCK ASSEMBLY

Removal

1. Remove tail gate window and right lower glass run channels as previously described.

2. With tail gate open in a gate position, remove three screws securing lock to tail gate lock pillar panel (Fig. 9-49).

3. Disengage tail gate inside handle cable assembly

(door operation) from lock (refer to View "A",

Fig. 9-45).

WARNING: I N THE FOLLOWING STEP DO

NOT PULL REARWARD ON T H E RIGHT

UPPER LOCK T O LOWER LOCK CON-

NECTING ROD ("8", Fig. 9-50) WHEN

DISENGAGING RIGHT UPPER LOCK

FROM END O F ROD. EXCESSIVE MOVE-

MENT O F THIS ROD COULD CAUSE THE

GATE T O DROP FROM THE RIGHT

LOWER LOCK WHICH COULD RESULT

TAIL GATE 9-43

HANDLE CONNECTING

L E F T LOCK

CONNECTING ROD

VIEW A

RIGHT LOCK

CONNECTING ROD

3266

Fig. 9-46-Dual Acting Tail Gate Lock Remote Control Assembly-Gate Operation (Center) r R E M O T E CONTROL BOLTS

Fig. 9-47-Dual Acting Tail Gate Torque Rod Retention

9-44 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 ~ R E A D I

L C O T T E R

T O LEFT U P P E R L O C K

3 3 2 B

Fig. 9-48-Tail Gate Lock Remote Control-Gate Operation

IN PERSONAL INJURY OR DAMAGE TO

THE TAIL GATE ASSEMBLY.

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 (Fig. 9-50).

5. On electric styles, disconnect tail gate cut-out switch (Fig. 9-40) and remove lock assembly through access hole.

R I G H T GLASS,

Fig. 9-49-Dual Acting Tail Gate Right Upper and Lower

Lock Attachment

Installation

1. With tail gate open in a gate position, install screws (three) securing lock to tail gate lock pillar panel (Fig. 9-49).

2. Loosen lower lock to upper lock connecting rod synchronization (adjusting) bolt located on upper lock (Fig. 9-51).

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 (Fig. 9-50).

WARNING: WITH TAIL GATE OPEN, IN A

GATE POSITION, A N D UPPER LOCKS

MANUALLY ENGAGED, THE TAIL

GATE HAS BEEN PLACED I N A VULNER-

ABLE POSITION A N D COULD DROP

FROM THE RIGHT LOWER LOCK I F 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 INOPERA-

TIVE (See Fig. 9-39).

4. Manually lock upper right and left locks as shown in Figure 9-38.

WARNING: IN THE FOLLOWING STEP DO

NOT PULL REARWARD O N THE RIGHT

UPPER TO LOWER CONNECTING ROD

DURING THIS ADJUSTMENT. REAR-

WARD MOVEMENT O F T H I S ' ROD

COULD CAUSE T H E TAIL GATE TO

DROP FROM THE RIGHT LOWER LOCK,

WHICH COULD RESULT I N PERSONAL

INJURY OR DAMAGE T O T H E TAIL

GATE ASSEMBLY.

5. 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

(Fig. 9-5 l), then tighten door lock, synchronization bolt (Fig. 9-5 1).

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.

TAIL GATE 8-46

1. Left Upper Hinge and

Lock Assembly

2. Tail Gate Remote t o

Left Upper Lock

Connecting Rod

3. Inside Handle (Gate

Operation)

Remote t o Inside

Handle Push Rod

Fig. 9-50-Dual A c t i n g T a i l Gate Lock and Remote Control Linkage

5. Tail Gate Remote t o

Right Upper Lock

Connecting Rod

6. Remote Control

Assembly (Gate

Operation)

7. Inside Handle and

Cable Assembly

(Door Operation)

8. Right Upper t o Lower

Lock Connecting Rod

9. Right Upper Lock

10.

Assembly

Right Upper and

Lower Lock

Synchronizing

(Adjusting) Screw

6. With right and left upper locks in a locked position, visually check gate remote synchronization holes in gate remote control levers (center of gate as shown in Fig. 9-51). I F T H E HOLES

D O NOT L I N E UP, loosen gate remote synchronization bolt (Fig. 9-51) 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

1 1 .

12.

Tail Gate W i n d o w

"Block-Out" Rod

Right Lower Lock through alignment hole in both levers (Fig. 9-

5 1). 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 Synchron- ization Checks as subsequently described.

9. Reinstall all previously removed components.

9 4 6 TAlL GATE

NOTE:

Fig. 9-51-Dual Acting Tail Gate Lock Synchronization Check

Service shims are available for tail gate striker assemblies. These shims are the same parts used in body side doors. If installing new lock, rubber dust seal must be transferred from removed lock.

4. Remove lower lock cover and disengage upper to lower lock connecting rod (Fig. 9-50).

5. 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. 9-49).

TAIL GATE RIGHT LOWER LOCK ASSEMBLY

6 . 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.

Removal and Installation

Open tail gate to a door position.

Remove inner panel cover, water deflector and access hole cover as previously described.

Loosen door lock synchronization (adjusting) bolt (Fig. 9-51).

7. Close tail gate and open to a gate position.

WARNING: IN T H E FOLLOWING STEP

WITH TAIL GATE OPEN A N D UPPER

LOCKS MANUALLY ENGAGED, T H E

TAIL GATE HAS BEEN PLACED I N A

VULNERABLE POSITION AND COULD

DROP FROM T H E RIGHT LOWER LOCK

TAlL GATE 9-47

I F THE INSIDE DOOR REMOTE HANDLE

WAS ACTIVATED, WHICH COULD RE-

SULT IN PERSONAL INJURY OR DAM-

AGE T H E 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 INOPERA-

TIVE (See Fig. 9-41).

8. Manually lock right and left upper locks as shown in Figure 9-38.

WARNING: D O NOT PULL REARWARD ON

THE RIGHT UPPER TO LOWER CON-

NECTING ROD DURING T H E FOLLOW-

ING ADJUSTMENT. REARWARD

MOVEMENT O F 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 AS-

SEMBLY.

9. 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

(Fig. 9-5 I), then tighten door lock synchronization (adjusting) bolt (Fig. 9-5 1).

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.

1 1. 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.

Fig. 9-52-Dual Acting Tail Gate Left Upper Hinge and Lock

Assembly (Typical)

2. Bolts "A" and "B" fit into a tapping plate and bolts "C" and "D" are retained by nuts. All bolts are pressed into the lock assembly and removed as a unit - not separately (Fig. 9-52).

3. Disengage clip securing remote control assembly rod and remove lock assembly (Fig. 9-50).

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.

WARNING: AS A SAFETY PRECAUTION,

PRIOR TO MANUALLY LOCKING EI-

THER RIGHT OR LEFT UPPER LOCKS,

APPLY BODY TAPE OVER INSIDE DOOR

REMOTE HANDLE TO RENDER SAME

INOPERATIVE (See Fig. 9-39). WITH TAIL

GATE OPEN A N D UPPER LOCKS MANU-

ALLY ENGAGED, THE TAIL GATE HAS

BEEN PLACED IN A VULNERABLE POSI-

TION A N D COULD DROP FROM THE

RIGHT LOWER LOCK I F THE INSIDE

DOOR REMOTE HANDLE WAS AC-

TUATED. A TAIL GATE DROPPING

FROM T H E RIGHT LOWER LOCK, WHEN

OPENED IN A GATE POSITION, COULD

RESULT IN PERSONAL INJURY OR

DAMAGE T H E TAIL GATE ASSEMBLY.

5. With tail gate open in a gate position, manually lock right and left upper locks as shown in Fig- ure 9-38.

6. With right and left upper locks in a locked position, visually check gate remote synchronization holes in gate remote control levers (center of gate as shown in Fig. 9-5 1). If the holes do not line up, loosen gate remote synchronization bolt

(Fig. 9-51) by turning to the right (left hand thread) approximately three turns.

9-48 TAlL GATE

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 (Fig. 9-

5 1). Then, tighten synchronization bolt to 57-87 inch pounds and REMOVE COTTER' PIN.

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 Synchron- ization Checks, as subsequently described.

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 Installation

Open tail gate assembly to a gate position and remove tail gate window as previously described.

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 (Fig. 9-44).

Lower tail gate and support in a full-open position. Remove support cable to left lower hinge to gate nut (Fig. 9-53).

4. WITH T H E A I D O F A HELPER, remove left lower hinge to gate attaching bolts.

NOTE: Bolt "A", Figure 9-53, fits into a tapping plate. Bolts "B" and "C", Figure 9-53 are pressed 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

(Fig. 9-54), then, remove hinge from body.

6. T o install, reverse removal procedure.

TAlL GATE LEFT UPPER HINGE A N D

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 (Fig. 9-54) and remove assembly from left body pillar

NOTE: The support cable spring, shown in Fig- ure 9-54, must be reinstalled in depicted position to insure proper movement of cable during gate operation.

Fig. 9-53-Dual Acting Tail Gate Left Lower Hinge-Removal

(Ty pica])

Fig. 9-54-Dual Acting Tail Gate Left Upper and Lower

Hinge and Support Cable Attachment

TAlL GATE 9-49

2. To install, reverse removal procedure.

NOTE: Shims of 1/4" and 5/16" are available as service parts.

WARNING: THIS LOCK STRIKER IS AN IM-

PORTANT ATTACHING PART IN THAT

IT COULD AFFECT THE PERFORMANCE

O F VITAL COMPONENTS A N D SYSTEMS,

AND/OR COULD RESULT I N MAJOR RE-

PAIR EXPENSE. IT MUST BE REPLACED

WITH ONE O F T H E SAME PART NUM-

BER OR WITH AN EQUIVALENT PART I F

REPLACEMENT BECOMES NECESSARY.

DO NOT USE A REPLACEMENT PART OF

LESSER QUALITY OR SUBSTITUTE DE-

SIGN. 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

Mark position of striker on back body pillar

(Fig. 9-55).

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.

WARNING: THIS LOCK STRIKER IS AN IM-

PORTANT ATTACHING PART I N THAT

IT COULD AFFECT THE PERFORMANCE

O F VITAL COMPONENTS A N D SYSTEMS,

AND/OR COULD RESULT IN MAJOR RE-

PAIR EXPENSE. I T MUST BE REPLACED

WITH ONE OF THE SAME PART NUM-

BER OR WITH AN EQUIVALENT PART I F

REPLACEMENT BECOMES NECESSARY.

DO NOT USE A REPLACEMENT PART OF

LESSER QUALITY OR SUBSTITUTE DE-

SIGN. TORQUE VALUES MUST BE USED

AS SPECIFIED DURING REASSEMBLY

TO ASSURE PROPER RETENTION O F

THIS PART.

Fig. 9-55-Dual Acting Tail Gate Right Upper and Lower

Striker Assemblies

Adjustments

Right upper striker assembliqs 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. 4469 195 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 (Fig. 9-55).

To install, reverse removal procedure.

9-50 TAlL GATE

WARNING: THIS LOCK STRIKER IS AN IM-

PORTANT ATTACHING PART IN THAT

IT COULD AFFECT THE PERFORMANCE

OF VITAL COMPONENTS AND SYSTEMS,

AND/OR COULD RESULT IN MAJOR RE-

PAIR EXPENSE. IT MUST BE REPLACED

WITH ONE O F THE SAME PART NUM-

BER OR WITH AN EQUIVALENT PART IF

REPLACEMENT BECOMES NECESSARY.

DO NOT USE A REPLACEMENT PART O F

LESSER QUALITY OR SUBSTITUTE DE-

SIGN. 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 A N D ASSIST LINK

Removal and Installation

1. Remove tail gate inner panel, water deflector and access hole cqver as previously described.

2. With tail gate open in a door position, remove right lower lock cover, bumperette and step plate.

3. Remove rear bumper as follows.

A. Remove the two rearward bumper to frame attaching bolts and loosen the forward two bolts (Fig. 9-56).

B. Remove the center bumper to frame bolt and lower bumper (Fig. 9-56).

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 position, remove torque rod assist link retainer attaching bolts (Fig. 9-57) 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 (Fig. 9-47).

WARNING: AS A SAFETY PRECAUTI.ON,

PRIOR TO MANUALLY LOCKING EI-

THER RIGHT OR LEFT UPPER LOCKS,

APPLY BODY TAPE OVER INSIDE DOOR

REMOTE HANDLE T O RENDER SAME

REARWARD BOLTS I R E M O V E ) h

3 7 2 7

Fig. 9-56-Bumper Removal (Typical)

INOPERATIVE (See Fig. 9-39). WITH TAIL

GATE OPEN IN A GATE POSITION, AND

UPPER LOCKS MANUALLY ENGAGED,

T H E TAIL GATE HAS BEEN PLACED IN

A VULNERABLE POSITION A N D COULD

DROP FROM THE RIGHT LOWER LOCK

I F THE INSIDE DOOR REMOTE HANDLE

WAS ACTUATED. A TAIL GATE DROP-

PING FROM T H E RIGHT LOWER LOCK

COULD RESULT I N PERSONAL INJURY

OR DAMAGE T O THE TAIL GATE AS-

SEMBLY.

NOTE: To raise electrically operated tail gate

Fig. 9-57-Dual Acting Tail Gate Assist Link

TAlL GATE 9-51 windows, with the gate open to the gate position, it is first necessary to manually lock both upper locks as shown in Figure 9-38.

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.

7. T o install, reverse removal procedure.

TAlL 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 (Fig. 9-54).

2. Support tail gate in a full-open gate position and remove support cable to left upper hinge and striker assembly attaching bolt (Fig. 9-54).

3. O n 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. W I T H T H E A I D O F A HELPER, remove left lower hinge to body attaching bolts (Fig. 9-54).

5. Manually lock right and left upper locks as shown in Figure 9-38. Then with the aid of a helper to support the tail gate, actuate the IN-

SIDE DOOR REMOTE H A N D L E (right side) to unlock and free the right lower lock from the striker assembly. Remove gate assembly by lifting upward, then rearward.

6. T o install, reverse removal procedure.

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: T h e 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 Attach- ment - Adjustable "up" or "down" and "laterally" (" 1 ", Fig. 9-58).

T o 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,

Adjustments

Proper evaluation of a misaligned condition can eliminate performing unnecessary adjustments. T o 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" o r 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.

Fig. 9-58-Dual Acting Tail Gate Left Upper and Lower

Hinge, Lock and Torque Rod Attachments

9-62 TAIL GATE

Fig. 9-59-Dual Acting Tail Gate Upper Left Lock Striker

Clearance 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 Fig. 9-59), and, where required, the upper left lock should be adjusted as described under adjustment " 3 " .

2. Lower Left Hinge Assembly at Gate Attach- ment

Adjustable "forward" or "rearward"

("2", Fig. 9-58).

"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.

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 - Adjust- able "up", "down", "forward" and "rearward"

("3", Fig. 9-58).

The "up" or "down" adjustment of the upper left lock is available to provide clearance (1/8" to 7/32") between the bottom of the lock frame and top of the hinge pin and striker plate (See

Fig. 9-59). T o 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 uppei 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. T o 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.

NOTE: 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. Upper Left Hinge and Striker Assembly - Ad- justable "in" or "out" from body pillar ("4", Fig.

9-58).

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. adjustment is available to provide proper engagement of the hinge pin and lock striker with the lock. 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

TAIL GATE 9-53

E. 9/32" shims lent

Part No. 8723091 or equiva-

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", Fig.

9-60) - Adjustable "forward" or "rearward",

"up" or "down" and "laterally" by using spacers.

CAUTION: The upper right lock striker should be removed prior to performing any other hinge or lock adjustments.

To properly adjust the upper right lock striker, first open tail gate as a door and remove striker with tool 5-23457 or equivalent. Check alignment of gate in body opening. T H E GATE

SHOULD BE PROPERLY ALIGNED IN

BODY OPENING PRIOR TO ADJUST-

MENT O F 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.

6. Right Lower Lock Striker and Support Assem- bly a. Lower Right Lock Striker

Adjustable "For- ward" and "Rearward" ("6", Fig. 9-60). b. Lower Right Lock striker 'Support

Adjusta- ble "Up", "Down" and "Sideways" ("7",

Fig. 9-60).

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 (Fig. 9-60). 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 9-60. 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

R U B B E R S T E P P A D

Fig. 9-60-Dual Acting Tail Gate Right Upper and Lower

Lock 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.

CAUTION: 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 bumperette to bumperette support. Adjust bumperette for proper alignment in bumper opening and tighten attaching nuts.

9-54 TAlL GATE

DUAL ACTING TAlL 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 same time prevent accidental operation of the lower right lock (which allows gate to be opened as a door).

The above "block-out" functions are accomplished by levers in the upper right lock. Figure

9-61 shows the upper right lock (in closed door position) and identifies the levers which perform block-out functions.

T o assure that the upper right lock levers perform the blockout functions properly, the upper right lock and gate remote control must be synchronized 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.

CAUTION: Whenever any of the locking system components inside the tail gate are serviced, the

GATE REMOTE LEVER ROD

WINDOW BLOCK-OUT LEVER-

B l o c k s Out A l l Lock

L e v e r s U n l e s s Window

Is I n Down P o s i t i o n

TRANSFER LEVER

O p e r a t e s Lock D e t e n t

R e l e a s e Lever When

Door Handle A c t u a t i n g

Lever i s A c t u a t e d

MCK DETENT RELEASE AND WINDOW

CUT-OUT SWITCH LEVER

With G a t e Opened As Door Or

G a t e , L e v e r D e p r e s s e s s w i t c h ,

I n t e r r u p t i n g Window Motor Up

C y c l e C i r c u i t

WINDOW CUT-OUT SWITCH 7

GATE REMOTE LEVER

With G a t e Opened As A G a t e ,

Lever Moves "Down" And

B l o c k s Gut Door Handle A c t - u a t i n g Lever

DOOR HANDLE ACTUATING

LEVER CABLE

WOR HANDLE ACTUATDiG LEVER

MWER MCK FJ3LEASE LEVER

Upper Lock I

i

SYNCHRONIZATION ADJUSTMENT BOLT

S y n c h r o n i z e s Lower Lock R e l e a s e

L e v e r With Upper Lock

Fig. 9-61-Dual Acting Tail Gate Lock Synchronization Check

locking system MUST BE synchronized as described under "Lock Synchronization Procedu- re".

Lock Synchronization Checks

1. Synchronization check for lower right lock.

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 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.

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

Open tail gate as a door.

WARNING: PLACE A PROTECTIVE SUP-

PORT UNDER RIGHT SIDE O F GATE

I N T H E EVENT GATE BECOMES

DISENGAGED FROM UPPER LEFT

LOCK.

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.

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.

Lock Synchronization Procedure

1. Open gate as a door then close gate securely.

Open tail gate to "gate" (horizontal) position.

TAIL GATE 9-56

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 9-39, 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 9-38.

5. With all locks in locked position, visually check gate remote synchronization holes in gate remote control levers (center of gate as shown in

Fig. 9-5 1). If holes line up, proceed with Step 7.

If holes d o not line up, loosen (turn to right approximately three turns) gate remove control synchronization bolt (this bolt has left hand threads). With synchronziation bolt loose, check that there is no bind in remote levers. Align holes by inserting cotter pin through alignment hole in both levers (Fig. 9-51). Then, tighten synchronization 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. 9-51).

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 (Fig. 9-51) while tightening door lock synchronization bolt to 76-1 16 inch lbs. Make sure tab on door lock remote syuchronization lever is properly engaged in hole (See Fig. 9-51).

CAUTION: The action of loosening the lock synchronization 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 occurring, reach through access hole and hold the upper-to-lower lock connecting rod

(See Fig. 9-51) FORWARD while loosening synchronization 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.

9-56 TAlL GATE

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.

DUAL ACTING T A l L GATE DIAGNOSIS AND SERVICING PROCEDURES CHART

CONDITION APPARENT CAUSE CORRECTION

1. Gate does not open as a gate.

1. Glass blockout lever of upper right hand lock not actuated.

NOTE: This condition prevents tail gate from operating either way.

2. Lower right hand lock not locked.

3. Synchronization

(adjusting) screw of the remote control loose (located at center of tail gate).

(A) Check to see if the glass blockout rod is installed and attached to the lever of the upper right hand lock.

(B) Check if the glass is in the full down position.

(A) Check if the lower right hand lock is locked by visually inspecting the fork bolt of the lower lock. If the fork is visible and approximately flush with the rear of the lock housing, the lock is locked. If the fork bolt is considerably forward or not visible, the lock is unlocked.

(This check can be performed with bumper removed.)

(B) Open as a door and slam it to lock.

NOTE: This condition can be determined by trying to unlock the upper locks.

Only the upper 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.

TAlL GATE 9-67

DUAL ACTING TAlL GATE DIAGNOSIS AND SERVICING PROCEDURES CHART (Continued)

APPARENT CAUSE

4. Horizontal lock rods and/or vertical rod from center handle to remote control not installed and/or attached.

CORRECTION

(B) After removing these parts, reach through the access hole and carefully, so as not to bend, pull the upper right horizontal lock rod towards the centerline of the body while simultaneously pulling gate handle. Open to gate position.

(D) Make lock synchronization check.

(A) This condition is charac- terized by the failure of the fipper 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 unattached or missing, attach or replace and then follow the upper lock synchronization procedure as previously described.

NOTE: Rod attachment must be made with gate fully closed.

1. Glass blockout lever of upper right hand lock not actuated, NOTE:

This condition prevents tail gate from operating either way.

(A) Follow procedure outlined in Condition 1, Solution

"A and B".

2. Upper right hand striker too far rearward. (Gate out-of- flush and/or chucks at right upper comer).

(A) This condition can prevent the upper left hand hinge lock from locking.

Readjustment of the right hand upper striker forward is necessary to allow both upper locks to lock.

9-58 TAlL GATE

DUAL ACTING TAlL GATE DIAGNOSIS AND SERVICING PROCEDURES CHART (Continued)

APPARENT CAUSE

3. Upper left hand hinge lock not locked.

4. Cable from door handle to upper right hand lock detached.

5. Rod from upper right hand lock to lower right hand lock detached.

CORRECTION

(A) Check for unlocked upper left hand lock by pulling on corner of gate

(gate will check 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 opening 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).

(A) Determine if rod is detached by visual inspection. If unattached:

1. Open tail gate as a gate.

2. If rod is disconnected at vpper lock, attach rod by moving the lever of the upper lock to the position of the rod.

WARNING: DO NOT PULL

UP O N THE LOCK ROD

AS THIS WILL UNLOCK

THE LOWER LOCK.

3. If rod is disconnected at lower lock, push rod forward to engage

TAlL GATE 9-69

DUAL ACTING T A l L GATE DIAGNOSIS AND SERVICING PROCEDURES CHART (Continued)

CONDITION

APPARENT CAUSE

Right hand lock synchronization screw loose.

2. Improper synchronization of upper locks.

3. Bent upper horizontal lock rods (caused by using rods to unlock gate).

1. Improper synchronization upper locks (loose set screw).

2. Bent vertical lock rod

(caused by using rod to unlock door).

3. Improper synchronization of right hand locks.

CORRECTION lock lever. Hold lock lever forward while engaging rod.

WARNING: 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.

- -

1. Synchronize both right hand locks as specified in lock synchronization procedure.

2. If loose, follow procedure outlined above in 2-5 (A).

(A) Refer to lock synchronization procedure.

(A) Replace rod and re- synchronize locks as outlined in lock synchronization procedure.

(A) Synchronize locks by following procedure outlined in lock synchronization procedure.

(A) Replace rod and re- synchronize locks by following lock synchronization procedure.

(A) Synchronize locks as outlined in lock synchronization procedure.

Released by: www.78ta.com

Serial Number: 72BDY-001-1009

960 TAlL GATE

DUAL ACTING T A I L GATE DIAGNOSIS AND SERVICING PROCEDURES CHART (Continued)

CONDITION

5. Tail gate window will not raise.

APPARENT CAUSE

1. Tail gate window cut- out switch inoperative.

CORRECTION

1. Open tail gate as a gate. Remove inner cover panel and water deflector.

2. Insert bare end of a tape insulated welding rod through belt glass openirig into BLUE WIRE connector on regulator motor.

3. Ground negative pole of

12V battery to tail gate.

4. Raise glass by connecting other end of welding rod to positive pole of battery.

5. Replace cut-out switch as previously described.

1. Refer to "Tail Gate Window

Electric Regulator Motor

Assembly Removal. "

SINGLE ACTING TAlL GATE

DESCRIPTION

PICK-UP DELIVERY STYLES

The single acting tail gate for pick-up delivery styles is fabricated primarily of an outer and an inner panel with reinforcements provided at critical attachment locations. Two large openings in the inner panel allow access to the locks, lock remote control and remote control rods. The tail gate is unlatched by a remote control handle located at top center of the inner panel and is supported in the open (horizontal) position by a support cable on each side of the gate.

Removal and Installation

1. Remove screws securing cover panel to inner panel and remove panel.

2. To install, reverse removal procedure.

TAlL GATE INNER COVER PANEL

The single acting tail gate employs an inner panel cover which is secured to the inner panel entirely by screws (Fig. 9-62). The cover panel may be removed with the tail gate in either the open or closed position.

TAlL GATE INNER PANEL ACCESS HOLE

COVERS

Access hole covers provide additional support for the cover panel and attachment provision for the lock remote control-to-lock rod support clips.

Removal and Installation

Right or Left

1. Remove tail gate inner cover panel as previously described.

TAlL GATE 981

ROD

LOCK CONTROL ROD 1

VIEWWA"

4747

Fig. 9-62-Single Acting Tail Gate Cover Panels

2. Remove screws securing access hole cover and disengage lock control rod support clip. Remove access hole cover (View "A", Fig. 9-62).

3. To install, reverse removal procedure.

TAlL GATE HINGE ASSEMBLY

Removal and Installation

1. Open tail gate and provide support on side from which hinge is to be removed. Mark location of hinge on tail gate.

2. Remove tail gate hinge attaching bolts from tail gate and body and remove hinge (Fig. 9-63).

3. To install, reverse removal procedure. Prior to installation, apply a coat of heavy-bodied sealer to surface of hinge that contacts body.

4. Check alignment of tail gate in body opening and adjust as required (Refer "Adjustments"

Tail Gate Assembly).

TAlL GATE SUPPORT CABLE(S)

Removal and Installation

1. Support tail gate in open position.

2. Disengage support cable return spring and remove cable attaching bolts on tail gate and body pillar (Views "A" and "B", Fig. 9-63).

Remove support cable.

3. To install, reverse removal procedure.

TAlL GATE ASSEMBLY

Removal and Installation

1. Open tail gate and support in horizontal position.

2. Disengage support cable return springs and remove support cable attaching bolts on tail gate

(View "B", Fig. 9-63).

9-62 TAlL GATE

1. Lock Sriker

2. Striker Spacer

3. Striker Adjusting

Plates

4. Tail Gate Hinge

Spacer

5 . Tail Gate Hinge

Fig. 9-63-Single Acting Tail Gate Hardware

6. Lock Remote

Control-to-Lock Rods

7. Lock Assembly

8. Remote Control

Assembly

3. With the aid of a helper, remove right and left tail gate hinge to gate attaching bolts and remove tail gate from body (Fig. 9-63).

4. To install, reverse removal procedure. Prior to installation, apply a coat of heavy-bodied sealer to surface of hinges that contact tail gate.

9. Remote Control

Adjusting Screw

10. Support Cable Return

1 1 .

Spring

Tail Gate Support

Cable check engagement of locks to strikers as described in

"Tail Gate Lock Striker Adjustment".

Adjustments

Up-down and fore-aft adjustment is provided at hinge to gate attaching bolts. Side to side adjustment is achieved at hinge to body attaching bolts with spacers (View "D", Fig. 9-63).

NOTE: Following any adjustment of the tail gate,

TAIL GATE LOCK REMOTE CONTROL

ASSEMBLY

Removal and Installation

1. Remove tail gate inner cover panel, access hole covers and remote control handle (Fig. 9-62).

2. Disconnect remote control-to-lock rods at remote assembly by sliding rod attaching clips out of engagement (View "C", Fig. 9-63).

TAlL GATE 9-63

3. Remove remote control attaching bolts and withdraw assembly from tail gate (Fig. 9-63).

4. T o install, reverse removal procedure.

Adjustments

To assure simultaneous action of right and left locks, loosen remote control adjusting nut, position lock rods to full outboard position and tighten remote control adjusting nut (View "D", Fig. 9-63).

TAlL GATE LOCK ASSEMBLY

RIGHT OR

LEFT

Removal and Installation

1. Remove tail gate inner cover panel and appropriate access hole cover (Fig. 9-62).

2. Disengage lock control rod at remote control lever (View "C", Fig. 9-63).

3. Remove screws securing lock assembly to tail gate and withdraw lock with control rod attached from gate. Remove control rod from lock if required, as a bench operation (Fig. 9-63).

4. To install, reverse removal procedure.

TAlL GATE LOCK STRIKER

RIGHT OR LEFT

Removal and Installation

I.. Open tail gate and mark position of striker on body pillar.

2. Remove lock striker attaching screws and remove striker, spacer(s) if present, and adjusting plates from body pillar (Fig. 9-63).

3. To install, align striker and components within marked area and install attaching screws.

Adjustments

1. T o adjust the tail gate lock striker up or down or forward or rearward, loosen striker attaching screws, shift striker and adjusting. plates to desired position and tighten attaching screws.

2. Dimensional specifications for use of door lock striker service spacers are as follows: a. Tail gate should be properly aligned before checking spacer requirements.

Fig. 9-64-Tail Gate Lock Striker Caulking Check b. T o determine if tail gate lock striker service spacers are required, apply modeling clay or body caulking compound in the lock striker notch where the lock extension engages and close tail gate to form a measureable impression the clay or caulking compound, as shown in Figure 9-64.

When dimension "A" from inside face of striker teeth to center of lock extenstion is less that 3/16" install service spacers and proper length striker attaching screws as follows:

1. Dimension "A" is 3/16" to l/8", use one spacer

1/16" thick, with original screw.

2. Dimension "A" is 1/8" to 1/16", use one spacer

1/8" thick, with service screw (1/8" longer).

3. Dimension "A" is 1/16" to 0, use one 1/8" spacer and one 1/16" spacer, 3/16" total thickness, with service screw (1/4" longer).

4. Dimension "A" is 0 to 1/16" interference, use two 1/8" spacer, 1/4" total thickness, with service screw (1/4" longer).

NOTE: Use zinc or cadmium-plated flat-head cross-recess screw with countersunk washer.

CAUTION: Dimension "B" from center of lock extension to inside face of striker should never be less than 1/16".

HEADLINING

10-1

SECTION 10

INDEX

SUBJECT PAGE

Headlining

Cloth and Vinyl Coated (Soft)

All Styles Except "56-66" Station Wagons 10-1

Description

Removal

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

10- 1

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

10-1

Installation

Description

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

10-4

Headlining "56-66" Station Wagon Styles

10-7

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

10-7

Front Headlining Assembly

Removal

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

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

10-7

SUBJECT

Installation

Removal

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

Rear Headlining Assembly

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

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

Installation

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

One Piece Formed Headlining

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

Description

Removal

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

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

Installation

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

PAGE

HEADLINING-CLOTH AND VINYL COATED

**(SOFT)-ALL STYLES EXCEPT "56-66" VISTA CRUISER**

STATION WAGONS

Quarter upper trim is covered in "Door and Quarter

Trim" section.

DESCRIPTION

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.

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").

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.

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").

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.

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. a. Windshield side and upper garnish moldings or finishing lace.

Rear view mirror support.

Sun shade supports.

Dome or rear quarter courtesy lamps.

Coat hooks.

Side roof rail moldings or finishing lace.

Back window garnish moldings or finishing lace.

Center pillar upper trim assembly.

Rear quarter trim, where necessary.

Quarter upper trim finishing panel.

Back body openin8 garnish moldings or finishing lace.

HEADLINING

10-3

SLOT IN ROOF FOR

WIRE SUPPORT

WIRE

LISTING WlRE SUPPORT

INSTALLED TO ROOF PANEL

VlEW "A"

TYPICAL OF ALL LISTING

WlRE SUPPORT LOCATIONS

VlEW "B"

Fig. 10-2-Typical Cloth or Vinyl Headlining Installation

"B, C, F and E" Body Styles

104

HEADLINING

Fig. 10-3-Side Roof Rail Garnish Moldings

1. Shoulder strap anchor plate and escutcheon.

Carefully remove tacks or staples securing headlining at windshield and back window opening or back body opening.

On styles using pronged retainer, use headlining inserting tool, J-2272 or similar wide-bladed tool and carefully disengage headlining from pronged retainers where present.

Carefully detach cemented edge of headlining around entire perimeter.

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, carefully 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.

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.

NOTE:

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.

If replacing headlining, remove listing wires from pockets of old headlining.

NOTE:

Listing wires removed from old headlining must be installed in corresponding pockets of new headlining.

Installation

1. If previously removed, install listing wires into corresponding pockets of new headlining assembly. 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 listing 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

10-1, View listing wire into clips (See Fig.

"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 remaining listing wires (See Fig. 10- 1, View

"C").

NOTE: Listing wires may be adjusted up or down by utilizing appropriate 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 headlining 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

ENGAGE MATERIAL UNDER

VlEW "A"

SbjAP LISTING

IRE IN RETAINER

VlEW "B"

VlEW "C" (LEFT SIDE)

Fig. 10-4-Headlining Installation

"D" Body Styles

104 HEADLINING

VlEW "D"

VlEW "F"

A \ SLlT AND HOOK LISTING WIRE

OVER TAB ABOVE BACK WINDOW

SLlT AT AIR DUCT, CEMENT EDGES, FOLD

EDGES INTO OPENING AND SECURE

INSTALL LISTING WIRE

POSITION TO CEMENTED

TRIMSTICK AND STAPLE OR TACK

4520 VIEW "E"

Fig. 10-5-Headlining Installation

'Dm

HEADLINING

107

Station Wagon Styles

DESCRIPTION

The "56-66" 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 " E n , 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.

Starting at front, carefully detach all cemented edges of headlining material from retainers and flanges.

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 headlining clean and remove old headlining assembly (See

Fig. 10-6, View "C").

NOTE: 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.

NOTE: Clean hands are essential when working with headlining material.

FRONT HEADLINING ASSEMBLY

Removal

Place protective covers over front seat cushion and back.

Prior to removal of the front headlining, remove the following items:

Sunshade supports.

Rear view mirror support.

Windshield upper corner escutcheons.

Center lock pillar upper finishing plates.

Side skylight front upper garnish molding.

Courtesy lamps.

Front headlining finishing lace.

Rear of headlining finishing lace.

Finishing lace over front and rear doors.

Shoulder strap anchor plate and escutcheon.

Installation

If previously removed, install listing wires into pockets of headlining.

NOTE: Listing wires removed from old headlining must be installed in corresponding pockets of replacement headlining.

Apply approved trim cement to headlining attaching surfaces.

Apply approved trim cement to metal retainers and flanges.

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 stretching and removing wrinkles. Reinstall all previously removed parts.

REAR HEADLINING ASSEMBLY

Removal

1. Place protective covering over seats and floor.

2. Prior to removing headlining, remove the following items: a. Sunshade supports located at the front skylight. b. Side skylight front upper garnish molding.

104 HEADLINING

- -

Fig. 10-6-Headlining Installation '56 and 66" Styles

HEADLINING 104

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.

NOTE:

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 ttim cement to retaining flanges of toof 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 "EN).

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 FORMED HEADLINING

DESCRlPTlON

The one piece formed headliner consists of molded fiber glass covered with foam and nylm 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.

2. Remove the screws located in the upper rear comer of the headlining (See Fig. 10-7, View

"DM).

NOTE:

These screws are exposed after upper quarter trim finishing panel is removed (see

"Door and Quarter" section).

3. Disengage the snap fasteners and carefully lower headliner from roof panel (See Fig. 10-7, View

"E" and "B").

4. Lower all windows on both sides of car to the full down position and remove headlining through window openings.

lnstallation

1. Load headliner into car through side window openings.

2. Raise one side of headliner to side roof rail, and then the other side.

10-10 HEADLINING

V l E W A

V l E W B

V I E W D

V l E W C

V l E W E

1 . Windshield

2. Sunshade Bracket

Holes

Fig. 10-7-One Piece Headlining

3. Roof Bow

4 . Snap Fastener

5. Headliner

6. Side Roof Rail

7. Coat Hook

8. Quarter Inner Upper

Panel

9. Retaining Screw

NOTE: Headlining must be loaded from the side and positioned to rest on side roof rails.

3. Align holes in rear of headlining with piercings in rear quarter, and cut-outs for sunphade brackets at attaching location.

4. Install screws in the sail area and sunshade brackets (See Fig. 10-7, Views "A" and "DM).

5. Install all previously removed hardware.

6. Engage snap fasteners (see Fig. 10-7, View "B" snap fastener and press upward until it engages.

CAUTION: To avoid damage of clips do not engage by exerting hard striking with any type of tool or hand.

ROOF 11-1

SECTION 11

SUBJECT PAGE

Fabric Roof Cover

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

Description

Removal

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

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

Installation-Styles with Pad and/or Pad with Roof Panel Moldings

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

Installation-Styles without Pad-with or without Roof Panel Moldings

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

Fabric Roof Cover Discrepancy Repair

Description

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

......

.......

Repair Utilizing Teflon Coated Graining

Tool

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

SUBJECT

Equipment and Material Requirements

Repair Procedure

....

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

Repair Utilizing Fabricated Plastic

Graining Die ..............................................

Equipment and Material Requirements

Repair Procedure

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

Repair of Cuts on Padded Roof Covers

Repair

....

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

Luggage Carrier ............................................

PAGE

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 Oldsmobile " E n 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 Fig. 11-1). Cadillac

68169 and 69347 styles utilize two outer pads which are cemented to the roof panel and then the cover is applied over the pad and cemented to the center section of the roof panel and along the outer perimeter of the cover assembly (refer to Fig. 1 1-1).

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 cover 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.

Removal

1. The following parts must be removed prior to removing the fabric roof cover.

O N 39687 STYLES,

FABRIC ROOF COVER PADS

CONSIST OF THREE PIECES

VER PADS CONSIST

T W O OUTER PADS

ONLY

Fig. I I-I-Typical Fabric Roof Cover Pads

1 1-2

ROOF a. Upper and both side wkdshield and back window reveal moldings (except on styles where the cover does not extend into the windshield opening). b. Roof drip molding scalps, weatherstrip retainers 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. 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 windou lower belt reveal molding

(on styles where fabric cover extends under molding). h. On "B" body station wagon styles, remove

OLD

S T 0

Fig. back body opening and quarter window reveal moldings. i. On all "A-27 and 37" and Olds "A-57" styles where cover extends below back window opening, remove valance retainer attaching nuts (refer to Fig. 11-8).

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.

Remove all drive nails that are present in windshield and back window opening and at roof extension area.

CAUTION: When removing drive nails, the edge of glass must be protected. Two 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.

Prior to removing fabric cover, application of heat to cemented areas will permit easier loosening of cemented edges.

CAUTION: 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.

Loosen all cemented edges of fabric roof cover, then, carefully remove fabric cover from remaining cemented area of roof panel.

CAUTION: On styles where a pad is present, exercise care when removing fabric cover to avoid damage to the pad.

On kyles 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 soften- ing of roof panel paint finish.

11-4 ROOF

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

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.

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 temperatures below 72 degrees, fabricated pliers will aid in removing wrinkles (see Fig. 11-2).

Determine center line 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 length- wise, 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.

Remove cover from roof panel and lay cover with lining side upward on a clean flat surface.

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 " (Fig. 1 1-3).

NOTE: It is recommended that 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, the following spray guns, pressure cups, specific fluid tips, and air caps should be used (or equivalents).

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 equivalent, 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 high- lights 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 68169 styles.

9. Cut relief notches in cover at all weld-on studs and angle cuts as required in corners of window openings (Fig. 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.

1 1. 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. 11-3).

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 68 169 and Oldsmobile and Cadillac "EM dition, install drive nails across top of windshield opening on 68169 styles (refer to View

"D", Fig. 11-3 for Oldsmobile and Cadillac "E" styles and View "A" and "G", Fig. 11-4 for

68169 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 operation is completed, fabric cover should be free of all wrinkles and draws in this area.

1 1-8 ROOF

On styles equipped with roof panel moldings, position roof panel molding retainers over weld- on studs and install retaining clips.

Trim fabric cover in a line along retainers. 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 (View "A", Fig. 11-3).

On 68 169 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 not removed, is also sealed (Fig. 1 1-3).

Remove all previously installed protective cov-

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

(hook, 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.

CAUTION: Be certain to follow manufacturer's directions when using cleaner.

3. 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 temperatures below 72 degrees, fabricated pliers will aid in removing wrinkles (see Fig. 11-2).

4. Determine centerline of roof panel by marking center points on windshield and back window opening with tape or equivalent.

5. Lay cover on roof panel and fold cover length- wise, 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.

6. Remove cover from roof panel and lay cover with lining side upward on a clean flat surface.

7. 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 that 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 equivalent 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 high- lights from excess cement build-up.

8. Allow cement on fabric roof cover to dry thoroughly.

9. 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).

11-8 ROOF

V I E W B V I E W C

V l E W C

Fig. 1 1-6-Typical Fabric Roof Cover Installation

Without Pad or Roof Panel Moldings

"A, B, C and F" Styles

10. Fold one half of cover back at centerline and apply nitrile type vinyl trim adhesive to exposed half of 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. 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.

NOTE: On all "A-27 and 37" and Olds "A-57" styles, the valance is a separate section retained by cement and metal clips at the outboard ends

(refer to Fig. 1 1-8). Ends of the valance material are folded over and cemented to the clips, forming a seam similar to the dielectric seam. The self-sealing clips are then attached to the body through holes in the rear compartment front panel and fastened with retaining nuts.

11-10 ROOF

SECTION " A - A "

(TOP VIEW)

SECTION " A - A "

(BOTTOM VIEW) 461 5

Fig. 11-8-"A-27 and 37" Style Fabric Roof Cover Valance

Installation

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 DAM-

AGE 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. Re-cement fabric cover to roof

(Fig. 1 1-9).

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 window opening, raise cemented edge and cut as required.

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

10). 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 5-2 1092 or equivalent may be used (Fig. 11-11).

21. On station wagon styles where the cover assembly extends down the rear body lock pillar, cement cover into the door and quarter window openings (Fig. 1 1-7).

22. Apply a "film" coat of silicone sealant such as

Dow Coming 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. 11-5, 11-6 and 1 1-9).

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.

24. Remove all previously installed protective covering from windshield, back glass and body.

25. Install all previously removeu 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

2

ROOF

TRIM COVER ALONG BOTTOM

OF OUTBOARD SIDE OF DRIP MOLDING

Fig. 11-10-Trimming Fabric Roof Cover at Drip Molding

Area 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 using back and forth strokes until wrinkle or bubble disappears.

Be certain shop towel does not become dry as excess heat will permanently damage fabric roof cover. Fig. 1 1-1 1-Fabric Cover Trimming Tool

FABRIC ROOF COVER DISCREPANCY REPAIR

DESCRIPTION

The fabric roof cover material is a vinyl coated fabric which exhibits a grain pattern in the exterior vinyl 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

12 and 11-13).

The repair procedures which follow describe two separate methods.

Fig. 1 1- 12-Typical Fabric Roof Cover Discrepancy Fig. 11-13-Typical Fabric Roof Cover Discrepancy

HEATING IRON AND STAND J23091-2

GRAINING TOOL J23091-1 OR J23091-8

ROOF 11.1

3

3624

Fig. 11-14-Fabric Roof Cover Repair Tool

1. Repair utilizing a teflon coated metal graining tool, heating iron, and a variable heat control unit, Fig. 11-14.

2. Repair utilizing a fabricated plastic body filler graining die and a heat gun, Fig. 1 1-1 5.

REPAIR PROCEDURE UlTlMZlNG

TEFLON COATED GRAINING TOOL-

A U STYLES EXCEPT CADILLAC

Equipment and Material Requirements

1. Repair tool kits for graining and curing vinyl repair patching compound are available as follows: a. Kit 5-2309 1 (or equivalent) includes graining tool 5- 2309 1- 1 (or equivalent), heating iron and stand tool 5-23091-2 (or equivalent) and variable heat control tool 5-23091-3 (or equivalent) and is applicable for 1972 and prior model year fabric roof cover material

(Fig. 11-14).

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

16).

3. Razor or Sharp Knife

- to be used for removing frayed edges from damaged area prior to application of vinyl patching compound (Fig. 11-

4. Vinyl Cleaner (Detergent Type)

- a11 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

16).

6. Vinyl Repair Patching Compound

' .

- a heat curing milky colored heavy bodied plastisol for repairing cut, torn, scuffed or gouged vinyl roof cover material (Fig. 1 1

16).

7. VinyI Repair Paint

- an approved, durable, waterprof, weather resistent and pliable vinyl coating for refinishing vinyl coated fabrics.

11-14

ROOF

Fig. 11-15-Fabric Roof Cover Repair Die and Hot Air Gun

Repair Procedure

1. Pre-heat graining tool at 60 setting, plus or minus 2, on variable heat control (5-23091-3 or equivalent) for a minimum of 15 minutes or until the temperature has reached 300 degrees.

2. Prepare surface as follows: a. If caver 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.

11-17).

Fig. 11-16-Fabric Roof Cover Repair Materials and Tools

ROOF 11-1

5

Fig. 1 1-17-Fabric Roof Cover Repair Trimming

NOTE: 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 viny 1 patching compound to edges of area as shown in Figure 11- 18. Where trimming was required, apply compound to area being repaired and trowel flush with adjacent surface as shown in Fig. 11-19. 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

Fig. 11-19-Vinyl Repair Patching Compound Application

(see Figs. 1 1-20 and 1 1-2 1). Curing and graining time can be increased slightly depending on size of repair.

NOTE: 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.

After graining operation i.s 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.

5. Apply vinyl paint (solid colors) as follows: a. 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.

Fig. 11-18-Vinyl Repair Patching Compound Application

-- --

Fig. 11-20-Vinyl Patching Compound Curing and Graining

Fig. 11-21-Vinyl Patching Compound Curing and Graining b. 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.

NOTE: 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. 1 1- 15).

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.

11-16).

Vinyl Repair Patching Compound

- a heat curing milky colored heavy-bodied plastisol for repairing damaged area (see Fig. 11-16).

5. Vinyl Repair Paint

- an approved, durable, water proof, weather resistant, pliable vinyl paint for final color refinishing (see Fig. 1 1-16).

6. Pallet Knife

- a small trowel for applying patching compound to repair area (see Fig. 1 1

16).

7. Heat Gun

- used to cure vinyl patching compound, 'preferably 500 degrees to 700 degrees heat range (Fig. 1 1- 15).

Repair Procedure

1. To fabricate a graining die, select a scrap piece of 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.

2. 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).

3. Prepare swface as follows: a. Using a soft lint-free cloth, wipe the repair area with solvent type vinyl cleaner. Allow area to dry completely.

CAUTION: Protect adjacent painted surfaces. b. 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 taper- ing angle of the repair surface walls provides greater surface for filler adhesion.

ROOF 11-17

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 sur- rounding 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.

CAUTION: 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 temperature. Further heating will result in loss of grain.

Perform graining operation as follows: a. After the last layer of filler material has been cured, the graining operation is performed.

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 has 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 uni- formity. Apply steady, even pressure to the back of graining die to provide an even impression.

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.

NOTE: 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.

Without detaching the cover from the roof panel, working through the point of damage, insert a piece of waterproof tape under the cut with the adhesive side out. The 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.

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 damaged area is adjacent to moldings or edge of fabric material. When using this method, the 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.

11-16

ROOF

Fig. 1 1-22-Luggage Carrier Installation

Factory Installed Option

ROOF 1 1-1 9

L U G G A G E C A R R I E R

DESCRIPTION

The luggage carrier is available as a factory or dealer installed option for "B" style staton 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:

Assemble supports and top rails with ten 3/8 inch long screws (Fig. 11-22).

Remove ten screws and washers from rubber support mounting nuts on roof (View "A", Fig.

11-22). Leave rubber nuts in place. Keep screws, discard washers.

Place five gaskets over rubber well nuts (gaskets are not required if vehicle is eqquipped with vinyl roof cover option).

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

(Fig. 1 1-22).

Tighten all screws securely. dealer installed option, procedure is as follows:

Locate patterns as illustrated (Fig. 11-23) and tape in place.

2. Center the skid strip in slots of front and rear patterns, five places each pattern.

CAUTION: 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 (Fig.

11-23) 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 remaining 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 i n the best installation.

1 1-20 ROOF

ALIGN FRONT EDGE OF FRONT PATTERN

WlTH ROOF CONTOUR n

&ENTER THESE EDGES OF REAR PATTERN'

WlTH BACK WINDOW SIDE MOLDINGS

Fig. 11-23-Luggage Carrier Installation

Dealer Installed Option

FOLDING TOP

12-1

SECTION 12

SUBJECT

Folding Top Trim Assembly

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

Description

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

Folding Top Cover and Back Curtain

......

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

Removal

Installation

Removal

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

Folding Top Cover

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

Installation

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

Back Curtain Assembly

Removal

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

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

Installation

Description

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

Hydro-Lectric System

"A" Bodies

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

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

Motor and Pump Assembly

Installation

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

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

Operation of Folding Top

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

Operation of Valve Assembly

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

Fluid Control Valve

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

Mechanical Checking Procedure

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

Electrical Checking Procedure

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

Hydraulic Checking Procedure

Folding Top Lift Cylinder

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

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

Filling of Hydro-Lectric Reservoir

Folding Top Adjustments

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

"A" Bodies

......

Adjustment of Front Roof Rail Guide

Adjustment of Front Roof Rail

......

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

Front Roof Rail Lock Assembly

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

Front Roof Rail Lock Adjustment

Adjustment of Top Control Link

Trouble Shooting Chart

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

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

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

Lubrication

"A" Bodies

"B and E M

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

Folding Top Styles

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

Description

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

Folding Top Trim

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

Folding Top Cover and Back Curtain

Assembly

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

Removal

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

Installation

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

Folding Top Cover (Less Back Curtain)

Removal

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

Installation

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

Rack Curtain Assembly

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

PAGE

INDEX

SUBJECT

Removal

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

Installation

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

Folding Top Silencer Assembly

Removal

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

Installation

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

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

Folding Top Side Quarter Pad Assembly

Removal

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

Installation

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

Folding Top Gutter

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

Removal and Installation

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

Folding Top Hardware Components

Front Roof Rail Lock

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

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

Removal and Installation

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

Front Roof Rail Locating Pin

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

Removal and Installation

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

Folding Top Electric Motor and/or

Relay

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

Removal and Installation

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

Folding Top Actuator Drive Cable-Right and/or Left

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

Removal and Installation

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

Back Window Guide Control Link and

Spring

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

Removal and Installation

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

Folding Top Actuator Assembly

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

Removal

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

Installation

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

Procedure for Synchronizing Folding

Top Actuators

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

Folding Top Adjustments

Description

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

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

Folding Top Stacked Position Tension

Adjustment

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

Locating Pin and Side Roof Rail Height

Adjustment

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

Description

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

Procedure

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

Checking 'Tension of (Up Position) Side

Roof Rails

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

Description

Procedure

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

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

Side Roof Rail Tension Adjustment

........

Front Roof Rail Lock Hook Adjustment

PAGE

12.2 FOLDING TOP

FOLDING TOP T R I M ASSEMBLY

"A"

BODIES

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 sta- pling 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 to^ cover to the side rails to minimize air leakage aloig the side roof rails.

1

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 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 beltline. Use sham- ened grease pencil (Item "C", Fig. 12-1).

Fig. 12-1-Reference Marks on Top Cover and Back Curtain

A. One Piece Trimstick 8. Top Cover Vertical

Edge Reference

C. Back Curtain Center

Reference

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 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).

FOLDING TOP 12-3

8. At underside of front bow, remove screws securing listing pocket retainer to front bow. Disen- gage 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).

NOTE: 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 during back curtain and/or side stay pad removal and installation.

VlEW A

VlEW B

Fig. 12-2-Hold Down Cable Attachment

12-4 FOLDING TOP

SECTION A - A

Fig. 12-3-Listing Pocket Retainer

MATERIAL PER STICK

A. Wood

1/2 x 1 x 14-1/2

B. Steel

1/32 x 1/2 x 2-1/2

C. Steel

1/32 x 1-1/2 x 7

Screw No. 6 x 1/2"

E. Bolt l / 4 - 2 0 U N C - 2 A x 1"

F. Wingnut 1/4 x 20 UNC

Washers 1/4" 1.D

CENTER BOW

CORD OR TAPE

Fig. 124Spacer Stick Installation

1516

Fig. 12-5.-Spacer Stick Fabrication

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 (Figs. 12-6 and

12-7).

12. Remove rear trimstick from body and position above quarter pinchweld finishing moldings.

NOTE: 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 beltline (Figs. 12-8, 12-9 and 12-10).

CAUTION: Avoid contact with or damage to top lift cylinder piston rod.

13. Perform the following operation o? car, or later on bench:

A. Using a suitably sharp pencil, ACCU-

RATELY 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 "V" notch on trimstick (See Fig.

12-1).

14. Detach and remove top cover from rear trimstick. Accurately mark location of balance of trimstick on back curtain. Note spacing of staples before removal.

15. 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 mark-

MALE H I N G E

TRIMSTICK

A T T A C H I N G

SHOULDER O N

A T T A C H I N G

V I E W A

MALE H I N G E

Fig. 12-6-Trimstick Attachment "A" Styles

FOLDING TOP

12-5

3 2 5 4

Fig. 12-7-Trimstick Removal "A" Styles

12-6 FOLDING TOP

Fig. 12-8-Raising End of Trimstick ings on back curtain, and remove curtain from trimstick. Note location and spacing of staples before removal.

17. Remove 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, 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

Fig. 12-9-Raising Balance of Trimstick

Fig. 12- 10-Trimstick Removed 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. Ap- ply an approved trim cement to stay pads uniformly and install polyurethane padding. Trim off salvage 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 surface 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.

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.

CAUTION: 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 curtain tb trimstick. Tack from center to ends. Avoid stretching, but keep material flat during tacking operations.

FOLDING TOP 12-7

TACKS SCREWS

- ma*

Fig. 12-1 1-Side Stay Pad Attachment

4. Transfer reference marks from removed to^ cover to new one as follows: Place new top cove; 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 comers of both covers. Secure both covers together at these locations. Care- fully lay out trim material of sail area of both covers and proceed as follows:

A. Transfer location marks for trimstick (UP-

PER 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;

CAUTION: 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

FRONT 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

Refeiences

B. Trimstick Lower Edge

Reference

C. Trimstick Upper Edge

Reference

Back Curtain Center

Reference

12-8 FOLDING TOP

Fig. 12-14-Cross Section at Rear Trimstick

A. 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 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 curtain to rear bow to protect back window during 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 (Fig. 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 supporing 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.

12-15).

NOTE:

Make certain trimstick is flush to quarter pinchweld finishing molding during all tacking operations. This will require assistance 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 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).

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).

Apply nitrile cement or neoprene type weatherstrip 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 weatherstrip attaching screws.

TACKING BACK CURTAl

T O REAR BOW

Fig. 12- 15-Tacking Back Curtain

1411

Install weatherstrips to help maintain position of quarter flaps while adhesive is drying.

While pulling top cover rearward slightly to straighten material over rear window, install tacks to secure cover to rear bow.

CAUTION: 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.

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 edge of front roof rail (Fig. 12- 16).

Lower top to stacked position. Carefully, apply nitrile cement or neoprene weatherstrip adhesive to cementing area of front roof rail, to corresponding surface of top cover, and to front corner flaps.

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,

Fig. 12-16-Marking Top Cover at Front Roof Rail

FOLDING TOP 12-9 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.

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.

Lower top and complete tacking of top cover to front roof rail. Trim off excess material (Fig.

12-12).

Carefully align, seal and install front roof rail and side roof rail weatherstrips.

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 escutch- ems. Tack from center outward to maintain a snug and straight fit. Length 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

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 beltline. Use sharp- ened 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 and center weatherstri~s. to^ to

- --

12-10

FOLDING TOP

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 attaching 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. Disen- gage 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 required by removing attaching bolts using a suitable box- socket type wrench to remove each bolt from

"outside" surface of male hinge (Figs. 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 beltline (Figs. 12-8,

12-9 and 12-10).

CAUTION:

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 mark right and left inner vertical edge of top cover on back curtain at trimstick (Fig. 12-1).

Detach top cover from rear trimstick and remove. Note spacing of staples before removal.

hstallation

1. Transfer reference marks from removed top cover to new one as follows:

A. 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.

B. 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.

C. Transfer location marks for trimstick (upper and lower trimstick edges, as well as ends as shown in Fig. 12-1).

D. 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.

CAUTION:

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 and 11 of Re- moval 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 from roof bow. Position retainer on front bow and install attaching screws (Fig. 12-

3).

FOLDING TOP 12-1 1

Apply nitrile cement or neoprene-type weatherstrip 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 full: ness from top cover valance over rear window.

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.

While pulling top cover rearward .slightly to straighten material over rear window, install tacks to secure cover to rear bow.

(Fig. 12-1).

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 comer flaps.

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 comer flaps to cemented surfaces.

Remove wood block and complete cementing top cover to front roof rail. Lower top and install several stay tacks.

Raise top and lock to windshield header. Check appearance of top trim, top operation and lock- inn action of tov. If additional tension is needed i n t o p 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 binding outside of deck seams should not exceed 6 inches and should be of uniform length on each side.

18. 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.

BACK CURTAIN ASSEMBLY

" A BODIES

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 sharp- ened 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 fol-

. lowing: 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

12-1 2 FOLDING TOP 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 s n u ~ l y 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 during back curtain and/or side stay pad removal and installation.

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 "V" 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.

Material Per Stick

A. Wood

1/2 x 1 x 14-1/2

B. Steel

1/32 x 1/2 x 2-1/2

C. Steel - 1/32 x 1-1/2 x 7

C. Screw 6 x 1/2"

E. Bolt 1/4

20 UNC

2A x 1"

F. Wingnut 1/4 x 20 UNC

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 (Figs. 12-6 and

12-7).

11. Remove rear trimstick from body and position above quarter pinchweld finishing moldings follows: as

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 body beltline (Fig. 12-9 and 12-10).

CAUTION: 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

Installation

1. With front roof rail locked 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

"Folding Top Cover and Back Curtain Assem- bly 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. Al- low 1/2 inch of back curtain material to extend below trimstick (Figs. 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, t'rim off excess material beyond the 1/2 inch allowance. Transfer center mark from bottom center of removed curtain to new one.

CAUTION: Transfer of reTerence 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 Steps 10 and 1 1 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- 15).

CAUTION: 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).

Disconnect rear trimstick as described in Step 10 of "Removal of Back Curtain" Procedure.

Remove rear trimstick from body and position above quarter pinchweld finishing moldings as described in Step 11 of "Removal of Back Cur- tain" Procedure.

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. Av- oid excessive stretching, but keep material flat during tacking operations (Fig. 12- 1).

FOLDING TOP 12-13

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 Cur- tain" 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.

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.

15. 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.

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.

17. Carefully, apply a bead of neoprene-type weatherstrip adhesive around each rear bow tack head, over unused staple holes, arld over screw holes for escutcheons.

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.

12-14 FOLDING TOP

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. The 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

Removal

1. Operate folding top to full "up" position.

2. Disconnect positive battery cable.

3. Place protective covering over rear seat cushion and back. y

GROUND WIRE

Fig. 12-17-Motor and Pump Installation

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.

7. To facilitate removal, apply a rubber lubricant to pump attaching grommets; then carefully disengage 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.

CAUTION: 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 disconnected 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 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-

Lectric Reservoir".

2. Connect hydraulic hoses, engage attaching grommets in panel and connect wiring.

3. Connect battery and operate top through its up and down cycles until all air has been "bled" 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.

FOLDING TOP

12-16

I J K L M

A. Motor Assembly

B. Motor Shaft "0" Ring

Seal

C. Reservoir Seal

D. Outer Pump Rotor

E. Inner Pump Rotor

F. Fluid Control Valve

Balls

Fig. 12- 18-Motor and Pump Components

G. Pump Cover Plate

Assembly

H. Pump Cover Anaching

Screws

I. Reservoir Tube and

Bracket Assembly

Reservoir Filler Plug

RESERVOIR TUBE

Disassembly From Motor and Pump Assembly

1. Remove motor and pump assembly from body.

K. Reservoir End Plate

Attaching Bolt

L. Reservoir End Plate

Attaching Bolt

Washer

M. Reservoir End Plate

Attaching Bolt fluid until fluid level is within 1/4" of lower edge of filler plug hole.

2. Scribe a line across pump end plate and reservoir tube to insure a correct assembly of parts. See

Figure 12- 19.

3. Using needle nose pliers, remove reservoir filler plug.

4. Drain fluid from reservoir into a clean container.

5. 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.

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,

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

Fig. 12-19-Motor and Pump Assembly

1724

12-16 FOLDING TOP 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 maximum pressure in the range of 340 psi 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 Fig- ure 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.

2. 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 the fluid to the top of each cylinder. The surplus hydraulic fluid due to piston rod displacement flows into the reservoir.

FROM BOTTOM

OF CYLINDER

Fig. 12-21-Operation of Pump to Lower Top

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 Lover 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 in 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 binding action. If a binding action is noted when the top is being locked at the

FLUID C O N T R O L

V A L V E ROCKER

A R M

Fig. 12-20-Operation of Pump to Raise Top

Fig. 12-22-Pump Cover Plate

FOLDING TOP 12-17 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

Adjustments". If a failure continues to exist after a check for mechanical failure has been completed, the, hydro-lectric system should then be checked for eleca trical 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, mechanical 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.

2. Connect light tester to central feed terminal of switch terminal block.

3. 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 a t the feed wire terminal of the 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 jumer 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

I EXCESS FLUID REQUIREMENTS

D R A W N IN F R O M RESERVOIR,

RESERVOIR SlDE

L PRESSURIZED FLUID

SEATS BALL

PREVENTING FLUID F R O M

ENTERING RESERVOR

1730

Fig. 12-23-Fluid Control Valve switch to motor lead wires can be checked as foliows

(See Fig. 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

b o Q msts1.

4. Actuate switch to "down" position. It Eester does not light, there is an open or short circuit in wire.

RESERV

SURPLUS FLUlD

(DUE T O PISTON ROD DISPLACEMRJT)

ENTERS RESERVOIR

THROUGH VALVE

PUMP SlDE

C ~ ~ ~ s s u ~ ~ ~ ~ ~

PREVENTING FLUID FROM

ENTERING RESERVOIR

Fig. 12-24-Fluid Control Valve

12-18 FOLDING TOP

Disconnect red switch-to-motor wire from motor lead.

Connect light tester to switch-to-motor wire feed terminal.

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 tqp.

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.

Fig. 12-25-Checking Wire Leads to Motor

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

Operate top to raised position.

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.

Place absorbent rags below reservoir at filler plug.

With needle nose pliers, remove filler plug. Fluid level should be within 1/4 inch of lower edge of filler plug hole.

If fluid is low, add Type A transmission fluid,

Dexron or equivalent to bring to specified level.

See "Filling of Hydro-Lectric Reservoir".

Install filler plug.

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. 1f 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".

FOLDING TOP 12-19

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.

CAUTION: ~xerci'se care so that transmission fluid does not come in contact with any painted or trimmed parts of the body.

Checking Pressure at the Pump

Remove motor and pump assembly from rear compartmen t.

Install plug in one port, and pressure gauge in port to be checked (Fig. 12-26).

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.

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.

If the pressure is not within specified limits, unit is defective and should be repaired or replaced, as required.

FOLDING TOP LIFT CYLINDER

Removal and Installation

Lock top to windshield header.

Disconnect positive battery cable to prevent accidental operation of motor and pump, particularly when hydraulic hoses are disconnected from cylinder.

Remove rear seat cushion and seat back.

Remove folding top compartment side trim panel assembly on side affected.

Remove clips securing hydraulic hose to rear seat back panel.

Fig. 12-26-Checking Pump Pressure

Remove attaching nut, bolt, bushing and washer from upper end of cylinder rod (Figs. 12-27 and

12-28).

Remove, inner and outer bolt securing cylinder to male hinge (Fig. 12-28).

Carefully move cylinder to inboard side of top compartment brace, exposing upper and lower hydraulic hose to cylinder connections.

Prior to disconnecting hydraulic connections, place suitable wiping rags under connections to absorb any drippage of hydraulic fluid.

Disconnect hydraulic connections from old cylinder and transfer to new cylinder assembly, if replacement is required.

Install cylinder to male hinge.

Connect positive battery cable to battery terminal.

Using power, raise cylinder piston rod to extended position.

Attach upper end of cylinder rod to folding top linkage using previously removed nut, bolt, bushing and washer.

Pperate folding top assembly down and up several times; then check and correct level of hydraulic fluid in reservoir. See "Filling of

Hydro-Lectric Reservoir". with clips and install all previously removed trim and hardware.

12-20 FOLDING TOP

Fig. 12-27-Folding Top Linkage Attachment

FILLING

OF HYDRO-LECTRIC RESERVOIR

This procedure virtually eliminates discharge or spil- lage 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.

' A "

3348

Fig. 12-28-Folding Top Lift Cylinder Attachment

1. Side Roof Rear Rail

2. Piston Rod Attaching

Bolt and Nut

3. Piston Rod Bushing

4. Piston Rod Anti-Rattle

Washer

5. Piston Rod

6. Male Hinge

7. Cylinder Attaching

Bolt 8. Cylinder

Bushing

9. Top Lift Cylinder

10. Hydraulic Hose

Retainer

2. Place absorbent rags below reservoir at filler plug. Using pliers, slowly pull filler, plug from reservoir.

FOLDING TOP 12-21

CAUTION: 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 reservoir 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

CAUTION: 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.

/ I

Fig. 12-29-Reservoir Filler Plug Adapter Fig. 12-30-Filling Reservoir with Hydraulic Fluid

12-22 FOLDING TOP

NOTE: Fluid level should be within 1/4 inch of lower edge of filler plug with top in down position.

CAUTION: D O NOT OVER-FILL

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 be 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 RAIL 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 follows:

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 RAIL

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 attaching 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 weatherstrip screws.

FRONT ROOF

Fig. 12-3 1-Front Roof Rail Guide and Lock Hook Fig. 12-32-Front Roof Rail and Lock Attachment

FRONT ROOF RAIL LOCK ASSEMBLY

Removal and Installation

1 . Lower top to half-lowered 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.

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).

FOLDING TOP 12-23

ADJUSTMENT OF TOP CONTROL LINK

If side roof rails are too high or too low over side windows, proceed as follows:

NOTE: When making top control link adjustments, 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 (Fig. 12-27).

3. Adjust top control link as required and tighten bolt.

4. Raise and lock top. Check alignment.

CONDITION

A. Difficult locking action at front.

B. Top does not lock tight enough to windshield header.

C. Top travels too far forward.

D. Top does not travel forward far enough.

APPARENT CAUSE

1 . Lock hook to short.

2. Misaligned front roof rail front weatherstrip.

3. Front roof rail misaligned.

1.

Lock hook too long.

2. Misaligned front roof rail weatherstrips.

3. Front roof rail misaligned.

1.

Front roof rail misaligned.

1. Front roof rail misaligned.

CORRECTION

Adjust lock hook counterclockwise.

Loosen, realign and retack front roof rail front weatherstrip.

Adjust front roof rail.

Adjust lock hook clockwise.

Loosen and realign front roof rail weatherstrips.

Adjust front roof rail.

Adjust front roof rail rearward.

Adjust front roof rail forward.

12-24 FOLDING TOP

DIAGNOSIS CHART

" A STYLES (CON'T)

CONDITION

E. Side roof rails low.

F. Side roof rails high.

G. Top material is too low over windows or side roof rails.

H. Top material is too high over windows or side roof rails.

APPARENT CAUSE

1. Center side roof rail hinge adjusting screw protrudes.

2. Control link misaligned.

CORRECTION

Back off adjusting screw

(View "B", Fig. 12-33).

Adjust control link downward.

Adjust control link upward. 1. Control link misaligned.

1. Front roof bow insufficiently shimmed.

2. Excessive width in top material.

1. Front roof bow shimmed too high.

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 excessive material along side binding as required; then hand sew binding to top material.

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.

J. Top material binds at side quarters.

K. One side staggers upon raising top from folding top compartment.

1. Top material improperly installed.

Reposition and retack top material as required.

1. Insufficient clearance. Install shim of necessary thickness between hinge and body.

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 recheck operation of top. Reinstall trim.

VIEW A

SCREWS

FOLDING TOP 12-25

VIEW C

FRONT B O W 7

H I N G E ADJUSTING SCREW

VlEW B

Fig. 12-33-Folding Top Adjustments

12-26

FOLDING TOP

When no shims are required or when installing only one shim, use attaching screw part No. 44 12844 (1 /4

20 x 5/8" oval head with external tooth lock external tooth lock washer, type "T-T" tapping washer, type "T-T" tapping screw, chrome finish or

When two shims are required, use attaching screw part No. 4412619 (1/4

20 x 3/4" oval head with screw, chrome finish or equivalent). equivalent).

LUBRICATION

On annual basis apply a limited amount of low temperature lubricant (a good grade machine oil or equivalent) to all friction surfaces.

The friction surfaces lubricated should include all washers, bushings and other contact surfaces.

3. To prevent soiling trim, wipe off excess lubricant

FOLDING TOP

"B and E" Styles

DESCRIPTION

"B and E" Convertible Styles feature an "inward" folding top. The convertible top involves a precise adjustment procedure which must be performed as outlined in this section.

Side roof rails are hinged at the front, center and rear. The hinging design enables the side roof rails to fold "inwardly" when the top is lowered. The roof cross bows, and trimstick stack to the rear of the side rails. The back window stacks under the roof rails and bows.

The inward foldi.ng top stacks to a flush position in the folding top compartment. The folding top well is shorter in length and provides full-width rear seat back comfort and leg room comparable to closed body styles.

Operation of the top is controlled by an electric switch. The top is powered by a reversible electric motor and two gear reduction units. One gear reduction unit, at the motor, operates the drive cables.

Other gear reduction units are integral with the top actuator assemblies at each main hinge. Drive cables supply power to the actuators which, in turn, multi- ply the power to operate the top. During top operation, the solid-tempered glass back window is controlled by a guide control link and spring at each lower corner. The inward folding top gutter of convertible top trim construction controls drainage of water at the rear belt rail.

The left side rail folds before the right rail upon stacking. The side rail folding sequence causes the front roof rail to be nonparallel to the ground during a portion of top operation. This is a normal condition.

CAUTION:

Before lowering the top, check the folding top compartment inside the car and in the rear compartment. Remove all luggage and parcels from the folding top compartment inside the car. Also, if necessary, clear away any luggage or miscellaneous parcels in the rear compartment which may have slid forward into the folding top compartment storage area. Failure to do so could result in breakage of the back window glass or damage to the folding top mechanism during operation of the top.

FOLDING TOP T R I M

FOLDING TOP COVER AND BACK CURTAIN

ASSEMBLY

Removal

NOTE:

Before removal operations are started, check and specifically note alignment condition of back curtain and top cover. Condition$, such as: wrinkles, draws, excess material, etc., can be corrected by adjusting trim material during assembly operations.

1. Apply protective covers to car as follows:

A. On rear deck section of car, particularly area pdjacent to quarter belt finishing moldings, apply heavy padded cover to protect moldings and paint finish. Mask securely in place.

B. On interior trim, floor and hood, use conventional covers.

FOLDING TOP 12-27

1. Front Roof Rail

2. Front Roof Rail Lock

3. Front Roof Bow and

Link Assembly

4. Side Roof Front Rail

6. Side Roof Inner Rear

Rail

6. Side Rmf Outer Rear

Rail

Fig. 12-34-Inward Folding Top Hardware Components

2. Side Roof Rear

Control Link'

8. Center Bow As'sembly

0. Side Roof Rail Set

Screw

10. Rear Roof Bow and

Link Assembly

11. Rear Belt Rail

Trimstick

12. Folding Top Actuator

Assembly

13. Main Hinge

14. Folding Top Cover

Pressure Bar

12-28 FOLDING TOP

FIGURE A

13 VlEW B

1. Top Cover Corner

Retainer

2. Staple Securing Top

Cover

3. Front Roof Rail

Locating Pin

4. Front Roof Rail Front

Weatherstrip

6. Top Cover

Fig. 12-35-Front Roof Rail Parts Attachment

6. Front Weatherstrip t o

Top Cover Sealer

7. Tacking Strip

8. Pinchweld Finishing

Lace

9, Staple Securing Front

Weatherstrip

10. Front Roof Rail

2. With top lowered, detach top cover at front roof rail as follows (Fig. 12-35):

A. Remove front roof rail front weathentrip.

B. Detach front roof rail rear weathentrip at outer ends.

C. Detach top cover from front roof rail. Use care to avoid disturbing silencer attachment at front roof rail (Fig. 12-43).

1 1. Front Roof Rail Rear

Weatherstrip

12. Front Roof Rail to

Windshield

Header Spacer

13. Spacer Attaching

Nail

14. Attaching Screw

D. With top a short distance above windshield header, remove attaching screws, loosen metal tabs and detach hold-down cables at front (Fig. 12-36).

WARNING: CONTROL LINKS ARE UN-

DER SPRING TENSION AND MUST BE

DETACHED WITH CARE TO AVOID

PERSONAL INJURY AND/OR DAM-

AGE TO TRIM MATERIAL. FOR

DE-

TACHMENT INSTRUCTIONS SEE:

"BACK WINDOW GUIDE CONTROL

LINK A N D SRING REMOVAL AND IN-

STALLATION'' (Fig. 12-49).

3. With top raised, detach guide control links from lower comers of back window, slip compartment bag over links and lay links on floor.

4. With top lowered half-way, remove side roof rail rear weatherstrips. Mark reference locations of quarter retainers on side rails (Fig. 12-38) and detach cemented retainers from side rails.

FOLDING TOP

12-29

5. Prepare center bow, rear trimstick and rear gutter assemblies for raising above body belt line as follows:

A. With front roof rail several inches above windshield header, remove lower rear bolt

(View "B", Fig. 12-39) securing trimstick to main hinge on each side. Bolt is removable toward inside of body. Welded anchor nut remains on trimstick.

B. In rear compartment, detach gutter retaining

VIEW X

VlEW Y

VlEW Z

Fig. 12-36-Hold-Down Cable Attachment and Convertible Top Reference Marking

1. Front Attaching

Screw

2. Hold-Down Cable

Front Bracket

3. Hold-Down Cable

4 . Hold-Down Cable

Rear Spring (Left

Side is Shown,

Connect Right Side with Hook Downward to Hold Spring Flat

Against Trimrtick)

12-30 FOLDING

TOP

SIDE QUARTER IFOAMl PAD \

FRONT ROOF RAIL

I f

SILENCER O N FRONT ROOF BOW

CENTER BOW

BACK CURTAIN

DRAIN

\ / CENTER BOW

, S A Y PAD

WEBBING

NINE (9) STAPLES

AS SHOWN

Tv\\

INSTALL SIX 1 1

01.

REINFORCEMENT

TACKS AS SHOWN REAR

GUTTER

-p

v

- -

. . .

- . -

COMPARTMENT BAG

I (ENLARGED)

ATTACHING SCREWS r INNER RETAINER

I N EXTENSION

BACK CURTAIN

1/8" RI

OUTER RETAINER

HOLD-DOWN CABLE

FRONT BRACKET

SKID STRIP

VlEW A

VlEW X

(ENLARGED)

BACK CURTAIN

CK CURTAIN EXTENSION

BACK CURTAIN

FORWARD FAClN

VlEW E

PO A

BACK CURTAIN

VlEW C

RETAINER

VlEW B

TACKS OR STAPLES

4678

VlEW D

Fig. 12-37-Back Curtain Assembly Aftachment and Reference Marking

Fig. 12-38-Side Roof Rail Rear Weatherstrip and Quarter

Retainer Attachment

1. Side Roof Outer Rear

Rail

2. Side Roof Inner Rear

Rail

3. Top Cover Rear

Quarter Retainer

(Flap)

4. Cementing Surfaces for Retainer

5. Retainer Seam

Aligned With Outer

Rear Rail

6. Side Roof Rail Rear

Weatherstrip

7. Anaching Screw rod from attaching clips, or detach clips from body (Fig. 12-44). Use care to prevent puncturing or tearing gutter during detachment.

A total of five attaching clips are located as follows: one on each side of rear compartment lid hinges and one at rear center. Then detach each end of retaining rod from body by moving rod rearward.

C. With top lowered about half-way, remove front. bolt and nut on each side (View "A",

Fig. 12-39) securing center bow assembly to main hinge. Bolt enters through bushing and threads into main hinge. Bolt is then secured with lock nut. Bushing is retained in outer rail and contacts main hinge.

NOTE: In some cases, access to bolt may require some deflection of quarter upper rear sealing strip yhich is metal reinforced and can be restored to proper alignment. Avoid losing nut or bolt behind trim by blocking adjacent openings with shop towels.

6. Lift rear trimstick, center bow and gutter assemblies as follows:

A. On one side of body, spring trimstick, center bow and gutter assembly inward. Check and

FOLDING TOP 12-31 position gutter retaining rod and trimstick to assure that they are clear for removal.

B.

Lift trimstick, center bow and gutter assembly forward and upward.

C. Duplicate lifting operation on opposite side of body, and position center bow, rear trimstick and gutter assembly on protected rear deck of car.

7. With suitable marking tool, such as pointed felt tipped pen, or tailor's chalk, accurately mark reference lines on top trim material as follows:

A. Vertical edge references of top cover on back curtain at trimstick (Item "Aw, Fig. 12-36).

B. Upper edge of trimstick on top cover. Press on trim material to determine accurate position of trimstick before marking (Item "BW,

Fig. 12-36).

C. Upper edge of trimstick on exposed portion

D. Center mark on trimstick and on back cur- sent, make one.

8. With staple removing tool, such as narrow screwdriver, detach both sides of top cover from trimstick. Pull top cover upward, and complete marking upper edge reference of trimstick on back curtain (Fig. 12-40).

9. Pull top cover upward and remove hold-down cable from top cover pocket on each side leaving

10. Turn front of top cover rearward for access to front listing. Detach front listing from front roof bow (View "A", Fig. 12-41).

11. Detach and remove back curtain assembly as

A. Detach side quarter foam pad from back curtain.extension up to center bow (Fig. 12-37).

If pad(s) are damaged during removal, they should be replaced with equivalent soft, foam rubber material. Use sharp blade, like razor, and carefully cut cemented bond while gently lifting foam pad.

B. Mark center on back curtain and on adjacent folding top parts as follows:

1. At front: On back curtain extension and on center roof bow.

12-32 FOLDING TOP

VlEW "B"

VlEW "A"

4365

Fig. 12-39-Center Bow Assembly and Rear Trimstrick Attachment

1. Attaching Bolt

2. Side Roof Outer Rear

Rail (Part of

Center Bow

Assembly)

3. Bushing

4. Threaded Hole in

Main Hinge

5. Lock Nut

8. Main Hinge

2.At rear: On back curtain lower inner valance and on gutter material at trimstick.

7. Rear Trimstick (Part of Center Bow

Assembly)

8. Anchor Nut (Part of

Trimstick)

Q. Center Bow tain along rear trimstick upper reference marks

(Figs. 12-36 and 12-40).

C. Detach back curtain from rear trimstick.

Note how folded material is secured below back window sides (Fig. 12-37).

D. Detach back curtain extension from center bow and remove back curtain assembly.

Installation

1. Since original top cover and back curtain are being replaced, carefully and uniformly cut away bottom of original top cover and back cur-

2. Transfer reference markings from original back curtain and top wver to replacement parts

as

follows:

A. Lay new back curtain flat on clean surface with inside face down. Position original back curtain over new one matching wrners of back window openings. Carefully position triin material flat in all directions.

B. With back window openings in alignment, accurately transfer trimstick reference to bottom of new back curtain by following along lower cut valance of original back curtain.

COVER DETACHED

THIS REFERENCE

ARK (BOTH SIDES)

4369

Fig. 12-#Completing Reference Marking On Back Curtain

Use a suitably pointed and legible marking pencil or tailor's chalk (Item "C", Fig. 12-36 and Fig. 12-40).

C. Transfer center reference mark from original back curtain to new one at front (on extension) and at rear (on valance) (Item "D", Fig.

12-36).

D. Transfer top. cover vertical edge reference from original back curtain to new one (Item

"A", Fig. 12-36).

E. Place new top cover flat on clean surface with inner surface down. Position original top cover over new one. Carefully align top cover

FOLDING TOP

12-33

sides, back window opening upper corners, and rear quarter upper corners.

F.

With both covers in alignment, transfer trimstick references, right and left, to bottom of new top cover by marking along cut rear edges (Item "B", Fig. 12-36).

3. Install back curtain assembly as follows:

A. Position center of new back curtain extension on center of center bow. Front edge of extension .should be flush with front rib of center bow. Staple or tack extension to center bow.

Start at center, keep trim material flat, and space tacks or staples about two (2) inches apart (Fig. 12-37).

B. With aid of helper, align rear center of back curtain with center of trimstick. At same time, carefully align horizontal upper edge reference mark at upper edge of trimstick

(Fig. 12-36).

NOTE: Original back curtains are stretched to a degree upon installation. Replacement back curtains are not stretched. During this operation, allow for uniform stretch in material for proper final appearance.

C. Working from center, staple or tack back curtain to trimstick. Maintain alignment of reference mark at trimstick, and keep material flat to trimstick between fasteners.

D. Fold back each side of curtain, shown in

CARDBOARD

FOUND4TION

FRONT

7'""

FRONT

BOW

2%" r

VIEW A

Fig. 12-41-Top Cover Attachment At Front Roof Bow

12-34 FOLDING TOP

View staples or tacks at this location.

E.

Space staples or tacks about two inches apart

(about 40 tacks or staples). Avoid excessive stretching of material (Fig. 12-37).

F. Allow 1/2 inch of back curtain to over-hang rear trimstick. Using scissors, cut off excess material beyond 1/2 inch over-hang (View

4. Cement original or replacement side quarter

(foam) pad (Fig. 12-37) between center bow and rear bow on each side. If pad(s) from center to rear bow were damaged upon removal, replace them with equivalent foam rubber material.

5. Fold replacement top cover assembly in half as shown in Figure 12-42. Determine precise centerline of top cover and carefully mark center of top cover on listing for front bow as shown in illustration.

6. Transfer cardboard foundations from original top cover, or install replacement foundations in front listing pocket as shown in Figure 12-41.

7. Insert hold-down cables in top cover. Use a length of welding rod to facilitate insertion (Fig.

12-36).

8. With aid of helper, install top cover as follows:

A. Align top cover at rear vertical reference mark and at trimstick horizontal reference

(Items "A" and "C", Fig. 12-36). With helper holding trim in aligned position, dou-

LRONT CORNER

MARK CENTER

Fig. 12-42-Determining Center of Top Cover ble tack or staple at this location using 12 ounce tacks or equivalent staples.

NOTE:

Original top covers are stretched to a degree upon installation. Replacement top covers are not stretched. During installation, allow for uniform stretch in new cover for proper final' appearance.

B. Apply trim cement to lower area of side roof rear rail and to top cover quarter retainer

(flap). Center top (laterally) by aligning horizontal reference on each side at trimstick.

Secure quarter retainer (flap) at bottom.

Also, double staple or tack top cover at front of trimstick (Fig. 12-38 and View "Z", Fig.

12-36) using 12 ounce tacks or equivalent staples.

C. Align top cover horizontal reference at center (in accordance with steps A and B above) and staple or tack in place. Work left and right from center. Keep material in alignment and flat. Avoid stretching. Space staples or tacks about two (2) inches apart.

D. Trim off excess material beyond 1/2 inch over-hang (Fig. 12-36).

NOTE:

If diagnosis prior to top cover removal revealed particular conditions (Such as:

Loose material, etc.) the conditions can be corrected by adjusting top cover on trimstick in steps A, B and C above.

9. Position five (5) clips on gutter retaining rod'.

Position clips according to Figure 12-44 as follows: One on each side of rear compartment lid hinge and one at rear center.

10. Position rear trimstick, center bow and gutter assembly into body in reverse order of removal.

With top half-lowered, start one end of trimstick and gutter into body, then position opposite end into body.

11. Secure trimstick, center bow and gutter assembly to body as follows: back window guide control links. For attachment of control links see: "Back Window

Guide Control Link Removal and Installa- tion" (Fig. 12-49).

B. Raise top several inches above windshield header. Install bushing in main hinge, align trimstick to main hinge attaching holes and install trimstick attaching bolts (View " B",

Fig. 12-39). TJse care to avoid dropping bolt.

FOLDING TOP 12-35

To avoid losing *bolt, block openings at wheelhouse with several shop towels.

C. Lower top half-way. With bushing properly positioned in each outer rail, install attaching bolts (View "A", Fig. 12-39) securing outer rail to main hinge. Each bolt threads into hinge and is secured with lock nut.

D. Secure rear gutter retaining rod and clips to body as shown in Figure 12-44.

Secure top cover front listing to front roof bow as follows (Fig. 12-41):

A. Check alignment of cardboard foundation at front listing pocket as shown in illustration.

Foundation must be at front of listing pocket as shown.

B. Center listing and foundation on center of front bow.

C. Secure listing in place. with staples or tacks spaced about two (2) inches apart. Distance from end of foundation to center of dielectric seam should be about 2-1/2 inches as shown in View "A", Figure 12-41.

With top several inches off windshield header, position and secure hold-down cables at front

(Fig. 12-36). Position bracket by inserting tab and secure bracket with screw, then secure metal tab.

Align and secure top cover at front roof rail as follows:

A. Raise top and lock to windshield header.

B. With aid of helper, pull top cover forward and down to remove wrinkles and irregulari- ties. Mark reference of front edge of front roof rail on top cover.

C. Unlock front roof rail, apply cement to attaching surfaces at front of cover and on front roof rail (Fig. 12-43). Apply cement to undqside of front roof rail. This includes tacking strip and both corners.

NOTE: For best results of top installation and appearance, step 15D should be done in conjunction with step 16 before securing either permanent1 y.

D Secure top cover to front roof rail according to reference marks above, and check appearance of top cover by locking top to windshield header. Adjust top cover by drawing material forward and/or laterally as required for proper alignment and appearance, and secure with cement. Front comer retainers

(flaps) secure only to front roof rail.

15. With top locked to windshield header, cement, align and secure upper areas of quarter retainers

(flaps) to side roof outer rear rails. Re-check alignment of top cover and align quarter retainer seams with edges of side roof rear rails. Remove all fullness from rear of top cover (Fig. 12-38).

A forward draw on cover outer sides will aid this operation. Align quarter retainers to each rear rail and cement securely in place. Top cover binding at quarter retainers should not curl away from rear rail. Apply adhesive, "3M" No.

8064 or equivalent, to hook and pile retainer on back curtain and top cover, (Fig. 12-37, View

"B"), align and join securely.

16. Lower top and secure top cover to front roof rail trimstick with staples or tacks spaced about two inches apart. Remove excess top material along rear of trimstick.

17. Using weatherstrip adhesive at outer ends, position and secure rear weatherstrip on front roof rail. Use outer attaching screw holes for locating purposes (Fig. 12-3 5).

18. Position, secure and seal front roof rail front weatherstrip (Fig. 12-35). Front weatherstrip must be properly positioned and sealed as shown in illustration.

19. Install and align side roof rail rear weatherstrips.

Adjust rear weatherstrips forward for butt fit when top is locked at windshield header. After tightening upper two screws, lower top part way to tighten lower screw.

NOTE: Side roof rail front weatherstrips are not designed to be adjusted "fore or aft". For improved contact at upper front comers, reposition windshield pillar weatherstrips upward.

20. Remove all protective covers and clean up.

FOLDING TOP COVER (LESS BACK

CURTAIN)

Removal

, NOTE: Before removal operations are started, check and specifically note alignment of top cover. Condi- tions, such as: wrinkles, draws, excess material, etc., can be corrected by adjusting trim material during assembly operations.

1. Apply protective covers to car as follows:

12-36

FOLDING TOP

A. On rear deck section of car, particularly area adjacent to quarter belt finishing moldings, apply heavy padded cover to protect moldings and paint finish. Mask securely in place.

B. On interior trim, floor and hood, use conventional covers.

With top lowered, detach top cover at front roof rail as follows (Fig. 12-35):

A. Remove front roof rail front weatherstrip.

B. Detach front roof rail rear weatherstrip at outer ends.

C. Detach top cover from front roof rail. Use care to avoid disturbing silencer attachment at front roof rail (Fig. 12-43).

D. With top a short distance above windshield header, remove attaching screws, unbend metal tabs, and detach hold-down cables at front (Fig. 12-36).

WARNINB:

CONTROL LINKS ARE UNDER

SPRING TENSION AND MUST BE DE-

TACHED WITH CARE T O AVOID PER-

SONAL INJURY AND/OR DAMAGE TO

TRIM MATERIAL. FOR DETACHMENT

INSTRUCTIONS SEE: "BACK WINDOW

GUIDE CONTROL LINK AND SPRING

REMOVAL AND INSTALLATION" (Fig.

12-49).

With top raised, detach guide control links from lower comers of back window, slip compartment bag over links and lay links on floor.

With top lowered half-way, remove side roof rail rear weatherstrips. Mark reference locations of quarter retainers on side rails (Fig. 12-38) and detach cemented retainers from side rails.

Detach center bow, rear trimstick and rear gutter assemblies for raising above body beltline as follows:

A. With front roof rail several inches above windshield header, remove lower rear bolt

(Item "B". Fig. 12-39) securing trimstick to main hinge on each side. Bolt is removable toward inside of body. Welded anchor nut remains on trimstick.

B. In rear compartment, detach gutter retaining rod from attaching clips or detach clips from body. Use care to prevent puncturing or tearing gutter during detachment. A total of five attaching clips are located as follows: One on each side of rear compartment lid hiages and one at rear center. Then detach each end of retaining rod from body by moving rod rearward.

C. With top lowered about half-way, remove front bolt and nut on each side (Item "A",

NOTE:

In some cases, access to bolt may require some deflection of quarter upper rear sealing strip which is metal reinforced and can be restored to proper alignment. Avoid losing nut or bolt behind trim by blocking adjacent openings with shop towels.

6. Lift rear trimstick, center bow and gutter assemblies from body as follows:

A. On one side of body, spring trimstick, center bow and gutter assembly inward. Check and position gutter retaining rod and trimstick to assure that they are clear for removal.

B. Lift trimstick, center bow and gutter assembly upward and forward.

C. Duplicate lifting operation on opposite side of body, and position center bow, rear trimstick and gutter assembly on protected rear deck of car.

7. With suitable marking tool, such as pointed felt tipped pen, or tailor's chalk, accurately mark reference lines on top trim material as follows:

A. Vertical edge references of top cover on back curtain at trimstick (Item "A", Fig. 12-36).

B. Upper edge of trimstick on top cover. Press on trim material to determine accurate position of trimstick before marking (Item "B*,

Fig. 12-36).

8. With staple removing tool, such as narrow screwdriver, detach both sides of top cover from trimstick.

9. Pull, top cover upward and remove hold-down cable from top cover pocket on each side leaving rear of cable attached (View "X*, Fig. 12-36).

10. Turn front of 3op cover rearward for access to front listing. Detach front listing from front roof bow (View "A", Fig. 12-41).

FOLDING TOP 12-37

Installation

Since original top cover is being replaced, carefully and uniformly cut off bottom of original top cover along trimstick upper reference mark.

Place new top cover flat on clean surface with inner surface down. Position original top cover over new one and reference mark as follows (Fig.

12-36):

A. Carefully align top cover sides.

B. Align back window opening upper comers.

C. Align rear quarter upper comers.

D. With both covers in alignment, transfer trimstick references, right and left, to bottom of new top cover by marking along cut bottom edges (Item "B", Fig. 12-36).

Fold replacement top cover in half as shown in

Figure 12-42. Determine precise centerline of top cover and carefully mark center of top cover on listing for front bow as shown in illustration.

Transfer cardboard foundations from original top cover, or install replacement foundations in front listing pocket as shown in Figure 12-41.

Insert hold-down cables in top cover. Use a length of welding rod to facilitate insertion (Fig.

12-36).

With aid of helper, install tap cover as follows:

A. Align top cover at rear vertical reference mark and at trimstick horizontal reference.

With helper holding trim in aligned position, double tack or staple at this location using 12 ounce tacks or equivalent staples.

NOTE:

Original top covers are stretched to a degree upon installation. Replacement top covers are not stretched. During installation, allow for uniform stretch in new cover for proper final appearance.

B. Apply trim cement to lower area of side roof rear rail and to top cover quarter retainer

(flap). Center top (laterally) by aligning horizontal reference on each side at trimstick.

Secure quarter retainer (flap) and seam at bottom. Also, double staple or tack top cover at front of trimstick (Fig. 12-38 and View equivalent staples.

C. Align top cover horizontal reference at center (in aocordance with Steps A and B above) and staple or tack in place. Work forward and rearward from center. Keep material in alignment and flat. Space staples or tacks about two inches apart.

D. Trim off excess material beyond 1/2 inch wer-hang (Fig. 12-36).

NOTE:

If diagnosis prior to top cover removal revealed particular conditions (Such as loose material, etc.) the conditions can be corrected by adjusting top cover on trimstick in steps A, B and C above.

7. Position five (5) clips on gutter retaining rod.

Position clips according to Figure 12-44 as follows: One on each side of rear compartment lid hinge and one at rear center.

8. Position rear trimstick, center bow and gutter assembly into body in reverse order of removal.

With top half lowered, start one end of trimstick and gutter into body, then position opposite end into body.

9. Secure trimstick, center bow and gutter assembly to body as follows:

A. Manually, raise top to up position. Secure back window guide control links. For attachment of control links, see: "Back Window

Guide Control Link Removal and Installa- tion" (Fig. 12-49).

B. Raise top several inches above windshield header. Install bushing in main hinge, align trimstick to main hinge attaching holes and install trimstick attaching bolts (View "B",

Fig. 12-39). Use care to avoid dropping bolt.

T o avoid losing bolt, block openings at wheelhouse with several shop towels.

D. Secure gutter retaining rod and clips to body

(Fig. 12-44).

10. Secure top cover front listing to front roof bow as follows (Fig. 12-41):

A. Check alignment of cardboard foundation at front of listing pocket as shown in illustration. Foundation must be at front of listing pocket as shown.

B. Center listing and foundation on center of fkont bow.

12-38 FOLDING TOP

C. Secure listing in place with staples or tacks spaced about two (2) inches apart. Distance from end of foundation to center of dielectric seam should be about 2-1/2 inches as shown in View "A", Figure 12-41.

With top several inches off windshield header, position and secure hold-down cables at front

(Fig. 12-36). Position bracket by inserting tab and secure bracket with screw.

Align and secure top cover at front roof rail as follows:

Raise top and lock to windshield header.

With aid of helper, pull top cover forward and down to remove wrinkles and irregulari- ties. Mark reference of front edge of front roof rail on top cover.

Unlock front roof rail, apply cement to attaching surfaces at front of cover and on front roof rail (Fig. 12-43). Apply cement to underside of front roof rail. This includes trimstick and both corners.

NOTE:

For best results of top installation and appearance, Step 12D should be done in conjunction with step 13 before securing either permanently.

D. Secure top cover to front roof rail according to reference marks above, and check appearance of top cover by locking top windshield header. Adjust top cover by drawing material forward and/or laterally as required for proper alignment and appearance and secure with cement. Front corner retainers (flaps) secure only to front roof rail.

With top locked to windshield header, cement, align and secure upper areas of quarter retainers

(flaps) to side roof outer rear rails. Re-check alignment of top cover over center bow and align quarter retainer seams with edges of side roof rear rails. Remove all fullness from rear of top cover (Fig. 12-38). A forward draw on cover outer sides will aid this operation. Align quarter retainers to each rear rail and cement securely in place. Top cover binding at quarter retainers should not curl away from rear rail. Apply adhesive, "3M" No. 8064 or equivalent, to hook and pile retainer on back curtain and top cover, (Fig.

12-37, View "B"), align and join securely.

Lower top and secure top cover to front roof rail trimstick with staples or tacks spaced about two inches apart. Remove excess top material along rear of trimstick.

Using weatherstrip adhesive at outer ends, position and secure front roof rail rear weatherstrip.

Use outer attaching screw holes for locating purposes (Fig. 12-35).

Position, secure and seal front roof rail front weatherstrip (Fig. 12-35). Front weatherstrip must be properly positioned and sealed as shown in illustration.

Install and align side roof rail rear weatherstrips.

Adjust rear weatherstrips forward for butt fit when top is locked at windshield header. After tightening upper one or two screws, lower top part way to tighten lower screw.

NOTE:

The side roof rail front weatherstrips are not designed to be adjusted "fore or aft". For improved contact at upper front corners, reposition windshield pillar weatherstrip upward.

Remove protective covers, shop towels, if used, and clean up.

BACK CURTAIN ASSEMBLY (LESS TOP

COVER)

Removal

NOTE:

Before removal operations are started, check and specifically note alignment condition of back curtain. Conditions, such as: wrinkles, draws, excess material, etc., can be corrected by adjusting trim material during assembly operations.

Apply protective covers to car as follows:

A. On rear deck section of car, particularly area adjacent to quarter belt finishing moldings, apply heavy padded cover to protect moldings and paint finish. Mask securely in place.

B. On interior trim and floor, use conventional covers.

WARNING:

CONTROL LINKS ARE UNDER

SPRING TENSION AND MUST BE DE-

TACHED WITH CARE TO AVOID PER-

SONAL INJURY AND/OR DAMAGE TO

TRIM MATERIAL. FOR DETACHMENT

INSTRUCTIONS SEE: "BACK WINDOW

GUIDE CONTROL LINK AND SPRING

REMOVAL AND INSTALLATION" (Fig.

12-49).

With top raised, detach guide control links from lower comers of back window, slip compartment bag over links and lay links on floor.

FOLDING TOP 12-38

3. With top lowered half-way, remove side roof rail weatherstrips. Mark reference locations of quarter retainers on side rails (Fig. 12-38) and detach cemented retainers from side rails.

4. Prepare center bow, rear trimstick and rear gutter assemblies for lifting above body beltline as follows:

A. With front roof rail several inches above windshield header, remove lower rear bolt

(View "B", Fig. 12-39) securing trimstick to main hinge on each side. Bolt is removable toward inside of body. Welded anchor nut remains on trimstick.

B. In rear compartment, detach gutter retaining rod from attaching clips or detach clips from body. Use care to prevent puncturing or tearing gutter during detachment. A total of five attaching clips are located as follows: One on each side of rear compartment lid hinges and one at rear center. Then detach each end of retaining rod from body by moving rod rearward.

C. With top lowered about half-way, remove front bolt and nut on each side (View "A",

NOTE:

5. Lift rear trimstick center bow, and gutter assemblies from body as follows:

A. On one side of body, spring trimstick, center bow and gutter assembly inward. Check and position gutter retaining rod and trimstick to assure that they are clear for removal.

B. Lift trimstick, center bow and gutter assembly forward and upward.

C. Duplicate lifting operation on opposite side of body and position center bow, rear trimstick and gutter assembly on protected rear deck of car.

6. With suitable marking tool, such as pointed felt tipped pen, or tailor's chalk, accurately mark reference lines on top trim material as follows:

A. Vertical edge references of top cover on back curtain at trimstick (Item "A", Fig. 12-36).

B. Upper edge of trimstick on top cover. Press on trim material to determine accurate position of trimstick before marking (Item "B",

Fig. 12-36).

C. Upper edge of trimstick on exposed portion of back curtain (Item "C", Fig. 12-36).

D. Center mark on trimstick and on back curtain (Item "D", Fig. 12-36). If none is present, make one.

7. With staple removing tool, such as narrow screwdriver, detach both sides of top cover from trimstick. Pull top cover upward, and complete marking upper edge reference of trimstick on back curtain (Fig. 12-40).

8. Lift top cover upward and detach hold-down cable at rear (Fig. 12-36).

9. Detach and remove back curtain assembly as follows:

A. Detach side quarter foam pad from back curtain extension up to center bow (Fig. 12-37).

If pad(s) are damaged during removal, replace them with equivalent soft, foam rubber material. Use sharp blade, like razor, and carefully cut cemented bond while gently lifting foam pad.

B. Mark center on back curtain and on adjacent parts as follows:

1. At top: On back curtain extension and on center roof bow.

2. At bottom: On back curtain lower inner valance and on gutter material at trimstick.

C. Detach back curtain from rear trimstick.

Note how folded material is secured below back window sides (Fig. 12-37).

D. Detach back 'curtain extension from center bow and remove back curtain assembly.

Installation

1. Since original back curtain is being replaced, carefully and uniformly cut away bottom of original back curtain along rear trimstick upper reference marks (Figs. 12-36 and 12-40).

2. Transfer reference markings from original back curtain to replacement back curtain as follows:

12-40

FOLDING TOP

A. Lay new back curtain flat on clean surface with inside face down. Position original back curtain over new one matching comers of back window openings. Carefully position trim material flat in all directions.

With back window openings in alignment, accurately transfer trimstick reference to bottom of new back curtain by following along lower cut valance of original back curtain.

Use a suitably pointed and legible marking pencil or tailor's chalk. (Item "C", Fig. 12-36 and Fig. 12-40).

Transfer center reference mark from original back curtain to new one at top (on extension) and at bottom (on valance) (Item

12-36).

Transfer top cover vertical edge reference from original back curtain to new one (Item

"A", Fig. 12-36).

3. Install back curtain as follows:

Position center of new back curtain extension on center of center bow. Front edge of extension should be flush with front rib of center bow. Staple or tack extension to center bow.

Start at center, keep trim material flat, and space tacks or staples about two (2) inches apart (Fig. 12-37).

With aid of helper, align bottom center of back curtain with center of trimstick. At same time, carefully align horizontal, upper edge reference mark at upper edge of trimstick (Fig. 12-36).

NOTE:

Original back curtains are stretched to a degree upon installation. Replacement back curtains are not stretched. During this operation, allow for uniform stretch in material by adjusting horizontal reference for proper final appearance.

Working from center, staple or tack back curtain to trimstick. Maintain alignment of reference mark at trimstick, and keep material flat to trimstick between fasteners.

D. Fold back each side of curtain, shown in Item

"D", Figure 12-37, and install three staples or tacks at this location.

E.

Space staples or tacks about two inches apart

(about 40 tacks or staples). Avoid excessive stretching of material.

F. Allow 1/2 inch of back curtain to over-hang rear trimstick. Using scissors, cut off excess material beyond 1/2 inch over-hang (Fig. 12-

4. Cement original or replacement side quarter

(foam) pad (Fig. 12-37) between center bow and rear bow on each side. If pad(s) from center to rear bow were damaged upon removal, replace them with equivalent foam rubber material.

5. Secure hold-down cables at rear (Fig. 12-36).

6. With aid of helper, install top cover as follows:

A. Align top cover at rear vertical reference mark and at trimstick horizontal reference

(Items "A" and "C", Fig. 12-36). With helper holding trim in aligned position, double tack or staple at this location using 12 ounce tacks or equivalent staples.

B.

Apply trim cement to lower area of side raof rear rail and to top cover quarter retainer

(flap). Center top (laterally) by aligning horizontal reference on each side at trimstick.

Secure quarter retainer (flap) at lower area.

Also, double staple or tack top cover at front of trimstick (Fig. 12-38 and View "Z", Fig.

12-36) using 12 ounce tacks or equivalent staples.

C. Align top cover horizontal reference at center (in accordance with steps A and B above), and staple or tack in place. Work forward and rearward from center. Keep material in alignment and flat. Avoid stretching. Space staples or tacks about two inches apart.

D. Trim off excess material beyond 1/2 inch over-hang (Fig. 12-36).

NOTE:

If diagnosis prior to top cover removal revealed particular conditions (Such as:

Loose material, etc.), the conditions can be corrected by adjusting top cover on trimstick at this time.

7. Position five (5) clips on gutter retaining rod.

Position clips according to Figure 12-44 as follows: One clip on each side of rear compartment lid hinges and one at rear center.

8. Position rear trimstick, gutter, and center bow assembly into body in reverse order of removal.

With top half lowered, start one end of trimstick and gutter into body, then position opposite end into body.

9. Secure trimstick, gutter and center bow assembly to body as follows:

A. Manually raise top to up position. Secure

FOLDING TOP 1241

C. At side quarter padding

Cement back window guidd control links. For attachment of control links, see: "Back Window

Guide Control Link Removal and Installa- tion" (Fig. 12-49).

B. Raise top several inches above windshield header. Install bushing in main hinge, align trimstick to main hinge attaching holes, and install trimstick attaching bolts (View "B",

Fig. 12-39). Use caution to avoid dropping bolt. To avoid losing bolt, block openings at wheelhouse with several shop towels.

D. Secure gutter retaining rod and clips to body

(Fig. 12-44).

10. With top locked to windshield header, cement, align and secure upper attaching surfaces of quarter retainers (flaps) to side roof outer rear rails. Align quarter retainer seams with edges of side roof outer rear rails to remove all fullness from rear of top cover (Fig. 12-38). A forward draw on cover outer sides will aid this operation.

Align quarter retainers to each rear rail and cement securely in place. Top cover binding along rear rails should not curl away from rails. Apply adhesive, "3M" No. 8064 or equivalent, to hook and pile retainer on back curtain and top cover,

(Fig. 12-37, View "B"), align and join securely.

11. Install and align side roof rail rear weatherstrips.

Adjust rear weatherstrips forward for butt fit when top is locked at windshield header. After tightening upper one or two screws, lower top part way to tighten lower screw.

NOTE:

Side roof rail front weatherstrips are not designed to be adjusted "fore or aft". For improved contact at upper front comers, position windshield pillar weatherstrips upward.

12. Remove protective covers and clean up.

FOLDING TOP SILENCER ASSEMBLY

The silencer is serviced as a complete assembly and consists of a section of deadener padding sewn to an inner lining trim cloth. The assembly is located under the folding top at the front, and is secured around its perimeter as follows (Fig. 12-43):

A. At the front roof rail

Cement and staples

B. At the front roof bow and staples

Slide-on listing pocket

1. With top lowered to stacked position, remove front roof rail front weatherstrip. Detach front roof rail rear weathentrip at outer ends (Fig.

12-35).

2. Reference mark front edge of front roof rail on top cover. Also place center mark on cover and on masked section of front roof rail.

3. Detach top cover and silencer assembly from front roof rail (staples and cement). Do not detach side quarter padding.

4. Raise top and, with front roof rail several inches above windshield header, detach hold-down cables at front (Fig. 12-36).

5. Turn back top cover and detach cemented side sections of silencer from side quarter padding

(Fig. 12-43).

6. Detach top cover listing from front roof bow by removing staples (Fig. 12-4 1).

7. Remove two attaching screws from bracket at one end of front roof bow and slip silencer assembly pocket from front roof bow.

lnrtallation

1. With deadener padding on top side of assembly, slip pocket of silencer assembly onto front roof bow (Fig. 12-43). Center silencer between side quarter padding and secure silencer pocket to front roof bow by installing one staple or tack at each outer end as shown.

2. Secure front roof bow attaching bracket with two attaching screws.

3. With top lowered, apply trim cement to front roof rail and to silencer as shown in Figure 12-

43. Lock top to windshield header. With silencer centered between side quarter padding pull assembly forward tightly and secure to front edge of front roof rail. Cement only at forward 1/2 inch edge of front roof rail.

4. Lower top and complete securing forward s e e tion of silencer to front roof rail and to tacking strip (Fig. 12-43). Space staples or tacks four inches apart. Trim off excess material beyond tacking strip.

5. With top raised and locked at windshield header, apply trim center sparingly to side quar-

1242 FOLDING TOP

VlEW C

10 CEMENT IN

VlEW D

4360

VlEW B

Fig. 12-43-Folding Top Silmcer Assembly Attachment

1. Front Roof Rail

2. Silencer Assembly

3. Deadener Pad

4. Front Roof Bow

5. Side Quarter Padding ter padding and to side sections of silencer. Posi- tion sides of silencer on padding and on front roof bow and press into place.

6. Position and center top cover listing and cardboard foundation on front roof bow as shown in

Figure 12-41 and secure in place with staples or tacks spaced about two inches apart.

NOTE:

Distance between center of dielectric seam and edge of foundation must be about 2-

1/2 inches as shown.

7. Turn top cover forward and, with top raised several inches, position hold-down cables and secure in place (Fig. 12-36).

6. Trim Cement

Securing Silencer to

Front Rail and

Tacking Strip

7. Front Roof Rail

Tacking Strip

8. Silencer Listing

Pocket

9. Staple

10. Trim Cement in

Shaded Area

Securing Silencer to

Side Quarter Padding

8. Apply trim cement to front roof rail, top cover and top cover comer retainers (flaps). With front roof rail several inches off windshield header, align top cover reference marks with front roof rail and secure top cover in place.

9. Lock top to windshield header and check alignment of top cover. Adjust top cover as required.

10. Lower top and secure top cover to trimstick with staples or tacks spaced about two inches apart.

11. Cement, align and secure front roof rail rear weatherstrip outer ends (Fig. 12-35).

FOLDING TOP 12-43

12. Seal, align and secure front roof rail front weatherstrip (Fig. 12-35).

FOLDING TOP SIDE QUARTER PAD

ASSEMBLY

A right and a left side quarter (stay) pad assembly

(Fig. 12-37) secures to the front roof rail and to the center bow assembly. The pad assemblies do not secure to the front roof bow. Pad assemblies consist of strong webbing material, a cloth cover, and soft foam padding approximately 1/4 inch thick. Rear comers of pad assemblies are reinforced with two (2) 12 ounce tacks. Additionally, the rear of pad assemblies are secured with staples. Pad assemblies are secured at the front with attaching screws. Access for removal and installation of a side quarter pad assembly requires detaching the top cover across the front and at the front roof bow, and detaching the back curtain extension at the side affected.

Apply protective covers as required to interior trim, hood and rear deck of car.

With top lowered, detach following from front roof rail:

A. Front roof rail front weatherstrip (complete)

(Fig. 12-35).

B. Front roof rail rear weatherstrip (at outer ends).

C. Top Cover.

NOTE: Before detaching top cover, reference mark complete front edge of front roof rail on top cover. Use care to avoid disturbing silencer attachment at front roof rail.

Raise top and lift several inches above windshield header. Qetach hold-down cables at front

(Pig. 12-36).

Turn front of top cover rearward and detach top cover front listing from front roof bow (Fig. 12-

41).

Using scissors or equivalent tool, make lateral cut through side quarter (foam) pad in line with center bow. Foam pad is cut for access to back curtain extension attachment. Detach back curtain extension from center roof bow where extension overlaps side quarter pad assembly (Fig.

12-37).

6. Detach affected side of silencer assembly where cemented to side quarter pad assembly (Fig. 12-

43).

7. Reference mark inner and outer edges of pad assembly on front roof.rai1 and on center bow.

Remove attaching screws securing pad assembly at front roof rail (Fig. 12-37).

8. Detach cemented cover of pad assembly (cemented at front, rear and outer edges) and carefully detach side quarter (foani) pad from webbing.

9. Detach side quarter pad assembly from center bow by removing staples and tacks, and remove pad assembly.

Installation

1. Install side quarter (stay) pad assembly as follows:

A. With to^ locked at windshield .header, and top cover pulled away for access, pad assembly at center bow reference marks as shown in Figure 12-37. With pad cover raised, secure webbing to center bow with nine (9) equally spaced staples. Align rear of pad flush with rear of center bow tacking strip.

B. Position and install two (2) 12 ounce reinforcement tacks to secure other rear comers of webbing at center bow (Fig. 12-37).

C. With aid of helper tighten the webbing by pulling forward, align webbing with reference marks at front roof rail and install inner four attaching screws (Fig. 12-37). Remove excess webbing at front roof rail trim line.

Make opening in webbing for hold-down cable metal tab and for attaching screw.

2. Complete side quarter pad assembly build-up as follows:

A. With top several inches above windshield header, secure back curtain extension to center bow (Fig. 12-37). Space staples or tacks about two ipches apart.

B. Lock top at front. Using trim cement spar-' ingly, position and secure (foam) pad to side quarter webbing (Fig. 12-37). Make butt joint between foam pad on webbing and on back curtain extension. Secure butt joint with length of two (2) inch cloth-back body sealing tape.

FOLDING TOP 1245

C. Using trim cement sparingly around edges, position and secure cover of side quarter pad assembly.

Using trim cement sparingly, cement affected side of silencer assembly to side quarter pad assembly (Fig. 12-43).

Position and secure top cover front listing to front roof bow (Fig. 12-41). For further information see: '"Top Cover Installation".

With top several inches above windshield header, position side quarter pad assembly at outer front corner and secure hold-down cable at front (Fig. 12-36).

Align and secure top cover to front roof rail

(Fig. 12-35). See "Top Cover Installation".

Install front roof rail front and rear weatherstrips (Fig. 12-35).

Remove protective covers and clean up as required.

FOLDING TOP GUTTER

The inward folding top rear gutter is constructed of convertible top trim material. The front of the gutter secures to the rear trimstick. The rear of the gutter secures to the body by means of a retaining rod and five (5) attaching clips (Fig. 12-44). The clips are spaced as follows: One clip on each side of each rear compartment lid hinge, and one clip at the rear center.

Removal and Installation

Detach back curtain assembly along bottom as described in "Back Curtain (Less Top Cover)

Removal and Installation" (Fig. 12-37).

Remove original gutter by cutting along rear trimstick. Use care during original gutter removal not to cut folding top compartrhent bag

(Fig. 12-44).

Determine and mark center on replacement gutter by folding gutter in half.

Transfer retaining rod from original to replacement gutter as shown in Figure 12-44. This operation can be done after securing gutter to trimstick.

Position center of replacement gutter over folding top compartment bag on center of trimstick and staple or tack in place (View "C", Fig. 12-

44). Start at center and work to each side. Space staples or tacks about four (4) inches apart.

Install back curtain and top cover assemblies as described in "Back Curtain (Less Top Cover)

Removal and Installation".

FOLDING TOP HARDWARE COMPONENTS

FRONT ROOF RAlL LOCK

3. To install, reverse removal operations. Check operation of locks. Always lock left side of top before locking right side.

CAUTION: A safeguard has been built into the front roof rail lock to prevent moving the lock handle to the closed position when the top is unlocked. Lower- ing a top with the lock handle in the closed or locked position causes breakage of the handle. The safeguard consists of a stop to prevent rotating the handle from the open to the closed position unless the lock hook is engaged. Do not attempt to force the lock handle past the stop.

FRONT ROOF RAlL LOCATING PIN

A locating pin, of plastic construction, secures to the front of each side roof front rail by an attaching screw (Fig. 12-46).

Removal and Installation

1. Manually, unlock and support front roof rail several inches above windshield header.

2. With lock handle in open position as shown in

Figure 12-45, detach spring, remove lock attaching screws and remove lock.

Removal and lnstallation

Lower top part-way, or completely.

Remove attaching screw and remove locating pin (Fig. 12-46).

To install, position locating pin on side roof front rail and install attaching screw.

12-48 FOLDING TOP

SIDE ROOF

FRONT RAIL

Fig. 12-45-Front Roof Rail Lock Attachment

4. Raise and lock top at windshield header.

FOLDING TOP ELECTRIC MOTOR AND/OR

RELAY

The folding top electric motor and relay are secured to the rear seat back panel and are accessible in the rear seat area (Fig. 12-47).

Removal and Installation

1. Remove rear seat cushion and rear seat back.

2. Detach drive cables at each top actuator.

3. Detach electric motor connectors from relay

(Fig. 12-47).

4. Detach relay attaching screw and remove relay.

5. Remove screw securing motor ground to rear seat back panel.

6. Detach rubber grommets securing motor support to rear seat back panel (Fig. 12-47).

7. Detach right and left drive cables from electric motor reduction unit (Fig. 12-47).

8. Remove two attaching screws securing motor support to motor and remove motor.

9. To install, reverse the removal operations. To ease installation of motor and attaching bracket, apply solvent (mineral spirits or equivalent) to grommets on motor bracket. Check operation of motor for proper ground before installing trim.

FOLDING TOP ACTUATOR DRIVE CABLE

Right and/or Left

Removal and lnstallation

1. Remove rear seat cushion and rear seat back.

2. Detach drive cable at top actuator assembly.

3. Detach right and/or left drive cable at electric motor reduction unit (Fig. 12-47). For removal of left drive cable, first detach motor.

4. To install, reverse removal operations. To facilitate engagement of drive cable, push and rotate cable opening on actuator by finger or with suitable tool.

BACK WINDOW GUIDE CONTROL LINK AND

SPRING

The purpose of guide control links and springs at the back window is to guide the back window downward beyond the rear trimstick when lowering the inward folding top. As shown in Figure 12-49, the links and springs secure to attaching brackets at the back window and at the folding top compartment floor. The actuator springs are located under the folding top compartment bag. Inward folding tops must not be lowered if control links and/or actuator springs are disconnected for any reason.

Removal and Installation

1. With top in raised position, remove hair pin clip Fig. 12-46-Front Roof Rail Locating Pin

FOLDING

TOP 1247

1. Electric Motor

2. Relay

3. Electric Motor

Connectors

4. Relay Attaching

Screw

Fig. 12-47-Folding Top Electric Motor and Relay

5. Motor Ground to Seat

Back Panel

6 . Electric Motor

Reduction Unit

7. Rubber Grommet(s) and washer from link attaching stud at back window.

2. Carefully lift control link, which is under spring tension, from attaching bracket. While carefully lowering control link, lift compartment bag over control link and lay control link on floor. Bush- ing need not be removed from stud unless necessary.

3. Through opening in compartment bag, detach and remove actuator spring, first from link, then from floor bracket.

4. Working through opening in compartment bag

8. Motor Support

9. Motor Attaching

Screw

10. Drive Cable

1 1. Seat Back Panel or through rear compartment, remove hair pin clip and washer from control link front attaching stud and remove control link.

To install, reverse removal operations.

FOLDING TOP ACTUATOR ASSEMBLY

A

folding top actuator assembly is secured to each main hinge by three attaching screws (Fig. 12-50) and to the side rail system by a shoulder bolt. The shoulder -bolt threads into the actuator link and is locked in place with a set screw. Actuator assemblies are operated by electrically powered drive cables.

1248

FOLDING

TOP

ATTACHING NUT

4174

Removal

Removal and installstion of top actuators is easier with the top lowered. However, actuators can be replaced with the top raised.

1. Remove rear seat cushion and rear seat back.

2. Reposition bottom of main hinge cover panel on side affected for access to attaching screws.

3. Disconnect drive cable from actuator assembly

(Fig. 12-48).

4. Remove actuator attaching screws (Fig. 12-50).

5. Loosen set screw in side rail actuator link and remove shoulder bolt securing sector arm to actuator link.

Fig. 12-48-Drive Cable To Top Actuator Attachment

WASHER

FIGURE A

CONTROL LINK

VIEW D

''-

VIEW IN DIRECTION OF ARROW B

Fig.

FOLDING TO? COMPARTMENT BAG

4361

FOLDING TOP

1249

Fig. 12-50-Folding Top Actuator Attachmmt (View in Direction of Arrow "A')

1. Main Hinge

2. Top Actuator

Assembly

3. Attaching Screws

4. Shoulder Bolt

Installation

1. Position top actuator assembly to main. hinge and install in reverse order of removal. Finger start attaching screws on inner face of main hinge.

2. Align side rail actuator link with sector arm of actuator. Lubricate shoulder of attaching bolt with grease (Lubriplate or equivalent), and install bolt. Tighten set screw on side rail actuator link to lock attaching bolt.

3. Tighten attaching screws.

4. Synchronize actuators, check operation of top and install previously removed trim parts.

5. Actuator Sector Arm

6. Shoulder Bolt

Locking Set Screw

7. Flat-head,

Cross-recessed

Attaching Screw

8. Side Rail Actuator

Link

PROCEDURE FOR SYNCHRONIZING

FOLDING TOP ACTUATORS

Both folding top actuators must be synchronized or

"in phase" for proper operation of the top. If synchronization is necessary due to removal or replace ment of a folding top actuator, or for some other service operation, proceed as follows:

1. Raise top and lock at windshield header.

2. Disconnect drive cables at each top actuator

(Fig. 12-48). Manually shake each side roof rail to stabilize in its proper position.

3. Connect drive cables to each top actuator. Ac- tuators are now synchronized for proper operation of top. Check operation of top.

FOLDING TOP ADJUSTMENT

DESCRIPTION

Before performing any adjustments on the inward folding top, the technician should read and under- stand the complete adjustment section as covered in this section. Knowledge of the design, operation, attachment and adjustment sequence of component units is essential to the technician performing top alignment operations. Side roof rail assemblies are designed to provide three basic functions for the proper operation of the inward folding top.

12-60 FOLDING TOP

The first function provides

a

lifting tension in the side rail system when the top is down or stacked. This tension is required to assist and coordinate the proper unfolding of the side roof rails when raising the top. The tension is achieved by an outward pull of the rear control link at the mounting plate.

The adjustment is controlled by the serrated bushing of the control link.

Improperly tensioned rear control links can cause binding and/or damage conditions to the rail system when raising the top.

The second function provides proper height and length to the side roof rails. Height of the side rails is important to side glass alignment. Length of the side rails positions the front roof rail locating pin with the striker in the windshield header.

The height and length adjustments are controlled simultaneously by the setting of the side roof rail set screw. side rails have mispositioned set sciews, the windows cannot be aligned properly and locating pins cannot be aligned with the windshield header.

The third function provides a measurable outward force by the side rails which is necessary for proper weatherstrip contact and side rail ri- gidity. The outward force of each side rail is adjustable and rests against the center bow stop on each side. The center bow assembly, consisting of the center bow and side roof outer rear rails, straddles the inward folding side roof rails.

Adjustment of the outward force is controlled by the fore-aft setting of the rear control link mounting plate.

Improper positioning of the rear control link mounting plate can cause corresponding folding top misalignment problems and/or, if over- adjusted, damage to folding top components.

FOLDING TOP STACKED POSITION TENSION

ADJUSTMENT

The inward folding top, when down or stacked, must possess a degree of tension in the side rail system to assist and coordinate the proper unfolding of the right and left side rails when the top is raised.

Stacked or down position tension adjustment must be completed before side roof rail (up position) tension adjustment is attempted. Stack tension adjustment is not affected by side roof rail (up position) tion) tension adjustment is affected by stack (or down position) adjustment. On a properly stacked top, the front roof rail is parallel to the beltine of the car, and allows for normal top boot installation.

To obtain proper folding top stack tension adjustment, proceed as follows:

Synchronize Folding Top Actuators - Refer to procedure for synchronizing folding top actuators. If synchronization does not correct stack height, correct tension adjustment by proceeding with following steps.

Lower top into folding top compartment.

Loosen top control link attaching nut (Item side roof rails to lay normally in folding top compartment.

Position top control link serrated bushing outward on each side by raising folded side rail at center and tighten attaching nut.

Check for tension on stacked folding top.

Repeat step 4 as necessary until proper and equal tension is obtained on each side. Tighten attaching nuts to proper torque.

LOCATING PIN AND SIDE ROOF RAIL

HEIGHT ADJUSTMENT

Description

When raising a top, always lock the left lock handle first. The left striker guide hole is round and the right striker guide hole is slotted laterally. To lock the left side of the top, pull down on the front roof rail with one hand to position the left locating pin in the striker hole. Then rotate the lock handle to the locked position. Repeat the operation on the opposite side. Manual assistance (up to 30 pounds) may be required to position locating pins in the windshield header. This is a normal condition.

Figure 12-52 illustrates a body dimensional specification from a bolt on the main hinge to the striker on the windshield header. The distance from the center of the striker guide hole, "Aw, to the center of the minus 3/ 16". Adding the tolerance, the maximum measurement is 56-13/32". Subtracting the tolerance, the minimum measurement is 56- 1/32".

The locating pin and height of the side roof rails are controlled simultaneously by the side rail set screw

FOLDING TOP 12-51

TOP CONTROL

(3) BOLTS EACH SlDE

Fig. 12-51-Top Control Link and Mounting Plate Attachment

(Fig. 12-54). Figure 12-53 portrays proper adjustment of the set screw and conditions that can be caused by improperly adjusted set screws. While the set screw is adjustable, it has only one proper setting.

B. Dimensiorl "B" edge and vertical measurement as shown) is

13-1/8" plus or minus 1/8".

Procedure

1. Raise top and back off set screw located at center of each side rail (Fig. 12-54). Set screw is 1/8 inch hex head.

4. With side rails at proper height, adjust each set screw clockwise until it bottoms at side rail.

Then, back off set screw one-half turn. Readjust each set screw, if necessary to correct side rail height, after all other tensioning adjustments are completed.

2. Position locating pins in windshield header striker guides and lock top to header. Position left pin first.

NOTE: Application of high quality, plastic thread adhesive to exposed threads on each set screw

(Fig. 12-54) is recommended at this time. Follow label directions.

3. Manually position and then support each side roof rail at proper height over side windows.

Specified dimension from outer comer of side rail to quarter panel (Fig. 12-55) is as follows:

A. Dimension "A" (measured directly with tape measure) is 17" plus or minus 1/8".

CHECKING TENSION OF (UP POSITION) SlDE

ROOF RAILS

Description

The side roof rails of an inward folding top exert a

12-62

FOLDING OP

CARDBOARD

FOUNDATION

FRONT

LISTING

FRONT

3K.'

BOW

VIEW A

Fig. specified outward force at the center hinge area when the top is raised and locked at the windshield header.

The outward force is required for proper contact of weatherstrips to side windows and for stability of the side roof rails.

When the top is raised and locked, the inner side rails rest with an outward pushing force on a stop at each end of the center bow. Figure 12-56 portrays a cross- section of the left and right side roof inner rear rails resting on center bow stops.

The outward force exerted by each side rail is adjustable and can be measured accurately at the center bow area in the car. Figure 12-57 illustrates a tension checking tool which can be used to measure the tension of side roof rails. Tool J-23790 or BT-7 1 1 1,

(which is shown) or equivalent may be used.

The side roof rail tension checking procedure involves separating one side roof rail inwardly from the center bow stop by pulling simultaneously on both side roof inner rear rails. The side roof rail with the least tension always separates first. Check the separation with due care and with proper lighting. The best location to check the separatibn is inside the car from the rear of the center bow as shown in Figure 12-58.

Check the separation accurately on the side fleeted with a 1/16" shim. Before tensioning side rails with a tensioning tool, study the relationship of each side rail to center bow stop as shown in Figure 12-56.

Procedure

Following is the procedure for checking the tension of inward folding side roof rails. Corrective adjustments are indicated by the alignment conditions present.

1. With top raised and locked at windshield header, mount tension checking tool (J-23790 or

BT-7 11 1, or equivalent) on ,each inner rear rail at center bow (Fig. 12-57).

2. Tighten tensioning device in small increments while observing ends of cen'ter bow for separation at affected side rail. Tighten tensioning device until a . 1/16" separation occurs. Use flashlight and 1/16' shim. The separation should not exceed 1/ 16".

VIEW A

"HIGH SHOULDER CONDITION" CAUSED BY SET SCREW TOO DEEP

LOCATING PIN TOO SHORT

FOLDING

TOP 12-63

"PROPER ADJUSTMENT CONDITION" FOR PROPER SETTING SEE:

"SIDE ROOF RAIL AND LOCATING PIN ADJUSTMENT PROCEDURE"

"LOW SHOULDER CONDITION" CAUSED BY SET SCREW NOT DEEP ENOUGH

LOCATING PIN TOO LONG

4721

Fig. 12-53-Side Roof Rail and Set-Screw Adjustment

12-64 FOLDINO TOP

3. When f 1/ 16") separation occurs at one side rail at a scale reading below 50 pounds, same side rail is insufficiently tensioned and requires adjustment. Adjust affected control link mounting plate rearward to increase tension.

4. Cross-check body with tram gauge or tape measure as described in Figure 12-59. Side rails are in good alignment when both diagonal measurements are within 3/8 of an inch. Re-check measurements to assure accuracy. If difference between measurements exceeds 3/8 of an inch. side rail of longer measurement requires adjustment to decrease tension. In this event, adjust affected control link mounting plate forward.

5. An inward folding top is in proper alignment when following two conditions are present:

A. When tension checking tool indicates a minimum of 50 pounds of force to separate side rail 1/16 of an inch from center bow stop.

B. When diagonal measurements illustrated in

Figure 12-59 are within 3/8 of an inch.

SlDE RQOF RAlL UP POSITION TENSION

ADJUSTMENT

In event one or both side roof rails require tension adjustment, it is first necessary to check and, if neccs- sary, to complete the "Folding Top Stacked Position

Adjustment", then proceed as follows:

1. Raise top two to three feet above windshidd header.

2. Scribe fore-aft location of mounting plate at main hinge for accuracy of controlling adjustment.

3.. Loosen three mounting plate attaching bolts

(Fig. 12-5 1).

4. Using pry-bar or suitable tool, slide mounting plate in small increments (1/16 to 1/8 of an inch) "forward" (to decrease tension), or "rearward" (to increase tension).

5. Tighten only two mounting plate bolts for checking purposes.

SIDE R O O F INNER REAR RAIL--,

SlDE R O O F FRONT RAlL

U 7 7

Fig. 12-54-Side Roof Rail Set-Screw

6. Raise and lock top at windshield header.

7. Check terision of side roof rails with tension checking tool. (See: "Procedure For Checking

(Up Position) Side Roof Rail Tension").

8. Repeat adjustment of mounting plate (Steps 3,-

4,5,6 and 7) until tension checking tool indicates a minimum of 50 pounds of force to separate side rail from center bow stop, and diagonal measurements illustrated in Figure 12-59 are within 3/8 of an inch.

9. Tighten all three mounting plate attaching bolts.

10. Check operation of top.

FRONT ROOF RAlL LOCK HOOK

ADJUSTMENT

Conditions of unsatisfactory lock operation caused by the lock hook can be corrected as follows:

1. To tighten or increase locking action, turn lock hook clockwise.

2. T o reduce or decrease locking action, turn lock hook counterclockwise (Fig. 12-45).

NOTE:

Always lock left side of top before locking right side.

FOLDING TOP 12-55

SIDE ROOF RAIL

DIMENSION A

QUARTER OUTER

UPPER CORNER

(LESS REVEAL MLDG.)

Fig. 12-55-Height of Side Roof Rails

DIMENSION B

4689

12-68

FOLDING TOP

1. Center Bow Stop

(Left)

2. Center Bow Assembly

Fig. 12-56-Cross Section of Side Rail to Center Bow Stop Alignment

3. Side Roof Inner Rear

Rail (Left)

4. Side Roof lnner Rear

Rail (Right)

5. Center Bow Stop

(Right)

FOLDING TOP 12-57

1. Side Roof Inner Rear

Rail

Fig. 12-57-Inward Folding Top Tension Checking Tool

2. Attaching Hook

3. Turn-Buckle

4. Tension Scale

5. Cable

1. Center Bow

2. Center Bow Stop

3. Side Roof Inner Rear

Rail

Fig. 12-58-Checking Separation of Side Rail from Center Bow Stop (Inside Car)

4. 1/16" Separation

Occurs Here

5. Check With Shim in

Direction of Arrow

6. Rear Control Link

7. Side Roof Outer Rear

Rail (Part of Center

Bow Assembly)

ROOF RAlL

FOLDING TOP 12-59

LEFT

OUTER Y

Fig. 12-59-Diagonal Check of Side Roof Rails

' k OUTER

DOOR AND.QUARTER TRIM 13-1

SECTION 13

SUBJECT PAGE

Door and Quarter Trim

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

Introduction

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

Door Pull Handles

Door Arm Rests

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

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

Door Outside Mirror Remote Controls and Escutcheon

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

Door' and Quarter Inside Handles..

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

Door Trim Assemblies

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

Door Trim Panel Moldings and

Appliques

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

Rear Quarter Arm Rest

2-Door Closed Styles

"A and X"

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

Rear Quarter Arm Rest - "A, B, C and

E" 2-Door Hardtop Styles and "B and E"

Convertible Styles

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

Rear Quarter Arm Rest

Convertible Styles

"A"

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

Rear Quarter Trim Assembly

2-Door Styles Except "F" Styles ..............

Rear Quarter Trim Panel

All

- "F" Styles

......

Rear Quarter Trim Finishing Panel

All 4-Door and "A-80" Styles

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

INDEX

SUBJECT PAGE

Rear Quarter Upper Trim (Above Belt)

All Styles

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

Center Pillar Trim

Except 68 169

- All Styles

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

Center Pillar Upper and Lower Trim

- 68169 Style

Body Lock Pillar Windlace Assembly

- "A, B and C" Coupe Styles

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

13-15

Rear Quarter Trim Front Finishing

Panel - "A and B" Station Wagon

Styles

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

Rear Quarter Wheelhouse Trim Cover

Panel (Right Side) - "A and B"

Station Wagon Styles ............................... 13-15

Spare Tire Cover Panel

Station Wagon Styles

"A and B"

............................... 13-16

Rear Quarter Wheelhouse Trim Cover

Panel (Left Side)

"A and B"

Station Wagon Styles

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

Back Window Panel Trim

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

Rear Seat to Back Window Panel Trim

Assembly - All Styles

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

13-20

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

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 stud 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 D&R AND QUARTER TRlM

Door and quarter inside handles are retained by either screws or spring clips (Figs. 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

Fig. 13- 1 -Typical Door Pull Handle Attachment

DOOR AND QUARTER INSIDE HANDLES

and plastic bearing plate (Fig. 13-1 1). 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 TRlM ASSEMBLIES

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). Ex- posed clips can be disengaged from remote control spindle with a screwdriver.

There are two basic types of door trim assemblies, a one piece trim assembly that is used on all "A and

X u "B, C,

E and F " styles.

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

On "A and X u the door inner panel across the top and is secured by clips or nails down the sides, and by screws across

DOOR AND QUARTER TRIM 13-3

Fig. 13-2-Typical Door Pull Handle Attachment

Fig. 13-3-Typical Door Arm Rest Applied After Trim

Installation the bottom (Fig. 13-12 is a composite illustration of the various types of door trim panel fasteners). On

"B, C, E and F" 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 bottotn. The lower portion is retained by screws across the top and by clips down the sides and across the bottom.

Removal and Installation

* .

1. Remove all door inside handles as previously described.

2. Remove door inside locking rod knob.

3. On styles equipped with door pull handles, remove screws inserted through handle into door inner panel (For location of screws, refer to

Figs. 13-1 and 13-2).

134 DOOR AND QUARTER TRIM

Fig. 13-4-Typical Door Arm Rest Assembled to Door

4. On styles with remote control mirror assemblies, remove remote mirror escutcheon and disengage end of mirror control cable from escutcheon as previously described (Figs. 13-5 and 13-6).

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 (Figs. 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 (Fig. 13-4) or styles with integral arm rest, remove screws inserted through pull cup into arm rest hanger support. On styles with arm rest applied after door trim installation (Fig. 13-3), remove arm rest to door inner panel attaching screws.

8. On Cadillac styles, remove windshield wiper control switch to "pod" attaching screw (Fig.

13-13) and disconnect wire harness at switch assembly.

9 . On "B, C, E and F" styles, with two piece trim assemblies, remove attaching screws located at outer lower corners of upper trim assembly.

Then, using tool J-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.

NOTE: On styles with electric switches located in door trim assembly, disconnect wire harness at switch assembly.

T o remove lower trim, on

"B,

C, E and F " styles remove attaching screws along upper edge of lower trim assembly. Then, starting at a lower corner, insert tool J-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 (Fig. 13-14),

DOOR AND QUARTER TRIM 13-6

10. On " A

Fig. 13-5-Typical Remote Mirror Cable and Escutcheon Attachment, All Except Cadillac Styles 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 beltline. On styles with electric switches located in the door trim assembly, disconnect wire harness and remove trim assembly from door.

1 1. 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.

Fig. 13-6-Door Armrest Switch Cover Plate and Remote

Mirror Cable Attachment (Cadillac Styles)

13-6 DOOR AND QUARTER TRlM

VIEW "A"

SPRING CLIP

4304

Fig. 13-7-Typical Door Lock Remote Control Handle

Installations

DOOR TRlM PANEL MOLDINGS AND

APPLIQUES

Door trim moldings and appliques are secured from

Fig. 13-9-Typical Window Regulator Handle Assembly

Installation the outboard side of the door trim panel with several types of metal fasteners (Fig. 13-15) or bend-over tabs.

Removal and Installation

1. Remove door trim assembly as previously described.

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 INSIDE H A N D L E

Fig. 13-lbClip Retained Door Inside Handle Removal

2. For removal of type "A" fasteners, Figure 13- 15, use tool 5-23554 or equivalent.

3. To remove type

"B"

fasteners, Figure 13-15,

- - -

- cient working space to insert wire cutter; then, cut fastener and discard.

Fig. 13-13-Windshield Wiper Control Switch Removal and

Installation (Cadillac Styles)

Fig. 13- 14-Courtesy Lamp Removal and Installation

Fig. 13-12-Typical Types of Door Trim Retention Fig. 13-15-Door Trim Pad Molding and Applique Removal

138 DOOR AND QUARTER TRIM

4. For removal of type "C" fasteners, Figure 13-1 5, use a cross head type screwdriver.

5. T o install, reverse removal procedure.

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. Re- moval is simply a matter of removing two attaching screws (Fig. 13-16). T o 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).

Removal and Installation

1. Remove rear seat cushion and back assemblies.

2. Remove arm rest front and lower attaching screws.

3. On "B, C and E" styles, remove attaching screw at upper rear of arm rest (Fig. 13-17).

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 &m rest (View "B", Fig. 13-19).-

V I E W B

Fig. 13- 16-Quarter Trim Assembly Attachment Two-Door Sedan Styles

3 8 4 2

DOOR AND QUARTER TRlM 13-8

VIEW "A" VIEW "C"

VIEW "D"

4354

VlEW "B"

Fig. 13-17-Quarter Trim Assembly Attachment Two-Door Hardtop Styles ("B" Style Shown)

5. To install, connect electrical wiring and reverse removal operations.

REAR QUARTER ARM REST

" A Convertible

Styles

Arm rests are a "Floor-Mounted Type" and include an integral folding top compartment side trim panel

(Fig. 13-20).

Removal and lnstallation

1. Remove rear seat cushion and back assemblies.

2. Remove attaching screws at front of arm rest.

5. To install, connect electrical wiring and reverse removal operations.

REAR QUARTER TRIM ASSEMBLY

All

Two-Door Styles, Except "F" Styles

Removal and lnstallation

1. Remove rear seat cushion and back assemblies.

3. Remove attaching screws from folding top compartment side trim panel as shown (Fig. 13-20).

4. Where present, detach electrical wiring and remove arm rest (View "A", Fig. 13-21).

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).

13-10 DOOR AND QUARTER TRlM

SEAT BACK

FILLER PANEL

V l E W A

QUARTER TRI

V l E W B

FLOOR-MOUNTED

ARM REST

V I E W C

3 8 3 6

V l E W D

Fig. 13-18-Quarter Trim Assembly Attachment Two-Door Hardtop Styles ("A" Style Shown)

5. Where present, detach fasteners securing qpar-

13-16) with cool ~ 1 9 8 8 6

U J U

W I N D O W SECTION A-A

SWITCH

IERMINAL*-

VlEW B

ASH TRAY

6. Detach quarter trim by lifting assembly off han- gar retention.

7. Where present, detach electrical wiring and remove trim assembly.

8. To install, connect electrical wiring and reverse removal operations.

REAR QUARTER T R l M PANEL

"F" Styles

The rear quarter trim panel consist of a one-piece plastic panel with an integral arm rest (Fig. 13-22).

Removal and Installation

1. Remove rear seat back and applicable rear seat cushion.

2. Remove rear quarter upper trim.

1265

3. Remove attaching screws from lower front

(View "C", Fig. 13-22) and upper rear (View

3g. 13-19-Quarter Arm Rest Ash Tray and Electric Switch

Plate (Hardtop Styles)

DOOR AND QUARTER TRlM 13.1 1

FOLDING TOP COMPARTMENT

SIDE TRlM PANEL

QUARTER TRlM

Fig. 13-20-Quarter Trim Assembly Attachment Convertible

Styles

4. Remove door opening sill plate. Then, slide trim panel forward and remove 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.

O C K E T

A R M RE

R E T A I N I N G S C R E W S

S N A P - O U T L E N S

V I E W A

Fig. 13-2 1-Quarter Arm Rest Courtesy Lamp Convertible

Styles

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 and remove trim panel.

"B", Fig. 13-24)

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 fasteners (View "A", Fig. 13-25). Then remove trim.

NOTE: Part 1 of fastener, as shown in Figure 13-

25, secures to quarter inner panel. Part 2 of fastener (Fig. 13-25) is stapled foundation of quarter upper trim. For best results during removal, confine prying operations between the fasteners.

5. To install trim assembly, feed courtesy lamp wire through trim panel. Also, position trim assembly at lower retaining clip ("D", Fig. 13-25) and along front and rear edges. Then, secure fasteners with a moderate hand pressure. Re- verse

' balance of removal operations. When necessary, use non-staining vinyl trim adhesive to cement trim at back window retainer.

-CENTER PILLAR TRlM All Styles, Except

68169 Style

Removal and Installation

1. Remove front and rear door sill plates.

13-12 DOOR AND QUARTER TRIM

S E C T I O N A - A

Fig. 13-22-Rear Quarter Trin? Attachment

"F" Styles

SECTION 8-6

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 1313

Fig. 13-25-Quarter Upper Trim Attachment

Typical Installation

13-14 DOOR AND QUARTER TRlM

PART l FASTENER

A T T A C H I N G H O L E S

Q U A R T E R

UPPER TRIM

Q U A R T E R U P P E R TRIM.

( B A C K - S I D E )

. ,

Fig. 13-26-Quarter Upper Trim Attachment

Typical Installation

CENTER PILLAR T R l M F I N I S H I N G C A P

NTER PILLAR T R l M P A N E L

...., , . . 3 2 9 0

Fig. 13-27-Center Pillar Trim Attachment "A, B and C"

Hardtop Styles

2. On hardtop styles, remove attaching screws securing trim finishing cap (Fig. 13-27). Then, 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. T o remove lower trim after upper trim has been removed, lift trim straight-up to clear retaining flanges on center pillar.

4. T o install reverse removal operations.

CENTER PILLAR UPPER AND LOWER TRlM

681 69

Style

Removal and lndtallation

1. Remove center .pillar upper trim by gently prying serrated attaching nails from center pillar

(Fig. 13-28).

- -

DOOR AND QUARTER TRlM 1315

CENTER PILLAR

UPPER T R I M

Fig. 13-28-Center Pillar Trim Attachment

Typical

Installation

2. Remove front and rear door sill plates.

3. Remove attaching screws from center pillar lower trim.

4. With flat-bladed tool, such as J-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

"A8 B and C Coupe Styles

Removal and Installation

1. Remove rear quarter trim assembly and detach door sill plate.

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 (Fig. 13-

30).

4. T o install, reverse removal operations.

REAR QUARTER TRlM FRONT FINISHING

PANEL

"A and B" Station Wagon Styles

Removal and Installation

1. Detach quarter window lower garnish molding.

Fig. 13-29-Body Lock Pillar Windlace

" A " Styles

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. 13-31).

6. To install, position finishing panel to rear lock pillar and reverse removal operations.

REAR QUARTER WHEELHOUSE TRlM

COVER PANEL

(Right Side)

"A and

B"

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 snare tire cover panel.

- - -

13-16 DOOR AND QUARTER TRlM

VlEW "A"

4356

VlEW "B"

Fig. 13-30-Body Lock Pillar Windlace

"B and C" Styles

4. Remove second folding seat back lock striker and bumper assembfy from wheelhouse (Fig. 13-

5. Remove attaching screws from perimeter of trim cover panel and remove panel.

6. To install, reverse removal operations.

SPARE TIRE COVER PANEL

"A and

B"

Station Wagon St,yles

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 bottom by a striker and folding (catch-type) lock handle (Fig. 13-32). To remove cover, open lock handle, swing bottom of cover outward to release at beltline and remove. To install, reverse removal procedure.

NOTE: On styles with tail gate window defogger, disconnect hose from defogger outlet grille to complete removal.

REAR QUARTER WHEELHOUSE TRlM

COVER PANEL

(Left Side)

"A and B"

Station Wagon Styles

Removal and Installation

1. Remove quarter window lower and front garnish molding.

DOOR AND QUARTER TRIM 13-17

2. On all "B" styles and "A" styles with optional split seat, remove seat back bumper or seat back lock striker (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. Detach electrical wiring from cover panel components and remove cover panel.

6. To install, connect electrical wiring and reverse removal operations.

V I E W I N CIRCLE 6

S E C T I O N A - A

31 61

Fig. 13-31-Quarter Front Trim Finishing Panel "A and B"

Station Wagon Styles

13-18 DOOR AND QUARTER TRIM

W I

V l E W IN CIRCLE ' 0 '

V l E W IN CIRCLE ' A '

Fig. 13-32-Wheelhouse Trim Cover Panels (Right Side) "A and B" Station Wagon Styles

DOOR AND QUARTER TRIM 13-19

Fig. 13-33-Wheelhouse Trim Cover Panel (Left Side) "A and B" Station Wagon Styles

13-20

DOOR AND QUARTER TRlM

BACK

WINDOW

PANEL

TRlM

REAR SEAT TO BACK WINDOW PANEL

TRlM ASSEMBLY

All Styles

Removal and Installation

1. Remove rear seat cushion and back assemblies.

2. Detach shoulder straps if so equipped. Also, where 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. T o 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 TRIM 1

SECrION A-A

,.."

Fig. 13-34-Back Window Panel Trim Attachment All Styles

SEATS 14-1

SECTION 14 SEATS

SUBJECT PAGE

Introduction

Front Seat

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

- Full Width

1 .........

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

Front Seat Dealer Relocation Provisions

Seat Torque Specifications

....

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

Manually Operated Seat Adjuster

Trouble Diagnosis Chart

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

Manually Operated Seat Adjuster

Control Arm Knob

.................................. ;.

Front Seat Assembly

Seat Assembly

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

- Manually Operated

..........

Adjuster Assembly

Seat Assembly

Manually Operated

Power Operated

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

Power Operated Seat Adjuster

Trouble Diagnosis Chart

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

Adjuster Assembly - Power Operated

........

Two-way Seat Power Adjuster

Major Components

Electric Motor

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

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

Horizontal Gearnut Assembly

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

Horizontal Jackscrew

Plastic Slides

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

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

Four-Way Seat Adjuster Major

Components ................................................

Electric Motor ............................................

Vertical Gearnut

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

Horizontal Actuator

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

Jackscrew

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

Horizontal and Vertical Drive Cables

Transmission

........

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

Disassembly and Assembly of

Transmission ........................ .....................

Six-Way Seat Adjuster Major

Components-Full Width Seats

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

Electric Motor

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

Horizontal Actuator

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

Horizontal Actuator Adjustment

Front and Rear Vertical Gearnut

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

Lower or Upper Channel and

Plastic Slides

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

Drive Cables ................................................

Transmission

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

Disassembly and Assembly of

Transmission ... ..:. .......................................

Six-Way Seat Adjuster Major

Components-60-40 Seats

Electric Motor

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

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

Rear Vertical Drive Cable

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

Adjuster and Horizontal or Front

Vertical Drive Cables ................................

Transmission Assembly

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

- Transmission 14-27

INDEX

SUBJECT PAGE

Front Seat Back Assembly - Four-Door

Styles With Full Width Seat

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

Seat Back Panel Courtesy Lamp Switch ......

Seat Back Assist Strap and Clock

Seat Back Assembly

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

- Four-Door Style

Full Width Seat With Notch Down

Center Arm Rest and 60-40 Seat

Seat Back Assembly

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

- Two-Door Style

Full Width Seat With Notch Down

Center Arm Rest and 60-40 Seat

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

Seat Back Manually or Electrically

Operated Lock- Conventional Full

Width Seats

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

Electric Seat Back Lock Trouble

Diagnosis Chart ........................................

Front Seat Back Manually Operated

Lock, Lock Control and Lock Rod

Conventional Full Width Seats or

60-40 Seats ..................................................

Seat Back Electric Lock Solenoid and Support Assembly ................................

Front Seat Back Head Restraint

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

Head Restraint Lock and Escutcheon

Assembly..

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

Head Restraint Guide Tube

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

Center Arm Rest and Curtain Assembly

-Full Width Seat Back ................................

Center Arm Rest and Support Assembly

-Full Width Seat Back ................................

Center Arm Rest and Curtain Assembly

-Notch Down Seat Back ............................

Center Arm Rest Assembly

-Notch Down Seat Back ............................

Foot Rest Assembly

68169 Style

Cadillac

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

Bucket Front Seats

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

Manually Operated Bucket Seat

Assembly ....................................................

Power Operated Four-Way Bucket

Seat Assembly ............................................

Manually Operated Bucket Seat

Adjuster ......................................................

Power Operated Four-Way Bucket

Seat Adjuster ..............................................

. Major Components

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

Motor and Transmission Drive

Belt and Pulleys

Motor Assembly

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

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

Transmission Assembly and Horizontal and Vertical Drive Cables ........................ 1446

14-2 SEATS

SUBJECT P AGE

Disassembly and Assembly of

Transmission ..............................................

Adjuster Vertical Gearnut

Adjuster Jackscrew

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

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

Adjuster Horizontal Actuator

Assembly ....................................................

Torque Tube Assembly ............................

Adjustable Front Seat Back Assembly

-Chevrolet "F" Styles

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

Seat Back Lock Striker and Seat

Back Side Inner Bar Stop

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

Strato-Front Seat Back Panel

Seat Back Head Restraint

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

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

Seat Back Head Restraint Retainer and Guide Tube ........................................

Seat Back Manually and Electrically

Operated Lock Assembly

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

1447

1448

1449

14-50

14-5 1

Electric Seat Back Lock

Trouble Diagnosis Chart

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

Strato Bucket Seat Back Assembly

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

Rear Seats

Rear Seat Cushion

All Styles

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

Rear Seat Back Assembly

All

Styles Except Station Wagons

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

14-52

14-53

14-54

14-55

Rear Seat Back Center Arm Rest and Curtain ................................................ 14-57

Rear Seat Back Center Arm Rest

Hanger Plate and Linkage

Auxiliary Seat Assembly

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

- Cadillac

14-58

Limousine Styles

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

14-58

Auxiliary Seat Adjustments

Limousine Styles

Cadillac

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

14-58

Auxiliary Seat Lower Support Assembly

- Cadillac Limousine Styles

Seat Trim Buttons

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

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

Station Wagon Folding Rear Seats and Floor Panels

"56-66" Styles

- All Except

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

Rear Floor Side Filler Panel

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

Luggage Compartment Panel and

Hinge Assembly

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

Folding Third Seat Cushion

Seat Styles-" A" Body

- Three

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

Folding Third Seat Cushion Panel

14-59

14-61

14-62

14-63

Assembly and Support-" A" Body

Three Seat Styles ......................................

Folding Third Seat Back Trim

Assembly-" A" Body Three Seat

Styles

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

Folding Third Seat Back Panel

14-64

14-65

Assembly-" A" Body Three Seat

Styles

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

Folding Third Seat Back Lock

-"A" Body Three Seat Styles

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

14-65

Compartment Floor Panel Assembly

(At Kick-Up) All Styles

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

14-66

Second Seat Back Filler Panel

-All Styles

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

Second Seat Cushion

"A" Styles

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

14-66

SUBJECT PAGE

Folding Second Seat Back Trim and Spring Assembly- "A" Styles..

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

Folding Second Seat Back Trim,

Panel and Linkage Assembly

-"A" Styles

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

Folding Second Seat Back Linkage

Assembly (Right or Left Side)

-"A" Styles

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

Luggage Compartment Lock Cylinder

-Two Seat Styles

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

Luggage Compartment Lock

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

Folding Second Seat Back Lock

All " A and B" Styles (Except

"A-56,66" Styles)

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

Folding Seats and Floor Panels

-"56,66" Styles

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

Folding Second Seat Assembly

-"66" Styles

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

Folding Second Seat Cushion

Assembly-" 66" Styles

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

Folding Second Seat Back Trim and Spring Assembly-" 66" Styles

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

Folding Second Seat Front Floor

Pan Linkage-"66" Styles

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

Folding Second Seat Rear Floor

Pan Linkage-"66" Styles

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

Folding Second Seat Side Inner

Linkage-"66" Styles ..................................

Folding Second Seat Side Outer

Linkage-"66" Styles

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

Folding Second Seat Back Lock

-"66" Styles

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

Folding Second Seat Back Panel and Filler Panel-" 66" Styles

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

Folding Third Seat and Floor Panel

Assembly-" 66" Styles

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

Folding Third Seat Cushion Trim

Assembly-" 66" Styles

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

Folding Third Seat Back Trim

Assembly or Seat Back Panel

Assembly-"66" Styles

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

Folding Third Seat Back Lock

-"66" Styles

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

Luggage Compartment Cover Panel and Filler Panel-" 66" Styles

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

Folding Seats and Load Floor

Panels-"B" Station Wagon

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

Third Seat Cushiop and Back

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

Third Seat Back Lock and Striker

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

Third Seat Back Trim Foam Pad and

Foundation Board Assembly

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

Second Seat Cushion

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

Second Seat Back Trim Foam Pad and

Wire Mat Assembly

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

Second Seat Back and Filler

Panel Assembly

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

Second Full Width Seat Back

Linkage and Two-Thirds Seat

Back Outer Linkage

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

Released by: www.78ta.com

Serial Number: 72BDY-001-1009

SEATS 14-3

SUBJECT PAGE

Second Two-Thirds Seat Back

Assembly and Inner Linkage

Assembly..

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

14-80

Second One-Third Seat Assembly

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

14-81

Second One-Third Seat Back Outer

Linkage Assembly

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

14-82

Lap Belts and Shoulder Belts

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

14-83

Standard Front Lap Belt Retractor

(Plastic Buckle Cover)

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

14-84

SUBJECT

PAGE

Front Lap Belt Retractor

Body Coupes

- "X"

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

14-84

Standard Front Lap Belt Retractor

(With Vinyl Cover)

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

14-84

Deluxe Front Lap Belt Self-Locking

Retractor

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

Rear Seat Bail Type Retractor

Lap Belts and Shoulder Belts

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

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

14-84

14-85

14-86

FRONT AND REAR SEATS

INTRODUCTION

All front seats incorporate a front seat back head restraint on the drivers and passengers seat back. 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. How- ever, 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. On all two-door front seats (except strato seats and "A, F and X" body seats) the seat back lock is actuated by a coptrol lever at the outboard side of the seat back. On two-door styles with strato seats the seat back lock is actuated by a control button located at the upper center of the seat back. On " F and X" body bucket seats, the seat back lock is actuated by a control'lever located at the lower rear outboard 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 passenger seat (60 percent of front seat width).

All front and rear seat backs have formed polyurethane 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.

FULL WIDTH FRONT SEATS

FRONT SEAT DEALER RELOCATION

PROVlSlONS

All front seat adjusters, except Chevrolet "X" and provision. The Buick"'EM style full width seats can be relocated approximately one ihch forward by removing the adjuster-to-floor pan bolts moving the seat assembly forward sufficiently to reinstall bolts through adjuster rear set of attaching holes. Buick

"E" style full width seats can be relocated approximately one inch forward by removing the adjuster- to-floor pan bolts moving the seat assembly forward sufficiently to reinstall bolts through adjuster rear set of attaching holes.

On the Chevrolet "X" body adjusters, 1 inch additional rearward can be obtained as follows:

1. Remove seat assembly and place upside-down on a clean surface. Disconnect assist spring at both adjusters.

2. Move both adjusters to the full forward position, as shown in Figure 14-1, use a 1/4 inch drill bit to drill out roller stop dimple in upper channel.

Remove any drillings left in adjuster channels.

3. Move both adjusters to the full rearward position, as shown in Figure 14-2. Install a 10-32 1/4 inch long type "C" Pan Head Cross Recess Tap- ping Screw

Cadmium or Zinc Plated (Part No.

164072 or equivalent) in the hole provided in the rear of the adjuster upper channel at location shown'in Figure 14-2.

WARNING: FAILURE TO INSTALL SCREW

COULD RESULT I N THE ADJUSTER UP-

PER CHANNEL SLIDING OUT O F THE

LOWER CHANNEL UNDER CERTAIN

FORWARD LOAD CONDITIONS.

SEAT TORQUE SPECIFICATIONS

The following torque specifications should be used when servicing seat assemblies:

1 4 4 SEATS

Fig. 14-1-"X" Body Front Seat Dealer Rearward Relocation

BOLT OR NUT LOCATION AND TORQUE

FT. LBS.

1. Seat Adjuster and Folding Seat Back-to-Floor

Pan Bolts or Nuts - 12- 18 ft. lbs.

2. Seat Adjuster-to-Seat Frame Bolts - 12- 18 ft. lbs.

3. Seat Back to Cushion Frame Bolts - 7-1 1 ft. lbs.

4. Seat Back Hinge Bolts - 7-1 1 ft. lbs.

5. Seat Back Lock Attaching Screws

7-1 1 ft. lbs.

6. Seat Back Lock Striker and Inner Side Bar Stop

12-18 ft. lbs.

Fig. 14-2-"X" Body Front Seat Dealer Rearward Relocation

WARNING: 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

O F VITAL COMPONENTS AND SYSTEMS.

THEY MUST BE REPLACED WITH ONE

O F T H E SAME PART NUMBER OR WITH

AN EQUIVALENT PART I F REPLACE-

MENT BECOMES NECESSARY. 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 O F THESE

PARTS.

MANUALLY OPERATED SEAT ADJUSTER TROUBLE DIAGNOSIS CHART

CORRECTION APPARENT CAUSE

-- -

1. Locking wire too tight.

2. Adjuster lock bar spring disconnected or broke.

3. Adjuster lock bar sticking or binding.

1. Adjust locking wire tension hook into another hole to loosen wire (see Figs. 14-6 and 14-7).

2. Connect spring or install new spring

(see Figs. 14-6 and

14-7).

3. (a)Lubricate lock bar pivot (see Figs. 14-6 and 14-7).

(b)If bar is binding eliminate cause. of binding or replace adjuster.

SEATS 14-6

2. Adjuster will not unlock. 1. Locking wire too loose or disconnected.

2. Adjuster lock bar sticking or binding.

1. Adjust locking wire tension hook into another hole to tighten wire. Connect locking wire to adjusters.

2. (a)Lubricate lock bar pivot.

(b)If bar is binding eliminate cause of binding or replace adjuster.

I 3. When left adjuster locks right adjuster is between lock positions.

1. Right adjuster either rearward of forward of left adjuster.

1. Loosen adjuster to floor pan bolts or nuts

- move one adjuster forward or rearward as far as possible and the other adjuster the opposite direction.

14-6 SEATS

MANUALLY OPERATED SEAT ADJUSTER

TROUBLE DIAGNOSIS CHART

CONDITION APPARENT CAUSE CORRECTION

4. Seat hard to move forward or rearwal-d.

1. Adjuster(s) improperly lubricated.

2. Adjuster(s) binding due to bent or damaged channels. alignment with each other.

1. Lubricate adjuster channels with Lubri- plate AAW or equivalerlt.

2. Replace adjuster

3. Loosen floor pan attaching bolts or nuts, align adjusters on floor pan and retighten bolts or nuts.

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 aperated seat adjuster with the control arm knob it will be necessary to remove the knob fiom the old adjuster and install it on the new adjuster or install a new knob.

NOTE1 Contrbl arm knobs can generally be removed 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. 14-3 and

14-4).

Removal

Using a heavy body spoon, a long drift pin and a piece of wood as a fulcrum, as shown in Figure 14-3, 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 arfn.

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. One round rubber plug (Part No. 4802102 or equivalent) to fit over "C" clamp swivel pad to help prevent swivel pad from slipping off control 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.

1.

Place pencil mark on seat adjuster control arm, one inch from end 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 hand pressure making certain knob is started on straight.

NOTE: Install knob so that "gate" mark (on one face of knob) is facing seat and L seats with the control arm at the front of the seat, install knob so that gate mark is facing down.

3. Insert sheet metal screw or drift pin in hole provided in adjuster control arm and place "C" clamp in position as shown in Figure 14-4. Use round rubber plug (Part No. 4802 102 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).

SEATS 1 4 7

Fig. 14-3-Front Seat Adjuster Control Knob

Removal - Side Control Knob Shown

Front Control Knob Typical

4 I N C H ' C ' C L A M P PROTECT SEAT TRIM

ER PLUG

(

# 4 8 0 2 1 0 2 )

ER ' C ' C L A M P

N D O F F SHARP

O F SCREW

1 1 8 "

FOR

1UGH E X I S T I N G H O

' c ' C L A M P G R I P

2891

Fig. 14-4-Front Seat Adjuster Control Knob

Installation

Side Control Knob Shown

Front Control Knob Typical

14-8 SEATS

FULL WIDTH CONVENTIONAL 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.

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.

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

S E A T A D J U S T E R F R O N T B O L T

Fig. 14-5-Front Seat Adjuster-to-Floor Pan Attachment

Manually Operated " A and X"

Fig. 14-6-Front Seat Adjuster

Manually Operated Full Width Conventional Seats

"B, C and E" Body

3. Adiuster-to-Seat 1. Adiuster-to-Floor Pan

tia aching

Bolts

2. Adjuster-to-Floor Pan

Spacer ("E" Buick

Only)

Bolts

4. Adjuster Assist

Spring

6. Adjuster Locking

Wire

7. Locking Wire Tension

Hooks

8. Tension Hook

Adjusting Holes In

Seat Frame

Q. Seat

Frame-to-Adjuster

Ground Strap

SEATS 149 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 manually 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.

Fig. 14-7-Front Seat and Adjuster

Manually Operated 60/40 Seats (Passenger Side Shown

Driver Side Typical)

1. Adjuster Assembly

2. Adjuster Rear

Pedistal Covers

3. Outer

Adjuster-to-Floor Pan

Bolts

4. Inner

Adjuster-to-Floor Pan

Nuts

5. Adjuster-to-Seat

Frame Bolts

6. Adjuster Assist

Spring

7. Adjuster Lock Bar

Spring

8. Adjuster Locking

Wire

9. Ground Strap

1410 SEATS

Fig. 14-8-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 1. M o t o r and

Transmission Support

Attaching Screws

12. Adjuster Track Cover

Retainers

13.

14.

15.

Horizontal Drive

Cable-Black

Vertical Drive

Cable-Blue

Transmission

16.

Assembly

Motor-to-Transrniss~on

Coupling

Motor Assembly

SEATS

141 1

At rear of adjusters, 'remove adjuster-to-floor pan rear attaching nuts or bolts (Figs. 14-5, 14-6 and 14-7).

Operate seat to full rearward position. Remove adjuster- to-floor pan front attaching bolts. On seats incorporating any electrical equipment, tilt seat assembly rearward sufficiently to disconnect feed wires at connectors under seat. With aid of a helper, remove seat assembly from body.

To install seat assembly, reverse removal procedure. 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 Full Width and

60-40

Seat8

Removal and In8tallation

1. Remove front seat assembly with adjusters attached, as previously described, and place upside-down on a clean protected surface.

2. Remove seat adjuster assist spring from adjuster to be removed (see Figs. 14-6 and 14-7).

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. 14-6 Item "3", and 14-7 Item

" 5 "1.

5. To install, reverse removal procedure. If adjuster with control arm is being replaced, install new adjuster control knob as described under

"Manually Operated Seat Adjuster Control

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. 14-6, Item "8").

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.

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 vertical 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, a double contact in the switch first energizes the correct solenoid which engages the solenoid plunger with the driving gear dog, then energizes the motor. 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 it from the driving gear dog.

14-1 2 SEATS

POWER OPERATED FOUR-WAY OR SIX-WAY SEAT ADJUSTER MECHANICAL TROUBLE DIAGNOSIS CHART

NOTE: If it is apparent or suspected that the trouble is in the electrical system refer to "Electrical Section

Power Seats

Trouble Diagnosis Chart".

CONDITION

1. Horizontal operation of seat not smooth

APPARENT CAUSE

1. Improper lubrication of adjuster shoes and channels.

2. Adjuster horizontal actuator gear too tight to rack gear.

3. Adjuster shoes too tight in upper channel.

CORRECTION

1. Lubricate adjuster upper channel and plastic shoes.

2. See "Horizontal

Actuator Adjustment".

3. Install new shoes on adjuster lower channel.

2. Horizontal chuck or' looseness

1. Horizontal actuator improperly adjusted to rack gear.

1. See "Horizontal

Actuator Adjustment".

3. One adjuster will not operate horizontally.

4. One adjuster will not operate vertically.

5. Both adjusters will not operate horizontally and/or vertically.

6. Vertical chuck or looseness.

1. Horizontal drive cable disconnected or damaged.

2. Horizontal actuator inoperative.

1. Vertical drive cable disconnected or damaged.

2. Vertical gear nut inoperative.

1. Inoperative horizontal and/or vertical solenoid in transmission.

2. Damaged, broken or inoperable solenoid plunger, shaft, dog, dog spring, gear or drive gear (see Figs.

14-21 and 14-23).

1. Excessive clearance at vertical gear nut tension spring.

1. Check horizontal drive cables, replace if damaged.

2. Replace horizontal actuator assembly.

1. Check vertical drive cables, replace if damaged.

2. Replace vertical actuator assembly.

1. See "Electrical

Section

Checking the Solenoid "

2. Replace damaged, broken or inoperable sdenoid part with new part.

1. Grind down top at vertical gear nut shoulder nut 1/64" to 3/64" maximum.

Removal and Installation

1. If seat is operable, operate seat to full forward position. On four-way or six-way power seats, operate seats to full up position.

2. Where 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.

4. Remove seat adjuster-to-floor pan rear attaching bolts (Figs. 14-8, 14-9 through 14-15).

5. Operate seat to full rearward position. Remove adjuster-to- floor pan front attaching bolts. Tilt seat assembly rearward sufficiently to discon-

SEATS 14-13 nect 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 or wires. With aid of a helper remove seat assembly from body

6. To install seat assembly, reverse removal procedure. Where seat adjuster-to-floor pan spacers were present reinstall spacers in same position.

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 o~eration

- - - of both seat %ck locks (see Figs. i4-8, 14-9 through 14- 15).

Fig. 14-9-Front Seat Adjusters

Power Operated Horizontal

Oldsmobile and Cadillac

1. Seat Adjuster-to-Floor

Pan Attaching Bolts

2. Horizontal Drive

Cables

3. Adjuster Horizontal

Gear Nut and

Shoulder Screws

4. Adjuster Jack Screw

5 . Jack Screw Support

Pin

6. Electric Motor

7. Motor-to-Seat Frame

Anaching Screws

8. Horizontal Drive

Cable Straps

9. Seat

Frame-to-Adjuster

Ground Strap

10. Adjuster-to-Seat

Frame Attaching

Bolts

14-1 4 SEATS

NOTE: 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 o r 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 o r 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.

Operate seat control switch until other ad-

Fig. 14-10 Power Operated Horizontal Seat Adjusters

60-40

Drivers Seat

1. Adjuster Assembly

2. Adjuster-to-Floor Pan

Attaching Bolts

3. Adjuster-to-Floor Pan

Adjusting Nuts

4. Adjuster-to-Seat

Frame Attaching

Bolts

5. Adjuster Horizontal

Gear Nut and

Attaching Screw

6. Adjuster Jack Screw

7. Jack Screw Support

8. Electric Motor and

Support

9. Motor

Support-to-Seat

Frame Attaching

Screws

10. Seat

Frame-to-Adjuster

Ground Strap

.Fig. 14-11-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

Cable-Yellow

6. Horizontal Actuator

7. Horizontal Actuator

Drive Cable-Black

8. Rear Vertical

Actpator

9. Rear Vertical

Actuator Drive

Cable

(I nboardQreen,

Outboard-Blue)

10. Electric Motor

Assembly

11. Motor Control Relay

12. Transmission

Assembly

13. Motor and

Transmission

Support

Attaching Nuts

14. Carpet Retainers

15. Adjuster Track Upper

Rear Cover

16. Adjuster Track Lower

Cover

17. Rear Vertical Cable

Route When ca*er is Installed

18. Seat

Frame-to-Adjuster

Ground Strap

19. Inner Adjuster Floor

Pan Anchor Plate and Studs

SEATS

14-1 6

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. 14-12-Front Seat Adjusters

Power 6-Way 60-40

6. Horizontal Actuator

7. Horizontal Actuator

Drive Cable-Blue

8. Rear Vertical

Actuator

9. Rear Vertical

Actuator Drive

Cable

(Inboard-Green.

Ou tboard-Blue)

10. Electric Motor

Assembly

11. Motor Control Relay

12. Transmission

. Assembly

13. Motor and

Transmission

Support

Attaching Nuts

14. Carpet Retainers

15.

16.

17.

18.

Adjuster Track Upper

Rear Cover

Adjuster Track Lower

Cover

Seat

Frame-to-Adjuster

Ground Strap

Inner Adjuster Floor

Pan Anchor Plate and Studs

14-1

6

SEATS juster reaches the fully raised positibn 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 com- peated-on an "as requireim basis if aijusters 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

1. Operate seat to a midway horizontal position; on four-way and six-way seats also operate seat to fully raised Position.-

Fig. 14-13-Front Seat Adjusters

Power CWay

Conventional Full Width Seats

1. Seat Assembly

2. Seat Adjuster-to-Floor

Pan Bolts

3. Seat

Frame-to-Adjuster

Ground Strap

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

Cable-Black

9. Rear Vertical

Actuator

10. Rear Vertical Drive

CableConventlonal

Seat-Blue

Strato

Seat-Orange

11. 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

SEATS

14-1 7

4265

Fig. 14-14-Front Seat Adjusters

Power CWay

Buick "En

1. Seat Adjuster

Assembly

2. Seat Adjuster-to-Floor

Pan Bolts and Nuts

3. Seat Adjuster-teFloor

Pan Anchor Plate and Attaching Bolts

4. Seat Adjuster-teSeat

Frame Bolts

5. Front Vertical

Actuator

6. Front Vertical Drive

Cable-Yellow

7. Horizontal Actuator

8. Horizontal Drive

Cable-Black

9. Rear Vertical

Actuator

2. Remove front seat assembly with adjusters a: tached, as previously described, and place upside-down on a clean protected surface.

3. Detach power drive cables from gear nuts of adjuster to be removed (Figs. 14-8, 14-9 through

14- 15).

10. Rear Vertical Drive

Cablearange

11. Electric Motor

Assembly

12. Motor Control Relay

13. Transmission

Assembly

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

4. Remove adjuster-to-seat bottom frame front and rear attaching bolts and remove adjuster from seat assembly (Figs. 14-8, 14-9 through 14-1 5).

5. To install seat adjuster assembly, reverse removal procedure. On seats with adjuster upper

1. Motor and

Transmission

Support

2. Motor Control Relay

3. Adjuster-to-Floor Pan

Front Attachlng Bolt

4. Seat

Frame-to-Adjuster

Ground Strap

Fig. 14-15-Front Seat Adjuster

Power 4-Way

" A Body Full Width Seat

5. Adjuster-to-Floor Pan

Rear Attaching Nuts

6. Adjuster Rear Carpet

Retainer

7. Adjuster-to-Seat

Frame Attachlng

Bolt

8. Adjuster-to-Seat

Frame Spacers

(13857-67 Styles

Only1

9. Adjuster Track Rear

Lower Cover

10. Adjuster Track Upper

Cover

11. Four-Way Switch

Assembly

12. Motor and

Transmission

Support

Attaching Screws track covers, make sure track cover supports are installed between adjuster and seat frame. (Figs.

14-8, 14-9 through 14-15). 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").

13. Horizontal Drive

Cable-Black

14. Vertical Drive

Cable-Yellow

15. ,Transmission

Assembly

16. Coupling

17. Motor Assembly

NUMBER OR WITH AN EQUIVALENT

PART I F REPLACEMENT BECOMES

NECESSARY. DO NOT USE A REPLACE-

MENT PART OF LESSER QUALITY OR

SUBSTITUTE DESIGN. TORQUE VALUES

MUST BE USED AS SPECIFIED DURING

REASSEMBLY TO ASSURE PROPER RE-

TENTION OF THIS PART.

WARNING: THE SEAT ADJUSTER-TO-SEAT

FRAME ATTACHING BOLTS ARE IM-

PORTANT ATTACHING PARTS IN THAT

IT/THEY COULD AFFECT THE PER-

FORMANCE OF VITAL COMPONENTS

AND SYSTEMS. THEY MUST BE RE-

PLACED WITH ONE OF THE SAME PART

TWO-WAY SEAT ADJUSTER MAJOR

COMPONENTS-

"C"

Body Full Width Seat and

60-40 Drivers Seat

The following service procedures cover replacement

SEATS 14-19 of the major component parts of the power operated two-way seat adjusters used on seats or the drivers 60-40 seat.

"C" body full width

ELECTRIC MOTOR-' Power Two-Way Full

Width Seat and 60-40 Drivers Seat

Removal and Installation

1. 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. 14-10).

2. Disconnect both power drive cables from motor

(Fig. 14-9).

3. Disconnect feed wire harness from actuator motor.

4. Remove screws that secure actuator motor support bracket to seat bottom frame and remove actuator motor with attached support bracket from seat assembly (Figs. 14-9 and 14-10).

5. Remove screws securing motor to motor support bracket and remove motor assembly.

6. To install, reverse removal procedure. Check for proper seat operation to extreme limits of travel.

HORIZONTAL GEARNUT ASSEMBLY- Power

Two-Way Full Width Seat and 60-40 Drivers

Seat

Removal and lnstallation

1. Remove front seat assembly with adjusters attached and place upside-down on a clean, protected surface.

2. Detach power drive cable from gearnut to be removed.

3. Using a "clutch" type screwdriver or others suit-

. able tool, remove two shoulder bolts securing gearnut to upper slide portion of seat adjusters

(Figs. 14-9 and 14-10).

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 from rear end of jackscrew; then, remove gearnut from jackscrew.

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".

HORIZONTAL JACKSCREW- Power Two-Way

Full Width Seat and 60-40 Drivers Seat

Removal and lnstallation

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 sh~ulder bolts securing gearnut to upper slide portion of seat adjuster assembly (Figs. 14-9 and 14-10).

4. Remove retainer that secures stop bracket cros- spin to adjuster front pedestal and remove cros- spin (Figs. 14-9 and 14-10).

5. Remove jackscrew assembly from seat adjuster.

6. To install, reverse removal procedure.

NOTE: When replacing jackscrew 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 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 lnstallation

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 td upper channel to seat adjuster assembly (Figs. 14-9 and 14- 10).

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

14-20

SEATS.

now be disengaged from positioning slots on lower track.

4. To install, reverse removal procedure makirlli 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 lnstallation

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 bottom (see Fig. 14-15).

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 position.

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

VERTICAL G E A R N U T 1 r

JACKSCREW

JACKSCREW RIVET 7

I I l-

HORIZONTAL

ACTUATOR

/--L'

Fig. 14-16-Four-Way Seat Adjuster

"A" Styles tool, remove shoulder screws securing linkage tc vertical gearnut being replaced (Fig. 14-16).

5. If right adjuster gearnut is being replaced, at front of jackscrew, remove double nut that acts as a jackscrew "down" stop.

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 Assembly

Removal and In- stallation".

HORIZONTAL ACTUATOR- " A Body

Four-Way Full Width Seat

Removal and Installation

1. Remove adjuster vertical gearnut as previouslv described.

2. Discqnnect drive cable from horizontal actuator.

3. Remove screws securing horizontal actuator assembly to adjuster lower track; then remove actuator from adjuster assembly (Fig. 14-16).

4. 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. Readjust 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 under "Front Seat Assembly

Removal and In- stallation".

JACKSCREW- " A Body Four-Way Full Width

Seat

Removal and Installation

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.

14-1 5).

3. As a bench operation, remove jackscrew-to- adjuster linkage attaching rivet and remove jackscrew from adjuster assembly (Fig. 14- 16).

4. T o 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 Installation

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. 14-15).

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.

SEATS 1421

Check operation of seat to full limits of travel.

TRANSMISSION- " A Body Four-Way Full

Width Seat

Removal and Installation

1. Remove front seat assembly from body with attached adjusters, motor and transmission and place upside-down on a clean, protected surface.

2. Disconnect wire harness connector from transmission.

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 housings and remove component parts of transmission assembly (Fig. 14-17).

3. To assemble transmission, reverse removal procedure.

NOTE: 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.

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 E" body full width seats.

1422 SEATS

GEAR H O U S I N G DRIVING GEAR HARNESS SOLENOID

RUBBER COUPLER DOG SPRING

SOLENOIDS A N D SOLENOID

DOG SHAFT COVER PLATE HOUSING

1691

Fig. 14-17-Four-Way Seat Adjuster Transmission

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. 14-13 and 14-14).

3. Remove motor and transmission support-to-seat frame attaching bolts (Figs. 14-13 and 14-14).

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 E" Body

Six-Way Full Width Seats

Removal and Installation

1. Remove seat assembly from body, as previously desoribed and place upside-down on a clean, protected surface.

2. Detach three power drive cables from adjuster to be removed (Figs. 14- 13 and 14- 14).

3. Remove screws securing seat adjuster to seat bottom frame (Figs. 14-13 and 14-14) and remove adjuster from seat assembly.

4. At top of adjuster remove front and rear vertical gearnut attaching nuts and tension springs (Figs.

14- 19 and 14-20).

5. Lift front of adjuster upper channel upward; then remove screws securing horizontal actuator to adjuster upper channel assembly and remove actuator from adjuster (Figs. 14-19 and 14-20).

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. Readjust 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

SEATS 1423

APPLY PRESSURE S U F F I C I E N T

T O E Q U A L I S T O 26 ON

H O R I Z O N T

A C T U A T O R

. free play between gear teeth. While maintaining outward pressure against horizontal actuator, tighten actuator atttaching screws.

A T T A C H I N G S C R E W S n

I K~~~~~~~~

R E A R W A R D O F L O W E R TRACK A N D C H E C K (OBSERVE)

FOR HORIZONTAL CHUCK

Fig. 14-18-Horizontal Actuator Adjustment

"B and C"

Power Operated Six-way Seat Adjusters

(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 approximately 3/4 full forward position.

2. Loosen horizontal actuator attaching screws

(see Fig. 14-1 8). Using a large screw driver, inserted as shown in Figure 14-18 apply outward pressure on horizontal actuator (sufficient to equal 15 to 25 lbs. on horizontal actuator) and at the same time 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

GEARNUT ATTACHING NUTS li-

GEARNUT TENSION SPRINGS

UPPER CHANNEL 3

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.

5. At top of adjuster, remove both vertical gearnut attaching nuts and tension springs (Figs. 14-19 and 14-20).

6. Lay adjuster on its side and remove front vertical gearnut attaching screws; then, remove gearnut from adjuster (Fig. 14-20).

NOTE: If seat was not in forward 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-

20).

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".

REAR VERTICAL

GEARNUT

HORIZONTAL

ACTUATOR

FRONT VERTICAL

GEARNUT

Fig. 14-19-Six-Way Seat Adjuster

"B, C and E n

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.

1424 SEATS

Fig. 14-20-Six-Way Seat Adjuster Components - "B, C and

1. Upper Channel

Assembly

2. Upper Channel to

Gearnut Attaching

Bolts

3. Gearnut Tension

Springs

4. Gearnut Shoulder

Nuts

5. Rear Vertical Gearnut and Attaching

Screws

6 . Horizontal Actuator and Attaching

Screws

7. Front Vertical

Gearnut and

Attaching Screws

8. Plastic Shoes

9. Lower Channel

3. Remove screws securing seat adjuster to seat bottom frame and remove adjuster from seat assembly.

4. At top of adjuster, remove both vertical gearnut attaching nuts and tension springs (Figs. 14-19 and 14-20). Lift front of adjuster upper channel upward; then, remove horizontal actuator attaching screws and remove horizontal actuator from adjuster (Fig. 14-20).

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 plastic 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 E Body Six-Way Full

Width Seats

Removal and Installation

1. Remove front seat assembly from body with attached adjusters, motor and transmission and place upside-down on a clean, protected surface.

2. 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; then, disengage cables from end plate.

4. To install horizontal and vertical cables, reverse removal procedure. Install colored drive cables as shown in Figure 14-1 3 for conventional and strato full width seats (except Buick "E" strato seat) and Figure 14- 14 for Buick width strato seat.

"E" body full

TRANSMISSION- "B, C and E Body Six-Way

Full Width Seats

Removal and Installation

1. Remove front seat assembly from body with attached adjusters, motor and transmission and place upside-down on a clean, protected surface.

2. Disconnect wire harness connector from transmission.

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;

SEATS

1426

SOLENOID HOUSING ka a s

HARNESS

CONNECTOR

.-cIIIIcI. e _

DRIVING GEAR

THRUST WASHER

GEAR HOUSING

RUBBER

COUPLING

4276

Fig. 14-21-Six-Way Seat Adjuster Transmission

"B and C" Full Width Seat then, disengage transmission from motor drive coupling and remove transmission from seat assembly (Figs. 14-13 and 14-14).

5. T o install, reverse removal procedure. "Hori- zontal and Vertical Drive Cables" or as shown

- 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 housings and remove component parts of transmission assembly (Fig. 14-2 1).

3. T o assemble transmission, reverse removal procedure.

NOTE:

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,

1426 SEATS

disengage motor from drive coupling and remove motor. If seat is inoperative in "down" position remove motor from under rear of seat.

4. To install, reverse removal procedure. Check operation of seat assembly to limits of horizontal and vertical travel.

SIX-WAY SEAT ADJUSTER REAR VERTICAL

DRIVE CABLE- 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 rear vertical cable from rear vertical gearnut at rear of adjuster.

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. 14-22).

4. To install rear vertical cable@), reverse removal procedure. Check operation of seat assembly to limits of horizontal and vertical travel.

SIX-WAY SEAT ADJUSTER ASSEMBLY AND

HORIZONTAL OR FRONT VERTICAL DRIVE

CABLES- Pontiac, Buick, Oldsmobile and

Cadillac 60-40 Seats

Removal and Installation

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 drive cables from adjuster being removed.

3. At adjuster being removed, remove nut securing motor and transmission support at front of adjuster (Figs. 14-11 Item " 13", and 14-12 Item

Fig. 14-22-Six-Way Seat Adjuster Motor, Transmission, Cable and Support -, Disassembled

Pontiac, Buick, Oldsmobile and

Cadillac 60-40 Seats

Electric Motor

Motor-to-Transmission

Coupling

Transmission

Assembly

4. Transmission End

Plate and Anaching

Screws

5. Front Vertical Drive

Cable

Yellow

6. Rear Vertical Drive

Cable

Inboard -

Green; Outboard

Blue

7. Horizontal Drive

Cable

Black

8. Motor Relay and

Anaching Screw

9. Motor and

Transmission Support

10. Transmission

Attaching Screws

SEATS 14-27

" 13"). Remove seat adjuster to seat frame front and rear attaching bolts; then, remove adjuster from seat assembly.

4. To remove horizontal and/or front vertical ca- cable(s) is being removed. Remove transmission end plate attaching screws (Fig. 14-22); 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(s) 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.

14-22).

3. Disengage and remove motor and transmissih support from adjuster. As a bench operation, remove screws securing transmiss~on 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 14-22. 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.

2. Remove screws securing solenoid housing to gear housing; then, carefully separate housings and remove component parts of transmission assembly (Fig. 14-23).

3. T o assembly transmission, reverse removal procedure..

NOTE: 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 I

"B" and "C" Body Four-Door Styles with

Conventional Full Width Seat

Removal and Installation

1. Remove front seat assembly from body and place it upside- down on a clean, protected surface. Remove seat side panels; where present. On seats where seat back panel covers seat back frame attaching bolts, detach or remove seat back panel.

2. Remove hog rings securing lower edge of seat back trim to seat cushion springs (see Fig. 14-

24).

3. Raise lower edge of seat back trim, detach fiber- board breakover foundation and bend out tabs on seat back frame securing seat cushion springs. Disengage springs from tabs (Fig. 14-

24).

4. At each end of seat, remove hog rings securing lower edge of seat back trim to seat bottom frame. Raise or turn back seat back trim to expose bolts,securing seat back frame to seat cushion frame (Fig. 14-24). Where seat back lighter or couhesy 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.

14-28 SEATS

GEaR HOUSING

D P G SPRING

SOLENOIDS AND

COVER PLATE

SOLENOID

HOUSING t

DRIVING GEAR

THRUST WASHERS

HARNESS CONNECTOR

Fig. 14-23-Six-Way Seat Adjuster Transmission

Disassembled

Pontiac, Buick, Oldsmobile and Cadillac 60-40 Seats rg d

FRONT SEAT BACK PANEL COURTESY

LAMPS AND/OR LAMP SWITCH- Oldsmobile

Luxury Sedan

Removal and lnstallation

1. Remove exposed screws securing courtesy lamp or lamp switch to panel; then, disengage lamp or switch from panel.

2. Disconnect lamp or switch wires (see Fig. 14-25) and remove lamp or switch.

3. To install front seat back courtesy lamp and/or switch, reverse removal procedure.

SEAT BACK

ATTACHING BOLTS

VlEW "A"

VlEW "0"

4271

Fig. 14-24-Front Seat Back Attachment

Attachment

Typical Four Door

Styles with Full Width Conventional Seat

FRONT SEAT BACK ASSIST STRAPS, BACK

PANEL ASSEMBLY AND CLOCK ASSEMBLY- flldsmobile Luxury Sedan

Removal and Installation

1. At the center and outer ends of the assist straps, carefully pry (snap) off assist strap escutcheons

(Fig. 14-26, Views "Aw and

"B").

SEATS 1429

OF ARROW "0"

Fig. 14-25-Front Seat Back Clock, Courtesy Lamps and Lamp Switch

Oldsmobile Luxury Sedan

4730

2. Remove assist strap and panel attaching screws

(Fig. 14-26) and remove assist straps. At bottom center of panel remove two panel attaching screws (Fig. 14-26). Lift panel assembly upward to disengage from hanger brackets; then, disconnect clock and courtesy lamp wire harness connector (see Fig. 14-25) and remove panel assembly from seat back.

3. To remove clock assembly, remove screws from front side of panel securing clock (see Fig. 14-25) and remove clock assembly from panel.

4. To install clock assembly, panel assembly or assist straps, 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 installation

1. Remove front seat assembly from body and

, place upside-down on a clean, 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. 14-27 or 14-28).

2 3

TRIM PANEL

TRIM FINISHING

M O L D I N G

TRIM PANEL LOWER

ATTACHING SCREWS

ASSIST STRAPS

ASSIST STRAP

ESCUTCHEONS

(SNAP

O N )

ASSIST S ~ R A P

PANEL ATTACHING SCREWS

Fig. 14-26-Front Seat Back Assist Straps and Panel Assembly

Oldsmobile Luxury Sedan b. Remove seat side panel where present or outer hinge arm cover (Fig. 14-27 or 14-28); then, using a flat-bladed tool carefully remove retainer securing seat back outer arm to hinge pin (Fig.

14-27 or 14-28).

4. On notch back seats detach trim sufficiently to expose seat back attaching bolt access holes (Fig.

14-27); then, through access holes remove 'seat back lock-up screws (Fig. 14-27). On 60- 40 seats detach trim at outer hinge arm sufficiently to remove outer hinge arm lock-up screw (Fig. 14-

28).

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. 14-27 or 14-

28).

6. To install seat back assembly, reverse removal procedure. If seat back outer arm retainer is

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

Removal and installation

1. On seat with seat cushion side panel, remove side panel and detach seat cushion trim sum-

SEATS 1431

INNER HINGE PIN

VIEW "8"

SEAT BACK

4270

Fig. 14-27-Front Seat Back Attachment (Right or Left)

Four-Door Style Notch Back Seat and 60-40 Seats ciently to expose outer hinge pin and retainer

(Fig. 14-29 or 14-30).

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 o r detach fastener securing cover and remove cover (Fig. 14-29 or

14-30).

2. Using a flat-bladed tool carefully remove retainer, securing seat back outer arm to hinge pin

(Fig. 14-29 or 14-30).

3. Carefully disengage seat back outer arm from hinge pin; then, tilt seat back forward and up-

' ward 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.

NOTE: On seats equipped with electric seat back locks, lay seat back on seat cushion and carefully disengage lap belt webbing plastic protector (see

Fig. 14-29 or 14-31) 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. 14-31); then, carefully pull feed wire up through seat cushion and remove seat back from body.

4. T o install seat back assembly, reverse removal

1432 SEATS

/a-

LOCK-UP BAR

VlEW "A"

VlEW "D"

INNER HINGE

PIN COVER

VlEW "B"

OUTER ARM

RETAINER

VIEW "A" VIEW "C"

Fig. 14-%Front Seat Back Attachment (Right or Left)

Four-Door Style 60-40 Seat

4274

SEATS 1433 procedure making sure washers are installed over hinge pins prior to installing seat back. If outer retainer is damaged, install new retainer.

WARNING: CHECK OPERATION O F SEAT

BACK LOCKS. ON SEATS EQUIPPED

WITH MANUALLY OPERATED LOCKS

THE SEAT BACK SHOULD LOCK WITH

NO MORE THAN 10 LBS. REARWARD EF-

FORT APPLIED AT THE TOP OUTBOARD

CORNER O F THE SEAT BACK. ON SEATS

EQUIPPED WITH ELECTRIC SEAT BACK

LOCKS BOTH SEAT BACK LOCKS

SHOULD LOCK IN THE UPRIGHT POSI-

TION WHEN THE DOORS ARE CLOSED.

I F EITHER SEAT BACK DOES NOT LOCK

REFER TO "ELECTRIC SEAT BACK

LOCK".

C U S H I O N TRlM

SIDE F A C I N G

USWfOM SlDE

:OVE'

SEATS W I T H C U S H I O N SIDE PANELS

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

Description

All two-door styles are equipped with either manually operated front seat back locks or optional (on

"A, B, C and E" styles) electrically operated seat back locks. The manually operated seat back locks on "F, A and X" body styles are operated by a control lever at the lower rear outboard comer of the rated lock is operated by a control handle on the upper outboard side of the seat back. The electrically operated seat back locks are operated by an electrical

TRlM WASHER

SEATS WITHOUT C U S H I O N SlDE PANELS 3235

Fig. 14-29-Seat Back Attachment

Two-Door Style

Conventional Seat solenoid attached to the seat back lock frame. When either front door is opened, a jamb switch at the front body hinge pillar energizes the solenoid at both seat back locks which unlocks both seat backs. When both doors are closed, the solenoids are de-energized and return springs in the solenoid return the lock to a locked position.

ELECTRIC SEAT BACK LOCK TROUBLE DIAGNOSIS CHART

TWO-DOOR STYLE CONVENTIONAL SEATS

CONDITION

1. Seat back lock does not lock when doors are closed.

APPARENT CAUSE

1. Current at actuator solenoid does not cut off - jamb switch remains open.

2. Seat back relay contacts sticking.

CORRECTION

1. Refer to Electrical

Checking Procedure - where required, install new jamb switch.

2. Refer to Electrical

Checking Procedure - where required, install