14 1963 CH-Body

SECTION 14
BODY AND SHEET METAL

CONTENTS OF THIS SECTION
Body 14-1
Sheet Metal 14-88
1963 BODY
INDEX
Page Page
General Description 14- 1 Rear Compartment 14-49
Service Operations 14- 2 Tail Gate 14-54
Cleaning Soft Trim 14- 2 Front Seats 14-61
Front End 14- 6 Front Seat Assembly Six-Way 14-61
Windshield Assembly 14- 6 Bucket Type Front Seats 14-61
Body Ventilating System 14- 6 Headlining Assembly 14-63
Instrument Panel Assembly 14- 7 Roof Panel Fabric Cover 14-67
Front and Rear Doors 14- 8 Folding Top 14-70
Front Doors 14-11 Folding Top Adjustment 14-70
Rear Doors 14-22 Service Diagnosis 14-74
Side Roof Rail Weatherstrip 14-33 Folding Top Trim Assembly 14-76
Rear Quarter 14-35 Hydro-lectric System 14-76
Trim and Hardware 14-35 Exterior Moldings 14-78
Rear End 14-47 Special Tools 14-87
Back Window Assembly 14-47
GENERAL DESCRIPTION
Throughout this section, the various body styles will SERIES NUMBER DESCRIPTION
be referred to by number. The following chart lists Biscayne Bel Air Impala
these numbers and relates them to body descriptions. 1100 1200 1500 1600 1700 1800
6 Cyl 8 Cyl 6 Cyl 8 Cyl 6 Cyl 8 Cyl
If service information refers only to one particular
1111 1211 1511 1611 2 Dr. Sedan-
body style, or group of body styles, it will be so stated 6 Pass.
in the headings large size type preceding each serv 4 Dr. Sedan-
1169 1269 1569 1669 1769 1869 6 Pass.
ice outline. Service procedures not covered herein may
be performed as outlined in the 1961 Shop Manual. 1739 1839 4 Dr. Sport Sedan-
6 Pass.
1747* 1847* Sport Coupe-
5 Pass.
1767* 1867* Convertible-
5 Pass.
1135 1235 1535 1635 1735 1835 4 Dr. Sta. Wagon-

6 Pass.
1545 1645 1745 1845 4 Dr. Sta. Wagon-
9 Pass.
*Also available in Super Sport models.
PASSENGER CAR SHOP MANUAL SUPPLEMENT

BODY 14-2
FIg. 1-1963 Impala
Fig. 2-1963 Impala Station Wagon
SERVICE OPERATIONS
CLEANING SOFT TRIM
There are four general types of trim materials used 3. Coated fabrics vinyl or mylar.
in automotive bodies: 4. Polyurethane foam.
1. Fabrics that may be either plain fabrics broad
cloth, gabardine, etc. or pattern fabrics which Dust and dirt particles that accumulate on the up
are manufactured with natural or snythetic nylon holstery of a car should be removed every few weeks,
orion, rayon, viscose, etc. fabrics. or oftener if the car is given constant hard use. This is
2. Genuine leather. done with a whisk broom or vacuum cleaner.
BODY 14-3
CAUTION: Do not use a whisk broom on fabrics 6. If a ring should form on the fabric when removing
having raised tapestry patterns since damage a stain, the entire area of the trim assembly should
to the fine threads may result. On polyurethane be cleaned as described in the preceding steps.
foam material use only a soft bristle brush-do 7. The cleaned upholstery should be allowed to dry
not use a whisk broom or vacuum cleaner. completely before using.
Before attempting to remove spots or stains from Some volatile cleaners are toxic and harmful; there
upholstery fabrics, determine as accurately as pos fore, the following safety precautions should be used:
sible: 1. Always use in a well ventilated area. Car windows
1. Nature and age of the spot or stain. and garage doors must be open when such cleaners
2. The effect of stain removing agents on the color are used.
structure and general appearance of the fabric. 2. Avoid prolonged or repeated breathing of vapors
For best results, stains should be removed from from cleaner.
upholstery as soon as possible after they have been 3. Avoid prolonged or repeated contact with the skin.
made. If they are allowed to stand for some time, they 4. Keep away from eyes and mouth.
often become set, and removal becomes more difficult
-frequently, impossible. 5. Some cleaners are flammable, and every precau
There are three basic types of acceptable cleaners tion and care must be exercised in handling these
available: cleaners.
1. Volatile cleaners colorless liquids
2. Synthetic detergents. PROCEDURE FOR CLEANING FABRICS WITH
SYNTHETIC DETERGENTS
3. Neutral soap nonalkaline
1. Make a solution of the synthetic detergent in luke
The volatile cleaners are recommended since they
warm water, working up a thick, frothy suds.
have great solvent powers for grease, oils and general
road grime. Synthetic detergents generally loosen up 2. With a clean cloth or sponge, dampened with luke
stains satisfactorily; however, the use of improper type warm water, apply suds only to the surface of the
detergents involves risk of damage to the color or fin upholstery using light to medium pressure, repeat
ish of fabrics. ing several times, applying more suds with a clean
portion of the cloth or sponge.
PROCEDURE FOR CLEANING FABRICS WITH 3. With a second clean cloth, dampened with luke
VOLATILE CLEANERS warm water, rub over the area with medium pres
sure to remove excess detergent and loose mate
Care should be taken not to use too much solvent rial.
and to apply it only with clean cloths. It is the solvent
that does the work-so only a minimum of pressure 4. With a clean dry cloth, wipe off all excess mois
should be applied. ture. A vacuum cleaner may also be used.
1. Brush away all loose particles of dirt and soil. 5. Allow the upholstery to dry partially; then repeat
2. Dampen a clean cloth cheese cloth may be used the above treatment if necessary to remove stain.
with the volatile cleaner. Open the cloth and allow 6. When the upholstery is satisfactorily cleaned, al
a portion of the cleaner to evaporate so that the low to dry completely before using.
cloth is just slightly damp.
3. Using very light pressure and circular lifting PRECAUTIONS FOR CLEANING FABRICS
motion, rub the stained area, starting at the outer
edge and working toward the center until the en 1. Solutions containing water are not recommended
tire area has been covered. Change to a clean por for general cleaning of broadcloths. Water has
tion of the cloth every few strokes. great destructive powers on the high face or high
gloss finish of broadcloths, causing the nap to curl
4. Before proceeding, wait several minutes to allow and roughen to such an extent that the finish is
most of the volatile cleaner to evaporate. This will destroyed or made very unsightly. However, in
avoid the danger of the cleaner penetrating to the some cases where it is necessary to use a solution
padding under the upholstery. Certain cleaners containing water to remove a stain, the resultant
will deteriorate sponge rubber which is often used disturbance to the finish of material may be pref
as padding. erable to the stain.
5. It may be necessary to repeat Steps No. 2, 3, and
4 several times before the stain has been satisfac 2. Do not use as a cleaning solvent any gasoline
which is colored or which contains tetraethyl lead.
torily removed. Each time a clean cloth should be
used. 3. Do not use solvents such as acetone, lacquer thin-

BODY 14-4
ners, enamel reducers and nail polish remover, as PROCEDURE FOR CLEANING VICODEC
a cleaning solvent. FOLDING TOP MATERIAL
4. Do not use laundry soaps, bleaches or reducing The top should be washed frequently with neutral
agents, such as the following: chloride of lime, soap suds, lukewarm water and a brush with soft
javelle water, hydrogen peroxide, sodium hydro bristles. Rinse top with sufficient quantities of clear
sulphite, potassium permanganate, chlorine or water to remove all traces of soap.
chlorine water, sulphurous acid sulphur dioxide, If the top requires additional cleaning after using
sodium thiosulphate Photographers’ hypo. The soap and water, a mild foaming cleanser can be used.
use of these agents tends to weaken fabric and to Rinse the whole top with water; then apply a mild
change its color. foaming type cleanser on an area of approximately two
5. Do not use too much cleaning fluid; some interior square feet. Scrub area with a small soft bristle hand
trim assemblies are padded with rubber, and vola brush, adding water as necessary until the cleanser
tile cleaners are generally solvents for rubber. The foams to a soapy consistency. Remove the first accu
application of too much cleaner may destroy these mulated soilage with a cloth or sponge before it can be
rubber pads. ground into the top material. Apply additional cleanser
to the area and scrub until the top is clean. Care must
be exercised to keep the cleanser from running onto
PROCEDURE FOR CLEANING GENUINE body finish as it may cause streaks if allowed to run
LEATHER AND COATED FABRICS down and dry. After the entire top has been cleaned,
rinse the top generously with clear water to remove
Care of genuine leather and coated fabrics includes all traces of cleanser. If desired, the top can be sup
vinyl coated formed headlining is a relatively simple ported from the underside during the scrubbing oper
but important matter. The surface should be wiped ations.
occasionally with a dry cloth, and whenever dirt accu After cleaning always be sure the top is thoroughly
mulates, the following cleaning instructions should be dry before it is lowered. Lowering the top while it
used: is still wet or damp may cause mildew and unsightly
1. Lukewarm water and a neutral soap should be wrinkles.
used. Apply a thick suds, worked up on a piece of Do not use volatile cleaners or household bleaching
gauze or cheesecloth, to the surface. agents on the top material.
2. The operation should be repeated, using only a

damp cloth and no soap. PROCEDURE FOR CLEANING
FLOOR CARPETS
3. The surface should then be wiped dry with a soft
cloth. Thoroughly brush or vacuum the floor carpet. In
many instances the floor carpet may require no further
Polishes and cleaners used for auto body finishes, cleaning. If carpet is extremely soiled remove carpet
volatile cleaners, furniture polishes, oils, varnishes from car and thoroughly vacuum to remove loose dirt;
or household cleansing and bleaching agents should then with a foaming type upholstery cleaner, clean
never be used. approximately one 1 square foot of carpet at a time.
After each area is cleaned, remove as much of the
cleaner as possible with a vacuum cleaner. After clean
PROCEDURE FOR CLEANING POLYURETHANE ing the carpet use an air hose to "fluff" the carpet pile,
FOAM MATERIAL then dry the carpet. After the carpet is completely
Normal soilage such as dirt and finger prints can be dried, use an air hose to again fluff the carpet pile.
removed with a cleaning solution of approximately two
NOTE: If the carpet is not extremely soiled, the
2 ounces of white detergent powder mixed in a gal
carpet may be cleaned in the car by applying a
lon of water. Immerse a clean cellulose sponge in
sparing amount of foaming type upholstery
cleaning solution. Wring the sponge out thoroughly
cleaner with a brush.
leaving suds only; then clean soiled area carefully.
Rinse off the cleaned area with sponge and clean water If oil or grease spots are still present on the carpet
-DO NOT soak the cleaned area. they may be removed by using a volatile cleaner.
Soilage such as cements, sealers, and grease can be
removed by first cleaning the soiled area with a deter
gent solution as described above-DO NOT RINSE. INSTRUCTIONS FOR THE REMOVAL OF
Leaving suds on the soiled area, clean area with a SPECIFIC STAINS FROM AUTOMOTIVE
clean cloth that has been dipped in a good volatile UPHOLSTERY MATERIALS
upholstery cleaner and thoroughly wrung out. Then
clean soiled area with detergent suds and rinse as Some types of stains and soilage, including blood,
described above. ink, chewing gum, etc., require special consideration

BODY 14-5
for most satisfactory results. For these, and other lukewarm water. After the spot is dry, rub it lightly
stains, specific instructions are outlined in succeeding with a cloth dipped in a volatile cleaner.
paragraphs. It must be expected, particularly where
water treatment is specified, that discoloration and Chewing Gum
finish disturbance may occur. In some cases fabric dis
turbance may be considered preferable to the stain Harden the gum with an ice cube, and scrape off
itself. By following the procedures outlined with nor particles with a dull knife. If gum cannot be removed
mal care and caution, reasonably satisfactory results completely by this method, moisten it with a volatile
can be expected. cleaner and work it from the fabric with a dull knife,
while gum is still moist.
Battery Acids
Fruit, Fruit Stains, Liquor and Wine
Apply ordinary household ammonia water with a
brush or cloth to the affected area, saturating it thor Practically all fruit stains can be removed by treat
oughly. Permit the ammonia water to remain on the ment with very hot water. Wet the stain well by apply
spot about a minute, so that it will have ample time to ing hot water to the spot with a clean cloth. Scrape all
neutralize the acid. Then rinse the spot by rubbing excess pulp, if present, off the fabric with a dull knife;
with a clean cloth saturated with cold water. then rub vigorously with a cloth wet with very hot
This treatment will suffice for both old and new water. If the stain is very old or deep, it may be neces
stains. However, no type of treatment will repair dam sary to pour very hot water directly on the spot, fol
age to fibers resulting from the action of the acids on lowing this treatment with the scraping and rubbing.
the fibers-particularly after the spot has dried. Direct application of hot water to fabrics is not recom
mended for general use since discoloration usually
results.
Blood If the above treatments do not remove stain, allow
Do not use hot water or soap and water on blood fabric to dry thoroughly; then rub lightly with a clean
stains since they will set the stain, thereby making its cloth dipped in a volatile cleaner. This is the only
removal practically impossible. further treatment recommended.
Rub the stain with a clean cloth saturated with cold Soap and water are not recommended since they will
water until no more of the stain will come out. Care probably set the -stain and cause a permanent discolor
must be taken so that clean portions of cloth are used ation. Drying the fabric by means of heat such as the
for rubbing the stain. use of an iron is not recommended.
This treatment should remove all of the stain. If it
does not, apply a small amount of household ammonia Grease and Oil
water to the stain with a cloth or brush. After a lapse
If grease has been spilled on the material, as much
of about one minute, continue to rub the stain with a
as possible should be removed by scraping with a dull
clean cloth dipped in clear water.
knife or spatula before further treatment is attempted.
If the stain remains after the use of water and am
Grease and oil stains may be removed by rubbing
monia, a thick paste of corn starch and cold water may
lightly with a clean cloth saturated with a volatile
be applied to the stained area. Allow the paste to re
cleaner. Be sure all motions are toward the center of
main until it has dried and absorbed the stain. Then
the stained area to decrease the possibility of spreading
pick off the dry starch. Brush the surface to remove
starch particles that remain. For bad stains, several the stain.
applications of starch paste may be necessary.
Ice Cream
Candy The same procedure is recommended for the re
moval of ice cream stains as that used in removing
Candy stains, other than candy containing choco fruit stains.
late, can be removed by rubbing the affected area with If the stain is persistent, rubbing the spot with a
a cloth soaked with very hot water. If the stain is not cloth wet with warm soap suds mild neutral soap
completely removed, rub area lightly after drying may be used to some advantage after the initial treat
with a cloth wet with a volatile cleaner. This will usu ment with hot water. This soap treament should be
ally remove the stain. followed with a rinsing, by rubbing with a clean cloth
Candy stains resulting from cream and fruit-ifiled wet with cold water. After this dries, rubbing lightly
chocolates can be removed more easily by rubbing with a cloth wet with volatile cleaner will clear up
with a cloth soaked in lukewarm soap-suds mild neu the last of the stain, by removing fatty or oily matter:
tral soap and scraping, while wet, with a dull knife.
This treatment is followed with a rinsing by rubbing
the spot with a cloth dipped in cold water. Nausea
Stains resulting from chocolate or milk chocolate can Sponge with a clean cloth, dipped in clear cold water.
be removed by rubbing the stain with a cloth wet with After most of the stain has been removed in this way,

BODY 14-6
wash lightly with soap mild neutral, using a clean then remove as much of the tar as possible with a dull
cloth and lukewarm water. Then rub with another knife. Follow this operation by rubbing the spot lightly
clean cloth dipped in cold water. If any of the stain with a cloth wet with the cleaner until the stain is
remains after this treatment, gently rub clean with a removed.
cloth moistened with a volatile cleaner.
Urine
Shoe Polish and Dressings Sponge the stain with a clean cloth saturated with
On types of shoe dressings which contain starch or lukewarm soap suds mild neutral soap and then
dextrine or some water soluble vehicle, allow the pol rinse well by rubbing the stain with a clean cloth
ish to dry; then brush the spot vigorously with a brush. dipped in cold water. Then saturate a clean cloth with
This will probably be all the treatment that is neces a solution of one part household ammonia water and
sary. If further treatment is required moisten the spot five parts water. Apply the cloth to the stain and allow
with cold water and after it has dried, repeat the brush solution to remain on affected area for one minute;
ing operation. then rinse by rubbing with a clean wet cloth.
Paste or wax type shoe polishes may require using
a volatile cleaner. Rub the stain gently with a cloth lipstick
wet with a volatile cleaner until the polish is removed.
Use a clean portion of the cloth for each rubbing oper The compositions of different brands of lipstick
ation and rub the stained area from outside to center. vary, making the stains very difficult to remove. In
some instances a volatile cleaner may remove the
stain. If some stain remains after repeated applications
Tar of the volatile cleaner, it is best to leave it rather than
Moisten the spot slightly with a volatile cleaner, and try other measures.
FRONT END
WINDSHIELD ASSEMBLY
BODY VENTILATING SYSTEM
1961 service information is applicable to 1963 vehi
cles. Note, however, that the windshield garnish mold
ing removal and installation procedure differs from
1961.
The windshield checking blocks J-8372 have been
replaced by the new J-8942 blocks which are designed
to fit over the new, deeper pinchweld flange. The new
blocks may also be used in place of the older style on
earlier vehicles.
Windshield Garnish Moldings

The windshield garnish moldings consist of an upper
right and left, side right and left. All moldings are
secured by screws except the lower garnish molding
which is a one-piece molding and is attached by clips.
Removal and Installation Fig. 3-Garnish Moldings

1. Place protective covering over front seat and in
strument panel.
2. Remove moldings in following order: side, lower
and upper moldings.
The lower garnish molding is attached by clips.
Remove side moldings and, with a suitable tool
inserted in hole at the left end of the molding,
slide the molding toward the left until the retain
ing tabs are disengaged from the clips fig. 5 and
remove the molding. Fig. 4-Garnish Moldings

BODY 14-7
same as covered in the 1961 Passenger Car Shop Man

ual. Figures 6 through 8 will provide sufficient infor
Fig. 7-Instrument Panel Trim Moldings
Fig. 5-Lower Garnish Molding Removal
On "67" styles remove the side garnish molding

attaching screws. Raise top, remove screw attach
ing side reveal to windshield header, pry up corner
of side reveal molding overlapping windshield
header and remove side garnish molding. Remove
sunshade supports prior to removing upper garnish
moldings.
3. To install the lower molding, mark the location of
molding clips that are attached to the instrument
panel on the outside of the windshield. Place mold
ing along front edge of the instrument panel, align
ing retaining tabs on molding, press molding down
into place until retaining tabs engage with clips.
Instrument Panel Assembly

Instrument panel trim procedures are basically the Fig. 8-Instrument Console and Ash Tray
ATTACH 10 PLACES
MARKED X
flEW B
Fig. 6-instrument Panel Compartment Fig. 9-Instrument Panel Cover

BODY 14-8
mation to perform any necessary service on the instru Removal and Installation
ment panel. 1. Remove side and lower garnish moldings.
The instrument panel cover attachment differs from
that covered in the 1961 manual and will be covered 2. Loosen or remove any necessary instrument
here. items, glove box, etc.
3. From underside of instrument panel remove the
ten 10 attaching stud nuts and carefully remove
Instrument Panel Cover the cover assembly.
The instrument panel cover is secured to the instru 4. To install, reverse the removal procedure making
ment panel by studs and nuts fig. 9. certain cover is properly aligned before securing
The studs are an integral part of the cover assembly. in place.
DOORS AND CENTER PILLAR

Service operations for doors are covered in the fol
lowing sections:
A. Service operations which are the same or similar for
DOOR WINDOW
both front and rear doors.
INNER STRIP
ASSEMBLY OUTER STRIP
B. Service operations for front doors only. ASSEMBLY
C. Service operations for rear doors only. DOOR OUTER
ATTACHING PANEL
0. Service operations for side roof rail weatherstrips CLIP
except convertible styles.
DOOR INNER ATTACHING

FRONT AND REAR DOORS PANEL CLIP
Front and Rear Door Window Glass Run

Channel Inner and Outer Strip Assemblies
Glass run channel strip assemblies are used on all
doors on all styles incorporating a dropping window Fig. 10-Front and Rear Glass Run Channel Inner and Outer Strip Assembly
and are designed to prevent cold air and water from
entering the body between the door window lower Removal and Installation
sash channel and door inner and outer panels. The
inner strip assembly is constructed of a pile fabric 1. Lower door window and apply masking tape over
material with a metal backing and is secured to top of door outer panel adjacent to outer strip assembly
door trim pad by a series of staples. The inner strip to protect paint finish.
is not normally removed separately for service proce
2. Check outer strip assembly for location of attach
dures. The outer strip assembly is constructed of a
ing screws. This location varies with style and
molded rubber and is secured to a metal retainer by a
size of door, however; on most styles, the front
series of staples. On styles equipped with a door win door ventilator will have to be removed to gain
dow belt reveal molding, the metal retainer is an inte
access to forward attaching screw. If necessary,
gral part of this molding which is attached to the door
remove the front door ventilator assembly as
outer panel by three screws. On styles not equipped
described in the "Front Door" section of the body
with a molding the outer strip assembly is attached to
service manual.
the door outer panel by a series of attaching clips and
is further retained by two attaching screws. 3. On some styles it may be necessary to remove the
On all styles, the inner strip assembly remains in a door window lower stop or stop bumper and lower
stationary position during operation of door glass. On door window as far down as possible to gain access
the outer strip assembly, however, the inboard section to the outer strip assembly attaching screws.
of the sealing lip is lifted and held in position by the
door window lower sash channel or filler when door 4. Remove all outer strip assembly attaching screws
glass is raised. The outer strip assembly has been in three screws on styles equipped with a belt re
creased in length and thickness for the 1963 model and veal molding and two screws on all other styles.
is an effective weatherseal with glass in the fully closed See Figure 11 for styles with a belt reveal molding
position fig. 10. and Figure 12 for all other styles.
___________________ ________
BODY 14-9
bly in a downward motion to disengage attaching

clips from door outer panel return flange and re
ATTACHING
SCREWS move strip assembly from door outer panel.
.7. To install, reverse removal procedure.
Front and Rear Door Inside Handles

Removal and Installation
MOLDING a. On styles equipped with door inside remote control

"paddle" handles, proceed as follows:
1. Remove door arm rest as described under "Front
and Rear Door Arm Rests."
2. Remove handle-to-remote attaching bolt and re
move handle from door.
3. To install, reverse removal procedure.
b. On styles not equipped with "paddle" handles and
ft
SECTION A-A SECTION B-B
for removal of manually operated door ventilator
and window inside handles, proceed as follows:
1. Depress door trim assembly at handle sufficient
ly to install tool J-7797 between handle and
bearing plate.
Fig. 11-Door Window Glass Run Channel Outer Strip Assemblies 2. Push handle retaining spring out of engagement
With Belt Reveal Molding and remove handle and bearing plate from door.
3. To install, position retaining spring on handle
5. On styles equipped with a belt reveal molding, the
and bearing plate over regulator spindle. Posi
outer strip assembly and molding can now be
tion handle on spindle at same angle as handle
removed.
on opposite door and push handle until spring is
6. On all other styles, firmly press outer strip assem engaged fig. 13.
NOTE: Handles are installed in a horizontal
OUTER STRIP..... ATTACHING CLIP position with open end forward when glass
is in a full up position.
Front and Rear Door Arm Rest Assemblies

SECTION B-B SECTION A-A Removal and Installation
1. Remove screws securing arm rest to door inner
panel and remove assembly from door fig. 14.
2. To install, reverse removal procedure. It may be
C
necessary to seal arm rest attaching screw holes in
door inner panel with body caulking compound
prior to installation.
RETAINING SPRING
DISENGAGED
INSIDE HANDLE PUSH TOOL IN
DIRECTION OF
ARROW.
SCREW
,,,-- ‘P1- H
TOOL J-7797
SECTION C-C
Fig. 12-Door Window Glass Run Channel Outer Strip Assemblies

Without Belt Reveal Molding Fig. 13-Disengaging Handle Retaining Spring

BODY 14-10
4. Place tool J-6335, or other suitable flat-bladed tool,

between water deflector and door trim assembly
at lower edge of trim assembly. Working upward,
carefully loosen front and rear edges of door trim
assembly from door inner panel.
NOTE: Exercise care not to disturb inner panel

water deflector.
5. Lift trim assembly upwards and carefully disen

gage trim from top of door inner panel; then re
move trim assembly from door.
NOTE: On styles equipped with electric window

regulator, after trim assembly is dsengaged
SECTION D.D from top of door inner panel, disconnect switch
terminal blocks from switch assemblys.
6. To install, reverse removal procedure. Broken re

Fig. 14-Door Arm Rest Assemblies taining nails should be replaced with repair tabs,
which are available as service parts.
Front and Rear Door Trim Assemblies
All door trim assemblies are the hang-on type and
are further secured by attaching screws along bottom Front and Rear Door Water Deflectors
edge and by retaining nails inserted into plastic retain A waterproof paper deflector is used to seal the door
ing cups in the door inner panel see Views "D" and inner panel and prevent entry of water into body. The
"E" in Figure 15. polyethylene black side of the deflector is placed
against the inner panel. The deflector fits into a re
Removal and Installation taining slot at the lower section of the door inner
panel and deflects water to bottom of door and out
1. Remove door inside hardware, locking rod knob door bottom drain holes. The deflector is further se
and arm rest assembly. cured by a string loaded sealing material along both
front and rear edges and by the application of water
2. Remove screws securing trim assembly to door
proof sealing tape at front and rear lower corners.
inner panel fig. 15.
Whenever work is performed on front or rear doors
3. With a clean rubber mallet, tap trim assembly
where the water deflector has been disturbed, the
along front and rear edges to free trim assembly
deflector must be properly resealed and taped to the
retaining nails in slots.
inner panel to prevent serious waterleaks. It is impor
tant that all service personnel performing door hard
ware adjustments or sealing operations are aware of
the importance of using the specified material and the
recommended removal and installation or replacement
procedures.
For service sealing, body caulking compound is rec
ommended if additional sealing material is required.
When access to the door inner panel is required to
perform service operations, the deflector may be par
tially detached or completely removed from the inner
panel. If the existing water deflector is damaged so
that it will not properly seal the door inner panel,
replacement of deflector is absolutely necessary.
The following procedure covers complete removal
and installation of the water deflector. If only partial
detachment is required, perform only those steps which
4 & 2 DR. are necessary to expose the required area of the door
Fig. J 5-Door Trim Assembly inner panel.

BODY 14-11
Removal Front and Rear Door Outside Handle Assembly

1. Remove door trim assembly. Removal and Installation:
2. Remove strips of waterproof body tape securing
lower corners of water deflector. 1. Raise door window. Remove door trim assembly
and detach upper rear corner of inner panel water
3. With a putty knife, or other suitable flat-bladed deflector sufficiently to gain access to door outside
tool, carefully break cement bond securing upper handle attaching screws.
corners of water deflector to door inner panel.
Make sure string, located within sealer, is against 2. Remove screws and door lock handle and gaskets
water deflector and carefully slide putty knife from outside of body.
between sealer and door inner panel along both 3. To install, reverse removal procedure.
sides of door to disengage sides of water deflector
from door inner panel.
4. Disengage lower edge of water deflector from re Assembly and Disassembly of
taining slot in door inner panel and remove water Door Outside Handle Push Button
deflector.
1. Remove door outside handle.
Installation 2. Depress retainer slightly and turn one-quarter
1. Inspect water deflector and repair any tears or ¼ turn. Remove retainer, spring, push button
holes with waterproof body tape applied to both and shaft and sealing ring from handle.
sides of deflector. If bond between polyethylene 3. To assemble, reverse disassembly procedure fig.
and deflector paper has been torn, cut or damaged, 16.
apply waterproof body tape to both sides of de
flector over damaged area to prevent water from
wicking on uncoated side of deflector paper. I.
/
2. If a new deflector is to be installed, use old water
deflector as a template to trim new deflector to
proper size and to cut holes for door inside hard /1 ATTACHING SCREWS
ware. If old sealer does not effect an adequate seal,
remove all old cement from door inner panel and
replace with a continuous bead of body caulking
compound approximately " diameter.
3. If the door arm rest attaching screw holes are lo
cated in the door inner panel, seal these holes with
body caulking compound.
L f
HANDLE RING
pfr==wtmr,
SEALING PUSH BUTTON
AND SHAFT
SPRING
RETAINER
4. Position water deflector to door inner panel with Fig. 1 6-Front-Rear Door Outside Handle Disassembled
polyethylene coated side black of deflector
against inner panel. Insert lower edge of deflector FRONT DOORS
in retaining slot and firmly roll or press sealed
areas to obtain a good bond between deflector and Front Door Weatherstrip
door inner panel.
A new type of front door weatherstrip assembly has
g. Seal lower corners of water deflector with 2" or been designed which incorporates nylon component
2½" waterproof body sealing tape. fasteners. This new fastener takes the place of wire
6. Clean off any excessive cement or caulking com clips and attaching clip sealing plugs used on rear door
pound and install previously removed door trim weatherstrip assemblies.
and inside hardware. A significant change is the incorporation of the com
ponent nylon fastener. This fastener is the same size
at all locations 3/" diameter and is available as a
Spring Clips service part.
A spring clip is used to secure remote control con Tool J-21104 is designed for removal of the new
necting rods and inside locking rod connecting links to weatherstrip. If this tool is not available, it can be
door levers. A slot in the clip provides for disengage fabricated from any other comparable metal tool as
ment of the clips, thereby, facilitating detachment of shown in Figure 17.
linkage. When a removal tool is fabricated, make sure all
To disengage a spring clip, use a screwdriver, or sharp edges or metal burrs are removed so as not to
other suitable tool, to slide clip out of engagement. damage weatherstrip or paint finish during its usage.

BODY 14-12
WEATHERSTRIP
RETAINER
C; :C
L = -
TOOL J.2 1104 ‘/"

Fig. 18-Front Door Weatherstrip
Fig. 17-Front Door Weatherstrip Removal
Removal
1. Remove snap fasteners securing ends of weather

strip at belt line of door hinge and lock pillar
panels fig. 18. A
2. Carefully break cement bonds securing weather

strip to door. A flat-bladed tool, such as a putty
knife, will prove helpful in breaking cement bond
fig. 19.
3. Slide tool J-21104, or other suitable tool, under VIEW B
weatherstrip at a fastener location and grip fas
tener as close to door panel as possible. Then
gently pry fastener out of its respective door pierc WEATHERSTRIP
ing fig. 20. ADHESIVE
CAUTION: Exercise care not to damage serra VIEW A

tions or fasteners during removal as they are
necessary to maintain a good weatherseal. Fig. 19-Front Door Weatherstrip Cementing

BODY 14-13
Fig. 21 -Front Door Weatherstrip Adhesive Application
Removal
1. Carefully break cement bond securing weather
strip to door. If necessary, a flat-bladed tool, such
as a putty knife, can be used to help break cement
bond fig. 21.
Fig. 20-Using Weatherstrip Removal Tool

2. Slide tool J-21104, or other suitable tool, under
weatherstrip at a fastener location and grip fas
Installation tener as close to door panel as possible; then,
gently pry fastener out of its respective door pierc
1. Check weatherstrip nylon fasteners for damage ing fig. 20.
and replace, if necessary.
CAUTION: Exercise care not to damage serra
2. Clean off old cement from door to insure a clean
tions of fasteners during removal as they are
cementing surface. Apply a bead of an approved
necessary to maintain a good weatherseal.
weatherstrip adhesive to lock pillar facing of door.
Begin adhesive application at belt line and con
tinue down door for approximately seven to nine Installation
inches fig. 19.
1. Check weatherstrip nylon fasteners for damage
NOTE: Cement usage is usually limited to door and replace, if necessary.
lock pillar panel at belt line and at forward
lower corner of door. Cement, however, can be 2. Clean off old cement from door to insure a clean
applied at any point where additional reten cementing surface. Apply a bead of an approved
tion of weatherstrip is needed. weatherstrip adhesive to hinge and lock pillar
facing of door. Begin adhesive application slightly
3. Beginning at either front or rear section of door, above belt line and continue down door for ap
install snap fasteners. Install weatherstrip fasten proximately seven to nine inches. If necessary,
ers by pressing fasteners into door panel piercings. weatherstrip adhesive can also be applied to lower
A protected hammer can also be used if necessary. forward corner of door fig. 21.
NOTE: In the event a weatherstrip becomes
damaged at a fastener location and will not NOTE: Cement usage is usually limited to door
properly retain the fastener, remove fastener hinge and lock pillar panel at belt line and at
and cement weatherstrip into place. If, how forward lower corner of door. Cement, how
ever, two or more consecutive fasteners will not ever, can be applied at any point where addi
remain engaged in the weatherstrip, replace tional retention of weatherstrip is needed.
ment of the weatherstrip will probably be
3. Position front door weatherstrip so that preformed
necessary.
section is at upper rear corner of door header and
All door weatherstrips are impregnated with a sili install weatherstrip fasteners by pressing fasteners
cone lubricant and additional lubrication is not re into door panel piercings. A protected hammer can
quired. also be used if necessary.

BODY 14-14
NOTE: In the event a weatherstrip becomes

damaged at a fastener location and will not
properly retain the fastener, remove fastener
and cement weatherstrip into place. If, how
ever, two or more consecutive fasteners will
not remain engaged in the weatherstrip, re
placement of the weatherstrip will probably be
necessary.
4. Clean off any excess weatherstrip adhesive.
NOTE: All door weatherstrips are impregnated
with a silicone lubricant and additional lubri
cation is not required.
Front Door Hardware

47-67-39 Styles
Fig. 23-Proper Position of Fully Lowered Door Window
Figure 22 is typical of hard top coupe and sedan
style front doors with the trim assembly and inner Front Door Assembly and Hinges
panel water deflector removed. This illustration iden
tifies the component parts of the front door assembly, The front door hinges are the swing-out type with
their relationship and various attaching points. an integral door check on the top hinge assembly and
a two position hold open on the lower hinge assembly.
The hinges are attached to the front body hinge pillar
and to the door assembly with bolts and anchor plates.
Either of two methods may be used to remove the door
from the body.
a. The door and hinges can be removed as an assembly
from the body hinge pillar.
b. The door can be removed from the hinge straps.
Removal
1. Place a protective covering over front fender at
door opening to protect paint finish.
2. If door and hinges are to be removed from body
pillar, additional access may be obtained at lower
hinge by loosening front fender lower rear attach
ing bolt.
3. Mark hinge locations on door or hinge pillar de
pending on method of removal being used.
4. On bodies equipped with electrically powered
window regulators, proceed as follows:
a. Remove door trim assembly and detach inner
panel water deflector sufficiently to gain access
Fig. 22-Front Door Assembly-39, 47, 67 Styles
to wire connectors at motors.
1. Front Door Ventilator Extension 9. Front Door Outside Handle
Casting Assembly b. Detach wire harness from inner panel as re
2. Front Door Ventilator Assembly 10. Front Door Lock Cylinder and quired and disconnect motors from harness at
3. Front Door Ventilator Division Connecting Rod connectors.
Channel 11. Front Door Lock Assembly
4. Front Door Window Front 12. Front Door Window Inner c. Remove electric conduit from door and re
Up-Stop Panel Cam move wire harness from between door panels
5. Front Door Window Lower Sash 13. Front Door Remote Control to
Channel Cam through opening in door hinge pillar.
Lock Connecting Rod
6. Front Door Lock to Locking
Lever Rod 14. Front Door Remote Control 5. With door properly supported, remove bolts secur
7. Front Door Window Rear Up- Assembly ing upper and lower hinges to front body hinge
Stop 15. Front Door Window Lower Stop pillar or door hinge pillar. With aid of a helper,
8. Front Door Window Rear 16. Front Door Window Regulator
Guide Assembly Assembly remove door assembly from body fig. 24.
11-35-45-69 Styles Installation
Figure 23 is typical of all closed style front doors, 1. As an anti-squeak precaution, before installing
illustrating the proper position of a fully lowered door door, coat attaching surface of hinge with heavy
window for maximum glass stability. bodied sealer.

BODY 14-15
NOTE: After performing any door adjustments

on 39-47-67 styles, the front door ventilator
and window should be checked for proper
alignment with the side roof rail weatherstrip
and adjusted as required. In addition, the door
lock to striker engagement should be checked
and adjusted if necessary.
1. For in and out or up and down adjustments, loosen
hinge to door pillar attaching bolts fig. 24. Ad
just door as required and tighten bolts.
NOTE: When performing in and out adjust
ments, adjust one hinge at a time so as not to
disturb up and down adjustment.
2. To adjust door fore or aft, loosen hinge to body
pillar attaching bolts fig. 24. Adjust door as re
quired and tighten bolts.
NOTE: One or more of the attaching bolts are
not accessible due to inadequate wrench clear
ance. When fore and aft adjustments are per
formed, therefore, the recommended procedure
is to remove the obstructing attaching bolt and
perform adjustments with the remaining three
bolts. After satisfactory adjustments have been
made, replace the previously removed bolt.
The removal of the obstructing bolt and subse
quent adjustments can best be accomplished
with a racheting box end wrench.
Front Door Lock Strikers

1. With a pencil, mark position of striker on body
Fig. 24-Front Door Hinge Attachment pillar.
2. Remove three door lock striker attaching screws
2. With aid of a helper, reinstall door to body open and remove striker and adjusting plates from
ing. Align hinges within scribe marks and tighten pillar.
bolts. Check door for proper alignment. 3. To install, seal all striker plate attaching screw
3. On bodies equipped with electrically-operated clearance holes with body caulking compound.
window regulators proceed as follows: 4. Apply a 1/8" bead of body caulking compound
around entire back surface of striker plate. No
a. Install wire harness between door panels and skips must exist in caulking compound. Place
reinstall harness to door inner panel. Connect striker and adjusting plates within marks on pillar
regulator motor. and install striker plate attaching screws.
b. Install conduit to door inner panel. Check oper IMPORTANT: Whenever a door has been re
ation of electric window assembly. moved and installed, or realigned, the door
4. Where required, seal door inner panel water de SHOULD NOT be closed completely until a vis
flector as specified in "DOOR INNER PANEL ual check is made to determine if lock exten
WATER DEFLECTOR" and reinstall previously sion will engage in striker notch. Where re
removed parts. quired, door lock striker service spacers should
be installed so that door can be closed and an
5. For lubrication information see "LUBRICATION accurate check made to determine spacer re
SECTION." qu ire men ts.
5. Clean off all excess caulking compound.
Adjustments
Adjustments
In or out or up and down adjustments are provided 1. To adjust striker up or down or in or out, loosen
at door hinge pillar. Fore and aft adjustments are pro striker plate attaching screws and shift striker and
vided at front body hinge pillar. adjusting plates as required, then tighten screws.

BODY 14-16
Dimensional Specifications for Use of Front Door Lock Cylinder Assembly

Door Lock Striker Service Spacers
1. Door should be properly aligned before checking
door spacer requirements. 1. Raise door window. Remove door trim assembly
and detach inner panel water deflector sufficiently
2. To determine if door lock striker emergency to expose large access hole.
spacers are required, apply modeling clay or body
caulking compound in door lock striker notch 2. Through access hole, with a screwdriver o other
where lock extension engages and then close door suitable tool, disengage door lock cylinder to lock
to form a measurable impression in clay or caulk connecting rod from door lock See "DOOR
ing compound fig. 25. LOCK SPRING CLIP".
3. On all except "39" models, with a suitable flat
bladed tool, slide lock cylinder retaining clip for
ward from door lock pillar facing sufficiently to
permit removal of lock cylinder with attached
connecting rod from door. On "39" models, disen
gage spring clip from inside of door.
NOTE: Door lock cylinder connecting rod may
be removed from lock cylinder as a bench
operation or prior to removing cylinder.
4. To install, reverse removal procedure. Check op

eration of lock cylinder and lock prior to installing
inner panel water deflector.
Disassembly and Assembly

1. Remove lock cylinder assembly from door.
2. Remove pawl retaining clip, pawl and lock cylin
der retaining clip fig. 26.
Fig. 25-Striker Engagement Check LOCK CYLINDER PAWL PAWL RETAINING

CLIP
When dimension "A" from rear face of striker teeth
to rear edge of depression in clay is less than 11/32/’,
install service spacers and proper length striker attach
RETAINJCCLIP
ing screws as indicated.
DISASSEMBLY OF FRONT DOOR
No. of Striker LOCK CYLINDER
Dimension Spacers Spacer Attaching
Fig. 26-Disassembly of Front Door Lock Cylinder
"A" Required Thickness Screws*
3. To assemble, reverse disassembly procedure.
11/32" to
732 " 1 1/
/16
" Original NOTE: The lock cylinder housing scalp used in
production is usually damaged when removed
%2" to and must be replaced by a new scalp which is
7/ longer
/32
‘F
1 ¼" ‘/8" available as a service part. The service lock
cylinder housing scalp is secured by tabs.
‘/32 to 11/io/’ Spacer
5/ /
11,," Spacer 3/ IF
/32 /16 1/81’ longer
Front Door Inner Panel Cam Assembly
%2" to
3/ I,
2-’/8" Spacer 1/4" 1%" longer Removal and Installation
/32
1. Raise door window. Remove door trim assembly

*Zinc or cadmium-plated flat-head cross recess screw and detach inner panel water deflector.
with countersunk washer.
2. Remove bolts securing door inner panel cam as
NOTE: Dimension "B" in the illustration should sembly and disengage cam from regulator balance
never be less than 1/s ". arm and remove cam from door fig. 27.
BODY 14-17
Fig. 27-Front Door Hardware-Hardtop Styles
3. To install, reverse removal procedure. Prior to

installation, lubricate entire length of cam with 630
AAW Lubriplate or equivalent.
Adjustments Fig. 28-Front Door Lock Pillar
1. To correct a condition where the glass is cocked

in the glass run channels, loosen inner panel cam 5. Remove door lock attaching screws from lock pil
attaching screws, adjust either end of cam up or lar facing of door and remove lock assembly from
down as required and tighten screws. door fig. 28.
6. To install, reverse removal procedure. Prior to in
stallation, apply a ribbon of medium-bodied sealer
Front Door Lock Assembly
approximately ¼" in diameter across face of
All the locks are the rotary bolt type lock with the lock frame. Check unit for proper operation and,
safety interlock feature. With the safety interlock fea if necessary, adjust glass run channel for proper
ture it is important that the lock extension and hous alignment prior to installation of inner panel water
ing engages properly in the door lock striker and that, deflector.
where necessary, striker emergency spacers of the
proper thickness are used to obtain proper engagement.
Front Door Remote Control Assembly
Removal and Installation and Connecting Rod
1. Raise door window. Remove door trim assembly Removal and Installation
and detach inner panel water deflectGr.
2. Through access hole, disengage spring clips secur and detach inner panel water deflector.
ing lock cylinder rod, remote control connecting
rod and inside locking rod to lock and disengage 2. Remove remote control attaching screws and dis
rods from lock See "DOOR LOCK SPRING engage remote control from connecting rod fig.
CLIPS". 27.
3. On 39-47-67 styles, remove door window rear glass 3. To remove remote control connecting rod, care
run channel lower attaching screw and loosen fully disengage spring clip securing rod to lock
upper attaching screws on lock pillar facing of and remove rod from lock. Disengage rod from
door and at top of door inner panel to permit re spring clip on door inner panel where necessary,
moval of lock. and remove rod.
4. On 11-19-35-45-69 styles, from inside of door, re 4. To install, reverse removal procedure. Check door
move rear glass run channel lower attaching nut lock and remote control assemblies for proper
or screw and pull channel forward to permit re operation prior to installing inner panel water
moval of lock. deflector.

BODY 14-18
Front Door Ventilator Assembly-

VENT LOWER FRAME Manual and Electric
ATTACHING BOLT VENTILATOR TO DOOR
OUTER PANEL RETURN 39-47-67 Styles
‘FLANGE ATTACHING
SCREW Removal and Installation
1. Remove door trim assembly and detach inner
panel water deflector.
2. Lower door window. Remove ventilator to door
outer panel return flange attaching screw fig. 29.
3. At front of ventilator assembly, break cement
bond securing front door hinge pillar sealing strip
at belt to ventilator assembly.
4. Remove ventilator division channel lower adjust
ing stud and nut fig. 29.
5. On styles equipped with electrically operated ven
tilator assemblies, disconnect motor and regulator
assembly from ventilator frame and remove motor
and regulator unit through large access hole in
door inner panel.
6. Remove ventilator lower frame attaching bolt and
ventilator lower frame adjusting stud nut fig. 29.
7. Remove ventilator regulator.
8. Lift ventilator assembly upward and remove from
door.
installation of ventilator assembly, apply a bead
I DIVISION CHANNEL LOWER of body caulking compound to door outer panel
1ADJUSTING STUD & NUT
return flange along area contacted by ventilator
Fig. 29-Front Door Ventilator Assembly Adjustments assembly. Adjust ventilator assembly as described
under "FRONT DOOR VENTILATOR ADJUST
Front Door Ventilator Regulator- MENTS."
Manual and Electric
Front Door Ventilator Adjustments
1. Raise door window. Remove door trim assembly 39-47-67 Styles
and detach inner panel water deflector sufficiently The front door ventilator assembly can be adjusted
to gain access to regulator attaching bolts. up or down and in or out at the top and forward sec
2. On styles equipped with electric ventilator regu tion for alignment in the door opening and proper
lators, disconnect regulator motor wires at con weatherstrip contact in the ventilator area. The lower
nector. portion of the ventilator division channel can be ad
3. Remove ventilator tee shaft attaching bolt and justed in or out and fore and aft for alignment with
ventilator regulator attaching bolts fig. 29. the door window glass.
4. Disengage ventilator regulator shaft from venti To adjust the ventilator assembly, proceed as
lator tee shaft and remove regulator and motor follows:
assembly from door through access hole. 1. Remove door trim assembly and detach inner
5. To install, reverse removal procedure. Check oper panel water deflector.
ation of ventilator assembly prior to installing 2. Remove ventilator frame to outer panel attaching
inner panel water deflector. screw.
3. Loosen ventilator lower frame attaching bolt.
Front Door Ventilator Regulator Adjustments
4. Loosen ventilator division channel lower adjusting
1. Excessive "play" flutter of ventilator at pivot stud nut and ventilator lower frame adjusting stud
shaft, when ventilator is in an open position, can nut.
be corrected by tightening ventilator "T" shaft to 5. a. To adjust ventilator assembly fore or aft to
regulator attaching bolt fig. 29. windshield pillar side roof rail weatherstrip,
NOTE: Bolt should be tightened carefully to position lower frame adjusting stud and nut and
avoid stripping threads in regulator spiral gear division channel stud and nut as required and
shaft. tighten attaching nuts.

BODY 14-19
b. To adjust ventilator assembly in or out, turn Adlustments

adjusting studs on either the lower frame, divi To adjust ventilator division channel in or out or
sion channel or both, as required, and tighten fore. or aft, remove door trim assembly and detach
nuts. inner panel water deflector sufficiently to loosen divi
c. After the necessary adjustments have been per sion channel lower adjusting stud nut. Adjust stud in
formed, tighten all nuts and bolts and replace or out as required or position channel fore or aft as
ventilator to door outer panel attaching screw. required; then tighten stud nut.
NOTE: In some cases it may be necessary to
relocate ventilator to door outer panel return Front Door Window Assembly-
flange attaching screw. Manual and Electric
6. Seal water deflector to door inner panel and in 39-47-67 Styles
stall door trim and inside hardware.
Front Door Ventilator Assembly 1. Raise door window. Remove door trim assembly
and detach inner panel water deflector.
11-35-45-69 Styles 2. Through holes in inner panel, remove screw secur
Removal and Installation ing window assembly front and rear stops to lower
1. Remove door trim assembly and detach inner window sash channel. Then lower window slightly
panel water deflector. and remove stops fig. 27.
2. Remove ventilator regulator assembly. 3. Lower door window to expose window lower sash
3. Lower door window. Remove ventilator to door channel cam attaching screws. Then on styles
outer panel return flange attaching screw. equipped with electric window regulators, discon
4. Remove ventilator division channel lower adjust nect wiring harness feed wire from regulator
ing stud and nut. motor at connector.
5. Remove ventilator upper attaching screws along NOTE: It may be necessary to loosen the venti
window frame fig. 30. lator frame and tilt it forward to facilitate re
6. Lower ventilator assembly sufficiently to tilt as moval of door window.
sembly inward; then lift ventilator assembly up 4. Remove window lower sash channel cam attach
ward and remove from door. ing screws and disengage cam from window sash
7. To install, reverse removal procedure. channel. Then lift window assembly upward and
remove from door.
CAUTION: DO NOT OPERATE REGULATOR MO
TOR after window assembly is disengaged
from regulator. Operation of motor with load
removed may damage unit.
5. To install, reverse removal procedure. Before in
stalling window lower sash channel cam, lubricate
entire length of cam with 630 AAW Lubriplate or
equivalent. Check window for proper operation
prior to installing inner panel water deflector and
door trim pad.
Front Door Window Adjustments

39-47-67 Styles
Adjustments
The door window glass may be adjusted to provide
proper contact with the side roof rail weatherstrip.
Adjustments have also been provided to relieve a bind
ing door glass due to misalignment of the glass run
channels. To perform the following adjustments, re
move door trim assembly and detach inner panel water
deflector, where necessary, to gain access to hardware
attaching points; then proceed as follows:
1. To correct a condition where glass is "cocked" in
glass run channels, loosen inner panel cam attach
ing screws, adjust cam up or down as required
Fig. 30-Front Door Ventilator Assembly Attachments and retighten screws fig. 27.

BODY 14-20
2. To adjust upper front portion of window assembly 6. To install, reverse removal procedure. Check win
in or out for proper contact with side roof rail dow for proper operation before installing inner
weatherstrip, adjust ventilator assembly in or out panel water deflector. Prior to installation, lubri
as described under "FRONT DOOR VENTILA cate entire length of lower sash channel cam
TOR ADJUSTMENTS." with 630 AAW Lubriplate or equivalent.
3. To adjust lower portion of ventilator division
channel for alignment with window assembly, Front Door Window Adjustments
lower door window and loosen ventilator division
channel adjusting stud nut. Turn adjusting stud in 11-35-45-69 Styles
or out or position lower end of channel fore or aft, Adjustments
as required; then, retighten adjusting stud nut
fig. 29. 1. To correct a condition where glass is "cocked" in
glass run channels, loosen inner panel cam attach
4. To adjust upper rear of window assembly in or ing screws, adjust cam up or down as required
out for proper contact with side roof rail weather and tighten screws fig. 30.
strip, or to adjust rear of window assembly in
or out at belt line, loosen rear glass run channel 2. To adjust lower portion of ventilator division
attaching screws at lock pillar facing of door and channel for proper alignment with door window
screw at top of door inner panel. Position channel assembly, lower door window and loosen venti
in or out as required and tighten screws fig. 28. lator adjusting stud nut. Turn adjusting stud in
or out or position lower end of channel fore or
NOTE: Adjustments 2, 3 and 4 must be coordi aft as required; then tighten adjusting stud nut
nated to provide a properly operating front fig. 30.
door window. 3. To adjust lower portion of window glass run
channel in or out for proper alignment with door
5. To adjust limit of "up" travel of window assembly
window, raise door window. From inside door,
for proper contact with side roof rail weather loosen glass run channel lower attaching nut or
strip, raise door window and through inner panel screw, adjust channel as required and tighten
access holes loosen door window front and rear nut or screw fig. 30.
stop assembly attaching bolts. Adjust stops up or
down as required, then tighten attaching bolts
fig. 27. Front Door Window Regulator Assembly
39-47-67 Styles
Front Door Window Assembly-
Manual and Electric Manual and Eeiectric
Removal and Installation:
11-35-45-69 Styles
Removal and Installation panel water deflector.
1. Lower door window. Remove door trim assembly 2. Remove ventilator division channel lower adjust
and detach inner panel water deflector. ing stud and nut fig. 29.
2. Remove door ventilator assembly as previously 3. On styles equipped with manual window reg
described under "FRONT DOOR VENTILATOR ulators, lower window. Remove window lower
-REMOVAL AND INSTALLATION." sash channel cam attaching screws and disengage
sash channel cam from window lower sash chan
3. On styles equipped with electric window regu nel; then raise window and prop in full up posi
lators, disconnect wiring harness feed wires from tion. Disengage sash channel cam from window
regulator motor at connector. regulator arm rollers.
CAUTION: DO NOT OPERATE REGULATOR MO 4. On styles equipped with electric window reg
TOR after window assembly is disengaged ulators, remove door ventilator assembly and
from regulator. Operation of motor with load front door window.
removed may damage unit.
5. On styles equipped with electric window regula
4. Remove screws securing window lower sash chan tors, disconnect wire harness feed wires from reg
nel cam to window assembly and carefully disen ulator motor at connector.
gage cam from window lower sash channel. CAUTION: DO NOT OPERATE REGULATOR
5. Rotate rear edge of window assembly upward and MOTOR after window assembly is disengaged
remove window assembly from between inner and from regulator. Operation of motor with load
outer panels. removed may damage unit.

BODY 14-21
6. Remove window regulator attaching bolts. Dis

engage regulator balance arm roller from inner
panel cam and carefully remove regular assembly
from door fig. 27.
NOTE: On some models only one end of inner
panel cam is open sufficiently to permit removal
of regulator arm roller.
7. To install, reverse removal procedure. Check
window for proper operation prior to installing
inner panel water deflector and door trim pad.
Front Door Window Regulator Assembly

Fig. 31-Door Window Regulator and Motor Assembly
11-35-45-69 Styles
Manual and Electric NOTE: The position of regulator assembly in
vise will vary with type of regulator and posi
Removal and Installation tion of lift arm.
1. Remove door trim pad and detach inner panel 2. Drill a 1/4" hole through back plate and sector at
water deflector. location indicated at either A, B, or C, depending
2. Remove ventilator division channel lower adjust on position of lift arm.
ing stud and nut fig. 30.
NOTE: Do not drill into motor housing, part of
3. On styles equipped with electric window reg which is indicated by dotted line. In addition,
ulators, disconnect wire harness feed wires from locate hole a sufficient distance from edge of
regulator motor at connector. sector to insure proper retention of the sector.
CAUTION: Do not operate regulator motor with
load removed. 3. Insert " bolt through hole in back plate and
sector and install nut to bolt. Do not tighten nut.
4. Remove door window lower sash channel cam
fig. 30. CAUTION: BE SURE TO PERFORM STEPS #2 and
5. Roll window to a full up position and place a 2" #3 BEFORE ATTEMPTING TO REMOVE MOTOR
FROM REGULATOR. The regulator lift arm,
or 2½" piece of body tape over door upper frame
which is under tension from the counter-bal
and top of door glass on both sides of glass. This
ance spring, can cause serious injury if motor
is necessary to positively hold the door window
assembly is removed without locking the sector
in a full up position.
in position with a nut and bolt.
6. Remove inner panel cam and window regulator
attaching bolts and carefully remove regulator 4. Remove motor attaching bolts and remove motor
assembly from door fig. 30. assembly from regulator fig. 31.
7. To install, reverse removal procedure. Check NOTE: Clean off steel chips from regulator sec
window for proper operation prior to installing tor and motor pinion gear.
inner panel water deflector and door trim pad.
5. To install, reverse removal procedure. If difficulty
is encountered when trying to line up motor at
Front Door Window Regulator Electric
taching holes, the regulator lift arm may be moved
Motor Assembly up or down manually so that motor pinion gear
All Styles with powered-Operated will mesh with teeth on regulator sector and regu
lator attaching holes will line up.
Window Assemblies
NOTE: Be sure to remove temporary nut and
The electric motor assembly which powers the win
dow regulator on electrically operated windows, is a bolt from regulator before installing it in door.
twelve volt, reversible direction motor with a built-in
circuit breaker and a self-locking gear drive. The Front Door Window Glass Run
motor is secured to the regulator assembly by screws. Channel Assembly
Removal and Installation 11-35-45-69 Styles
1. Remove front door electric window regulator as Removal and Installation
sembly from door as previously described and 1. Lower door window. Remove door trim assembly
clamp it in a vise fig. 31. and detach inner panel water deflector.

BODY 14-22
2. Remove front door ventilator assembly and slide

window forward slightly to expose lock pillar por
tion of glass run channel.
NOTE: Exercise care so that exposed front edge
of glass does not come in contact with body
metal.
3. Through inner panel access hole loosen nut or
screw securing lower end of glass run channel
fig. 30.
4. Squeeze glass run channel together along upper LOCK PILLAR
and lock pillar sections of window frame and pull - RETAINING SCREW
or carefully pry channel assembly from window -
- ATTACHING CLIP
frame. Remove channel assembly from door. WEATHERSTRIP
SECTION "A-A"
REAR DOORS
Rear Door Weatherstrips Fig. 33-Rear Door Weatherstrip Attaching Clip Screw
39 Styles
Removal
The rear door weatherstrip is a one-piece mechani
cal retained type. Mechanical retention consists of a 1. Remove snap fasteners securing ends of weather
series of weatherstrip attaching clips which fit into strip at belt line of door hinge and lock pillar
individual sealing plugs along door bottom and sides. panels fig. 32.
The weatherstrip is also mechanically retained by 2. On "39" style rear doors, remove the single
nylon snap fasteners at belt line of hinge and lock weatherstrip attaching clip screw located at upper
pillar panels. In addition, "39" style rear door weather- radius of lock pillar fig. 33.
strips are further retained by a single weatherstrip
attaching clip and screw at upper radius of lock pillar 3. Carefully break cement bond securing weather
panel. Cement usage is limited to door lock pillar strip to door. A flat-bladed tool, such as a putty
panels at belt line and at forward lower corners of knife, will prove helpful in breaking cement bond
door. Cement, however, can be applied at any point fig. 34.
where additional retention of weatherstrip is needed.
REPAIR TAPE
ATTACHING
CLIPS SECTION C-C
VIEW "A"
39-89 STYLES
B
VIEW "B"
29 STYLES
VIEW "A’ / VIEW "A"
Fig. 32-Rear Door Weatherstrip Attaching Clips Fig. 34-Rear Door Weatherstrip Adhesive Application

BODY 14-23
2. Inspect all attaching clip sealing plugs. Any miss

ing plugs should be replaced. A plug which is
loose and will not remain engaged in the door
panel piercing can be corrected by installing a
1/2" by 1" piece of cloth-backed waterproof tape
over piercing and making an "X" pattern slit in

tape to accommodate sealing plug. If, after this
operation, the plug is still loose; install a second
piece of tape over the existing repair. This proce
dure can also be used to repair any waterleaks
that develop at sealing plug locations. A damaged
sealing plug must be replaced see Section "D-D"
in Figure 34.
weatherstrip adhesive to lock pillar facing of door
and at lower front corner of door see Views "B"
and "C" in Figure 34. When applying weather
strip adhesive to lock pillar facing of door, begin
application at belt line and continue down door
for approximately seven to nine inches. If neces
sary, weatherstrip adhesive can also be applied to
hinge pillar facing of door.
4. Beginning at either front or rear section of door,
Fig. 35-Usage of Tool J-5757
install snap fasteners. Install weatherstrip attach
4. Insert tip of tool J-5757, or any other suitable tool, ing clips into their respective sealing plugs by
placing notched end of tool J-5757 into loop of
at retaining clip locations and carefully snap clips
wire clip and pushing clip into sealing plug fig.
from sealing plugs fig. 35. 35.
Installation NOTE: Do not distort weatherstrip attaching

clips or unsatisfactory weatherstrip retention
1. Check weatherstrip attaching clips for proper will result.
contour and reform, if necessary, using clip re
forming tool J-5984 fig. 36. All door weatherstrips are impregnated with a
silicone lubricant and additional lubrication is not
required.
Rear Door Hinge Pillar Sealing Strip At Belt

39 Styles
1. Remove snap fasteners securing sealing strip to
hinge pillar facing of rear door and remove strip
fig. 37.
Rear Door Weatherstrips

35-45-69 Styles
The rear door weatherstrip is a one-piece design,
cemented at belt line and retained by weatherstrip
attaching clips for the remainder of the door. Around
bottom of door, from belt line of hinge pillar to belt
line of lock pillar, the attaching clips fit into sealing
plugs.
Removal
1. Insert tip of mechanically retained weatherstrip
Fig. 36-Reforming Weatherstrip Clips inserting tool J-5757, or other suitable tool, at clip

BODY 14-24
FASTENERS
FASTENER
Fig. 39-Rear Door Weatherstrip Adhesive Application
3. Carefully break cement bond securing weather

VIEW IN, CIR.CL A strip to door. If necessary, a flat-bladed tool, such
SEALING as a putty knife, can be used to help break cement
STRIP
bond fig. 39.
Fig. 37-Rear Door Hinge Pillar Sealing Strip 4. Insert tool J-5757 at clip locations on door upper
frame and carefully snap clips from piercings and
locations and carefully snap clips from sealing remove weatherstrip from door.
plugs fig. 35.
Installation
2. Some weatherstrips may be additionally secured 1. Check all weatherstrip attaching clips forproper
by a two-prong clip, attached to lock and/or hinge contour and reform, if necessary, using clip re
pillar of door at belt line. This clip is attached by forming tool J-5984 fig. 36.
a single screw and must be removed prior to re
2. Inspect all attaching clip sealing plugs. Any miss
moval of weatherstrip. When clip is reinstalled,
ing or damaged plug must be replaced. A plug
make sure both prongs are positioned over wire that is loose and will not remain engaged in the
located in center of weatherstrip. Figure 38 shows door panel piercing can be corrected by installing
clips attached to a front door weatherstrip but is a ½" by 1" piece of cloth-backed waterproof tape
typical of rear doors. This clip can be satisfactorily over piercing and making an "X" pattern slit in
used to retain almost any area of a rear door tape to accommodate sealing plug. If plug is still
weatherstrip that proves troublesome fig. 38. loose, repeat this operation by installing a second
piece of tape over existing repair.
weatherstrip adhesive to hinge and lock pillar
facings of door. Begin adhesive application slightly
above belt line and continue down door for ap
proximately seven to nine inches. If necessary,
weatherstrip adhesive can also be applied to lower
corners of door fig. 39.
4. Position rear door weatherstrip so that preformed
section is at upper front corner of door header.
5. Install weatherstrip into door upper frame by
CLIP inserting tool J-5757 into loop of wire clips and
pushing clips into their respective piercings fig.
Fig. 38-Two Prong Weatherstrip Attaching Clip 35.

BODY 14-25
6. Press weatherstrip into place at cemented areas

and, if applicable, reinstall weatherstrip two-
prong attaching clip. Make sure prongs of clip are
inserted over wire of weatherstrip fig. 38.
7. Install weatherstrip into attaching clip sealing
plugs by installing tool J-5757 into ioop of wire
clips and pushing clips into their respective plugs
fig. 35.
IMPORTANT: Do not distort weatherstrip at
taching clips as unsatisfactory weatherstrip re
ention will result.
8. Clean off any excess weatherstrip adhesive.

NOTE: All door weatherstrips are impregnated
with a silicone lubricant and additional lubri
cation is not required.
Rear Door Hardware

35-39-45-69 Styles
Fig. 41-Typical Hardtop Style Rear Door Hardware
Figure 40 is typical of sedan and station wagon style
A. Rear Door Window Assembly I. Rear Door Window Rear Guide
rear doors with the trim pad and inner panel water B. Rear Door Window Front Cam Assembly
deflector removed. This illustration identifies the com Female Wedge Plate J. Rear Door Lock Remote Control
ponent parts of the rear door assembly, their relation C. Rear Door Window Lower Sash Assembly
ship and various attaching points. Channel Cam K. Rear Door Window Guide Front
D. Rear Door Window Rear Female Cam Assembly
Wedge Plate L. Rear Door Window Electric
Figure 41 is typical of a hard top sedan "39" E. Rear Door Outside Handle Regulator and Motor Assembly
style rear door with the trim assembly and inner panel Assembly M. Rear Door Window Regulator
F. Rear Door Lock to Locking Assembly-Manual
Lever Rod N. Rear Door Inside Locking
G. Rear Door Lock Assembly Rod
H. Rear Door Lock Remote Control 0. Rear Door Window Inner Panel
to Lock Rod Assembly Cam Assembly
water deflector removed. This illustration identifies

the component parts of the rear door assembly, their
relationship and various attaching points.
I
Figure 42 is typical of "69" style rear doors. This
illustration indicates a fully lowered door window in
K proper position for maximum glass stability.
Fig. 40-Typical Closed Style Rear Door Hardware

A. Rear Door Window Assembly G. Rear Door Lock Remote Control
8. Rear Door Window Glass Run to Lock Rod Assembly
Channel H. Rear Door Inner Panel Cam
C. Rear Door Window Lower Sash I. Rear Door Lock Remote Control
Channel Cam Assembly
D. Rear Door Outside Handle J. Rear Door Window Electric
Assembly Regulator and Motor Assembly
E. Rear Door Inside Locking to K. Rear Door Window Regulator
Lock Rod Assembly Assembly
F. Rear Door Lock Assembly 1. Rear Door Inside Locking Rod Fig. 42-Proper Lowered Window Positioning-69 Styles

BODY 14-26
Fig. 43-Proper Lowered Window Positioning-35 and 45 Styles
Figure 43 is typical of "35" and "45" style rear

doors. This illustration indicates a fully lowered door
window in proper position for maximum glass sta
bility.
LOWER ADJUSTING
STUD AND NUT
Rear Door Hinges
The rear door hinges are attached to the center
Fig. 45-Rear Door Hinge Attachments
pillar with two butt-type hinges. The hinges are se
cured to the center pillar and door hinge pillar by
1. On "39" styles, lower door window.
screws and anchor plates. The lower hinge incorpo
rates an integral door check and hold-open. 2. Clean off excess sealer around each hinge strap and
mark location on door hinge pillar or center pillar,
Removal depending on method of removal being used.
The door and hinges can be removed as an assembly 3. On bodies equipped with electrically powered
from the center pillar or the door can be removed window regulators, proceed as follows:
from the hinge straps. a. Remove door trim assembly and detach inner
panel water deflector sufficiently to gain access
to wire connector at motor.
b. Detach wire harness from door inner panel and
disconnect regulator motor from harness at
connector.
CENTER PILLAR c. Remove electrical conduit from door and re
ATTACHING SCREWS
move harness from between door panels
through opening in door hinge pillar.
4. With door properly supported, remove three’up
per and lower hinge attaching screws at door
hinge pillar or center pillar depending on method
of removal fig. 44.
NOTE: On "39" styles, the rear door lower
hinge to center pillar middle attaching bolt is
also the rear door jamb switch. Be sure to dis
LOWER HINGE TO
CENTER PILLAR connect wire before removing door.
5. With aid of helper, remove door from body.
Installation
1. With a scraper and mineral spirits, clean off old
sealing compound at hinge attaching areas. This
operation should be performed carefully to avoid
Fig. 44-Rear Door to Center Hinge Pillar Attachment the possibility of soiling adjacent trim material.
BODY 14-27
2. To adjust door fore or aft, loosen hinge to center

pillar attaching screws, adjust door fore or aft as
required and tighten screws fig. 44.
CAUTION: The rear door upper hinge on 35-

45-69 styles is constructed of die cast alumi
num which will break under strain of bending
in an attempt to short-cut adjustments. Use
only the recommended procedures for adjust
ing rear doors.
Rear Door Lock Assembly-All Styles

Locks are the rotary bolt type with the safety inter
Fig. 46-Door Hinge Assemblies lock feature. With the safety interlock feature, it is
very important that the lock extension engages prop
2. Apply a coat of heavy-bodied sealer to attaching erly in the door lock striker notch and that, where
surfaces of hinge straps or corresponding surfaces necessary, striker emergency spacers of the proper
of door or body fig. 46. thickness can be used to obtain proper engagement.
3. With a helper, lift door into position. Install
screws loosely, align strap within scribe marks on Removal and Installation
pillar and tighten bolts. Check door for proper
alignment. 1. Raise door window. Remove door trim assembly
4. On doors equipped with power operated windows,
proceed as follows: 2. On "35," "45" and "69" styles, through large ac
a. Install wiring harness inside of door. Connect cess hole, remove screw securing lower end of
regulator motor and install wiring harness to glass run channel at door lock pillar and raise end
inner panel. of channel to expose lock assembly fig. 47.
b. Install conduit to door hinge pillar. Check
operation of electric window assembly.
5. Where required, seal door inner panel water de
flector as specified in "DOOR INNER PANEL
DEFLECTOR" and reinstall all previously re
moved parts.
6. For lubrication information see "LUBRICA
TION" section.
Adjustments
In or out or up and down adjustments are provided
at door hinge pillar. Fore and aft and a slight up and
down adjustment are provided at center pillar. When
checking the door for alignment, remove door lock
striker from body pillar to allow door to hang free on
its hinges.
NOTE: After performing any adjustments, the
rear door window on "39" styles should be
checked for proper alignment with the side
roof rail weatherstrip. In addition, door lock
extension to striker engagement should be ex
Fig. 47-Rear Door Window Glass Run Channel
amined and adjusted if necessary.
1. For in and out or up and down adjustment, loosen 3. Through access hole, disengage spring clips and
hinge to door pillar attaching screws, adjust door detach inside lock connecting rod and remote con
as required and tighten screws fig. 45. trol connecting rod from lock assembly see
"DOOR LOCK SPRING CLIPS".
NOTE: When performing in and out or fore
and aft adjustments, adjust one hinge at a 4. At lock pillar facing, remove door lock attaching
time so that "up and down" adjustment is screws and remove lock assembly through access
maintained. hole.

BODY 14-28
5. To install door lock, reverse removal procedure. Dimensional Specifications For Use of Door Lock
Check all operations of door lock before installing
door trim and inside hardware. Striker Service Spacers
The door lock striker spacer information previously
provided under the "FRONT DOORS" heading ap
Rear Door Lock Strikers plies as well to the rear doors.
1. With a pencil, mark position of striker on body Rear Door Inner Panel Cam
pillar. The inner panel cam is attached to the door inner
2. Remove three door lock striker attaching screws panel by two /16" attaching bolts and is designed as
and remove striker and adjusting plates from a guide for the door window regulator balance arm.
pillar.
3. To install, seal all striker plate attaching screw 1. Raise door window, remove door trim pad and
clearance holes with body caulking compound. detach inner panel water deflector sufficiently to
4. Apply a W’ bead of body caulking compound expose inner panel cam attaching bolts fig. 48.
around entire back surface of striker plate; skips 2. Remove inner panel cam attaching bolts and dis
must not exist in caulking compound. Place strik engage cam from window regulator balance arm
er and adjusting plates within marks on pillar and roller and remove cam from door.
install striker plate attaching screws. 3. To install, reverse removal procedure. Prior to
installation of inner panel cam, lubricate entire
NOTE: Whenever a door has been removed length of cam with 630 AAW Lubricate or equiv
and installed or realigned, the door should not alent.
be closed completely until a visual check is
made to determine if lock extension will en NOTE: The forward end of the inner panel cam
gage in striker notch. Where required, door is adjustable up or down. This adjustment can
lock striker service spacers should be installed be used to help correct a rotated or cocked door
so that door can be closed and an accurate window.
check made to determine proper spacer re
quirements. Rear Door Lock To Locking Lever Rod
5. Clean off all excessive body caulking compound.
1. Raise door window, remove door trim pad and
Adjustments detach inner panel water deflector sufficiently to
expose locking rod assembly.
To adjust striker up or down or in or out, loosen 2. Remove inside locking rod knob from rod.
striker plate attaching screws and shift striker and
adjusting plates as required and tighten screws. 3. On 35-45-69 styles, remove screw securing lower
end of glass run channel at door hinge pillar to
gain access to spring clip securing rod to lock
fig. 47.
4. Disengage spring clip securing inside locking rod
assembly to door lock and disengage rod from
lock.
5. Disengage rod from spring clip on door inner panel.
Remove inside locking rod attaching bolt and re
move assembly from door fig. 48.
6. To install, reverse removal procedure. Check oper
ation of inside locking rod assembly before install
ing water deflector and door trim pad.
Rear Door Remote Control Assembly and

Connecting Rod
and detach inner panel water deflector sufficiently
Fig. 48-Rear Door Hardware to gain access to remote control attaching bolts.

BODY 14-29
2. Remove remote control attaching bolts and remove Rear Door Window Regulator Assembly
control from connecting rod fig. 48. Manual and Electric
3. On 35-45-69 styles, remove glass run channel lower
attaching screw to gain access to spring clip secur Removal and Installation
ing rod to lock fig. 47. 1. Lower door window. Remove door trim assembly
4. Disengage remote control connecting rod from lock and detach inner panel water deflector.
and remove rod from door. 2. Remove door window lower sash channel cam.
Then carefully raise window and prop in a raised
5. To install remote control and connecting rod,
position.
reverse removal procedure. Position remote control
rearward sufficiently to take up slack in linkage so 3. On styles equipped with electric window regu
that all clearances are taken out of linkage in lators, disconnect wiring harness feed wires from
a rearward position. Check all operations of door regulator motor at connector.
lock before installing door inner panel water 4. On 39 styles, equipped with electric window
deflector and trim pad. regulators, loosen rear guide cam upper attaching
screw and bolt and remove lower adjusting stud
Rear Door Window Lower Sash Channel Cam and nut. This is necessary to move lower section
of rear guide cam rearward far enough to permit
removal of electric window regulator and motor
1. Remove door trim pad and detach inner panel assembly. Figure 50 shows the rear guide cam
water deflector. attachments and is typical of rear guide cams
2. Lower door window sufficiently to gain access to equipped with power windows.
sash channel cam two attaching screws through
access holes in door inner panel and remove
screws fig. 49.
F .JL FEMALE WEDGE PLATE
CAM ATTACHING UPPER ATTACHING ATTACHING BOLT
BOLT BOLT
i.E WEDGE PLATE

EACHING SCREWS
I
Fig. 49-Rear Door Hardware
3. While supporting window by hand, carefully dis Fig. 50-Rear Door Hardware
engage cam from window lower sash channel and
rollers on window regulator arms and remove CAUTION: Do not operate regulator motor after
cam from door. window assembly is disengaged from regula
CAUTION: After removal of lower sash channel tor. Operation of motor with load removed
cam, carefully lower door window to bottom may damage unit.
of door to prevent damage to glass. 4. Remove regulator attaching bolts four, disen
4. To install, reverse removal procedure. Prior to gage balance arm from inner panel cam and
installation, lubricate entire length of window remove regulator assembly through large access
lower sash channel cam with 630 AAW Lubriplate hole fig. 50.
or its equivalent. Check operation of window 5. To install, reverse removal procedure. Check
prior to installing inner panel water deflector and operation of window before installing inner panel
door trim pad. water deflector and rear door trim pad.

BODY 14-30
Rear Door Window Regulator Electric may be moved up or down manually so that
Motor Assembly motor pinion gear will mesh with teeth on reg
ulator sector, and regulator attaching holes will
The electric motor assembly which powers the win line up.
dow regulator on electrically-operated windows is a
12-volt reversible motor with a built-in type circuit NOTE: Be sure to remove temporary nut and
breaker and a self-locking gear drive. The motor is bolt from regulator before installing it into
attached to the regulator assembly with bolts. door or rear quarter panel.

1. Remove electric window regulator assembly from Rear Door Window Assembly
door and/or rear quarter and clamp securely in 35-45-69 Styles
vise fig. 51.
LIFT ARM 1. Lower door window. Remove door trim assembly
BALANCE ARM ELECTRIC MOTOR 2. Remove lower sash channel cam attaching screws
COUNTER
BALANCE
/ and disengage cam from sash channel fig. 52.
SPRING
BACK PLATE
SECTOR GEAR
Fig. 51-Rear Door Window Regulator Motor Assembly
NOTE: The position of the regulator clamped

in the vise will vary with type of regulator and
position of lift arm.
CAUTION: BE SURE TO PERFORM STEPS 2 AND

3 BEFORE ATTEMPTING TO REMOVE MOTOR
FROM REGULATOR. The regulator lift arm,
which is under tension from the counterbalance
spring, can cause serious injury if the motor is
Fig. 52-Rear Door Run Channels and Cam
removed without locking the sector in position.
2. Drill a ¼" hole through sector and back plate NOTE: On styles equipped with electric win
within area indicated by "A" fig. 51. dow regulators, disconnect wiring harness
electrical feed plug from regulator motor at
NOTE: Locate hole a sufficient distance from connector. Do NOT operate regulator motor
edge of sector to insure proper retention of
after window assembly is disengaged from
the sector.
regulator. Operation of motor with load re
3. Inset a /16" bolt through hole in back plate and moved may damage unit.
sector and install nut to bolt do not tighten
nut. 3. On "69" styles, rotate rear edge of window assem
4. Remove motor attaching bolts and remove motor bly downward and remove glass from door.
assembly from regulator see fig. 51.
NOTE: Clean off steel chips from regulator installation of window lower sash channel cam,
sector and motor pinion gear after drilling lubricate entire length of cam with 630 AAW
operation. Lubriplate or equivalent. Check operation of
window assembly and, where required, adjust
5. To install, reverse removal procedure. If diffi window as described under "REAR DOOR WIN
culty is encountered when trying to line up motor DOW GLASS RUN CHANNEL ASSEMBLIES
assembly attaching holes, the regulator lift arm AND REAR DOOR INNER PANEL CAM".

BODY 14-31
Rear Door Window Glass Run Channel

69 Styles
panel water deflector. Disengage lower sash chan
nel cam from window sash channel.
2. Remove door window assembly.
3. Remove front and rear attaching screws from
hinge and lock pillar facing of door inner panel LOWER DOOR UPPER
RETAINER FRAME
fig. 53.
DOOR UPPER
FRAME
ATTACHING
BOLT
SECTION A-A RUN CHANNEL
RUN
CHANNEL RUN Fig. 54-Rear Door Window Glass Run Channel-35 and 45 Styles
CHANNEL
5. Lower door window. Disengage run channel
LOWER
attaching clips along lock pillar portion of window
RETAINER
frame. Then carefully raise rear run channel and
BOLT remove from door.
VIEW B
VIEW IN DIRECTION OF ARROW C
eration of rear door window and adjust rear glass
Fig. 53-Rear Door Window Glass Run Channel-69 Styles run channel as required before installing water
deflector.
4. Carefully disengage glass run channel attaching
clips. Beginning along front of door window frame,
pull glass run channel inboard and upward and
remove channel from between inner and outer
panels.
eration of rear door window and, where required, ATTACH ING
adjust glass run channel for proper operation of SCREWS
window assembly.
Rear Door Window Rear

Glass Run Channel
35 and 45 Styles
1. Raise door window, remove door trim assembly
2. From inside door, remove bolt securing lower
end of glass run channel at door lock pillar fac
DOOR LOCK
ing fig. 54. PILLAR
3. Remove screws securing door belt trim support
rear finishing plate three and remove plate
fig. 55.
4. Remove screws securing rear door window glass
run channel rear retainer from rear of window
frame assembly and remove retainer. Fig. 55-Rear Door Belt Support Finishing Plate-35 and 45 Styles

BODY 14-32
Rear Door Window Front Glass Run Channel Rear Door Window Guide Front Cam Support
35-45 Styles 39 Styles
1. Remove rear door window rear glass run channel 1. Remove door trim assembly and detach inner
and remove rear door window assembly. panel water deflector.
2. Remove glass run channel lower attaching bolts 2. Raise door window. Through inner panel access
from hinge pillar facing of door. hole remove front guide cam upper attaching bolt
3. Carefully disengage glass run channel attaching fig. 50.
clips along top and hinge pillar portion of window 3. At door hinge pillar facing, remove two screws
frame. Then pull glass run channel inboard and securing guide cam support and remove support
upward and remove from door. through access hole.
4. To install, reverse removal procedure. Check 4. To install, reverse removal procedure. Check op
operation of rear door window and adjust chan eration of window assembly and, where required,
nel as required. adjust window as described under "REAR DOOR
WINDOW ADJUSTMENTS."
Rear Door Window Glass Run
Channel Adjustments Rear Door Window Guide Rear Cam Assembly
35-45-69 Styles 39 Styles
To adjust front or rear glass run channel in or out
or up or down, loosen channel attaching screws, 1. Raise door window. Remove door trim assembly
adjust channel as required and tighten screws. After and detach inner panel water deflector.
any adjustments, check window for proper operation. 2. Remove rear cam upper attaching screws and
lower adjusting stud and nut fig. 50.
NOTE: Adustment of both channels must be
coordinated to provide proper operation of the 3. Carefully disengage cam from roller on window
rear door window assembly. guide assembly and remove rear cam through
large access hole.
Rear Door Window Guide Front Cam Assembly installation, lubricate entire length of cam with
39 Styles 630 AAW Lubriplate or equivalent. If exposed,
seal cam lower adjusting stud and nut with body
The window guide front cam assembly incorpor caulking compound.
ates an attaching support bracket at the upper edge
of the guide cam which is attached to the door hinge 5. Check operation of window assembly and, where
pillar facing by two bolts. The front cam can be required, adjust window as described under
removed without removing this attaching bracket. "REAR DOOR WINDOW ADJUSTMENTS."
Removal and Installation Rear Door Window Assembly-

1. Raise door window. Remove door trim assembly Manual and Electric
and detach inner panel water deflector. 39 Styles
2. Through inner panel access hole remove front Removal and Installation
guide cam upper attaching screws and front
guide cam lower adjusting stud and nut fig. 50. 1. Raise door window. Remove door trim assembly
3. Carefully disengage guide cam from window low
er sash channel roller and remove guide cam 2. Through access holes in door inner panel remove
through access hole. screws securing rear door window front and rear
male wedge plates to window lower sash channel
4. To install, reverse removal procedure. Prior to and remove wedge plates fig. 50.
installation, lubricate entire length of guide cam
with 630 AAW Lubriplate or equivalent. Reseal 3. Lower door window and remove lower sash chan
front guide cam lower adjusting stud and nut with nel cam attaching screws fig. 49.
body caulking compound. NOTE: On styles equipped with electric win
5. Check operation of window assembly and, where dow regulators, disconnect wiring harness
required, adjust window as described under electrical feed plug from regulator motor at
"REAR DOOR WINDOW ADJUSTMENTS". connector.

BODY 14-33
CAUTION: DO NOT OPERATE REGULATOR MO NOTE: On styles where lower adjusting stud
TOR after window assembly is disengaged and nut are not covered by a water de
from regulator. Operation of motor with load flector, seal stud and nut with body caulk
removed may damage unit. ing compound.
4. Carefully raise door window and remove from 3. The in and out adjustment of the rear door win
door. dow assembly can be obtained by adjusting the
5. To install, reverse removal procedure. Check win front and rear guide cams in or out as required.
dow for proper alignment and, where necessary, It is desirable, however, to adjust only one guide
align window as described under "REAR DOOR cam at a time in order to maintain the fore and
WINDOW ADJUSTMENTS." Prior to installa aft adjustment of the window assembly.
tion of window lower sash channel cam, lubricate a. To adjust front of window* assembly in or out
entire length of cam with 630 AAW Lubriplate or proceed as follows:
equivalent. Also lubricate lower sash channel 1 With window in full up position, loosen
cam rollers and pivot area of rear door window front guide cam adjusting stud nut fig.
rear guide. 50.
Adjustments 2 Loosen front female wedge plate attaching
IMPORTANT: The rear door assembly should screw.
be properly aligned in the body opening be 3 Loosen two front guide cam support at
fore adjusting the rear door window. taching screws on door hinge pillar facing.
Adjustments have been provided to insure proper 4 Position front of window assembly in or
contact of the rear door window with the side roof out as required and adjust front female
rail weatherstrip and the rear door window front wedge plate accordingly; then tighten
frame weatherstrip. Unless otherwise specified, the wedge plate attaching screw.
following window adjustments are for both manually 5 Adjust front guide cam lower adjusting
and electrically-operated windows. stud in or out as required and tighten nut.
Tighten front guide cam support attaching
NOTE: To perform the following rear door
window adjustments, remove door trim assem screws on door hinge pillar facing.
bly and detach inner panel water deflector. 6 Reseal lower adjusting stud and nut with
caulking compound.
1. Up and down adjustment of door window as
sembly. 7 Position window assembly in or out as
required; then tighten screws.
a. Through inner panel access holes, loosen
screws securing front and rear male wedge 8 Adjust lower adjusting stud in or out as
plates to window lower sash channel. required and tighten stud nut. Check win
dow for proper operation.
b. Reposition window assembly as required, ad
just front and rear male wedge plates up or NOTE: On styles where lower adjusting
down as required; then tighten wedge plate stud and nut are not covered by a
attaching screws. Check operation of window water deflector, seal stud and nut with
assembly. body caulking compound.
IMPORTANT: The front or rear of window
assembly may be adjusted up or down by SIDE ROOF RAIL WEATHERSTRIP
adjusting either front or rear male wedge The side roof rail weatherstrip assembly is a one-
plate up or down as required. In cases of piece type which is secured to the front body hinge
malor adjustment, however, both wedge pillar with a snap fastener. The remainder of the
plates should be adjusted. weatherstrip is secured to the side roof rail by weath
2. Fore or aft adjustment of rear door window as erstrip adhesive and a weatherstrip retainer and re
sembly. veal molding assembly.
a. Loosen lower adjusting stud nut on both front
and rear guide cams fig. 50. Side Roof Rail Weatherstrips-47 Styles
b. Loosen screws securing upper end of front Removal
and rear guide cams, position window fore or 1. Remove snap fastener securing weatherstrip at
aft as required, then tighten screws and front body hinge pillar.
lower stud nut on each cam. 2. Carefully disengage inner lip of side roof rail
c. Check window for proper operation and, if weatherstrip from retainer. Using a flat-bladed
necessary, readjust rear door window front tool, carefully break cement bond between weath
and/or rear male wedge plates fore or aft to erstrip and weatherstrip retainer and reveal mold
insure proper contact with female wedge plates ing assembly.
on door inner panel. 3. Remove side roof rail weatherstrip from body.

BODY 14-34
Installation
1. Clean off old cement from side roof rail weather
strip retainer to insure a clean cementing surface.
2. Apply a continuous bead approximately 3/"
diameter of weatherstrip adhesive along entire
outboard surface of side roof rail weatherstrip
retainer See Section "B-B" in Figure 56.
Fig. 57-Side Roof Rail Weatherstrip Assembly-39 and 47 Styles
outboard surface of side roof rail weatherstrip re

tainer see Section "B-B" in Figure 57.
3. With a flat-bladed tool, engage inboard edge of
weatherstrip and then outboard edge of weather
strip into weatherstrip retainer.
4. Install snap fastener at front body hinge pillar and
clean off all excessive weatherstrip cement.
Fig. 56-Side Roof Rail Weatherstrip Assembly-47 Styles Side Roof Rail Weatherstrip Adjustments
39-47 Styles
3. With a flat-bladed tool, engage inboard edge of With doors and windows closed, front door window
weatherstrip and then outboard edge of weather and rear door or rear quarter window upper frames
strip into weatherstrip retainer. should make an even continuous contact with the side
4. Install snap fastener at front body hinge pillar and roof rail weatherstrip. If necessary, adjust weather
clean off all excessive weatherstrip cement. strip, ventilator assembly, front door window and rear
door or rear quarter window to obtain proper weath
Side Roof Rail Weatherstrip erstrip contact.
39 Styles The attaching holes in the side roof rail weather
strip retainer are elongated, allowing in and out ad
The side roof rail weatherstrip assembly is a one- justment of the side roof rail weatherstrip; however,
piece type which is secured to the front body hinge the amount of adjustment is small and is not intended
pillar with a snap fastener. The remainder of the to correct improper ventilator or door window align
weatherstrip is secured to the side roof rail by weath ment. It is necessary to remove the weatherstrip to
erstrip adhesive and a weatherstrip retainer and re adjust the retainer.
veal molding assembly.
IMPORTANT: Before attempting to adjust the
Removal
side roof rail weatherstrip, first check that the
1. Remove snap fastener securing weatherstrip at body side glass is properly aligned and,
front body hinge pillar. where necessary, adjust for proper alignment
2. Carefully disengage inner lip of side roof rail as directed under Ventilator, Front Door Win
weatherstrip from retainer. Using a flat-bladed dow, Rear Door Window and Rear Quarter
tool, carefully break cement bond between weath Window Alignment.
erstrip and weatherstrip retainer and reveal mold
1. To adjust the side roof rail weatherstrip "in or
ing assembly.
out," first determine and mark retainer at area
3. Remove side roof rail weatherstrip from body. or areas to be adjusted.
Installation 2. Remove side roof rail weatherstrip.
1. Clean off old cement from side roof rail weather 3. Loosen retainer attaching screws slightly in area
strip and weatherstrip retainer to insure a clean to be adjusted and adjust retainer in or out as
cementing surface. required.
2. Apply a continuous bead approximately /16" 4. Tighten retainer attaching screws and install side
diameter of weatherstrip adhesive along entire roof rail weatherstrip.

BODY 14-35
REAR QUARTER
TRIM AND HARDWARE
Service procedures are arranged according to body
style in the following sequence:
Two Door Sedans "11" Styles
Two Door Coupes "47" Styles
Convertibles "67" Styles
Four Door Sedans "39" and "69" Styles
Station Wagons "35" and "45" Styles
Fig. 59-Rear Quarter Hardware-i 1 Styles-Electric
A. Rear Quarter Window Assembly.

B. Rear Quarter Window Glass Run Channel.
C. Rear Quarter Window Front Guide.
D. Rear Quarter Window Rear Guide.
E. Rear Quarter Window Regulator.
F. Rear Quarter Window Lower Stop.
Fig. 58-Rear Quarter Hardware-i 1 Styles-Manual
A. Rear Quarter Window Assembly.

B. Rear Quarter Window Front Upper Glass Run. Channel.
C. Rear Quarter Window Front Lower Glass Run Channel.
D. Rear Quarter Window Rear Glass Run Channel.
E. Rear Quarter Window Regulator.
NOTE: Use caution when performing service

operations on or near the rear quarter window
as it is made of solid tempered safety plate
glass and edge chips or deep scratches can
cause it to shatter.
Trim Assembly
11 Styles
1. Remove rear seat cushion and seat back assem
blies.
2. Remove rear quarter garnish moldings and rear Fig. 60-47 Style Rear Quarter
quarter arm rest assembly. On styles with manu A. Rear Quarter Window E. Rear Quarter Window
ally operated windows, remove window regulator Assembly Front Guide
B. Rear Quarter Window Lower F. Rear Quarter Window
handle. Sash Channel Cam Regulator-Manual
C. Rear Quarter Window Upper G. Rear Quarter Window
3. Using a trim panel removing tool No. J-6335, Stop Regulator-Electric
carefully pry rear quarter trim assembly retaining D. Rear Quarter Window Rear H. Rar Quarter Window
Guide Lower Stop
PASSENGER CAR SI-fOP MANUAL SUPPLEMENT

BODY 14-36
Fig. 62-Rear Quarter Hardware Attachment-i 1 Styles-Manual
4. Remove glass from between the panels by lifting it

Fig. 61-67 Style Rear Quarter
inboard, front edge of glass coming out first.
1. Rear Quarter Window Electric Sash Channel Cam
Motor and Regulator Assembly 6. Rear Quarter Window 5. To install, reverse the removal procedure.
2. Rear Quarter Window Assembly Guide Assembly-
3. Rear Quarter Window Hinge Includes Window Upper Stop
Bolt 7. Rear Quarter Window Window Adjustments-Manual
4. Rear Quarter Window Hinge Regulator-Manual
Adjusting Plate 8. Rear Quarter Window 11 Styles
5. Rear Quarter Window Lower Lower Stop
1. To obtain proper horizontal alignment so that the
nails from tacking strip; then lift assembly up- window seats properly in the upper glass run
wards to disengage from retainers at top of rear channels when the window is operated to the "up"
quarter inner panel and remove assembly from position, proceed as follows:
quarter panel. a. Operate the window to the "full up" position
and loosen the window regulator attaching
NOTE: On styles with electrically-operated
screws fig. 62.
windows disengage trim assembly from re
tainers at top of inner panel; then disconnect b. Insert a flat-bladed tool under the window
window switch junction block from switch and lower sash channel and pry the window upward
remove trim assembly. until the lower sash channel is aligned with,
and is making good contact with, the outer seal
4. To install rear quarter trim assembly, reverse re ing strip.
moval procedure. c. Operate window regulator handle rapidly back
and forth a few times one-eighth turn each
Rear Quarter Window-Manual way to eliminate "slack" or "play" and then
tighten regulator attaching screws.
11 Styles
2. To insure proper operation and proper engage
Removal and Installation ment of the window in the rear run channel when
1. Remove rear quarter trim assembly and inner the window is operated to the full down position,
panel access hole cover. proceed as follows:
2. Remove snap ring retainer securing regulator lift a. Loosen rear glass run channel attaching screw
arm to pivot pin on window lower sash channel fig. 62.
fig. 62. b. Operate window to full down position.
3. Disengage rear of window from rear glass run c. Adjust rear glass run channel lower end so
channel. Lower window sufficiently to disengage that it makes slight contact with window as
nylon guide on window front sash channel from sembly and tighten glass run channel attaching
window front glass run channel. screw.

BODY 14-37
Window Regulator-Manual Rear Glass Run Channel-Manual

11 Styles 11 Styles
Removal and Installation Removal and Installation
1. Remove rear quarter trim and inner panel access 1. Remove rear quarter trim assembly, quarter win
hole cover. dow garnish moldings, and inner panel access
hole cover. Operate window to almost full down
2. Remove snap ring retainer securing regulator lift position.
arm to pivot pin on window lower sash channel
fig. 62. 2. Remove rear glass run channel attaching screw
3. Support glass with one hand and disengage regu fig. 62.
lator lift arm from window. Lift window to "full
3. Disengage glass run channel retainers from side
up" and prop it in that position.
roof rail by prying inboard at retainer locations.
4. Remove regulator attaching screws fig. 62 and Disengage tab at rear of run channel from side
remove regulator through access hole. roof rail by moving run channel downward and
5. To install, reverse removal procedure. Adjust rearward.
regulator for proper window operation as de
scribed in "Rear Quarter Window Adjustments" 4. Disengage lower end of run channel from window
for manual "11" styles. assembly and remove run channel from body.
Upper Front Glass Run Channel-Manual installation, apply a bead of body caulking com
pound to rabbet of side roof rail to effect a weath
11 Styles
ertight seal.
After installation, adjust glass run channel attach
1. Remove rear quarter window front and rear gar ing screw for proper window operation as de
nish moldings. Operate rear quarter window to scribed under "Rear Quarter Window Adjust
full down position. ments" for manual "11" styles.
2. Disengage upper forward end of rear glass run
channel from side roof rail sufficiently to allow Window Glass Run Outer Sealing Strip
removal of front glass run channel.
11 Styles
3. Using a thin flat-bladed tool inserted between
front glass run channel and body upper lock pil Removal and Installation
lar, disengage snap-in type clips on run channel 1. Remove rear quarter trim assembly and inner
from lock pillar. panel access hole cover.
NOTE: Make certain prying tool is inserted
2. Disengage window assembly from regulator lift
behind clip to prevent clip from tearing loose
arm by removing snap ring retainer fig. 62.
from run channel.
4. Pull top of run channel inboard sufficiently to 3. Lower window assembly to bottom of quarter
enable lifting channel upward to disengage it from panel and rest it against outer panel.
nylon guide on window front sash channel. 4. Remove screws at front and rear of sealing strip.
5. To install, reverse removal procedure. Prior to Disengage sealing strip clips from quarter outer
installation, apply a bead of body caulking com panel return flange by forcing strip downward at
pound to rabbet of lock pillar to effect a weather- clip locations. Remove sealing strip from body.
tight seal.
NOTE: Use care not to damage strip assembly
or adjacent painted surfaces.
Lower Front Glass Run Channel-Manual
5. To install outer sealing strip, reverse removal
11 Styles procedure.
1. Remove rear quarter trim assembly, and inner Rear Quarter Window-Electric
panel access hole cover. 1611 Styles
2. Remove lower front glass run channel attaching Removal and Installation
screw fig. 62 and remove run channel through
access hole. 1. Lower rear quarter window. Remove rear quarter
window garnish molding. Remove rear quarter
3. To install, reverse removal procedure. arm rest and quarter trim assembly.

BODY 14-38
Window Glass Run Outer Sealing Strip-Electric

1611 Styles
FRONT GUIDE GLASS RUN CHANNEL
UPPER ATTACHING ATTACHING SCREW Removal and Installation
I
SCREW
1. Remove rear quarter trim assembly and inner
-.
panel access hole cover.
2. Remove window lower stop attaching screws and
operate window to full down position.
3. Remove screws at front and rear of sealing strip.
Disengage sealing strip clips from quarter outer
panel return flange by forcing strip downward at
clip locations. Remove sealing strip from body.
NOTE: Use care not to damage strip assembly
or adjacent painted surfaces.
4. To install outer sealing strip, reverse removal

procedure.
:
WINDOW REGULATOR
ATTA - - ---- -IS
Window Glass Run Channel-Electric
1611 Styles
1. Lower rear quarter window. Remove rear quarter
window garnish molding, rear quarter trim as
Fig. 63-Rear Quarter Hardware Attachment-161 1 Styles-Electric
sembly.
2. Remove access hole cover from inner panel. 2. Remove rear quarter window glass run channel
Loosen window front guide upper attaching attaching screw fig. 63. Carefully disengage
screw. Remove window rear guide attaching glass run channel retainers from lock pillar and
screws and remove guide fig. 63. side roof rail and remove run channel.
3. Lift rear quarter window assembly upward and 3. To install glass run channel, reverse removal
rearward and disengage window cam from regu procedure.
lator arm roller. Tilt window inward, disengage
window from front guide and remove window
from between rear quarter panels. Window Front Guide Assembly-Electric
4. To install rear quarter window assembly, reverse 1611 Styles
removal procedure. Prior to installing the window
lower sash channel cam, lubricate channel of cam Removal and Installation
with Lubriplate or its equivalent along length of 1. Remove rear quarter trim assembly.
channel.
Adjust rear quarter window for proper alignment 2. Remove access hole cover from inner panel.
and operation as described under "Rear Quarter Win 3. Remove front guide upper and lower attaching
dow Adjustment" for "11" electric styles. screws fig. 63. Disengage guide from roller on
Seal large access hole cover and front and rear guide window lower sash channel; move front guide
attaching screws as specified under "Rear Quarter assembly rearward between panels sufficiently to
Inner Panel Sealing" for "11" electric styles. allow upper end of guide to be started out through
large access hole; then remove guide assembly.
Window Adjustment-Electric 4. To install front guide assembly, reverse removal
1611 Styles procedure. Prior to installing guide, lubricate
channel of guide with Lubriplate or its equivalent
The upper front corner of the rear quarter window along entire length of channel.
should seat properly in the front glass run channel
through the complete window lowering and raising Adjust rear quarter guide for proper window align
cycle. To accomplish this, loosen the front and rear ment and operation as described under "Rear Quarter
guide attaching screws fig. 63; then adjust the front Window Adjustments" for "11" styles. Seal inner
guide forward and the rear guide upward and forward panel hole cover and front guide attaching screws as
and retighten the attaching screws. specified under "Rear Quarter Inner Panel Sealing."

BODY 14-39
Window Rear Guide Assembly-Electric Rear Quarter Arm Rest Assembly

1611 Styles 47 Styles
1. Remove rear quarter trim assembly. 1. Remove rear seat cushion, seat back, and seat back
filler panel.
2. Remove large access hole cover from inner panel. 2. Remove attaching screws at front and rear of arm
3. Remove rear guide attaching screws fig. 63. rest.
4. Disengage rear guide from roller on window lower 3. On styles with electrical devices in arm rest assem
sash channel and remove rear guide from body. bly carefully detach arm rest from rear quarter
inner panel sufficiently to disconnect wire harness
5. To install rear guide assembly, reverse removal connectors.
procedure. Prior to installation of guide, lubricate
4. Remove arm rest assembly from rear quarter
channel of guide with Lubriplate or its equivalent.
panel.
Seal inner panel access hole cover and rear guide
attaching screws as specified under "Rear Quarter 5. To install arm rest assembly, reverse removal pro
Inner Panel Sealing." cedure. Check operation of any electrical devices.
Window Regulator Assembly-Electric Trim Assembly

1611 Styles 47 Styles
1. Lower rear quarter window and remove rear quar
blies.
ter trim assembly.
2. Remove rear quarter arm rest assembly. Remove
2. Remove access hole cover from inner panel. Re quarter belt finishing moldings where present.
move front guide upper attaching screw and glass 3. On styles with manually-operated windows, re
run channel attaching screw fig. 63. move window regulator handle and anti-friction
3. Disconnect feed wire plug from electric motor. washer.
4. Remove screws securing rear quarter filler panel
CAUTION: DO NOT OPERATE REGULATOR MO
to quarter panel and remove filler panel.
TOR after the window assembly is disengaged
from the regulator or after the regulator assem 5. Using a trim panel removing tool No. J-6335,
bly is removed from the body. Operation of the carefully pry trim assembly retaining nails from
motor with the load removed may damage the tacking strip; then lift trim assembly upward to
unit. disengage from retainers at top of rear quarter
inner panel and remove assembly from body.
4. Remove window regulator attaching screws fig. 6. To install rear quarter trim assembly, reverse re
63, disengage regulator arm roller from window moval procedures.
lower sash channel cam and remove regulator as
sembly through large access hole. NOTE: If any retaining nails are broken off,
NOTE: The procedure for removing the electric they can be replaced with door trim assembly
motor from the rear quarter window regulator nailing strip replacement tabs which are avail
is described and illustrated under "Rear Door able as a service part.
and/or Rear Quarter Window Regulator Electric
Motor Assembly" in the Door Section. Window Assembly-Manual or Electric
5. To install window regulator assembly, reverse 47 Styles
removal procedure. Prior to installing regulator, Removal and Installation
lubricate regulator and window guide cams with 1. Remove rear seat cushion and seat back assem
Lubriplate or its equivalent. blies and rear quarter arm rest and trim assem
Seal access hole cover and any screws which have blies. Remove inner panel access hole cover.
been disturbed as specified under "Rear Quarter NOTE: On models equipped with electric win
Inner Panel Sealing."
dow regulators, disconnect feed wire connector
Adjust window front guide as specified under from electric motor.
"Rear Quarter Window Adjustments" for "11"
CAUTION: Do not operate regulator motor after
electric styles.
the window assembly is disengaged from the
Check operation of window prior to installing rear regulator, operation of the motor with the load
quarter trim and inside hardware. removed may damage the unit.

BODY 14-40
Window Adjustments
47 Styles
blies. Remove rear quarter arm rest and trim
assemblies.
2. To adjust the window fore or aft, loosen the front
and rear guide attaching stud nuts fig. 64. Posi
tion the window and guides fore or aft as required;
then tighten the attaching stud nuts.
3. To adjust the rear quarter window in or out,
loosen the front guide upper attaching stud nuts
fig. 64. Adjust the studs in or out as required;
then tighten the stud nuts.
4. To adjust the top of the rear quarter window in
or out, loosen the front guide lower attaching stud
nut fig. 64. Adjust the stud in or out as required
then tighten the stud nut.
5. To relieve a binding condition between the chan
nels of the front and rear guide, loosen the front
Fig. 64-Rear Quarter Hardware-47 Style-Manual and rear guide adjusting stud nuts fig. 64. Oper
ate window to full up position and tighten upper
2. Remove rear quarter window rear guide attaching stud nuts on the front guide and forward attach
screw fig. 64. Disengage rear guide from roller ing screw on rear guide. Operate window to full
on window lower sash channel and remove guide. down and tighten remaining nuts.
3. With the rear quarter window in the half-down 6. To limit the forward and upward travel of the
position, remove the lower sash channel cam at rear quarter window, adjust the regulator lift arm
taching screws fig. 64. Detach cam from roller stop as required fig. 64.
on regulator arm and remove cam. 7. To limit the down travel of the rear quarter win
dow, remove the inner panel large access hole
4. Remove rear quarter window front guide adjust cover, loosen the lower stop assembly attaching
ing stud nuts fig. 64. bolt located at the lower end of the window front
guide cam and adjust stop up or down as re
5. With the rear quarter window in the half down quired.
position, disengage the front guide adjusting studs
from the adjusting stud holes in the rear quarter NOTE: After performing window adjustments,
inner panel, then disengage front guide from roll seal hardware attaching screws which have
ers on rear quarter window. Remove rear quarter been disturbed, as specified under "Rear Quar
window from between the panels by lifting up ter Inner Panel Sealing" for 47 styles.
ward and inward.
6. To install rear quarter window, insert the window Window Regulator Assembly-Manual or Electric
between the panels and prop in the "up" position. 47 Styles
Engage front guide channels to rollers on window Removal and Installation
lower sash channel frame. Allow window to drop
to the half down position and insert front guide 1. Remove rear quarter window as described under
adjusting studs into the adjusting stud holes in the "Window Assembly Manual or Electric
- Re- -
rear quarter inner panel. Install previously re moval."

moved parts. NOTE: On styles equipped with electric window
Prior to installation of window lower sash channel regulators, disconnect feed wire plug from
cam and front and rear guides, lubricate the channels electric motor.
of the cam and guides with Lubriplate or its equiva CAUTION: Do not operate regulator motor after
lent along the entire length of the channel. the window assembly is disengaged from the
regulator or after the regulator assembly is
Adjust rear quarter window for proper alignment removed from the body. Operation of the motor
and operation as described under "Rear Quarter Win with the load removed may damage the unit.
dow Adjustments" for 47 styles. Seal all hardware
attachments that have been disturbed and the inner 2. Remove rear quarter window regulator attaching
panel access hole cover, as specffied under "Rear screws fig. 64; then remove regulator assembly
Quarter Inner Panel Sealing" for 47 styles. through large access hole.

BODY 14-41
NOTE: The procedure for removing the electric 3. To install, reverse removal procedure. Prior to
motor from the rear quarter window regulator installation of the rear guide lubricate the entire
is described and illustrated under "Rear Door length of the channel with Lubriplate or its
and/or Rear Quarter Window Regulator Elec equivalent.
tric Motor Assembly" in the Door Section. Adjust rear guide for proper window alignment
3. To install, reverse removal procedure. Seal all and operation as described under "Rear Quarter
hardware attaching locations that have been dis Window Adjustments" for 47 styles.
turbed as specified under "Rear Quarter Inner Seal rear guide attaching screws as specified
Panel Sealing" for 47 styles. under "Rear Quarter Inner Panel Sealing" for 47
styles.
Window Regulator Electric Motor Assembly
47 Styles Folding Top Compartment
Side Trim Panel Assembly
See "Rear Door and/or Rear Quarter Window Regu 67 Styles
lator Electric Motor Assembly" in the Door Section. Removal and Installation
1. Remove rear seat cushion and seat back.
Window Front Guide Assembly 2. Remove attaching screws securing front and rear
47 Styles of side trim panel.
Removal and Installation 3. Raise trim panel and move it inboard.
1. Remove rear seat cushion and seat back. Remove 4. Disconnect electrical leads, where present, and
rear quarter arm rest and trim assemblies. Re remove side trim panel.
move rear quarter inner panel large access hole 5. To install folding top compartment side trim panel,
cover. reverse removal procedure.
2. With window in "up" position, remove the win
dow front guide upper and lower attaching stud Rear Quarter T-rim Assembly
nuts fig. 64.
3. Maneuver guide assembly between rear quarter 67 Styles
panels so that upper end of guide can be started Removal and Installation
out of large access hole; then remove guide as 1. Remove folding top compartment side trim panel
sembly. assembly.
4. To install rear quarter window front guide assem
bly, reverse removal procedure. Prior to installa 2. On styles with manually-operated windows, re
tion of the front guide assembly, lubricate chan move window regulator handle and anti-fr.iction
nels of guide with Lubriplate or its equivalent washer.
along full length of channels. 3. Using a trim panel removing tool No. J-6335
Adjust front guide assembly for proper window carefully pry trim assembly retaining nails from
alignment and operation as described under "Rear tacking strips; then lift assembly upward to dis
Quarter Window Adjustments" for 47 styles. engage from retainers at top of rear quarter inner
Seal front guide attaching screws as specified panel and remove assembly from body.
under "Rear Quarter Inner Panel Sealing" for 4. To install rear quarter trim assembly, reverse re
"47" styles. moval procedure.
NOTE: If any retaining nails are broken off,
Window Rear Guide Assembly they can be replaced with door trim assembly
47 Styles nailing strip replacement tabs which are avail
able as a service part.
1. Remove rear seat cushion and back assemblies. Quarter Window Assembly-Manual or Electric
Remove rear quarter arm rest and trim assem 67 Styles
blies. Remove rear quarter inner panel large ac
cess hole cover. Removal and Installation
2. With the window in the "up" position remove the 1. Lower folding top and operate rear quarter win
window rear guide attaching screws fig. 64. dow to half down position. Remove rear seat cush
Disengage guide from roller on window lower ion and seat back. Remove folding top compart
sash channel and remove guide through access ment side trim panel and rear quarter trim as
hole. sembly.

BODY 14-42
2. On styles equipped with electric window regula Quarter Window Adjustments

tors, remove access hole cover and disconnect the 67 Styles
wiring harness electrical feed plug from the regu
lator motor. 1. To adjust the limit of the rear quarter window
up travel, loosen the window guide upper attach
CAUTION: DO NOT OPERATE REGULATOR ing screws fig. 65; then adjust upper stop to
MOTOR after window is disengaged from desired position and tighten guide attaching
regulator. Operation of motor with load re screws.
moved may damage the unit. 2. To adjust the rear quarter window up or down
or fore or aft; or to adjust the top or the rear of
3. Remove window pivot bolt fig. 65. Disengage the window in or out, the folding top compart
window male hinge from female hinge plate; then ment side trim panel and rear quarter trim assem
raise window to disconnect window lower sash bly must be removed to gain access to the pivot
channel cam from roller on window regulator bolt and adjusting studs.
lift arm and remove window. a. Up or down or fore or aft window adjustment:
Loosen pivot bolt and both adjusting stud nuts
fig. 65. Position window as required; then
tighten pivot bolt and stud nuts.
b. In or out adjustment of top of window: Loosen
lower adjusting stud nuts and slightly loosen
rear stud nut. Adjust lower stud in or out, as
required; then tighten both stud nuts fig. 65.
c. In or out adjustment of rear window: Loosen
pivot hinge rear adjusting stud nut and slight
ly lower adjusting stud nut. Loosen window
guide upper attaching nuts and center stud nut
fig. 65. Adjust rear adjusting stud in or out
as required, then tighten both stud nuts. Ad
just window guide for proper alignment with
window and tighten upper attaching nuts and
center stud nut.
NOTE: After performing any rear quarter win
dow adlustment, seal all attaching screws
which have been disturbed as specified under
"Rear Quarter Inner Panel Sealing" for "67"
styles.
Quarter Window Regulator-Manual or Electric

67 Styles
1. Remove rear seat cushion and back, folding top
compartment side trim panel and rear quarter
trim assembly.
2. Remove rear quarter inner panel access hole
Fig. 65-Rear Quarter Hardware-67 Styles
cover.
3. Operate window to "full up" and prop in that po
4. To install rear quarter window assembly, reverse sition.
removal procedure. Prior to installation, lubricate 4. On styles equipped with electric window regula
pivot hinge and window lower sash channel cam tors, disconnect feed wire plug from electric
with Lubriplate or its equivalent. motor.
Adjust rear quarter window for proper alignment CAUTION: DO NOT OPERATE REGULATOR
and operation, as described under "Rear Quarter MOTOR after the regulator assembly is dis
Window Adjustments" for "67" styles. Seal win engaged from the window assembly or after
dow pivot bolt and inner panel access hole cover it is removed from the body. Operation of
as specified under "Rear Quarter Inner Panel the motor with the load removed may damage
Sealing" for "67" styles. the unit.

BODY 14-43
5. Remove regulator attaching screws fig. 65. Dis

engage regulator lift arm roller from window
lower sash channel cam and remove regulator.
6. To install window regulator assembly, reverse re
moval procedure.
Lubricate regulator sector, window cams and pivot
hinge with Lubriplate or its equivalent.
Seal regulator attaching screws and inner panel
access hole cover as specified under "Rear Quarter
Inner Panel Sealing" for "67" styles.
Quarter Window Regulator

Electric Motor Assembly
67 Styles
The procedure for removing the electric motor from
the rear quarter window regulator assembly is similar
to the procedure described under "Rear Door and/or
Rear Quarter Window Regulator Electric Motor As
sembly" in the Door Section.
Fig. 66-Rear Quarter Inner Panel Sealing-i 1 Styles-Manual
Quarter Window Guide Rear Quarter Inner Panel Sealing

67 Styles 11-47-67 Styles
Removal and Installation Whenever the rear quarter inner panel seals have
been disturbed, the area must be resealed before the
1. Remove rear seat cushion and seat back. Remove rear quarter trim is reinstalled.
folding top compartment side trim panel, and rear
quarter trim assembly. Following are the rear quarter inner panel openings
and hardware attaching locations that must be sealed
2. Remove inner panel access hole cover and rear to prevent water entry and possible trim damage. The
quarter window assembly. On styles equipped item numbers are referenced to illustrations as follows:
with electric window regulators, remove window
regulator assembly. "11" styles Manual -Figure 66
"11" styles Electric -Figure 67
3. Remove window guide upper and center attaching
nuts and lower attaching screw fig. 65. Disengage
window guide and remove guide through large
access hole.
4. To install rear quarter window guide, reverse re
moval procedure. Adjust the window guide for
proper window alignment and operation as de
scribed under "Rear Quarter Window Adjust
ments" for "67" styles.
Seal window guide attaching screws, access hole
plug at lock pillar and inner panel access hole
cover as specified under "Rear Quarter Inner
Panel Sealing" for "67" styles.
Quarter Window Glass Run Outer Sealing Strip

67 Styles
1. Remove rear quarter window assembly.
2. Remove screws securing sealing strip to outer
panel and remove strip.
3. To install rear quarter window glass run outer
sealing strip, reverse removal procedure. Fig. 67-Rear Quarter Inner Panel Sealing-i 1 Styles-Electric

BODY 14-44
bead of body caulking compound 1/8" in diameter

across top and down sides of opening contacted
by cover.
After installation of cover, apply body caulking
compound at lower corners where cover crosses
over to inside of inner panel.
2. Window Guide and Glass Run Channel Attaching
Screws-Apply body caulking compound over
window guide attaching screws and holes to effect
a weathertight seal. On convertible styles apply
weatherstrip adhesive black around the window
3 guide attaching hole plug to effect seal between
inner panel and plug.
3. Manual Window Regulator Attaching Screws-
Apply weatherstrip adhesive black over attach-
ing. screws.
4. Electric Window Regulator Attaching Screws-
Apply weatherstrip adhesive black over attach-
ing screws.
5. Window Regulator Spindle Hole Sealing Washer-
Apply weatherstrip adhesive over exposed surface
Fig. 68-Rear Quarter Inner Panel Sealing-47 Styles of washer to seal pores of sponge rubber and joint
between inner panel and washer.
"47" styles-Figure 68 On convertible coupe styles with electrically oper
"67" styles-Figure 69 ated windows apply weatherstrip adhesive black
around the manual regulator spindle hole; then
NOTE: When body caulking compound is used, apply waterproof body tape over spindle hole.
work compound firmly to metal surfaces to
obtain good adhesion. 6. Wire Harness and Grommet Hole Styles with
electrically operated windows -Apply weather
1. Large and Small Access Hole Covers-Prior to in strip adhesive black around the grommet and
stallation of access hole cover apply a continuous wire to effect a seal between wire and grommet
and between grommet and inner panel.
7. Wire Harness Clip Hole Styles with electrically
operated window -Apply weatherstrip adhesive
over hole.
5
8. Gage Slot-Apply waterproof body tape over slot.
9
Items 9 and 10 for "11" styles only.
9. Arm Rest Anchor Nut "11" styles only-Apply
body caulking compound over anchor nut and
hole to effect a seal around anchor nut, hole and
attaching screw when arm rest is installed.
Arm Rest Anchor Nut Hole "11" styles only-
Where anchor nuts are not used, apply waterproof
1 body tape over hole. Press tape firmly to effect a
good bond.
10. Window Stop Attaching Screws "11" styles with
electrically operated windows -Apply weather
strip adhesive black over stop attaching screws.
Item 9 for "47" styles only fig. 68.

9. Seat Back to Quarter Panel Filler Panel Attach
ing Screw Holes-Apply weatherstrip adhesive
Fig. 69-Rear Quarter Inner Panel Sealing-67 Styles black over filler panel attaching holes.

BODY 14-45
Item 9 for "67" styles only fig. 69.

9. Window Hinge Attaching Screws-Apply body
caulking compound over hinge attaching screws.
Press compound firmly to assure a good bond and
watertight seal.
Rear Quarter Lower Trim Assembly

39-69 Styles
1. Remove rear seat cushion and back assemblies.
Remove back window side garnish molding and
side roof rail finishing molding.
2. Remove screw securing metal trim support in
upper center of trim assembly "69" styles only.
3. Using a trim panel removing tool No. J-6335
Fig. 70-Quarter Trim Assembly-Left Side
carefully pry trim assembly retaining nails from
tacking strip; then lift trim assembly upward to
disengage from retainers at top of rear quarter Rear Quarter Front Trim Panel
inner panel and remove trim from quarter panel. 35-45 Styles
4. To install rear quarter trim assembly, reverse Removal and Installation
removal procedure. 1. Remove rear quarter stationary window front
garnish molding.
Rear Quarter Upper Trim Assembly
2. Remove rear quarter front trim panel lower re
39 Styles tainer.
Removal arid Installation 3. Remove screws securing trim panel to body.
1. Remove back window side garnish molding and 4. With a clean rubber mallet, tap trim assembly
side roof rail rear finishing molding. along front edge to free trim assembly retaining
2. Carefully break cement bond securing trim nails in slots.
foundation to roof extension inner panel; then 5. With a suitable flat-bladed tool, carefully loosen
remove trim assembly. trim assembly from inner panel.
3. To install, first apply trim cement to contacting 6. Lift panel upwards to disengage from quarter
surfaces of trim foundation and roof extension inner panel, and remove assembly from body
inner panel. Position trim and press or roll to fig.70.
assure a good cement bond. Install back window 7. To install, reverse removal procedure.
side garnish molding and side roof rail rear finish
ing molding.
Rear Quarter Upper Trim Assembly

1847 Styles
1. Remove back window side garnish molding and
side roof rail rear finishing molding. Remove
quarter belt finishing molding, where present.
2. On styles with courtesy lamps in the upper trim
assembly, remove courtesy lamp lens and two 2
screws securing reflector and remove lamp assem
bly.
3. Carefully insert a trim panel removing tool
J-6335 or other suitable tool between headlin
ing and upper edge of upper trim assembly. Dis
engage upper trim assembly retaining clips from
roof extension inner panel by pulling inboard at
clip locations. Remove trim assembly from body.
4. To install, reverse removal procedure. Fig. 71-Rear Quarter Courtesy Light and Switch

BODY 14-46
Rear Quarter Rear Trim Panel Left Side Spare Tire Cover Panel
35-45 Styles 35-45 Styles
Removal and Installation The spare tire cover panel is secured to a retainer
1. On "45" styles, remove screws securing courtesy at the belt line by a folding catch type handle. To re
lamp and switch assembly to trim panel and care move the panel disengage the catch and lift the panel
fully remove assembly sufficiently to disengage upward. To install, reverse removal procedure.
wires at rear of lamp and switch. Remove rear The handle can be adjusted "in" or "out" to increase
finishing panel fig. 71. or decrease closing effort. To adjust, loosen the handle
2. Remove top screw in rear quarter front trim panel attaching screws; position the handle as desired and
and all screws in rear quarter rear trim panel. tighten the screws.
3. Lift panel slightly upward to disengage from
quarter inner panel and rearward to disengage
from rearward section of rear quarter front trim Rear Quarter Stationary Window Assembly
panel fig. 70. 35-45 Styles
4. On 1235 and 1635 styles, the rear quarter rear Removal
trim panel and wheelhouse covering are all one
panel. To remove, remove all attaching screws 1. Remove rear quarter stationary window garnish
and lift panel upward to disengage from quaiter moldings.
inner panel.
2. Remove rear quarter front trim panels, rear
5. To install, reverse removal procedure. quarter rear trim panel, rear quarter wheelhouse
panel cover, spare tire cover, and spare tire cover
support.
Rear Quarter Wheelhouse Panel Cover
Right Side 3. Remove rear quarter stationary window channel
lower retainers one 1 required for right side,
35-45 Styles two 2 required for left side, fig. 73.
1. Remove spare tire cover.
2. Remove attaching screw securing trim panel to
quarter inner panel and spare tire cover support.
STATIONARY WINDOW
GARNISH MOLDINGS
/
WHEELHOL
°ANEL COVER
Fig. 73-Stationary Window Assembly
4. Using a suitable tool, carefully break seal between

rubber channel and body opening. With aid of
helper, carefully push glass and rubber channel
inboard and remove assembly from opening.
Fig. 72-Rear Quarter Trim Assembly-Right Side
NOTE: Rubber channel may be removed from
3. Remove rear quarter front trim panel. Remove glass as a bench operation.
screws along front edge of wheelhouse cover panel.
CAUTION: Care should be exercised to make
4. Lift panel upward to disengage from quarter
certain glass does not strike body metal during
inner panel and remove panel from body.
installation. Edge chips can lead to future
5. To install, reverse removal procedure. breaks. Do not attempt to grind glass.

BODY 14-47
Installation
1. Clean off old sealer from rubber channel and body
opening to insure a smooth sealing surface. WEATHERSTRIP ADHESIVE BLACK
GLA/
2. Apply a ribbon of medium-bodied sealer com
pletely around window opening.
REAR QUARTER
3. Install window assembly and window channel OUTER PANEL
lower retainers. RUBBER
CHANNEL
4. Using a plews oiler or any other suitable applica
tor, apply an approved weatherstrip adhesive MEDIUM BODIED SEALER
black between glass and outer wall of rubber
channel completely around window. Clean off
excess sealer fig. 74.
5. Replace all previously removed parts. Fig. 74-Stationary Window Sealing
REAR END
BACK WINDOW ASSEMBLY Back Window Reveal Molding Retention
The back window, made of solid tempered safety All Styles
plate glass, is retained in the back body opening by a The back window reveal moldings are retained by
conventional rubber channel that has one cavity to clips which snap over the back window pinchweld or
accept the glass and another cavity which "lips over" retaining flange and engage, by means of barbed
and accepts the back window opening pinchweld or prongs, a flange on the molding, or, as in the case of
retaining flange. the lower reveal molding on "47" styles, another clip
To remove the back window and rubber channel in the molding.
Figures 75 and 76 illustrate the manner in which
assembly, it is necessary to first remove the reveal
the various types of attachment retain the molding.
moldings around the periphery of the back window. Figure 75 also illustrates the tool to be used and
Following are the procedures for servicing the entire the proper method for disengaging the molding from
back window assembly, beginning with molding re the pinchweld type clip.
moval, then back window removal, and, finally, back
window installation. Back Window Reveal Moldings
All Styles
With the exception of the lower reveal molding on
"47" styles, the back window reveal moldings are re
MOLDING MOLDING UPPER REVEAL

RETAINING CLIP RETAINING MOLDING
LOWER REVEAL
MOLDING
MOLDING MOLDING
MOLDING
RETAINING
DING
RETAINING CLIP
SECTION THROUGH SECTION THROUGH

BACK WINDOW BACK WINDOW-"47" STYLES
ALL STYLES EXCEPT "47"
Fig. 75-Removing Molding With Tool J-7898-O1 Fig. 76-Back Window Reveal Molding Retention

BODY 14-48
tamed entirely by pinchweld type clips. The procedure 4. Carefully push back window and rubber channel
for removing a molding secured in this manner is de assembly outward until lip of rubber channel is
scribed under "Pinchweld Clip Disengagement". disengaged from body pinchweld flange.
5. With the aid of a helper, lift complete assembly
Pinchweld Clip Disengagement from body opening and place on a protected sur
face. Remove rubber channel from glass.
Insert point of tool J-7898-O1 between back window
rubber channel and reveal molding. Slide tool along IMPORTANT: Care should be exercised to make
molding until a clip is contacted, then engage point certain glass does not strike body metal during
of tool between retaining clip and molding fig. 75. installation as edge chips can cause solid
Swing tool slightly to disengage prongs of clip from tempered safety plate glass to shatter. DO
moldings and lift molding free of clip. Repeat this NOT attempt to grind glass.
operation at each clip location. Installation
NOTE: Do not lift excessively on molding. If 1. Clean original sealer from back window body
clip is disengaged, molding will lift free of clip opening and rubber channel and install rubber
easily. If clip is not disengaged, any excessive channel to glass.
lift on molding will cause prongs of clip to
IMPORTANT: Before installing back window
bite harder into molding making disengage
glass, check the back window body opening
ment more difficult. If difficulty is being exper
ienced in disengaging clip, push molding at and pinchweld flange for any irregularities and
clip location to relieve pressure of clip prongs correct, where necessary.
while continuing efforts to disengage clip. 2. Check installation of reveal molding clips at pinch-
weld and retaining flanges and replace clips, where
An occasional application of silicone lubricant to end
necessary. If replacing clips, apply medium-bodied
of tool will help to slide tool between molding and
sealer to opening rabbet, prior to installing clips
rubber channel.
see "1" in View "A" Figure 77.
3. Apply a continuous ribbon of medium-bodied seal
Lower Reveal Molding er approximately ‘/2 inch wide by ¼ inch thick
1847 Styles on wall of rabbet, completely around opening see
"2" in Section "B-B" Figure 77.
Removal and Installat ion
4. Insert a strong cord into pinchweld cavity of rub
Remove belt reveal moldings as described in "Ex ber channel; tie ends together at bottom center
terior Moldings". Using reveal molding tool J-7898-O1 and tape to inside surface of glass.
insert point of tool between molding and rubber chan 5. Apply a continuous ribbon of medium-bodied seal
nel and push or pull molding clip sideways to slide er approximately 1/2 inch wide by ¼ inch thick
it out of engagement from pinchweld retaining clip to base of rubber channel across top and down
fig. 76. Perform this operation at each molding clip sides see "3" in Section "B-B" Figure 77.
location and remove molding from body.
6. With aid of a helper, position back window assem
To install, first slide molding clips in molding so bly into body opening. While helper is applying
that they will be in position to engage retaining clips hand pressure to outside surface of glass, use a
on body; then position molding to body and engage hooked tool or other suitable tool to pull inner lip
clips. of rubber channel located along lower portion of
channel over retaining flanges along bottom open
Back Window Assembly ing.
All Styles 7. With aid of helper applying hand pressure to out
side surface of glass, pull cords in rubber channel
Removal and, where necessary, use a hooked tool to seat
1. Place protective coverings over rear seat cushion lip of rubber channel over body flanges across
and seat back, over parcel shelf trim and over bottom, up sides and across top of window opening.
painted surfaces around back window. On all
IMPORTANT: If, during the string-pulling op
styles but "11"-"69" styles, remove back window
eration, the rubber lip is not seating properly
garnish moldings. On "11" and "69" styles remove
over the body flange, check for locations
headlining retainer finishing lace around back
where rubber channel is tight against the body
window.
flange preventing forward movement of the
2. Remove back window reveal moldings. glass and channel assembly into the opening.
3. From inside body carefully break seal between Using a hooked tool, seat the rubber lip over
lip of rubber channel and pinchweld flange com the body flange at any tight locations before
pletely around back window. proceeding with the cord-pulling sequence.

BODY 14-49
4 2
5Ø/
2
SECTION "C-C"
C
B
SECTION "B-B"
REVEAL MOLDING CLIP
VIEW "A"
Fig. 77-Back Window Sealing
8. Using a pressure-type applicator, apply sufficient to act as a counterbalance and hold-open for the lid.
medium-bodied sealer to completely fill any open Notches at the hinge end of the rods allow for adjust
ings between rubber channel and body completely ment of the rods to increase or decrease operating
around rubber channel see "4" in Section "C-C" effort of the lid.
Figure 77. The rear compartment lid lock employs a side-action
9. Using a pressure-type applicator Pistol-type snap-bolt mechanism that has provisions at the attach
oiler apply weatherstrip adhesive black be ing locations for lateral adjustment. Up and down
tween rubber channel and glass on inside and out adjustment is available at the striker attaching loca
side of glass around entire perimeter of glass see tions.
"5" in Section "C-C" Figure 77. Application of
All styles use a single section cement-on type weath
adhesive should be continuous with no skips.
erstrip which is cemented to the rear compartment
10. Install back window moldings as described under gutter completely around the lid opening.
"Back Window Reveal Moldings."
11. Clean off excess sealer and cement; install previ
ously removed parts and remove protective cover Rear Compartment Lid
ings. All Styles
REAR COMPARTMENT
1. Open lid and place protective covering along edges
The rear compartment lid employs two torsion rods of rear compartment opening to prevent damage
that are mounted between the lid and hinge assemblies to painted surface.

BODY 14-50
Rear Compartment Lid Hinge

All Styles
Removal
1. Place protective covering over body around upper

portion of rear compartment opening and provide
support for lid on side where hinge is to be re
moved.
2. Remove rear compartment side trim foundation at
hinge area if necessary. If left hinge is being re
moved, disengage wire harness from clip on left
hinge.
3. Mark location of hinge strap on lid inner panel and
remove bolts securing hinge strap to lid.
4. With a suitable tool disengage torque rod from
notched retainer on inboard face of opposite hinge
box "E" fig. 78.
NOTE: Mark retainer notch before removing
torque rod to insure that rod is installed in
same position.
5. Disengage opposite end of torque rod from mova
ble portion of hinge strap and remove rod.
6. Bend up hinge pin retaining tab on inboard face
of hinge box "D" fig. 78; remove hinge pin and
then remove hinge from box.
Fig. 78-Rear Compartment Hinge and Torque Rod
Installation
2. Disengage wire harness from clips on hinge and 1. Position hinge in hinge box and install hinge pin.
rear compartment lid inner panel and remove wire Bend over retaining tab to secure hinge pin.
harness from lid where necessary.
2. Position hinge strap within scribe marks on lid
3. Mark location of hinge straps on lid inner panel. inner panel and install attaching bolts.
4. With aid of helper, remove lid attaching bolts "A"
3. Install "U" shaped end of torque rod to hinge box
fig. 78 and remove rear compartment lid.
making certain outer end of rod is engaged in hole
5. To install rear compartment lid reverse removal in outboard face of hinge box.
procedure. Align lid with scribe marks before
4. Engage torque rod to lower movable portion of
tightening hinge attaching bolts.
hinge and engage other end of rod to correct re
taining notch in inboard face of opposite hinge
Rear Compartment Lid Adustments box.
All Styles 5. Check alignment of rear compartment lid and
1. To adjust compartment lid forward or rearward, make any necessary adjustments.
or from side to side in body opening, loosen both 6. Replace wire harness if left hinge was removed.
hinge strap attaching bolts and adjust lid as re 7. Replace all previously removed trim.
quired; then tighten bolts.
2. To adjust compartment lid at hinge area up or
down, install shims between lid inner panel and Rear Compartment Torque Rod Adjustment
hinge straps as follows: All Styles
a. To raise front edge of lid at hinge area, place The amount of effort required to open and close the
shim between lid inner panel and forward por rear compartment lid is determined by the position of
tion of one or both hinge straps at "C" Figure the torque rod in the notches on the inboard face of
78. the hinge boxes. If the torque rod is located in the
b. To lower front edge of lid at hinge area, place lowest most forward notch position #1, the amount of
shim between lid inner panel and rearward por effort required to open the lid is the greatest and the
tion of one or both hinge straps at "B" Figure amount of effort required to close the lid is the least.
78. If the torque rod is located in the top or most rearward
3. To check lid lock bolt engagement with striker, see notch position #3 the amount of effort to open the lid
"Rear Compartment Lid Lock Striker Engage is the least and the amount of effort to close the lid is
ment Check." the greatest. See "E" fig. 78.

BODY 14-51
NOTE: It is not necessary to adjust the left and 3. To install, position striker within scribed marks
right hand torque rods at the same time or to and install attaching screws. Check for proper
the same final position notch. alignment.
Rear Compartment Lid Lock Cylinder Rear Compartment Lid Lock Striker Engagement
All Styles All Styles
The rear compartment lid lock cylinder is secured to IMPORTANT: Since the rear compartment lock
the rear compartment lid by a metal retainer that must frame acts as a guide when entering the strik
be removed before the rear compartment lid lock as er, make sure rear compartment lid is properly
sembly can be removed. positioned in body opening before performing
Removal and Installation striker engagement check. To check for proper
1. Open rear compartment lid. Blow lock cylinder engagement of rear compartment lid lock bolt
and adjacent to rear compartment lid hemming with striker, use the following procedure:
flange, remove lock cylinder retainer attaching a. Insert a small quantity of modeling clay on
screws and remove retainer and lock cylinder as frame of lock at both sides of the lock bolt fig.
sembly. 79. Close lid with moderate force.
2. To install, reverse removal procedure. Make cer b. Open lid and check amount of engagement of
tain that lock cylinder gasket seals to the rear striker with lock frame as indicated by the com
compartment lid outer panel. Check lock cylinder pression of the clay. The striker bar impressions
for proper operation. in the clay should be even on both sides of the
/ lock frame. Where required, loosen striker or
Rear Compartment Lid Lock lock attaching screws; adjust lock sideways or
All Styles striker up or down to obtain proper engage
ment; then, tighten screws.
1. Remove lock cylinder retainer and lock cylinder
assembly. TAIL GATE
2. Remove lid lock attaching screws fig. 79 and re 35-45 Styles
move lock assembly. All tail gates incorporate either a manually operated
3. To install, reverse removal procedure. Check for or electrically operated tail gate window which can be
proper operation of lock and lock cylinder. lowered into the tail gate or raised into the upper por
tion of the back body opening. The manually operated
Rear Compartment Lid Lock Striker tail gate window is operated by means of a window
regulator control handle folding type located in the
All Styles tail gate outer panel. The electrically operated tail
Removal and Installation gate window can be operated from any one of two
1. Open rear compartment lid. Mark vertical posi control switches: 1 control switch located on instru
tion of striker by scribing line on striker at top of ment panel; 2 lock cylinder control switch key
striker support. Mark horizontal position of striker operated located in tail gate outer panel. In addition,
on striker support. on nine passenger station wagon styles, the window
2. Remove striker attaching screws fig. 79 and re can be operated by a control switch located in the
move striker. upper portion of the left rear quarter trim assembly.
A switch located at the right tail gate lock prevents
the up cycle operation of the electrically operated tail
gate window when the tail gate is not completely
closed.
After lowering the tail gate window the tail gate can
be opened by means of a tail gate lock remote control
inside handle located at the tail gate belt finishing
molding. On styles with the electrically operated tail
gate window the tail gate lock remote control incor
porates a safety feature which prevents operation of
the inside handle unless the tail gate window is in the
full down position.
The tail gate hinges are secured to the body rear
cross bar and the tail gate inner panel by screws,
which are accessible upon removal of the cross bar
Fig. 79-Rear Compartment Lid Lock and Striker hinge cover plate and tail gate inner cover panel.

BODY 14-52
The tail gate is counterbalanced by a single torque Tail Gate Assembly

rod that is secured at the left rear body opening pillar
by a mounting plate and between the tail gate panels
by a retainer welded to the tail gate right side facing. 1. Open tail gate and remove tail gate inner cover
When the tail gate is opened the portion of the panel lower retainer and inner cover panel.
torque rod inside of the tail gate rotates with the gate 2. Carefully remove inner panel water deflector.
while the end of the rod secured to the body pillar Through small hole in access hole covers disen
remains stationary. This creates an assisting torque to gage remote control to lock connecting rods from
hold the tail gate as the gate approaches and reaches clips on access hole covers by lifting rods upward.
the open position. This torque also assists in closing Remove both large access hole covers.
the tail gate. Figure 80 is a phantom view which iden
tifies and shows the relationship of major component 3. On styles equipped with electrically operated tail
parts of the tail gate assembly. gate window remove tail gate window. Remove
lock cylinder switch and escutcheon assembly as
described under "Lock Cylinder Switch and Es
cutcheon Assembly-Removal and Installation."
Detach harness connector from regulator motor.
4. On all styles, detach harness connectors from tail
lights in tail gate and detach harness from clips
inside the tail gate; then remove harness from
tail gate.
5. Mark position of tail gate hinge tail gate side to
facilitate installation in same position.
6. Raise tail gate to approximately a vertical posi
tion to relieve torque from torque rod. Remove
torque rod mounting plate attaching screws fig.
81 from left body pillar and remove mounting
plate.
7. Suitably support tail gate to facilitate detachment
of tail gate supports, then remove support attach
ing screws fig. 82 from both sides of tail gate and
fold supports against body.
8. With the aid of a helper remove tail gate to hinge
attaching screws fig. 83 from both hinges and
remove tail gate assembly from body.
9. To install tail gate assembly reverse removal pro
cedure. Prior to installation apply a coat of heavy
bodied sealer to surface of hinge straps that con
tact tail gate inner panel fig. 84.
Fig. 80-Tail Gate Assembly Components

A. Tail Gate Window I. Tail Gate Lock Remote Control
B. Tail Gate Window Regulator Inside Handle-to-Remote
Outside Handle or Lock Control Connecting Rod
Cylinder Switch and Escutcheon J. Tail Gate Locks
C. Tail Gate Window Regulator K. Tail Gate Lock-to-Remote
Manual Control Connecting Rods
D. Tail Gate Window Regulator L. Tail Gate Lock Remote Control
Electric M. Tail Gate Torque Rod
E. Tail Gate Window Glass Side N. Tail Gate Torque Rod Lower
Run Channels Retainer
F. Tail Gate Window Lower Sash 0. Tail Gate Torque Rod Side
Channel Cams Retainer
G. Tail Gate Window Anti-Rattle P. Tail Gate Torque Rod Mounting
Clip Plate-On Body Pillar
H. Tail Gate Lock Remote Control Q. Tail Gate Hinges
Inside Handle Fig. 81-Tail Gate Support and Torque Rod Attachment

BODY 14-53
To adjust the tail gate assembly forward or rear

ward in the body opening loosen the tail gate hinge to
rear body cross bar attaching screws, shift tail gate
assembly to the desired position and retighten the
screws.
If "up or down" or "in or out" adjustment of tail
gate has affected lock striker engagement, adjust
strikers as described under "Tail Gate Lock Striker
Adjustment."
Tail Gate Torque Rod

Fig. 82-Tail Gate Lock and Support Removal and Installation
1. Open tail gate and remove tail gate inner cover
Where necessary, adjust tail gate for proper align panel lower retainer, inner cover panel, inner
ment in body opening as specified under "Tail Gate panel water deflector, and both large access hole
Adjustments." covers.
2. Raise tail gate to almost a vertical position to re
Tail Gate Adjustments lieve torque from torque rod. Remove torque rod
To adjust the tail gate assembly "up or down" side mounting plate attaching screws from left body
ways in the body opening loosen the tail gate to hinge pillar and remove mounting plate fig. 81.
attaching screws fig. 83; shift tail gate to desired 3. Lower tail gate to open position. Remove screws
position and retighten screws. securing torque rod bearing plate to tail gate left
side lower facing and remove bearing plate and
bearing and bearing plate sealing washer through
access hole.
4. Remove torque rod lower retainer attaching screw
fig. 83 and remove retainer.
LOWER RETAINER 5. Remove remote control assembly attaching screws
ATTACHING SCREW
fig. 83 and lay remote control assembly on tail
gate window.
6. Work torque rod out of tail gate through torque
nut entrance hole at left lower corner of tail gate
side facing.
7. To install tail gate torque rod, reverse removal
procedure. Make sure left end of torque rod is
properly engaged in both notches of side retainer
at left side of tail gate fig. 80.
Lubricate nylon insert in torque rod mounting
Fig. 83-Tail Gate Hardware
plate with Lubriplate or its equivalent. Wipe off
excess lubricant.
Tail Gate Hinge

1. Remove tail gate assembly.
2. On side of body from which hinge is being re
TAIL GATE
OUTER PANEL moved, loosen rear bumper sufficiently to allow
hinge to be removed from body.
3. Scribe mark position of hinge to facilitate in
stallation in same position.
4. Remove hinge attaching bolts and remove hinge
from body.
5. To install tail gate hinge, reverse removal proce
dure. Prior to installation apply a coat of heavy
bodied sealer to surfaces of hinge strap which
contact tail gate inner panel and body rear cross
Fig. 84-Tail Gate Hinge Assembly bar fig. 84. Where necessary adjust tail gate for

BODY 14-54
proper alignment in body opening as described 3. Remove lower sash channel cam attaching screws
under "Tail Gate Adjustments." and lower window assembly into tail gate. Open
tail gate.
Tail Gate Window Assembly- In the event the window is inoperative in the full
Manual and Electric "up" position, the window regulator attaching screws
can be removed and the window and regulator lowered
Removal and Installation sufficiently to allow removal of the window lower sash
1. Remove inner cover panel lower retainer and in channel cam attaching screws.
ner cover panel.
Tail Gate Window Adjustments
2. Detach tail gate inner panel water deflector suffi
ciently to gain access to window lower sash chan 1. To adjust the tail gate window forward or rear
nel attaching bolts fig. 83. Remove tail gate inner ward for proper alignment with the window glass
panel access hole covers. run channels on the body and/or to eliminate a
3 Carefully operate window upward until the win binding condition of the window in the tail gate
dow lower sash right and left cam attaching bolts glass run side channels, loosen lower attaching
are accessible through access holes fig. 83. bolt at tail gate lock pillar; move lower end of
channel forward or rearward, as required, and
4. Remove window lower sash channel right and tighten lower attaching bolts.
left cam attaching bolts fig. 83 and disengage
cams from window lower sash channel. Remove NOTE: The vertical portion of the tail gate win
window assembly from tail gate. dow glass upper run channels are adjustable
forward or rearward for proper alignment with
NOTE: To open the tail gate on styles with the tail gate glass.
electric windows when window assembly is 2. To correct a condition where the glass is "cocked"
removed, depress tail gate lock remote control in the glass run channels, loosen window regu
locking lever through access hole at location lator attaching screws fig. 85, rotate regulator
"A," fig. 83 and at the same time operate the assembly clockwise or counterclockwise, as re
quired, to eliminate "cocked" condition.
tail gate remote control inside handle.
5. To install tail gate window assembly, reverse re Tail Gate Window Regulator Assembly-
moval procedure. Prior to installing window lower Manual or Electric
sash channel cams, lubricate channel portion of Removal and Installation
cams with "Lubriplate" or its equivalent. Prior to 1. Remove tail gate window assembly, as described
resealing tail gate inner panel water deflector, under "Tail Gate Window Assembly-Removal
check operation of window and tail gate locking and Installation."
mechanisms. Where necessary, adjust tail gate
window, tail gate lock strikers or tail gate lock 2. Detach tail gate lock remote control right con
remote control for proper operation. Reseal tail necting rod from remote control at "A" fig. 85.
gate inner panel water deflector as specified under 3. On styles equipped with electrically operated tail
"Tail Gate Inner Panel Sealing." gate window; disconnect tail gate harness connect
or from regulator motor.
If the tail gate cannot be opened due to the window
becoming inoperative while in an up position, proceed
as follows:
1. Using an offset screwdriver, remove tail gate inner
cover panel attaching screws. Lift panel upward
to disengage it from lower retainer.
NOTE: Due to inaccessibility, it may be neces

sary to cut lower left cover panel attaching
screws by chisel. To make chisel, taper one
end of an 18" x 1" x /e piece of steel. Cut
lower screws by inserting chisel between tail
gate inner panel and tail gate cover panel.
2. Remove inner panel access hole cover upper at

taching screws. Loosen access hole cover lower
attaching screws and remove cover by lifting it
upward. Fig. 85-Tail Gate Window Regulator

BODY 14-55
CAUTION: Do not operate regulator motor after NOTE: Do not locate hole less than ½ inch
window assembly is disengaged from the regu away from edge of backplate, sector or holes
lator or after the regulator is removed from the in backplate and sector. Do not use holes in
tail gate. Operation of the motor with the load backplate or sector as they are too large and
removed may damage the unit and make it locking bolt can slip out.
inoperative.
4. Insert a inch bolt through hole in backplate
4. Remove regulator attaching screws through ac
and sector and install nut to bolt. Do not tighten
cess holes at locations shown in Figure 85. Remove
nut.
regulator assembly through large access hole.
NOTE: To remove electric motor from regulator 5. Remove three 3 motor attaching bolts, at loca
tions shown in Figure 86, and remove motor as
assembly see "Tail Gate Window Regulator
sembly from regulator.
Electric Motor Assembly-Removal and Instal
lation." NOTE: Clean off steel chips from the regulator
5. To install tail gate window regulator assembly, sectors and motor pinion gear after drilling
reverse removal procedure. Prior to installing operation.
regulator, lubricate the teeth on the regulator sec
tors with "Lubriplate" or its equivalent. 6. To install regulator electric motor assembly, re
verse removal procedure.
Prior to resealing tail gate inner panel water de
flector, check operation of window and tail gate lock NOTE: Be sure to remove nut and bolt locking
ing mechanism. Where necessary, adjust tail gate sector after motor is installed.
window, tail gate lock strikers or tail gate lock remote
control for proper operation.
Tail Gate Window Regulator
Tail Gate Window Regulator Electric Outside Handle Assembly
Motor Assembly Removal and Installation
1. Remove inner cover panel lower retainer and in
ner cover panel.
1. Remove tail gate window regulator and electric
motor assembly as described under "Tail Gate 2. Detach tail gate inner panel water deflector suffi
Window Regulator Assembly-Removal and In ciently to gain access to holes "A" for removal of
stallation." handle attaching nuts fig. 87.
2. Place regulator assembly in a vise as shown in
Figure 86.
LOCATIONS FOR
REGULATOR MOTOR
ATTACI-
Fig. 86-Window Regulator Motor Removal
CAUTION: Be sure to perform steps 3 and 4

before attempting to remove the motor from
the regulator. The regulator lift arms which are
under tension from the counterbalance spring
can cause serious injury if the motor is re
moved without locking the sectors in position.
3. Drill a ¼ inch hole through regulator backplate
and main sector within area indicated by dotted
lines fig. 86. Fig. 87-Outside Handle and Lock Remote Control

BODY 14-56
3. Carefully raise window until holes in window ESCUTCHEON LOCK PAWL & SPRING
regulator are aligned with holes "A" in inner
panel. V,7/HANDLE DRIVER
CAUTION: Support portion of glass extending

out of tail gate fig. 87.
I/
LOCK
Through holes "A," remove outside handle attach HANDLE
CYLINDER
ing nuts and remove outside handle and gasket HINGE PIN
from tail gate.
To disassemble tail gate handle assembly, see "Tail HANDLE SPRING
Gate Handle Assembly-Disassembly and Assem
bly."
I I WASHER
HANDLE
4. To install tail gate handle, assembly, reverse re
I I HANDLE WASHER HINGE
moval procedure. Make sure sealing gasket is

I RETAINING RING PIN SCREWS
CLUTCH ‘HANDLE &
installed between tail gate outer panel and handle LCLUTCH RETAINING RING KNOB
escutcheon and make sure handle clutch is prop ASSEMBLY
erly engaged with window regulator clutch. Check
operation of window prior to resealing water de
flector. Reseal tail gate inner panel water deflector Fig. 88-Tail Gate Window Regulator Outside Handle Assembly
as specified under "Tail Gate Inner Panel Water
Deflector." 5. To remove lock cylinder and cap assembly, lock
ing pawl or locking pawl spring see "Tail Gate
Tail Gate Window Regulator Outside Handle Window Regulator Outside Handle Lock Cylinder
Lock Cylinder and Cap Assembly and Cap Assembly-Removal and Installation."
Removal and Installation To assemble tail gate window regulator outside
1. Remove tail gate window regulator outside han handle assembly, reverse disassembly procedure.
dle assembly from tail gate, as previously de Prior to assembly lubricate frictional surfaces
scribed. with "Lubriplate 630 AAW" or its equivalent.
2. Remove clutch retaining ring and slide clutch off
shaft of handle driver fig. 88. Tail Gate Electric Window Lock Cylinder,
3. Insert key in lock cylinder and turn key to lock Switch and Escutcheon Assembly
position. Depress locking pawl fig. 88, turn key Removal and Installation
lock cylinder approximately ¼ turn counter 1. Remove inner cover panel lower retainer and in
clockwise and remove lock cylinder assembly, ner cover panel.
locking pawl and locking pawl spring from handle
driver. 2. Detach tail gate inner panel water deflector suffi
4. To install lock cylinder assembly, reverse removal ciently to gain access to holes "A" for removal of
procedure. Prior to installing clutch on handle attaching nuts fig. 87.
driver lubricate frictional surfaces with "Lubri 3. Carefully operate window upward until holes in
plate 630 AAW" or its equivalent. window regulator assembly are aligned with holes
"A" in inner panel.
Tail Gate Window Regulator
CAUTION: Support portion of glass extending
Outside Handle Assembly
out of tail gate fig. 87.
Through holes "A," remove electric window lock
1. Remove tail gate window regulator outside han cylinder, switch and escutcheon assembly attach
dle assembly from tail gate, as previously de ing nuts, detach assembly from tail gate sufficient
scribed.
ly to disconnect junction block from switch; then,
2. Remove clutch retaining ring and slide clutch off remove assembly and gasket from tail gate.
shaft of handle driver fig. 88.
3. Using a snap ring removal tool, remove retaining To disassemble tail gate electric window lock cyl
ring securing handle assembly fig. 88, remove inder, switch and escutcheon assembly see "Tail
washer and spring washer from shaft of handle Gate Electric Window Lock Cylinder, Switch and
driver and remove handle assembly from es Escutcheon Assembly-Disassembly and Assem
bly."
cutcheon.
4. To remove handle and knob assembly, remove 4. To install tail gate electric window lock cylinder,
handle hinge pin screws fig. 88 and remove han switch and escutcheon assembly, reverse removal
dle and knob assembly from handle driver. procedure.

BODY 14-57
Tail Gate Electric Window Lock Cylinder, der and switch assembly into escutcheon and en
Switch and Escutcheon Assembly gage retainer.
1. Remove tail gate electric window lock cylinder, Tail Gate Support Assembly
switch and escutcheon assembly, as previously Removal and Installation
described.
1. Lower tail gate.
2. Disengage lock cylinder and switch retainer fig.
89 and remove lock cylinder and switch assembly 2. Suitably support tail gate to prevent damage to
from escutcheon. tail gate outer panel.
3. Remove tail gate support attaching screws secur
ing support plates to body and tail gate figs. 81
LOCK CYLINDER and 82 and remove support assembly.
& CAP ASSEMBLY
4. To install tail gate support assembly, reverse re
moval procedure. Install support plate to body
with positioning dimple towards front of body
fig. 81.
NOTE: Obiectionable slack in either tail gate
support when tail gate is open can be elimi
nated by rotating one or both support attach
ing plates at the body pillars. The following
adjustments can be obtained by rotating the
Fig. 89-Tail Gate Electric Lock Cylinder, Switch and Escutcheon Assembly support plate.
3. Using a pointed tool inserted through hole in lock 1. Positioning dimple towards bottom shortens sup
cylinder case, depress tab of switch retainer and port approximately ¾ inch from production in
remove retainer and switch fig. 89. stallation.
4. Using suitable pliers, grasp pin of switch cam
2. Positioning dimple towards top shortens support
firmly and pull switch cam straight out from lock
approximately 3/4 inch from production installa
cylinder fig. 89.
tion.
NOTE: Pin is pressed into lock cylinder and may
require a firm pull to release.
5. Using a suitable tool, bend out crimped flange of Tail Gate Lock Assembly-Right or Left
lock cylinder cap sufficiently to remove cap; then, Removal and Installation
remove lock cylinder cap and springs. 1. Remove tail gate window assembly.
NOTE: The crimped flange on production lock
cylinder cap necessitates damaging cap during 2. Remove tail gate window glass run side channel
removal from lock cylinder case; however, attaching screws fig. 82 and remove channel
service replacement caps are available which
have four 4 bend over tabs for installation.
6. Prior to assembly of lock cylinder and switch,
lubricate frictional surfaces with "Lubriplate" or TAIL__GATE
its equivalent. LOCK
To assemble lock cylinder and switch, first insert
lock cylinder in lock cylinder case, place cap and
springs in position and install a new service re
placement lock cylinder case cap.
Insert key in lock cylinder and turn key to off
position straight up and down. Carefully insert
switch cam into lock cylinder making sure notch
in switch cam is engaged with pawl on end of lock
cylinder and ends of spring are in cut-out of lock
cylinder case. Holding switch cam in position
check operation of key lock cylinder. If lock
cylinder operates properly, apply a small amount
of cement on serrated end of switch cam pin to
assure that pin will be securely retained to lock
cylinder; then install pin-press or tap pin in unifi
shoulder of pin is flush against switch cam. Install
switch into lock cylinder case. Position lock cylin Fig. 90-Tail Gate Lock Sealing

BODY 14-58
Tail Gate Lock Striker Adjustments

1. To adjust the tail gate lock striker up or down or
forward or rearward, loosen striker attaching
screws, shift striker and adjusting plates to de
sired position, then tighten striker attaching
screws.
2. DIMENSIONAL SPECIFICATIONS FOR USE
OF DOOR LOCK STRIKER EMERGENCY
SPACERS.
a. Tail gate should be properly aligned before
checking spacer requirements.
b. To determine if tail gate lock striker emergency
spacers are required, apply modeling clay or
body caulking compound in the lock striker
notch where the lock extension engages and
then close the tail gate to form a measurable
impression in the clay or caulking compound,
as shown in Figure 92.
When dimension "A" from inside face of striker
Fig. 9-TaiI Gate Lock and Remote Control teeth to center of lock extension is less than /16" in
stall emergency spacers and proper length striker at
from side of tail gate from which lock is being taching screws as directed.
removed.
3. Disengage spring clip and detach lock remote No. of Striker
control connecting rod from lock remote control Spacers Spacer Attaching
fig. 91. Dimension "A" Required Thickness Screws*
4. Remove tail gate lock attaching screws fig. 82
to 1 1/’ Original
and remove tail gate lock with attached connect
ing rod from tail gate; then detach connecting rod Screw
1/8 to 1/" 1 1//’ Emergency
from lock.
Screw %"
5. To install tail gate lock assembly, reverse removal longer
procedure. Prior to installing lock assembly into
1/16" to 0 1 %" 3//’ Emergency
tail gate, apply a bead of body caulking compound
to lock frame along the joint of the lock bolt hous Spacer Total Screw 4"
ing "1" in Figure 90. 1 1//’ longer
Spacer
To attach lock connecting rod to remote control
0 to 1/" 2 %" %" Emergency
lever, first, loosen connecting rod adjustment locking Interference Spacer Total Screw 4"
bolt at remote control fig. 91; then, install rod to longer
lever and tighten locking bolt.
*Zinc or cadmium-plated flat-head cross-recess screw
NOTE: Check clips at ends of remote control
levers for proper retention of connecting rods with countersunk washer.
and replace if necessary.
NOTE: Dimension "B" from center of lock ex
Prior to resealing water deflector, check operation tension to inside face of striker should never be
of tail gate locking mechanism. less than 1/16".
Tail Gate Lock Striker Tail Gate Lock Remote Control

Inside Handle Assembly
1. Open tail gate and with pencil, mark position of
1. Remove tail gate belt finishing molding and tail
striker on body pillar.
gate inner cover panel. Detach inner panel water
2. Remove lock striker attaching screws and remove deflector sufficiently to gain access to inner panel.
striker and adjusting plates from body pillar. 2. Loosen tail gate lock remote control attaching
3. To install tail gate lock striker, place striker and screws fig. 87 and move remote control towards
adjusting plates within marks on body pillar and bottom of tail gate sufficiently to disengage end of
install striker attaching screws. handle push rod from hole in remote control lever.

BODY 14-59
Installation
1. Engage inside handle push rod into hole in remote
control lever.
2. Adjust remote control assembly up or down until
tabs on push rod fig. 91 just contact remote con
trol lever.
3. To attach lock connecting rods to remote control
lever, first, loosen connecting rod adjustment lock
ing bolt fig. 91; then, install rods to levers and
tighten locking bolt.
NOTE: Check clips at ends of remote control
levers for proper retention of connecting rods
and replace if necessary.
IMPORTANT: If installing a new remote control
assembly, remove cotter key fig. 91 after ad
justment, to free locking lever.
4. Check operation of tail gate locking mechanism.
To open tail gate when window assembly is re
moved, depress tail gate lock remote control lock
ing lever and at the same time operate the tail
gate remote control inside handle.
Fig. 92-Tail Gate Lock Striker Engagement Check
5. Install tail gate window assembly as described
NOTE: In some instances it may be necessary under "Tail Gate Window Assembly-Installation."
to reach into tail gate and actuate remote con 6. Lower window to approximately ½ inch up from
trol lever to disengage push rod from lever. full down position; then adjust remote control
3. Remove handle attaching screws located under locking lever adjusting screw fig. 91 so that lever
handle and remove handle assembly includes is just contacting window lower sash channel
push rod from tail gate. frame. Check operation of remote control inside
handle-handle should remain locked until win
4. To install tail gate lock remote control handle as dow is lowered to within 1/4 inch of the full down
sembly, reverse removal procedure. Lubricate position.
frictional points of inside handle assembly with
"Lubriplate" or its equivalent.
Tail Gate Inner Panel Water Deflector
NOTE: To engage end of handle push rod into
hole in remote control lever, it may be neces On all station wagon styles a waterproof paper tail
sary to raise window in tail gate to gain ac gate inner panel water deflector is sealed to the tail
cess to lever. Adjust remote control upward gate inner panel and deflects water into the bottom
until tabs on handle push rod fig. 91 just con of the tail gate where it can drain out the bottom drain
tact remote control lever. holes. The bottom of the water deflector is sealed to
the inner panel in a manner that will deflect water
Prior to resealing tail gate inner panel water de towards designated access holes where the water can
flector check operation of tail gate lock mechanism readily enter into the bottom of the tail gate.
and, where necessary, adjust door lock strikers or re IT IS IMPORTANT THAT WHENEVER ANY
mote control for proper operation. WORK IS PERFORMED ON THE TAIL GATE
WHERE THE WATER DEFLECTOR HAS BEEN
Tail Gate Lock Remote Control Assembly DISTURBED, THE DEFLECTOR MUST BE PROP
ERLY SEALED TO THE TAIL GATE INNER
Removal PANEL.
1. Remove tail gate window assembly.
2. Disengage clips securing lock connecting rods to 1. Remove tail gate inner cover panel lower retainer
remote control fig. 91 and detach connecting and inner cover panel.
rods from remote control.
2. Using a sharp scraper or other suitable tool care
3. Remove tail gate lock remote control attaching fully lift up edge of deflector and detach sealer
screws fig. 87. Disengage remote control from and water deflector as required.
inside handle push rod and remove remote con
trol from tail gate. NOTE: DO NOT TEAR WATER DEFLECTOR.

BODY 14-60
in place of wire clips. The new nylon fasteners are the

same size at all locations and are available as service
replacement parts.
Tool J-21104 is designed for removal of the new
weatherstrip. If this tool is not available, it can be
fabricated from any other comparable metal tool. See
Figure 17 in "FRONT OR REAR DOOR WEATHER
STRIP" Section. When a removal tool is fabricated,
make sure all sharp edges or metal burrs are re
moved so as not to damage weatherstrip or paint
finish during its usage.
Removal
1. Remove tail gate belt finishing molding.
Fig. 93-Tail Gate Inner Panel Sealing 2. At both sides of tail gate, disengage button type
snap fasteners and screw securing upper ends of
Installation or Resealing Procedure weatherstrip.
1. If installing old deflector or resealing partially 3. With a sharp scraper, carefully break cement bond
detached deflector first inspect water deflector securing weatherstrip along tail gate lock pillars.
for any tears or holes and, where necessary, re
pair any tears or holes with waterproof body tape 4. Slide tool J-21104, or other suitable tool under
applied to both sides of deflector. weatherstrip at fastener locations and carefully
pry fasteners out of holes See Figure 20 in
2. If installing new deflector use old deflector or "FRONT OR REAR DOOR WEATHERSTRIP"
tail gate inner panel to trim new deflector to Section.
proper size.
CAUTION: Exercise care not to damage serra
3. Apply a bead of body caulking compound ap lions on fasteners during removal as they are
proximately /16 diameter to tail gate inner necessary to maintain a good weatherseal.
panel fig. 93.
Installation
IMPORTANT: The body caulking compound
1. Check weatherstrip nylon fasteners for damage
should be applied along the lower portion of
and replace, if necessary.
the tail gate exactly as shown in illustration
to assure proper drainage of water through 2. Clean off old cement from tail gate to insure a
designated inner panel access holes into bot clean cementing surface. Apply a bead of approved
tom of tail gate. weatherstrip adhesive to lock pillar facing of tail
gate starting at belt line and continuing down
4. Position water deflector to tail gate inner panel lock pillar for approximately 18 inches.
with polyethylene coated side of deflector against
inner panel. Firmly press or roll sealed areas to NOTE: Weatherstrip adhesive usage is usually
obtain a good bond between deflector and tail gate limited to lock pillar area; however, weather
inner panel. strip adhesive can be applied at any location
where additional retention of weatherstrip is
5. Clean off all excess caulking compound; then, in required.
stall previously removed tail gate inner cover
panel. 3. Install button type fasteners and screw securing
upper end of weatherstrip.
Tail Gate Weatherstrip 4. Install snap fasteners by pressing fasteners into
A new type tail gate weatherstrip assembly is be holes in tail gate panel. A protected hammer can
ing used which incorporates nylon component fasteners also be used, where necessary.

BODY 14-61
NOTE: In the event the weatherstrip becomes Electric Tail Gate Window Circuit
damaged at a fastener location and will not
The electric tail gate window circuit information
properly retain the fastener, remove fastener found on pages 9-115 through 9-117 of the 1961 Pas
and cement weatherstrip in place. If, however, senger Car Shop Manual apply as well to the 1963
two or more consecutive fasteners will not re vehicle. Only wiring installation and routing have
main engaged in the weatherstrip, replacement changed. Figures 94, 95 and 96 illustrate these changes.
of the weatherstrip will probably be necessary.
All weatherstrips are impregnated with a silicone

lubricant and additional lubrication is not ruired.
Tail Gate Bottom Drain Hole Sealing Strips

1. With a flat-bladed tool carefully pry out snap-on
fastener at each end of strip and remove sealing
strip from tail gate.
2. To install sealing strips, reverse removal pro

cedure. 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.
Fig. 95-Rear Cross Bar Wiring
SAFETY IT. TAIL MOTOR
REAR BODY WIRING RIGHT TAIL LIGHT

HARNESS CONNECTOR BLACK RIGHT STOP AND
9 PASSENGER DIRECTIONAL
‘LIGHT PURPLE
REAR QTR. COURTESY
SW. GROUND
QTR. COURTESY
- -
/ LP%P GROUND
- LIGHT BLUE
REAR QTR. TRIM PANEL. LEFT TAIL LIGHT BLACK
TAIL GATE ELECTRIC ‘
‘ DIRECTIONAL LIGHT
/ / PINK
GAS GAUGE BROWN
" REAR QTR. COURTESY LI. BACK-UP IT; DIRECTIONAL & I
RT. STOP &
REAR QTR. COURTESY LAMP

LAMP FEED RED
‘REAR QTR. COURTESY SW.
LIGHT-LIGHT
GREEN
STOPLIGHT-PURPLE
TO BODY RI. TAIL
/DIRECTIONAL
LIGHT-PINK
GROUNDLIGHT BLUE ON SWITCH GROUND TAN REAR LIGHT-BLACK
HARNESS RI. BACK-Ui LIGHT
-LIGHT GREEN
Fig. 94-Rear Body Wiring-Station Wagon Fig. 96-Tail Gate Power Window Wiring
FRONT SEATS
FRONT SEAT ASSEMBLY SIX-WAY SEAT BUCKET TYPE FRONT SEATS
Procedures covered under this heading in the 1961
All seat adjusters are bolted to the seat bottom
Passenger Car Shop Manual may be followed when
servicing a 1963 vehicle. Figure 97 illustrates the 1963 frame; however, a combination of bolts and/or nuts
electrical harness routing which differs slightly from are used to retain the adjusters to the floor pan
that shown on page 14-62 of the 1961 manual. assembly.

BODY 14-62
Fig. 97-Six-Way Seat Installation
Bucket Type Front Seat Assembly

Driver or Passenger-Manual
1. Turn back floor carpeting sufficiently to expose
seat adjuster-to-floor pan attaching nuts or bolts.
2. Operate seat assembly to rearward position.
3. Remove attaching nuts.
4. Operate seat assembly to full forward position.
5. At rear of seat, remove adjuster to floor pan at
taching nuts or bolts.
6. With aid of helper, remove seat assembly with
attaching adjusters from body.
7. To install, reverse removal procedure. Check seat
adjusters for proper operation.
Front Seat Adjusters RETAINER RETAINER

Driver or Passenger-Manual
HINGE PIN
1. Remove front seat assembly as previously de
scribed and place upside down on a clean, pro
tected surface. Fig. 98-Bucket Seat Removal

BODY 14-63
2. If adjuster to be replaced is equipped with an remove retainer from outer hinge pin fig. 98.
assist spring, remove spring from adjuster. 2. On all styles, tilt seat back forward and remove
3. Operate adjuster so that both front and rear retainer from inner hinge pin fig. 98.
attaching bolts are accessible. 3. On all styles, carefully disengage front seat back
4. Remove adjuster-to-seat bottom frame front and outer hinge arm from pin.
rear attaching bolts and remove adjuster from seat
4. Move entire seat back assembly inboard until
assembly. inner hinge pin is disengaged from extension on
5. To install, reverse removal procedure. seat assembly; then, remove seat back from body.
Front Seat Back Assembly 5. To install, reverse removal procedure. Prior to
installation of back assembly, be sure inner and
outer washers are installed over the hinge pins.
1. On all styles, using a flat-bladed tool, carefully fig. 98.
HEADLINING ASSEMBLY
N
VIEW N
1839 STYLE
VIEW E -
PLASTIC VIEW F
VIEW P
RETAINER
REAR LISTING
WIRE SUPPORT
VIEW R
Fig. 99-Headlining Installation-39 Style

BODY 14-64
Fig. OO-Headlining lnstallation-35 and 45 Styles
HEADLINING ASSEMBLY 2. Prior to removing headlining, remove following

hardware and trim assemblies if present.
The headlining assembly is formed to the contour of
the roof panel by concealed listing wires. Both ends a. Windshield side and upper garnish moldings.
of the listing wires are located in holes in the side b. Rear view mirror support.
roof rails. c. Sunshade supports.
The headlining is secured at the windshield by d. Dome or rear quarter courtesy lamps.
cement and tacks or staples and along the side roof e. Coat hooks.
rails by tacks, staples, cement or a pronged retainer.
f. Rear quarter window upper garnish moldings
The headlining on "11" and "69" styles is secured at
2 door styles.
the back window by cement and a finishing lace. On all
other styles, the headlining is secured at the back g. Side roof rail moldings.
window or back body opening by cement and tacks h. Back window garnish moldings "39" and "47"
or staples. styles.
CAUTION: Clean hands and tools are essential i. Rear quarter window front, rear and upper
when working with headlining material. moldings "35" and "45" styles.
Removal j. Back body opening upper and side garnish
1. Place protective coverings over seat cushions and moldings.
backs. k. Center pillar finishing moldings.

BODY 14-65
TACKS
B
VIEW B K
47 STYLE
L
TACKS
VIEW K TACKS
METAL
TAB
VIEW E VIEW L
VIEW F
Fig. 101-Headlining Installation-47 Style
1. Rear quarter trim, where necessary. 5. On "11", "35", and "45" styles, remove tacks or
m. Back window finishing lace "11" and "69" staples securing headlining at rear quarter win
styles. dows View "D", fig. 102 and View "G", fig. 100.
3. Carefully remove tacks or staples securing head 6. Remove tacks or staples at roof panel extension
lining at windshield and back window or back body areas, as required.
opening. 7. Carefully detach cemented edge of headlining
4. On "11", "69", "35" and "45" styles, use headlining around entire perimeter.
inserting tool J-2772 or similar wide-bladed tool 8. Working from front to rear of body, disengage
and carefully disengage headlining from pronged headlining listing wires from side roof rails, gather
retainer on side roof rails over door openings ing or folding headlining with listing wires on
View "C", fig. 100 and fig. 102. outside to keep headlining clean.
On "47" style, remove tacks or staples along
side roof rails and rear quarter areas View "K", IMPORTANT: Note in which holes ends of list
fig. 101. ing wires are installed in side roof inner rails.
On "39" style, remove plastic retainer from side Listing wires should be placed in same hole
roof rail pinchweld flange View "P", fig. 99. when replacing headlining.

BODY 14-66
VIEWA A
C
11 STYLE
VIEW E VIEW F
VIEW H VIEW D
69 STYLE
VIEW C
J
VIEW J
Fig. 102-Headlining Installation-i I and 69 Styles
9. At front roof bow, bend down metal tabs securing tam cement is applied to both sides of retainer
listing wire View "F", fig. 99, fig. 100, fig. 101, Views "D" and "J", fig. 102.
fig. 102. 3. Lift entire headlining assembly into body and in
10. Remove rear listing wire and pocket from rear stall rear listing wire into side roof rails. On "39"
listing wire support on "39" styles View "T", fig. styles, install rear listing wire and pocket on rear
99. listing wire support View "T", fig. 99.
11. Remove headlining assembly from body. 4. Center and align rearward end of headlining and
12. If replacing headlining, remove listing wires from where possible, stay tack headlining at center of
pockets of headlining. back window or back body opening.
IMPORTANT: Listing wires removed from old 5. Working forward, install ends of listing wires into
headlining must be installed in corresponding listing wire holes in side roof rails.
pockets of new headlining.
NOTE: Each listing wire should rest against
Installation roof panel deadener after it is installed. Listing
wires may be adjusted up or down by placing
1. If previously removed, install listing wires into
in appropriate holes in side roof inner rails.
pockets of new headlining assembly.
2. Apply approved trim cement to headlining attach 6. At front roof bow, bend up metal tabs securing
ing surface at windshield, side roof rail and back listing wire and listing wire pocket View "F",
window opening. On "11" and "69" styles, be cer figs. 99 through 102.

BODY 14-67
7. Using headlining inserting or suitable wide-bladed windshield, back window, back body, and rear
tool, install headlining around back window re quarter areas.
tainer on "11" and "69" styles. On all other styles, 10. On "11", "69", "35" and "45" styles, use headlining
stretch and stay tack headlining at back window inserting tool, J-2772, or similar wide-bladed tool
or back body opening. Stay tack headlining in rear and carefully tuck edge of headlining under
quarter area where required View "R", fig. 99, pronged retainer along both side roof rails View
View "G", fig. 100, View "D" and "J", fig. 102 and "C", fig. 100 and fig. 102. Permanently tack or
View "L", fig. 101. staple headlining at side roof rails on "47" styles
View "K", fig. 101. On "39" style, use headlining
8. Apply approved trim cement to side roof rail edge inserting tool and permanently install edge of
of headlining except where headlining is secured headlining around side roof rail pinchweld and
by pronged retainer. Remove all "fullness" or replace plastic retainer View "D", fig. 99.
"draws" from headlining material and secure to
11. Trim excess material from edge of headlining
side roof rails.
around entire perimeter.
9. Recheck for any "fullness" or "draws" in headlin 12. Install all previously removed hardware and trim
ing material and permanently tack headlining at assemblies and remove protective coverings.
ROOF PANEL FABRIC COVER

The roof panel fabric cover available on 1847 styles parts with dielectrically joined center section to side
only is a vinyl coated fabric covering applied to the section seams.
metal roof panel. The fabric covering is made of three The roof cover is attached at the windshield and
ROOF PANEL
FABRIC COVER
ROOF OUTER PANEL
REAR RETAINER FABRIC ROOF COVER

SECTION B-B
FLEXIBLE RETAINER
SIDE ROOF
RAIL DRIP
MOLDING
SCALP
TRIM COVER BELOW

VIEW A RETURN FLANGE OF
DRIP MOLDING
Fig. 103-Body Fabric Roof Cover

BODY 14-68
back window openings by drive nails. Screws or NOTE: A cleaner such as 3M Adhesive Cleaner
drive nails are used at the belt line of the rear quarter or equivalent, should be used to remove or
area. A flexible retainer secures the fabric cover inside smooth out excess old cement. Apply solvent
the right and left drip moldings. In addition, the roof and allow to soak before rubbing.
panel fabric cover is cemented to the entire surface of
the roof panel with a nitrile type non-staining cement. CAUTION: Be certain to follow manufacturer’s
directions when using cleaner.
Removal 2. To permit easier fitting and removing of wrinkles
1. The following parts must be removed prior to re from new cover assembly, where possible, install
moving the roof panel fabric cover: new cover at room temperature approximately
72°.
a. Windshield assembly
b. Back window assembly NOTE: Where new cover is installed at tem
peratures below 72°, pliers fabricated as
c. Windshield pillar finishing moldings shown in Figure 104 will aid in removing
d. Roof drip molding scalps wrinkles.
e. Rear quarter reveal moldings at belt
f. Roof extension panel emblem and/or plate
assembly
2. Clean off all excess sealer from windshield and
back window openings.
3. Remove drive nails from edge of fabric cover at
windshield and back window opening. At roof OLD FILE
panel extension at belt remove screws or drive ‘l’
3/4"
STOCK
nails.
NOTE: Drive nails can best be removed by
first driving a screwdriver or suitable tool under
the heads of the nails to loosen them. Diagonal
cutters or similar tool can then be used to grasp
WELD
nails and twist them out. Unnecessary enlarge
ment of holes in roof panel should be avoided.
4. Removal of flexible retainers securing fabric cover

inside right and left drip moldings can best be
completed by inserting tip of screwdriver or
similar tool under forward end of retainers. See
View "A" in fig. 103. Working from front to rear
of body, disengage fingers of retainers from side
roof rail drip molding flanges. Continue above
operation until retainers can be removed from
body.
NOTE: New retainers should be used when re
placing fabric cover.
5. Prior to removing fabric cover, application of heat Fig. 104-Fabric Cover Pliers
in rear quarter areas will permit easier loosening
of cemented edges. 3. Determine center line of roof panel by marking
6. Loosen cemented edges of fabric roof cover at center points on windshield and back window
windshield, side roof rails, back window, and rear openings with chalk or equivalent.
quarter areas; then, carefully remove fabric cover 4. Fold cover lengthwise, precisely at center location.
from remaining cemented area of roof panel. Mark center location at front and rear of cover.
5. Lay cover on roof panel and align to correspond
Installation with center line of roof panel. Determine proper
1. Check all cementing surfaces on body to insure a material overhang at windshield and back window
smooth surface. Cementing surface must be smooth openings.
to prevent "highlighting" of excess cement 6. Fold fabric cover on center line and lay on right
through fabric cover after new cover has been in side of roof panel, allowing proper material over
stalled. Clean off old cement as required. hang at windshield and back window opening.

BODY 14-69
cover to extend approximately 1" beyond dielec

SEAMS tric seam. Apply cement to corresponding area of
body fig. 105.
CEMENT 1" BEYOND
SEAM STEP #10 IMPORTANT: Application of cement should not
overlap with previously cemented area, as
"highlighting" of excess cement through fabric
cover will result.
11. Cement prepared portion of fabric cover to roof
CEMENT ALONG panel making certain dielectric seam is straight.
DRIP MOLDING 12. Fold over fabric cover and apply cement to re
STEP #12 maining portion of fabric cover and roof panel
and drip molding. Cement cover to roof panel and
drip molding fig 105.
CEMENT REAR NOTE: When installing fabric cover to inside
QUARTER AREA of drip molding, a small thin-edged piece of
CEMENT 8" STRIP TO LEAVING UNCEMENTED
AREA INDICATED plastic, or similar material, may be used to
LEFT OF CENTER LINE
STEP # STEP #13 insert cover in place inside drip molding. Exer
cise care so damage will not occur to cover
when performing this operation.
Fig. 105-Cementing Fabric Cover
13. Cement perimeter of fabric cover in rear quarter
area. Be certain fabric cover is cemented at em
7. Apply approximately an 8" wide strip of nitrile blem or plate assembly attaching locations. This
non-staining vinyl trim adhesive such as 3M type of cement application will permit easier fit
Vinyl Trim Adhesive or Permalastic Vinyl Trim
ting of cover in rear quarter area. fig. 105.
Adhesive or equivalent along exposed inner layer
of fabric cover adjacent to center line. fig. 105. 14. Repeat steps 10, 11, 12 and 13 on right side.
If nitrile non-staining cement is not available, 15. At windshield and back window openings cement
use neoprene type non-staining weatherstrip cover into openings as shown in View "A", Figure
cement such as 3M Super Weatherstrip Cement 106.
or equivalent.
Apply extra bead of cement to each side of
NOTE: When using nitrile non-staining cement, dielectric seam between fabric cover and roof
it may be necessary to apply two coats to
fabric cover.
IMPORTANT: Exercise care when applying
cement on inner layer of cover so cement does
not come in contact with outer layer.
8. Apply cement to corresponding area of roof panel,

which is to left of center line of roof panel.
9. At front and rear of fabric cover, grasp edge of
material at seam and center line locations. Slide DRIVE NAILS
folded cover to center line of roof panel. Securely OR SCREWS
hold cover at center line location at windshield APPLY EXTRA BEAD OF WEATHERSTRIP
opening. Pull cover at rear, making certain center CEMENT NEOPRENE TYPE
line of folded fabric cover corresponds to center AT EACH SIDE OF SEAM BETWEEN FABRIC
COVER
line of roof panel. Securely hold fabric cover at AND ROOF PANEL
back window opening. Turn folded left half of
fabric cover over and fasten cover to cemented DRIVE NAIL
portion of roof panel. TYPICAL OF ALL
SEAM LOCATIONS
NOTE: This operation should center fabric cover
on roof panel. Center marks on windshield and
back window openings must correspond to TRIMMED EDGE
center marks on fabric cover. DRIVE NAILS IN OF FABRIC COVER
RADIUS OF BACK WINDOW
VIEW "A"
10. Once 8" strip of fabric cover is cemented to roof
panel, fold over uncemented left side portion of
fabric cover. Apply cement on inner layer of fabric Fig. 106-Drive Nail Installation

BODY 14-70
panel at windshield and back window openings.

View "A", fig. 106.
16. Install drive nails at windshield and back window
openings. View "A", fig. 106 shows typical drive
nail installation.
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 windshield and
back window opening. This will aid in pre
venting cutting edge of fabric cover due to a
missed hammer blow when drive nails are
installed.
17. Install screws or drive nails at belt line of rear

quarter area. fig. 103.
18. Trim off material at windshield, back window, and
rear quarters. View "A" in Figure 106 shows
where trimmed edge should occur in openings.
NOTE: Install fabric cover at windshield pillar

area in same manner as original installation.
19. Using fabric cover trimming tool J-21092, or

suitable small knife, trim fabric cover just under
lip of roof drip molding. View "A", fig. 103.
A tool may be fabricated to trim material along Fig. 1 07-Fabric Cover Trimming Knife
side roof rail moldings as illustrated in Figure 107.

22. Install all previously removed moldings and
20. Prior to installing flexible retainers in side roof assemblies.
rail drip moldings, spread them slightly to insure
a tight fit. NOTE: If, after cover installation is completed,
creases or fold marks are still visible, they may
21. Install flexible retainer starting at radius area
be removed by applying heat to area affected.
above rear quarter window. Working toward rear
of body, if necessary, carefully drive retainer Care must be exercised so that material is not
downward with a blunt-edged tool. Working to overheated as loss of design pattern embossed
ward front of body, install remaining portion of in cover will result. Normally creases or fold
retainer. Retainer fingers should be seated in marks will gradually disappear aftei cover
flange of drip molding. View "A", fig. 103. assemby has been exposed to the elements.
FOLDING TOP
FOLDING TOP ADJUSTMENT by two hook type locks which are an integral part of
the two locking handles.
The folding top linkage consists of three sections of
right and left side roof rails and a front roof rail The following information outlines and illustrates
connected by bolts, hinges, and a series of connecting procedures which may be used to correct misaligned
links and bows. The top linkage is attached to the folding top linkage. To correct some top variations,
body at the rear quarter area by a male hinge. The only a single adjustment is required; other top varia
hinge is attached directly to the quarter panel brace. tions require a combination of adjustments. In con
The front roof rail is locked at the windshield header junction with adjustment of the folding top, it may

BODY 14-71
be necessary to adjust the door, door glass, rear countered at the front roof rail proceed as follows:
quarter glass, trim sticks or side roof rail weatherstrips.
1. Unlatch top and raise it above windshield header.
2. Loosen striker support attaching screws and ad

Adjustment of Top at Front just striker laterally as required; then tighten
Roof Rail Corner Brace attaching screws fig. 109.
If the top, when in a raised position, is too far for If, after adjusting the striker support, the locking
ward or does not move forward enough to allow the action of top is still unsatisfactory, or if a closer fit
guide studs on the front roof rail to enter holes in the of the front roof rail to windshield header is desired,
striker assemblies, proceed as follows: the hook lever on the front roof rail lock assembly
may be adjusted as follows:
1. Unlatch top and raise it above windshield header.
Remove side roof rail weatherstrip front attaching 1. To tighten locking action of top, turn hook lever
screws. clockwise.
2. Loosen corner brace attaching bolts and adjust 2. To reduce locking effort of top, turn hook lever
front roof rail fore or aft as required. Repeat on counterclockwise.
opposite side if necessary fig. 108.
NOTE: Hook lever may be adjusted with finger
pressure, no tools are required.
FRONT ROOF
RAIL
CORNER
BRACE
SIDE ROOF
RAIL FRONT
Fig. 108-Roof Rail Corner Brace Attachments
NOTE: This adjustment is limited. If additional

adjustment is required, it can be made at the
folding top male hinge.
3. When front roof rail corner brace is properly ad Fig. 1 09-Front Roof Rail Adjustment
justed, tighten attaching bolts and reinstall side

roof rail front weatherstrip attaching screws. Adjustment of Top Control Link Adjusting Plate
Check forward section of weatherstrip and reseal 1. With top in up position, if joint between front and
if necessary. center side roof rail is too high or too low, pro
ceed as follows:
Adjustment of Top at Sunshade and a. Remove folding top compartment side trim
Striker Support Assembly panel.
If a difficult locking action, caused by misalignment b. Mark location of control link adjusting plate
of the sunshade and striker support assembly is en- on folding top compartment brace.

BODY 14-72
after adjustment. After making an adjustment at male

hinge, check folding top at rear quarter area for
proper fit and, if necessary, adjust trim stick assembly.
1. If there is an excessive opening between side roof
rail rear weatherstrip and rear of rear quarter
window, or if front roof rail is too far forward
or rearward, proceed as follows:
SUPPORT MALE HINGE
ATTACHING AUACHING BOLTS a. Mark location of male hinge attaching bolt
BOLTS washers and control link assembly on folding
DECREASE top compartment brace.
STACK
HEIGHT
b. Loosen male hinge assembly bolts fig. 110.
CONTROL LINK c. Move hinge fore or aft as required to obtain
ADJUSTING
BRACE PLATE proper alignment between side roof rail rear
weatherstrip and rear quarter window; then
tighten bolts.
IMPORTANT: The entire male hinge assem

Fig. 11 0-Adjustment of Control Link Adjusting Plate bly must be adjusted forward or rearward
at a 900 angle to vertical line of male
c. Loosen two bolts securing control link adjust hinge attachment. Use mark at washers as
ing plate sufficiently to permit adjustment of guide. DO NOT allow male hinge to rotate
plate fig. 110. as rotation may cause damage to lift cylin
d. Without changing fore and aft location of ad der by allowing piston to bottom or rod to
justing plate, adjust side roof rail up or down bend after top has been operated.
allowing adjusting plate to move up or down
over serrations on support as required; then d. Lock front roof rail to windshield, where re
tighten bolts. quired, adjust front roof rail as previously de
scribed, and check fit of top material at rear
2. If top assembly does not stack properly when top quarter trim stick area. If necessary, adjust
is in down position, proceed as follows: trim stick; then tighten trim stick attaching
a. Mark location of control link adjusting plate on bolts.
folding top compartment brace. e. Check top assembly for proper stack height and
b. Loosen bolts securing control link adjusting proper alignment of side roof rails over door
plate sufficiently to permit adjustment of plate. and quarter windows. Where required, adjust
c. Without changing the up or down location of control link adjusting plate as previously de
adjusting plate, move adjusting plate forward or scribed. See steps No. 1 and 2 under "Adjust
rearward horizontally over serrations as re ment of Top Control Link Adjusting Plate".
quired to obtain desired height; then tighten NOTE: If top cannot be fully raised or
bolts. lowered, even after control link plate has
been adjusted, readjust male hinge assem
NOTE: If top cannot be fully lowered, even
bly as required. Check top for proper opera
after control link plate has been adjusted,
tion.
readjust male hinge assembly as required.
Check top for proper operation. 2. If side roof rail is too high or too low at rear
quarter window area, proceed as follows:
Adjustment of Top at Male Hinge Support a. Mark location of male hinge attaching bolt
Prior to making any adjustment of top linkage at washers and control link on folding top com
male hinge, loosen two bolts securing folding top rear partment brace.
quarter trim stick to rear quarter panel. This will pre b. Loosen male hinge assembly attaching bolts
vent any possible damage to top when it is raised fig. 110.

BODY 14-73
IMPORTANT: The entire male hinge assembly

must be adjusted straight upward or down
ward at a 900 angle to horizontal line of
male hinge attachment. Use mark at
washers as guide. DO NOT allow male
hinge to rotate as rotation may cause dam
age to lift cylinder by allowing piston to
bottom or rod to bend after top has been
operated.
d. Tighten attaching bolts, while maintaining

proper alignment of vertical scribe marks.
e. Check fit of top material at rear quarter trim
stick area and, if necessary, adjust trim stick.
If adjustment is not necessary, tighten trim
stick attaching bolts.
f. Check top assembly for proper stack height and
proper alignment of side roof rails over door
and quarter windows. Where required, adjust
control link adjusting plate as previously de
scribed. See steps No. 1 and 2 under "Adjust
Fig. 111-Center Side Roof Rail and Hinge
ment of Top Control Link Adjusting Plate".
c. Without changing fore and aft location of male NOTE: If top cannot be fully raised or lowered,
hinge, adjust male hinge up or down as re even after control link plate has been adjusted,
quired to obtain proper alignment between readjust male hinge assembly as required.
side roof rails and rear quarter windows. Check top for proper operation.
SEE FIG.108
Fig. 112Folding Top Parts Location

BODY 14-74
SERVICE DIAGNOSIS
The following procedure describes and illustrates their apparent causes and the recommended procedure
various types of folding top misalignment conditions, for their correction.
CONDITION APPARENT CAUSE CORRECTION
A. Difficult locking action 1. Sunshade support mia1igned. Adjust sunshade support laterally.
at front roof rail. 2. Lock hook lever improperly Adjust lock hook lever counterclock
* adjusted. wise.
3. Misaligned front roof rail front Loosen, realign and retack front roof
weatherstrip, rail front weatherstrip.
4. Front roof rail misaligned. Adjust front roof rail.
B. Top does not lock tight 1. Sunshade support misaligned Adjust sunshade support laterally.
enough to windshield 2. Lock hook lever improperly Adjust lock hook lever clockwise.
header. adjusted.
3. Misaligned front roof rail frozit Loosen, realign and retack front roof
weatherstrip, rail front weatherstrip.
4. Front roof rail misaligned. Adjust front roof rail.
C. Top travels too far 1. Front roof rail misaligned. Adjust front roof rail rearward
forward. fig. 108.
2. Male hinge assembly misaligned. Adjust male hinge assembly rear
ward fig. 110
D. Top does not travel for- 1. Front roof rail misaligned. Adjust front roof rail forward
ward far enough. fig. 108.
2. Male hinge assembly misaligned. Adjust male hinge assembly forward
fig. 110.
3. Improper spacing between rear Install an additional spacer between
trim stick and body metal. rear trim stick and body metal at
each attaching bolt location.
E. Side roof rail rear 1. Male hinge assembly misaligned. Adjust male hinge assembly rear-
weatherstrip too tight ward fig. 110.
against rear of rear
quarter window.
F. Gap between side roof 1. Male hinge assembly misaligned. Adjust male hinge assembly forward
rail rear weatherstrip fig. 110 and/or shim side roof rail
and rear of rear quar- rear weatherstrip forward as re
ter window. quired.
G. Side roof rail rear 1. Male hinge misaligned. Adjust male hinge upward fig. 110.
weatherstrip too tight
against top of rear
quarter window.
H. Gap between side roof 1. Male hinge misaligned. Adjust male hinge downward and/or
rail rear weatherstrip shim side roof rail weatherstrip down-
and top of rear quarter ward as required.
window.
I. Sag at front to center 1. Control link adjusting plate mis- Adjust control link adjusting plate
side roof rail joint. aligned, downward fig. 110.
2. Center side roof rail hinge adjust- Adjust screw counterclockwise fig.
ing screw improperly adjusted. 111.
J. Front and center side 1. Control link adjusting plate mis- Adjust control link adjusting plate
roof rail bows upward aligned, upward fig. 110.
at hinge joint. 2. Center side roof rail hinge adjust- Adjust screw clockwise fig. 111.
ing screw improperly adjusted.

________ _____ _____
BODY 14-75
CONDITION APPARENT CAUSE CORRECTION

K. Folding top dust boot 1. Improper stack height due to mis Adjust control link plate rearward
is difficult to install. aligned control link adjusting or forward as required fig. 85.
plate.
2. Misaligned folding top dust boot Where possible, align female with
female fastener. male fastener.
3. Rear seat back assembly is too far Relocate rear seat back panel rear
forward. ward until dimension "Z" between
upper rear edge of rear seat back to
forward edge of pinchweld finishing
molding is 19½ inches ± 1/i1’. The
dimension is measured at approxi
mate center line of body fig. 112.
4. Excessive build-up of padding in Repair side stay pads as required.
side roof rail stay pads.
L. Folding top dust boot 1 Improper stack height due to mis- Adjust control link plate forward
fits too closely. aligned control link adjusting plate. fig. 110.
2. Rear seat back assembly is too far Relocate rear seat back panel for
rearward. ward until dimension "Z" between
upper rear edge of rear seat back to
forward edge of pinchweld finishing
molding is 19½ inches ± 1/ The ".
dimension is measured at approxi

mate center line of body fig. 112.
M. Top material is too low 1. Front roof bow improperly *Install one or two 1/8" shims be
over windows or side shimmed. tween front roof bow and slat iron
roof rails. fig. 111.
2. Excessive width in top material. If top is too large, detach binding
along affected area, trim off exces
sive material along side binding as
required; then hand sew binding to
top material.
N. Top material is too high 1. Front roof bow i.mproperly *Remove one or two 1/8" shims from
over windows or side shimmed. between front roof bow and slat
roof rails. iron fig. 111.
2. Front roof bow felt silencer too Trim silencer to within 1/8" of top of
high. front roof bow fig. 111.
0. Top material has 1. Rear quarter trim stick improper Adjust rear quarter trim stick on
wrinkles or draws. ly adjusted. side affected.
2. Top material improperly installed Retack top material as required.
to center or rear quarter trim
stick.
P. Wind whistle or water- 1. Top does not lock tight enough to Adjust sunshade support laterally
leak along front roof windshield header. and/or adjust lock hook lever clock
rail. wise.
2. Misaligned front roof rail front Retack front weatherstrip to front
weatherstrip. roof rail.
3. Front roof rail contour does not Contour of front roof rail may be
conform to windshield header. changed slightly by reforming rail.
Q. Wind whistle or air leak 1. Top material hold-down cables Adjust top material hold-down
between top material improperly adjusted. cables as required.
and side roof rail stay
pads.
*When no shims are required, use attaching screw part #4824789 ¼-28 x %" # 12 oval head with external tooth lock washer, type "T" thread
cutting chrome finish.
When one shim is required, use attaching screw part #837811 x ¾" oval head with external tooth lock washer, type "T"
¼-28 #12 thread
cutting chrome finish.
When two shims are required, use attaching screw part #4824756 1/428 x /8"
cutting chrome # 12 oval head with external tooth lock washer, type ‘T" thread
finish.

BODY 14-76
FRONT ATTACHING REAR ATTACHING

SCREWS SCREWS
Fig. 11 3-Hold Down Cable Screws
FOLDING TOP TRIM ASSEMBLY and rear quarter trim sticks on the vinyl surface of the
top material. These marks should be transferred to the
All 1963 convertible top trim cover assemblies incor new top material upon installation.
porate a top material hold-down cable along the right
Folding of excess back curtain upper valance mate
and left side roof rails. The cables are installed through
rial rearward and tacking to rear bow is shown in Fig
a retaining pocket in the top material and are fastened
ure 115.
at the front and rear side rails by attaching screws.
The cables are designed to hold the top material tight
against the side roof rail stay pads, thus minimizing HYDRO-LECTRIC SYSTEM
air leakage between the top material and the stay pads. The new high pressure hydro-lectric unit used in
Folding top service operations remain much the 1963 convertible bodies consists of a 12 volt reversible
same as covered in the 1961 Passenger Car Shop Man type motor, a rotor type pump, two hydraulic lift cyl
ual. The following illustrations show minor variations. inders, and an upper and lower hydraulic hose as
Front and rear attaching screws for the hold-down sembly.
cable are shown in Figure 113. Figure 116 illustrates and identifies the parts of the
Figure 114 illustrates marking of both ends of rear motor and pump assemblies.

BODY 14-77
REAR ROOF BOW
Fig. 11 5-Back Curtain Installation
3. Lock top to windshield header.

4. Fully raise door and rear quarter window on side
Fig. 114-Marking Material
affected.
NOTE: When servicing the motor assembly or 5. Disconnect negative battery cable to prevent acci
pump end plate assembly, it is extremely im dental operation of motor and pump assembly.
portant that the small motor shaft "0" ring 6. Remove attaching nut, bolt, bushing and washer
seal is properly installed over the motor arma from upper end of lift cylinder fig. 117.
ture shaft and into the pump end plate assem 7. Remove side roof rear rail to male hinge attaching
bly prior to installing the pump rotors or drive nut and bolt.
shaft ball.
8. Remove folding top male hinge to top compart
ment brace attaching bolts.
Removal of Folding Top Lift Cylinder
9. Carefully pull male hinge with attached cylinder
1. Remove rear seat cushion and back. rearward until male hinge is disengaged from side
2. Remove folding top compartment side trim panel roof rear rail; then move hinge and cylinder as
assembly. sembly to inboard side of top compartment brace.
: L MNO P
A J K
0
Fig. 1 16-Hydro-Lectric Pump Explode
A. Motor Assembly. E. Outer Pump Rotor. I. Reservoir Tube and Bracket Assembly. M. Reservoir Filler Plug.
B. Motor Shaft ‘0’ Ring Seal. F. Inner Pump Rotor. J. Reservoir Seal. N. Reservoir End Plate Attaching Bolt "0" Ring Seal.
C. Fluid Control Valve Balls. G. Pump Cover Plate Assembly. K. Reservoir End Plate. 0. Reservoir End Plate Attaching Bolt Washer.
D. Reservoir Seal. H. Pump Cover Attaching Screws. L. Reservoir Filler Plug ‘0" Ring Seal. P. Reservoir End Plate Attuching Bolt.

BODY 14-78
10. Remove screws securing lift cylinder to male

hinge; then remove hinge from cylinder.
11. Disconnect and cap hydraulic connections on cyl
inder on each hose; then remove cylinder.
CAUTION: Prior to disconnecting hydraulic con
nections, place suitable wiping rags under
connections to absorb any drippage of hy
draulic fluid.
12. To install, reverse removal procedure with follow

ing exceptions:
a. To aid in installation of lift cylinder piston rod
to folding top side roof rear rail, connect battery
and use power to raise cylinder piston rod to
extended position.
b. Operate folding top assembly down and up to
insure proper linkage alignment of side rails.
Where required, adjust male hinge assembly as
described under "Folding Top Adjustments."
c. Operate folding top assembly down and up
several times, then check and correct level of
hydraulic fluid in reservoir. See "Filling of
Hydro-Lectric Reservoir." Fig. 1 7-Lift Cylinder Removal
EXTERIOR MOLDINGS
The exterior moldings are identified in Figures 118, 2. When a molding is overlapped the overlapping
119, 120 and 121. The moldings are secured to the body molding is indicated in the "Engages with other
by any one or a combination of the following attach- molding" column and must be removed first.
ments:
a attaching screws General Precautions
b bolt and clip assemblies with attaching nuts When removing or installing any body exterior
moldings certain precautions should be exercised.
c integral studs with attaching nuts
d bath tube type snap-on clips 1. Adjacent finishes should be protected with mask
ing tape to prevent damage to finish.
e snap-in studs to pre-installed retainers
2. Proper tools and care should be employed to guard
f snap-in clips
against molding damage.
Figure 122 illustrates typical attachments for body
side moldings. Sealing Operation
Before using the molding charts, the following in Detailed sealing operations for each individual mold
formation will be helpful when installing or removing ing are not described on the "Molding Removal Chart,"
exterior moldings. but the following information is given to permit a
1. Screw locations-the exact location for each screw satisfactory sealing operation when necessary.
is not shown or mentioned, but when hidden, the Medium-bodied sealer or body caulking compound
general location is indicated by naming the mold are the sealers most frequently used to provide a
ing or other part which conceals the screw and, watertight seal or for anti-rattle measures. Washers
therefore, must be removed to gain access to the and gaskets are also used and should be replaced if
screw. damaged.

BODY 14-79
A B
Fig. 118-Body Exterior Moldings-1669 Styles

A. Windshield Pillar Drip Molding Scalp. E. Quarter Belt Reveal Molding. I. Rear Compartment Lid Outer Panel Upper Molding.
B. Roof Drip Molding Scalp. F. Rear Fender Lower Molding. J. Rear Compartment Lid Outer Panel Lower Molding.
C. Front Door Outer Panel Lower Molding. 0. Rear Fender Emblem. K. Rear Body Emblem.
D. Rear Door Outer Panel Lower Molding. H. Rear of Rear Fender Molding.
Holes in body panels for screws, bolts or clips that Tools and Care
would permit water to enter the interior of the body
For ease of molding removal, it is sometimes impor
should be sealed with body caulking compound or pre
tant to start the removal at a particular location which
sealed screws, nuts or clips.
is generally the "front" or "rear" of the molding. This
Drip moldings require a ¼" bead of medium-bodied
position is indicated when necessary in the "Starting
sealer along the full length of the inner attaching sur
Location" column of the molding chart.
face. Door window scalps and center pillar scalps re
quire a 1/8" x ¼" x ¼" bead of caulking compound at The following groups of moldings are listed with the
5" intervals for anti-rattle purposes. Pinchwelds re name or description of the tool which is suitable for
quire medium-bodied sealer on both sides when pinch- molding removal.
weld clips are used. The exception is the rear quarter Roof Drip Scalps-pointed hook tool
pinchweld on convertible styles which requires water Door Window Scalps-thin flat-bladed tool
proof tape over the entire pinchweld, prior to clip putty knife
installation. Snap-on Clips-thin flat-bladed tool putty knife

BODY 14-80
A B C D E F G H I J K L M
R5
Fig. 119-Body Exterior Moldings-i 835 Styles
A. Windshield Pillar Drip Molding Scalp. I. Quarter Window Upper Reveal Molding. Q. Rear Fender Emblem.
B. Roof Drip Molding Front Scalp. J. Roof Drip Molding Rear Scalp. R. Rear of Rear Fender Molding.
C. Front Door Window Frame Upper Scalp Molding. K. Quarter Window Rear Reveal Molding. S. Rear of Rear Fender Insert Molding.
D. Front Door Window Reveal at Vent Molding. L. Back Body Opening Upper Pinchweld Finishing Molding. T. Tail Gate Outer Panel Upper Molding.
E. Front Door Window Reveal Molding. M. Back Body Opening Side Pinchweld Finishing Molding. U. Tail Gate Outer Panel Insert Molding.
F. Rear Door Window Reveal Molding. N. Front Door Outer Panel Lower Molding. V. Tail Gate Outer Panel Lower Molding.
G. Rear Door Window Frame Upper Scalp Molding. 0. Rear Door Outer Panel Lower Molding. W. Rear Body Emblem.
H. Quarter Window Lower Reveal Molding. P. Rear Fender Lower Molding.

BODY 14-81
A B C D E F

A. Front Door Window Reveal at Vent Molding. G. Front Door Outer Panel Lower Molding. L. Rear of Rear Fender Insert Molding.
B. Front Door Window Reveal Molding. H. Rear Door Outer Panel Lower Molding. M. Rear Compartment Lid Outer Panel Upper Molding.
C. Roof Drip Molding Front Scalp. I. Rear Fender Lower Molding. N. Rear Compartment Lid Outer Panel Insert Molding.
D. Roof Drip Molding Rear Scalp. J. Rear Fender Emblem. 0. Rear Compartment Lid Outer Panel Lower Molding.
E. Rear Door Window Reveal Molding. K. Rear of Rear Fender Molding. P. Rear Body Emblem.
F. Quarter Belt Reveal Molding.

BODY 14-82
A B C D E
N
M
H L
K
J
A. Door Window Reveal at Vent Molding. F. Door Outer Panel Lower Molding. K. Rear Comportment Lid Outer Panel Upper Molding.
B. Door Window Reveal Molding. G. Rear Fender Lower Molding. L. Rear Comportment Lid Outer Panel Insert Molding.
C. Roof Drip Molding Scalp. H. Rear Fender Emblem. M. Rear Compartment Lid Outer Panel Lower Molding.
D. Quarter Window Lower Reveal Molding. I. Rear of Rear Fender Molding. N. Rear Body Emblem.
E. Quarter Belt Reveal Molding. J. Rear of Rear Fender Insert Molding.

BODY 14-83
MOLDING
ROOF EXTENSION
OUTER PANEL
QUARTER
OUTER PANEL
OUTER PANEL
VIEW A VIEW B
UPPER MOLDING
BACK
GLASS
CLIP
RUBBER
CHANNEL
OUTER
BACK PANEL RETAINING
OUTER WINDOW
PANEL LOWER SCREW
REVEAL
BOLT & ATTACHING

CLIP ASSEMBLY NUT
VIEW C VIEW D
MOLDING
OUTER
PANEL
VIEW E
Fig. 122-Exterior Molding Attachment

BODY 14-84
EXTERIOR MOLDINGS
Method of Retention
Snap-On Studs
Spring Clips or Snap-On With Remove
Sell- Retainers Clips Attaching Engages With Hardware Starting
Molding Name Styles Screws Retained On Panel On Molding Nuts Other Moldings Or Trim Location
Windshield Pillar Drip 1600 - x -

0 - -
- Lower end
Molding Scalp 1835,45, 69 under drip
molding
Windshield Pillar to 1211, 35, 69 - x - - - - - Lower edge
Roof Drip Escutcheon
Roof Drip Molding 1611, 69 - x - - - Windshield Pillar Side Roof Front
Scalp 1847, 69 Drip Molding Scalp Rail lower edge
Weatherstrip
Retainer on
47 Style
Roof Drip Molding 1635, 45 - x - - - Rear Scalp Over- - Front
Front and Rear Scalp 1835, 45 lapped by Front lower edge
Scalp
1839 - x - - - Roof Drip Molding - Front
Front Scalp lower edge
Front Door Window 1800 Series x - - - - - Vent Upper -
Reveal At Vent Attaching

Screws
Front Door Window 1835,45, 69 x - - - - - Door Upper Rear
Frame Upper Scalp Run Channel lower edge
Vent
Front Door Window 1800 Series x - - - - - DoorWindow -
Lower Reveal Lower

Bumper
Stop
Front Door Outer 1200 x - - x - - - -
Panel Lower 1600 View A

1800 x - - x - - - -
View E
Rear Door Window 1835, 45, 69 x - - - - - Door Upper -
Frame Upper Scalp Glass Run

Channel,
Also Rear
on 69
Rear Door Outer Panel 1200, 1600 x - - x - - - -
Lower View A
1800 x x
View_£
Quarter Window Upper 1211, 1611 x - - - - - Quarter -
Scalp 35 & 45 Window

Styles
Quarter Window Rear 35 & 45 x - - - - Quarter Window Quarter -
Scalp Styles Upper Scalp Window

Quarter Window Front 35 & 45 x - - - - Quarter Window Quarter -
Scalp Styles Upper Scalp Window

Quarter Window Front 1211 x - - - - Quarter Window Quarter -
Reveal 1611 Upper Scalp Window

BODY 14-85
EXTERIOR MOLDINGS
Method of Retention
Snap-On Studs
Self- Retainers Clips Attaching Engages With Hardware Starting
Quarter Window Upper 1835, 45 x - - - - - Rear Quarter -
Reveal Window
Quarter Window Rear 1835, 45 x - - - - Rear Quarter Rear Quarter -
Reveal Window Upper Window

Reveal
Quarter Window Lower 1835, 45 x - - - - Quarter Window Rear Quarter -
Reveal Front and Rear Window

Reveal
1847, 67 x 0
0 - - - - Quarter
Window
on 67
Quarter
Window
Lower Stop
on_47
Quarter Belt Reveal 1611 - - - x - - - -
View B
1669, 1869 x x
ViewB - - - -
1847 x
View C Quarter
1839 x x B/W Lower Reveal Upper Trim
Panel
Rear Quarter Pinch- 1867 x - x - - Quarter Window Lower Top At
weld Finishing Lower Reveal to remove radius
tension on
back
curtain
Rear Fender Lower 1200, 1600 - - - x x - Spare. tire -
Except Cover-
3445 3545..
1800 - - - x
Except View A x - Spare tire
35-45 Cover-
35-45
Left side
1635, 45
1835,45 - - - x - - - -
Rear Fender Lower 1235 - - - x - - - -
Front Left Side View A

Rear Fender Lower 1235 - - - x - - - -
Rear Left Side View A

Gas Tank Filler Door 1235 x - - - - - - -
Rear of Rear Fender 1600, 1800 - - - - x - - -
1635,45 x - x - - - - -
1835, 45 View F

BODY 14-86
EXTERIOR MOLDINGS
Method of Retention
Snap-On Studs
Self- Retainers Clips Attaching Engages With Hardware Starting
Rear of Rear Fender 1800 - - - - - Rear of Rear - -
Insert Except Fender

35, 45
1835, 45 x - - - - Rear of Rear - -
Fender
Rear Compartment Lid 1600, 1800 x - - - - - - -
Outer Panel Lower

Rear Compartment Lid 1600, 1800 x - - - x - - -
Outer_Panel_Upper
Rear Compartment Lid 1839, 47, - - - - - - - -
Outer Panel Insert 67, 69

Back Body Opening 35-45 - - x - - Back Body Opening - -
Upper Pinchweld Styles Side Pinchweld

Finishing Finishing
Back Body Opening 35-45 - - x - - - - -
Side Pinchweld Styles

Finishing
Tail Gate Outer Panel 1635, 45 x - - x - - - -
Lower 1835, 45 View D .
Tail Gate Outer Panel 1635, 45 x - - x - - - -
Upper 1835, 45 View D .
Tail Gate Outer Panel 1835, 45 x - - - - Tail Gate Outer - -
Insert Panel Upper and

Lower
Rear Fender Name All 1200, - - - - x - Spare Tire -
Plate 1600 Cover-

Except 35-45
35, 45 Styles
left side
Rear Fender Name 35, 45 - - x - - - - -
Plate Left Side

Rear Fender Emblem 1800 - - - - x - Spare Tire -
Cover-
35-45
1835 Left - - x - - - - -
Side
Rear Compartment Lid 1211, 69 - - - - x - - -
Outer Panel Name

Plate
Rear Body Emblem 1211, 69, - - - - x - - -
1611, 69
1839, 47,
67, 69
1235 - - - - x - Tailgate -
1635, 45 Inner Panel

1835, 45

BODY 14-87
SPECIAL TOOLS
Fig. 123-Passenger Body Special Tools
1. J-7797 Door Handle Remover 2. J-6335 Trim Panel Removing Tool 3. J-7898-O1 Molding Removing Tool

14-978
CHASSIS SHEET METAL 14-88
CHASSIS SHEET METAL
INDEX
Page Page
General Description Removal 14-93
Maintenance and Adjustments... 14-88 Repairs 14-94
Hood Adjustment 14-88 Installation 14-94
Hood Hinge 14-88 Battery Tray 14-94
Hood Bumpers 14-89 Removal 14-94
Hood Catch 14-89 Installation 14-94
Sheet Metal Adjustments. 14-90 Radiator Support. 14-94
Service Operations 14-91 Removal 14-94
Front Bumper Assembly 14-91 Installation 14-94
Removal 14-91 Front Fender Assembly 14-95
Disassembly 14-91 Removal 14-95
Assembly 14-91 Installation 14-95
Installation 14-92 Front Fender Trim 14-95
Rear Bumper 14-92 Front Fender Skirt Assembly.. 14-95
Removal 14-92 Removal 14-95
Disassembly 14-92 Installation 14-96
Assembly 14-92 Hood Assembly 14-96
Installation 14-93 Hood Lock Assembly 14-97
Bumper Filler Panel... 14-93 Removal 14-97
Removal 14-93 Installation 14-97
Installation 14-93 Hood Trim and Insulation. 14-97
Grille Assembly 14-93 Special Tools
GENERAL DESCRIPTION
The distinctive break-line extending across the for parking and turn signal lamp, centered below each
ward area of the hood and front fenders is again a headlamp group, features an amber lens for improved
prominent feature of the front end styling. Twin wind- contrast against the illuminated headlamps.
splits, widely spaced, relieve the broad expanse of A bright metal moulding surrounds the grille with
hood. an upper segment, on the leading edge of the hood,
A new radiator grille, extending the full width of displaying the Chevrolet name in depress block letters.
the vehicle houses the individually mounted dual A deep-section front bumper contains a recessed
headlamps at the outer ends of the grille. An oblong license area, flanked by integral guards.
MAINTENANCE AND ADJUSTMENTS

HOOD ADJUSTMENT alignment obtained by hinge and bumper adjustment
is maintained when the hood is closed. Note that the
The alignment of the hood proper in relation to hood latch is not designed or intended to correct basic
other sheet metal parts is controlled by the position hood alignment faults.
of the hood hinges and the height of the two bumpers To align the hood and lock, proceed as follows:
located one at each end of the forward edge of the
hood. The adjustments at the hood latch must be Hood Hinge fig. 125
made after the hinges and bumpers are positioned
to yield the dimensions shown in Figure 127. Latch 1. Note that the mounting holes in the body mounted
adjustments are made so that effort is required to open end of the hinge are slotted to provide up and
and close the hood is reasonable and so that the hood down movement of the hood assembly while the

Fig. 124-Front Sheet Metal Explode
1. Radiator Support 5. Radiator Shroud 8. Skirt Rear Seal 11. Hood Hinge
2. Fender Tie Bar 6. Skirt Forward Seal 9. Left and Right Skirt 12. Left and Right Fender
3. Hood Catch Assembly 7. Skirt Intermediate Seal 10. Hood Hinge Support 13. Hood Assembly
4. Radiator
hood mounted end is slotted to provide fore and 2. Scribe a mark around the entire hinge plate which
aft movement. will be involved in the adjustment.
3. Loosen the appropriate screws and shift the posi
tion of the hood on the hinge plate the approxi
mate amount to correct misalignment using the
scribed marks to check amount of movement.
Check condition of adjustment by tightening cap
screws and closing hood.
Hood Bumpers
Hood bumpers must be adjusted so that the hood
top surface is flush with the fender top surface.
Hood Catch fig. 126

Hood lock plate mounting holes are slotted to pro
vide fore and aft adjustment of the hood lock bolt.
The hood lock bolt itself is adjustable for up and down
positioning of the lock bolt head so that its proper
Fig. 125-Hood Hinge engagement in the catch assembly may be provided

Fig. 126-Hood Catch and Bumpers
for, he distance that the lock bolt protrudes out of

the lock plate should be adjusted so that the hood
bumpers are slightly compressed by the fully latched
hood and so that the effort required to release the hood
catch is reasonable.
SHEET METAL ADJUSTMENTS

Fig. 128-Fender to Cowl and Rocker Panel Shimming
For proper operation of doors and hood, and for
presentable appearance, front sheet metal must fit sheet metal is adjustable at six points three on each
within the tolerances shown in Figure 127. The side of car by means of spacer shims shown in Figures
128 and 129.
SPL.
SPL. NUT
RADIATOR
SUPPORT
SHIM
FRAME
Fig. 1 27-Sheet Metal Adjustment Related Parts Fig. 129-Frame to Radiator Support Shimming

The fender-to-cowl and rocker panel shimming al should be loosened before raising or lowering radiator
lows adjustment of fender surfaces to door surface and support.
upper cowl surface. Note that it is possible and sometimes desirable to
The radiator support shimming provides a means shift entire front sheet metal assembly to the left or
of raising or lowering the forward part of front sheet right by loosening these shimmed mounts and applying
metal assembly to correct faulty sheet metal-to-front the necessary force. Cases of extremely poor hood fit,
bumper relationship and fender trailing edge-to-door overly wide fender-to-door gap, etc., will often be cor
parallelism cowl and rocker panel shimmed mounts rected by this method more quickly than by any other.
SERVICE OPERATIONS
FRONT BUMPER ASSEMBLY fig. 130 Disassembly
1. Remove bolts retaining bumper mounting braces,
Removal
to bumper mounting bar.
1. Raise vehicle from floor.
2. Remove bolts retaining center bracket assembly to
2. Remove six bolts three per side retaining bump mounting bar.
er brackets and mounting braces to front end of 3. Remove remaining bolts attaching mounting bar to
frame. left and right hand mounting brackets. Remove
3. Remove lower bolts retaining fender braces to mounting bar from bumper assembly.
bumper tips. 4. Separate face bar sections by removing three bolts
at each joint.
4. Remove screw retaining latch support bracket to
bumper center brace. From under hood, remove Assembly
latch support brace retaining nut from lower end
Assemble following disassembly procedure in re
of lock support.
verse order. Install all bolts loosely do not tighten any
5. Remove bumper from vehicle. bolts until all bolts are installed.
16
‘11
Fig. 1 30-Exploded View of Grille and Front Bumper

1. Face Bar Center Panel 5. Outer Mounting Bracket 9. Hood Latch Support 13. Retainer
2. Outer Face Bars 6. Mounting Bar 10. Grille End Baffle 14. Seal Beam Holder
3. Center Face Bar 7. Hood Latch Support Brace 11. Grille 15. Parking Lamp Body
4. Center Mounting Bracket 8. Bumper Filler Panel 12. Headlamp Bezels 16. Seal Beam Body

4,
Fig. 131-Exploded View of Rear Bumper
1. Mounting Brace 4. Spacer Not on Station Wagon 6. Center Face Bar

2. Mounting Bracket 5. Center Face Panel 7. Bumper Face Bar
3. Reinforcement
Installation NOTE: Disconnect license lamp wire.

1. Position assembled bumper on frame horns, aligu
ing holes in mounting brackets with holes in frame 2. Remove bumper from vehicle.
work.
Disassembly fig. 131
2. Install bolts, lock washers and nuts, but do not
tighten. 1. Remove license plate lamp by removing two re
Note that eight-sided eccentric washer is in taining screws.
stalled under forward bolt and regulates mounted 2. Remove four bolts retaining each mounting brack
height of bumper. "Dial" the washer within the et to bumper.
retaining notches on bracket to position the bump
er at desired height. 3. Center face panel may be separated from rein
3. Install bolts retaining mounting braces to frame forcements by removal of special clips shown in
horns. Figure 132.
4. Install bolts retaining fender lower corner to 4. Separate three sections of face bar by removing
bumper tips. bolts shown in Figure 131.
5. Tighten all mounting bolts securely.
Assembly
REAR BUMPER Assemble, following disassembly procedure in re
verse order. Install all bolts loosely do not tighten
Removal any bolts until all bolts are installed. Check con
1. Remove four bolts two-per side retaining bump dition of seal shown in Figure 133. Replace if neces
er brackets to frame horns. sary. Install license plate lamp on bumper.

FINAL
POSITION
PLIERS
Fig. 1 32-Special Clip
Installation
1. Position bumper assembly on vehicle. Align holes Fig. 1 34-Bumper Filler Panel
and brackets with holes in frame horn. Install all
bolts, nuts and washer assemblies loosely. BUMPER FILLER PANEL fig. 134
2. Note that eight-sided washer is installed under Removal

head of rearmost mounting bolt. Adjust bumper 1. Remove front bumper as outlined in this section.
to desired height by "Dialing" this washer within 2. At each end of panel:
retaining notches on bumper mounting bracket. a. Remove one screw retaining head lamp assem
3. With bumper adjusted to desired height, tighten bly to filler panel.
all mounting bolts securely. b. Remove two screws retaining filler panel to
skirt front flange.
c. Remove one screw retaining filler panel to
grille end baffle.
d. Remove one screw retaining filler panel to
lock support.
3. Remove filler panel from vehicle.
Installation
Position filler panel in vehicle, align all screw and
bolt holes with drift punch. Install all screws and bolts
loosely. Do not tighten any screws or bolts until all are
installed. Note that it will be necessary to aim head
lamps as outlined in Section 9 of this Shop Manual.
GRILLE ASSEMBLY figs. 130 and 135

Removal
1. Remove front upper and lower fender mouldings.
2. Remove screws from filler panel and grille and
baffles-to-radiator support.
3. Disconnect headlight and parking light wiring.
4. Remove screws from center mounting bracket and
Fig. 133-Rear Bumper-to-Body Seal grille upper support-to-radiator support.

Fig. 1 35-Grille Assembly
5. Remove screw holding grille to front fenders and

remove grille.
NOTE: Protect filler panel at parking light area
prior to removing grille.
Repairs
If hood lock support, end baffle, camber latch sup
port and headlight assemblies are undamaged, they
may be transferred to new grille by drilling out and
removing the rivets retaining them to the old grille.
Attachment to new grille may be made by using either Fig. 1 36-Radiator Support and Tie Bar
rivets, screws and nuts or patent clips.
2. Remove screws retaining radiator to radiator sup
Installation port. Note that it is not necessary to drain radiator
1. Position grille in vehicle aligning all screw holes. or to disconnect radiator hoses from engine if radi
Be sure all retaining screws are started before any ator is supported in vehicle.
final tightening is done.
2. Check head lamp aiming as outlined in Section 9 3. Remove screws retaining each end of support to
of the shop manual. fender assembly and hood catch assembly.
4. Remove screw retaining radiator support to for
BATTERY TRAY ward edge of fender skirt.
Removal 5. Remove mounting bolts retaining radiator support
1. Disconnect battery cables. to each frame horn. Record number of shims found
2. Remove screw and nut retaining battery hold- at each mount.
down assembly and remove battery from vehicle.
6. Spread fenders apart enough to allow radiator
3. Remove three screws retaining battery tray as
support to be removed from vehicle.
sembly to fender skirt and radiator support, and
remove battery tray from vehicle.
Installation
Installation
1. Position battery tray on fender skirt and install 1. Position radiator support on vehicle, aligning
cap screws. mounting screw and bolt holes with drift punch.
2. Place battery in tray and install retainer assembly.
2. Install cap screws and bolts loosely until all are
3. Install battery cables. started.
RADIATOR SUPPORT fig. 136 3. Replace all parts removed in Operation 1 in Re

moval procedure referring to write-up for part
Removal
involved.
1. Remove bumper assembly, grille assembly, filler
panel, horns, voltage regulator, battery tray, etc., 4. Aim head lamps as outlined in Section 9 of this
as outlined in this section. book.

ing fender to rocker panel and record number of

shims found at this location. Remove one screw
retaining fender to cowl and record number of
shims found at this location.
6. Remove two screws retaining fender to hood
hinge. Remove fender from vehicle.
Installation
When replacing fender, all screws should be in
stalled loosely. Refer to disassembly procedure for
location of screws. The shimmed screws located at
rocker panel and cowl should be installed and adjust
ments should be made before tightening any of the
other screws. Always start adjustment with original
amount of shims, then add or subtract shims as re
quired.
FRONT FENDER TRIM

Fig. 1 37-Radiator Support Installation To gain access to spear moulding and wind-split
moulding retaining nuts, remove skirt assembly as
FRONT FENDER ASSEMBLY outlined in the following section, remove rear fender-
to-cowl bolts and pry rear fender out several inches
Removal from body.
1. Referring to Figures 136 and 137: Remove two
screws retaining fender to radiator support. FRONT FENDER SKIRT ASSEMBLY
2. Referring to Figure 130: Remove one screw from Removal
bumper tip.
1. Jack up front end of vehicle with front suspension
3. Remove fender front moulding and grille screws. hanging free and remove front wheel.
4. Referring to Figure 138: Remove screws retaining 2. Remove all wires, hoses, etc. attached to skirt.
fender to skirt. Note that it is not necessary to remove battery
5. Referring to Figure 128: Remove one screw retain- tray if working on right hand side of car.
3. Remove cap screws retaining skirt to fender,
bumper filler panel and hood hinges in that
order. Observe length of screws as they are
removed; note that those screws installed at top
SKIRT
Fig. 138-Fender-to-Fender Skirt Attachment Fig. 1 39-Removing Front Fender Skirt

of wheel opening are somewhat shorter than the

others. Note also the location of pointed screws.
4. With all screws removed, lower the skirt toward
floor, rotate the upper portion toward you and
remove the skirt from the vehicle as shown in
Figure 139.
Installation
1. Position skirt on vehicle so that the front flange
lies between the fender and bumper filler panel
flanges in the area shown in Figure 140.
Fig. 141-Removing Spring with J-9559
opened position, spring may be removed as shown

in Figure 141.
3. As soon as spring is removed, insert long bolt
Fig. 140-Position of Left Front Fender Skirt supplied with J-9559 through holes in end of tool
passing it through spring and install nut on bolt.
2. Align hole in crown of skirt with hole in hood Spring may be removed from J-9559 ‘or J-9559 may
hinge and loosely install cap screw with large be installed in a new spring by the following method.
cupped washer in place.
3. Align holes and install remaining screws; do not
tighten until all screws are started. Be sure that
short screws and pointed screws are installed in
locations from which they were removed.
4. Install all wiring and/or hoses removed previ
ously.
5. Install wheel and lower vehicle to floor.
HOOD ASSEMBLY
Hood may be removed either with or without hinges.
To shorten aligning time, hood hinge plates may be
located by scribing a mark on hood and/or hood
mounting bracket which outlines entire plate. See
"Maintenance and Adjustments-Hood Hinge" for hood
adjustment procedure. Hood hinge springs may be
easily and safely removed and installed through the
use of Tool J-9559 as follows:
1. With hood opened only far enough to allow pas
sage of mechanic’s arm between hood and fender,
insert ends of J-9559 through bolt removed be
tween coils of spring until barrel of tool contacts
outer diameter of spring.
2. Open hood full while still holding spring with
tool installed in hand; when hood is near fully Fig. 142-Installing J-9559 in New Spring

1. Place a closed 6 or 8 inch "C" clamp in a vice

or fasten it to a heavy bench top bench should be
fastened to floor.
2. Hook one end of spring in clamp and the other end
in hook of chain hoist, "cherry-picker" or equiva
lent, as shown in Figure 142.
3. Stretch the spring enough to allow insertion of
J-9559. Install through bolt if spring is not to be
installed on hinge at once.
HOOD LOCK ASSEMBLY fig.126

Removal
1. Remove catch assembly as follows:
a. Remove two cap screws retaining catch assem
bly to radiator support.
b. Remove cap screw retaining catch assembly to
catch support assembly.
Fig. 143-Hood Trim and Insulation
2. Before removing hood lock plate from hood, lo
cate position on hood by scribing around "feet" 2. Align as outlined under "Maintenance and Adjust-
of lock plate. Remove four cap screws retaining ments-Hood Catch."
lock plate to hood and remove lock plate from
vehicle. HOOD TRIM AND INSULATION
Installation Figure 143 shows the installation details of both the
hood ornamentation and insulating pads. The hood
1. Install both catch and lock assemblies in reverse emblem and molding retaining nuts may be reached
order of removal procedure. from the underside of the hood panel.
SPECIAL TOOLS
Fig. 1 44-Special Tools-Sheet Metal
1. J.9559 Hood Spring Tools

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SECTION 14

BODY AND SHEET METAL

1135 1235 1535 1635 1735 1835 4 Dr. Sta. Wagon-

PASSENGER CAR SHOP MANUAL SUPPLEMENT

FIg. 1-1963 Impala

Fig. 2-1963 Impala Station Wagon

PASSENGER CAR SHOP MANUAL SUPPLEMENT

2. The operation should be repeated, using only a

PASSENGER CAR SHOP MANUAL SUPPLEMENT

PASSENGER CAR SHOP MANUAL SUPPLEMENT

Windshield Garnish Moldings

Removal and Installation Fig. 3-Garnish Moldings

PASSENGER CAR SHOP MANUAL SUPPLEMENT

same as covered in the 1961 Passenger Car Shop Man

Fig. 7-Instrument Panel Trim Moldings

Fig. 5-Lower Garnish Molding Removal

On "67" styles remove the side garnish molding

Instrument Panel Assembly

Fig. 6-instrument Panel Compartment Fig. 9-Instrument Panel Cover

PASSENGER CAR SHOP MANUAL SUPPLEMENT

DOORS AND CENTER PILLAR

DOOR INNER ATTACHING

Front and Rear Door Window Glass Run

bly in a downward motion to disengage attaching

Front and Rear Door Inside Handles

MOLDING a. On styles equipped with door inside remote control

Front and Rear Door Arm Rest Assemblies

Fig. 12-Door Window Glass Run Channel Outer Strip Assemblies

PASSENGER CAR SHOP MANUAL SUPPLEMENT

4. Place tool J-6335, or other suitable flat-bladed tool,

NOTE: Exercise care not to disturb inner panel

5. Lift trim assembly upwards and carefully disen

NOTE: On styles equipped with electric window

6. To install, reverse removal procedure. Broken re

PASSENGER CAR SHOP MANUAL SUPPLEMENT

Removal Front and Rear Door Outside Handle Assembly

PASSENGER CAR SHOP MANUAL SUPPLEMENT

TOOL J.2 1104 ‘/"

Fig. 17-Front Door Weatherstrip Removal

1. Remove snap fasteners securing ends of weather

2. Carefully break cement bonds securing weather

CAUTION: Exercise care not to damage serra VIEW A

PASSENGER CAR SHOP MANUAL SUPPLEMENT

Fig. 21 -Front Door Weatherstrip Adhesive Application

Fig. 20-Using Weatherstrip Removal Tool

PASSENGER CAR SHOP MANUAL SUPPLEMENT

NOTE: In the event a weatherstrip becomes

Front Door Hardware

PASSENGER CAR SHOP MANUAL SUPPLEMENT

NOTE: After performing any door adjustments

Front Door Lock Strikers

PASSENGER CAR SHOP MANUAL SUPPLEMENT

Dimensional Specifications for Use of Front Door Lock Cylinder Assembly

4. To install, reverse removal procedure. Check op

Disassembly and Assembly

Fig. 25-Striker Engagement Check LOCK CYLINDER PAWL PAWL RETAINING

1. Raise door window. Remove door trim assembly

Fig. 27-Front Door Hardware-Hardtop Styles

3. To install, reverse removal procedure. Prior to