1968 Chevrolet Chassis Service Manual

HASSIS
SERVICE! MANUAL
CHEVIOLET* CHEVELLE
CAMARO * CHEVY U
H EVROLET
________
________
_______
SECTION INDEX
SECTION NAME
GENERAL INFORMATION
1968 A
U AND LUBRICATION
HEATER AND
CHEVROLET CHEVELLE, I A
I M AIR CONDITIONING
CAMARO, 1B CORVETTE BODY
CHEVY II AND CORVETTE 2 FRAME
CHASSIS 3 FRONT SUSPENSION
SERVICE MANUAL 4 REAR SUSPENSION

AND_DRIvELINE
AND CORVETIE BODY SERVICE MANUAL
FOREWORD
5 BRAKES
This manual includes procedures for maintenance and 6 ENGINE

adjustments, minor service operations, removal and in
stallation for components, except the body, of Chevrolet,
Chevelle, Camaro, Chevy II and Corvette vehicles, and 6K ENGINE COOLING
service information for Corvette bodies. Procedures in
volving disassembly and assembly of major components for
these vehicles are contained in the 1968 Chassis Overhaul
6M FUEL SYSTEM
Manual. Service information for 1968 Chevrolet, Chevelle, AIR INJECTION
Camaro and Chevy II body items is contained in the 1968
Body Service Manual.
6T REACTOR SYSTEM
The Section Index on this page enables the user to
quickly locate any desired section. At the beginning of each 6 ENGINE ELECTRICAL
section containing more than one major subject is a Table
of Contents, which gives the page number on which each
major subject begins. An Index is placed at the beginning 7 CLUTCH AND TRANSMISSION
of each major subject within the section. FUEL TANK AND
Summaries of Special Tools, when required, are found
at the end of major sections while specifications covering
8 EXHAUST_SYSTEM
vehicle components are presented at the rear of the
manual.
This manual should be kept in a handy place for ready
9 STEERING
reference. If properly used, it will enable the technician

to better serve the owners of Chevrolet built vehicles. 10 WHEELS AND TIRES
All information, illustrations and specifications con
tained in this literature are based on the latest product
information available at the time of publication approval.
11 CHASSIS SHEET METAL
ELECTRICAL-BODY
The right is reserved to make changes at any time without
notice.
‘
2 AND_CHASSIS
... ‘1 3 RADIATOR AND GRILLE
CHEVROLET MOTOR DIVISION

General Motors Corporation
14 BUMPERS
DETROIT, MICHIGAN
Reprinted with Permission of 15 ACCESSORIES
SPECIFICATIONS
© 1967 Printed in U.S.A.
"Reproduced by Detroit Iron IS with permission of General Motors LLC under License."
SECTION 0
GENERAL INFORMATION AND LUBRICATION
CONTENTS OF THIS SECTION
Page
General Information 0-1
Lubrication 0-9
GENERAL INFORMATION
Page Page
Model Identification and Vehicle Dimensions 0-1 Unit and Serial Numbers 0-3
Chevrolet 0-1 Engine and Transmission Number V.I.N. 0-3
Chevelle 0-2 Vehicle Serial Number 0-4
Chevy U 0-2 Keys and Locks 0-4
Camaro 0-2 Pushing, Towing and Lifting 0-4
Corvette 0-3
MODEL IDENTIFICATION-CHEVROLET
Model Number .
Description
6-Cyl. - V-8
15311 15411 2-Door Sedan, 6-Pass.
15369 15469 4-Door Sedan, 6-Pass.
15335 15435 4-Door Station Wagon, 2-Seat
15511 15611 2-Door Sedan, 6-Pass.
15569 15669 4-Door Sedan, 6-Pass.
15545 - 15645 4-Door Station Wagon, 3-Seat
16387 16487 2-Door Sport Coupe, 5_Pass.*
16467 2-Door Convertible, 5_Pass.*
16369 16469 4-Door Sedan, 6-Pass.
16339 16439 4-Door Sport Sedan, 6-Pass.
16435 4-Door Station Wagon, 2-Seat
16445 4-Door Station Wagon, 3-Seat
Custom 16347 16447 2-Door Custom Sport Coupe, 5_Pass.*
16647 2-Door Custom Sport Coupe, 5_Pass.*
16639 4-Door Custom Sport Sedan, 6-Pass.
16635 4-Door Custom Wagon, 2-Seat
16645 4-Door Custom Wagon, 3-Seat
*4passenger when optional bucket front seats are specified.
VEHICLE DIMENSIONS-CHEVROLET
Pertinent dimensions for the different models are shown in the following chart.
2-Door Convertible Station
Model Sedan
- Sport Coupe Coupe Wagon
Length Overall - 214.8" 214.8" 214.8" 214.6"
Width Overall Body 79.6" 79.6" 79.6" 79.6"
Height Overall - 55.4" 54.4" 55.3" 56.7"
Wheelbase - 119.0" 119.0" 119.0" 119.0"
Tread-Front 62.5" 62.5" 62.5" 63.5"
62.4" 62.4" 62.4" 63.4"
Curb Weight: Approximately 3580 lbs. 4-Door Sedan with L-6 Engine; 3720 lbs. with V-8 Engine.
CHEVROLET CHASSIS SERVICE MANUAl.
GENERAL INFORMATION 0-2
MODEL IDENTIFICATION-CHEVELLE
Model Number
Series Description
6-Cyl. V-8
300 13127 13227 2-Door Pillar Coupe, 5-Pass.
Nomad 13135 13235 4-Door Station Wagon, 2-Seat
13327 13427 2-Door Pillar Coupe, 5-Pass.
300 Deluxe 13369 13469 4-Door Sedan, 6-Pass.
13337 13437 2-Door Sport Coupe, 5-Pass.
Nomad Custom 13335 13435 4-Door Station Wagon, 2-Seat
13569 13669 4-Door Sedan, 6-Pass.
13539 13639 4-Door Sport Sedan, 6-Pass.
Malibu 13537 13637 2-Door Sport Coupe, 5_Pass.*
13567 13667 2-Door Convertible, 5_Pass.*
13837 2-Door Sport Coupe, 5_Pass.*
SS 396
13867 2-Door Convertible, 5_Pass.*
Concours 13735 13835 4-Door Station Wagon, 2-Seat
13380 13480 2-Door Sedan Pickup, 3-Pass. Reg.
El Camino 13580 13680 2-Door Sedan Pickup, 3-Pass. Deluxe
13880 2-Door Sedan Pickup, 3-Pass. Super Sport
4-Passenger when optional front bucket seats are ordered.
VEHICLE DIMENSIONS-CHEVELLE
Pertinent dimensions for the different models are shown in the following chart.
2-Door Convertible Station Sedan
Model Sedan .
Sport Coupe Coupe Wagon Pickup
Length Overall 200.8" 196.8" 196.8" 207.2" 207.2"
Width Overall Body 76.0" 76.0" 76.0" 76.0" 76.0"
Height Overall 53.5" 52.8" 52.8" 54.3" 54.3"
Wheelbase 116.0" 112.0" 112.0" 116.0" 116.0"
Tread-Front 59.0" 59.0" 59.0" 59.0" 59.0"
Tread-Rear 59.0" 59.0" 59.0" 59.0" 59.0"
Curb Weight: Approximately 3207 lbs. 4-Door Sedan with L-6 Engine 3350 lbs. with V-8 Engine.
MODEL IDENTIFICATION-CHEVY II MODEL IDENTIFICATION-CAMARO

Model Number Model Number .
Description Description
6-Cyl. V-8 6-Cyl. V-8
11327 11427 2-Door Sport Coupe, 5-Pass. 12337 12437 2-Door Sport Coupe, 4-Passenger
11369 11469 4-Door Sedan, 6- Pass.
12367 12467 2-Door Convertible, 4 Passenger
VEHICLE DIMENSIONS-CHEVY II
2-Door
VEHICLE DIMENSIONS-CAMARO
Model Sedan
Sport Coupe
Model Sport Coupe Convertible
Length Overall 187.7" 187.7"
Width Overall Body. . 70.5" 70.5" Length Overall 184.7"
Height Overall 53.7" 54.4" Width Overall Body - . 72.8"
Wheelbase 111.0" 111.0" Height Overall 50.8"
Tread-Front 59.0" 56.8" Wheelbase 108.0"
Tread-Rear 58.8" 56.3" Tread-Front 59.0"
Tread-Rear 58.88"
Curb Weight: Approximately 2668 lbs. 4-Door Sedan
with L-4 Engine; 2911 lbs. with L-6 Weight: Sport Coupe with L6 Engine 2912 lbs.; with
Engine; 3053 with V-8 Engine. V-8 Engine 3063 lbs.
CHEVROLET CHASSIS SERVICE MANUAL
MODEL IDENTIFICATION-CORVETTE The prefixes on certain units identify the plant in which
the unit was manufactured, and thereby permits proper
follow-up of the plant involved to get corrections made
Model Description when necessary.
Number
19437 2-Door Sport Coupe, 2-Passenger
19467 2-Door Convertible, 2-Passenger ENGINE AND TRANSMISSION NUMBER
The Vehicle Identification Number is stamped on the
engine and transmission of each vehicle see chart for
VEHICLE DIMENSIONS-CORVETTE location.
Sport Example:
Model Convertible Coupe
182.5" 100001
Length Overall
68.9" yIN Sequential Serial
Width Overall Body . .
48.0" i- Number
Height Overall 48.0"
98.0" Assembly Plant
Wheelbase
Tread-Front 56.8" It Designation
Tread-Rear 57.6 -Model Year
Division Identification
Curb Weight: 3145 lbs. Conve’rtible Number Chevrolet
3135 lbs. Sport Coupe
with Base V-8
At multi-car plants where more than one Chevrolet
series is produced, the VIN sequence numbers will be
staggered to eliminate duplication of component identifi
UNIT AND SERIAL NUMBER LOCATIONS cation numbers.
For the convenience of servicemen when writing up

certain business papers, such as L. & M.R.’s Product Example:
Information Reports, or reporting product failures in
any way, we are showing on a chart, the ]Location of Los Angeles VIN Sequence
various unit numbers. These unit numbers and their 15000-16000 Series
prefixes and suffixes are necessary on these papers for First Vehicle 100001
various reasons- -such as accounting, follow-up on pro 12000 Series
duction, etc. First Vehicle 500001
VEHICLE COMPONENIT SERIAL AND UNIT NUMBER LOCATION

Component Model Location
Vehicle Serial Number Plate All Top of instrument panel left, front
Body Number, Trim and Chevrolet Upper right-hand side of dash panel
Point Plate Chevelle Upper left-hand side of dash panel
Chevy II Upper left-hand side of dash panel
Camaro Upper left-hand side of dash panel
Corvette Upper left-hand door hinge pillar
Engine and Transmission 4 & 6 Cyl. On pad at right-hand side of cylinder block at rear of
Vehicle Identification distributor
Number 8 Cylinder On pad at front, right-hand side of cylinder block
3-Spd. B-W On boss right rear corner of extension
4-Spd. Muncie On left-side of case at lower rear of cover flange
3-4 Spd. Saginaw On lower left side of case adjacent to rear of cover
Powerglide On right rear vertical surface of oil pan
Turbo Hydra-matic On light blue plate at right-side, VIN on cast pad left
side of transmission
Rear Axle Number All except Corvette On right or left axle tube adjacent to carrier
Corvette On bottom surface of carrier at cover mounting flange
Delcotron All On top drive end frame
Starter All Stamped on outer case, toward rear
Battery All On cell cover segment, top of battery
Vehicle Serial Number operates the ignition switch and front door locks. The
round-head key operates the locks for the glove box and
A typical vehicle serial number tag yields manufac rear compartment lid spare tire compartment lid lock
turer’s identity, vehicle type, model year, assembly on Corvette.
plant and production unit number when broken down as
shown in the following chart. PUSHING, TOWING AND LIFTING
rushing
Manufacturer Body Model Assembly Unit NOTE: Towing car to start is not recommended
Identity1 Style2 Year3 Plant4 Number5 due to the possibility of the disabled car ac
1 5645 8 F 100025 celerating into tow car.
1. Manufacturers identity number assigned to all

Chevrolet built vehicles.
2. See Model Identification in this section. AUTOMATIC TRANSMISSION
3. Last number of model year 1968. Do not attempt to start the engine by pushing the car.
4. F-Flint Should the battery become discharged, it will be neces
5. Unit numbering will start at 100,001 at all plants. sary to use an auxiliary battery with jumper cables to
start the engine.
CAUTION: To prevent damage to electrical
KEYS AND LOCKS system, never connect booster batteries in ex
Four keys two hexagonal head and two round head are cess of 12 volts and connect positive to positive
provided with each vehicle. The hexagonal-head key and negative to negative.
DRIVE ON HOIST
BUMPER JACK LIFTING AT FRAME ATTACHMENT ONLY

FLOOR JACK OR HOIST LIFT
Fig. 1-Vehicle Lifting Points-Chevrolet
DRIVE ON HOIST
BUMPER JACK LIFTING AT FRAME ATTACHMENT ONLY
FLOOR JACK OR HOIST LIFT
Fig. 2-Vehicle Lifting Points-Chevelle
Manual Transmission Front

When a push start is necessary turn off all electrical Connect standard chain hooks near the outer ends of
loads such as heater, radio, and if possible, lights, turn the front suspension lower control arms in between the
on the key, depress the clutch, and place the shift lever coil springs and the stabilizer bar link bolt fig. 3.
in high gear. Release the clutch when your speed reaches The chains should be attached to the lower lifting sling
10 to 15 miles per hour. bar so that when the vehicle is raised the rubber straps
protect the front valance panel fig. 4. Caution should
TOWING be exercised when attaching the lower lifting bar that the
upper lifting bar does not damage the hood header panel.
The car may be towed safely on its rear wheels with
the selector lever in "N" Neutral position at speeds
Rear
of 35 miles per hour or less under most conditions.
However, the drive shaft must be disconnected or the Connect standard chain hooks around the axle tube from
the underneath side between the axle rear spring pad and
car towed on its front wheels if 1 Tow speeds in excess
the brake flange plate fig. 5. It is mandatory that the
of 35 MPH are necessary, 2 Car must be towed for ex
chain hook be positioned as stated above so that the brake
tended distances over 50 miles or, 3 Transmission is
lines are not damaged.
not operating properly. If car is towed on its front
wheels, the steering wheel should be secured to maintain The lower lifting bar should be positioned in below the
a straight ahead position. vehicle so that the rubber straps protect the rear valance
panel. With the lower bar in this position, it is necessary
that the bar be spaced down a minimum of 1 5/8" to pre
TOWING THE CAMARO vent damage to the fuel tank. This can be accomplished
The recommended method for towing the Camaro is as by placing 6.0" section of 2x4’ wood blocks below the
follows. rear section of each rear spring fig. 6.
Fig. 5-Attachment of Towing Chain Hooks to Axle TUbe

Fig. 3-Attachment of Towing Chain Hooks
to Lower Control Arms
To facilitate towing without a helper it will be neces

sary to attach the 2x4’ s to the rear spring by a strap or
tape. See Figure 7.
Also it will be necessary to lock the steering wheel in
the straight ahead position prior to actually moving the
vehicle.
Lifting with Auto Jack
The shaded areas on both the front and the rear
bumpers, as shown in Figures 1, 2, 8, are recommended
auto jack lifting points. The jack load rest must locate
under the bumper at these points. Be sure the load rest
is positioned properly on the jack before raising the
vehicle. On Corvettes, position jack on shaded areas
indicated on Figure 9. Be sure jack load rest properly
contacts frame before raising vehicle.
Fig. 6-Towing Sling Attachment-Rear
REAR SPRING
EYE
AXLE TUBE
WOOD
BLOCK
Fig. 4-Towing Sling Attachment-Front Fig. 7-Strapping Wood Block to Rear Sprin9
Fig. 8-Vehicle Lifting Points-Chevy II and Camaro
Lifting Car with Drive-on Hoist a. If no rear axle or suspension work is contem
plated, use either suspension adapters or drive-
Many dealer service facilities and service stations are on adapters at the front, and drive-on adapters
now equipped with a type of automotive hoist which must at the rear. If a need for axle work develops, use
bear upon some part of the frame in order to lift the jack star"is beneath the frame side rails on each
vehicle. In Figures 1, 2, 8, 9, 10 the shaded areas indi side and lower rear post.
cate areas recommended for hoist contact. b. If rear axle work is contemplated, use either
suspension adapters or drive-on adapters at the
LIFTING THE CORVETTE front and frame lift adapters as shown in Figure
Shaded areas in Figure 9 indicate recommended points 10. If frame lift adapters are not available, use
jack stands.
for hoist or jack contact. When using a sing]Le post hoist
place hoist on frame side rail behind kickup at front and NOTE: Wooden blocks, bolted to steel beam
forward of #3 body mount at rear. When using a twin- shown in Figure 10 are necessary to allow beam
post hoist, two methods are recommended. to clear exhaust system.
LUBRICATION 0-8
DRIVE-ON HOIST, TWO -POST HOIST

WITH DRIVE-ON ADAPTORS l hIIIIII1 JACK STANDS
VA FLOOR JACK, JACKSIANDS,

CENTER POST HOIST
Fig. 9-Vehicle Lifting Points-Corvette
Fig. 10-Frame Lift Adapters-Corvette
LUBRICATION 0-9
LUBRICATION
INDEX
Page Page
Engine Crankcase Oil 0-9 Rear Axle and 3-Speed and Overdrive
Crankcase Capacities 0-9 4-Speed Transmission 0-11
Lubrication . 0-9 Recommended Lubricants 0-11
SAE Viscosity Oils . . 0-9 Multi-Purpose Gear Lubricants 0-11
Types of Oils 0-10 Lubricant Additions 0-11
Maintaining Oil Level 0-10 Lubricant Changes 0-11
Oil and Filter Change Intervals o-io Powerglide Transmission 0-11
Oil . 0-10 Turbo Hydra-Matic 0-12
Filter 0-10 Front Wheel Bearings 0-12
Crankcase Dilution 0-10 Manual Steering Gear 0-12
Automatic Control Devices to Minimize Power Steering 0-12
Crankcase Dilution 0-10 Air Conditioning 0-12
Manifold Heat Control Valve 0-10 Brake Master Cylinder 0-12
Crankcase Ventilation System 0-11 Parking Brake 0-12
Valve Type 0-11 Clutch Cross-Shaft 0-12
Air Injection Reactor A.I.R. 0-11 Chassis Lubrication 0-12
Fuel Filter Hood Catch and Lock Plate 0-12
Air Cleaner 0-il Lubrication Diagrams
Polyurethane Type 0-11 Body Lubrication Chevrolet, Chevelle, Chevy II, Camaro
Oil Wetted Paper Element Type 0-11 Body Lubrication Points Corvette 0-12
Battery Terminal Washers 0-11
Distributor 0-11
The selection of the proper lubricant and its correct ficulty in starting will be experienced at each sudden
application at regular intervals does much to increase the drop in temperature.
life and operation of all moving parts of the vehicle.
Consequently, it is important that the correct grade of SAE Viscosity Oils
oil or grease, as noted in the following pages, be used.
SAE Viscosity Numbers indicate only the viscosity or
body of the oil, that is, whether an oil is a light or a
ENGINE CRANKCASE OIL heavy body oil, and do not consider or include other
properties or quality factors.
The lower SAE Viscosity Numbers, such as SAE SW
Crankcase Capacity and SAE lOW which represent the light body oils, are
4 Cylinder 4 qt. recommended for use during cold weather to provide
6 Cylinder 4 qt. easy starting and instant lubrication. The higher SAE
8 Cylinder 302 4 qt. Viscosity Numbers such as SAE 20 and SAE 20W, which
8 Cylinder 307 4 qt. represents heavier body oils, are recommended for use
8 Cylinder 327 4 qt. during warm or hot weather to provide improved oil
8 Cylinder 350 4 qt. economy and adequate lubrication under high operating
8 Cylinder 396 4 qt. temperatures.
8 Cylinder 427 Chevrolet 4 qt. Oils are available which are designed to combine the
8 Cylinder 427 Corvette 5 qt.
For 4 Cyl. Add .5 qt. with filter change; easy starting characteristics of the lower SAE Viscosity
1 qt. for 6 and 8 Cyl. engines. Number with the warm weather operating characteristics
of the higher SAE Viscosity Number. These are termed
"multi-viscosity oils," SAE 5-lOW, SAE 5W-20, SAE
Lubrication
1OW-20W, and SAE 1OW-30.
Crankcase oil should be selected to give the best per The following chart will serve as a guide in selecting
formance under the climatic and driving conditions in the the proper oil viscosity. In addition to providing proper
territory in which the vehicle is driven. lubrication, the correct viscosity helps assure good cold
During warm or hot weather, an oil which will provide and hot starting by reducing friction and thus increasing
adequate lubrication under high operating temperatures cranking speed.
is required.
During the colder months of the year, an oil which will Anticipated Temperatures Viscosity Number
permit easy starting at the lowest atmospheric tempera
ture likely to be encountered, should be used. Above Freezing +32°F SAE 20W, SAE 1OW-30
When the crankcase is drained and refilled, the crank Below Freezing and Above 0°F SAE lOW, SAE 1OW-30
case oil should be selected, not on the basis of the exist
ing temperature at the time of the change, but on the Below 0°F SAE SW, SAE 5W-20
lowest temperature anticipated for the period during *or "Engine Oil Supplement"
which the oil is to be used.
Unless the crankcase oil is selected on the basis of NOTE: When changing oil consider the antici
viscosity or fluidity of the anticipated temperature, dif pated temperatures for the next 4 months.
LUBRICATION 0-10
* SAE SW and 5W-20 oils are not recommended for Crankcase Dilution
sustained high speed driving.
* SAE 30 and SAE 2OW-40 oils may be used at tem Probably the most serious phase of engine oil deterio
peratures above 90°F. ration is that of crankcase dilution which is the thinning
* SAE 5W-30 oils may be used at temperatures below of the oil by fuel vapor leaking by pistons and rings and
32°F. mixing with the oil and by condensation of water on the
* SAE 1OW-40 oils may be used at temperatures be cylinder walls and crankcase.
tween 0 and 90°F. Leakage of fuel, or fuel vapors, into the oil pan occurs
Types of Oils mostly during the "warming up" period when the fuel is
not thoroughly vaporized and burned. Water vapor enters
In service, crankcase oils may form sludge and varnish
the crankcase through normal engine ventilation and
and under some conditions, corrosive acids unless pro
through exhaust gas blow-by. When the engine is not
tected against oxidation.
To minimize the formation of these harmful products completely warmed up, these vapors condense, combine
and to assure the use of oil best suited for present day with the condensed fuel and exhaust gases and form acid
operating conditions, automobile manufacturers have de compounds in the crankcase.
veloped a series of sequence tests designed to evaluate As long as the gases and internal walls of the crank
case are hot enough to keep water vapor from con
the ability of any oil to properly lubricate automobile
densing, no harm will result. However, when the engine
engines.
It is recommended that only those oils which are is run in low temperatures moisture will collect and
certified by their suppliers as meeting or exceeding the unite with the gases formed by combustion resulting in
maximum severity requirements of these sequence tests an acid formation. The acid thus formed is likely to
or GM Standard 6O41-M be used in Chevrolet engines. cause serious etching or pitting which will manifest itself
Certified sequence tested oils will be described as such in excessively rapid wear on piston pins, camshaft bear
ings and other moving parts of the engine, oftentimes
on their containers.
causing the owner to blame the car manufacturer or the
Maintaining Oil Level lubricating oil when in reality the trouble may be traced
back to the character of the fuel used, or a condition of
The oil gauge rod is marked "Full" and "Add Oil."
the engine such as excessive blowby or improper carbu
These notations have broad arrows pointing to the level retor adjustment.
lines. The oil level should be maintained between the
two lines, neither going above the "Full" line nor under Automatic Control Devices to Minimize
the "Add Oil" line. DO NOT OVERFILL. After operating Crankcase Dilution
vehicle allow a few minutes for oil to return to crankcase All engines are equipped with automatic devices which
before checking oil level. aid greatly in minimizing the danger of crankcase
Check the oil level frequently and add oil when dilution.
necessary. The thermostat, mounted in the cylinder head water
Oil and Filter Change Intervals outlet, restricts the flow of water to the radiator until a
predetermined temperature is reached, thus minimizing
NOTE: Under prolonged dusty driving condi the length of time required to reach efficient operating
tions, it is recommended that these operations temperature, reducing the time that engine temperatures
be performed more often. are conducive to vapor condensation.
A water by-pass is included in the cooling system,
OIL utilizing a hole in the front of the cylinder block. This
To insure continuation of best performance, low main allows a limited circulation of coolant, bypassing the
tenance cost and long engine life, it is necessary to thermostat until thermostat opening temperatures are
change the crankcase oil whenever it becomes contami reached. This system provides a uniform coolant tem
nated with harmful foreign materials. Under normal perature throughout the engine, eliminating localized
driving conditions draining the crankcase and refilling hot-spots, improving exhaust valve life, provides fast
with fresh oil every 4 months or every 6000 miles which warm-up of lubricating oil and fast temperature rise in
ever occurs first, is recommended. the coolant which provides fast heater operation in cold
It is always advisable to drain the crankcase only after weather.
the engine has become thoroughly warmed up or reached A thermostatic heat control on the exhaust manifold
normal operating temperature. The benefit of draining is, during the warming up period, automatically directs the
to a large extent, lost if the crankcase is drained when hot exhaust gases against the center of the intake mani
the engine is cold, as some of the suspended foreign fold, greatly aids in proper vaporization of the fuel.
material will cling to the sides of the oil pan and will not An automatic choke reduces the danger of raw or Un-
drain out readily with the cold, slower moving oil. vaporized fuel entering the combustion chamber and leak
OIL FILTER ing into the oil reservoir.
Change engine oil filter at first engine oil change and An efficient crankcase ventilating system drives off
every second oil change thereafter. fuel vapors and aids in the evaporation of the raw fuel
and water which may find its way into the oil pan.
NOTE: For Vehicles in heavy duty operation
i n v o lv i n g continuous start-stop or prolonged MANIFOLD HEAT CONTROL VALVE
idling, engine oil should be changed after 2500- Every 6,000 miles, check valve for freedom of opera
3000 miles of operation. The filter should be tion. If valve shaft is sticking, free it up with GM Mani
changed after 5000-6000 miles of operation. fold Heat Control Solvent or its equivalent.
LUBRICATION 0- I
CRANKCASE VENTILATION VALVE Recommended Lubricants

Standard Rear Axles--SAE 90 "Multi-Purpose" gear
VALVE TYPE lubricant.
NOTE: Under prolonged dusty driving condi Positraction Rear Axles - - Use special Positraction
tions, it is recommended that these operations lubricant.
be performd more often. Every 12,000 miles
CAUTION: Straight Mineral Oil gear lubricants
or 12 months the valve should be replaced.
must not be used in hypoid rear axles.
Connecting hoses, fittings and flame arrestor
should be cleaned. At every oil change the sys Transmissions- - SAE 90 "Multi- Purpose" gear
tem should be tested for proper function and lubricant.
serviced, if necessary.
The SAE 90 viscosity grade is recommended for year
round use. However, when extremely low temperatures
AIR INJECTION REACTOR A.I.R. are encountered for protracted periods during the winter
The Air Injection Reactor system should have the months, the SAE 80 viscosity grade may be used.
A.I.R. pump filter serviced and the drive belt inspected "Multi-Purpose" Gear Lubricants
for wear and tension every 12 months or 12,000 miles, Gear lubricants that will satisfactorily lubricate hypoid
whichever occurs first. In addition, complete effective rear axles have been developed and are commonly re
ness of the system, as well as full power and perform ferred to as "Multi-Purpose" gear lubricants meeting
ance, depends upon idle speed, inition timing, and idle U.S. Army Ord. Spec. MIL-L-2l05B.
fuel mixture being set according to specif:Lcation. A These lubricants can also be satisfactorily used in
quality tune-up which includes these adjustments should manual transmissions.
be performed periodically to assure normal engine effi
ciency, operation and performance. CAUTION: With Positraction. rear axles use
special Positraction lubricant.
AIR CLEANER "Multi- Purpose" gear lubricants must be manufac
NOTE: Under prolonged dusty driving condi tured under carefully controlled conditions and the
tions, it is recommended that these operations lubricant manufacturer must be responsible for the
be performed more often. satisfactory performance of his product. His reputation
is the best indication of quality.
POLYURETHANE TYPE-
Lubricant Additions
Every 12,000 miles clean element in solvent, squeeze
out solvent, then soak in engine oil and squeeze out The lubricant level in the axle and transmission hous
excess. ings should be checked periodically. Every 6,000 miles.
It is recommended that any additions required to bring
OIL WETTED PAPER ELEMENT TYPE- up the lubricant level be made using the same type lubri
cant already in the housing.
First 12,000 miles inspect element for dust leaks, When checking lubricant level in transmission or rear
holes or other damage. Replace if necessary. If satis axle the unit being checked should be at operating tem
factory, rotate element 1800 from originally installed perature. With unit at operating temperature the lubri
position. Replace at 24,000 miles. Element must not be cant should be level with bottom of the filler plug hole.
washed, oiled, tapped or cleaned with an air hose. If the lubricant level is checked with the unit cold the
If so equipped, replace Bow-Tie filter every 24,000 lubricant level should be 1/2 inch below the filler plug
miles. hole.
BATTERY TERMINAL WASHERS Lubricant Changes
The rear axle lubricant does not require changing for
Battery terminals have felt washers between top of the life of the vehicle. If additions are needed, or when
case and cable connections to minimize corrosive action
refilling the axle after service procedures, use lubricants
of battery acid. These felt washers should be saturated
described above.
with engine oil every 6,000 miles.
DISTRIBUTOR POWERGLIDE TRANSMISSION

NOTE: At first transmission fluid change, it is
4 and 6-Cylinder Engine--Remove distributor cap and recommended that the Powerglide low band be
rotate lubricator 1/2 turn at 12,000 mile intervals. Re adjusted as specified in Section 7 of this manual.
place at 24,000 mile intervals.
8-Cylinder Engine--Change cam lubricator end for end
at 12,000 mile intervals. Replace at 24,000 mile Every 6,000 miles check fluid level on dipstick with
intervals. engine idling, selector lever in neutral position, parking
brake set and transmission at operating temperature. If
fluid level is below full mark on dipstick, add small
REAR AXLE AND 3-SPEED AND amount of automatic transmission fluid. Recheck fluid
OVERDRIVE, 4-SPEED TRANSMISSIONS level and again add a small amount of fluid if needed to
The passenger car operates under the most severe bring level to full mark. DO NOT OVERFILL.
lubrication conditions at high speed and requires a hypoid General Motors DEXRON Automatic Transmission
lubricant which will meet this condition. Fluid, Part numbers 1050568, 69, 70 which has been
LUBRICATION 0-12
especially formulated and tested for use in your auto

matic transmission is recommended. Other Automatic MANUAL STEERING GEAR
Transmission Fluids identified with the mark DEXRON Check lubricant level every 36,000 miles. If required,
are also recommended. add E P Chassis Lubricant which meets GM Specification
Every 24,000 miles more frequently, depending on GM 6O31M.
severity of service, if vehicle is used to pull trailers,
carry full loads during high ambient temperatures, op POWER STEERING
erate in mountainous terrain or operate under other se On models equipped with power steering gear, check
vere conditions remove fluid from the transmission fluid at operating temperature in pump reservoir. Add
sump and add 2 quarts* U.S. measure 1 2/3 quarts* GM Power Steering Fluid, or, if this is not available, use
Imperial measure of fresh fluid for Chevrolet and Dexron Automatic Transmission Fluid to bring level to
Chevelle; add one and a half 1 1/2 U.S. measure and full mark on dip stick.
1 1/4 quarts Imperial measure for Chevy II and Camaro.
Operate transmission through all ranges and check fluid AIR CONDITIONING
level as described above. Every 6,000 miles check sight glass under the hood,
It is not necessary to remove the pan because a drain after the system has been in operation for several
plug is provided. minutes. Sight glass should be clear but may, during
Lubricate shift linkage with water resistant EP chassis milder weather, show traces of bubbles. Foam or dirt
lubricant which meets GM Specification GM 6O31M. indicate a leak which should be repaired immediately.
Lubrication for the Turbo Hydra-Matic will, except
for fluid capacity and filter change1 listed below, follow BRAKE MASTER CYLINDER
the Powerglide recommendations above. After checking
transmission fluid level it is important that the dipstick Check level every 6,000 miles and maintain 1/4" below
be pushed all the way into the fill tube. lowest edge of each filler opening with GM Hydraulic
Every 24,000 miles after removing fluid from the Brake Fluid Supreme No. 11.
transmission sump, approximately 7 1/2 pints U.S. mea
sure 6 pints Imperial measure of fresh fluid will be PARKING BRAKE
required to return level to proper mark on the dipstick. Every 6,000 miles, apply water resistant lubricant
Every 24,000 miles the transmission sump strainer which meets GM Specification GM 6O31M to parking
should be replaced. brake cable, cable guides and at all operating links and
levers.
FRONT WHEEL BEARINGS
It is necessary to remove the wheel and hub assembly CLUTCH CROSS-SHAFT
to lubricate the bearings. The bearing assemblies should Periodic lubrication of the clutch cross shaft is not
be cleaned before repacking with lubricant. Do not pack required. At 36,000 miles or sooner, if necessary;
the hub between the inner and outer bearing assemblies remove plug, install lube fitting and apply EP CHASSIS
or the hub caps, as this excessive lubrication results in LUBRICANT which meets GM Specification GM 6031M.
the lubricant working out into the brake drums and
linings. CHASSIS LUBRICATION
Front wheels of all passenger car models are equipped
with tapered roller bearings and should be packed with a For chassis lubrication, consult the lubrication chart.
high melting point water resistant front wheel bearing It shows the points to be lubricated and how often the
lubricant which meets GM Specification GM 6031M when lubricant should be applied.
ever wheel and hub are removed. The term "chassis lubricant" as used in this manual,
describes a water resistant EP chassis lubricant which
CAUTION: "Long fibre" or "viscous" type meets GM Specification GM 6031M designed for applica
lubricant should not be used. Do not mix wheel tion by commercial pressure gun equipment.
bearing lubricants. Be sure to thoroughly clean
bearings and hubs of all old lubricant before HOOD CATCH AND LOCK PLATE
repacking.
Every 12,000 miles or 12 months, whichever occurs
The proper adjustment of front wheel bearings is one first, apply Lubriplate or its equivalent to the hood catch
of the important service operations that has a definite and lock plate.
bearing on safety. A car with improperly adjusted front
wheel bearings lacks steering stability, has a tendency to BODY LUBRICATION
wander or shimmy and may have increased tire wear. See Body Service Manual for Body Lubrication. Ex
The adjustment of these bearings is very critical. The cept Corvette
procedure is covered in Section 3 of this manual under
Front Wheel Bearings--Adjust. BODY LUBRICATION POINTS CORVETTE
*Except if vehicle is equipped with transmission provid
Lubricate the following items when possible.
ed in heavy duty service optiOns. If so equipped, drain
converter and sump every 24,000 miles and add ap
proximately 9 quarts U.S. Measure 7 1/2 quarts Hood Latch Mechanism and Hinges --Apply light engine oil
to pivot points. Don’t oil lock pins or catch plates.
Imperial Measure of fresh fluid for Chevrolet and
Chevelle and 7 1/2 quarts U.S. Measure 6 1/4 quarts Rear Compartment Lid Release and Hinges--Apply light
Imperial Measure for Chevy II. engine oil.
LUBRICATION 0-13
3-SPEED
4-SPEED 6
OVERDRIVE
AUTOMATIC
9
3 8 3 11
J LUBRICATE EVERY 6,000 MILES GL-MUITI-PURPOSE OR

UNIVERSAL GEAR
CL-CHASSIS LUBRICANT
REPLACE EVERY 24,000 MILES LUBRICANr AT-DEXRON AUTOMATIC TRANSMISSION FLUID
LUBRICATE EVERY 36,000 MILES WB-WHEEL BEARING LUBRICANT BF-BRAKE FLUID

WHENEVER BRAKES
* REFILL POSITRACTION REAR AXLE ARE SERVICED
WITH SPECIAL LUBRICANT ONLY
Fig. 11-Lubrication Diagram-Chevrolet

1. Front Suspension 4. Air Cleaner 6. Transmission 9. Battery
2. Steering Linkage 5. Front Wheel 7. Rear Axle 10. Parking Brake
3. Steering Gear Bearings 8. Oil Filter 11. Brake Master Cylinder
Side Door Hinge Pins - - Apply light engine oil. Window Regulators and Controls and Door Lock Remote
Link -- Apply light engine oil.
Door Lock Rotor and Striker Plate -- Apply light engine oil Gas Tank Filler Cap Hinge- Apply light engine oil.
or stainless stick lubricant.
Weatherstrips and Rubber Bumpers-- Coat lightly with a
Lock Cylinders Lubricate with powdered graphite. rubber lubricant.
LUBRICATION 0-14
6 3 SPEED
4 SPEED
AUTOMATIC OVERDRIVE
3 8 3 4 2 1 5 11
LUBRICATE EVERY 6000 MILES GL -Multi-purpose Gear Lubricant* AT -DEXRON Automatic Transmission Fluid
WB-Wheel Bearing Lubricant BF -Hydraulic Brake Fluid
REPLACE EVERY 24,000 MILES CL -Chassis Lubricant
LUBRICATE EVERY 36000 MILES

* Refill Positraction Rear Axle with Special Positraction Rear Axle
Lubricant Only.
Fig. 12-Lubrication Diagram-Chevelle

LUBRICATION 0-15
3-SPEED
4-SPEED
AUTOMATIC
5 11
Q LUBRICATE EVERY 6000 MILIES GL -GEAR LUBRICANT’ AT -DEXRON AUTOMATIC

TRANSMISSION FLUID
WB -WHEEL BEARING LUBRICANT
REPLACE EVERY 24,000 MILES WHENEVER BRAKES ARE SERVICED BF -BRAKE FLUID
LUBRICATE EVERY 36000 MILES CL-CHASSIS LUBRICANT
‘Refill positraction rear axle with
special lubricant only.
Fig. 13--Lubrication Diagram-Chevy II and Camaro

LUBRICATION 0-16
6
3-SPEED
4-SPEED
5 1 2 4 9 AUTOMATIC
7
5 1 2 3 8 11 10
LUBRICATE EVERY 6,000 MILES GL-MULTI-PURPOSE OR CL-CHASSIS LUBRICANT

UNIVERSAL GEAR
- REPLACE EVERY 24,000 MILES LUBRICANT’ AT- DEXRON AUTOMATIC TRANSMISSION FLUID
J LUBRICATE EVERY 36,000 MILES WB.WHEEL BEARING LUBRICANT

WHENEVER BRAKES
BF-BRAKE FLUID
REFILL POSITRACTION REAR AXLE ARE SERVICED

WITH SPECIAL LUBRICANT ONLY
Fig. 14-Lubrication Diagram-Corvette

1. Front Suspension 4. Air Cleaner 6. Transmission 9 Battery
SECTION 1A
HEATER AND AIR CONDITIONING
Page
Heater lA-i
Air Conditioning . 1A-8
HEATER
INDEX
Subject Page
General Description lA-i

Controls 1A-2
Chevrolet, Chevelle, Chevy II and Camaro 1A-2
Corvette 1A-2
Component Replacement and Repair 1A-3
Blower Assembly 1A-3
Air Distributor Duct and Core - All Vehicles 1A-4
Heater Hoses 1A-4
Control Head Assembly 1A-5
Defroster Duct - All Vehicles 1A-6
Bowden Cables -- All Vehicles 1A-7
Blower Switch - All Vehicles 1A-7
Resistor - All Vehicles 1A-7
GENERAL DESCRIPTION
Heating components are attached to the firewall on the Since the unit has no water valve, water circulation
right side of the vehicle. The blower and air inlet as keeps the core hot at all times. Air passing through the
sembly and water hoses are located on the engine side of core receives maximum heat from the core.
the firewall while the heater core and distributor duct Heater airflow is determined by positioning the three
are on the passenger side. doors Air, Temperature and Defroster located in the
The heater operates on outside air only with the blower distributor duct as shown in Figure 1.
receiving its airflow from the cowl vent plenum chamber.
BLOWER
DEFROST
urn DASH
PANEL
AIR FROM
COWL PLENUM CHAMBER
OUTLET DOOR DOOR bOOR
Fig., 1-Heater Air Flow - All Vehicles
HEATER AND AIR CONDITIONING A-2
CORVETTE
CONTROLS
The Corvette controls are of a new thumb-wheel design
CHEVROLET, CHEVELLE, CHEVY II AND CAMARO fig. 3, located in the floor console. Distributor duct
door location and heater airflow are basically the same
as Chevrolet, Chevelle, Chevy II and Camaro fig. 1.
The Chevrolet, Chevelle and Camaro controls are lo
cated in the middle of the dash panel while the Chevy II
controls are located on the left hand side of the dash. Fan Lever
The control panels vary in size but are of the same basic
design fig. 2. In operation, three levers control all The blower fan lever is located at the forward side of
heater operations. the control panel. With the lever fully left, fan is in
operative. Moving the lever to the right actuates the
Air-Fan Level three- speed blower LOW- MED-HIGH. The blower
should not be turned on unless the AIR door has been
The AIR- FAN lever is a combination control. Moving opened at least half-way.
the lever half-way, opens the AIR door by means of
bowden cable, to supply outside air to the three-speed
blower. Further movement of the lever actuates the Temperature Control
three-speed fan lever LOW-MED-HIGH, which controls
the blower motor and determines the volume of air flow The TEMPERATURE thumb-wheel right hand side of
ing through the heater core and into the car. control panel, through use of a bowden cable, controls
the positioning of the TEMPERATURE door in the dis
tributor duct. Moving the control from "cold" to "hot"
Temperature Lever changes the proportion of heated and unheated air flowing
from the system.
This lever, through use of a bowden cable, controls the
positioning of the TEMPERATURE door in the distributor
duct. When in the "cold" position full left, air leaving Air De-Ice Control
the heater core is blocked off allowing only "outside" air
through the distributor duct. In the "hot" position full The AIR DE-ICE thumb-wheel left hand side of control
right, outside air is blocked off and only maximum panel, also makes use of a bowden cable. Moving the
heated air passes through the system. Fitial heater out control to the "air" detent position. opens the AIR door,
put is dependent upon the proportion of heated and un allowing air to enter system. Moving the control through
heated air blended together according to the setting of the the "air" position, starts to open the DEFROSTER door,
door. diverting partial airflow to the defroster outlets. In the
"de-ice" position, almost all airflow is to the defroster
ducts. The amount of air flowing from the floor and de
Defrost Lever froster ducts is varied by moving the control from "air"
The defrost lever controls the position of the DE to "de-ice".
FROSTER door located in the distributor duct. In the
"off" position, full airflow is directed to the floor duct for
heating purposes. In the "de-ice" position, the door
drops down and diverts almost all airflow to the de
froster duct. A "detent" position is built into the linkage FAN HI
of this lever which will provide partial airflow to the de
froster duct for defogging operations.
CI HOT
Fig. 2-Heater Controls - Chevrolet, Chevelle,

Chevy II and Camaro Fig. 3-Heater Controls - Corvette
HEATER AND AIR CONDITIONING JA-3
COMPONENT REPLACEMENT AND REPAIR

BLOWER ASSEMBLY-Figure 4 NOTE: Assemble the blower wheel to the mo
tor with the open end of the blower away from
Chevrolet the motor.
Removal
Chevy II
1. Remove battery and battery tray. Gain access to
forward battery tray securing bolts by removing Replacement
headlamp bezel. 1. Disconnect battery ground cable.
2. Remove all wires, hoses, etc. attached to skirt. 2. Remove all wires, hoses, etc. attached to the right
3. Raise front of vehicle on hoist. fender skirt.
4. Remove inner skirt to cowl brace. 3. Remove all skirt-to-fender and fender reinforcement
5. Remove skirt attaching bolts. screws and lower skirt on wheel.
6. Remove lower fender attaching bolt. 4. Remove blower motor wire.
7. Pull lower portion of fender outward slightly, pushing 5. Remove blower to case attaching screws and remove
skirt upward and inboard. Once skirt is freed, blower assembly. Pry the flange gently if the sealer
lower and rest skirt on wheel. acts as an adhesive.
8. Disconnect the blower motor wire at the motor 6. Remove the blower wheel retaining nut and separate
flange. the blower and motor.
9. Remove the motor attaching screws and remove 7. To install, reverse the removal procedure.
motor. Pry the flange gently if the sealer acts as NOTE: Assemble the blower wheel to the mo
an adhesive. tor with the open end of the blower away from
10. Remove the blower wheel retaining nut and separate the motor.
blower and motor.
11. To install, follow the removal procedure in reverse Camaro
order.
Replacement
NOTE: Assemble the blower wheel to the mo 1. Remove battery and battery tray.
tor with the open end of the blower away from 2. Disconnect hoses, wiring, etc. at fender skirt.
the motor. 3. Remove wheel opening trim if so equipped.
4. Remove rocker panel molding to fender and rear
quarter panel screws and remove molding.
Chevelle 5. Loosen rear lower fender to body bolt.
Replacement 6. Remove fender extension to fender and filler panel
1. Disconnect battery ground cable. screws and remove extension.
2. Remove battery. Remove all heater hoses, wires, 7. Remove all fender skirt attaching screws.
etc. attached to the right fender skirt. 8. Pull out on lower edge of fender at rear edge of
3. Raise front of vehicle on hoist. wheelhouse, push ihward on skirt until flange clears
4. Remove all skirt-to-fender attaching bolts and lower fender and then lower fender on wheel.
skirt on tire. 9. Remove the blower to case attaching screws and re
5. Disconnect blower motor wire and remove screws move blower assembly. Pry the flange gently if the
retaining blower motor to case. Remove blower mo sealer acts as an adhesive.
tor. 10. Remove the blower wheel retaining nut and separate
6. Remove the blower wheel retaining nut and separate the blower and motor.
blower and motor. 11. To install, reverse the removal procedure.
7. Reverse the removal procedure for installation. NOTE: Assemble the blower wheel to the mo
the motor.
Corvette
Replacement
1. Disconnect battery ground cable.
SEALER 2. Remove radiator supply tank screws, if so equipped,
and lay to one side.
3. Disconnect blower motor wire.
4. Remove the blower motor to case mounting screws
and remove motor assembly. Pry the flange gently
if the sealer acts as an adhesive.
5. Remove the blower wheel retaining nut and separate
blower and motor.
VIEW A
6. To install, reverse the removal procedure.
NOTE: Assemble the blower wheel to the mo
Fig. 4-Blower and Case Typical the motor.
HEATER AND AIR CONDITIONING 1A-4
AIR DISTRIBUTOR DUCT AND CORE- 7. Pull distributor duct from firewall mounting. When
ALL VEHICLES Fig. 5 clearance is obtained, remove resistor wires. Lay
distributor duct on the floor.
Replacement
NOTE: When removing distributor duct, be
very careful not to bend or kink the bowden
2. Drain radiator.
cables.
3. Disconnect heater hoses at core connections by air
inlet assembly and install plugs in core tubes to pre 8. Remove the core assemblyretaining springs and re
vent spilling coolant when removing core and air move core.
distributor assembly. 9. To install, reverse the removal procedure. Check
for coolant leaks.
NOTE: The hose from the water pump must
go to the top heater core pipe; the other hose NOTE: Be sure the core to case sealer is in
runs from the thermostat housing to the lower tact before replacing core. Replace with new
core pipe fig. 6. sealer if necessary. Replace drilled-out stud
4. Remove the nuts from air distributor duct studs on with a new screw and pall nut stamped nut.
engine side of firewall.
5. Chevrolet and Chevy II - Remove glove box and door
assembly. Corvette - Remove right instrument panel
pad See Section 1B. Remove defroster duct to dis
tributor screw.
HEATER HOSES
6. Chevrolet - Remove right kick pad vent cable to dash Heater hoses are routed from the water pump and
panel screws and lay vent cable on floor. Chevelle, thermostat housing to the core inlet and outlet pipes as
Chevy II and Camaro - From under dash, drill out shown in Figure 6. Hoses are attached at each end with
lower right hand distributor stud with a 1/4" drill. spring type clamps.
CHEVELLE
CAMARO
ONLY
CHEVY II
CORVETTE
ONLY
Fig. 5-Heater and Air Distributor
HEATER AND AIR CONDITIONING 1 A-5
CHEVROLET SHOWN AS TYPICAL
Fig. 6-Heater Hose Routing Chevrolet Shown as Typical
Replacement CONTROL HEAD ASSEMBLY

The heater core can be easily damaged in the area of
the core tube attachment seams whenever undue force is Chevrolet, Chevelle and Camaro
exerted on them. Whenever the heater core hoses do not
Replacement Figs. 7, 8 and 9
readily come off the tubes, the hoses should be cut just
forward of the core tubes. The portion of the hose re
maining on the core tube should then be split longitudi
nally. Once the hoses have been split, they can be re
moved from the tubes without damage to the core.
BLOWER
SWITCH
VIEW A
AIR
CABLE
DEFROSTER
CABLE A’
DEFROSTER CABLE
CABLE
Fig. 7-Chevrolet Control Head Assembly Fig. 8-Chevelle Control Head Assembly
2. Remove hand brake to dash screws and push unit to

BLOWER SWITCH the left as far as it will go.
3. Remove control cables from lower side of control
head.
4. Remove screws attaching control head to instrument
panel and lower control head far enough to disconnect
wiring.
5. Disconnect control head wires and remove unit from
vehicle.
Corvette
Replacement Fig. 11
2. Remove floor console trim plate screws and remove
trim plate.
3. Remove control panel screw and lift up, pulling
slightly rearward.
AIR CABLE 4. Disconnect bowden cables and wiring and remove
DEFROSTER CABLE control head assembly.
TEMPERATURE CABLE
Fig. 9-Camaro Control Head Assembly DEFROSTER DUCT-ALL VEHICLES

2. Chevrolet - Remove instrument panel bezel. Defroster duct installation is illustrated in Figure 12.
Chevelle and Camaro - Remove ash tray. Remove Replacement
three screws attaching ash tray retainer to dash and 1. Follow Air Distributor Duct removal procedure as
remove. outlined previously.
3. Remove radio see Section 14. 2. Chevrolet, Chevelle and Camaro - Remove heater
4. Camaro - Remove trim plate to instrument panel control head as outlined under "Control Head As-
screws and remove trim plate. sembly".
5. Remove control head to instrument panel screws and Chevy II.- Remove radio assembly as outlined in
lower control assembly from dash. Section 14.
6. Remove bowden cables and wires from control head
and remove control head.
7. To install, reverse the removal procedures.
CABLE
Chevy II
Replacement Fig. 10 TEMPERATURE
1. Disconnect battery ground cable. CABLE
Fig. 10-Chevy II Control Head Assembly Fig. 11-Corvette Control Head Assembly
CHEVROLET CHA5515 SERVICE MANUAL
HEATER AND AIR CONDITIONING IA-?
VIEW A
CHEVROLET CHEVY II AND CAMARO
CHEVELLE CORVETTE
Fig. 12-Defroster Ducts
3. Remove defroster duct to firewall mounting screws BLOWER SWITCH-ALL VEHICLES

and carefully lower from vehicle.
Replacement
1. Chevrolet, Chevelle and Camaro - Follow Control
Head Assembly Replacement Steps 1-5.
Chevy II and Corvette - Follow Control Head Assem
bly Replacement Steps 1-3.
BOWDEN CABLES-ALL VEHICLES 2. Remove blower switch to control assembly screws
Chevelle, Chevy II and Corvette vehicles incorporate a and remove switch assembly.
new plastic bowden cable. Chevrolet and Camaro use the 3. Remove blower switch electrical connector.
1967 design cable. 4. To install, reverse the removal procedure.
Bowden cable attachment should. be made in the follow
ing manner: RESISTOR-ALL VEHICLES
1. With the cables attached to the control assembly Replacement
levers, move the levers to their fully left or closed 1. All except Corvette - Remove glove box and door
position. Move the appropriate distributor duct door assembly.
to the full off position. 2. Disconnect wire at resistor unit.
2. Attach cable wires to the duct door lever and tighten 3. Remove two screws to distributor duct and remove
cable attaching bracket screws. resistor unit.
3. Check for proper cable operation. 4. To install new unit, reverse removal procedure.
AIR CONDITIONING
INDEX
Subject Page Subject Page
General Description 1A-8 Foreign Material In The System IA-35

Four-Season System 1A-9 Refrigerant Line Connections 1A-36
Controls 1A-9 Repair Of Refrigerant Leaks 1A-36
Four-Season System Except Corvette 1A-9 Refrigerant Hose Failure 1A-37
Four-Season System Corvette lA-il Condenser 1A-37
Comfortron System lA-li Receiver-Dehydrator 1A-39
System Components lA-li Sight Glass Replacement - All Vehicles 1A-39
Controls lA-l4 Compressor lA-40
GM Chevrolet Air Conditioner lA-l5 Compressor Failure 1A-41
Controls lA-15 Collision Procedure - All Systems 1A-41
General Information lA-l6 Four-Season And Comfortron Systems lA-41
Precautions In Handling Refrigerant-12 1A-16 Blower Motor 1A-41
Precautions In Handling Refrigerant Evaporator Core 1A-43
Lines lA-17 Evaporator Control Valve P.O.A. lA-44
Maintaining Chemical Stability In The Expansion Valve 1A-44
Refrigeration System lA-l7 Vacuum Tank 1A-44
J-8393 Charging Station lA-18 Kick Pad Valve lA-45
Gauge Set lA-18 Plenum Valve 1A-45
Vacuum Pump lA-l9 Fuses 1A-47
Leak Testing The System 1A-l9 Four-Season Systems Only 1A-47
Availability Of Refrigerant-l2 1A-20 Air Distrthutor and Heater Core 1A-47
Compressor Oil 1A-20 Control Head 1A-50
Compressor Serial Number 1A-20 Lower Heater Hose 1A-50
Inspection and Periodic Service 1A-2l Water Valve - Corvette Only 1A-51
Pre-Delivery Inspection lA-2i Ambient Temperature Switch 1A-51
6000 Mile Inspection 1A-2l Diverter Door Switch 1A-51
Periodic Service lA-2l Comfortron Systems Only 1A-5l
Installing Charging Station Gauge Set To Air Distributor and Core Assembly 1A-51
Check System Operation 1A-2l Control Head lA-52
Performance Test lA-22 Amplifier 1A-53
Performance Data 1A-22 Power Servo 1A-53
Comfortron System Operational Test lA-23 Duct Feedback Potentiometer 1A-53
Chevrolet Comfortron Tester 1A-23 In-Car Sensor 1A-54
Check-Out Of Complete Electrical Circuit 1A-25 Sun-Ambient Sensor 1A-54
Complete System Checks lA-25 Master Delay and High Blower Delay Relays . . . . 1A-54
Vacuum System Component Function 1A-27 Blower Speed Resistor 1A-54
Maintenance and Adjustments 1A-30 Thermal Vacuum Valve 1A-54
Evaporator Control Valve P.O.A. 1A-30 Transducer 1A-56
Thermostatic Switch 1A-31 GM Chevrolet Air Conditioning System Only lA-57
Expansion Valve 1A-32 Entire Evaporator Assembly 1A-57
Engine Idle Compensator lA-32 Blower Assembly 1A-57
Evacuating and Charging Procedures 1A-32 Expansion Valve, Evaporator and/or
1968 Air Conditioning System Capacities 1A-32 Evaporator Case 1A-58
Purging The System 1A-32 Thermostatic and/or Blower Switches 1A-58
Evacuating and Charging The System 1A-33 Resistor 1A-59
Checking Oil 1A-33 Fuse 1A-59
Component Part Replacement and Minor Repair 1A-35 Wiring Diagrams 1A-60
All Systems 1A-35 Special Tools 1A-66
Preparing System For Replacement Of Component
Parts 1A-35
GENERAL DESCRIPTION
Three air conditioning systems are covered in this type, location and method of attachment on all of the
section. They are: above systems. The six- cylinder reciprocating com
1. The Four-Season System all vehicles. pressor is bracket-mounted to the engine and belt driven
2. The Confortron System Chevrolet. from the crankshaft pulley. The condenser is mounted
3. The GM Chevrolet Air Conditioner Chevrolet, ahead of the engine cooling radiator and the receiver-
Chevelle, Chevy II, Camaro. dehydrator is mounted in the refrigerant line downstream
Underhood components that is, the compressor, con of the condenser. All cooling system components are
denser and receiver-dehydrator are much the same in connected by means of flexible refrigerant lines.
HEATER AND AIR CONDITIONING JA-9
Evaporator size and location differ from system to either outside air or recirculated air enters the system
system as do methods of temperature control and air and is forced through the system by the blower. As the
supply and distribution. air passes through the evaporator core, it receives max
imum cooling if the air conditioning controls are calling
FOUR-SEASON SYSTEM Fig. 13 for cooling. After leaving the evaporator, the air enters
the Heater and Air Conditioner Selector Duct Assembly
The Four-Season System may be identified by the fact where, by means of manually operated diverter doors, it
that it uses an evaporator pressure control known as the is caused to pass through or to bypass the heater core in
POA Pressure Operated Absolute suction throttling the proportions necessary to provide the desired outlet
valve. temperature. Conditioned air then enters the vehicle
Both the heating and cooling functions are performed by through either the floor distributor duct or the dash out
this system. Air entering the vehicle must pass through lets. Remember that the heater core will be hot at all
the cooling unit evaporator and through or around the times except Corvette with controls set for max. cold.
heating unit, in that order, and the system is thus re When, during cooling operations, the air is cooled by the
ferred to as a "reheat" system. evaporator to below comfort level, it is then warmed by
The evaporator provides maximum cooling of the air the heater to the desired temperature; during "heating
passing through the core when the air conditioning sys only" operations the evaporator will not be in operation
tem is calling for cooling. The control valve acts in the and ambient air will be warmed to the desired level in the
system only to control the evaporator pressure so that same manner. The side dash outlets may be rotated to
minimum possible temperature is achieved without core provide either soft, diffused airflow or spot cooling. Ro
freeze-up. The valve is preset, has no manual control, is tate half way to shut off airflow. The barrel type outlet
automatically altitude compensated, and non- repairable. in the center of the dash will direct air up or down or, if
On all models except Corvette, the heater core will be desired, shut it off.
hot at all times since no water valve is present in the
system. The Corvette incorporates a water shut off CONTROLS
valve which shuts off coolant flow through the heater core
when the system is set for maximum cold left hand con FOUR-SEASON SYSTEM EXCEPT CORVETTE
trol set at "cold" detent. Full control of the Four-Season System is obtained
The heater core will be hot at all times since no water through use of a single control panel fig. 15. The con
valve is present in the system. trol knobs make use of a vacuum supply and bowden ca
System operation is as follows See Figure 14. Air, bles to activate the various doors and switches necessary
AIR DISTRIBUTOR
EVAPORATOR COVER
Fig. 13-Four-Season System Components Chevrolet Shown as Typical
_________
HEATER AND AIR CONDITIONING IA-b
EVAPORATOR
CORE
BLOWER
TEMPERATURE DOOR
DEFROSTER OUTLETS
OUTLET DEFROSTER DOOR DOOR
HEATER
OUTLET
AIR
INLET
COOLED AIR OUTLETS
Fig. 14-Airflow - Four-Season and Comfortron
for system operation. Control adjustment is a matter of Outlets Lever

properly setting these controls. The following paragraphs
explain each control. The OUTLETS lever center lever directs the condi
tioned air to either the heater outlet, the dash outlets or
Temperature Lever both heater and dash outlets for bi-level operation.
When the TEMPERATURE lever is in the "off" posi NOTE: In "Heater Mode", the OUTLETS lever
tion, the system is totally inoperative; air flow is shut should be fully right, cutting off compressor
off, the fan switch will not operate the blower and the operation.
compressor is off. In the "vent" position, the air selec
tor door and/or doors are in the "outside air" position. Defroster Lever
When the lever is in the "cold" detent, the compressor is The DEFROSTER lever directs air which is flowing to
on if ambient temperature is above 30°F and/or OUT the heater outlet up to the defroster outlets. With the
LETS lever is fully right, the air selector door is in the DEFROSTER lever in the "off" position, a fixed bleed
"recirculated air" position, the temperature door is in permits a small quantity of air to flow to the defroster
the "cold" position and the blower is automatically on outlets while the major volume of air flows from the
"low" speed. Moving the lever right of "cold" out of heater outlet. In the "de-ice" position, all air is diverted
detent moves the air selector door and/or doors to the to the defroster outlets. Since the air must be in the
full "outside air" position while temperature door and heater duct in order to be directed by the defroster door,
compressor functions remain the same as at the "cold" the OUTLETS lever must be fully right in the "heater"
position. Continuing lever movement to the right opens position, causing air to flow to the lower outlet.
the temperature door fig. 14 to obtain desired air
temperature. Fan Switch
The fan switch controls the operation of the three-
speed blower motor except when the TEMPERATURE
lever is in the "off" position. This switch controls the
volume of conditioned air flowing from the system.
Operating Hints
MAXIMUM HEAT
1. Move the upper and center levers fully right.
Fig. 15-Four-Season Controls Except Corvette 2. Move fan switch to "Hi".
HEATER AND AIR CONDITIONING lA-i I
MAXIMUM COOLING dash outlets. At the dot detent between "A/C" and
1. Move upper lever to "cold" position. "HTR", bi-level operation is obtained conditioned air
2. Move fan switch to "Hi". from both dash and floor outlets. In the "Htr" detent,
DE-ICE all air is directed to the floor outlet and the compressor
1. Move all three levers fully right. is inoperative. Moving the indicator between "HTR" and
2. Move fan switch to "Hi". "De-ice", actuates the cable operated defroster door,
directing either a portion or all airflow to the defroster
NOTE: The above conditions may be tempered outlets.
by changing the setting of the three- speed fan or
by moving the temperature lever from the detent Operating Hints
just right of "cold" position towards the "hot"
position. MAXIMUM HEAT
1. Left hand indicator at "hot".
2. Right hand indicator at "Htr".
FOUR-SEASON SYSTEM CORVETTE
3. Fan switch on "Hi".
The Corvette controls are of a new thumb-wheel design
fig. 16, located in the floor console. Airflow is basi MAXIMUM COOLING
cally the same as Chevrolet, Chevelle, Chevy II and’ 1. Left hand indicator at "cold".
Camaro fig. 14. 2. Right hand indicator at "A/C".
3. Fan switch on "Hi".
Fan Lever DE-ICE
The blower fan lever is located at the forward side of 1. Left hand indicator at "hot".
the control panel. Moving the fan lever from left to right 2. Right hand indicator at "de-ice".
actuates the three-speed blower. 3. Fan switch on "Hi".
NOTE: The above conditions may be tempered
Air-Temperature Control by changing the setting of the three-speed fan or
by moving the temperature indicator between
The left hand thumb-wheel controls air source "out
"hot" and "cold".
side" or "recirculated" and temperature range. With
the indicator needle in the "off" position, the complete
system is inoperative. With the indicator at "vent" COMFORTRON SYSTEM
detent, the vacuum operated air selector doors are in the The Chevrolet Comfortron Air Conditioning System is
"outside" air position. With the indicator at the "cold" basically the same as the Chevrolet Four-Season system
detent, the air selector doors are in the "recirculated" but with the additional feature of completely automatic
air position, the compressor is on if ambient tempera control. See Figures 17, 18 and 19 for views of the
ture is above 30°F and/or right hand indicator is on the Comfortron system. To the customer, the most notice
"A/C" side of "Htr" detent, the temperature door is in able difference between the two systems, will be in the
the "cold" position and the blower is automatically on control panel. In place of the three-lever/one-switch
"low" speed. Continuing indicator movement past "cold" panel of the Four-Season system, the Comfortron has a
detent, opens the vacuum operated heater water shut off single control lever plus a temperature dial similar to
valve and temperature door to obtain desired in-car that found in a home thermostat. After the dial is set to
temperature. the desired temperature indication and the lever is moved
to place the system in operation, the Comfortron will
Outlets-Defroster Control automatically control the heating and air conditioning
With the right hand indicator in the "A/C" position, the functions to maintain the selected interior temperature
vacuum operated outlets, door directs all air through the regardless of changes in outside air temperatures.
Most Comfortron parts are located in the passenger
compartment fig. 19.
r
IFAN j
i: SYSTEM COMPONENTS
In-Car Sensor
J__
The function of the in-car sensor is to determine the
temperature of the interior of the automobile. It is lo
cated beneath the overhang of the instrument panel.
Feedback Potentiometer
The feedback potentiometer indicates to the amplifier
system the position of the temperature door.
Control Head Fig. 17

HOT
A thumb wheel is provided to select the desired in-car
temperature. A control lever performs the following
functions:
1. Operates a switch that allows the customer to select
Fig. l6-Corvette Four Season Controls the type of blower program desired.
SOR
SWITCH.
Fig. I 7-Comfortron Engine Compartment Components
2. Operates the control head vacuum switch except when the portions of hot and cold air being blended and
the TEMPERATURE lever is in the OFF position, discharged into the car.
thus programming the vacuum system. 2. Operates the power servo vacuum valve which de
3. Operates the defroster through the control head vac termines the air flow paths for heating and air
uum switch. The defroster door is partially opened conditioning.
in the "DE-FOG" position, and fully open in the 3. Contains a printed circuit board which controls the
"DE-ICE" position. blower speed. The power servo position determines
A two transistor amplifier is located on the bottom side the blower speed, but the control lever switch can
of the control head. It receives information from the over-ride the blower program depending upon the
sensors, and in turn operates the transducer. customer’s preference.
4. Contains the "Hi" blower delay thermistor and the
Transducer "master delay thermistor".
The transducer will produce a vacuum output that is
completely adjustable by varying the input voltage which Outside Air Diaphragm
is provided by the amplifier. An increase in the applied
voltage results in a reduced vacuum output. When there is no vacuum applied to the hose, the out
side air door is closed under spring tension. With the
Power Servo door closed, air is taken from the inside of the automo
The power servo receives a vacuum signal from the bile and recirculated. Applying vacuum to the diaphragm
transducer, and it is capable of assuming any position opens the door for outside air.
that is called for by the sensors, amplifier, and trans
ducer. The power servo performs the following functions: Mode Door Diaphragm
1. Positions the temperature mix door via the tempera Located behind the duct work, the mode door diaphragm
ture door link. The position of this door determines directs the air flow out either the air conditioning outlets,
the heater floor outlet, or both the heater and air condi
tioning outlets. This is a push-pull type diaphragm actu
ated by vacuum through two hoses and controlled by the
power servo vacuum switch.
Defroster Door
The defroster door is in the defog position until vacuum
is applied to the actuator to obtain either full heat or full
de-ice position.
Master Delay Thermistor

This thermistor delays the initial operation of the
Fig. 18-Comfortron Control blower when the system is in the heat mode. When the
Fig. 1 9-Comfortron Underdash Components
thermistor passes enough current to energize the master if the system is calling for outside air. In cold weather
relay, the blower will operate at about 11 volts. This is this allows outside ram air to flow through the system
the only thermistor which operates when the control is in thereby purging the cold air in the ducts gradually until
the "Lo Front" position. the coolant reaches about 105°F.
High Blower Delay Thermistor Vacuum RelayValve

This relay valve will shut off transducer vacuum to the
The high blower delay thermistor is located on the power servo whenever the vacuum from the engine intake
power servo housing under the power servo vacuum valve manifold falls below the vacuum in the power servo sup
and printed circuit board assemblies. This thermistor ply line engine stopped or operating at low manifold
has the same function as the master delay thermistor; vacuum. This causes the power servo to be held in
however, it only operates in the "Hi Front" position. position when the vacuum supply falls too low to maintain
When the thermistor passes enough current to energize servo control.
the High Blower Relay, the blower will operate at about
14 volts. Vacuum Bleeder
Vacuum Tank A vacuum bleeder insures that the outside air door will
close diaphragm will bleed down after the system has
During heavy acceleration, the vacuum supply from the been shut down. This prevents outside air from entering
carburetor drops. The vacuum tank, using a check valve,
when starting the system on a cold day before the engine
stores vacuum so that under these conditions vacuum will
coolant temperature reaches 75° F.
be available for the Comfortron.
Sun-Ambient Sensor
Thermal Vacuum Valve Hot Water Vacuum Switch
The sun-ambient sensor measures the temperature of
When engine coolant temperature reaches 75°F, the the air entering the air intake grille in front of the wind
valve opens and supplies vacuum to the outside air door shield. The sensor is exposed to sun light so that it can
HEATER AND AIR CONDITIONING lA-H
resistance plus that of the 10 ohm resistor drops

enough to actuate the high blower relay.
5. If the controls are set for DE ICE, full outside air
and full voltage to the blower motor are effective
immediately regardless of temperatures or elapsed
times.
In accomplishing automatic control, the system follows
three steps to transform an electronic signal into me
chanical energy through which the control is achieved.
Electronic Circuit
Two temperature sensors Thermistors, and the duct
potentiometer connected in series, are located so as to
sense the temperature of the outside air, inside air and
system output air. The resistance of each sensor will
Fig. 20-Sun-Ambient Sensor vary according to its temperature. The control head
temperature dial varies in resistance as it is adjusted by
lower the in-car temperature slightly when the sun is the operator to suit his comfort requirements. The re
shining fig. 20. sistance of the temperature dial control is applied di
rectly to the amplifier and is not in series with the
Ambient Switch sensors and duct potentiometer. Thus temperature dif
The ambient switch operates the air conditioning com ferences in the sensor string plus the requirements fed
into the system by the operator cause changes in total
pressor clutch. When the outside temperature is above
40°F. the switch will be closed and the compressor will circuit resistance which allow a varying current flow
through the circuit.
be running. This switch is included as part of the sun-
ambient sensor assembly, but operates independently.
Changing the Electronic Signal to Electrical Voltage
Resistor Assembly This minute current flow from the sensor string -
The blower resistors are located in the evaporator temperature dial circuit - is fed into the amplifier where
housing. The printed circuit board switch in the power it is transformed into a usable amplifier output voltage,
servo determines which of the resistors is being used, the strength of which is determined by the strength of the
and as in conventional systems, the resistors control the original amplifier input signal. This voltage is then sup
blower speed. plied to the transducer.
System Operation Changing the Electrical Voltage to a Vacuum Signal

When starting the Comfortron System in cold weather, Amplifier output voltage, varying according to temper
the following sequence of events occurs: ature requirements, is converted by the transducer into a
1. Initially the system is inoperative. In LO FRONT modulating transducer output vacuum. This modulated
vacuum is applied to the Power Servo.
position the master delay thermistor is warming
self-heating because current is flowing through it
and its resistance is decreasing. In the HI FRONT Changing the Vacuum Signal to Mechanical Energy
position, two thermistors the master delay and high The Power Servo, controlled by the modulated Trans
blower delay thermistors are warming. The air ducer output vacuum, operates the vacuum, electrical and
door is in recirculation position until the engine mechanical components of the system as required to pro
coolant reaches 75 degrees. vide automatic control of system operation.
2. The coolant reaches the 75 degrees and the thermal Other major system components are mounted conven
vacuum valve opens applying vacuum to the air door tionally in the engine compartment. Underhood compo
to admit outside air unless the temperature dial is nents and system airflow remain much the same as in the
set for cooling. Ram air will flow through the sys Four-Season system except for the addition of the auto
tem when the car is moving. matic control provisions. The system operates on 100%
3. Next, the master delay thermistor attains the tem outside air, a mixture of outside and inside air, or 100%
perature at which it will pass sufficient current to recirculated air depending on the demands of the system.
close the circuit through the master delay relay. The The diaphragm operated air selector door will modulate
relay circuit powers the blower motor at 9 volts. outside air to the system during maximum air condition
4. If the control is in the HI FRONT position, the high ing requirements when the control unit is in "Hi Front"
blower delay thermistor will close the circuit position. Control of the blower is also completely auto
through the high blower relay which supplies full matic and dependent upon system demands.
available voltage to the blower motor. This function
occurs after the master delay thermistor has taken
effect because the high blower delay thermistor uses CONTROLS
the master delay type thermistor with a 10 ohm 1/4 The Comfortron Controls regulate the Chevrolet air
watt resistor connected in series. The high blower conditioner and heater in such a precise manner that the
delay thermistor must then warm to a higher tem automobile temperature remains relatively constant un
perature than the master delay thermistor before its der all driving conditions. By adjusting the thumb wheel
on the Control Head to any temperature desired between and as a result, full heat with "Hi" blower are the only
65° and 85°F. See Figure 18 the automatic system will conditions that can be received. The system will turn on
adjust the in-car temperature even though the outside immediately in this position even though the engine cool
weather conditions may vary considerably. The system ant might be cold.
will provide maximum capacity for heating or cooling
until the in-car temperature reaches the pre-set Control General Information
Head Temperature. Where cooling is required, the sys
tem will start immediately upon being turned "ON". Dur Three start up conditions can be achieved with Com
fortron.
ing marginal ambient temperatures the system will not
always start at the highest blower speeds of the control
Weather Method of Starting System
setting. Therefore, occasionally the system can’t be
heard starting.
Cold System starts as soon as engine coolant is
Five over- riding functions are available so that special
hot.
conditions can be handled. Each Control Head function
Hot System starts immediately when AC is re
will be discussed in detail below:
quired.
Any System starts immediately in "De-Ice" po
"Off" Position sition.
In the "Off" position, the blower is turned off and the
outside air door is closed. No outside air should enter GM CHEVROLET AIR CONDITIONER Fig. 21
the automobile.
A self-contained unit, the dealer installed G.M. Chevro
"Lo Front" Position let Air Conditioning System operates on recirculated air
only and entirely independent of the vehicle heater. Re
The blower has five low to moderate speeds. The circulated inside air is drawn into the unit, passed
blower voltage will shift as directed by the automatic through the evaporator core and into the car through the
controls. The "Lo Front" position provides a quieter adjustable outlets in the evaporator case. The entire
mode of automatic operation due to reduction of blower unit mounts compactly beneath the dash. Temperature
noise. control is by means of a thermostatic switch.
The compressor used with this system is identical to
"Hi Front" Position that used for the Four-Season system except for dis
The "Hi Front" position provides five high blower placement. Underhood components are similar in place
speeds as called for by the automatic controls: The use ment, as noted inFigure 22.
of the "Hi" blower speed results in a rapid cool down in
hot weather and rapid heating during cold weather. As CONTROLS
the in-car temperature approaches the temperature set System controls are the AIR knob controlling the three
ting on the Comfortron Control Head, the blower speed speed blower motor switch and the TEMP knob which
will change, provided mild outside temperatures are controls the setting of the thermostatic switch. When
experienced. During very hot or cold weather, the blower operating this system, the Heater must be fully off for
will reduce ita speed only to the point where it is still maximum cooling.
capable of maintaining the correct in-car temperature.
Air Knob
"Rear" Position
Turning the AIR knob clockwise operates the three
The "Rear" position provides five high blower speeds. speed blower motor.
The automatic controls select these speeds and blend the
discharge air to the proper temperature. By the use of Temp Knob
high blower speeds, increased airflow is obtained for
better rear seat passenger comfort. This knob may be regulated to control the degree of
cooling desired. Fully clockwise at CITY provides max
"De-Fog" Position imum cooling; however, turning the knob to HIWAY pro
vides adequate cooling for highway operation.
In the event that the front windshield should require
removal of a fogging condition, the owner at his option NOTE: Reduced cooling could be encountered
may direct air to the windshield. The "De- Fog" position when operating at highway speeds with the con
directs part of the air to the windshield while retaining a trols at the "CITY" setting.
certain amount through the floor outlets. The temper
ature of the air remains the same as it was prior to the
control being placed in the "De-Fog" position. Five
blower speeds are available. The temperature of the air
and the blower speed are selected by the automatic con
trols and are dependent upon the in-car temperature.
"De-lce" Position
The "De-Ice" position provides full heat with "Hi"
blower directing the entire airflow to the windshield to
melt ice. The automatic controls are completely defeated Fig. 21-GM Chevrolet Air Conditioner Unit
HEATER AND AIR CONDITIONING iA-i 6
RECEIVER &
&
MUFFLER ASM.
EVAPORATOR
ASM.
CONDENSER
ASM.
Fig. 22-G.M. Chevrolet Air Conditioning System Components
GENERAL INFORMATION
In any vocation or trade, there are established proce noncorrosive except when in contact with water. The
dures and practices that have been developed after many following precautions in handling R- 12 should be ob
years of experience. In addition, occupation hazards served at all times.
may be present that require the observation of certain * All refrigerant drums are shipped with a heavy metal
precautions or use of special tools and equipment. Ob screw cap. The purpose of the cap is to protect the
serving the procedures, practices and precautions of valve and safety plug from damage. It is good prac
servicing refrigeration equipment will greatly reduce the tice to replace the cap after each use of the drum.
possibilities of damage to the customers’ equipment as *. If it is ever necessary to transport or carry a drum
well as virtually eliminate the element of hazard to the or can of refrigerant in a car, keep it in the luggage
serviceman. compartment. Refrigerant should not be exposed to
the radiant heat from the sun since the resulting in
PRECAUTIONS IN HANDLING REFRIGERANT-i 2 crease in pressure may cause the safety plug to re
lease or the drum or can to burst.
Refrigerant- 12 is transparent and colorless in both the * Drums or disposable cans should never be subjected
gaseous and liquid state. It has a boiling point of 21.7°F to high temperature when adding refrigerant to the
below zero and, therefore, at all normal temperatures system. In most instances, heating the drum or can
and pressures it will be a vapor. The vapor is heavier is required to raise ‘the pressure in the container
than air and is noninflammable, nonexplosive, nonpoi higher than the pressure in the system during the
sonous except when in contact with an open flame and operation. It would be unwise to place the drum on a
CHEVROLET CHA5515 SERVICE MANUAL
gas stove, radiator or use a blow torch while pre refrigerant. However, proceed very cautiously re
paring for the charging operation, for a serious gardless of gauge readings. Open very slowly, keep
accident can result. Don’t depend on the safety ing face and hands away so that no injury can occur
plug - many drums have burst when the safety plug if there happens to be liquid refrigerant in the line.
failed. Remember, high pressure means that great If pressure is noticed when fitting is loosened, allow
forces are being exerted against the walls of the it to bleed off very slowly.
container. A bucket of warm water, not over 125°F,
or warm wet rags around the container is all the heat CAUTION: Always wear safety goggles when
opening refrigerant lines.
that is required.
* Do not weld or steam clean on or near the system. * In the event any line is opened to atmosphere, it
Welding or steam cleaning can result in a dangerous should be immediately capped to prevent entrance of
pressure buildup in the system. moisture and dirt.
* When filling a small drum from a large one, never * The use of the proper wrenches when making con
fill the drum completely. Space should always be nections on "0" ring fittings is important. The use
allowed above the liquid for expansion. If the drum of improper wrenches may damage the connection.
were completely full and the temperature was in The opposing fitting should always be backed up with
creased, hydraulic pressure with its tremendous a wrench to prevent distortion of connecting lines or
force would result. components. When connecting the flexible hose con
* Discharging large quantities of R-l2 into a room can nections it is important that the swaged fitting and
usually be done safely as the vapor would produce the flare nut, as well as the coupling to which it is
no ill effects; however, in the event of an accidental attached, be held at the same time using three dif
rapid discharge of the system, it is recommended ferent wrenches to prevent turning the fitting and
that inhalation of large quantities of R-12 be avoided. damaging the ground seat.
This caution is especially important if the area con * "0" rings and seats must be in perfect condition.
tains a flame producing device such as a gas heater. The slightest burr or piece of dirt may cause a leak.
While R-12 normally is nonpoisonous, heavy con * Sealing beads on hose clamp connections must be
centrations of it in contact with a live flame will free of nicks and scratches to assure a perfect seal.
produce a toxic gas. The same gas will also attack
all bright metal surfaces. MAINTAINING CHEMICAL STABILITY IN THE
* Protection of the eyes is of vital importance: When REFRIGERATION SYSTEM
working around a refrigerating system, an accident
The metal internal parts of the Chevrolet refrigeration
may cause liquid refrigerant to hit the face, lithe
system and the refrigerant and oil contained in the sys
eyes are protected with goggles or glasses, no seri
tem are designed to remain in a state of chemical sta
ous damage can result. Just remember, any R-12
bility as long as pure R- 12 and uncontaminated refrigera
liquid that touches you is at least 21.7° F below zero. .tion oil is used in the system.
If R-12 liquid should strike the eyes, here is what to
However, when abnormal amounts of foreign materials,
do:
such as dirt, air or moisture are allowed to enter the
1. Keep calm.
system, the chemical stability may be upset. When ac
2. Do not rub the eyesl Splash the affected area with
celerated by heat, these contaminants may form acids
quantities of cold water to gradually get the temper
and sludge and eventually cause the breakdown of com
ature above the freezing point. The use of mineral,
ponents within the system. In addition, contaminants may
cod liver or an antiseptic oil is important in provid
affect the temperature-pressure relationship of R-12,
ing a protective film to reduce the possibility of in
resulting in improper operating temperature and pres
féction.
sures and decreased efficiency of the system fig. 23.
3. As soon as possible, call or consult an eye specialist
for immediate and future treatment.
REMEMBER - "An ounce of prevention is worth a
pound of cure."
PRECAUTIONS IN HANDLING REFRIGERANT LINES

* All metal tubing lines should be free of kinks, be
cause of the restriction that kinks will offer to the
flow of refrigerant. The refrigeration capacity of the
entire system can be greatly reduced by a single kink.
* The flexible hose lines should never be bent to a
radius of less than 10 times the diameter of the hose.
* The flexible hose lines should never be allowed to
come within a distance of 2-1/2" of the exhaust
manifold.
* Flexible hose lines should be inspected at least once
a year for leaks or brittleness. If found brittle or
leaking they should be replaced with new lines.
* Use only sealed lines from parts stock.
* When disconnecting any fitting in the refrigeration
system, the system must first be discharged of all Fig. 23-System Contaminants
HEATER AND AIR CONDITIONING iA-18
The following general practices should be observed to by using this unit. Since the refrigerant is metered into
insure chemical stability in the system. the system by volume, the correct amount may be’ added
* Whenever it becomes necessary to disconnect a re to the system and charged to the customer. This, coupled
frigerant or gauge line, it should be immediately with the fact that the unit remains "plumbed" at all times
capped. Capping the tubing will also prevent dirt and and thus eliminates loss of refrigerant in purging of lines
foreign matter from entering. and hooking-up, combines to enable the operator to get
* Tools should be kept clean and dry. This also in full use of all refrigerant purchased by the dealership.
cludes the gauge set and replacement parts. All evacuation and charging equipment is hooked to
* When adding oil, the container should be exception gether in a compact portable unit fig. 24. It brings air
ally clean and dry due to the fact that the refrigera conditioning service down to the basic problem of hooking
tion oil in the container is as moisture-free as it is on two hoses, and manipulating clearly labeled valves.
possible to make it; therefore, it will quickly ab This will tend to insure that the job will be done without
sorb any moisture with which it comes in contact. skipping operations. As a result, you can expect to save
For this same reason the oil container should not be time and get higher quality work, less chance of an over
opened until ready for use and then it should be or undercharge, or comeback.
capped immediately after use. The pump mount is such that the dealer may use his
* When it is necessary to open a system, have every own vacuum pump. The gauges and manifold are in com
thing you will need ready and handy so that as little mon use. Thus a current air conditioning dealer can use
time as possible will be required to perform the the equipment on hand and avoid duplication.
operation. Don’t leave the system open any longer
than is necessary. GAUGE SET
* Finally, after the operation has been completed and
The gauge set fig. 25 is an integral part of the J-8393
the system sealed again, air and moisture should be
evacuated from the system before recharging. Charging Station. It is used when purging, evacuating,
charging or diagnosing trouble in the system. The gauge
J-8393 CHARGING STATION at the left is known as the low pressure gauge. The face
The J-8393 Charging Station is a portable assembly of is graduated into pounds of pressure and, in the opposite
a vacuum pump, refrigerant supply, gauges, valves, and direction, in inches of vacuum. This is the gauge that
most important, a five 5 pound metering refrigerant should always be used in checking pressures on the low
charging cylinder. The use of a charging cylinder elim pressure side of the system. When all parts of the sys
inates the need for scales, hot water pails, etc. tem are functioning properly the refrigerant pressure on
The chief advantage of this unit is savings. A very the low pressure side never falls below 0 pounds pres
definite savings in refrigerant and time can be obtained sure. However, several abnormal conditions can occur
that will cause the low pressure to fall into a partial
vacuum. Therefore, a low pressure gauge is required.
The high pressure gauge is used for checking pres
sures on the high pressure side of the system.
The hand shutoff valves on the gauge manifold do not
control the opening or closing off of pressure to the
gauges. They merely close each opening to the center
connector and to each other. During most diagnosing and
service operation, the valves must be closed. The only
occasion for opening both at the same time would be to
1 2
LOW PRESSURE HIGH PRESSURE
CONTROL CONTROL
N /
3 4
VACUUM FREON
CONTROL’ ‘ CONTROL
Fig. 24-J-8393 Charging Station Fig. 25-Gauge Set
bypass refrigerant vapor from the high pressure to the

low pressure side of the system, or in evacuating both
sides of the system.
The charging station provides two flexible lines for
connecting the gauge set to the system components.
VACUUM PUMP
A vacuum pump should be used for evacuating air and
moisture from the air conditioning system.
The vacuum pump fig. 26, is a component part of
Charging Station J-8393, described previously. The fol
lowing precautions should be observed relative to the
operation and maintenance of this pump.
* Make sure dust cap on discharge outlet of vacuum
pump is removed before operating.
* Keep all openings capped when not in use to avoid
moisture being drawn into the system.
* Oil should be changed after every 250 hours of nor
mal operation.
To change oil, simply unscrew hex nut located on back
side of pump, tilt backward and drain out oil fig. 26.
Recharge with 8 ounces of vacuum pump oil Frigidaire
150 or equivalent fig. 26. If you desire to flush out the
pump, use this same type clean oil. Do not use solvent.
NOTE: Improper lubrication will shorten pump
life.
* If this pump is subjected to extreme or prolonged
cold, allow it to remain indoors until oil has reached
approximate room temperature. Failure to warm
oil will result in a blown fuse.
* A five ampere time delay cartridge fuse has been in
stalled in the common line to protect the windings of
the compressor. The fuse will blow if an excessive
load is placed on the pump. In the event the fuse is
blown, replace with a five ampere time delay fuse -
do not use a substitute fuse as it will result in dam
age to the starting windings.
* If the pump is being utilized to evacuate a burnt-out
system, a filter must be connected to the intake
fitting to prevent any sludge from contaminating the
working parts, which will result in malfunction of the
pump.
* Do not use the vacuum pump as an air compressor.
LEAK TESTING THE SYSTEM
Whenever a refrigerant leak is suspected in the system

or a service operation performed which results in dis
Fig. 26-Vacuum Pump
turbing lines or connections, it is advisable to test for
leaks. Common sense should be the governing factor in
performing any leak test, since the necessity and extent alter the stability of the refrigeration system and
of any such test will, in general, depend upon the nature
cause malfunctions.
of the complaint and the type of service performed on the 3. Dye type leak detectors which are insoluble form a
system. It is better to test and be sure, if in doubt, than
curdle which can block the inlet screen of the ex
to risk the possibility of having to do the job over again. pansion valve.
NOTE: The use of a leak detecting dye within Leak Detector

the system is not recommended because of the Tool J-6084 fig. 27 is a propane gas-burning torch
following reasons: which is used to locate a leak in any part of the system.
1. Refrigerant leakage can exist without any oil leakage. Refrigerant gas drawn into the sampling tube attached to
In this case the dye will not indicate the leak, how the torch will cause the torch flame to change color in
ever, a torch detector will. proportion to the size of the leak. Propane gas fuel
2. The addition of additives, other than inhibitors, may
to green or yellow-green when sampling hose draws

in very small leaks of R-12. Large leaks will be
indicated by a change in color to a brilliant blue or
purple; when the sampling hose passes the leak, the
flame will clear to an almost colorless pale-blue
again. Observations are best made in a semi-
darkened area. If the flame remains yellow when
unit is removed from leak, insufficient air is being
drawn in or the reaction plate is dirty.
NOTE: A refrigerant leak in the high pressure
side of the system may be more easily detected
if the system is operated for a few minutes, then
shut off and checked immediately before system
pressures equalize. A leak on the low pressure
side may be more easily detected after the en
gine has been shut off for several minutes sys
tem pressures equalized; this applies particu
larly to the front seal.
AVAILABILITY OF REFRIGERANT-i 2
Ref rigerant-12 is available through Parts Stock in 25
lb. drums and in 15 oz. disposable cans.
Normally, air conditioning systems are charged making
Fig. 27-Leak Detector use of the J-8393 Charging Station which uses the 25 lb.
drum. Evacuating and charging procedures are noted
cylinders used with the torch are readily available com later in this section.
mercially throughout the country. The 15 oz. disposable cans are generally used for mis
cellaneous operations such as flushing.
CAUTION: Do not use lighted detector in any
place where combustible or explosive gases, COMPRESSOR OIL
dusts or vapors may be present.
Special refrigeration lubricant should be used in the
Operating Detector system. It is available in 1 quart graduated bottles
1. Determine if there is sufficient refrigerant in the through Parts Stock. This oil is as free from moisture
system for leak testing. and contaminants as it is possible to attain by human
2. Open control valve only until a low hiss of gas is processes. This condition should be preserved by im
heard, then light gas at opening in chimney. mediately capping the bottle when not in use.
3. Adjust flame until desired volume is obtained. This See "Air Conditioning System Capacities" for the total
is most satisfactory when blue flame is approxi system oil capacity.
mately 3/8" above reactor plate. The reaction plate Due to the porosity of the refrigerant hoses and con
will quickly heat to a cherry red. nections, the system refrigerant level will show a definite
4. Explore for leaks by moving the end of the sampling drop after a period of time. Since the compressor oil is
hose around possible leak points in the system. Do carried throughout the entire system mixed with the re
not pinch or kink hose. frigerant, a low refrigerant level will cause a dangerous
lack of lubrication. Therefore, the refrigerant charge in
NOTE: Since R-12 is heavier than air, it is
good practice to place open end of sampling tube the system has a definite tie-in with the amount of oil
found in the compressor and an insufficient charge may
immediately below point being tested, particu
eventually lead to an oil build-up in the evaporator.
larly in cases of small leaks.
CAUTION: Do not breathe the fumes that are COMPRESSOR SERIAL NUMBER
produced by the burning of R- 1.2 gas in the de
The compressor serial number is located on the serial
tector flame, since such fumes can be toxic in
number plate on top of the compressor. The serial num
large concentrations of R- 12.
ber consists of a series of numbers and letters, This
5. Watch for color changes. The color of the flame serial number should be referenced on all forms and
which passes through the reaction plate will change correspondence related to the servicing of this part.
INSPECTION AND PERIODIC SERVICE

PRE-DELIVERY INSPECTION
1. Check that engine exhaust is suitably ventilated.
2. Check the belt for proper tension.
3. With controls positioned for operation of the system,
operate the unit for ten minutes at approximately
2000 rpm. Observe the clutch pulley bolt to see that
compressor is operating at the same speed as the
clutch pulley. Any speed variation indicates clutch
slippage.
FITTING
4. Before turning off the engine, check the sight glass
to see that the unit has a sufficient Refrigerant
charge. The glass should be clear, although during
milder weather it may show traces of bubbles. Foam
in the flow indicates a low charge. No liquid visible
and no temperature differential between compressor
inlet and outlet lines, indicates no charge. FOUR-SEASON AND COMFORTRON SYSTEMS
5. Check hose clamp connections. If clamp screw torque
is less than 10 lb. in., retighten to 20-25 lb. in. Do
not tighten to new hose specifications or hose leak LOW PRESSURE FIllING
age may occur.
6. Leak test the complete system.
7. If there is evidence of an oil leak, check the com
pressor to see that the oil charge is satisfactory.
8. Check the system controls for proper operation.
6000 MILE INSPECTION

CONNECTOR BLOCK MUFFLER
1. Check unit for any indication of a refrigerant leak.
2. If there is an indication of an oil leak, check the GM CHEVROLET AIR CONDITIONING SYSTEM
compressor for proper oil charge.
3. Check sight glass for proper charge of Refrigerant-
12. Fig. 28-Compressor Connector Block - Typical
4. Ti.ghten the compressor brace and support bolts and
check the belt tension.
5. Check hose clamp connections as in step 5 above.
6. Check thermostatic switch setting GM Chevrolet the low pressure gauge fitting is on the POA valve while
Air Conditioner. the high pressure fitting is located on the muffler Cor
vette high pressure fitting is located on the connector
PERIODIC SERVICE block.
* Inspect condenser regularly to be sure that the fins
are not plugged with leaves or other foreign material. GM Chevrolet Air Conditioning System
* Check evaporator drain tubes regularly for dirt or 1. Install Gauge Adapter J-5420 or J-9459 onto the
restrictions. high and low pressure hoses of the gauge set.
* At least once a year, check the system for proper 2. With the engine stopped, remove the caps from the
refrigerant charge and the flexible hoses for brittle cored valve gauge connectors on the compressor
ness, wear or leaks. connector block.
* Every 6000 miles check sight glass for low refriger 3. Connect the gauge lines with adapters to the threaded
ant level. fittings on the compressor connector block.
* Check belt tension regularly.
Four-Season and Comfortron Systems
INSTALLING CHARGING STATION GAUGE SET Installation of the gauge set onto the Four-Season and
TO CHECK SYSTEM OPERATION Comfortron systems is accomplished in the same manner
Compressor Suction and Discharge Connector as outlined above except that system performance checks
must be performed with the low pressure hose line and
The compressor connector assembly is of the same adapter attached to the fitting on the POA valve. Charg
basic design on all vehicles. It consists of inlet suction ing procedures should be performed with the high pres
and outlet discharge connections, gauge fittings and sure gauge line connected to the high pressure gauge
muffler. Systems may vary in location of gauge fittings fitting located on the outlet line muffler connector block
and muffler and in structure of connector block fig. 28. on Corvette,
On GM Chevrolet Air Conditioning Systems, both low
and high pressure gauge fittings are located on the con CAUTION: When removing gauge lines from
nector block. On Four-Season and Comfortron Systems, the compressor fittings block be sure to re
move the adapters from the fittings rather than Four-Season and Comfortron System
the gauge lines from the adapters.
Chevrolet
Refrigerant Charge 3 Lbs. - 12 Oz.
PERFORMANCE DATA
Temperature of
Air Entering 70° 80° 90° 100° 110° 120°
The following Performance Data define normal opera Condenser
tion of the system under the above conditions. Relative
humidity does not appear in the tables because after Engine rpm 2000
running the prescribed length of time on recirculated air
and maximum cooling, the relative humidity of the air Compressor 135- 155- 185- 215- 250- 285-
passing’ over the evaporator core will remain at ap Head Pressure 145 165 195 225 260 295
proximately 35% to 40% regardless of the ambient tem
perature or humidity. Evaporator Pres- 29.5 - 30.5 psi
Should excessive head pressures be encountered at sure at POA
higher ambient temperatures, an 18" fan placed in front
of the vehicle and blowing into the condenser will provide Discharge Air 38- 39- 41- 42- 43- 45-
the extra circulation of air needed to bring the pressures Temp. at Right 41 42 43 45 46 48
to within the limits specified. Hand Outlet
PERFORMANCE TEST
This test may be conducted to determine if the system

is performing in a satisfactory manner and should be Refrigerant Charge 3 Lbs. - 12 Oz.
used as a guide by the serviceman in diagnosing trouble
within the system. The following fixed conditions must Temperature of
be adhered to in order to make it possible to compare the Air Entering 70° 80° 90° 100° 110° 120°
performance of the system being tested with the stand Condenser
ards below:
1. Doors and windows closed. Car inside or in shade. Engine rpm 2000
2. Hood up and engine exhaust suitably ventilated.
3. Vehicle in NEUTRAL with engine running at 2000 Compressor 160- 195- 220- 270- 300- 345-
rpm. Head Pressure 170 205 230 280 310 355
4. Air Conditioning controls set for -
* Maximum cooling CITY setting on GM Chevro Evaporator Pres- 29.5 - 31.0 psi 29.5-
let Air Conditioner. sure at POA 34.0
* High blower speed.
5. TEMP control set for full recirculating air and all Discharge Air 41- 42- 44- 45- 47- 51-
air conditioning outlets open. On Comfortron sys Temp. at Right 44 45 47 48 50 54
tems move the control lever to REAR and pull the Hand Outlet
white vacuum hose from the transducer. Plug the
hose. An alternate method is to install the J-22368
Tester described later in this section and operate
it on MANUAL control to maintain maximum cooling
and blower speed. Chevy II
6. Gauge set installed.
7. System settled out run-in approximately 10 minutes. Refrigerant Charge 3 Lbs. - 12 Oz.
8. A thermometer placed in front of vehicle grille and
another in the right hand diffuser outlet. Temperature of
Air Entering 70° 80° 90° 100° 110° 120°
Condenser
NOTE: Higher temperatures and pressures
will occur at higher ambient temperatures. In Engine rpm 2000
areas of high humidity it is possible to have
thermometer and gauge readings approach but Compressor 165- 195- 225- 260- 290- 330-
not reach the figures listed in the performance Head Pressure 175 205 235 270 300 340
tables and still have a satisfactory operating
unit. However, it is important to remember Evaporator Pres- 29.5 - 30.5 psi
that low pressure has a direct relationship to sure at POA
nozzle outlet temperature. If pressure is too
low, ice will gradually form on the evaporator Discharge Air 40- 40- 41- 42- 43- 45-
fins, restricting airflow into the passenger area Temp. at Right 43 43 44 45 46 48
and resulting in insufficient or no cooling. Hand Outlet
Camaro
Refrigerant Charge = 3 Lbs. - 12 Oz.
Temperature of
Air Entering 70° 80° 90° 100° 110° 120°
Condenser
Engine rpm 2000
Compressor 145- 170- 205- 255- 260- 295-

Head Pressure 155 180 215 265 270 305
Evaporator Pres- 29.5 - 30.5 psi

sure at POA
Discharge Air 38- 39- 41- 42- 43- 45-

Temp. at Right 41 42 43 45 46 48
Hand Outlet
Corvette Fig. 29-Comfortron System Tester

Refrigerant Charge - 3 Lbs. 4 Oz.
considering the existing ambient and in-car temperatures.
Temperature of Temperature dial movement will not provide maximum
Air Entering 70° 80° 90° 100° 110° 120° heat in hot weather or maximum cooling in cool weather.
Condenser With warm ambient and in-car temperatures, turning the
temperature dial between 65°F and 85°F will cause the
Engine rpm 2000 system to operate between maximum cooling and partial
heating. With cold ambient and in-car temperatures,
Compressor 145- 170- 200- 215- 220- 240- turning the temperature dial between 65°F and 85°F will
Head Pressure 155 180 210 225 230 250 cause the system to operate between partial cooling and
maximum heating.
Evaporator Pres- 29.5 - 30.5 psi
sure at POA
CHEVROLET COMFORTRON TESTER Fig. 29
Discharge Air 46- 47- 49- 50- 51- 53-
Temp. at Right 49 50 52 53 54 56 The J-22368 Automatic Temperature Control Tester,
Hand Outlet when in AUTOMATIC position, may be used to perform
Comfortron system checks without disturbing normal car
operation.
GM Chevrolet Air Conditioner All Vehicles Under MANUAL control, tester allows the operator to
set and hold a predetermined blower speed and temper
Refrigerant Charge = 3 Lbs. ature. The tester can also be used to measure external
system voltages by using the probe.
Temperature of
Air Entering 70° 80° 90° 100° 110° 120°
To Install the Tester Fig. 30
Condenser
1. Remove the three-terminal male connector from the
Engine rpm 2000 Amplifier on the Comfortron control head.
2. Plug this connector into the three terminal female
Compressor 125- 135- 160- 195- 220- 250- connector with green wire on the Tester.
Head Pressure* 135 145 170 205 230 260 3. Plug the remaining three-terminal male connector
on the Tester into the Amplifier on the control head.
Suction Pres- 8 9 9 11 14 16 4. Attach the black ground lead to any good ground
sure psi" point available in the car.
5. Remove the large vacuum hose from Transducer and
Discharge Air 32- 32- 32- 32- 33- 34- connect it to the Tester vacuum hose nipple.
Temperature* 37 37 37 37 38 39 6. Connect the Tester vacuum hose short hose to the
Transducer.
* When compressor clutch disengages.
Quick Test Procedure
COMFORTRON SYSTEM OPERATIONAL TEST
With the J-22368 Tester installed as outlined above,
The Comfortron System normally operates within the the following quick checks may be made pinpoint
heating and cooling ranges that are needed for comfort the cause of system malfunctions. This quick check
Fig. 30-Comfortron Tester Installation
Tester Settings
Rocker Manual Tester Should

Step Switch Voltage Control Indicate: To Correct Abnormal Indication:
1 Manual Source 150 Battery Voltage Check fuse and wiring.
2 Manual Sensor 150 Battery Voltage Check for open in sensor circuit.
3 Manual Amplifier a. Max. 0-4 Volts See Service Manual:

or Heat* Malfunctioning Amplifier or Temperature
Control Dial.
Cal. b. Max. 8 Volts Mm.
Cold"’
4 Manual Trans- a. Max. 8 Volts Mm. Check for open or bad ground in trans
ducer Cold"’ 0-3 in. Vac. ducer circuit.
Check vacuum relay valve when voltage
b. Max. 0-4 Volts is correct but vacuum is incorrect in
Heat* 9 in. Mm. Vac. max. cold position.
5A Manual Amplifier Set to 6.5 Volts Rotate car temperature dial until meter
or 150 for reads 6.5 volts. Car temperature should
Control Comfortron indicate 75°. If not, see temperature
Cal. System calibration which follows.
SB Auto- Amplifier Same as 5A. 5.5 to 7.5 Volts After 5 minutes of operation check for
matic or Allow 5 mm. defective sensor.
Control for system
Cal, to stabilize
, with doors
and windows
closed.
*This setting should result in HIGH blower speed. Refer to shop manual for further operational checks.
procedure is reproduced on the "swing out" plastic 5. After car has run windows and doors closed for at
instruction card attached to the back of the Tester. least 10 minutes, switch Rocker switch to AUTO
Before performing the checking procedure, start the MATIC. Voltage reading should reamin at 6.5. A
engine and allow to run on fast idle until operating tem change in the voltage indicates a bad sensor.
perature is reached. Then set the dash control lever to 6. 11 a bad sensor is indicated in Step 5, check each
HI-FRONT position and the dash control Temperature sensor, disconnected from the system, with an ohm
Dial to 75° and proceed with steps outlined on page 1A-24. meter. Approximate resistance of each sensor at
NOTE: If water entry has occurred in the 75° F. should be as follows:
vacuum harness, system malfunction will be en In-car Sensor -- 50-75 ohms
countered when the vehicle is operated in am Ambient Sensor -- 55 ohms or less
bient temperatures below freezing. Some blower Feedback -- 70 ohms approx. with "0"
operation will be encountered; however, im Potentiometer vacuum on servo. 15 ohms
proper outlet air temperature and/or mode will approx. with 10+ vacu
result. The system, when checked in a warm um on servo.
building, will operate properly after the ice has Master Delay -- 70 ohms
melted. Thermistor
High Blower Delay -- 70 ohms
CHECK-OUT OF COMPLETE ELECTRICAL CIRCUIT Thermistor
Providing the air conditioning system is operating Located in Power Servo casting
properly, perform the following steps: NOTE: See "System Checks" Diagram for
1. Install Tester J-22368 as previously described. Feedback Potentiometer check.
2. Start the engine and run at fast idle. Move the Com
fortron control lever to HI-FRONT. COMPLETE SYSTEM CHECKS
* Set Rocker switch to MANUAL. The following information should be used whenever
* Set Manual Control Knob to 150 ohms on scale. preliminary checks indicate the need for further, more
3. Set the Tester Voltage switch to AMPLIFIER. specific, tests. Together with the Electrical Test Dia
4. Rotate Comlortron Temperature dial until the Tester gram fig. 31 and the Vacuum Diagram fig. 32, they
voltmeter reads 6.5 volts. The dial should read 75°. may be used to accurately pinpoint any malfunction of the
Adjust dial if necessary. system.
These tests should be performed with the engine at operating temperature.
SYSTEM CHECKS
Control Tester_Settings
Head Func- Manual Tester Should If not, check Electrical Diagram Voltmeter
Setting tion Control Voltage Indicate: the following: Probe Points: should read
High Manual Max. Trans High Blower Fuse in Block 1-2 Battery Voltage
Front Heat ducer Maximum Heat In Line Fuse 8-9 Battery Voltage
High Blower 10-21 Battery Voltage
Delay Relay 20 Minimum 6 volts
Duct Delay 18 Battery Voltage
Thermistor
High Blower 19 Minimum 6 volts
Delay_Sensor
Power Servo 39-46 Battery Voltage
Blower Switch 3-17 Battery Voltage
Resistor 22-15 Battery Voltage
Blower Motor 16 Battery Voltage
Wiring Harness Checked during
above procedure.
This is a com
plete step-by-step
high blower circuit
check which also
checks wiring
harness.
Lo Reduced Blower Blower Switch 4 Battery Voltage
Front Speed Master Delay 5 Battery Voltage
Thermistor 6 Minimum 6 volts
Master Delay 12-13 Battery Voltage
Relay 7 Minimum 6 volts
Resistor 14 Battery Voltage
22-15 Minimum 8 volts
Power Servo 39-46 Minimum 8 volts
Blower Motor 16 Minimum 8 volts
HEATER AND AiR CONDITIONING 1 A-26
RESISTOR CHECK
Head Func- Mnual Tester Should If not, check Electrical Diagram Voltmeter
Lo Manual Rotate Trans- Complete series of Resistor 14 Battery Voltage

Front from ducer blower changes from 22-40-42-44- 15 Minimum 8 volts
Max. Hi to Lo to Hi
Heat to again.
Max.
Cold
AMPLIFIER CHECK
Hi Manual 150 Ampli- Remove conn. from control head temperature dial.
Front fier Voltage reading should be 9 volts minimum.
Short this lead to ground.
Voltage reading should be 0 volts.
No voltage change indicates malfunctioning of amplifier.
COMPRESSOR CLUTCH CHECK
Hi Manual Max, Trans- Cooling System Compressor Clutch 24-25-26-27-28 Battery Voltage
Front Cold ducer Operation Grille Temp. must
be above 40°.
DE-ICE CIRCUIT
De-Ice Auto- Max. Probe Assuming rest of Blower Switch 3-23 Battery Voltage
65° on Matic Cold system is operating Master Delay 20-10-21 Battery Voltage
Temp. normally: Max. Heat Relay
Dial to windshield. Transducer 38 Zero Voltage
SENSOR STRING CHECK
Hi Auto- - Probe - Sensor String 29-30-31-32-33- Battery Voltage

Front matic 34-35-36
POWER SERVO FEEDBACK POTENTIOMETER CHECK
Hi Manual Rotate Trans- Remove Power Servo 6-terminal connector and

Front slowly ducer install ohmmeter at pink and yellow connections
from point.s 32 and 33. Ohmmeter needle should
max. move smoothly from approximately 70 ohms at
cold max. cold to approximately 15 ohms at max.
to heat, or vice-versa. If an erratic movement
max. is noted, the feedback potentiometer
heat is defective.
and
vice-
versa
TRANSDUCER CHECK
Hi Manual Max. Trans- 0-3" Vac. Reading Transducer voltage 37-38 Battery Voltage
Front Cold ducer 8 Volts Mm. at Max. Cold Note: If voltage is correct but vac
position uum is incorrect, check vacuum
relay valve as noted on page 1A-27.
Max. 9" Mi Vac. Reading Transducer Ground
Heat 0-4 Voltage Reading
VACUUM RELAY VALVE CHECK
Head Func- Manual Tester Should If not, check Electrical Diagram Voltmeter
Hi Manual Max. Trans- With large vacuum hose from transducer connected
Front Cold ducer to tester and open end of hose green removed
from transducer closed off, vacuum gauge should
indicate no vacuum. If vacuum is indicated,
vacuum relay valve is defective.
VACUUM FUNCTION CHECKS
Hi Manual Max. Trans. Hi Blower Outside Defective Power Servo; Leak in Vacuum
Front Heat air air door closed System; Temp.; Door Link Disconnected
to car body. Hot air or Jammed; Defective Vacuum Relay
from heater outlets. Valve
Max. Hi Blower Recirc. Defective Mode Door Diaphragm
Cold Air air door open
to car body cold air
from A/C outlets.
VACUUM SYSTEM COMPONENT FUNCTION
Component Vacuum Applied No Vacuum Applied
Air Door Diaphragm Air Door Open to Outside Air Air Door Open to
Closed to Car Body Recirculated Air
Open to Car Body
Power Servo Maximum Heat Maximum Cooling
Vacuum Relay Valve Vacuum Applied to One Port Opens a Passage No Vacuum Applied Closes
Through the Valve to Allow Transducer Vacuum Vacuum Supply to Power
to be Supplied to the Power Servo Servo
Mode Door Diaphragm Vacuum to Linkage Side Vacuum to Covered Side Airflow Out of Upper and
Lower Outlets. Door Open
Air Flow Out Heater Airflow Out of Upper 1" from 100% Lower Out-
Ducts Outlets let Position
Defroster Diaphragm Full Airflow Out Heater Full Airflow Out Defroster Airflow Divided 1/3 Out
Outlet Outlets Full De-Ice Defroster Outlets, 2/3
Out Heater Outlets
Transducer Supplies Modulated Vacuum to Power Servo
Zero Voltage Applied to Transducer 10 Volts Applied to Transducer

Results in Maximum Vacuum Supply Results in No Vacuum Supply
Thermo Vacuum Valve Coolant Hot Passes Vacuum When System is Calling For Outside Air
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LjI I]
HIGH BLOWER
EL MASTER FEEDBACK
DELAY DELAY POTENTIOMETER
THERMISTER THERMISTER
Fig. 31 B-Comfortron Wiring Diagram - Underdash
THERMAL VACUUM
VALVE TO ENGINE
VACUUM
SOURCE
VACUUM STORAGE
TANK
FIREWALL
BROWN
OUTSIDE AIR
DIAPHRAGM
RED
VACUUM
RELAY
Fig. 32-Comfortron VaCuUm Diagram
MAINTENANCE AND ADJUSTMENTS

EVAPORATOR CONTROL VALVE POA of elevation. The following table lists gauge readings at
different altitudes. If a valve gives improper gauge
Four-Season-All Vehicles and Chevrolet readings, it must be replaced since it is not repairable
Comfortron or adjustable fig. 33.
The only check for proper POA valve operation is to 29.5 psig. - - Sea Level
30.0 psig. -- 1000 ft.
check the suction pressure at the valve as during a
performance test. The POA valve is an absolute valve 30.5 psig. -- 2000 ft.
31.0 psig. -- 3000 ft.
and will provide different gauge readings based on the
altitude where the readings are being taken. Correct 31.5 psig.. -- 4000 ft.
gauge reading at sea level is 29.5 .psig. Gauge readings 32.0 psig. -- 5000 ft.
will be one-half psi higher for each additional 1000 feet 32.5 psig. -- 6000 ft.
33.0 psig. -- 7000 ft.
* If the compressor does not operate, regardless of

OUTLET the position of the knob, a loss of the power ele
ment charge is indicated provided that it has
been established that power is supplied to the
switch. This, of course, results in no cooling.
TO OIL
BLEED LINE Replace the switch.
* Check the switch adjusting screw for stripped or
otherwise damaged threads.
GAUGE
FITTING
Adjusting Switch
If, after the above checks, the switch seems to be
operating properly, adjust for proper setting if necessary,
/
TO EXPANSION
VALVE
as follows:
1. Vehicle must be set up as described in "Perform
ance Test."
2. The suction side of the system, read on the low
pressure gauge, should pull down to the pressure
shown in the chart in "Performance Data" under the
INLET ambient temperature at the time the switch is being
set.
3. Remove the face plate retaining screws and remove
Fig. 33-Evaporator Pressure Control Valve - PCA face plate assembly.
NOTE: When removing face plate, note the po
sition of the air sensing capillary so that it can
33.5 psig. - - 8000 ft.
be reinstalled in the same location as when re
34.0 psig. - - 9000 ft.
moved.
34.5 psig. -- 10000 ft.
4. Remove the thermostatic switch retaining screws
THERMOSTATIC SWITCH and remove switch. Remove the non-metal end plate
from the switch to gain access to the switch adjust
GM Chevrolet Air Conditioning System ing screw.
5. if the low side pressure was less than the prescribed
This system makes use of a thermostatic switch with pressure at the end of each cooling cycle, turn the
a self-supporting air sensing capillary. This capillary adjusting screw See Figure 35 a partial turn clock
controls the switch by sensing the temperature of the air wise.
leaving the fins fig. 34. 6. If the pressure was more than the prescribed pres
sure, turn the adjusting screw counter-clockwise.
Checking for Proper Operation 7. Reinstall switch end plate and install switch in face
1. Install the gauge set and set up the vehicle as de plate. Install face plate on evaporator assembly.
scribed under "Performance Test." Be sure that the air sensing capillary has been re
2. Movement of the temperature control knob should placed properly.
result in a definite change in suction pressure and 8. Check system performance. If further adjustment
cycling of the compressor clutch.
* If compressor continues to operate regardless of
the knob adjustment, it indicates that the switch
points are fused which will lead to evaporator
freeze-up. Replace the switch,
Fig. 34-Thermostatic Switch Removal Fig. 35-Thermostatic Switch Adjustment
HEATER AND AIR CONDITIONING A-32
is needed, repeat Steps 3 through 7 until the pre

scribed pressure is reached.
CAUTION: Do not attempt to run a Perform-
ance Check with the face plate and switch re
moved from the evaporator assembly- -inaccu
rate readings would be the result. Always
replace the switch and face plate assemblies
before checking system performance.
EXPANSION VALVE
A malfunction of the expansion valve will be caused by
one of the following conditions: valve stuck open, valve
stuck closed, broken power element, a restricted screen
or an improperly located or installed power element bulb.
The first three conditions require valve replacement.
The last two may be corrected by replacing the valve
inlet screen and by properly installing the power element
bulb.
Attachment of the expansion valve bulb to the evapor
ator outlet line is very critical. The bulb must be at
tached tightly to the line and must make good contact
with the line along the entire length of the bulb. A loose
bulb will result in high low side pressures and poor cool
ing. On bulbs located outside the evaporator case, in
sulation must be properly installed.
The external equalizer line shown in Figure 36 is not Fig. 36-ExpanSion Valve
used in the G.M. Chevrolet Air Conditioning system.
Indications of expansion valve trouble provided by the hot weather periods is included with all air conditioned
Performance Test are as follows:
vehicles. The idle compensator is a thermostatically
VALVE STUCK OPEN controlled air bleed which supplies additional air to the
Noisy Compressor. idle mixture. On V-8 engines, with factory installed air
No Cooling - Freeze Up. conditioning systems, the compensator is located within
VALVE STUCK CLOSED, BROKEN POWER ELEMENT the carburetor and is accessible when the engine air
OR PLUGGED SCREEN cleaner is removed. On all other vehicles the compen
Very Low Suction Pressure. sator is threaded into a manifold fitting below the car
No Cooling. buretor. All compensators are factory set and are non-
POORLY LOCATED POWER ELEMENT BULB adjustable. A malfunctioning unit should be replaced.
Normal Pressure.
Poor Cooling. NOTE: If engine idle is erratic, hold the idle
compensator valve closed with a pencil or
wooden dowel while adjusting the idle mixture
ENGINE IDLE COMPENSATOR screws. Never attempt to bend the bimetal
This additional aid to prevent stalling during prolonged strip or attempt any valve adjustment.
EVACUATING AND CHARGING PROCEDURES

1968 AIR CONDITIONING SYSTEM CAPACITIES PURGING THE SYSTEM
Refrigerant In replacing any of the air conditioning components the

Charge Oil Charge system must be completely purged or drained of refrig
Four-Season Systems 3 lbs., 12 oz. 11 ozs. erant. The purpose is to lower the pressure inside the
Chevrolet, Chevelle, 525 viscosity system so that a component part can be safely removed.
Chevy II and Camaro 1. With engine stopped, install high and low pressure
Comfortron System lines of Charging Station gauge set to the proper
Chevrolet high and low pressure gauge fittings. See "Install
Four-Season System 3 lbs., 4 oz. 11 ozs. ing Gauge Set to Check System Operation".
Corvette 525 viscosity
NOTE: Before installing lines, be sure that all
GM Chevrolet Air Condi- 3 lbs. 11 ozs. four controls on the gauge set are closed.
tioning Systems Chev- 525 viscosity
rolet, Chevelle, Chevy II
and Camaro 2. Disconnect vacuum line at Charging Station vacuum
pump and lay end of line on a clean rag on the floor.
3. Crack open high 2 and low 1 pressure control Refrigerant Control Valve 4 and allow 1/2 pound of
valves, and allow refrigerant to purge from system. R-12 to enter system. Locate and repair all leaks.
4. After evacuating for 15 minutes, add 1/2 pound of
CAUTION: Do not open valves too much or R-12 to system as described in Step 7 above. Purge
compressor oil may be discharged with the re this 1/2 pound and reevacuate for 5 minutes. This
frigerant. Oil loss can be easily detected on rag second evacuation is to be certain that as much con
at discharge line. tamination is removed from the system as possible.
5. Only after evacuating as above, system is ready for
EVACUATING AND CHARGING THE SYSTEM charging. Note reading on sight glass of charging
cylinder. If it does not contain a sufficient amount
GENERAL NOTE: In all evacuating proce
for a full charge, fill to the proper level.
dures shown below, the specification of 26-28
6. With High and Low pressure Valves 1 and 2 open,
inches of Mercury vacuum is used. These fig
close Vacuum Control Valve 3 and open Freon
ures are only attainable at or near Sea Level
Control Valve 4. Operating the heater and air
Elevation, For each 1000 feet above sea level
conditioner blower with the controls set for cooling
where this operation is being performed, the
will help complete the charging operation.
specifications should be lowered by 1 inch.
Example: at +5000 ft. elevation, only 21 to 23 NOTE: if the charge will not transfer com
inches of vacuum can normally be obtained. pletely from the station to the system, close
the high pressure valve at the gauge set, set the
Whenever the air conditioning system is open for any
air conditioning controls for cooling, check that
reason, it should not be put into operation again until it
the engine compartment is clear of obstructions,
has been evacuated to remove air and moisture which
and start the engine. Compressor operation
may have entered the system.
The following procedures are based on the use of the will decrease the low side pressure in the sys
tem.
J-8393 Charging Station.
System is now charged and should be perform
Filling Charging Cylinder ance tested before removing gauges.
1. Open control valve on refrigerant drum.
2. Open valve on bottom of charging cylinder allowing CHECKING OIL
refrigerant to enter cylinder. In the six cylinder compressor it is not recommended
3. Bleed cylinder valve on top behind control panel as that the oil be checked as a matter of course. Gener
required to allow refrigerant to enter. When re ally, compressor oil level should be checked only where
frigerant reaches desired level see "Air Condition there is evidence of a major loss of system oil such as
ing System Capacities", close valve at bottom of might be caused by:
cylinder and be certain bleed valve is closed se * A broken refrigerant hose.
curely. * A severe hose fitting leak.
* A very badly leaking compressor seal.
NOTE: It will be necessary to close bleed * Collision damage to the system components.
valve periodically to allow boiling to subside to
As a quick check on compressor oil charge, with the
check level in sight glass.
engine off, carefully crack open the oil drain plug on the
Installing Charging Station to System bottom of the compressor. If oil comes out, the com
1. Be certain all valves on charging station are closed, pressor has the required amount of oil. To further check
2. Connect high pressure gauge line to high pressure the compressor oil charge, should the above test show
insufficient oil, it is necessary to remove the compressor
gauge fitting. See "Installing Gauge Set to Check
from the vehicle, drain and measure the oil.
System Operations."
3. See Figure 37. Turn high pressure control 2 one
Checking Compressor Oil Charge
turn counter-clockwise open. Crack open low
pressure control 1 and allow refrigerant gas to hiss 1. Run the system for 10 minutes at 500-600 engine
from low pressure gauge line for three seconds, rpm with controls set for maximum cooling and high
then connect low pressure gauge line to low pressure blower speed.
gauge fitting. 2. Turn off engine, discharge the system, remove com
4. System is now ready for performance testing. pressor from vehicle, place it in a horizontal posi
tion with the drain plug downward. Remove the drain
Evacuating and Charging System plug and, tipping the compressor back and forth and
1. Install charging station and purge system. as noted rotating the compressor shaft, drain the oil into a
under "Purging the System." clean container, measure and discard the oil.
2. After system has been purged as above, connect the 3. a. If the quantity drained was 4 fluid oz. or more,
vacuum line to the vacuum pump, turn on vacuum add the same amount of new refrigerant oil to
pump, and open Vacuum Control Valve 3. Run the replacement compressor.
pump until 28-29 inches vacuum is obtained See b. If the quantity drained was less than 4 fluid oz.,
"General Note" under "Evacuating and Charging the add 6 fluid oz. of new refrigeration oil to the re
System". Continue to run pump for 15 minutes placement compressor.
after the system reaches 28-29 inches vacuum. c. If a new service compressor is being installed,
3. If 28-29 inches cannot be obtained, close Vacuum drain all oil from it and replace only the amount
Control Valve 3 and shut off vacuum pump. Open specified in Steps 3a and 3b above.
HEATER AND AIR CONDITIONING IA-34
POA VALVE LOW PRESSURE HIGH PRESSURE MUFFLER

GAUGE FITTING GAUGE FITflNG
COMPRESSOR
Ioo, op
CHARGING STATION CONTROLS
Fig. 37-Charging Schematic Typical
d. If a field repaired compressor is being installed, Adding Oil to the System

add an additional 1 fluid oz. to the compressor.
The system should be completely assembled and un
4. In the event that it is not possible to idle the com charged before adding oil. Use only uncontaminated
pressor as outlined in Step 1 to effect oil return to Frigidaire 525 viscosity refrigeration oil and add as
it, proceed as follows: follows:
1. Connect the Charging Station low pressure gauge line
a. Remove the compressor, drain, measure and to the low pressure gauge fitting on the POA valve
discard the oil. Four-Season and Comfortron Systems or to the low
b. If the amount drained is more than 1-1/2 fluid pressure fitting on the compressor connector block
oz. and the system shows no signs of a major GM Chevrolet Air Conditioning System.
leak, add the same amount to the replacement 2. Connect the high pressure line from the charging
compressor. station gauge set to the compressor muffler or high
c. if the amount drained is less than 1-1/2 fluid oz. pressure side of the connector block.
and the system appears to have lost an excessive 3. Disconnect the high pressure line from the gauge set,
amount of oil add 6 fluid oz. of clean refrigeration make certain that the line is clean, and place the
oil to replacement compressor, 7 fluid oz. to a end in a graduated container.
repaired compressor. 4. Pour enough refrigeration oil into the container so
If the oil contains chips or other foreign ma that the required volume may be drawn into the sys
terial, replace the receiver-dehydrator and flush tem by the high pressure hose.
or replace all component parts as necessary. Add 5. Close the high pressure valve at the gauge set, and
the full specified volume of new refrigeration oil open the low pressure valve.
to the system. 6. Operate the vacuum pump to drop the pressure with
in the system and cause atmospheric pressure to
5, Add additional oil in the following amounts for any force oil through the high pressure line into the sys
system components being replaced. tem. When the oil level has dropped the required
Evaporator 3 fluid oz. volume, pull the line out of the oil container and
Condenser 1 fluid oz. continue vacuum pump operation to force the oil
Receiver-Dehydrator . . ii fluid oz. contained in the line into the system.
7. Shut off the vacuum pump and connect the high pres
NOTE: When adding oil to the compressor, it sure line to the gauge set. Open the high pressure
will be necessary to tilt the rear end of the valve and evacuate the system through the high and
compressor up so that the oil will not run out low pressure sides of the system. Complete the
of the suction and discharge ports. Do not set charging operation as outlined in Step 6 under "Evac
the compressor on the shaft end. uating and Charging System".
COMPONENT PART REPLACEMENT AND MINOR REPAIR
Component replacement has been separated into five Great emphasis must be placed upon keeping the sys
categories as follows: tem clean. Use plugs or caps to close system compo
All Systems - Contains removal or repair procedures nents and hoses when they are opened to the atmosphere.
that would apply to all three air conditioning systems. Keep your work area clean.
Four-Season and Comfortron Systems - Refers to In removing and replacing any part which requires un
components that are identical with both Four-Season and sealing the refrigerant circuit the following operations,
Comfortron systems, but does not include procedures which are described in this section, must be performed
already outlined in the All Systems section. in the sequence shown.
The last three categories "Four-Season Only", "Com 1. Purge the system by releasing the refrigerant to the
fortron Only" and "GM Chevrolet Air Conditioner Only" atmosphere.
contain removal and repair procedures peculiar to that 2. Remove and replace the defective part.
system only. 3. Evacuate and charge the system with R-12.
ALL SYSTEMS CAUTION: Always wear protective goggles

when working on refrigeration systems. Goggles
PREPARING SYSTEM FOR J-5453 are included in the set of air conditioning
REPLACEMENT OF COMPONENT PARTS special tools. Also, beware of the danger of
carbon monoxide fumes by avoiding running the
Air conditioning, like many other things, is fairly engine in closed or improperly ventilated ga
simple to service once it is understood. However, there rages.
are certain procedures, practices and precautions that
should be followed to prevent costly repairs, personal FOREIGN MATERIAL IN THE SYSTEM
injury or damage to equipment. For this reason it is
strongly recommended that the preceding information in Whenever foreign material is found in the system, it
this section be studied thoroughly before attempting to must be removed before restoring the system to oper
service the system. ation.
In the case of compressor mechanical failure, perform

the following operations: MAKE ANGULAR CUT
1. Remove the compressor. FOR HOSE REMOVAL
2. Remove the receiver-dehydrator and discard the
unit.
3. Flush the condenser to remove foreign material
which has been pumped into it.
4. Disconnect the line from the receiver-dehydrator at
the inlet connection of the expansion valve. Inspect
the inlet screen for the presence of metal chips or
other foreign material. If the screen is plugged,
replace it. Reconnect the line to the expansion
valve.
5. Install a new receiver-dehydrator.
6. Install the replacement compressor.
‘7. Add the necessary quantity of oil to the system one
fluid ounce because of receiver-dehydrator replace
ment plus the quantity needed for the replacement
compressor-see "Checking Compressor Oil Charge"
under "Checking Oil."
8. Evacuate and charge the system.
9. Check system performance.
REFRIGERANT LINE CONNECTIONS
"0" Rings f:.-z

LTJ
Always replace the "0" ring when a connection has SEALING LOCATING
been broken. When replacing the "0" ring, first dip it BEADS BEAD
in clean refrigeration oil. Always use a backing wrench
on "0" ring fittings to prevent the pipe from twisting and
damaging the "0" ring. Do not overtighten. Correct
torque specifications are as follows: Fig. 38-Hose Clamp Connections
Metal Thread and Steel Alum. torque. DO NOT RETORQUE. The clamp screw
Tube Fitting Tubing Tubing torque will normally decrease as the hose conforms
O.D. Size Torque* Torque* to the force of the clamp. The screw should be re
torqued only if its torque falls below 10 lb. in. In
I 1/4 7116 13 6 this cas etorque to 20-25 lb. in. Further tighten
3/8 578 33 12 ing may damage the hose.
i 1/2 3/4 33 12
5/8
3/4
7/8
1-1/16
33
33 - 20
25
Removal
1. Carefully, with a sharp knife, make an angle cut in
the hose as shown in Figure 38. This should loosen
* Foot Pounds the hose so that it may be worked off the fitting.
2. Cut off slit end of hose when reinstalling. Reinstall
NOTE: Where steel to aluminum connections as described above.
are being made, use torque for aluminum tubing.
CAUTION: Use only approved refrigeration
Hose Clamps hose. Never use heater hose. Use extreme
care not to nick or score the sealing beads when
When hose clamp connections are encountered, special
cutting off the hose. Cutting the hose length
procedures are necessary for both installation and re wise may result in this problem.
moval.
Installation REPAIR OF REFRIGERANT LEAKS

1. Coat tube and hose with clean refrigeration oil. Any refrigerant leaks found in the system should be
2. Carefully insert hose over the three beads on the
repaired in the manner given below:
fitting and down as far as the fourth, or locating
bead. Hose must butt against this fourth bead,
Leaks at "0" Ring Connection
CAUTION: Use no sealer of any kind. 1. Check the torque on the fitting and, if too loose,
tighten to the proper torque. Always use a backing
3. Install clamps on hose, hooking the locating arms wrench to prevent twisting and damage to the "0"
over the cut end of the hose. ring. Do not overtighten. Again leak test the joint.
4. Tighten the hose clamp screw to 35-42 lb. in. 2, If the leak is still present, discharge the refrigerant
from the system as described under "Evacuating and

Charging Procedures."
3. Inspect the "0" ring and the fitting and replace if
damaged in any way. Coat the "0" ring before re
installed with clean refrigeration oil and install
carefully.
4. Retorque the fitting, using a backing wrench, and
then add, 1/2 to 1 lb. of R-12 to the system and re
check for leaks.
CAUTION: Do not operate the system with this
small refrigerant charge.
5. Purge the system, thus removing the 1/2 to 1 lb.
installed in Step 4 above.
6. Evacuate and charge the system.
Leaks at Hose Clamp Connection

1. Check the tightness of the clamp itself and tighten if
necessary. Recheck for leak.
2. If leak has not been corrected, discharge the sys
tem, loosen clamp and remove hose from connection.
Inspect condition of hose and connector. Replace
scored or damaged parts.
3. Dip end of new hose in clean refrigeration oil and
carefully reinstall over connector. Never push end
of hose beyond the locating bead. Properly torque
the clamp. Fig. 39-Chevrolet Condenser
4. Recheck the system for leaks by installing 1/2 to 1 6. Reverse the above procedure when installing the new
lb. of R-12 into the system. Do not run compressor. assembly in vehicle. Add 1 oz. refrigeration oil.
5. Purge the system, thus removing the 1/2 to 1 lb.
installed in Step 4 above. NOTE: Use new "0" ring seals coated with
6. Evacuate and charge the system. clean refrigeration oil when connecting inlet
and outlet lines.
Compressor Leaks Chevelle
if leaks are located around the compressor shaft seal Replacement Fig. 40
or shell, replacement of necessary seals should be made 1. Purge the system of refrigerant.
as outlined under "Compressor" in the Chassis Overhaul 2. Remove five hood catch screws and remove catch
Shop Manual. assembly from vehicle.
3. Remove the hood catch support screws to header
REFRIGERANT HOSE FAILURE panel, filler panel and radiator support. Drill out
rivets to grille and bend support to left side of ve
After a leak or rupture has occurred in a refrigerant
hicle to allow clearance for condenser removal.
hose, or if a fitting has loosened and caused a consider
able loss of refrigerant and oil, the entire system should
be flushed and recharged after repairs have been made.
If the system has been open to atmosphere for any pro
longed period of time the receiver-dehydrator should be
replaced.
CONDENSER
Chevrolet
Replacement Fig. 39
1. Purge the system of refrigerant.
2. Remove five hood catch screws and remove catch
assembly from vehicle.
3. Remove the hood catch support by removing two
grille screws and one radiator support screw.
4. Disconnect the inlet and outlet pipe "0" ring con
nections.
NOTE: Cap or tape the inlet and outlet con
nections at once.
5. Remove the four condenser to radiator support
screws and remove condenser from vehicle. Fig, 40-Chevelle Condenser
4. Disconnect the inlet and outlet hose clamp connec

tions.
NOTE: Cap or tape the inlet and outlet con
nections at once.
5. Remove the four condenser to radiator support
screws and remove condenser from vehicle.
6. Reverse the above procedure when installing the new
assembly in vehicle. Use new rivets, patent clips
or sheet metal screws to replace the removed rivets.
7. Evacuate, charge and check the system. Add one
fluid oz. refrigeration oil after installing a new con
denser.
Chevy II
Replacement Fig. 41
2. Remove the five hood catch screws and remove catch
3. Remove the hood catch support assembly by remov
ing screws to radiator support, filler panel and filler
panel reinforcement. Fig. 42-Camaro Condenser
4. Disconnect inlet and outlet hose clamp connections, 3. Remove hood catch support screws from header
NOTE: Cap or tape inlet and outlet connec panel, valance panel and radiator support and re
tions at once. move support from vehicle.
4. Disconnect the inlet and outlet hose clamp connec
5. Remove the four condenser to radiator support tions.
screws and remove condenser from beneath vehicle.
6. Reverse the above procedure when installing the new NOTE: Cap or tape the inlet and outlet con
assembly in vehicle. nections at once.
7. Evacuate, charge and check the system. Add one 5. Remove the condenser to radiator support screws
fluid oz. refrigeration oil after installing a new con
and remove condenser from vehicle.
denser. 6. Reverse the above procedure when installing the new
Coma ro assembly in vehicle.
Replacement Fig. 42 7. Evacuate, charge and check the system. Add one
1. Purge the system of refrigerant. fluid oz. refrigeration oil after installing a new con
2. Remove five hood catch screws and remove catch denser,
Corvette
Replacement Fig. 43
2. Remove the hood from the car, first scribing the
hinge attachment location.
3. With headlamps in the up position, remove the head
lamp actuator assemblies.
4. Remove the receiver-dehydrator bracket outer, cen
ter screw.
5. Disconnect the receiver-dehydrator outlet connection
and the condenser inlet hose clamp.
NOTE: Cap or tape inlet and outlet connec
tions at once.
6. Remove the condenser to radiator support screws
and remove the condenser and receiver-dehydrator
assembly from the vehicle.
7. Reverse the above procedure to install, the new as
sembly.
NOTE: Use a new "0" ring seal coated with
clean refrigeration oil when installing outlet
line to receiver - dehydrator. Torque connection
to 13 ft. lbs.
8. Evacuate, charge and check the system. Add one
fluid oz. refrigeration oil when installing a new con
Fig. 41-Chevy II Condenser denser.
CHEVROLET CHASSIS SERViCE MANUAL
Fig. 43-Corvette Condenser
RECEIVER-DEHYDRATOR
Replacement-All Vehicles Figs. 44 and 45
2. Chevelle and Chevy II - Disconnect cables and re
move battery.
3. Disconnect the receiver-dehydrator inlet and outlet
lines and cap or tape the connections at once.
4. Chevrolet - Remove the receiver-dehydrator to radi
ator support attaching screws and remove unit from
vehicle.
Chevelle, Chevy II and Camaro - Remove the re
ceiver-dehydrator to right front fender skirt attach
ing screws and remove unit from vehicle.
Corvette - Remove the receiver-dehydrator to con
denser bracket attaching screws and remove unit
from vehicle.
5. With the new receiver-dehydrator in place, install
the attaching screws.
NOTE: Do not uncap the new receiver-dehy

drator until the last instant before installation.
6. Connect the inlet and outlet lines using new "0" ring
seals coated with clean refrigeration oil and torque
to 13 ft. lbs.
7. Add one fluid oz. refrigeration oil, evacuate, charge
and check the system.
SIGHT GLASS REPLACEMENT-ALL VEHICLES

If damage to the sight glass should occur, a new sight
glass unit should be installed. The unit contains the sight
glass, seal and retainer. See Figure 46.
1. Purge system. Fig. 44-Receiver-Dehydrator-All Except Corvette
COMPRESSOR
The same basic six cylinder reciprocating compressor
is used in all systems.
Two variations of the basic compressor are used. One,
with a displacement of 12.6 cu. in. is used with the Four-
Season System except Corvette and Comfortron System.
The second model, having displacement of 10.8 cu. in. is
used with the Corvette Four-Season System and all GM
Chevrolet Air Conditioning Systems.
All Systems
Removal
1. Purge the refrigerant from the system.
2. Remove connector attaching bolt and connector. Seal
connector outlets.
3. Disconnect electrical lead to clutch actuating coil.
4. Loosen brace and pivot bolts and detach belt.
5. Remove the nuts and bolts attaching the compressor
brackets to the mounting bracket figs. 47 and 48.
6. Before beginning any compressor disassembly, drain
and measure oil in the compressor. Check for
evidence of contamination to determine if remainder
of system requires servicing. Compressor Servic
ing information is located in the Chassis Overhaul
Manual.
Installation
1, If oil previously drained from the compressor upon
Fig. 45-Receiver-Dehydrator Mounting Corvette removal shows no evidence of contamination, replace
a like amount of fresh refrigeration oil into the com
2. Remove the sight glass retainer nut using a screw pressor before reinstallation. If it was necessary to
driver and remove old glass and seal. service the entire system because of excessive con
3. Install the new glass and seal and retainer nut, being tamination in the oil removed, install a full charge
careful not to turn the nut past the face of the hous of fresh refrigeration oil in the compressor. See
ing. To do so may damage the "0" ring seal. Checking Compressor Oil Charge under Checking
4. Evacuate and recharge the system. Oil.
Fig. 46-Sight Gloss Replacement
have been damaged in any way, the condenser

should be replaced with a new one.
-
b. The receiver-dehydrator should be replaced if
there is any evidence of its having sustained
either internal damage or a fracture at any of the
lines or welded joints or if the system has been
exposed to the atmosphere for an undetermined
period of time.
c. Examine the compressor for any visible external
damage.
d. The evaporator should be examined for damage
and, if necessary, removed or replaced or the
entire unit processed where damaged or exposed
to the atmosphere.
e. All connecting lines and flexible hoses should be
examined throughout their entire length for dam
age. If damaged in any manner, replace with new
Fig. 47-Compressor Mount-L-6 Engines Typical lines.
f. Check all controls and connecting wires for dam
age and replace with new parts where needed.
2. Position compressor on the mounting bracket and g. Check the clutch pulley for proper operation and
install all nuts, bolts and lock washers. freedom from damage.
3. Install the connector assembly to the compressor 3. Install Charging Station.
rear head, using new "0" rings. 4. Purge the system. Pressure should not exceed 3 to
4. Connect the electrical lead to the coil and install and 5 pounds.
adjust compressor belt. 5. Remove the compressor from mounting and remove
5. Evacuate and charge the system. the oil test fitting.
6. Leak test the system and check for proper operation. 6. Pour out the oil into a clean glass container and ex
Compressor Belt Tension Adjustment amine it for any foreign substance such as dirt,
Adjust the compressor belt to the specifications shown water, metal particles, etc. If any of these are
in the Tune-Up chart in the Engine section of this manual. present, the compressor and receiver-dehydrator
should be replaced and the other system components
should be flushed with liquid refrigerant.
COMPRESSOR FAILURE.
7. If the oil is clean and free of any harmful substance,
If the compressor has failed mechanically to the extent replace oil with Frigidaire 525 Viscosity Oil, avail
that metal chips and shavings are found in it, the system able through Parts Stock.
should be checked for foreign material and cleaned as
described under Foreign Material in the System. NOTE: If the system components have been
replaced or flushed, replace the full charge of
oil. If not, add no more fresh oil than was
COLLISION PROCEDURE- ALL SYSTEMS drained in Step 6.
Whenever a car equipped with air conditioning unit is 8. Charge up the compressor to drum or can pressure
involved in a collision or wreck, it should be inspected as and leak test the compressor seals prior to installa
soon as possible. The extent of damage to any or all of tion of compressor.
the component parts and the length of time the system 9. Reinstall the compressor and evacuate the system
has been exposed to the atmosphere will determine the by following the Evacuating Procedure.
replacement of parts and processing that will be re 10. Introduce R-12 vapor at cylinder room temperature
quired. The greater the length of time of exposure to the and pressure.
atmosphere, the greater will have been the chances for 11. Leak test all fittings and connections and give partic
air, moisture and dirt to have entered and damaged the ular attention to a leak test at the compressor shaft
system. Every case may be entirely different so it is seal if compressor has not been leak tested on the
not possible to establish a hard and fast procedure to bench.
follow each time. Good judgment must be used to de 12. Complete system processing and charge system.
termine what steps should be taken in each specific case.
The following procedure is presented as a guide for FOUR-SEASON AND COMFORTRON SYSTEMS
use when inspecting a damaged vehicle equipped with air
conditioning. BLOWER MOTOR
1. Remove the drive belt. Cut belt off if necessary.
2. Visually inspect the condenser, receiver-dehydrator, On all vehicles except Corvette, replacement proce
dures are basically the same as with the heater blower
compressor, mounting brackets, conditioning unit,
all connecting lines, and all controls to determine the motor see "Heater Blower Motor Replacement" in the
extent and nature of the damage. Heater Section.
a. No repairs, such as soldering, welding or braz NOTE: On Chevelle and Chevy II vehicles, the
ing, should be attempted on the condenser because refrigerant lines are routed through the forward
of its construction. If the vapor passages in the end of the fender skirt. When lowering the skirt,
horizontal tubes or return bends or manifolds extreme caution should be used to prevent dam-
CHEVROLET CHASSIS SERVICE MAHUAL
307-327-350 V-8
CHEVROLET, CHEVELLE, CHEVY II, AND CAMARO
396-427 V-8
CHEVROLET, CHEVELLE, AND CAMARO-CORVETTE 396 V-8 ONLY
427 V-8
CORVETTE
Fig. 48-Compressor Mount-V-8 Engines Typical
age to these hoses; remember, the air condition 3. Remove the front three sill plate molding screws and
ing system is still charged. pry out to gain access to right splash shield retain
ing bolts.
Corvette 4. Remove splash shield retaining bolts and remove
splash shield.
Replacement 5. Remove motor to case mounting screws and lower
1. Disconnect the battery ground cable. motor assembly through splash shield opening. Pry
2. Disconnect blower motor wire and rubber air cooling the flange gently if the sealer acts as an adhesive.
tube, 6. To install, reverse Steps 1-5.
EVAPORATOR CORE 5. Corvette only - Remove windshield wiper door ac

The evaporator and blower assembly is designed so tuator assembly. Remove POA valve bracket to case
that the core may be removed without having to remove screws.
the entire unit from the vehicle. 6. Disconnect all wires and vacuum hoses attached to
the evaporator assembly.
7. Remove evaporator cover to firewall stud nuts and
All Except Chevy II and Camaro V-8 Engines cover to evaporator case screws.
Replacement NOTE: On some engines, it may be necessary
1. Disconnect battery ground cable. to remove the A.I.R. combustion pipe.
2. Purge system of refrigerant.
3, Remove carburetor air cleaner assembly. 8. Pull cover outward and upward, being careful not to
4. All except Corvette - Disconnect the expansion valve damage the core in any way.
outlet and the POA valve inlet lines. Remove the 9. Remove core retaining screws and remove core.
expansion valve bulb from the core outlet line.
Corvette - Disconnect the expansion valve inlet and 10. Reverse the above steps for core replacement.
the POA valve outlet lines.
1 1. Add three fluid ounces of refrigerant oil after in
NOTE: Cap and seal all open lines at once. stalling a new core. Evacuate and charge the system.
Fig. 49-P. O.A. Valve Installation
Replacement
Chevy II and Camaro V-8 Engines 1. Disconnect battery ground cable and purge system.
Replacement 2. Remove the expansion valve power element bulb
1. Disconnect battery ground cable. from the low pressure line and the equalizing line
2. Discharge refrigerant system. from the POA valve.
3. Remove carburetor air cleaner. 3. Remove the low and high pressure connectors from
4. Disconnect air compressor brace and swing com the valve, in that order, Remove the screw and
pressor aside, bracket attaching the expansion valve to the blower
5. Remove right bank engine valve cover. or evaporator case and remove the valve.
6. Remove screws and stud nuts attaching side cover to 4. Before replacing the valve, check to be certain the
firewall. inlet screen is not clogged. If the screen is plugged,
7. Remove screws attaching side cover to Evaporator replace it and check valve operation. If screen is
& Blower Case. Leave side cover hang free. clear or if valve still malfunctions after screen re
8. Disconnect evaporator pipes at Expansion Valve and placement proceed with the valve replacement.
POA valve connectors. Remove capillary tube from 5. Install the new valve by connecting the lines. Clamp
evaporator pipe. the power element bulb of the new valve to the top of
9. Remove evaporator core. the low pressure line and the equalizing line to the
NOTE: The side cover can be removed from suction throttling valve.
the vehicle once the evaporator core has been NOTE: Be sure to replace the insulation
removed. around the power element bulb and make sure
10. To install new core, place side cover in its respec the power element makes good physical contact
tive assembly location. Install evaporator core be with the suction line.
tween side cover and case and reverse Steps 1 6. Connect battery ground cable.
through 8 above. 7. Evacuate and charge the system.
8. Check the system for proper operation.
EVAPORATOR CONTROL VALVE POA VACUUM TANK

During heavy acceleration, the vacuum supply from the
No repairs or adjustments are available on the POA carburetor drops. The vacuum tank, using a check valve,
valve. A malfunctioning valve must be replaced. Fig- stores vacuum so that under these conditions, vacuum
ure 49 illustrates valve installation on all vehicles. will be available for continuous use.
The vacuum tank is mounted to the engine side of the
firewall as illustrated in Figures 51, 52, and 53.
Replacement
1. Disconnect battery ground cable and purge the sys
tem of refrigerant.
2. Remove inlet, outlet, oil bleed and expansion valve
lines and cap lines immediately.
3. Remove valve body bracket to evaporator case or
case bracket screw and remove valve and bracket
from vehicle.
4. To install new POA valve, reverse the removal pro-
cedure, evacuate and charge the system.
EXPANSION VALVE Fig. 50

The thermostatic expansion valve is factory adjusted
and pre-set and cannot be adjusted after installation. A
malfunctioning valve must be replaced. However, before
proceeding, check all other possible causes of the trouble.
Make certain that the power element bulb is properly po EXPANSION
sitioned on the low pressure line, tightly clamped and VALVE
has the insulation in place. Make certain the liquid inlet
screen, between valve and receiver-dehydrator line, is
not clogged. After checking the screen and the location OUTLET LINE
and mounting of the thermo-bulb, proceed with replace LOW PRESSURE
ment of the valve assembly. A malfunctioning valve may
result from a stuck open or shut needle caused by cor
rosion, or a discharged power element caused by a broken
anillary line or tip. Fig. 50-Expansion Valve Installation Typical
Fig. 51-Vacuum Tank-Chevrolet Fig. 53-Vacuum Tank-Chevy II and Camaro
Replacement stallation on all vehicles. A vacuum tank and check valve

1. Disconnect battery ground cable. is used to assure that the air door will not change its po
2. Disconnect vacuum hoses at tank. sition due to variations in engine vacuum.
3. Remove two screws attaching tank to firewall and
remove tank.
4. To install, reverse removal procedure.
PLENUM VALVE
NOTE: The Corvette does not incorporate a
The plenum valve is not used on the Chevrolet. Chev
separate vacuum tank. Vacuum for the air con
elle, Chevy II, Camaro and Corvette all incorporate
ditioning system is supplied by the production
plenum valves to admit outside air to the system.
tank located in the left fender area.
KICK PAD VALVE Chevelle

Figures 54, 55, 56 and 57 illustrate kick pad valve in-
Replacement
1. Raise hood. Disconnect valve vacuum lines.
2. Remove four scre’ws securing valve bracket to cowl.
Fig. 52-Vacuum Tank-Chevelle Fig. 54-Chevrolet Kick Pad Valve
PLENUM VALVE
KICK PAD VALVE
Fig. 55-Chevelle Air Inlet Valves Fig. 57-Corvette Air Inlet Valves
3. With a screw driver or similar object, reach through

the slotted hole and press valve arm forward out of
plenum door. Remove valve and bracket assembly
from vehicle.
4. To install, reverse Steps 1 through 3.
Chevy II and Camaro
Replacement
1. Remove windshield wiper arms.
2. Remove cowl vent grille.
3. Remove screws securing plenum valve assembly to
plenum chamber. Disconnect vacuum line. Posi
tion door in closed position and lift assembly from
vehicle.
Corvette
Replacement
1. Remove vacuum operated windshield wiper door,
arms, linkage, actuator and remove vent grille; see
Section 12.
2. Remove clip securing valve link to door and push
link up out of door.
3. Remove vacuum valve bracket screws and remove
valve and bracket as a unit.
4. Once removed from vehicle, valve may be removed
from the bracket.
Fig. 56-Chevy II and Camaro Air Inlet Valves 5. To install, reverse Steps 1 through 4.
FUSES floor. Scribe location of temperature door camming

plate on distributor duct and remove camming plate.
A fuse, located in the junction block protects the entire
Remove core and core housing from the distributor
air conditioning system except for the blower when op
assembly.
erating at high speed.
A second fuse, to protect the high speed blower circuit,
is located in the electrical wiring between the horn relay
and the Air Conditioner relay. Chevelle Fig. 59
Replacement
FOUR-SEASON SYSTEM ONLY 1. Disconnect battery ground cable.
2. Drain radiator do not purge refrigerant from sys
AIR DISTRIBUTOR AND HEATER CORE tem.
3. Remove heater hoses at core connections and plug
Chevrolet Fig. 58 core tubes to prevent coolant spillage.
4. Remove nuts from distributor case studs projecting
Replacement
through the firewall.
5. Remove glove box and door assembly.
2. Drain radiator do not purge refrigerant from sys
6. Remove right kick pad cover and remove recircula
tem.
ting air valve.
3. Remove nuts from distributor case studs projecting
7. Remove center duct to distributor screws and re
through firewall. move center duct.
4. Remove heater hoses from core tubes and install 8. Remove floor distributor duct.
plugs in core tubes to prevent coolant spillage.
9. Drill out lower right hand distributor duct stud from
5. Remove glove box and door assembly. inside vehicle.
6. Remove right kick pad cover and remove kick pad
10. Remove remaining screws securing air distributor
valve.
to firewall and lower distributor assembly. Remove
7. Disconnect the left, right and center dash outlet hoses
bowden cables and all electrical connections. Scribe
from the center duct. Remove center duct to dis
location of temperature door camming plate on dis
tributor screws and remove center duct.
tributor duct and remove camming plate. Remove
8. Remove floor distributor duct.
core and core housing from distributor assembly.
9. Remove distributor duct to firewall screws and care 11. To install, reverse Steps 1 through 10.
fully pull distributor from firewall.
10. Remove bowden cables and electrical wires attached NOTE: Replace the drilled-out-stud with a
to distributor assembly and lower distributor to screw and pall nut stamped nut.
Fig. 58-Chevrolet Air Distributor and Ducts
DASH
VIEW A
Fig. 59-Chevelle Air Distributor and Ducts
Fig. 60-Chevy II Air Distributor and Ducts
Chevy II Fig. 60 10. Lay distributor assembly on floor and remove core
Replacement and core housing.
1. Disconnect battery ground cable. Drain radiator. 11. To install, reverse Steps 1 through 10.
Do not purge refrigerant from system.
2. Disconnect heater hose from upper core pipe. Re Camaro Fig. 61
move accessible nuts from air distributor studs. Replacement
3. Remove right fender skirt to fender and skirt re 1. Disconnect battery ground cable. Drain radiator.
inforcement screws, Lower skirt to wheel. Re Do not purge refrigerant from system.
move remaining stud nut. 2. Disconnect heater hose from upper heater core pipe.
4. Remove heater hose from lower core pipe. Install Remove accessible nuts from air distributor duct
plugs in both core tubes to prevent coolant spillage. studs.
5. Remove glove box and door assembly. 3. Remove right lower rocker molding. Remove lower
6. Remove right kick pad recirculating air valve. fender attaching bolts. Remove skirt to fender and
7. Remove center duct to distributor attaching screws skirt to reinforcement screws. Pull out on lower
and remove center duct. portion of fender, prying the skirt away from the
8. Remove floor duct. Remove screws securing left fender flange and firewall. Block the skirt with a 2"
half of distributor to right half and separate. x 4" block of wood.
9. Remove screws securing right half of distributor to 4. Disconnect lower heater hose and remove right lower
firewall and remove distributor. Disconnect bowden stud nut at heater housing. Plug heater core tubes
cables and electrical connections. Scribe location of to prevent coolant spillage.
temperature door camming plate on distributor duct 5. Remove glove box and door assembly.
and remove camming plate. 6. Remove right kick pad recirculating air valve.
CENTER DASH
OUTLET
FOOT
COOLER
Fig. 61-Camaro Air Distributor and Ducts
HEATER AND AIR CONDITIONING lA-SO
7. Disconnect left, right and center dash outlet hoses 7. Remove distributor duct from vehicle. Remove tem
from center duct. Remove center duct from distrib perature door camming plate from distributor duct.
utor assembly. Remove core and core housing.
8. Remove floor outlet duct. Remove screws securing 8. To install, reverse steps 1-7
left half of distributor to right half and separate the
two halves. CONTROL HEAD
9. Remove screws securing the distributor to firewall
and lower carefully. Remove bowden cables and The Four-Season control heads are attached to the in
strument panel in much the same manner as the heater
electrical connections as soon as clearance is ob
tained, control head. Refer to the Heater Section for replacement
10. Remove distributor from vehicle. Scribe location of procedures.
temperature door camming plate on distributor duct LOWER HEATER HOSE
and remove camming plate. Remove core and core
housing from distributor. The Camaro and Chevy II lower heater hoses are inac
11. To install, reverse steps 1-10, cessible without removing the right front fender skirt as
sembly. The following procedures should be used when
Corvette Fig. 62 heater hose removal is desired.
Replacement
1. Disconnect battery ground cable. Drain radiator. Chevy II
Do not purge refrigerant from system. Replacement
2. Disconnect heater hoses at core connections and plug 1. Drain radiator.
core tubes to prevent coolant spillage. 2. Remove fender skirt to fender and skirt reinforce
3. Remove nuts from distributor studs on engine side of ment screws and lower skirt to wheel.
firewall. 3, Disconnect lower heater hose at core connection.
4. Remove the right hand dash pad Section 1B and the 4. To install, reverse steps 1-3.
center instrument cluster Section 12.
5. Disconnect right dash outlet duct from center duct.
Camaro
Remove screws attaching center duct to distributor Replacement
duct and remove center duct. 1. Drain radiator.
6. Remove screws attaching distributor to firewall and 2. Remove right rocker panel moulding.
pull distributor rearward and to the right. Once 3. Remove lower fender attaching bolts.
clearance is obtained, remove bowden cables and 4. Remove skirt to fender and skirt to reinforcement
wire connectors. bolts.
Fig. 62-Corvette Air Distributor and Ducts
HEATER AND AIR CONDITIONING lA-Si
DIVERTER DOOR SWITCH
THAT
Fig. 63-Corvette Water Valve
ACTUATES DIVERTER DOOR CABLE
5. Pry the skirt away from the fender flange and away SWITCH A/C-HEATER CABLE
from the firewall. Block the skirt with a 4" long
piece of 2" x 4" block of wood, Disconnect hose at
lower core tube.
6. To install, reverse steps 1-5. Fig. 65-Diverter Door Switch Typical
Replacement
WATER VALVE-CORVETTE ONLY 1. Disconnect battery ground cable.
Installation of the water valve is illustrated in Figure 2. Disconnect electrical connector at switch.
63. An inoperative valve must be replaced. 3. Remove two switch to case screws and remove
switch.
AMBIENT TEMPERATURE SWITCH 4. Install new switch by reversing steps 1 through 3.
When the controls are set for bi-level operation, the DIVERTER DOOR SWITCH
compressor is operative. The ambient switch has been
added to the system to prevent the compressor from op The purpose of this switch is to prevent compressor
erating in below 30°F ambients when controls are in the operation when controls are set for heater mode center
bi-level position. This switch is located in the blower lever fully right on all vehicles except Corvette - Right
and evaporator case as illustrated in Figure 64. hand control at HTR on Corvette.
Replacement Fig. 65
2. All except Corvette - Remove glove box and door
AMBIENT TEMPERATURE assembly.
SWITCH 3. Corvette - Remove air distributor assembly.
4. Remove two screws attaching switch to distributor
duct and remove switch.
5. Reverse steps 1 through 4 to install new switch.
COMFORTRON SYSTEM ONLY

AIR DISTRIBUTOR AND CORE ASSEMBLY
Removal
2. Drain radiator do not purge refrigerant system.
3. Disconnect the four vacuum hoses coming from
the underdash through the large fire wall grommet.
Push the hose grommet through the fire wall to the
rear.
4. Disconnect the heater hoses from the core tubes.
5. Remove the accessible nuts from heater and air dis
tributor case studs which project through the fire
wall from the dash side. Only three nuts are ac
cessible from under the hood 2 top nuts and far left
Fig. 64-Ambient Temperature Switch Typical lower nut.
6. Raise front of vehicle. Remove right side fender

skirt to fire wall bracket. Access lower right-hand
heater and air distributor case stud nut through
opening created by removal of the bracket. If a
ADJUSTMENT
larger opening is required, remove the three screws
in the concave of the skirt and pry the skirt down SCREW
ward.
7. Remove screw retaining right-hand courtesy light,
leave light assembly hang.
8, Remove right-hand kick pad and disconnect vacuum
line at "Outside-Air" diaphragm.
9. Remove glove box door and interior. Remove ash
tray and ash tray retainer.
10. Remove floor outlet duct. Remove center and right-
hand duct from heater and air distributor assembly.
Remove right-hand flex hose.
11. Remove sensor cage mounting screws. Pull cage up
and rest on top side of dash. Remove instrument
panel bezel.
12. Remove radio knobs, center panel trim plate, radio
assembly and radio rear support.
13. Remove two 2 screws retaining control head. Dis
connect all electrical not vacuum connectors at
control head.
14. Disconnect power servo electrical leads. Remove
three 3 screws retaining Power Servo assembly to Fig. 66-Mode Shift Vacuum Diaphragm
heater and air distributor assembly. Tilt Servo as
sembly to access Servo cover screws. Remove
cover screws. Disconnect vacuum line from Servo 4. Adjust mode door without vacuum applied to dia
diaphragm and remove vacuum head. Remove Servo phragm. The door should be open one inch from
cover and disconnect link at Power Servo leaving it sealing against the air distributor opening inside of
attached at temperature door pivot. Remove Servo case - See Figure 66.
assembly.
15. Remove screws retaining transducer to heater and CONTROL HEAD
air distributor assembly NOTE: One of these
The control head is attached to the instrument panel in
screws secures a grounding wire. Bring trans
much the same manner as the Chevrolet heater control
ducer to front of dash leaving vacuum hoses at panel Figure 67. Two screws hold the head in place.
tached. The vacuum lines are not disconnected so as The amplifier and blower switch are a part of the control
to minimize error when reinstalling assembly. head assembly.
16. Remove heater and air distributor and control head
as an assembly.
17. Remove the screws attaching the die cast plate to the
air inlet side of the case. Disconnect the tempera
ture door linkage at the door shaft.
18. Remove the die cast plate with core from the case.
Remove the core mounting screws and remove core.
Installation
1. Seal the replacement core to the cast plate with non-
hardening sealer and attach the core with the mount
ing straps and screws.
2. Install the plate to the case and connect the tempera
ture door linkage.
3. Reverse removal procedures 1-16 to reinstall air
distributor and control head assemblies.
Mode Shift Vacuum Diaphragm
Replacement
1. Remove the heater distributor from the vehicle as
outlined under "Air Distributor and Core Assembly".
2. Reach into the distributor through the AIR door open
ing to reach and remove the vacuum diaphragm
mounting screws and diaphragm to door link screw
remove plug from case to reach this screw.
3. Reverse this procedure to replace. Fig. 67-Comfortran Control Head Installation
Fig. 68-Amplifier Removal

Fig. 69-Temperature Dial Adjustment Typical
AMPLIFIER
After the control head is removed from the instrument should not be attempted without an accurate ohmmeter
for calibration.
panel, the amplifier may be removed as shown in Figure
68. Replacement
1. Remove the power servo assembly as outlined under
Temperature Dial Adjustment "Power Servo".
1. Install Tester J-22368 as previously described. 2. Loosen allen set screw in the calibration clutch on
2. Set Tester Voltage switch to Control Calibrate posi the potentiometer shaft.
tion. 3. Remove the clutch from the shaft.
3. Start the engine fast idle and set Comfortron Con 4. Remove potentiometer locknut and lock washer and
trol lever to HI-FRONT. remove potentiometer.
4. Switch Rocker switch to MANUAL. 5. Reverse the above procedure for reinstallation.
5. Set Manual Control Knob to 150 ohms on scale.
6. Rotate the Control Head Temperature Dial until the Calibration
voltmeter on the tester reads 6.5 volts. The Tem 1. With the power servo electrically disconnected, place
perature Dial should now indicate 75°. an ohmmeter across the terminals of the potenti
7. If the Temperature Dial does not indicate ‘75°, insert om ete r.
Tool J-21530 in slot to the left of the Dial as shown 2. With no vacuum to the servo, adjust the slotted screw
in Figure 69. on the end of the potentiometer shaft for 68 ± 2 ohms.
8. With tool in position, rotate the Temperature Dial
so that it indicates 75° F.
POWER SERVO
The Power Servo is attached to the distributor duct.
The entire installation consists of the Servo Assembly
and its link assembly to the TEMP door. The Servo is
attached to the Air Selector Duct as shown in Figure 70.
Removal
2. Remove glove box door.
3. Disconnect electrical leads. Remove screws retain
ing servo to distributor assembly. Tilt servo to gain
access to servo cover screws and remove screws.
4. Disconnect vacuum line from servo diaphragm and
remove vacuum head. Remove servo cover.
5. Disconnect link at servo and remove servo.
6. To install, reverse steps 1-5.
DUCT FEEDBACK POTENTIOMETER

The feedback potentiometer is located in the power
servo assembly. Replacement of the potentiometer Fig. 70-Power Servo Installation
Fig. 71-Comfortron In-Car Sensor Fig. 72-Comfortron Sun-Ambient Sensor Installation
IN-CAR SENSOR
Removal Fig. 71 hole in the evaporator housing used in the Four Season
1. Disconnect battery ground cable. system for resistor installation.
2. Disconnect sensor connector at harness. Remove
plastic connector from terminals. Attach a suitable BLOWER SPEED RESISTOR
piece of mechanic’s wire to terminals.
3. Remove sensor cage mounting screws, remove sen Figure 74 illustrates the location and installation of
sor cage from dash and pull assembly and wire the blower speed resistor assembly.
through dash opening. Remove wire from terminals.
THERMAL VACUUM VALVE
Installation
1. Remove plastic connector from terminals of new This heat operated vacuum valve is located In the
sensor assembly. Attach mechanic’s wire to ter heater core input line. Figure 75 illustrates valve in
minals. Start sensor wiring harness through dash stallation with clamps attaching the water hoses as well
opening. as the vacuum hoses in place.
2. Continue passing wiring harness through dash open
ing by gently pulling on mechanic’ s wire from under
dash.
3. Once the sensor harness assembly has been com
pletely passed through dash opening, remove the
wire and reinstall plastic connector on terminals.
Connect sensor assembly to Comfortron harness as
sembly.
4. Install sensor cage mounting screws. Reconnect
battery ground cable.
SUN-AMBIENT SENSOR
This combination unit, which engages the compressor
clutch at about 40°F and also senses outside air tempera
ture and sun load, is mounted to the firewall within the
engine compartment with its long neck extending deep
into the cowl vent plenum chamber as illustrated in Fig-
ure 72.
MASTER DELAY AND HIGH BLOWER

DELAY RELAYS
These two relays are both mounted on the evaporator
case as shown in Figure 73. The mounting bracket forms
a common ground for the relays and as a plug for the Fig. 73-Comfortron Relays
HEATER AND AIR CONDITIONING 1A-SS
Fig. 74-Blower Speed Resistor Fig. 75-Thermal Vacuum Valve
Fig. 76-Comfortron Underhood Vacuum Lines
HEATER AND APR CONDITIONING iA-56
Fig. 77-Comfortron Underdash Vacuum Lines
TRANSDUCER tery ground cable, the transducer can be replaced by

opening the glove box door, removing vacuum lines, elec
The transducer is bracket mounted to the air distrib
trical connections and the bracket to case screws,
utor assembly fig. 77. After disconnecting the bat-
SUN-AMBIENT
SENSOR AND COMPRESSOR
Fig. 78-Comfortron Underhood Wiring
7. Remove screws securing grommet retainer to fire

GM CHEVROLET AIR CONDITIONING
wall. Remove wire from grommet through slit.
SYSTEM ONLY 8. Disconnect electrical lead at connector.
In order to replace the Blower Motor, Blower Wheels, 9. Remove unit mounting bolts. Remove unit from
Evaporator, Expansion Valve, Evaporator and/or Evap vehicle, carefully pulling compressor electrical lead
orator Case, the entire evaporator assembly must be re through firewall.
moved from the vehicle.
Once the unit has been removed from the vehicle, con
ENTIRE EVAPORATOR ASSEMBLY Fig. 79 tinue with component replacement as follows:
Removal
1. Disconnect battery ground cable. BLOWER ASSEMBLY
2. Purge system of refrigerant.
3. Remove glove box interior to gain access to evap Removal
orator case mounting bolts. 1, Remove the cover plate and separate the upper and
4. Disconnect inlet and outlet refrigerant lines from lower case halves. Remove blower motor mounting
the back of unit. strap screw and remove strap.
5. Disconnect drain tubes from evaporator case. 2. Remove blower assembly. Loosen the blower wheel
6. Disconnect electrical connector from compressor. setscrews and remove the wheels from the motor
Remove the terminal See Figure 80 and allow con shaft.
nector to hang on ground wire.
Fig. 79-Evaporator Mounting
HEATER AND AIR CONDITIONING iA-58
SCREW DRIVER
NARROW BLADE
TERMINAL
THERMOSTATIC SWITCH SCREEN
CAPILLARY TUBE MESH
CONNECTOR
TANG
GROOVE
BUMPER EXPANSION VALVE
A. Insert screw driver in groove & press
tang toward terminal to release.
B. Pry tang back out to insure locking
when reinstalled into connector. Fig. 82-Expansion Valve and Sensor Installation
2. Remove inlet and outlet lines from the expansion

Fig. 80-Terminal Removal valve. Remove sensing bulb from the evaporator
outlet manifold. Remove expansion valve.
Installation 3. Remove evaporator core retaining screws and re
1. Install the blower wheels on the motor so that the move core.
lower blades curve toward the firewall side of the 4. Remove blower motor and harness assembly from
unit when the motor is placed in the case as illus case.
trated in Figure 81. Do not tighten setscrews at this
point. Installation
2. Place the motor in the bracket with the electrical 1. Reverse applicable steps in the removal procedure.
connector side of the motor to the right side of the 2, Reverse steps 1-9 of the "Entire Assembly" re
bracket. Attach the mounting strap. Align blower moval procedure.
wheels so that they do not contact case. Tighten
setscrews. THERMOSTATIC AND/OR BLOWER SWITCHES
3. Assemble the case halves and attach the cover plate. Replacement
4. Reverse steps 1-9 on the "Entire Evaporator As 1. Remove the cover plate and separate the upper and
sembly" removal procedure. lower case halves,
2. Remove two screws securing either switch to the
EXPANSION VALVE, EVAPORATOR AND/OR cover plate and remove appropriate switch fig.
EVAPORATOR CASE 83.
Removal Fig. 82 3. Install replacement switch, reinstall cover plate and
1. Remove the cover plate and separate upper and lower reverse steps 1-9 of the "Entire Evaporator Assem
bly" removal procedure.
case halves.
NOTE: When installing thermostatic switch,
be sure to position sensing capillary as when
unit was removed.
I
CORRECT
BtOWER
BLADE
ANGLE
Fig. 81-Blower Assembly Shown Upside Down Fig. 83-Thermostatic and Blower Switches
RESISTOR
BLACK & RED The blower motor resistor is located on the top of the
unit. The entire unit must be removed to replace the re
sistor fig. 84.
IGNITION. FUSE
SWITCtj
The GM Chevrolet Air Conditioning Unit does not in
corporate an in-line fuse as does the Four-Season and
Comfortron Systems. The lead wire is connected to the
Heater Wiring Harness fig. 90 and operates off the 25
amp Heater Fuse.
WIRE
BLOWER LEAD
RESISTORS
ASM.
EVAPORATOR & BLOWER ASM.
Fig. 84-Underdash Wiring Typical
WIRING DIAGRAMS
*Whenever Temperature control lever Is

set at "COLD" or "HOT" fan will run at 14BRN
"LOW’ speed in switch "OFF" position.
LEGEND: L_.__Wire is Vac Switch
Lo Blo Blower
* =Splice part at A/C Vac to air
Switch intake
- - - =Production wiring Inst Panel Intake Valve
Contacts used
=Wlre is part of equipment Harness
=Air conditioning wiring
=Views shown indicate wire
entry side at connector
l.A. =Inside air
0. A.=Outside air
N. C. P. B. =Normally closed contacts,
push button operated.
To battery EXTENSION WIRE ASM.
p/positive
rnrelay Bat’terminal/ /
ter
* Hose to actuator vented
Fig. 85-Chevrolet--Four-Season Wiring Diagram
_______
Vacuum Actuator
in Series with
Blower !
HIGH Bto L&H

"Whenever Temperature control lever Is
set at "COLD" or "HOT" fan will run
"LOW" speed in switch "OFF" position.
TEMP CONTROL LEVER

Operates temp control
cable, vacuum switch &
b-blower switch
Temp valve
begins to
open
.Cold
O.A.
*COMPREOR
Clutch coil
Bbo
N.C.P.B.
Fan speed
switch
LEGEND:
* Splice
- - - Production wiring
=WIre Is part of equipment
=Air conditIoning wiring
P Lo Blo
Control Switch
Vac Switch
Vac to air Blower
‘
=VIews shown indicate wire Lever Intake Valve intake
of connector PositIon Contacts Actuators used
0. A. Outside air OFF 2tonone On -
N. C. P. B. =Normally closed contacts, Panel

push button operated VENT 2tol Off* O.A.
EXTE l.A. . On l.A.
To battery positive
WIRE ASM L -
+ terminal DO.A.
r.Horn relay "Bat" °.2
Off* O.A.
terminal
lOB HOT *"E.2
_-,
S
* Hose to actuators vented
Fig. 86-Chevelle--Four-Season Wiring Diagram
________
________ ________ ____ ______ _______ _____________
_
Vacuum Actuator
I. A. Valve Fan eed Selector Switch
Blower Blower
‘‘Recirc air
Motor Intake flNormauY closed Lever Resistance
air ,7T,.91JI/
II H pring Position Contacts in Series with
Blower Motor j
12PPL 1i0!
OFF5 Tto - -;;::1
128
LOW 1 to 2 -I
MED 1 to 2 & 3 Rl & R2 ara1leled
ifiGli 1 to 2 & 4 None 1
SwflCH Normally open, 5Whenever Temperature control lever is
Thermal spring set at "COLD" or "HOT" fan will run at
2 "LOW" speed in switch "OFF" position.
‘ Opens below
freezing temp
1l
RESISTOR DASH-.,.
PANEL’
I Vacuum Actuator
Diverter Door
TEMP CONTROL LEVER
Outlets positions:
91 Operates temp control
RELAY i- Upper A/C
Si-level cable, vacuum switch &
Lower Heater o-blower switch
r
Temp valve
Lo Blo begins to
14 LI.!1,Sl I Switch oPen
oa,_
1I N. C. P. B. CONTROL
c.iceQ ASM
I ontacts ,._...j
--
-
F’-’
able
Temp valv
arm
, *
$1 .%lOpen
Fuse
*"
-
ii _c,
9 -
.C0W
0. A.
‘
in-line -COLD
; LA.
Clutch coil
ESSOR ,.
1 1 iI
dooi’ switch
-_
i IL.C.B.__‘
-
cable
---I-0
,o ..
14, -
Outlets-....
-
L..cuum
- -
I r0ntce
e,
0 16Y
16GY
16Y Fan speed
- 180R switch
oit
16LBL
LEGEND:
* =lice 14BRN
- -
=Production wiring
F"- Wire
-
=Wire is part of equipment is emp Vac Switch Blower

=Air conditioning wiring z part of A/C Vac to air
Views sbuwn indicate wire Inst Panel Intake Valve intake
Contacts used
entry side of connector Harness - Position Actuators
I.A.lnside air
O.A. =Outside air OFF 2to none On
TL.-Fuse
N. C.P. B. =Normally closed contacts, Panel
push button operated. VENT 2tol otto O.A.
EXTENSION. gLA. On LA.

battery positive
V_To
+ terminal WIRE ASM L1 L s-"
Horn relay "Bat" D&
nina1 - 0ff O.A.
10, HOT 2
- Lcgn.sw.
Accsy term 4 Hose to actuators vented
Fig. 87-Chevy Il--Four-Season Wiring Diagram
‘Whenever Temperature control lever is

set at "COLD" or "HOT" fan will run at
"LOW" speed in switch "OFF" position.
TEMP CONTROL LEVER

Operates temp control
cable, vacuum switch &
b-blower switch
LEGEND:
. =lice
- -
- =Production wiring
=Wire Is part of equipment Temp Lo Blo Vac Switch
=Air conditioning wiring Control
Switch Vac to air
=Vlews shown indicate wire Lever Contacts Intake Valve
entry aide of connector Poitinn Actuators
I,,A.=Inside air
O.A.Outside air
N. C. P. B.=Normally closed contacts,
push button operated.
,.-To battery positive

V terminal
Horn relay "Bat"
Hose to actuators vented
Fig. 88--Camaro--Four-Season Wiring Diagram
LEGEND:
- - =Production wiring
-
=Wire Is part of equipment

=Alr conditioning wiring
-Views shown indicate wire
r--- entry side of connector
l.A. -Inside air
O.A.itside air
OUTLE’ffi DIAL OPERATION
Diverter
switch
contacts
Resistance
Lever in series with
position blower mutor
Fig. 89-Corvette--Four-Season Wiring Diagram
_____
_____
LEGEND:
- - - a
=
EXISTING WIRE
WIRING IS PART OF EQUIPMENT
; h
a AIR CONDITIONING WIRING
a VIEWS SHOWN INDICATE WIRE
---- ENTRY SIDE OF CONNECTOR
GROUND
CLUTCH COIL
WIRE ASM.
CONNECTOR
I -
I 1-HEATER BLOWER
I FUSE BROWN -
I ‘ PANEL
---.-.
H
I
CONNECTOR
SWITCH
FUJI,
PANEL ASM.
BLOWER
MOTOR
IGNITION SWiTCH
ACCESSORY
TERMINAL
CONTROL
EVAPORATOR & BLOWER ASM.
Fig. 90-G.M. Chevrolet Air Conditioning System Wiring Diagram TypiCal
________
SPECIAL TOOLS
5
1
U
7
ci’
23 2425 29
22 26 28 - --
30
Fig. 91-Air Conditioning--Special Tools
J-8393 Charging Station 15. J-93999/16’ Thin Wall Socket

1A. J-22368Comfortron System Tester 16. J-9401Hub and Drive Plate Assembly Remover
1 B. J-21530Comfortron Temperature Dial Adjuster 17. J-9480Hub and Drive Plate Assembly Installer
2. J-5453 Goggles 18. J-9392 Seal Remover
3. J-9459 90° Gauge Line Adapter 19. J-9393 Seal Seat Remover
4. J-5420 Gauge Line Adapter 20. J-9398 Pulley Bearing Remover
5. J-6084 Leak Detector 21. J-9481 Pulley and Bearing Installer
6. J-8433 Puller 22. J-8092 Handle
7. J-9395 Puller Pilot 23. J-21352 Internal Assembly Support Block
8. J-6271 Fitzall Valve Single Can 24. J-5139 Oil Pickup Tube Remover
9. J-542 1Pocket Thermometers 2 25. J-9432 Needle Bearing Installer
10. J-5403 #21 Snap Ring Pliers 26. J-9553 Seal Seat "0" Ring Remover
11. J-6435 #26 Snap Ring Pliers 27. J-21508 Seal Seat "0" Ring Installer
12. J-9396 Compressor Holding Fixture 28. J-22974 Shaft Seal Protector
13. J-9397 Compressing Fixture 29. J-9527 Pressure Test Connector
14. J-9403 Clutch Hub Holding Tool 30. J-9402 Parts Tray
SECTION ‘lB
CORVETTE BODY
INDEX
Page Page
General Description lB-i Spare Tire Mount lB-20

Maintenance and Replacement lB-i Rear Grille and Plenum Air Door 1B-20
Front End lB-i Rugs and Interior Trim lB-21
Adjustments lB-i Cleaning Soft Trim 1B-21
Hood lB-i Carpets and Covers-All Models 1B-22
Hood Assembly 1B-2 Seats 1B-22
Hood Prop 1B-2 Body Mounting 1B-22
Front Emblem 1B-2 Body Repairs 1B-22
Cowl Area Trim 1B-2 General Instructions 1B-22
Console Assembly iB-4 Repair Panels iB-22
Rear View Mirror iB-4 Precautions 1B-25
Outside iB-4 Plastic Solder Kit 1B-25
Inside iB-4 Resin Kit 1B-25
Sun Visor 1B-6 Specific Repairs iB-27
Windshield 1B-6 Scratched Panels, Spot Refinishing iB-27
Cowl Ventilator Assembly iB-7 Dents in Panels-Surface Cracks 1B-29
Doors 1B-7 Cracked Panels iB-30
Adjustments iB-7 Fractures 1B-31
Door Lock Striker 1B-7 Panel Replacement iB-33
Door Window iB-8 Hardtop 1B-35
Trim Panel and Inside Handles. lB-li Care and Storage 1B-35
Weatherstrip lB-il Rear Window 1B-36
Window Outer Seal Assembly . lB-li Top Attachments * . . . 1B-37
Window Inner Seal Assembly . lB-il Headlining 1B-37
Window Glass 1B-i2 Weatherstrip and Drip Molding 1B-37
Inner Molding 1B-l3 Vinyl Covering 1B-37
Glass Run Channels 1B-13 Folding Top * . . . 1B-41
Window Regulator- Manual 1B-14 Care of Folding Top * * . . 1B-41
Window Regulator-Power 1B-i5 Care of Rear Window 1B-41
Door Lock and Remote Controls iB-16 Adjustments 1B-41
Outer Handle and Lock Cylinder 1B-i7 Top Assembly-Removal and Installation. 1B-42
Hinges-Door Assembly 1B-17 Top Trim and Rear Window Assembly. 1B-42
Rear Quarter 1B-l8 Frame and Linkage 1B-44
Door Sill Plate and Molding . 1B-i8 Weatherstrip 1B-44
Underbody Storage Compartment iB-18 Sport Coupe Model 19437 1B-46
Rear End lB-iS Roof Panels 1B-46
Folding Top Compartment Lid iB-18 Adjustments 1B-46
Adjustments lB-18 Headlining 1B-46
Hinges lB-18 Weatherstrip 1B-46
Lock iB-i8 Interior Trim 1B-46
Control iB-20 Storage Tray 1B-46
Gas Tank Door and Rear Trim lB-20 Rear Window 1B.-46
Rear Filler Panel . lB-20 Special Tools * . . . iB-47
GENERAL DESCRIPTION
A structural network of steel makes up the frame of the There are two body styles available-the regular con
Corvette body See Figure 1. Combined with fiber glass vertible with a folding top or removable hardtop, and the
reinforced plastic body panels, the steel plastic unit new coupe series that features removable roof panels.
displays properties of increased torsional rigidity and On convertible model base equipment, either top is
greater beaming strength. standard and both are optional.
MAINTENANCE AND REPLACEMENTS

FRONT END Hood
The position of the hood in relation to the hood body
ADJUSTMENTS opening and fender surfaces is determined by the position
Refer to Figure 2 of the hinges and position and adjustment of catch and
Adjustments should be made in order-hood position bumpers.
first, followed by catch adjustments. The fore and aft adjustment of the hood is performed by
CORVETTE BODY 1 B-2
Fig. 1-Steel R&nforCing Members
loosening the hinge retaining bolts lower and moving the anticipated, the hood, prop track and slide should be
hood to the limit of slotted holes in hinge strap. secured by placing a 1/4 inch bolt and nut through the
The upper surface of hood may be brought flush with existing hole. This will prevent accidental closing of
adjacent surfaces by shimming under hinges and adjusting the hood.
bumper screw and catch bolt engagement. Figure 3 in
dicates specified spacing. FRONT EMBLEM
Entrance of catch bolt into the plate may be adjusted
by loosening two 2 catch bolt mounting screws to allow Front emblem including flags, numbers, and molding
movement of bolt assembly. inserts, are retained by special nuts which may be
Synchronization of catch release may be made by reached by raising hood.
adjusting the cable retainer located at left hand catch
bolt assembly. COWL AREA TRIM
HOOD ASSEMBLY Figure 5 illustrates the mounting and location of
instrument panel pads and side trim panels.
Removal
1. if hood is to be reinstalled, scribe a line around hood Removal
hinge upper strap as shown in Figure 4. The right-hand dash pad, instrument panel pad and
2. With aid of helper to support hood, remove screws assemblies are removed by:
that retain hinge straps and support assembly to 1. Remove two mounting screws on the outboard flange.
hood. If hinges are removed from vehicle, note 2. Remove two screws at inner flange of center cluster
number of shims under each hinge. panel.
3. Pull pad outward to release special plastic retaining
Installation clips along top of panel.
In replacing original hood, align hinge with scribe 4. Pull pad upward to release spring clip at top of
marks made on removal, and install retaining screws trim side panel.
removed from hinges and support. Cowl ventilator and kick panel is removed by: See
If adjustment is required, proceed as outlined in this Figure 6.
section under Adjustments - Hood- Hood Catch. 1. Loosen four 4 screws securing sill plate enough
to release force on kick panel.
HOOD PROP 2. Remove one 1 screw at center of kick panel.
3. Lift out panel with a force in the rearward direction.
Retention Feature
4. For installation, follow above steps in reverse order.
When extended under hood service operations are Side trim panels left and right can now be lifted
CORVETTE BODY 1 B-3
r
Fig. 2-Hood Hinge and Catch
CORVETTE BODY 18-4
Fig. 3-Hood Spacing
out by pulling forward and upward to release two move two screws at side flanges of front console
spring clips at front console assembly. assembly.
5. Having first disassembled heater and si.de vent
controls, shift knob assembly, boot assembly, and
Console Assembly trim plate, remove front console assembly by care
fully pulling rearward and upward fig. 7.
Refer to Figure 6
Because of overlap design, it is necessary that the rear REAR VIEW MIRROR
console assembly be first removed or sufficiently
loosened before the front console assembly can be Outside
removed. Steps for removing the console assemblies Removal
are in the following sequence: The outside rear view mirror is removed from the
1. Remove two 2 screws, one located on left and one door by removing the allen head set screw located on the
on right-hand side of rear console assembly. outboard side of the mirror support. See Figure 8.
NOTE: It is suggested to compress seat cush Mounting assembly is removed by removing two screws
ion with sheet of heavy cardboard to avoid to body fig. 8.
damage to cushion while using screw driver. Installation
2. With right rear storage compartment box removed, Mirror may be installed by following removal pro
remove one 1 hex bolt and washer located at cedures in reverse order.
center of underbody panel.
3. Lift out rear console assembly housing by care
Inside
fully lifting upward making certain to clear parking Installation of inside mirror is illustrated in Figure 9.
brake handle. Tension of mirror stud is increased by tightening adjust
4. With left and right side trim panels removed, re ing screw.
CORVETTE BODY 1 B-5
5. Remove side retainer moldings L and R by re

moving three 3 screws to frame as shown in
Figure 12.
6. Remove side reveal molding L and R by removing
one 1 remaining screw fig. 13.
7. After indexing molding and header rail with tape to
insure proper reinstallation, remove upper reveal
molding by carefully prying out at corner with screw
driver as shown in Figure 14 and then pulling out
remainder by hand.
8. Secure one end of steel music wire to piece of wood
for handle. Insert other end through caulking ma
terial at lower corner of windshield; then secure
end of wire to another piece of wood fig. 15.
9. With the aid of helper, carefully cut through caulking
material using a sawing motion with the steel wire;
up side of windshield, across top, down opposite
side, and across bottom.
10. Remove old glass from windshield opening.
11. Using a sharp scraper or wood chisel, remove
adhesive caulking material from pinchweld flange.
Fig. 4-Scribing Line Around Hood Hinge
NOTE: It is not necessary to clean off all the
old caulking material completely from wind
shield frame; however, there should not be any
loose pieces of caulking material left in the
opening.
12. Check all upper reveal molding retaining clips for
SUN VISOR damage 4 clip assemblies required. Replace those
that are bent or distorted.
Attachment of sun visor assembly to windshield header 13. Using weatherstrip adhesive, cement rubber spacers
is made as shown in Figure 9. Thrning of adjusting at bottom, sides, and top of window opening. The
screw clockwise increases friction. step-type spacers are used at bottom, the flat type
are used at the top, and at the sides, window opening
as shown in Figure 16.
WINDSHIELD 14. Using suction cup holders, position replacement
The 1968 Corvette windshield installation incorporates glass in body opening. Carefully check relathnship
a synthetic self-curing rubber adhesive caulking com of glass to body pinchweld completely around open
pound that adheres to both glass and pinchweld frame ing. The overlap of glass to body pinchweld and
in place of the rubber channel that was formerly used. retaining flganges should be equal with a minimum
Applied to the glass while in a soft state, the material overlap of 3/16". Where necessary, position shims
begins to cure soon after exposure to air. It is therefore under the lower spacers to obtain required overlap
essential that installation of glass into body opening of glass to body upper and lower flanges.
quickly follow application of material to glass. It is 15. After proper glass to pinchweld relationship has
recommended to use the materials provided in GM Kit been attained, mark position with grease pencil on
part number 4226000 which consists of: glass and windshield pillar.
a. One tube of Adhesive Caulking Material. 16. Remove glass from body opening and place on pro
b. Pressure Sensitive Adhesive Sealing Strip. tected surface.
c. Steel Music Wire .020" diameter. 17. Clean inside edge surface of glass so that glass is
d. Adhesive Caulking Primer. free of any foreign material oil, grease, etc.. By
Additional materials required: first pealing off paper backing, apply pressure
a. Caulking gun sensitive sealing strip approximately 1/4 inch from
b. Two pieces of wood for wire handles. edge of inside surface of glass completely around
c. Black weatherstrip adhesive. glass. Then apply a film of silane primer to inside
d. Rubber glass spacers. edge surface completely around glass; also apply
silane primer to sealing surface of windshield frame.
Removal 18. Cut off painted portion of cartridge nozzle along
Refer to Figure 10 for parts identification. edge of paint line.
1. Set windshield wiper access door in open position. 19. Mix adhesive caulking material and accelerator
2. Remove windshield wipers. thoroughly according to directions on container.
3. Remove weatherstrips L and R from frame by
removing mounting screw, prying from channel, and NOTE: Once caulking material is mixed, there
carefully pulling downward as shown in Figure 11. will be approximately 35 minutes of working
4. Remove lower corner reveal moldings L and R by time with the material. Subsequent steps should
removing two 2 screws located at end flanges to be performed immediately after caulking ma
fender, and carefully prying out from retaining clips. terial is mixed.
CORVETTE BODY 1 B-6
Fig. 5-Cowl Area Trim
1. Instrument Panel Pad L. H. 4. Dash Panel Pad R. H. 7. Special Washer

2. Side Trim Panel L. H. 5. "J" Nut 8. Screw
3. Side Trim Panel R. H. 6. Screw 9. Special Washer
20. Place caulking material in cartridge as shown in shield opening flanges. Paddle material where nec
Figure 17. essary to insure proper seal.
21. Carefully apply a smooth continuous bead of caulking 25. Water test windshield immediately using a cold
material on inside surface of glass next to edge water spray. If any water leaks are encountered,
completely around glass fig. 18. Caulking material use flat bladed screw driver or stick, and paddle
should be approximately 1/4 inch wide at the base caulking material into leak point to correct leak.
and form a pyramid 3/8 inch high. If during appli Correction of leak is usually more effectively per
cation the pyramid collapses, wait about 2-3 minutes formed by padding material from inside the body.
for material to set up. If an air bubble is en
countered in material, back up the applicator and CAUTION: DO NOT RUN A HEAVY STREAM
apply sufficient material to fill void and to dispense OF WATER DIRECTLY ON CAULKING MA-
the bubble before continuing. TERIAL WHILE THE MATERIAL IS STILL
22. The reveal molding clips are self-sealing and do not SOFT.
require sealing before installing glass.
23. With aid of helper, lift glass and carefully position 26. Install previously removed hardware and trim in the
glass on spacers, matching up marks on glass and following order: upper reveal molding, side reveal
frame as shown in Figure 19. molding, side retainer molding, lower corner reveal
24. Press glass lightly to set caulking material to wind- molding, and windshield pillar weatherstrip.
CORVETTE BODY 1 B-7
Fig. 6-Front and Rear Console Assemblies
COWL VENTILATOR ASSEMBLY DOORS

The following procedure includes either the left or
right-hand side. Refer to Figure 20.
ADJUSTMENTS
Adjustment Door Lock Striker

The door lock striker consists of a single metal bolt
Turn plastic adjustment link, located at middle of
and washer assembly that is threaded into a tapped,
control cable underneath dash panel, in order to attain
floating cage plate located in the body lock pillar. With
desired adjustment. Ventilator valve should be com
this design, the door is secured in the closed position
pletely closed when knob is at forward position.
when the door lock fork-bolt snaps over and engages the
Removal striker bolt.
1. Remove cowl kick panel. 1. To adjust striker up or down, or in or out, loosen
2. Disengage control cable fastened to bracket by striker bolt and shift striker as required, and then
screw. tighten striker.
3. Remove knob assembly retaining screw. 2. To determine if striker fore or aft adjustment is
4. With console trim plate lifted out, remove nut re required, proceed as follows:
taining guide. a. Make certain door is properly aligned.
5. Remove screw retaining cable at inside front of b. Apply modeling clay or body caulking compound
console assembly. to lock bolt opening as shown in Figure 21.
6. Disassemble control mechanism. c. Close door only as far as necessary for striker
7. Remove cable assembly by disconnecting at adjusting bolt to form an impression as shown in Figure 21.
link and pulling through. CAUTION: DO NOT CLOSE DOOR COM
Installation PLETELY. COMPLETE DOOR CLOSING WILL
Install vent assembly following removal procedure in MAKE CLAY REMOVAL VERY DIFFICULT.
reverse order. Check operation and adjust accordingly. d. Measure striker impression as follows:
CORVETTE BODY 1 B-B
Fig. 7-Front Console Assembly Fig. 9-Sun Visor and Inside Rear View Mirror
Striker head should be centered fore and aft as 5/64" Spacer Part No. 4469196
shown; however, some tolerances are allowed. 5/32" Spacer Part No. 4469197
In this alignment, it is important that minimum 1/4" Spacer Part No. 4469194
dimensions as outlined in Figure 21, be strictly 5/16" Spacer Part No. 4469195
maintained. The following spacers are available If check indicates need for emergency spacers, proceed
as service parts and can be used individually or as follows:
in combination to achieve the specified alignment: 1. Mark position of striker on body lock pillar using a
pencil.
2. Insert a 5/16" wrench into hex-head fitting in head
of striker bolt and remove striker fig. 22.
3. To install, reverse removal procedure. Make cer
tain striker is positioned within pencil mark.
IMPORTANT: Whenever a door has been re
moved and reinstalled or realigned, the door
should not be closed completely until a visual
check is made to determine if lock fork-bolt is
correctly engaging with striker.
Door Window
Refer to Figure 23
To move the top of the window IN AND OUT, the
following procedure is followed for each channel.
1. Remove door trim panel as outlined in this section.
2. Loosen two 2 outer screws located at top of inner
door panel View A.
3. Remove hex nut securing adjusting stud View B.
4. Turn adjusting stud to desired window position.
5. Tighten hex nut and two 2 screws.
For UP AND DOWN adjustment, two screw and stop
assemblies are located at the upper and lower ends of
each channel assembly. The adjustment procedure in
volves the following steps:
1. Loosen two 2 Phillips head screws.
2. Slide channel to desired window height.
Fig. 8-Outside Rear View Mirror 3. Tighten screws and check window position.
CORVETTE BODY 1 1-9
12
17
14
Fig. 10-Windshield Moldings and Weatherstrips
1. Header Molding 5. Retainer Molding 8. Clip 11. Windshield Glass 14. Screw
2. Screw 6. Upper Retainer 9. Front Weatherstrip 12. Folding Top Assembly 15. Screw
3. Header Corner Molding 10. Windshield Header 13. Windshield Pillar 16. Weatherstrip
4. Reveal Molding 7. Nut Assembly Weatherstrip 17. Front Rail Weatherstrip
CORVETTE BODY 18-10
Fig. 13-Removing Side Reveal Molding

front straps of hinges; up and down position is deter
Fig. 11-Removing Weatherstrips From Frame
mined by adjustment of rear hinge straps in slots of
FORE AND AFT adjustment is performed by loosening inner door panel. To adjust door, proceed as follows:
the two 2 inner hex bolts at top of plate assembly View 1. Remove door trim panel as outlined in this section.
A, and one 1 hex bolt at bottom of channel. Channel is 2. Remove lock striker bolt after first scribing line on
adjusted to full extent of slotted holes. lock pillar surface following circular flange. This
enables proper installation position.
Door Hinges 3. For up-and-down adjustment, remove hinge cover
2 screws for access to upper hinge retaining
Refer to Figure 24 screws.
The position of the door assembly in the body opening 4. For in-and-out, and fore-and-aft adjustment, it is
is determined by the striker position previously de necessary to first remove instrument panel left
scribed, and the position of the door on the hinge rear door only, right dash pad right door, cowl kick
straps. The position of the door is adjusted by sliding panel, air inlet duct, and radio speaker, in order to
the door fore and aft to the limit of the slotted holes in gain access to hinge retaining screws.
hinge pillar; in and out adjustment is done by installation 5. Adjust door as required. Do not allow doors to
and removal of shims located between hinge pillar and hang on one hinge without support.
Fig. 12-Removing Side Retainer Molding Fig. 14-Prying Out Upper Reveal Molding
CORVETTE BODY 1 B-1 1
Fig. 15-Removing Old Glass From Opening
6. Install previously removed striker assembly, trim

pads and panels and lubricate door hinges with
lubriplate or equivalent.
NOTE: After performing any door adjustment,
the window and lock pillar should be checked for
alignment and adjusted as necessary. Do not
slam door after adjustment without first check
ing the door lock and striker engagement. An
adjustment may be necessary.
TRIM PANEL AND INSIDE HANDLES

Fig. 17-Placing Caulking Material in Cartridge
Refer to Figure 25
1. Using Tool J-7797, remove clips retaining window
crank and lock control as shown in Figure 26. WEATHERSTRIP
2. Remove four 4 screws securing trim panel located
at inside corners of inner door panels. Figure 28 illustrates weatherstrip mounting location
3. Remove trim panel by carefully prying out at plastic on door. When installing new weatherstrip, all dirt,
fastener clips located around perimeter of panel. loose paint and old cement must be removed to ensure
4. Remove door lock handle by removing one 1 screw a good bond. Use only high quality cement designated
and sliding handle forward fig. 27. by the manufacturer as being suitable for weatherstrip
5. Remove formed plastic polyureathane cover by application.
peeling along edge at adhesive bead.
6. For installation follow above steps in reverse order WINDOW OUTER SEAL ASSEMBLY
making sure trim panel is properly aligned.
1. Lower window all the way down.
2. Remove two 2 screws located at both ends of seal
fig. 29.
3. Carefully pry out at six 6 retaining clips.
4. Lift seal assembly outward and upward.
5. For installation, secure clips and install the two
screws.
WINDOW INNER SEAL ASSEMBLY

2. Remove six 6 screws located on top surface of
inner door panel securing tabs of inner seal assem
bly fig. 29.
3. Remove seal assembly by lifting upward and re
volving outward while clearing tabs through opening.
Fig. 16-Windshield Rubber Spacers 4. For installation, follow above steps in reverse order.
CORVETTE BODY 1 B-i 2
Fig. 19-Installing Windshield Glass
4. Remove two 2 sash screws on horizontal guide

channel while holding nut with other hand fig. 30.
5. Disengage stop by removing one 1 Phillips head
screw at top of channel assembly.
6. Adjust front and rear channel assemblies to ex
treme outboard position to allow ample clearance
for window removal.
7. Carefully pull window upward making certain to
clear roller assemblies through opening in inner
door panel fig. 31.
Installation
Fig. 18-Applying Caulking Material to Glass If replacement glass is necessary, disassemble two
2 pads and fasteners, and frame assembly by removing
three 3 mounting bolts through glass fig. 32. Mount
WINDOW GLASS frame assembly and pads onto new glass before installa
Removal tion into door.
1. Remove door trim panel as outlined in this section. The following steps are necessary for installation:
2. Remove window outer and inner seal assemblies as 1. Insert glass in door pocket with convex curvature
outlined in this section. towards outside of vehicle.
3. Position window all the way up to line up two 2 sash 2. Install and tighten 2 sash bolt and nut assemblies
screws through access holes. through horizontal guide channel and glass frame.
VIEW B VIEW A
Fig. 20-Cowl Ventilator and Controls
CORVETTE BODY lB-i 3
Fig. 21-Checking Adjustment of Striker

3. Adjust front and rear channels to proper in and out
position.
4. Install inner and outer window seals, and door trim
panel.
Fig. 23-Window Adjustment Points
INNER MOLDING
2. Remove window outer and inner seals as outlined in
Refer to Figure 29 this section.
1. Remove window glass assembly as outlined in this 3. Position screw driver through access holes in inner
section.
door panel and remove five 5 screws along face of
molding as shown in fig. 33.
4. Remove molding by lifting upward.
GLASS RUN CHANNELS

Removal
For parts identification, refer to Figure 23. Removal
of either front or rear channel involves the following
steps.
1. Remove door trim assembly as outlined in this
section.
2. Remove window glass assembly as outlined in this
section.
3. Remove retaining screw at lower end of channel and
two 2 screws retaining channel to top surface of
door inner panel.
4. Remove two 2 screws retaining stationary hori
zontal guide channel.
5. Remove nut from adjusting stud.
6. Adjust stud to extreme clockwise position to allow
proper removal clearance.
7. Carefully lift channel through upper slot as shown in
Figure 34, making certain to clear opening.
Installation
1. Position run channel in door and install retaining
bolts loosely.
Fig. 22-Removing Striker Bolt 2. Install window glass as outlined in this section.
Fig. 24-Side Door Hinges
3. Make necessary adjustments to channel as outlined

under Doors - Adjustments - Door Windows. Replace
door trim panel.
WINDOW REGULATOR-MANUAL
For parts identifications refer to Figure 35.
Removal
1. Remove trim panel as outlined in this section.
2. Remove access cover by removing five 5 bolts.
3. Position window all the way up.
4. Remove two 2 sash bolt and nut assemblies re
taining window glass.
RETAINING SPRING
DISENGAGED
INSIDE HANDLE PUSH TOOl. IN
DIRECTION OF
ARROW.
Oi t
TOOL .1-7797
Fig. 25-Door Trim Panel Assembly Fig. 26-Removing Window Crank with J 7797
CORVETTE BODY 1B-15
Fig. 27-Door Lock and Remote Control

5. Remove two 2 screws securing stationary hori rails and rollers when regulator is disassembled. Test
zontal channel. regulator thoroughly before installing door trim panel.
6. Remove window crank housing by removing three Adjust window as outlined in this section.
3 screws.
7. Remove crank shaft, pin and washer spring. WINDOW REGULATOR-POWER
8. Remove two 2 screws located adjacent to spring
opening retaining regulator. In the case that window will not operate, check elec
9. Remove lower bolt securing front glass channel. trical connections first. Figure 37 illustrates location of
10. Remove nut securing adjusting stud, and adjust front junctions, switches, and circuit breaker.
channel outward to provide adequate clearance for Removal
window regulator removal. Perform Steps 1 through 12 following Window
11. Collapse regulator linkage to elongated position. Regulator-Manual Removal. Note that electrical con
12. While depressing front channel outward, slide reg nectors must be removed from motor before performing
ulator assembly forward and rearward to remove any operation on regulator. Figure 3’? illustrates location
through access hole as shown in Figure 36. of regulator on door and wiring.
Installation Disassembly
Regulator may be installed by following removal pro
cedure in reverse order. Always lubricate all guide NOTE: Do not attempt to remove motor from
CORVETTE BODY 1B-i6
Fig. 28-Door Weatherstrip
1. Weatherstrip 3. Screw 5. Striker

2. Screw 4. Spacer 6. Lock Pillar
regulator until the following operations are per DOOR LOCK AND REMOTE CONTROLS
formed. Arm is spring-loaded and should be
For parts identification, refer to Figure 27.
locked in position when motor is removed.
Refer to Figure 38. Removal
1. Place regulator assembly in vise. 1. Raise window fully up.
2. Using jumper leads to 12 volt DC source, operate 2. Remove door trim panel as outlined in this section.
motor until semi-circular hole in sector gear cen 3. Remove cover from top-rear access hole.
ters over one of two weld nuts on mounting plate. 4. Disengage upper control rod assembly by removing,
3. Screw a 1/4" - 20 x 1" bolt into weld nut so that end first, plastic guide clip, releasing carburetor type
passes through hole in sector gear. It may be nec clips at both ends, and removing rod through access
essary to enlarge hole in gear slightly with file or hole.
drill. Install nut on bolt to lock arm in position. 5. Disengage lock control rods by releasing clips at
both ends and lifting outward.
Installation 6. Remove remote control assembly by removing four
Be sure lock bolt is removed if regulator has been 4 screws to inner door panel.
disassembled. 7. Remove "crank link" intermediate pivot by re
1. Install lubricated regulator assembly and guide rails moving two 2 screws to inner panel.
in reverse order of removal. 8. Remove door lock by removing three 3 screws and
2. Install window as outlined in this section. lifting assembly out through access hole.
3. Making sure connectors are securely installed on
motor, test operation of window thoroughly. Installation
4. Install door trim panel and control handles as out For installation, follow preceeding steps in reverse
lined in this section. order. After assembly of lock mechanism, adjust linkage
CORVETTE BODY 1B-17
Fig. 29-Window Glass Seals and Molding
for proper operation, by removing clip and turning

threaded rods. All components should be lubricated
before installation.
OUTER HANDLE AND LOCK CYLINDER

Refer to Figure 39
Removal
1. Remove handle assembly by removing three 3 nuts
securing studs to handle housing.
2. Remove lock cylinder by removing two 2 screws
located at top of assembly.
Installation
1. If required, install new seal.
2. Position handle housing in place, and install handle
assembly.
3. Carefully check operation of door lock.
4. Install door trim panel as outlined in this section.
HINGES-DOOR ASSEMBLY
Refer to Figure 40
Removal
Fig. 30-Removing Sash Screws 2. Remove hinge access cover from door inner panel.
edge trim, is mounted to the body by four 4 screws.

The upper molding is replaced by removing seven 7
screws; the lower molding is replaced by first removing
the upper molding and then removing five 5 screws and
four 4 nuts at face of molding.
UNDERBODY STORAGE COMPARTMENT

Located directly behind the front seats, the underbody
storage compartment assembly is divided into three
separate storage areas.
Refer to Figure 42.
1. Remove right hand box by opening lid, and lifting
box upward.
2. Unfasten storage assembly by removing eight 8
screws along inner flange of frame and lower strap
of door hinges.
3. Remove assembly from underbody by lifting upward.
4. Doors are removed from assembly by removing
three 3 screws outer doors and two 2 screws
center door at upper hinge strap.
5. Center storage compartment box is removed by re
moving seven 7 screws located around inside top
edge of box.
Fig. 31-Removing Glass Assembly REAR END

3. For lower hinge removal, remove door sill plate, FOLDING TOP COMPARTMENT LID
cowl kick panel, and radio speaker. Refer to Figure 43 for parts identification.
4. For access to upper hinge attaching screws, remove
lower mast jacket cover and instrument panel pad Adjustment
left side, or dash panel pad right side, and air
inlet ducts. Hinges
5. If entire door is to be removed and door has electric The folding top compartment lid should be adjusted so
power window, disconnect and remove wiring be that, in the closed position, the surface of the lid is flush
tween hinge pillar and door. with surrounding body surfaces, and space between lid
6. 1.1 hinge is to be replace in same position, scribe edge and body is 1/16" to 3/16" at sides and 3/16" to
around inner strap on door panel and record number 1/4" at rear. Whenever lid position is changed on hinges,
of shims found between hinge strap and door panel. lock engagement must be inspected and adjusted if neces
7. Remove bolts retaining hinge to door. DO NOT sary. Adjust hinge position as follows:
ALLOW DOOR TO HANG UNSUPPORTED ON ONE 1. Scribe a line on lid surface following contour of
HINGE. hinge strap. This line will assist in observation of
8. Remove bolts retaining hinge to body. lid movement during adjustment fig. 44.
2. To raise or lower top surface of lid, add or remove
Installation hinge shims as required.
1. if door assembly has been removed from car, scribe
around lock striker as explained under Adjustments- Lock
Door Lock Striker, and remove striker from lock Lock engagement is adjusted as follows:
pillar. 1. Lock striker is adjusted in and out to the extent of
2. Install hinges, replacing same number of shims re slotted mounting holes.
moved, and aligning door hinge straps with marks 2. Release of lock is adjusted by loosening lock assem
scribed at disassembly. bly retaining bolts and moving lock fore and aft to
3. As necessary, perform door adjustments as outlined the limit of slotted holes in lock base. Further ad
in this section. justment is performed by moving cable retainer in
4. if door is equipped with power window, reinstall appropriate direction.
wiring. 3. After adjustment, lock release should be tested and
5. Replace a 11 trim and panels removed during readjusted as required.
disassembly
Hinges
REAR QUARTER Removal
1. Scribe around hinge as shown in Figure 44.
DOOR SILL PLATE ANb MOLDING 2. Hinge is removed as an assembly by opening top
Figure 41 illustrates assembly details of both the door compartment lid fully, and removing three 3 re
sill plate and molding. The sill plate, which retains the taining screws. Note number of shims found between
carpet, the cowl trim kick panel, and lock pillar front hinge frame and compartment floor.
CORVETTE BODY 1B-19
14
.10
9 10 is
5
16
4 11
12
Fig. 32-Glass and Frame Assembly
1. Glass 5. Pad 9. Washer 13. Washer

2. Frame 6. Nut 10. Nf 14. Cam Idler
3. Filler 7. Bolt 11. Screw 15. Pad
4. Fastener 8. Bushin9 12. Channel 16. Rivet
3. Remove spring from hinge assembly by c:Losing top 2. If spring has been removed from hinge, install spring
compartment lid as far as possible and inserting in J-9559 and place spring on hinge with compart
Tool J-9559 between expanded coils in spring. Open ment lid raised; closing lid releases J-9559 for
ing top compartment lid fully allows removal of removal. Upper end of spring should rest in the one
spring as shown in Figure 45. of three notches yielding best lid operation. Ap
4. Directly after spring is removed, insert long bolt proximately three pounds force is necessary to
supplied with J-9559 through holes in end of tool close lid.
through the spring, and install nut on bolt.
Top Lock
Spring may be removed from J- 9559 or J-9559 may be 1. For locks on either side, remove cable mounting
installed in a new spring, by the following method: clamps by removing one 1 hex screw.
1. Place a closed 6 or 8 inch "C" clamp in vise or 2. Remove two 2 nut-washer assemblies.
or fasten it to a bench top anchored to floor. 3. After disassembling lock from mounting studs, care
2. Hook one end of spring in clamp and the other end fully remove cover and gasket from compartment lid.
in hook of chain hoist, or "cherry picker", as shown 4. For installation, follow above steps in reverse
in Figure 46. order. Test lock and control mechanism for proper
3. Elongate the spring enough to allow insertion of operation.
J-9559. Install through bolt if spring is not to be
installed on hinge immediately. Lock
Installation Removal
1. Install same number of shims as removed or, if 1. Remove cable mounting clamps. Remove retainer
repairing collision damage, etc., position hinge in from control cable assembly and disengage cable
compartment, install upper mounting screws, fill from control.
gap between floor and hinge frame with shims and 2. Scribe a mark, on lid along outer contour of lock
install lower mounting screw. assembly.
CORVETTE BODY i B-20
Fig. 33-Removing Molding Screws
Fig. 34-Removing Front Glass Channel
3. Remove three 3 lock assembly retaining screws

and remove lock from compartment lid.
REAR FILLER PANEL
1. Remove rear license plate and housing as explained
Installation in Section 14,
1. Place lock assembly on compartment lid aligned 2. Remove tail pipes from mufflers.
with scribed line and install retaining screws. 3. Remove eight 8 mounting screws retaining filler
2. Install end of cable in control assembly and fasten panel to body fig. 47,
retainer securely. 4. For installation, follow above steps in reverse order.
3. Test operation of lock thoroughly, and adjust if nec
essary as outlined in this section.
Control SPARE TIRE MOUNT
Removal Refer to Figure 48.
1. Remove inner mounting clamps from both cables,
Removal
and disengage cables from control by removing
1. Remove spare tire as outlined in Owner’s Manual.
retainers.
2. Loosen pivot bolt lock nuts and turn pivot bolts out
2. Remove four 4 mounting screws and remove con
of weld nuts in crossmember.
trol from compartment lid.
3. Remove two 2 screws retaining swivel bolts as
Installation sembly to body.
1, Position control on compartment lid and install 4. Remove four bolts holding cover assembly to, body.
mounting screws.
2. Install ends of cables in control and fasten securely
with retainers. Installation
3. Engage push rod with retainer. Installation is made by following removal procedure in
4. Test operation of locks and adjust if necessary. reverse order, Before installing swivel bolt assembly,
coat nut and bolt threads with chassis grease.
GAS TANK DOOR AND REAR TRIM
Figure 47 illustrates installation details of gas tank
door, letter trim, and tail pipe bezel. REAR GRILLE AND PLENUM AIR DOOR
Gas tank door assembly and bezel are replaced by Refer to Figure 49
removing sheet metal screws located around inner sur 1. Remove four 4 screws retaining grille to rear deck
face of bezel. panel.
The holding force of door latch mechanism is adjusted 2. Remove three 3 screws securing frame, plenum
by removing assembly and turning individual lock pins air door, and gasket assembly.
with allen head wrench. 3. For replacement of rubber door, new fasteners are
Trim letters are retained by special nuts accessible required.
from underneath vehicle. 4. For installation, follow above steps in reverse order.
CORVETTE BODY 1 B-21
6
4
VIE Wf.I
Fig. 35-Manual Window Regulator
1. Roller and 2. Channel Assembly 4. Housing 6. Shaft

Slide Assembly 3. Screw 5. Washer-Spring 7. Pin
RUGS AND INTERIOR TRIM water as necessary until the cleaner foams to a soapy
consistency. Remove the first accumulated soilage with
CLEANING SOFT TRIM a cloth or sponge before it can be 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
Procedure for Cleaning Folding Top Material cleanser from running on body finish as it may cause
The top should be washed frequently with neutral soap streaks if allowed to run down and dry.
suds, lukewarm water and a brush with soft bristles.
Rinse top with sufficient quantities of clear water to re ‘Procedure for Cleaning Coated Fabrics
move all traces of soap. Care of genuine leather and coated fabrics includes
If the top requires additional cleaning after using soap vinyl coated formed headlining is a relatively simple
and water, a mild foaming cleanser can be used. Rinse but important matter. The surface should be wiped oc
the whole top with water; then apply a mild foaming type casionally with a dry cloth, and whenever dirt accumu
cleanser on an area of approximately two square feet. lates, the following cleaning instructions should be used:
Scrub area with a small soft bristle hand brush, adding 1. Lukewarm water and a neutral soap should be used.
CORVETTE BODY 1B-22
here to floor after original carpet is pulled up.

2. Apply 3M- 1711 cement or equivalent, following di
rections furnished with package. Be sure floor is
reasonably clean and dry before applying cement.
SEATS
Removal
1. Remove bolt retaining each forward support to floor.
2. Fold seat back forward.
3. Loosen two bolts retaining each seat hold-down
bracket.
4. Move seat forward and out of brackets,
Adjustment
Height of seats is adjustable at both front and rear by
means of shims or washers.
Angle of seat backrest may be changed by adjusting
stops located on lower edge of seat back.
BODY MOUNTING
Figure 49 illustrates underbody attachment-to-frame
body mounting brackets. Shims which are shown on
rear crossmember are cemented in place.
The torque of all body mounting bolts should be checked
periodically as an aid to preventing annoying squeaks
Fig. 36-Removing Window Regulator and rattles. All bolts shown in Figure 49 should be
torqued 40 to 50 lb. ft.
Apply a thick suds, worked up on a piece of gauze or
cheesecloth, to the surface. BODY REPAIRS
2. The operation should be repeated, using only a damp
cloth and no soap. GENERAL INSTRUCTIONS
3. The surface should then be wiped dry with a soft The following gives information necessary for repair
cloth. of collision damage and performance of general main
Polishes and cleaners used for auto body finishes, tenance on Corvette bodies. Included here is information
volatile cleaners, furniture polishes, oils, varnishes or dealing with availability of repair panels, general in
household cleaning and bleaching agents should never stallation procedures for installing panels and repairing
be used. damage to the body.
Repair of fiber glass reinforced plastic bodies can be
Procedure for Cleaning Carpet a relatively easy matter if precautions are observed.
Thoroughly brush or vacuum the floor carpet. In many In cases where welding must be done on steel parts
instances the floor carpet may require no further clean which are installed on body, do not allow flame or weld
ing. If the carpet is extremely soiled remove carpet ing heat to come into direct contact with plastic body
from car and thoroughly vacuum to remove loose dirt; panels. The general area around the welding operation
then with a foaming type upholstery cleaner, clean ap should be protected with wet asbestos or any other like
proximately one 1 square foot of carpet at a time. After method several thicknesses of aluminum foil makes an
each area is cleaned, remove as much of the cleaner excellent heat shield if out of the way of direct flame.
as possible with a vacuum cleaner. After cleaning the Straightening of steel parts while still in body must be
carpet use an air hose to "fluff" the carpet pile, then done with care. When applying hydraulic jacks or like
dry the carpet. After the carpet is completely dried, equipment which operates by exerting force, bear in
use an air hose to again fluff the carpet pile. mind that the part being used to brace the stationary end
of tool must be able to withstand such usage and that
NOTE: If the carpet is not extremely soiled, fiber glass parts, though tougher than steel, will not yield
it may be cleaned in the car by applying a small or "take a set" as with steel parts, so they cannot be
amount of foaming type upholstery cleaner with "straightened". If poor alignment exists due to collision
a brush. or other physical damage, check steel reinforcements in
cowl and sill areas with care.
CARPETS AND COVERS-ALL MODELS Tracing line of damaging force and checking body
Removal of front compartment carpeting will require carefully for broken bonds and cracks before, during
removal of sill plates and loosening of console trim; and after repairs will pay off repeatedly.
service of these items is covered in this section under Small cracks and faults in bonds and panels will usually
Front End-Cowl Area and Console Trim. grow larger if left unattended.
In areas where carpeting is to be cemented, proceed
as follows: REPAIR PANELS
1. Remove all old carpeting, jute, etc. which may ad- Body repair panels are illustrated in Figures 51
Fig. 37-Power Window Regulator
Fig. 39-Door Handle, Lock Wedge
Fig. 38-Locking Arm in Place
Fig. 40-Side Door Hinges
CORVETTE BODY 18-25
6. Be careful not to get any resin material on clothing.

7. Use the right materials for the job. It is important
to use the approved kits because other materials
available may not meet the required engineering and
safety standards.
8. Keep materials, utensils and work area clean and
dry. These repairs involve chemical reactions, and
dirt or moisture may upset the chemical balances
and produce unsatisfactory results.
9. Before starting repair operations, look for hidden
damage by applying force around the damaged area,
looking for hairline cracks and other breakage.
Check for minor damage at other points in the vehi
cle such as around exhaust pipes, grille, headlamps
and points of wear. Early repair of minor damage
may prevent major repair later.
PLASTIC SOLDER KIT
The Plastic Solder Repair Kit is used for minor re

pairs on the Corvette body. These materials will produce
Fig. 41-Sill Plate and Trim Molding an easy, quick and lasting repair in the case of small
cracks, surface imperfections and small holes.
through 54. Those shown are typical of panels which are 1. Use paint remover or power sander, and remove
available through Chevrolet parts sources. Procedures finish from damaged area. Carefully inspect for
which may be used for installing panels are explained in other areas requiring repair.
the following paragraphs. 2. Mix the materials fig. 56.
Figure 55 illustrates various bonds which will be en 3. Apply the material, using a putty knife or rubber
countered during repair procedures. squeegee, Figure 57. Work the material into the
repair and build the material up to the desired
PRECAUTIONS contour. For deep filling and on vertical surfaces,
several layers may be used, each about 1/2" thick.
Creams are available to protect the skin from a con 4. Finish the repair by grinding, sanding and painting
dition known as occupational, or contact dermatitis. This in the usual manner, Figure 58.
common type of dermatitis is not contagious. Improved
resin formulas in the approved kits have almost elimi
RESIN KIT
nated skin irritation. Cream is supplied with the kit for
persons who may have a tendency toward skin irritation
from the resins or dust. The Resin Repair Kit, for major repairs, contains
The application of these creams is recommended resin, hardener, Thixatrope, fiberglass cloth, protecting
whenever the Resin Kit materials are used. Generally, creams and mixing utensils. Repairs such as torn panels
the cream is not required when the plastic solder kit is and separated joints require the adhesive qualities of the
being used. Directions for using the cream is as follows: resin and the reinforcing qualities of the glass fibers.
The following procedure is basic for repairing any
1. a. Wash hands clean. Dry thoroughly. plastic fiberglass component or panel.
b. Squeeze about 1/2 inch or 1/2 teaspoonful of 1. Look for hidden damage. Apply force by hand around
#71 cream into palm of hand,
the damaged area.
c. Spread evenly and lightly until cream disappears. 2. Use paint remover and remove finish from around
Work cream into cuticle, between fingers and damage area. Inspect area again for signs of other
around wrists. damage.
d. Apply second coat, repeating Steps b and c. 3. Grind or file the damaged area to form a "V" at
e. Hold hands briefly under cold running water to
the broken or cracked portion. Side of "V" should
set cream.
have a ‘shallow pitch for maximum bonding surface.
2. Remove resin mixture from hands as soon as possi
ble and imperatively before mixture starts to gel. A belt sander With a vacuum attachment will mini
This can be observed by the action of the material mize the dust problem, Figure 59.
being used. Resin may be removed with lacquer 4. If rear of damage is accessible, use a button-type
thinner by washing in soap and water. repair. Clean back of area to permit the use of
3. Respirators are recommended when grinding. Also laminate resin- saturated glass- cloth on both sides
of damaged area.
some minor skin irritation from glass and powdered
cured resin may be evident. Washing in cold water 5. Cut fiberglass cloth to size. Make certain a minimum
of five layers is cut for the average repair.
will help to minimize.
4. Use a belt sander with a vacuum attachment for dust 6. Mix resin and hardener, 1 part hardener to 4 parts
control whenever possible. resin. Add Thixatrope to the mix to give the mix
body and reduce the "runniness" of the material.
5. Resin mixtures may produce toxic fumes and should
be used in well ventilated areas. CAUTION: Cleanliness is most important. Be
CORVETTE BODY I B-26
Fig. 42-Underbody Storage Compartment

1. Cylinder and 4. Retainer 8. Cylinder and 11. Bumper 15. Hinge 10. Door 22. Center Compartment
Case Assembly 5. Screw Case Assembly 12. Striker 16. Hinge 20. Seal 23. Spring NUt
2. Escutcheon 6. Bumper 9. Center Door 13. Rivet 17. Screw 21. Nut 24. Lens AsSembly
3. Door 7. Cover 10. Screw 14. Striker 18. Rivet 25. Shield
67 8
3
22
4
2
4
Fig. 43-Folding Top Lid Assembly
1. Lid Assembly 8. Stop 14. Rod 19. Shim

2. Cable 9. Control Assembly 15. Weatherstrip 20. Body Upper Panel
3. Lock Assembly 10. Spacer
4. Grommet 11. 16. Spacer 21. Screw-Lock Washer Assembly
Plate
5. Shim 12. Clip 17. Plate 22. Spring
6. Clamp 13. Cable 18. Hinge Assembly 23. Top Lock
7. Screw
certain all containers are dry and clean and suitable. A belt sander with a vacuum cleaner at
the resin and hardener cans are kept closed tachment will minimize the dust problem. Feather
when not in use. Do not use waxed cups for edge and finish sand.
mixing and do not allow resin to enter hardener
can or vise versa. NOTE: After Resin Repair, small pits or ir
regularities may appear in finished surface.
7. Saturate layers of fiberglass fig. 60. Place lami Imperfections should be repaired using the
nate over damage area. Smooth out wrinkles and Plastic Solder Repair Kit.
make sure general contour of area is maintained,
Figure 61. SPECIFIC REPAIRS
8. Apply heat to repair area. Heat lamps are recom
mended, used at least 12" away from repair. Allow Scratched Panels, Spot Refinishing
15 to 20 minutes curing time. Trim repair to shape In many instances, a scratched panel will involve only
at gel stage. a paint refinishing job. Figure 62 shows the top of a
9. After the repair is cured, grind, file or sand to fender panel which has been scratched through to the
contour. Files other than body files may be more plastic.
Fig. 44-Marking Hinge Position Fig. 46-lnstalling Tool J-9559 in New Spring
1. Remove all paint down to the plastic from the area CAUTION: Do not sand too deeply into fiber
surrounding the scratch with Lacquer Removing glass mat. Should it be necessary to cut fairly
Solvent. deep into the glass mat use the repair pro
2. Featheredge the repair area with No. 220 wet or cedure suggested for dents and pits in plastic
dry sandpaper and finish block sand with No, 320 panels.
wet or dry paper, Figure 63.
3. Clean up repair area using Prep-Sol or equivalent,
then finish the clean-up with a tack rag.
4. Protect surrounding panels by masking before per
forming paint refinishing operations. Use only non
staining type masking tapes on Corvette plastic body.
Fig. 45-Removing Hinge Spring Fig. 47-Gas Tank Door and Rear Trim
1 ‘4
5
8 10
3
2
5
Fig. 48-Spare Tire Mount
1. Cover 4. Swivel Bolt Nut 7. Swivel Bolt Pin 9. Lock Case

2. Strap Assembly 5. Swivel Lock Bolt 8. Tray 10. Lock Cover
3. Strap Assembly Pivot Bolt 6. Swivel Bolt Bracket
5. Refinish panel as described in paint refinishing

portion of this manual.
Dents or Pits in Panels, Cracks in Glaze Coat

Figure 64 shows a panel which has received a heavy
glancing blow, resulting in an indentation or large pit
in the panel. The following procedure is advised for a
repair of this type of damage. Cracks in the glaze or
finish coat of plastic and paint may also use this
procedure.
NOTE: This repair may be used wherever the
damage is not extensive and the plastic is not
pierced, but the damage area does require a
plastic build-up.
1. Remove paint down to the plastic from area sur
rounding the damage with Lacquer Removing Solvent,
or its equivalent.
2. Scuff area surrounding damaged area to provide a
good bonding surface.
3. Clean up work area with Prep-Sol then use tack
rag for finish clean-up. Fig. 49-Rear Grille and Air Door
Fig. 50-Body Mounts
1. Bolt 4. Cushion Assembly 6. Cushion 8. Screw

2. P. Washer 5. Shim 7. Nut 9. Access Cover
3. Cushion
4. Use the Plastic Solder Repair previously described 4. Remove all cracked and fractured material along
to fill the imperfections. the break. Bevel the attaching edges of the panels
5. Feather-sand damaged area with No. 220 sandpaper at approximately a 30° angle with a file or grinder
and finish sand with No. 320. and scuff plastic surfaces along edges of break.
6. Prepare repair area for paint refinishing operation. NOTE: Mask surrounding panels using a non-
Cracked Panels staining masking tape.
NOTE: For best results, temperature should be 5. Use "C" clamps to align panel portions allowing
at least 70°-75°F. approximately 1/8" between the panels or as neces
sary to provide proper alignment of panels, Figure
1. In the case of a cracked panel, such as shown in 66.
Figure 65, cut along the break line with a hacksaw 6. Cut two pieces of woven glass fiber cloth for backup
blade and remove broken portion of the panel. of sufficient size to overlap the fracture by approxi
2. Remove the paint down to the plastic from both mately two inches.
portions of the panel with a Lacquer ‘Remover or 7. Clean up repair area with Prep-Sol, then use tack
equivalent. rag for finish cleanup.
3. Remove dirt and deadener thoroughly, back ap
8. Use the Resin Repair Procedure previously
proximately 2 to 3 inches from the fracture, on described.
the under side of both portions of the panel. Also,
remove paint and scuff area clean to provide a good NOTE: In some cases it may be advantageous
bonding surface. to provide additional reinforcements along a
Fig. 51-Front Body Constructon
1. Panel-Hood 4. Bonding Strip-Front Fender 6. Reinforcement-Front Fender 8. Bonding Strip-Front Fender

2. Panel-Access Door Upper to Lower 7. Reinforcement-Front Fender Lower Front to Rear
3. Panel-Grille 5. Panel-Front Fender Lower Rear 9. Panel-Radiator Grille Lower
fracture. This may be accomplished by placing Fractured Panels

glass cloth strips in the panel break before
applying the plastic mixture. Sometimes damage will occur to panels where the
13
10
Fig. 52-Center Body Construction
1. Pad-Instrument Panel 6. Pillar-Body Hinge 10. Plenum Side Panel Extension 14. Molding
2. Reinforcement-Instrument Panel 7. Plenum Side Panel 11. Filler Panel 15. Molding-Upper
3. Door Hinge Assembly 8. Dash Extension Panel 12. Panel-Side Door Outer 16. Door Sill
4. Panel-Plenum Side Extension 9. Sill Inboard Extension 13. Pillar Assembly-Door Lock 17. Sill Plate
5. Bonding Strip-Lower Outer Windshield
underside is inaccessible or for reasons of panel con NOTE: Avoid over-rich plastic areas in the
tour it is impractical to use back plies of fiberglass glass cloth, as the strength of the patch is
cloth. The following repair operations are typical of directly proportional to the glass content of
this type of damage. the patch.
1. Prepare the damaged area by grinding or filing all
cracked and splintered material away from the 9. Position plastic impregnated fiberglass over the
fracture. fracture on the exterior of the panel, lap the break
2. Bevel the edge of the fracture at approximately a by 1 to 2 inches, and depress into fracture.
20° angle. 10. Carefully work excess plastic out of woven glass by
3. Remove paint from area surrounding fracture with sponging from the center of the break outward.
Lacquer Solvent, or its equivalent.
4. Scuff surface to provide a good bonding surface. NOTE: Hold woven glass in place until plastic
Then, clean up area with Prep-Sol and wipe dry. resin "gels" with Saranwrap or some similar
5. Protect adjacent panels by masking, use non-staining material.
masking tape.
6. Cut a strip of fiberglass cloth of sufficient size, so 11. Trim excess or loose strands of fiberglass from
the fracture will be lapped from 1 to 2 inches on all patch.
sides. 12. If low spots exist, prepare another plastic mixture
7. Prepare plastic mixture in an unwaxed paper cup. of resin and hardener and mix thoroughly. To this
See Resin Repair Kit procedure. mixture add short fibers cut from glass cloth to
8. Impregnate glass fiber cloth by brushing or dipping give the mixture a putty-like consistency.
in plastic mixture. Squeeze excess mixture from 13. Liberally apply the plastic mixture with a spatula
cloth. to fracture and surrounding area. Deposit enough
Fig. 53-Underbody Construction
1. Panel-Underbody 4. Lid Lock Striker Anchor 7. Panel-Underbody Closing 9. Reinforcement-Body Bolt

2. Support-Console 5. Reinforcement 8. Reinforcement-Folding Top 10. Shield-Rear Quarter
3. Panel-Wheel Housing 6. Support-Body Rear Hinge Support 19467 11. Panel-Body Lock Pillar
Closing-Right Hand
material build-up to allow for filing and sanding thoroughly remove all dirt and paint from the under
operations. side of the old panel or panels for a distance of
14. Allow the patch to harden. approximately 2 to 3 inches back from the attaching
15. File or grind patch to match the general contour of line.
the panel. Exercise care when performing these 2. Remove the paint from the finish side, for a distance
operations to avoid gouging the patch or surrounding of 2 to 3 inches on the panel adjacent to the re
panel. placement panel location with lacquer solvent or
16. Use plastic solder as necessary to fill any equivalent.
imperfections. 3. Scuff the surface on both the replacement panel and
17. Allow fill to harden, then sand finish preparatory adjacent panel for a distance of 2 to 3 inches back
to paint operation. from the attaching line and wipe clean.
4. Bevel all attaching edges at approximately 30° across
the entire thickness of the plastic so a single "V"
Panel Replacement butt joint will be formed on the finish surface when
To install a replacement panel, the following method the pieces are joined. If the replacement panel does
may be used. Various repair panels are available for not fit closely to the break, reshape to suit.
service. See Repair Panels in general instructions at 5. Cut two backup pieces of woven glass fiber cloth
beginning of this section. These complete panels may to run the entire length of, the joint or shorter
be used or sections may be cut to accommodate the lengths of fiber cloth may be lapped over entire
type of repair necessary. The panels should be fitted length of joint, also cut wide enough to lap the
in and all attaching parts installed to insure proper junction line on either side by two or three inches.
alignment. 6. Prepare a sufficient amount of liquid plastic in an
To replace panel, proceed as follows: un-waxed paper cup by mixing resin with hardener
1. Cut out damaged panel with a hacksaw blade and See Resin Repair procedure.
CORVETTE BODY 1B-34
Fig. 54-Rear Body Construction
1. Panel-Body Rear Upper 6. Extension-Body Rear 11. Panel-Body Rear 15. Support-Body Rear
2. Bezel-Fuel Tank Upper Panel Upper Upper Panel
Filler Door 7. Support-Body Rear Upper Panel 12. Bonding Strip-Body 16. Bonding Strip-Body
3. Reinforcement Roof- 8. Lid-Folding Top Comportment Rear Upper Panel Rear Upper
Right Hand 9. Panel-Rear Quarter- 13. Panel-Rear Quarter- 17. Body Rear Lower Panel
4. Panel-Rear Roof Inner Right Hand Left Hand 18. Support-Body Rear
Center-Left Hand 10. Bonding Strip-Body Rear 14. Bonding Strip-Body Lower Upper Panel
5. Panel-Rear Roof Inner Upper Panel to Quarter Panel to Quarter 19. Shield-Rear Quarter Splash
Rear-Left Hand Panel-Right Hand Panel-Left Hand 20. Panel-Rear Filler
7. Align replacement panel, then clamp panel in place panels in alignment or use straps and sheet metal
to form a closed "V" butt joint at the panel junction. screws.
When panel cannot be clamped, use 3/16" bolts with 8. Impregnate backup plies of woven glass cloth with
large washer on inner and outer of panel to hold prepared plastic mixture by dipping or brushing.
rn
Fig. 57-Applying Plastic Solder
10. Prepare another plastic mixture of resin and

hardener and mix thoroughly. To this mixture add
cut glass fiber 1/2" lengths until mixture has a
putty-like consistency, or utilize glass cloth.
11. Fill "V" groove with reinforced plastic material
or saturated glass cloth. Build up surrounding area
with sufficient mate r i a 1 to allow for finish
Fig. 55-Typical Body Bonds operations.
12. Allow patch to harden.
13. File or sand #80-D sandpaper to general panel
Remove excess plastic from cloth by squeezing. contour.
9. Place impregnated backup plies on underside of
14. Allow plastic fill to harden, then sand, preparatory
panels. If necessary, hold backup plies in place with
to paint operations.
paper until plastic "gels."
HARD TOP
CARE AND STORAGE
The outside painted finish of the hard top should be
Fig. 56-Mixing Plastic Solder Material Fig. 58-Finishing Plastic Solder Repair
Fig. 62-Typical Scratched Panel
Fig. 60-Applying Resin Mixture to Fiberglass
cleaned in the same manner as the rest of the body. The

inside headlining should be cleaned as outlined under
Cleaning Soft Trim.
When hard top is not in use, it should be stored indoors
where it can be kept clean and dry. If stored for a long
period of time, keep covered to prevent dirt settling on Fig. 63-Repair Area Finish Sanded
headlining and outside surface.
REAR WINDOW
Refer to Figures 67 and 68 for parts identification.
Fig. 61-Applying Laminate to Body Fig. 64-Typical Pitted Panel
CNEVROLET CHASSIS SERVICE MANUAL
Fig. 66-Cracked Panel Preparation

and lock mechanisms. With headlining removed as out
Fig. 65-Typical Cracked Panel lined in this section, to adjust left and right hand locks
fore and aft, mark original position, loosen two 2
Removal mounting bolts, and move in desired direction. Make
1. Remove hard top from vehicle and place protective certain that lock is engaged in serrations before tighten
covering over headlining. ing mounting screws.
2. Mark position of right-hand upper reveal molding Up-and-down adjustment is performed by turning hexa
end fig. 69 and pry out from retaining clips. Re gonal latch bolts clockwise and counter-clockwise re
peat for left-hand and lower molding assemblies. spectively. Header guide pins and rear pin housings are
3. Remove lower inside garnish molding by removing retained by mounting screws located at flanges. Center
four 4 nuts from fixed studs and carefully pulling trim plate is removed by first removing center lock,
molding outward. and then four 4 retaining screws.
4. Follow Steps 8 through 13 as outlined in the section
entitled FRONT END--WINDSHIELD for removal of HEADLININGS
glass.
The headlining assembly is secured to the top by
Installation plastic fasteners located around the periphery of the
1. Position replacement glass in opening and carefully hard top inner panel as shown in Figure 68. The head
check relationship of glass to flange completely lining is removed by carefully disengaging fasteners by
around opening. Overlap of glass should be equal prying outward with fingers on flat-bladed instrument.
with a minimum overlap of 3/16 inches. After removal from plastic top, the headlining can be
2. Where necessary, place shims under lower spaces disassembled into three parts ‘by removing retaining nuts
to obtain required overlap of glass to upper and at inside surface of headlining. For installation, make
lower flanges. certain to align headlining to top before engaging plastic
3. After proper alignment is attained, mark position on fasteners.
glass and top surface with grease pencil.
4. Follow Steps 16-22 in the section entitled FRONT WEATHERSTRIP AND DRIP MOLDING
END--WINDSHIELD for installation of glass.
As shown in Figure 67, door window weatherstrip and
5. Press glass lightly to set caulking to window opening
drip molding are retained by screws to top assembly.
flanges. Paddle material where necessary to ensure
Side outer and rear outer weatherstrip are mounted to
proper seal.
6. Water test immediately using a cold water spray. body at ends by screw and around periphery by special
If water leaks are encountered, use flat bladed screw plastic retaining clips. Weatherstrip is replaced by re
driver or splint, and from the inside, paddle caulking moving two 2 screws and carefully pulling outward at
material into point of leakage. clip location.
Inner forward weatherstrip is replaced by removing
CAUTION: DO NOT RUN A HEAVY STREAM mounting screws and disengaging special clips along
OF WATER DIRECTLY ON CAULKING MA length of weatherstrip.
TERIAL WHILE THE MATERIAL IS STiLL VINYL COVERING
SOFT.
Removal
7. Install previously removed moldings in reverse
1. Remove weatherstrip assemblies.
order of removal.
2. Remove reveal moldings.
3. Prior to removing fabric cover, application of heat
TOP ATTACHMENTS to cemented areas will permit easier loosening of
Figure 68 illustrates location and installation of guides cemented edges.
c.
Fig. 67-Molding and Weatherstrip
CAUTION: Apply heat by lamps held 18" mini- heated over 200°F, the fabric may loose its
mum from fabric only until fabric is warm. If grain, blister, or become very shiny.
lamps are held too close, or fabric cover is 4. Loosen cemented edges of fabric roof cover.
wE
AB
wf
Fig. 68-lop Attachments and Headlining
CORVETTE BODY I B-40
Installation
1. Wipe roof panel with a Xylol solvent such as 3M
Adhesive cleaner or equivalent. Remove or smooth
out excess old cement. Apply solvent and allow to
soak before rubbing.
2. Where possible, install new cover at room tempera
ture approximately 72° to permit easier fitting and
removing of wrinkles from the cover assembly.
3. Determine center line of roof panel by marking
center points on front of hard top and back window
opening. Fold cover lengthwise. Lay cover on roof
panel. Determine overhang approximately 1".
4. Apply mtrile non-staining vinyl trim adhesive such
as 3M Vinyl Trim Adhesive to the roof panel ad
jacent to center line of fabric roof cover.
5. Application of nitrile vinyl trim cement should be as
thin as possible. An excessive amount of cement may
result in trapped solvents blisters between fabric
cover and roof panel. A mohair roller should be
used for thin adhesive application.
NOTE: If nitrile non-staining cement is not
Fig. 69-Marking Molding Position available, neoprene type non-staining weather-
ji
Fig. 70-Folding Top Adjustments
CORVETTE BODY 1B-41
strip cement 3M weatherstrip cement or of the top material, do not keep the top folded for ex
equivalent may be used. tended periods of time if it is damp or water soaked.
Permit top to dry out in a raised position before stowing.
6. Apply cement to entire fabric roof cover.
Also avoid pasting advertising stickers, gummed labels
NOTE: Allow approximately 15 minutes for or masking tape on the plastic back window. In addition
cement to dry. to being difficult to remove, the adhesive on these
stickers may also be injurious to the plastic composition
7. Fold vinyl cover back to contact adhesive on roof
of the window.
panel. Vinyl cover seam must be parallel to center
line of vehicle.
8. Repeat above steps for opposite side of roof.
Care of Rear Window
9. Use suitable spatula or roller to remove wrinkles The large plastic rear window in the folding top will
and/or bubbles from vinyl cover. remain in good condition for the life of the top if given
10. Trim excess vinyl around entire top to provide a proper care. Due to the texture of the plastic window,
minimum of 1/2" flange which will be cemented to it is susceptible to scratches and abrasions; therefore,
substructure of removable hardtop with adhesive. when cleaning the window, follow the steps outlined below.
11. Reinstall reveal moldings and weatherstrips. 1. To remove superficial dust, do not use a dry cloth.
Use a soft cotton cloth moistened with water and
Vinyl Roof Cover Repairs wipe cross-wise of the window.
Certain types of fabric roof cover discrepancies can 2. To wash’ the rear window, use cold or tepid not hot
successfully be repaired without replacing or removing water and a mild neutral soap suds. After washing,
the cover. rinse with clear water and wipe with a slightly
moistened clean soft cloth. A high quality plastic
Scuffs or Small Cuts Near Exterior Moldings window cleaner is available from Chevrolet parts
If a small cut is present, an attempt should be made to sources.
cement the loose ends prior to performing the following:
1. Obtain a scrap piece of fabric roof cover material, CAUTION: Never use solvents such as alcohol
or material from a hidden area directly on complaint or volatile cleaning agents on the plastic window.
These liquids may have a deteriorating effect on
car such as under reveal moldings.
the plastic and if spilled, may spot the painted
2. Using an electric wood burning needle or low heat
finish on the rear body panels directly below
soldering gun, scrape off an appropriate amount of
vinyl from scrap piece of material or from hidden the rear window.
area and immediately apply to scuffed or cut area 3. When removing frost, snow or ice from the plastic
on car. window, DO NOT USE A SCRAPER. In an emer
CAUTION: Be certain’ low heat is maintained to gency, warm water may be used. Use care that the
prevent discoloration of cover. warm water does not contact the glass windows or
windshield.
3. Carefully blend applied vinyl to fabric roof cover,
utilizing electric needle or soldering gun. ADJUSTMENTS
Wrinkles, Blisters and Bubbles To correct variations in the top fit, adjustments are
1. Pierce each wrinkle, blister and bubble on fabric made at three locations shown in Figure 70. A combina
roof cover with a small needle. tion of adjustments may be necessary to correct any
2. Completely saturate a clean shop towel with water given problem, including door and window adjustments
and wring out. which are covered elsewhere in this section.
3. Apply cloth to wrinkle or blistered area.
The folding top adjustments are:
4. Apply a home type laundry iron over shop towel using
back and forth strokes until towel is dry. If iron Header
has heat control settings, control should be set to
After removing header trim panel, header assembly
"wool’’.
may be moved fore and aft when the two clamping screws
CAUTION: Do not continue to use iron after are loosened. This will correct such conditions as header
towel has become dry as excess heat may cause latch guide pin alignment with the holes in the windshield
permanent damage to vinyl roof cover. upper frame. Indications of misalignment are loose top
trim when top is up and locked, and excessive effort
5. Remove towel and inspect area. If slight wrinkles or
required to engage header locks. Note that it will be
blisters are still present, perform the following
necessary to remove side roof rail weatherstrip to gain
steps:
access to header outer clamping screw. Refer to Weath
6. Using a syringe and hypodermic needle filled with
erstrip portion of this section.
clear water, inject sufficient water into wrinkle or
bubble to dampen fabric backing. Hinge
7. Repeat Steps 2 through 4.
The hinges may be moved up and down and fore and aft
to the limit of the slotted holes in hinge plate and body.
FOLDING TOP To gain access to hinge, remove rigid plastic trim as
explained in Interior Trim portion of this section. Re
CARE OF THE FOLDING TOP positioning hinge will correct conditions such as poor top
To avoid water stains, mildew, or possible shrinkage fit at upper and rear edge of windows; faulty fore and aft
engagements of rear bow hold-down pins in lock assem thoroughly adjusted as outlined in this section. As loose
blies and loose or over-tight top rear panel when top is parts are removed such as stay straps and pads, their
raised and properly locked in position. installed positions should be marked as an aid to in
stallation of replacements.
Rear Bow Hold-Down Locks Removal
Fore and aft adjustment is provided by slotted holes 1. Remove rear side rail window sealing weatherstrip
in lock housing. Turning of locating pins adjusts force as explained further on in this section; also remove
that holds seal to folding top lid. The hold-down pins may screws from ends of header inner weatherstrip.
be moved to left or right to center top on body in raised Note, however, that it is not necessary to remove
position; thus correcting poor alignment at windows and header weatherstrip entirely and that header strip
difficult entry of pins in locks. must be in place during final installation procedures
of top trim so that correct tension of installed trim
TOP ASSEMBLY REMOVAL AND INSTALLATION is achieved.
2. Remove tacks securing top and header outer
The entire top assembly frame with trim attached weatherstrip to header fig. 72.
may be removed from vehicle as follows:
3. Pull cemented trim from rear side rail Section
1. Raise top, but do not engage header or rear bow
C-C.
locks.
4. Remove end caps from wire-on binding; remove
2. Remove rigid plastic trim as outlined in Interior
tacks securing binding to #3 bow View F.. See
Trim portion of this section.
frame and linkage portion for bow identification.
3. Mark installed position of hinge by scribing outline
5. Remove staples securing trim to #3 bow.
of hinge plate on lock pillar surface.
4. Remove two screws retaining each hinge to lock 6. Remove tacks securing upper ends of stay straps to
#3 bow. Pads may be removed at this time, if de
pillar and remove top assembly from vehicle.
sired. Mark position of pads and straps on head and
5. When installing top assembly, carefully match hinge
#3 bow before removal.
plate with scribed marks on body lock pillar and
7. Disconnect rear bow from top frame assembly. Two
install screws. If necessary, proceed as outlined
screws retain at each side Figure 73.
under Top Adjustments.
8. Remove trim-rear bow assembly from vehicle to
TOP TRIM AND REAR WINDOW ASSEMBLY clean work bench or table.
9. Remove plastic filler from rear bow weatherstrip
The following information deals with removal and and pull weatherstrip and trim from rear bow.
installation of the folding top trim and window assembly Section A-A shows installed position of these com
complete. Figure 71 may be referred to for parts identi ponents. Refer also to Figure 74.
fications. Lettered sections i.e. Section A-A referred
to in the instructions may also be found in Figure 71. Installation
Note that the sections are illustrated as they would ap 1. Find and mark center of header, #3 bow, rear bow
pear if the parts were cut through on the lettered lines and leading and trailing edges of top trim. Align
on the top assembly and the cut surface exposed. Arrows these marks during installation and recheck their
indicate direction in which you would have to look in alignment from time to time while installation is in
order to see the view shown. progress, especially during tacking or stapling.
Before old trim assembly is removed, top should be 2. Assemble top trim and weatherstrip to rear bow,
MATERIAL FOR ATTACHMENT

FRONT HEADER PANEL
WIRE-ON
PAD BINDING TOP TRIM
WINDOW
SECTION
CEMENT SECURELY TO}C

REAR RAIL ONLY
Fig. 71-Folding Top Trim Installation
WEATHERSTRIP
TACKING STRIP TRIM
HEADER PANEL
A
VIEW A
Fig. 72-Trim at Header

referring to Section A-A and Figure 74. Note that 7. Draw window extension up to #3 bow, aligning cen
filler strip locks this assembly together and goes tering marks. Turn an ample amount of fabric under
in last. Align center marks. and tack to #3 bow. Apply neoprene trim cement,
3. 1.1 new pads are required, install at this time, align GM Part #3695016 or equivalent, to area shown in
ing with marks made when old pads were removed. View D of Figure 71. Follow directions on package.
Figure 75 shows pad construction; Figure 76 shows 8. Draw roof portion of trim over #3 bow, align marks
pad installed. and tack on staple.
4. Install top trim-rear bow assembly on top frame 9. Trim off excess material and install wire-on binding
with four screws removed at disassembly.
5. Lock down rear bow in desired "top up" position.
Pull up stay straps and staple or tack to #3 bow
fig. 77.
6. Pull leading edge of trim up to header and align
center marks. Smooth out fabric and clamp, tack
or staple temporarily to header.
Fig. 73-Rear Bow Retaining Screws Fig. 74-Installing Trim and Weatherstrip to Rear Bow
Fig. 75-Pad Construction
as shown in Figure 78 and View D of Figure 71.

Install binding caps.
10. Remove temporary clamps or fastenings holding
trim to header.
11. With header locked down, pull trim assembly up tight
and mark for final installation.
12. Apply trim cement to header and rear side rail.
13. Release header from windshield. Tack or staple trim
to header fig. 72.
14. Apply trim to rear side frame, previously cemented.
15. Install weatherstrips which were removed at dis
assembly and install retaining screws in headet
weatherstrip.
16. Install header trim panel.
Fig. 76-Pad Installed 17. Make any adjustments necessary, following instruc
tions listed under Folding Top-Adjustments.
FRAME AND LINKAGE

Figure 79 illustrates construction features of the
folding top frame and linkage. Various cross sections in
Figure 79 show the pivoting joints and their assembly.
If an operation is being performed which requires
removal of folding top trim, follow directions in this
section. The entire frame assembly may be removed and
replaced as a unit. Follow instructions for Folding Top
Trim and Rear Window Assembly and Top Assembly-
Removal and Installation.
The pivoting joints should be lubricated with light
machine oil once a year. Apply oil sparingly so as not
to stain top trim.
WEATHERSTRIP
Side Rail Weatherstrip
Figure 80 illustrates installation of side rail weather
strip which acts to seal window opening. The weather
strip is held in place by loose screws which are part of
the weatherstrip assembly, and by neoprene base cement
which is applied between weatherstrip and side rail
surface.
When replacing weatherstrip remove all rust, old
Fig. 77-Installing Stay Strap cement and foreign material from the surfaces to be
Fig. 78-Installing Binding
2 BOW
BOW
SECTION C-C
REAR BOW
SECTION B-B 9J
SECTION D-D
SECTION A-A
Fig. 79-Top Frame and Linkage
cemented, to assure successful bonding. Use only good Header Weatherstrip

quality neoprene cc m e nt suitable for weatherstrip Weatherstrip assembly is retained to the header panel
application. by a combination of studs, sheet metal screws and special
3 BOW
REAR
BOW
Fig. 81-Header Weatherstrip
first align two 2 locating pins, and then secure plastic

fasteners.
The rear quarter trim panel is replaced by removing
CEMENT four 4 screws located at both ends and adjacent to rear
roof headlining.
The rear roof trim panel is replaced by first removing
the rear window lock assemblies, and then removing
Fig. 80-Side Rail Weatherstrip two 2 screws and the four 4 remaining screws along
roof.
fasteners as shown in Figure 81 along with neoprene
base weatherstrip cement. STORAGE TRAY
The storage tray which provides a means of storing
SPORT COUPE MODEL 19437 rear window assembly when removed from vehicle, is
replaced by removing hinge screws at rear body panel
ROOF PANELS or from hinge strap to tray. The latch is adjusted by
Adjustment bending for proper engagement.
The two inner lances which are received at the center REAR WINDOW
strut, incorporate a floating mount design and are ad
justed fore and aft, and in and out, by loosening two 2 Glass Replacement
hex screws. Up and down adjustment is achieved by To replace rear window glass, the following procedure
adding or removing shims. The front outboard locating is recommended.
pins are adjusted in the same manner with the exception 1. Remove rear window assembly from vehicle and
of shims. place on bench.
For adjustment of contour alignment at outer rear 2. Using small rod or nail less than 1/16" dia., care
corner, loosen floating notched receiver and adjust until fully drive dowel pins out at both corners of frame
desired alignment is attained. assembly.
To adjust for proper spacing, the triangular attachment 3. Remove lower frame member from old glass and
bolt at upper rear pillar is turned for fore and aft ad frame assembly.
justment. Also, the front and rear holding locks are 4. Remove glass from upper frame member and clean
adjusted fore and aft to the extent of slotted mounting out sealer by carefully scraping from groove around
holes. entire perimeter of frame.
5. Apply bead of caulking material polysulfide or
Headlining equivalent around slot of both frame components.
The headlining panel is replaced by removing two 2 6. Insert replacement glass into curved frame member.
7. Assemble frame by aligning lower member with
screws per side, and separating plastic fasteners lo
glass and installing dowel pins.
cated around perimeter of panel.
8. Clean excess caulking material from surface of
Weatherstrip glass.
The weatherstrip is replaced by removing screws at Adjustment

both ends and prying out plastic clips along length of The locks and lower receiving plates which determine
weatherstrip. The front drip molding is pressed on the holding force are adjusted to the extent of slotted
and must therefore be carefully pulled outward for mounting holes to attain an even, adequate seal.
replacement.
Weatherstrip
INTERIOR TRIM The weatherstrip between the rear window assembly
The rear window trim panel is removed by carefully and rear body opening is replaced by cementing to rear
pulling outward at plastic fasteners. For installation, inner body surface around opening.
SPECIAL TOOLS
1
2
Fig. 82-Special Tools
1. J-9559 Hood Spring Tool 2. J-7797 Door Handle Clip Remover
SECTION 2
FRAME
INDEX
Page Page
General Description 2-1 Car Preparation 2-1

Chevrolet 21 Tramming Sequence 2-1
Chevelle 2-1 Reference Point Dimensions 2-1
Repair Procedures 2-1
Checking Frame Alignment 2-1
GENERAL DESCRIPTION
CHEVROLET AND CHEVELLE vide a sturdy foundation for the engine mounts and clear
ance for front wheel movement. From the kick-up
Frames used on Chevrolet and Chevelle lines are basi rearward, box-sectioned side rails provide fore and aft
cally the same, consisting of full length right and left support for the rear axle and suspension. Lateral sup
side members joined laterally by crossmembers. Sev port is provided by five variously shaped welded-in
eral different frames are used in each line to meet the
crossmembers, including the front unit, which formerly
various vehicle size and function requirements but the
was bolted-in.
basic shape for each line remains the same. Differences
between frames in a given line exist only in metal gauge,
part size and numbers of parts necessary to meet CHEVY II AND CAMARO
the particular structural requirements of the models Frames used on Chevy II and Camaro lines are identi
involved. cal consisting of half frame and half unibody construction.
The frame consists of short side members extending
CORVETTE from behind the front doors to the front of the vehicle
The Corvette frame is a rigid perimeter unit, with five joined laterally by crossmembers. This is to provide
crossmembers. From the rear kick-up forward, trap support for the steering mechanism, front suspension,
azoidal shaped, closed side members outline and protect engine and transmission. The rear section has the frame
the passenger compartment. At the cowl area, the side as an integral part of the body and will be covered in the
members curve inward in a sweeping "S" shape, to pro- Body Service Manual.
REPAIR PROCEDURES
CHECKING FRAME ALIGNMENT it means that corrections will have to be made.
If a tram gauge is not available, the "plumb bob"
Vehicles involved in an accident of any nature which method of checking may be used. To assure any degree
might result in a "swayed" or "sprung" frame should of accuracy when using this method, the vehicle should
always be checked for proper frame alignment in addi be on a level floor.
tion to steering geometry and wheel alignment. By using this method, it is only necessary to have a
piece of cord attached to an ordinary surveyor’s plumb
CAR PREPARATION bob. When measuring the distance between two points,
Preparing the car for the frame alignment check in the free end of the cord should be placed on the reference
volves the following: point allowing the plumb bob to hang on the floor. A check
1. Place the car on level surface. mark should be made on the floor just under the tip of
2. The weight of the car should be supported at the the plumb bob. This operation should be repeated at all
wheel locations. reference points. With these points located on the floor,
3. A visual damage inspection should be made to elim they may easily be measured with a rule.
inate needless measuring. Obviously damaged or The second step is checking the vertical dimensions
misaligned areas can often be located by sight. from the datum plane to the points to be trammed. With
the proper settings the tram bar will be on a plane
TRAMMING SEQUENCE parallel to that of the frame. The exception to this would
be when one of the reference locations is included in the
When checking a frame for alignment in case of dam
age, the first step is horizontal "X" checking with a misaligned area; then the parallel plane between the
frame and the tram bar may not prevail. After com
tram from similar given points on opposite side of the
pletion of the repairs, the tram gauge should be set at
frame.
the specified dimension to check the accuracy of the re
Frame alignment checks on all models should be made
pair operation.
with the tram points set at the center of each locating
point indicated and the cross bar level to insure
accuracy.
ALIGNMENT REFERENCE POINT DIMENSIONS
When "X" checking any section of the frame, the Dimensions to holes are measured to dead center of
measurements should agree within 3/16". If they do not, the holes and flush to the adjacent surface metal.
ALL DIMENSIONS TO HOLES ARE MEASURED TO THE CENTER OF THE HO1.ES
INDICATES THAT THE DIMENSION IS TO THE UNDERSIDE OF EITHER
THE FRAME TOP SURFACE OR BODY MOUNT. I
I
I
I Fig. 1-Frame Dimensions-Chevrolet
A
R.H. SIDE
I
TO BE WITHIN R.H. SIDE TO BE
0 1/8 OF L.H. WITHIN 3/16 OF L.H.
A
I
in
Fig. 2-Frame Dimensions-Chevelle
c
CENTER LINE
DETERMINED BY CENTER OF
HOLE CY AND EQUIDISTANCE
FROM HOLE CX AND CW.
1
A
I
A
I
Fig. 3-Frame Dimensons-Corvette
ALL DIMENSIONS TO HOLE ARE MEASURED TO CENTER OF HOLE
0 INDICATES THAT THE DIMENSION IS TO THE UNDERSIDE OF THE
FRAME TOP SURFACE OR BODY MOUNT
A
I
A
I
-‘I
z
Fig. 4-Frame Dimensions-Camaro and Chevy II
FRAME 2-6
BODY MOUNTS are shown in Figures 5 and 6. Torque specifications are

The various type of body mounts and their application listed in the following chart.
Model Mount Torque

Radiator Support to Frame 30 ft. lbs.
Chevrolet Body Strut 3 bolts 25 ft. lbs.
#1 thru #7 35 ft. lbs.
Radiator Support to Frame 35 ft. lbs.
Chevelle
#1 thru #7 40 ft. lbs.
Camaro #1 35 ft. lbs.
Chevy #2 and #3 80 ft. lbs.
Corvette All 45 ft. lbs.
Fig. 5-Body Mount Application-Corvette
CWEVOLET CHASSIS SERVICE MANUAL
PRAMR 2-7
CHEVROLET WAGONS & CONV. ALL MODELS
4 DR. HARDTOPS,
CONV. & WAGONS
RADIATOR
TO FRAME I
HARDTOPS,
CONy. ONLY WAGONS
4 DR. HARDTOPS, & CONy.
SEDANS
CONy. & STATION
AU. MODELS WAGONS
CAMARO
&
CHEVY U
RADIATOR SUPPORT
TO FRAME CUSHION
CHEVELLE
RADIATOR
TO FRAME
Fig. 6-Body Mount Application
SECTION 3
FRONT SUSPENSION
INDEX
Page Page
General Description 3-1 Chevrolet, Chevelle, Camaro, Chevy II and Corvette. . 3-12
Maintenance and Adjustments 3-2 Inspection 3-13
Front Wheel Bearing Adjustment 3-2 Chevrolet and Corvette 3-13
Front End Alignment 3-3 Removal 3-13
Alignment Preliminary Steps 3-3 Installation 3-13
Caster and Camber Adjustments 3-4 Chevelle, Camaro and Chevy II 3-13
Chevelle, Camaro, Chevy II and Corvette . 3-4 Removal 3-13
Chevrolet 3-5 Installation 3-14
Steering Axis Inclination 3-5 Lube Fittings 3-14
Toe-In Adjustment 3-5 Lower Control Arm 3-14
Riding Height and Coil Spring Sag 3-6 Chevrolet 3-14
Repair Procedures 3-7 Removal 3-14
Front Brake Drum Chevrolet, Camaro, Chevelle, Installation 3-14
Chevy II 3-7 Chevelle, Camaro and Chevy II 3-15
Removal 3-7 Removal 3-15
Installation 3-7 Installation 3-15
Front Wheel Hub 3-7 Corvette 3-15
Replacement 3-7 Removal 3-15
Replacement of Hub Wheel Bolts 3-7 Installation 3-15
Front Wheel Bearings 3-8 Lower Control Arm Bushings 3-15
Removal 3-8 Chevrolet 3-15
Inspection 3-8 Removal 3-15
Repairs 3-8 Installation 3-15
Replacement of Bearing Cups 3-8 Chevelle, Camaro and Chevy II 3-15
Installation 3-8 Removal and Installation Large Bushing 3-16
Steering Knuckle 3-8 Removal and Installation Small Bushing 3-16
Removal 3-8 Cross Shaft and/or Bushings 3-16
Installation 3-9 Corvette 3-16
Shock Absorber 3-9 Removal 3-16
Chevrolet, Chevelle, Camaro, Chevy II and Installation 3-17
Corvette 3-9 Upper Control Arm Spherical Joint 3-17
Removal 3-9 Chevrolet, Chevelle, Camaro, Chevy II and
Stabilizer Bar 3-9 Inspection 3-17
Removal 3-9 Replacement 3-17
Installation 3-9 Lube Fittings 3-17
Strut Rod 3-10 Upper Control Arm 3-18
Chevrolet 3-10 Chevrolet, Chevelle, Camaro, Chevy II and
Removal 3-10 Corvette 3-18
Installation 3-10 Removal 3-18
Front Coil Springs 3-10 Installation 3-18
Chevrolet 3-10 Upper Control Arm Cross Shaft
Removal 3-10 and/or Bushings 3-18
Installation 3-11 Chevrolet, Camaro, Chevelle and Chevy 3-18
Chevelle, Camaro and Chevy II 3-11 Removal 3-18
Removal 3-11 Installation 3-19
Corvette 3-12 Removal 3-19
Installation 3-12 Special Tools 3-20
Lower Control Arm Spherical Joint 3-12 Specifications At rear of Book
GENERAL DESCRIPTION
The 1968 Chevrolet, Chevelle, Camaro, Chevy II and arm inner support shaft shims.
Corvette front suspensions are basically similar, being Caster angle is adjusted on the Chevrolet by means of
of the S.L.A. short-long arm type with independent coil a strut rod which runs from the lower control arm for
springs. The springs ride on the lower control arms. ward to the frame brace; on the Chevelle, Camaro, Chevy
Spherical joints connect the upper and lower control II and Corvette by means of upper control arm inner
arms to the steering knuckle. Tapered roller wheel support shaft shims.
bearings are used. A stabilizer bar is used on all Chevelle, Camaro and
Camber angle is adjusted on the Chevrolet by means of Corvette models. Chevrolet Impalas, Station Wagons and
a lower control arm inner pivot cam; on the Chevelle, all Chevrolet and Chevy II models equipped with V-8
Camaro, Chevy II and Corvette by means of upper control engines are fitted with stabilizer bars.
FRONT SUSPENSION 3-2
Fig. 1-Front SUSpenSion-Chevrolet

Maintenance intervals recommended for lubrication of dures will apply to all five vehicles covered in
front suspension components have been fully covered in this manual.
Section 0 of this manual. Only actual adjustment pro
cedures will be covered here. FRONT WHEEL BEARING ADJUSTMENT
NOTE: Unless otherwise inthcated all proce Proper front wheel bearing adjustment has a definite
Fig. 2-Front SUspenSon-Chevelle
Fig. 3--Front Suspension-Camaro and Chevy II
bearing on the operation of a vehicle. Improperly ad FRONT END ALIGNMENT

justed front wheel bearings will result in a lack of steer
Front end alignment, that is alignment of the inter
ing stability causing wheel wander, shimmy and excessive
related steering components of the front suspension sys
tire wear. Very accurate adjustment is possible because
tem, must be correctly maintained to assure ease and
the spindles are drilled both vertically and horizontally
and the adjusting nuts are slotted in all six sides. stability of steering and satisfactory tire life.
NOTE: Wheel bearings should not be repacked Alignment Preliminary Steps

or adjusted as a part of "New Car Conditioning". Several different types of machines are available for
1. With wheel raised, remove hub cap and dust cap and checking all the factors of front end alignment. The in
then remove the cotter pin from the end of the structions furnished with each particular machine should
spindle. be followed. In all cases, however, checks should be
2. While rotating wheel, tighten spindle nut to 12 lbs. ft. made with the vehicle level and at curb weight.
torque. Since steering complaints are not always the result of
3. Back off adjusting nut one flat and insert cotter pin. improper alignment a check should be made to see if any
If slot and pin hole do not line up, back off the adjust of the following conditions exist. Any such conditions
ing nut an additional 1/2 flat or less as required to should be corrected before proceeding further.
insert cotter pin. 1. Steering gear loose or improperly adjusted.
4. Spin the wheel to check that it rolls freely and then 2. Steering gear housing loose at frame.
lock the cotter pin by spreading the end and bending 3. Excessive wear or play in spherical joints or steer
it around. ing shaft coupling.
4. Tie rod or steering connections loose.
5. Improper front spring heights.
NOTE: Bearings should have zero preload and
6. Unbalanced or underinflated tires.
.001" to .008" end movement when properly 7. Improperly adjusted wheel bearings.
adjusted. 8. Shock absorbers not operating properly.
5. Install dust cap, hub cap or wheel disc and lower Wheel alignment should always be made with the ve
wheel. hicle rolled forward taking out any slack in the same
6. Perform the same operation on each front wheel. manner as when the vehicle is traveling forward.
Fig. 4-Front Suspension-Corvette
Caster and Camber Adjustment quickly released to allow car to return to its
normal height.
NOTE: Before adjusting caster and camber Chevelle, Camaro, Chevy II and Corvette
angles, the front bumper should be raised and Caster and camber adjustments are made by means of
STEERING AXIS VERTICAL

CASTER ANGLE
CASTER CAMBER
Fig. 5-Caster and Camber
shims inserted between the upper control arm inner sup

port shaft and the support bracket attached to the frame
fig. 6. Shims may be added, subtracted or transferred
to change the readings as follows:
1. Caster - transfer shims, from front to rear or rear
to front.
The transfer of one shim to the front bolt from the
rear bolt will decrease positive caster. One shim
1/32" transferred from the rear attaching bolt to
the front attaching bolt will change caster approx.
1/2°.
2. Camber - change shims at both the front and rear of
the shaft.
Adding an equal number of shims at both front and
rear of the support shaft will decrease positive cam
ber. One shim 1/32" at each location will move
camber approx. 1/5° Chevelle, Camaro and Chevy
II; 1/6° Corvette.
To adjust for caster and camber, loosen the upper sup
port shaft to crossmember nuts, add or subtract shims as
required and retighten nuts.
NOTE: Caster and camber can be adjusted
in one operation.
Caster and camber specifications will be found in the
specifications section of this book.
Chevrolet
The caster angle is adjusted by turning the two nuts at Fig. 6-Caster and Camber Adjustment Typical- Chevelle,
the front of the lower control arm strut rod fig. 7. Camaro, Chevy II and Corvette
Shortening this rod will increase caster. Lengthening
will decrease caster. If a new knuckle is installed, caster, camber and toe-in
Camber angle is adjusted by loosening the lower con must be readjusted.
trol arm pivot bolt and rotating the cam located on this
pivot fig. 7. This eccentric cam action will move lower Toe-In Adjustment
control arm in or out, thereby varying camber. Toe-in, the inward pointing of both front wheels, is
Steering Axis Inclination Adjustment checked with the wheels in the straight ahead position. It
is the difference of the distance measured between the
"Camber" is the outward tilt of the wheel and "steer extreme front and the distance measured between the ex
ing axis inclination" is the inward tilt of the knuckle. treme rear of both front wheels. Correct toe-in specifi
Camber cannot be changed without changing steering axis cations will be found in the specifications section.
inclination. Correct specifications will be found at the
end of this section. If, with the camber correctly ad NOTE: Toe-in must be adjusted after caster
justed, the steering axis inclination does not fall within and camber adjustment.
the specified limits the knuckle is bent and should be A. If the equipment being used measures the toe-in of
replaced. each wheel individually:
TURN TO ADJUST
CAMBER
Fig. 7-Caster and Camber Adjustment Points-Chevrolet
CNVROLET ChASSIS SERVICE MANUAL
Fig. 8-Checking Riding Height
1. Set the steering gear on the high point, mark 12 b. Chevelle--Position the tie rod clamp bosses
o’clock position on the steering shaft and position down to 450 forward to avoid interference.
the steering wheel for straight ahead driving. c. Chevy II and Camaro--Position inner tie rod
2. Loosen the clamp bolt at each end of each tie rod clamps with open end of clamp and slot in line.
and adjust to the total toe-in as given in the speci Position relative to ground unimportant. P0-
fications at the end of this book. sition clamps with bolt top and 30° either
B. If a tram gauge is being used, proceed as follows: side of vertical. Position relative to slot
1. Set the front wheels in the straight ahead position. unimportant.
2. Loosen the clamp bolts on one tie rod and adjust d. Corvette--Position inner tie rod clamps with
for the proper toe-in as given in the specifications bolt horizontal and down. Position outer clamps
at the end of this book. with bolt vertical and to the rear.
3. Loosen the clamp bolts on the other tie rod. Turn
both rods the same amount and in the same direc RIDING HEIGHT AND COIL SPRING SAG
tion to place the steering gear on its high point and
position the steering wheel in its straight ahead The following check will quickly determine whether or
position. not the vehicle riding height is correct.
C. After the adjustment has been made: 1. Place the vehicle on a smooth, level floor and bounce
1. a. Chevrolet--Position inner tie rod clamp bosses and rock the front end several times. Raise vehicle,
forward to 900 down to avoid stabilizer link bolt then allow it to settle to a normal height.
interference. 2. Measure the following two distances fig. 8.
a. From the floor to the center of the inner pivot of boss for the spherical joint on the same side of
the lower control arm. On the Chevrolet, the vehicle.
Camaro and Chevy II this measurement must be Camaro and Chevy II-- From the floor to the
made at the rear end of the pivot. lower inboard edge of ball seat.
b. Chevrolet- -Measure the distance from the floor 3. The difference between these two measurements
to the lower face of the lower steering knuckle should be as outlined in the Specifications given at
boss for the spherical joint on the same side of the end of the book with the vehicle at curb weight
the vehicle. full tank of gas, spare tire and jack in trunk, no
Chevelle--From the floor to the outer pivot passengers.
which is located 1/8" .12 inboard from the ball 4. Measure the opposite side of the vehicle in the same
stud ‘boss at the lower surface of the arm. manner. The measurements for both sides should
Corvette- -Measure the distance from the floor differ no more than 1/2".
to the lower face of the lower steering knuckle 5. To correct the height, springs must be replaced.
REPAIR PROCEDURES
Unless otherwise indicated all repair procedures will 1-1/16 x 1-1/16 x 2 inches in length, between
apply to all five vehicles covered in this manual. the brake pads as the caliper is being removed.
Once removed the caliper assembly can be wired
CAUTION: During any operations which in or secured in some manner away from the
clude breaking the ball stud loose from the concerned area.
knuckle boss extreme care must be used to
assure that the ball stud seal is not damaged or 2. Pry out hub grease cap, cotter pin, spindle nut and
cut. A recommended way to loosen the stuLd is to washer, and remove hub. Do not drop wheel bearings.
place a flat bar stock against the knuckle boss 3. Reverse the procedure to install.
and strike the bar rather than the knuckle.
Replacement of Wheel Hub Bolts
It may be necessary to replace damaged wheel hub
FRONT BRAKE DRUM-CHEVROLET, CAMARO, bolts. In this case, service the hub in the following
CHEVELLE, CHEVY II manner.
Removal NOTE: On all vehicles with disc brakes except
1. Remove hub caps, partially loosen wheel nuts and
Corvette, the hub must be separated from the
raise vehicle from floor. Remove wheel nuts and
wheel. disc. Before removing attaching bolts, index the
hub to the disc for assembly. Torque all attach
2. Remove brake drum. In some cases it may be nec
essary to back off brake adjustment because of ing bolts to 60 lb. ft. Hub and disc are balanced
as an assembly.
scored drum or unevenly worn brake linings, see
Section 5. 1. Remove the hub bolts with a press or hammer.
3. Check brake drum for concentricity, damaged pilot These bolts are not peened into the hub. Do not
diameter or scored braking surface. Lightly sand damage wheel mounting surface on hub flange.
braking surface and wipe clean. 2. Install new serrated bolt into hole in hub. Tap lightly
Installation with a hammer to start bolt serrations in hole, mak
1. Install drum over hub bolts making sure alignment ing sure that bolt is square with hub flange.
3. Press bolt into flange until head is fully seated
dowel on drum web indexes with hole in wheel hub.
This will assure proper drum alignment with hub against hub flange fig. 9.
bolts and hub pilot diameter.
2. Install wheel and partially tighten wheel nuts.
3. Re-adjust brake shoes to original setting. It may be
necessary to re-adjust brake shoes on both front
and/or rear wheels to assure balanced brake adjust
ment. See Section 5 for brake adjustment procedure.
4. Lower vehicle to floor, tighten hub wheel nuts and in
stall hub cap.
FRONT WHEEL HUB

Replacement
1. Remove hub caps, break loose the wheel stud nuts
and raise vehicle. Remove wheel nuts, wheel and
tire and brake drum or brake caliper.
NOTE: Vehicles equipped with disc brakes;

hub and disc are serviced as a complete as
sembly. Remove bolts holding brake caliper to
its mounting and insert a fabricated block Fig. 9-Pressing Front Hub Bolts Typical
washer and nut. Adjust front wheel bearing as shown

"Reproduced
i by Detroit
in Iron
thisIS with permission of General Motors LLC under License."
section.
3. Wash all parts thoroughly in cleaning solvent and

blow dry.
Inspection
1. Check bearings for cracked separators or worn or
pitted rollers and races.
2. Check brake drum for out-of-round or scoring.
3. Check fit of bearing outer cups in hub.
Repairs
Replacement of Beating Cups
1. Using steel bar stock, make press-out tools shown in
Figure 10.
2. Insert removers through hub, indexing ends into slots
in hub shoulder behind bearing cup.
3. Using a suitable extension pipe or rod, press bearing
cups from hub.
4. Install new bearing cup in hub using Tool J-8849 on
the outer and Tool J-8850 on the inner cup fig. 11.
Use Driver Handle J-8092 with the installers. Make
sure that the bearing cups are not cocked and are
fully seated against shoulder in hub.
Installation
1. Pack both inner and outer bearings using a high
melting point wheel bearing lubricant.
Fig. lO-Front Wheel Bearing Cup Removers 2. Place inner bearing in hub, then install a new inner
bearing lip seal assembly. Seal flange should face
FRONT WHEEL BEARINGS bearing cup.
3. Carefully install wheel hub over steering spindle.
Removal 4. Install outer bearing, pressing it firmly into the hub
1. Remove wheel hub as described above. by hand.
NOTE: Discard cotter pin. Install new cotter 5. Install spindle washer and adjusting nut. Draw up
tight and adjust wheel bearings as outlined under
pin when assembling.
"Front Wheel Bearing Adjustment".
2. Remove outer roller bearing assembly from hub with
fingers. The inner bearing assembly will remain in STEERING KNUCKLE
the hub and may be removed after prying out the
inner bearing lip seal assembly. Discard seal. It is recommended that vehicle be raised and supported
on a twin-post hoist so that the front coil spring remains
BUSHING LINK 801T

TYPICAL OF
CHEVROLET, CHEVELLE, CAMARO AND CHEVY II
Fig. 14-Stabilizer Bar
2. Insert stabilizer brackets over bushings and connect rear retainer, sleeve and bushing on rod so pilot
to frame. Do not torque at this point. Connect sta diameter faces forward.
bilizer ends to link bolts on lower control arms. 2. Insert strut rod in bracket. Install forward bushing
Torque bracket bolts and link nuts as shown in the on sleeve so raised pilot diameter faces rear to
Specifications. enter hole in bracket and rear bushing, then install
forward retainer and nut on rod.
NOTE: "Reproduced
Never get lubricant by Detroit
on outside Iron IS with permission
of frame 3. of Generalstrut
Attach Motors
rodLLC
to under
top ofLicense."
lower control arm with two
a. From the floor to the center of the inner pivot of boss for the spherical joint on the same side of
the lower control arm. On the Chevrolet, the vehicle.
Camaro and Chevy II this measurement must be Camaro and Chevy II-- From the floor to the
made at the rear end of the pivot. lower inboard edge of ball seat.
b. Chevrolet--Measure the distance from, the floor 3. The difference between these two measurements
to the lower face of the lower steering knuckle should be as outlined in the Specifications given at
boss for the spherical joint on the same side of the end of the book with the vehicle at curb weight
the vehicle. full tank of gas, spare tire and jack in trunk, no
Chevelle-- From the floor to the outer pivot passengers.
which Is located 1/8" .12 inboard from the ball 4. Measure the opposite side of the vehicle in the same
stud boss at the lower surface of the arm. manner. The measurements for both sides should
Corvette- -Measure the distance from the floor differ no more than 1/2".
to the lower face of the lower steering knuckle 5. To correct the height, springs must be replaced.
REPAIR PROCEDURES
Unless otherwise indicated all repair procedures will 1-1/16 x 1-1/16 x 2 inches in length, between
apply to all five vehicles covered in this manual. the brake pads as the caliper is being removed.
Once removed the caliper assembly can be wired
CAUTION: During any operations which in or secured in some manner away from the
clude breaking the ball stud loose from the
concerned area.
knuckle boss extreme care must be used to
assure that the ball stud seal is not damaged or 2. Pry out hub grease cap, cotter pin, spindle nut and
cut. A recommended way to loosen the stud is to washer, and remove hub. Do not drop wheel bearings.
place a flat bar stock against the knuckle boss 3. Reverse the procedure to install.
and strike the bar rather than the knuckle.
Replacement of Wheel Hub Bolts
FRONT BRAKE DRUM-CHEVROLET, CAMARO, It may be necessary to replace damaged wheel hub
bolts. In this case, service the hub in the following
CHEVELLE, CHEVY II manner.
Removal
NOTE: On all vehicles with disc brakes except
1. Remove hub caps, partially loosen wheel nuts and
Corvette, the hub must be separated from the
raise vehicle from floor. Remove wheel nuts and
disc. Before removing attaching bolts, index the
wheel.
hub to the disc for assembly. Torque all attach
2. Remove brake drum. In some cases it may be nec
ing bolts to 60 lb. ft. Hub and disc are balanced
essary to back off brake adjustment because of
as an assembly.
scored drum or unevenly worn brake linings, see
Section 5. 1. Remove the hub bolts with a press or hammer.
3. Check brake drum for concentricity, damaged pilot These bolts are not peened into the hub. Do not
diameter or scored braking surface. Lightly sand damage wheel mounting surface on hub flange.
braking surface and wipe clean. 2. Install new serrated bolt into hole in hub. Tap lightly
Installation with a hammer to start bolt serrations in hole, mak
1. Install drum over hub bolts making sure alignment ing sure that bolt is square with hub flange.
3. Press bolt into flange until head is fully seated
dowel on drum web indexes with hole in wheel hub.
against hub flange fig. 9.
This will assure proper drum alignment with hub
bolts and hub pilot diameter.
2. Install wheel and partially tighten wheel nuts.
3. Re-adjust brake shoes to original setting. It may be
necessary to re-adjust brake shoes on both front
and/or rear wheels to assure balanced brake adjust
ment. See Section 5 for brake adjustment procedure.
4. Lower vehicle to floor, tighten hub wheel nuts and in
stall hub cap.
FRONT WHEEL HUB

Replacement
1. Remove hub caps, break loose the wheeJL stud nuts
and raise vehicle. Remove wheel nuts, wheel and
tire and brake drum or brake caliper.
NOTE: Vehicles equipped with disc brakes;

hub and disc are serviced as a complete as
sembly. Remove bolts holding brake caliper to
its mounting and insert a fabricated block Rg. 9-Pressing Front Hub Bolts Typical
__________
BUSHING
TYPICAL OF
CHEVROLET, CHEVELLE, CAMARO AND CHEVY II
Fig. 14-Stabilizer Bar
2. Insert stabilizer brackets over bushings and connect rear retainer, sleeve and bushing on rod so pilot
to frame. Do not torque at this point. Connect sta diameter faces forward.
bilizer ends to link bolts on lower control arms. 2. Insert strut rod in bracket. Install forward bushing
Torque bracket bolts and link nuts as shown in the on sleeve so raised pilot diameter faces rear to
Specifications. enter hole in bracket and rear bushing, then install
forward retainer and nut on rod.
NOTE: Never get lubricant on outside of frame 3. Attach strut rod to top of lower control arm with two
stabilizer bar bushings or they may slip out of bolts, washers and nuts.
brackets. 4. Lower vehicle to floor, check caster, camber and
toe angles and adjust where necessary. Torque nuts
STRUT ROD FIG. 15 as shown in Specifications.
Chevrolet
Removal FRONT SPRING
1. Raise vehicle to provide sufficient working Chevrolet
clearance.
Removal
2. Remove forward nut, retainer and rubber bushing
1. With an open end wrench hold the shock absorber
from front end of strut rod.
upper stem from turning, and then remove the upper
3. Remove two nuts from strut rod to lower control
stem retaining nut, retainer and rubber grommet.
arm bolts and remove bolts and washers.
4. Withdraw strut rod from bracket. 2. With the car supported by the frame so that the con
5. Remove remaining rubber bushing, retainer, sleeve trol arms hang free, remove the wheel and tire as
and nut from strut rod. sembly replace one wheel nut to retain the brake
drum, shock absorber, stabilizer bar to lower con
6. Inspect rubber bushings for aging and replace if
trol arm link, strut rod to lower control arm attach
necessary.
ing nuts, bolts and lock washers and tie rod end.
Installation
1. Screw rear nut on forward end of rod and position it
approximately 3/4" from end of threads. Install
1 Y,"-i-Y"-i
Fig. 15-Strut Rod-Chevrolet Fig. 16-Spring Removal Tools-Chevrolet
3. Scribe the position of the inner pivot camber adjust

ing cam bolt and then remove the nut, lock washer
and outer cam.
4. Install a steel bar fabricated as shown in Figure 16
through the shock absorber mounting hole in the
lower control arm so that the notch seats over the TOOL J22734
bottom spring coil and the bar extends inboard and
under the inner bushing. Fit a 5" wood block See
Figure 16 between the bar and the bushing as shown
in Figure 17.
5. With suitable jack or hoist, lift up slightly on the end
of the bar to remove the tension from the inner pivot
cam bolt, which can then be removed.
6. Carefully lower the inner end of the control arm.
Tension on the spring will be removed before the
spring can be removed from the vehicle.
7. Remove the spring.
Fig. 18-Tool J-22739 Mounted on Jack
Installation
1. With the suspension set up as in Step 2 of the disas bolts and lock washers, the stabilizer bar link, the
sembly procedure, insert a block of wood between the shock absorber, the tie rod end, and the wheel and
upper control arm and the spring tower to keep the tire.
arm up out of the way. 7. Lower vehicle to floor and install the shock absorber
2. Set the spring in place on the crossmember after upper stem retaining nut retainer and grommet.
checking on proper positioning necessary. 8. Check the camber adjustment.
3. Install the steel bar and wood block as shown in Fig
ure 17 and lift the control arm up until the inner Chevelle, Camaro and Chevy II
pivot cam bolt can be installed.
Removal
NOTE: Lubricate the flat and thread area of 1. With an open end wrench hold the shock absorber
the cam bolt with water resistant EP chassis upper stem from turning, and then remove the upper
lube. stem retaining nut, retainer and rubber grommet.
4. Install the outer cam identification mark on cam 2. With the car supported by the frame so that the con
should be against the frame and loosely install the trol arms hang free, remove the wheel and tire as
lock washer and nut. sembly replace one wheel nut to retain the brake
5. Set the cam bolt on the mark scribed during the re drum, shock absorber, and stabilizer bar to lower
moval procedure and hold in this position while tight control arm link. As a safety precaution install a
ening the nut See specifications at the end of this chain through the spring and lower control arm as
book. depicted in Figure 19.
6. Replace the strut rod to lower control arm nuts, 3. Bolt Tool J-22739 to a suitable jack as shown in
Figure 18.
4. Place tool under lower control arm bushings so that
the control arm bushings seat in the grooves of the
tool.
5. Raise the jack to remove tension on the lower con
trol arm pivot bolts and remove bolts.
6. Lower control arm by slowly releasing jack until
spring can be removed Fig. 19.
Fig. 17-Front Spring Removal-ChevroIe Fig. 19-Removing Spring
Fig. 20-Removing Front Coil Spring-Corvette

7. Remove chain. Remove spring.
3. Connect the stabilizer bar link and install bolts
Installation retaining shock absorber to the lower control arm.
1. Properly position spring on the control arm and lift 4. Lower vehicle and install the shock absorber upper
control arm. grommet, retainer and nut.
2. Position control arm into crossmember and install
pivot bolts. Lower jack. LOWER CONTROL ARM SPHERICAL JOINT
3. Replace the stabilizer bar link, shock absorber, and
wheel and tire. Chevrolet, Chevelle, Camaro, Chevy II and Corvette
4. Lower vehicle to floor and install the shock ab
sorber upper stem retaining nut, retainer and Inspection
grommet. The lower control arm spherical joint should be re
placed whenever wear is indicated in the upper joint
Corvette inspection.
Removal NOTE: The lower control arm spherical joint
1. Remove nut, retainer and grommet from top of shock is a loose fit in the assembly when not connected
absorber. to the steering knuckle.
2. With vehicle on a suitable hoist, support front of
Only if inspection of each upper joint indicates them
vehicle so control arms swing free.
3. Disconnect stabilizer bar from lower control arm both to be within limits, inspect each lower joint for ex
and remove bolts retaining shock absorber to lower cessive wear as follows:
control arm, remove shock absorber. 1. After reconnecting upper joints to steering knuckles,
support vehicle weight on wheels or wheel hubs.
4. Bolt Tool J-22944 to, a suitable jack and place tool
2. With outside micrometer or caliper, measure dis
under lower control arm bushings so that the control
tance from top of lubrication fitting to bottom of ball
arm bushings seat in the grooves of the tool fig. 20.
stud, and record the dimensions for each side.
As a safety precaution install a chain through the
3. Then support vehicle weight at outer end of each
spring and lower control arm.
lower control arm, so that wheels or wheel hubs are
5. Remove cross shaft rear retaining nut and the two
free, then repeat Step 2.
front retaining bolts.
4. If the difference in dimensions on either side is
6. Lower control arm by slowly releasing jack until
spring can be removed fig. 20. greater than 1/16" .0625", the joint is excessively
worn and both lower joints should be replaced.
7. Remove chain. Swing control arm forward and re
If inspection of lower spherical joints does not indicate
move spring.
excessive wear, inspect further as follows:
Installation 5. On Chevrolet and Corvette Only--Examine lubrica
1. Properly position spring on the control arm and lift tion hole in each joint assembly after cleaning out
control arm. hole. Look for evidence of the liner partially or
2. Using a large drift position control arm to cross- fully blocking lubrication opening. Such evidence
member and install cross shaft retaining bolts. indicates that wear is sufficiently advanced that both
Torque to specifications. lower spherical joints should be replaced.
Another indication of lower spherical joint excessive

wear is indicated when difficulty is experienced when
lubricating the joint. If the liner has worn to the point
where the lubrication grooves in the liner have worn
away, then abnormal pressure is required to force lu
bricant through the joint. This is another reason to
recommend replacement of both lower joints.
If the above inspections do not indicate any reason for
spherical joint replacements, test the torque tightness of
the lower ball stud in the knuckle on each side as follows:
1. Wire-brush off nut and cotter pin attaching spherical
joint ball stud to steering knuckle and examine for
evidence of looseness of stud in knuckle.
2. If no evidence of looseness, remove cotter pin and
with prick punch or equivalent, mark nut stud and
knuckle to identify relative location.
3. Tighten nut as installed and observe torque reading.
If less than 45 lbs. ft., stud may have been loose in
steering knuckle and replacement of both lower
spherical joints may be recommended.
4. Check to see if torque of 60-94 lbs. ft. can be ob
tained without bottoming stud or ball joint against
knuckle. If bottoming occurs, replace bail joint or
steering knuckle.
Chevrolet and Corvette

Removal
Fig. 22-Installing Lower Spherical Joint-Chevelle
1. Support lower control arm at outer end on floor jack,
Camaro and Chevy II
with hoist or jack pad clear of lower ball stud nut
and seal. NOTE: On Corvettes or Chevrolets equipped
with disc brake remove caliper assembly as
outlined in "Wheel Hub Removal".
tIL 2. Remove upper and lower ball stud nuts, free ball
studs from steering knuckle and wire knuckle and
brake drum or disc assembly up to fender skirt to
preclude interference while performing next step.
3. Being careful not to enlarge the holes in control
arm, cut off rivets.
Installation
1. Install new joint against underside of control arm and
retain in place with special bolts and nuts supplied
with new joint.
CAUTION: Use only alloy bolts supplied for
this operation. The special thick headed bolt
must be installed in the forward side of the
contr ol arm.
2. Tighten bolts and nut on ball stud to Specification
shown at the end of this book.
3. Lubricate the joint.
Chevelle, Camaro and Chevy II

Removal
1. Support lower control arm at outer end on floor jack,
with hoist or jack pad clear of lower ball stud and
1
remove the wheel.
NOTE: On vehicles equipped with disc brakes

remove caliper assembly as outlined in "Wheel
Hub Removal".
Fig. 21-Removing Lower Spherical Joint-Chevelle, 2. Remove the upper and lower ball stud nuts, free the
Camaro and Chevy II ball studs from the steering knuckle and wire the
Fig. 23-Lower Control Arm Attachment
knuckle and brake drum or disc assembly out of the replacement spherical joint assemblies are supplied less
way to preclude interference while completing the the lube fitting. Therefore it will be necessary to install
lower ball stud removal procedure. a self threading type fitting into the untapped hole pro
3. Use a screw driver to pry off the seal and retainer. vided when replacing the entire assembly.
Install Tools J-9519-10, J-9519-17 and .J-9519-7 as
shown in Figure 21 and turn down on the hex head LOWER CONTROL ARM
screw until the spherical joint is pushed out.
Chevrolet Fig. 23
Installation
1. Start the replacement spherical joint into the control Removal
1. Remove the coil spring as outlined previously.
arm and install Tools J-9519-10, J-9519-16 and
2. Remove lower control arm ball stud cotter pin and
J-9519-17 as shown in Figure 22.
loosen nut. Loosen the ball stud, then remove nut
NOTE: When installing spherical joint position and lower control arm.
air vent in rubber boot facing inboard.
CAUTION: Use extreme care not to damage
2. Turn down on the hex head screw until the spherical the seal during this operation.
joint is seated properly in the control arm.
NOTE: Inspect cam bolt for shouldering, re
3. Install the stud into the steering knuckle, secure in
place if necessary. If new caps are to be used- -
place with the attaching nut and install the cotter pin.
replace with large front caps at both ends of
4. Replace the wheel and tire.
the control bushing.
5. Lower the vehicle.
Installation
1. Insert lower control arm ball stud into the steering
Lube Fittings knuckle boss, install the nut and insert new cotter
Special self threading type lube fittings are used in the pin.
spherical joint assemblies. If it is necessary to replace 2. Install the coil spring as outlined previously.
a fitting a standard threaded type may be used. However, 3. Tighten nuts to torque shown in Specifications.
Chevelle, Camaro and Chevy II Fig. 23

Removal
1. Remove the front coil spring as outlined previously.
2. Remove lower control arm ball stud from the steer
ing knuckle boss as outlined under "Lower Control
Arm Spherical Joint".
3. Remove the lower control arm assembly.
Installation
1. Install lower control arm ball stud into steering
knuckle boss.
2. Install the coil spring as outlined in "Front Coil
Spring".
3. Tighten the nuts to torques as shown in Specifications.
Corvette Fig. 23
Removal
1. Remove the front coil sprtng as outlined under
"Front Spring, Removal".
2. Remove lower control arm ball stud from the steer
ing knuckle boss as outlined under "Lower Control
Arm Spherical Joint."
3. Remove the lower control arm assembly from the
vehicle.
Installation
1. Install lower control arm ball stud into steering Fig. 25-Lower Control Arm BUshing-Chevrolet
knuckle boss. Torque to specifications. 24 and using Tool J-22717 remove bushing stake so
2. Install coil spring as outlined under "Front Coil that bushing may be removed without extensive scor
Spring Installation". ing of the control arm bushing seat.
3. Tighten cross shaft bolts to specifications. 3. Install Tools J-21058-8, J-21058-15, J-21830-7,
4. With unit on floor, tighten cross shaft bushing bolts J-9519-17, J-21474-8, special thrust washer and a
to torque shown in Specifications. flat washer as shown in Figure 25. Use J-21878 as
shown to prevent collapse of the control arm.
LOWER CONTROL ARM BUSHING 4. Turn down on the puller screw nut to remove the
bushing from the control arm.
Chevrolet
Installation
Removal 1. With Spacer J-21878 in place to pevent collapse of
1. Remove the lower control arm.
the control arm, install Tools J-21058-8,J-21058-15,
2. Install lower control arm in vise as shown in Figure
J-21830-7, J-9519-17, J-21474-2 special thrust
washer and flat washer as shown in Figure 25.
2. Turn down on the puller screw nut to install the
bushing in the control arm.
Chevelle, Camaro and Chevy II

The following bushing removal and installation pro
cedures apply to all three vehicles and will be referred to
as large or small bushings. Location of the large or
small bushing vary from front to rear. The following
chart shows location by vehicle.
Bushing Location in
Vehicle
Size Control Arm
Large Bushing Rear

Small Bushing Front
Large Bushing Front
Small Bushing Rear
II Large Bushing Front
Small Bushing Rear
Fig. 24-Relieving Lower Control Arm Stake
2. To remove the large bushing, use Tools J-21058-8,

,J-21058-15 J-21058-15, J-21474-5, J-21474-8, J-22323-1 and
I,
J-22323-1 the thrust bearing installed as shown in the re
J-21058-8 moval illustration in Figure 26.
/ 3. Turn down on the hex head screw of J-21058-15 until

the bushing is pushed out. Discard the bushing.
4. Install the new bushing with Tools J-21058-8, J
21058-15, J-21474-13, J-22175, J-22323-1 and the
T
thrust bearing installed as shown in the installation
illustration in Figure 26.
5. Replace the control arm.
J-21474-8
THRUST J-21474-5
Small Bushing
BEARING REMOVAL
Removal and Installation
1. Remove and install the small bushing as described
J-22323-1
J-22175 above using Tools J-21058-8, J-21058-15, J-21474-5,
/
J-21474-6, J-22323-1 and the thrust bearing for
J-21058-8 installation and Tools J-21058-8, J-21058-15, J
I
/ 21474-6, J-21474-13, J-22323-1 and the thrust bear
ing for removal as shown in Figure 27.
CROSS SHAFT AND/OR BUSHINGS

J-21474-13 Corvette
J-21058-15 AND THRUST BEARING Removal
INSTALLATION 1. Remove bolt, lock washer and collar from each end
of cross shaft.
Fig. 26-Lower Control Arm Large Bushing 2. Thread a 7/16 x 20 capscrew furnished with Tool
J- 5888 to the bottom of the threads in one end of the
Large Bushing cross shaft.
Removal and Installation 3. Support control arm in an arbor press on Tool
1. Remove the lower control arm. J-5888-3, as shown in Figure 28.
NOTE: Be certain bushing flange does not
J-22323-1 contact support.
J-21474-5
4. Press on cap screw until bushing is free of control
J-21058-8 arm. Discard bushing.
7/ox20
REMOVAL
J-21474-6 /
J-21058-15
AND THRUST BEARING
CAPSCREW
J-21058-8 J214746
TOOL
J 5888-3
TOOL
J-22323-1
J-21474-13 /
J-21058-15
AND THRUST BEARING
‘-i 7052-1
INSTALLATION
Fig. 27-Lower Control Arm Small Bushing Fig. 28-Removing Lower Control Arm Cross Shaft Bushing Corvette
5. Remove cap screw from cross shaft. Insert it in

other end of shaft. Invert control arm on support.
Again be certain bushing flange does not contact
support.
6. Press on cap screw until bushing is free of control
arm. Discard bushing.
Installation
1. With cross shaft in control arm and Tool J-7052-1
in position, place control arm on Tool J-5888-3.
Hand start bushing into control arm and over end of
cross shaft.
NOTE: The end of the shaft with the two bolt
holes should be toward front of control arm.
2. Install Tool J-7052-5 over bushing. Be certain
three-piece spacer is not over-lapping bushing holes
in control arm.
3. Press bushing into control arm until flange contacts
control arm fig. 29.
4. Invert arm in press and repeat the process on the
other bushing. After installation, cross shaft should
be free enough to be rotated by hand.
5. Install collar, lock washer and cap screw in each end
of cross shaft. Tighten to torque shown in Specifica
tions after spring installation.
UPPER CONTROL ARM SPHERICAL JOINT

Chevrolet, Chevelle, Camaro, Chevy II and Corvette
Inspection
The upper spherical joint is checked for wear by
checking the torque required to rotate the ball stud in the
assembly. After performing the first four steps under
"Replacement" below, install a stud nut on the stud and
measure the torque required to turn the stud in the as
sembly with a torque wrench. Specified torque for a new Fig. 30-Upper Control Arm Attachments
joint is 3 to 10 lbs. ft. If torque readings are excessively
high or low, replace the ball joint. If excessive wear is NOTE: This inspection does not necessitate
indicated in upper joint, both upper and lower joints upper control arm removal.
should be replaced.
Replacement
1. Support the vehicle weight at the outer end of the
lower control arm.
2. Remove the wheel and tire assembly.
3. Remove cotter pin and nut from upper control arm
ball stud.
4. Remove the stud from knuckle.
5. Cut off the ball joint rivets with a chisel.
6. Enlarge ball stud attaching holes in control arm to
21/64" to accept 5/16" bolts included in unit.
7. Install new joint and retain in place with the special
nuts and bolts supplied.
8. Reassemble ball stud to the steering knuckle.
LUBE FITTINGS
Special self threading type lube fittings are used in the
spherical joint assemblies. If it is necessary to replace
a fitting a standard threaded type may be used. However,
replacement spherical joint assemblies are supplied less
the lube fitting. Therefore it will be necessary to install
a self threading type fitting into the untapped hole pro
Fig. 29-Installing Lower Control Arm Cross Shaft Bushing Corvette vided when replacing the entire assembly.
INSTALLATION
CHEVROLET
J-7052.2
CHEVELLE, CAMARO
AND CHEVY II
J-21482
I
J-7052-5 -‘
J-5888.3
Fig. 31-Removal and Installation of Upper Control Arm Bushings
UPPER CONTROL ARM

Corvette--Install same number of shims as removed
Chevrolet, Chevelle, Camaro, Chevy II and Corvette at each bolt.
Fig. 30 3. Torque nuts as shown in the Specifications at the end
Removal of this book.
1. Support vehicle weight at outer end of lower control 4. Install ball stud through knuckle, install nut, tighten
arm. and install cotter pin.
2. Remove wheel and tire assembly. 5. Install wheel and tire assembly.
3. Remove cotter pin and nut from upper control arm 6. Lower vehicle to floor.
ball stud. 7. Bounce front end of vehicle to centralize bushings
4. REMOVE the stud from knuckle. and tighten bushing collar bolts as shown in the
5. Remove two nuts retaining upper control arm shaft Specifications.
to front crossmember. Chevelle, Camaro, Chevy II
and Corvette--Note number of shims at each bolt. UPPER CONTROL ARM
6. If necessary, remove the bolts attaching the control CROSS SHAFT AND/OR BUSHINGS
arm to the frame to allow proper clearance for Chevrolet, Chevelle, Camaro and Chevy II
control arm removal.
7. Remove upper control arm from vehicle. Removal
1. Remove cap screws, lock washers and collars from
Installation both ends of cross shaft.
1. Install upper control arm in vehicle. 2. Install a 3/8-24 cap screw in one end of cross shaft.
2. Install locknuts, bolts retaining upper control arm 3. Support control arm in an arbor press on Tool
shaft to frame. Chevelle, Camaro, Chevy II and J-5888-3 as shown in Figure 31.
FRONT SUSPENSION 3-}9
TOOL
J 7052-5
‘-_.-._ ¾ x 24
CAP SCREW
J70522
TOOL
5-7052-2
TOOL
J 5888-3
TOOL
-J-5888-3
Fig. 33-Installing Upper Control Arm Cross Shaft Bushings-

Corvette
Fig. 32-Removing Upper Control Arm Cross Shaft Bush ings- Corvette
Corvette Removal
1. Remove cap screws, lock washers and collars from
both ends of cross shaft.
NOTE: Be certain flange of bushing does not 2. Install a 3/8-24 cap screw furnished with Tool
contact support. J-5888 in one end of cross shaft.
4. Press out bushing, invert control arm and repeat 3. With control arm supported in an arbor press on
process on other bushing. Discard bushings. Tool J-5888-3 and Tool J-7052-2 in place as shown
5. Remove cap screw from cross shaft. in Figure 32.
NOTE: If bushing rubber is deteriorated to the NOTE: Be certain flange of bushing does not
extent that the bushing sleeve cannot be pushed contact support.
out, release the press, install J-9502-5 as shown
in Figure 31 and press out the sleeve. 4. Press out bushing, invert control arm and repeat
process on other bushing. Discard bushings.
Installation 5. Remove cap screw from cross shaft.
1. Install arm in arbor press with Tool J-7052-2
Chevrolet or J-21482 Chevelle, Camaro and Chevy Installation
II in place and press in one bushing using J-7052-5 1. Install arm in arbor press with Tool J-7052-2 in
as shown while supported on Tool J-5888-3 as place and press in one bushing while supported on
shown in Figure 31. Tool J-5888-3 as shown in Figure 33.
2. Install cross shaft in arm, invert in press, and press 2. Install cross shaft in arm, invert in press, and press
in second bushing as above. in second bushing as above.
3. Cross shaft should be able to be turned by hand. 3. Cross shaft should be able to be turned by hand.
4. Install collar, lock washer and cap screw in ends of 4. Install collar, lock washer and cap screw in ends of
cross shaft. Do not tighten. cross shaft. Do not tighten.
SPECIAL TOOLS
14
‘I
In
8
‘Ii 9
10
23
9
0
19
6 aa 30
31
1. J-5888-3 Support 10. J-8849 Installer

2. J-22739 Spring Remover Chevelle, J-9519-10 Clamp 29. J-21482 Spacer
11. J-8850 Installer J-9519-16 Installer 30. J-21830-7
Camaro and Chevy II Receiver Bridge
12. J-9502-3 Remover J-9519-17 Receiver
3. J-22944 Spring Remover Corvette 31. J-21878 Spacer
13. J-9226 Remover 22. J-21058-8 Nut
4. J-7052-2 Spacer 32. J-21474-3 Not Illustrated
14. J-9513-J Remover J-21058-15 Screw 33.
5. J-7052--5 Installer J-21474-4 Not lIlustraed
15. J-9513-2 Remover 24. J-21474-2 Installer 34.
6. J-7079-2 Driver Handle J-21474-5 Not Illustrated
16. J-9513-3 Installer 25. J-21474 Receiver
7. J-7574-2 Installer 35. J-21474-6 Not Illustrated
17. J-9514 Spacer J-21474-8 Remover
8. J-7574-.4 Support 36. J-22323-1 Not Illustrated
18. J-9519-7 Remover
9. J-8092 Driver Handle
SECTION 4
REAR SUSPENSION AND DRIVE LINE

Page Page
Rear Suspension 4-1 Propeller Shaft and Universal Joints 4-35
Drive Line 4-24 Special Tools 4-41
Rear Axle 4-24
REAR SUSPENSION
INDEX
Page Page
General Description 4-1 Installation 4-12

Chevrolet 4-1 Chevrolet Lower 4-12
Chevelle 4-1 Removal 4-12
Chevy II and Camaro 4-2 Bushing Replacement 4-13
Corvette Installation 4-13
Maintenance and Adjustments 4.4 Chevelle Upper and Lower 4-14
Riding Height Check Chevrolet, Camaro, Removal 4-14
Chevelle and Chevy II 4-4 Bushing Replacement 4-14
Wheel Alignment Corvette 45 Installation
Wheel Bearing Adjustment Corvette 45 Rear Suspension Tie Rod Chevrolet 4-16
Component Parts Replacement Chevrolet, Camaro, Removal 4-16
Chevelle and Chevy II 4_7 Bushing Replacement 4-16
Coil Spring 4..7 Installation 4-16
Chevrolet 4...7 Component Parts Replacement Corvette 4-17
Removal Wheel Spindle and Support 4-17
Installation 47 Removal 4-17
Chevelle 4-8 Repairs 4-17
Installation 4-8 Differential Carrier Support Bracket Replacement 4-18
Leaf Spring, Spring Seat Pads, Spring Eye Shock Absorber 4-18
Bushings, Spring Leaf 4-8 Removal 4-18
Camaro and Chevy U 4-8 Installation 4-19
Removal 4-8 Strut Rod and Bracket 4-19
Spring Leaf Replacement 4.9 Removal 4-19
Installation Repairs 4-19
Shock Absorber 4-10 Installation 4-19
Chevrolet and Chevelle 4-10 Spring 4-20
Installation 4-10 Repairs 4-21
Chevy U 4-11 Installation 4-21
Removal 4-11 Torque Control Arm 4-21
Camaro 4-11 Repairs 4-22
Installation 4-11 Suspension Crossmember 4-23
Control Arm 4-11 Removal 4-23
Chevrolet Upper 4-11 Repairs-Isolation Mount 4-23
Bushing Replacement 4-11 Stabilizer Shaft Replacement 4-24
GENERAL DESCRIPTION
CHEVROLET acting shock absorbers are provided for additional ride
control.
The link type rear suspension fig. 1 has two lower
control arms which maintain proper axle to frame re CHEVELLE
lationship and also take the acceleration, drive and The rear suspension fig. 2 is of the four-link design
braking forces. A single upper control arm on light- utilizing axle mounted, full coil springs and direct,
duty models or two upper control arms on heavy-duty double-acting shock absorbers.
models and all station wagons limits axle rotation when Two rubber-bushed lower control arms, stretching
drive, acceleration or braking forces are applied. Lateral slightly outboard from axle-mounted brackets to frame
movement of the axle is restricted by the axle--to-frame side member mounted brackets, maintain fore and aft
tie rod. Two full coil springs and two direct, double relationship of the axle assembly to the vehicle proper.
REAR SUSPENSION AND DRIVE LINE 4-2
COIL SPRING
Fig. 1-Chevrolet Rear Suspension Components
These lower control arm axle brackets also mount the CHEVY II AND CAMARO
axle compression bumpers and provide for lower attach
ment of the shock absorber. Upper attachment of the The Chevy II and Camaro rear suspension fig. 3 and 4
shock absorber is a platform mount to the rear of the coil consists of two uniformly stressed rear springs of a
spring frame bracket. The coil springs are pigtailed single leaf or multi-leaf design. The multi-leaf springs
at both ends; the upper end is isolated from the frame are used on all Chevy II models equipped with 327 or
seat by a rubber insulator, while the lower end seats 350 V-8 engines with 4-speed transmissions and
on the axle mounted spring bracket which has a vertical Camaro’s equipped with 327 cu. in. 4 Bbl. V-8 engines
flange to retain the spring. with 4-speed transmissions and all 350 and 396 cu. in.
Sideways movement of the axle assembly is controlled V-8 engines. All other models use the single leaf design.
by two angularly mounted, rubber-bushed upper control Shock absorbers are staggered mounted to the spring
arms. Projecting ears, cast as part of the differential lower seats. The right hand shock absorber is mounted
carrier, provide for rear attachment and frame cross- forward of the axle with the left hand shock absorber
member mounted brackets retain them at the forward mounted behind the axle. The springs are rubber mounted
end. at both axle and frame attaching points, thus ensuring
Fig. 2-Chevelle Rear Suspension Componenets
SPRING REAR SHACKLE
AXLE ASSEMBLY
SHOCK ABSORBER
PROPELLER SHAFT SPRING FRONT MOUNT
Fig. 3-Chevy II Rear Suspension Components
uniform spring loading, minimizing transmittal of road strut rods, drive shafts and torque control arms forming
vibration to passenger compartment, and providing a the three links at each wheel, and a transversely mounted
pivot to absorb axle wind-up. The single leaf springs multi-leaf spring fig. 5.
are positioned to the axle spring seats by locating pins The box section trailing torque control arms are
butt welded to the spring leaf. The multi-leaf springs mounted at the forward end into frame side member
are positioned to the axle spring seat by a locating bolt openings through pivot bolts and rubber bushings, and
which passes through the center of the spring leafs. extend rearward to connect to the leaf spring. The
wheel spindles and spindle supports are attached to the
torque control arms through four bolts pressed into the
CORVETTE arm. Rear wheel toe-in angle is adjusted through the use
The Corvette independent three-link type rear sus of variable thickness shims inserted between the torque
pension consists of a fixed differential carrier which is arm and the frame side member web at the forward
rubber mounted to the frame at three points, with the pivoting joint.
SPRING REAR SHACKLE
AXLE ASSEMBLY
SHOCK ABSORBER
PROPELLER SHAFT SPRING FRONT MOUNT
Fig. 4-Camaro Rear Suspension Components
Fig. 5-Corvette Rear Suspension and Driveline Components
The rear wheel spindles are driven through double The direct, double-acting shock absorbers are at
"U" jointed, tubular driveshafts which are flange mount tached at the upper eye to a frame bracket and at the
ed to a splined spindle flange at their outboard end and lower eye to the strut rod mounting shaft which incor
bolted to the differential side gear yokes at their in porates a threaded stud for the shock absorber lower
board end. Wheel spindle support houses the inner and eye.
outer tapered roller bearings, two to each wheel. Bear The transversely mounted multi-leaf spring is clamp
ing adjustment is made through the use of a spacer and bolted at the center section to a lower mounting surface
variable thickness shims between the bearings. on the differential carrier cover. The outer ends of the
The spindle supports also incorporate integrally main leaf are provided with a hole through which the
forged, fork-shaped mounting brackets to accept the spring is link bolted to the rear of the torque control
outer ends of the rubber-bushed strut rods. The strut arms. The spring assembly is provided with full length
rods are mounted laterally from the spindle support to liners.
a bracket bolted to the lower surface of the axle car An optionally available stabilizer shaft attaches to the
rier. The strut rod connection at this point is with an upper rear section of the torque control arms, and
eccentric cam arrangement and provides for rear wheel stretches rearward where it is connected to the frame by
camber adjustment. two rubber-bushed mounting brackets.

Periodic maintenance and adjustments are not required RIDING HEIGHT CHECK
for the rear suspension components. The suspension Chevrolet, Chevelle Camaro and Chevy II
system should be checked for shock absorber action, In case of vehicle riding height complaints, a spring
condition of suspension bushings, tightness of suspension height check will show if the rear suspension is at the
attaching bolts and an overall visual inspection of com right height.
ponents for defects. 1. Position car on smooth level floor.
Fig. 6-Measuring Rear Riding Height Chevrolet and Chevelle

Fig. 7-Measuring Rear Riding Height Camaro and Chevy II
2. Vehicle must be at curb weight full gas tank, no

passengers, spare and jack in trunk. Car should be frame side member, After correct shim stack has been
raised up a few times to allow suspension to settle selected, install pivot bolt and hardened washers fig.
with car weight to eliminate friction at a:rm pivots. 9 making sure that all shims are retained - torque nut
3. On Chevrolet and Chevelle models, measure riding to specifications and install cotter pin. If specified torque
height as the distance from the top of the axle hous does not permit cotter pin insertion, tighten nut to next
ing to frame kick-up fig. 6. flat.
4. On Camaro and Chevy U models measure riding
height as the distance from jounce bumper upper WHEEL BEARING ADJUSTMENT CORVETTE
attaching bolt to top of axle housing fig. 7. Inspection
5. Riding heights vary between models. Refer to speci The tapered-roller spindle bearings should have end
fications section for vehicle and model application. play of .001" to .008". During inspection, check end
play and, when necessary, adjust as outlined in this
WHEEL ALIGNMENT CORVETTE section.
1. Raise rear or vehicle until wheels clear ground.
Camber 2. Disengage bolt lock tabs and disconnect outboard end
Wheel camber angle is obtained by adjusting the eccen of axle drive shaft from wheel spindle flange.
tric cam and bolt assembly located at the inboard mount 3. Mark camber cam in relation to bracket. Loosen and
ing of the strut rod fig. 8. Place rear wheels on turn camber bolt until strut rod forces torque control
alignment machine and determine camber angle. To arm outward. Position loose end of axle drive shaft
adjust, loosen cam bolt nut and rotate cam and bolt as to one side for access to spindle.
sembly until specified camber is reached. Tighten nut 4. Remove wheel and tire assembly. Mount dial in
securely and torque to specifications. dicator Tool J-8001 on torque control arm
Toe-In
Wheel toe-in is adjusted by inserting shims of varying
thickness inside the frame side member on both sides
of the torque control arm pivot bushing fig. 9. Shims
are available in thicknesses of 1/64", 1/32", 1/8" and
1/4". To adjust toe-in, remove torque control arm pivot
bolt; then position torque control arm to obtain specified
toe-in. Shim gap toward vehicle centerline between torque
control arm bushing and frame side inner wall.
NOTE: Do not use thicker shim than necessary,
and do not use undue force when shimming inner
side of torque control arm - to do so may cause
toe setting to change.
Shim outboard gap as necessary to obtain solid stack-
up between torque control arm bushing and inner wall of Fig. 8-Adjusting Rear Wheel Camber Corvette
Fig. 9-Toe-In Adjusting Shim Location Corvette
adjacent surface and rest pointer on flange or spindle

end fig. 10.
5. Grasp brake disc and move axially in and out while Fig. 11-Removing Drive Spindle from Support Corvette
reading movement on dial indicator. If end movement
is within the .001" to .008" limit, bearings do not drive spindle, make sure puller plate is posi
require adjustment. If not within .001" to .008" tioned vertically in the torque control arm be
limit, record reading for future reference and adjust fore applying pressure to the puller screw.
bearings as outlined below. 5. Remove shim and bearing spacer from spindle
Adjustment support.
1. Apply parking brake to prevent spindle from turning 6. Note size of shim used. If dial indicator reading
and remove cotter pin and nut from spindle. was more than .008", select a shim thinner by the
2. Release parking brake and remove drive spindle amount needed to bring end play within limits. If
flange from spUmed end of spindle. dial indicator reading was less than .001", select a
3. Remove brake caliper and brake disc as outlined in shim thicker by the amount needed to bring end play
Section 5. within limits.
4. Install Thread Protector J-21859-1 over spindle NOTE: Shims are available in thicknesses from
threads; then remove drive spindle from spindle .097" to .148" in increments of .003".
support, using Tool J-22602 as shown in Figure 11.
EXAMPLE: Bearing end play reading obtained
CAUTION: When using Tool J-22602 to remove on dial indicator was .011", .003" over limit.
Bearing shim removed from spindle measures
.145". New shim installed measures .139", .006"
smaller. End play is now decreased by .006" and
is .005", which is within the .001" to .008" limit.
Fig. 10-Checking Wheel Bearing Adjustment Corvette Fig. 12-Installing Drive Spindle to Support Corvette
7. After determining shim thickness, install bearing washer and Tool J-4731. Discard nut and use a
spacer and shim on spindle. Position spindle in new one for final assembly.
spindle support. 9. Position drive flange over spindle, making sure
CAUTION: Place large end of spacer facing flange is aligned with spindle splines. Install washer
outer bearing with shim located between spacer and nut on spindle then tighten nut to specifications
and inner bearing. and install cotter pin. If specified torque does not
permit cotter pin insertion, tighten nut to next flat.
8. Press inner bearing race and roller assembly on 10. Seat spindle support outer seal in bore by using
spindle as follows. screw driver, or other suitable tool, to press against
a. Position Tool J-4731 over spindle and against metal portion of seal.
bearing inner race. 11. Install brake disc and caliper. Refer to Section 5
b. Position washer and spindle nut on spindle and for details of brake disc and caliper installation.
proceed to tighten nut until bearing is forced on 12. Install axle drive shaft, wheel and tire assembly,
spindle sufficiently to allow spindle drive flange adjust camber cam to original position and torque
to be installed fig. 12. Remove spindle nut, all components to specifications.
COMPONENT PARTS REPLACEMENT

Chevrolet, Chevelle, Chevy II and Camaro
control arm, with the nut finger tight on the spring

COIL SPRING retainer bolt.
Chevrolet NOTE: Omit the lock washer under the special
high carbon bolt, so that sufficient bolt thread
Removal will be available to start the nut. The lock
To remo,e either or both rear coil springs proceed washers will be installed later in Step 4.
as follows:
1. Raise rear of vehicle and place jack stands under 2. By alternately raising the axle slightly and them
frame. Support vehicle weight at rear, using either re-snugging the nut on each spring lower seat bolt,
a jack or post of twin-post hoist under axle. move the axle upward until vehicle weight is fully
2. Remove both rear wheels from vehicle. supported on the jack. With the spring now com
3. With the car supported as in Step 1, so that the rear pressed to approximately curb height, positively
springs are compressed by weight of vehicle; per position the springs in the lower seats by torquing
form the following: the nut on the lower seat bolt fig. 14.
a. Disconnect both rear shock absorbers from the 3. Re-connect shock absorbers, torque rear attach
anchor pin lower attachment. ment of upper and lower control arms, and re
b. Loosen the upper control arms rear pivot bolt connect the axle tie rod at proper torque.
do not remove the nut. 4. With the rear of vehicle still supported by jack under
c. Loosen both ° left and the right lower control axle; remove the nut from the lower seat bolt of one
arm rear att. .ment do not disconnect from axle rear spring, slide proper lock washer on the bolt
brackets. and reinstall the nut to proper torque. Similarly
d. Remove the rear suspension tie rod from the
stud on the axle tube.
4. At the lower seat of both rear coil springs, slightly
loosen the nut on the bolt that retains the spring and
seat to the control arm. When the nut has been
backed off the maximum permissible, all threads of
the nut should still be engaged on the bolt.
CAUTION: Under no condition should the nut,
at this time, be removed from the belt in the
seat of either spring.
5. Slowly lower the support jack or hoist post that has
been in place under the rear axle, thereby allowing
the axle to swing down, carrying the springs out of
their upper seat and providing access for spring
removal.
6. Remove the lower seat attaching parts from each
spring, then remove the springs and insulators from
the vehicle fig. 13.
Installation
1. Position the springs and upper rubber insulator in
their upper seat so that end of top coil is 3/8" ± 1/8"
from end of stop. Install the lower seat parts on the Fig. 13-Coil Spring Installation Chevrolet
install a lock washer at the lower seat of the other LEAF SPRING, SPRING SEAT PADS, SPRING EYE
rear spring. BUSHINGS, SPRING LEAFS
5. Install rear wheels and lower vehicle to floor.
Camaro and Chevy II Fig. 16
Chevelle
Removal
Removal 1. Raise rear of vehicle sufficiently to allow axle as
The following procedure may be utilized to replace sembly to hang freely; then support weight of vehicle
either or both rear coil springs. at both frame side rails and near front eye of spring.
1. Raise vehicle to a height that will allow axle assem 2. Raise axle assembly so that all tension is removed
bly to hang freely, and position supports under both from spring.
frame side rails. 3. Loosen and remove shock absorber lower attaching
2. Support axle assembly with an adjustable lifting bolt.
device, and disconnect shock absorber at axle 4. Loosen the spring eye-to-bracket retaining bolt.
bracket. Shock absorber on side opposite need not 5. Remove the screws securing the spring retainer
be disconnected if only one spring is being removed. bracket to the underbody.
Refer to Shock Absorber Removal procedures out 6. Lower axle assembly sufficiently to permit access to
lined in this section. spring retainer bracket and remove bracket from
3. Lower axle assembly until suspension reaches end spring.
of travel; then pry lower pigtail over vertical re 7. The spring eye bushing can be replaced without
tainer on axle bracket and remove spring and insula completely removing the spring from the vehicle,
tor from vehicle. if bushing requires replacement proceed as follows.
Installation a. Position remover adapter J-21978-1 over puller
1. Position rubber insulator on end of spring. Install screw J-21058-15 so that adapter is against head
insulator and spring in upper spring seat fig. 15. of puller screw. Refer to Figure 17 for view of
2. Pry lower pigtail portion of spring over vertical removal tools.
flange of the axle bracket spring seat. b. Position puller screw through eye of bushing so
that remover adapter J-21978-1 is against un
3. Raise axle to allow shock absorber installation.
flanged side of bushing.
Position shock absorber in axle bracket. Torque nut
c. Position large end of barrel J-22553-1 over
as outlined in Shock Absorber Installation
puller screw and seat barrel against spring eye.
procedures.
4. Lower vehicle and check rear riding height. d. Position thrust bearing on puller screw then in
stall and tighten nut J-21058-8 against thrust
bearing.
e. Check to make sure that all puller parts are
properly aligned then proceed to tighten nut until
bushing is pulled free of spring eye--disassemble
puller tool.
Fig. 14-Installing Coil Spring to Lower Control Arm Chevrolet Fig. 15-Coil Spring Installation Chevelle
i. Dissassemble bushing installation tools and re

move from spring.
8. Pry parking brake cable out of the retainer bracket
mounted on the spring mounted plate.
A 9. Remove lower spring plate-to-axle bracket retaining
nuts fig. 19. Lower plate-to-axle attachments are
shown in Figure 16.
10. Remove upper and lower rubber spring pads, spring
plate.
11. Support spring, then remove lower bolt from spring
rear shackle. Separate shackle and withdraw spring
from vehicle.
12. Remove rear spring shackle upper bolt and withdraw
shackle bushings from frame.
Spring Leaf Replacement

MULTI-LEAF INSTALLATION
1. Place spring assembly in a bench vise and remove
spring clips.
2. Position spring in vise jaws, compressing leaves at
center and adjacent to center bolt.
Fig. 16-Rear Spring-Exploded View Camaro and Chevy II 3. File peened end of center bolt and remove center bolt
nut. Open vise slowly to allow spring assembly to
f. Position installer adapter J-22553-2 over flange expand.
end of b u s hi n g then position puller screw 4. Replace spring leaf as required, also replace any de
J-21058-15 through installer adapter and bush fective spring leaf inserts at this time,
ing. Refer to Figure 18 for view of installation 5. Align center holes in spring by means of a drift and
tools. compress spring leaves in a vise.
g. Position puller screw through spring eye until 6. Remove drift from center hole and install a new cen
bushing contacts spring. Install small end of ter bolt - peen bolt to retain nut.
barrel J-22553-1 over puller screw and seat 7. Align spring leaves by tapping with hammer, then
barrel against spring.. bend spring clips into place.
h. Install thrust bearing and nut J-21058-8. Check
puller tools and bushing for proper alignment; NOTE: Spring clips should be tightened suffi
then tighten nut to pull bushing into spring. ciently to maintain alignment, but not tight
enough to bind spring action.
NOTE: Do not apply additional torque to nut
J-21058-8 after bushing flange contacts spring.
Unnecessary torque applied after flange is Installation
seated will tend to distort flange and reposition 1. Position spring front mounting bracket to spring
bushing in spring. front eye. Spring attaching bolt must be installed
Fig. l7-Removing Spring Frorlt Bushing Camaro and Chevy II Fig. l8-lnstalling Spring Front Bushing Camaro and Chevy II
so that head of bolt is toward center of vehicle. SHOCK ABSORBER

2. Position spring shackle upper bushings in frame,
position shackles to bushings and loosely install Chevrolet and Chevelle
bolt and nut, Removal
3. Install bushing halves in spring rear eye, place 1. Raise rear of v e hi c 1 e and support rear axle
spring to shackles and loosely install shackle lower assembly.
bolt and nut. 2. If equipped with superlift shock absorber, disconnect
air line from shock absorber.
NOTE: When installing spring, make sure
spring is positioned so that parking brake cable 3. Disconnect shock absorber at upper mounting bracket
by removing the two retaining bolts. Refer to Figure
is on underside of spring.
20 for shock absorber mounting details. Chevelle
4. Raise front end of spring and position bracket to components shown as typical.
underbody. Guide spring into position so that it will 4. Disconnect shock absorber at lower attaching bracket
index in the axle bracket and also make sure that and remove shock.
the tab on spring bracket is indexed in slot pro NOTE: When performing any service opera
vided in the underbody. tions that requires removal or loosening of the
5. Loosely install spring-to-underbody bracket. lower attaching nut, it is essential that the stud
6. Position spring upper cushion between spring and be prevented from turning. A hex is located on
axle bracket so that spring cushion ribs align with the stud between the axle bracket and shock
axle bracket locating ribs. absorber in order that a wrench may be used
7. Place lower spring cushion on spring so that cushion for this purpose. Failure to hold the stud in
is indexed on locating dowel. Upper cushion and low this manner will result in damage to the me
er cushion will be aligned if installation is correct. chanical bond between the shock absorber bush
ing and the mounting stud.
8. Place lower mounting plate over locating dowel on
spring lower pad and loosely install retaining nuts.
Installation
9. If new mounting plate was installed, transfer parking 1. Loosely install the two shock absorber upper at
brake cable retaining bracket to new plate. taching bolts.
10. Position shock absorber to spring mounting plate and 2. Position lower attaching stud in axle bracket and
loosely install eye bolt and nut - head of bolt should loosely install lock washer and nut.
be toward front of vehicle. 3. Torque upper attaching bolts to specifications.
11. Position parking brake cable in retaining bracket and 4. Torque lower attaching nut to specifications, ob
securely clamp bracket to retain cable. serving procedure outlined in Removal procedure.
5. If equipped with superlift shock absorbers, connect
12. Remove stand jacks and lower vehicle so that weight air line to shock absorber and add air to obtain a
of vehicle rests on suspension components. Torque minimum of 10 psi.
all affected parts to specifications. 6. Lower vehicle and check shock absorber action.
Fig. 19-Removing Lower Plate Fig. 20-Shock Absorber Mounting-Exploded View Chevelle
gasket, upper grommet and retainer and nut to the

shock absorber rod. Torque nut to specifications.
2. Position shock absorber bracket to underbody and
install bracket retaining screws. Torque retaining
screws to specifications.
3. Insert shock absorber eye into lower bracket, install
bolt with head toward front of vehicle. Torque nut to
specifications.
4. Lower vehicle and test shock absorber action.
CONTROL ARM
Chevrolet Upper
Removal
1. Using a suitable hoist that will support the rear axle
housing or wheels such as a twin post or drive on
ramp type, remove the rear pivot bushing bolt at
the rear axle housing fig. 23.
NOTE: The rear axle must be supported in
such a way as to prevent the axle housing from
rotating about the lower control arm rear pivot,
and to also relieve load on the pivot bushing.
2. Remove the three bolts, lock washers and nuts at
taching the upper control arm bracket to the
crossmember.
3. Separate the control arm bracket from the cross-
member. Remove the arm from under vehicle.
4. Remove the bolt, nut and washer attaching the upper
control arm to the bracket. Separate the control
Fig. 21-Shock Absorber Mounting-Exploded View Chevy II
arm from the bracket.
Chevy II Bushing Replacement
1. Clamp control arm securely in a vise and remove
Removal Refer to Fig. 21 bracket from forward end of arm.
1. Raise vehicle and support axle housing with adjust
able jackstand.
2. Loosen and remove shock absorber lower mounting
bolt from shock absorber eye.
3. Remove shock absorber upper mounting bracket
bolts and withdraw shock absorber.
Installation
1., Loosely install the two shock absorber upper at
taching bolts.
2. Insert shock absorber eye into lower bracket, install
bolt with nut to rear and torque to specifications.
3. Torque upper bolts to specifications.
4. Lower vehicle and test shock absorber action.
Camaro
Removal Refer to Fig. 22
1. Raise rear of vehicle and -support rear axle
assembly.
2. Loosen and remove shock absorber lower attaching
bolt from shock absorber eye.
3. Remove shock absorbe:r upper mounting bracket-to-
underbody retaining sc:rews and withdraw shock ab
sorber and bracket.
4. Remove nut, upper retainer and grommet, gasket
and bracket, and lower grommet and retainer from
the shock absorber rod.
5. Inspect rubber grommets and gasket for damage and
deterioration- - replace as required.
Installation
Fig. 22-Shock Absorber Mounting-Exploded View Camaro
1. Assemble lower retainer and grommet, bracket and
REAR SUSPENSION AND DRIVE’LINE 4-12
2. Place Puller Screw J-21058-15 through Puller

Adapter J-21830-2. Position puller screw through
small end of bushing then install Receiver J-21830-4
and Bridge J-21830-7 over opposite end of bushing.
Center receiver and bridge over flanged end of
bushing then position t h r u s t bearing and Nut
J-21058-8 on puller screw. Refer to Figure 24 for
installation of removal tools.
3. Turn Nut J-21058-8 to withdraw bushing, making
sure Remover Adapter J-21830-2 is centered and
will clear hole in control arm.
4. Disassemble puller tools and position Installer
Adapter J-2-1830-2 on flanged end of new bushing.
Install Spacer J-21830-6 over small end of bushing
so that it makes contact with J-21830-2.
5. Position Puller Screw J-21058-15 through J-21830-2
and bushing so that head of screw rests against
J-21830-2. Position this assembly in control arm
as shown in Figure 25.
6. Install receiver, bridge, thrust bearing and nut to
complete installation as shown in Figure 25. Fig. 24-Upper Control Arm Bushing Removal Chevrolet
7. Turn Nut J-21058-8 to pull bushing into control
arm. Check position of bushing when installing to
make sure bushing is properly aligned. When bush
ing is properly installed, Spacer J-21830-6 will stop 4. Position vehicle so that weight is on suspension
against control arm. components and torque all affected pa r t s to
8. Dissassemble bushing installation tools and reinstall specifications.
attaching bracket to control arm. Install bracket
pivot bolt so that nut will be on outboard side of arm. Chevrolet Lower
1. Position rear of control arm into axle bracket and 1. Raise vehicle and remove shock absorber and spring
loosely install the pivot bolt. as outlined in this section.
2. Align the forward end of the control arm with the NOTE: If both rear suspension lower control
rear crossmember and install front bracket bolts arms are to be removed, support the rear axle
through holes. Raise or lower nose of carrier as in such a manner to prevent damage to brake
required to help align bracket and crossmember. lines and to prevent assembly from falling.
3. Install lock washers and nuts to retain bracket in
place. 2. Note position of control arm in forward attaching
Fig. 23-Rear Suspension Upper Control Arm

Attaching Points Chevrolet Fig. 25-Upper Control Arm Bushing Installation Chevrolet
bracket and disconnect control arm at forward and b. Install Receiver J-21830-4 and Bridge 3-21830-7
rearward attaching points. Remove assembly from over screw and against control arm. Position
vehicle. thrust bearing against J-21830-7 and screw
Bushing Replacement J-21058-8 snugly against bearing. Install Spacer
Lower control arm front and rear bushing assemblies J-21830-3 between sides of control arm and over
are not interchangeable and require separate removal bushing.
and installation procedures. c. Check tool installation for proper alignment and
1. Replace the front bushing as follows. tighten J-21058-8 to withdraw bushing from con
a. Center Receiver J-7574-4 over flanged end of trol arm. Refer to Figure 28 for installed view
bushing and position Spacer J-7574-3 over bush of tools.
ing and between sides of control arm. Using d. Disassemble tools and position Installer Adapter
J-21830-2 on flanged end of new bushing. Posi
Remove J-7574-1 against small end of bushing,
press bushing from control arm. Refer to Figure tion bushing in control arm making sure of cor
26 for installed view of tools. rect installation. Small end of bushing will pass
b. Position bushing in control arm making sure of through one side of arm without any interference.
correct installation. Small end of bushing will e. Install 3-21830-4, J-21830-7, thrust bearing and
pass through one side without any interference. J-21058-8 on threaded end of J-21058-15 as
c. Position Puller Screw J-21058-15 through In shown in Figure 29. Tighten J-21058 to main
staller Adapter J-7574-2--head of puller screw tain proper relationship of parts; then position
should rest against flat side of adapter. Spacer 3-21830-3 over bushing and between sides
d. Install adapter and screw through bushing with of control arm.
adapter resting against flange portion of bushing. f. Tighten J-21058-8 until bushing is fully seated
Install Receiver J-21058-6 and Bridge 3-21058-7 against side of control arm. Do not apply undue
on opposite side of control arm fig. 27. pressure to J-21058 after bushing is seated--to
do so may cause permanent distortion to control
e. Install thrust bearing and Nut J-21058-8. Screw arm.
nut against J-21058-7 to maintain proper relation g. Disassemble tools and check bushing for proper
ship of parts, then install Spacer J-7574-3 over installation.
the partially installed bushing and between the
sides of the control arm. Installation
f. Continue to tighten J-21058-8 until bushing is 1. Position the control arm between the mounting
pulled flush against control arm. Do not exert
undue force against control arm after bushing is
installed. Overtightening of 3-21058-8 will cause
damage to walls of control arm.
g. Disassemble tools and inspect bushing for proper
installation.
2. Replace the rear bushing as follows:
a. Position Puller Screw J-21058-15 through Re
mover Adapter J-21830-2 so that head of screw
is opposite button end of remover. Install this
assembly, threaded end of screw first, through
bushing to be removed.
Fig. 27-Lower Control Arm Front Bushing Installation

Fig. 26-Lower Control Arm Front Bushing Removal Chevrolet Chevrolet
Fig. 30-Control Arm Bushing Removal Chevelle
1. Raise vehicle to a height that will allow axle assem

bly to hang freely and position supports under both
frame side rails.
2. Support axle assembly with an adjustable lifting de
vice and raise rear axle assembly until tension is
relieved in control arm being removed.
3. Disconnect control arm at forward and rearward
attaching points and remove from vehicle.
Fig. 28-Lower Control Arm Rear Bushing Removal Chevrolet Bushing Replacement
The upper control arm front bushing and carrier ear
brackets and loosely install the pivot bolt retaining bushings are of the same part number and are inter
nuts in the proper position. changeable. However, the lower control arm bushings
2. Install spring and shock absorber as outlined in this are of a different rubber material and are not inter
section. changeable with the upper bushings. Replacement proce
3. Lower vehicle so that weight is placed on sus dures are indicated below.
pension components and torque all affected parts to 1. Replace the upper and lower control arm installed
specifications. bushings as follows:
a. Position control arm in a vise, or other suitable
Chevelle Upper and Lower holding device, so that clamping action is against
Removal closed section of control arm.
b. Place Puller Screw J-21059-15 through Puller
NOTE: If both upper control arms and both Adapter 3-21474-2. Position puller screw through
lower control arms are to be removed at the small end of bushing then install Receiver
same time, remove both coil springs as outlined J-21474-5. Thrust Bearing and Nut J-21058-8
under "Coil Spring Removal". in that order onto puller screw. Install Spacer
J-21474-1 between sides of control arm and over
bushing so that spacer follows contour of bushing.
Refer to Figure 30 for installation of removal
tools.
Fig. 29-Lower Control Arm Rear Bushing Installation

Chevrolet Fig. 31-Control Arm Bushng Installation Chevelle
Fig. 32-Carrier Mounted Suspension Bushing

Removal Light-Duty Chevelle Fig. 34-Carrier Mounted Suspension Bushing Removal
Heavy-Duty Cheve lIe
c. Turn Nut J-21058-8 to withdraw bushing, making
sure Remover Adapter J-21474-2 is centered 2. Replace the carrier mounted, upper control arm
and will clear hole in control arm. rear bushing using the following procedure.
d. Disassemble puller tools and position Installer
Adapter J-21474-2 on flanged end of new bushing. Light-Duty Carrier
Position Puller Screw J-21058-15 through in a. Position Puller Adapter J-21474-2 on Puller
staller adapter and bushing; then place assembly Screw J-21058-15 then place puller screw through
through hole in control arm. small end of bushing.
e. Install Receiver J-21474-5, Thrust Bearing, and b. Install Receiver J-21830-4, Bridge J-21830-7,
Nut J-21058-8 in that order onto puller screw. Thrust Bearing, and Nut J-21058-8 in that order
Install Spacer .J-21474-1 between sides of control onto puller screw. Refer to Figure 32 for in
arm and over bushing so that spacer follows stalled view of tools.
contour of bushing. Refer to Figure 31 for in c. Turn Nut J-21058-8 to remove bushing from
stalled view of tools. carrier ear, making sure Remover Adapter
f. Turn Nut J-21058-8 to pull bushing into control J-21474-2 is centered and will clear hole in
arm. Check position of bushing when installing carrier ear.
to make sure bushing is properly aligned. Seat d. Disassemble puller tools and position Installer
flanged end of bushing firmly against control Adapter J-21474-2 on flanged end of bushing.
arm, but do not apply unnecessary force after Install Puller Screw J-21058-15 through receiver
bushing is seated - to do so will distort control so that screw head is seated against receiver.
arm.
Fig. 33-Carrier Mounted Suspension Bushing Fig. 35-Carrier Mounted Suspension Bushing Installation
installation Light-Duty Cheve lie Heavy-Duty Cheve lIe
Installation
1. Place control arm into position between the forward
and rearward mounting brackets and install retaining
bolts. Refer to Figure 36 for installation view of
control arms.
2. Support vehicle at axle and remove supports from
beneath the frame side rails.
3. Install lock, washer and nut to retaining bolts and
torque to specifications.
REAR SUSPENSION TIE ROD-CHEVROLET

Fig. 36-Upper and Lower Control Arm Assembly Chevelle Removal
1. Remove the nut, washer and bolt from the left side
Position this assembly through inboard side of aid the nut and washer from the stud on the right
carrier ear. side that secure the tie rod to the brackets fig. 37.
e. Position bushing and Installer Adapter J-21474-2 Withdraw the rod from under the vehicle. An ex
onto puller screw with small end of bushing to ternal shell service bushing is available for left side
ward carrier ear. Refer to Figure 33 for in on all models and both right and left on station
stalled view of tools. wagons and service tie rods.
f. Install Thrust Bearing and Nut J-21058-8 onto
NOTE: The above operations need not be per-
puller screw. Turn nut to pull bushing into car
rier ear. Check position of bushing when install formed on a hoist. However, to provide ample
working space, the use of a hoist or proper jack
ing to make sure bushing is properly aligned.
stand is recommended.
Heavy-Duty Carrier
a. Install a 1/2 x 20 nut on Puller Screw 3-21058-15, Bushing Replocement
install thrust bearing against nut. Position puller The following bushing removal procedure is effective
screw through Bridge and Receiver J-21830-4 for both ends of the tie rod used on station wagons all
and 7. service tie rods and the left end of the tie rod used on all
b. Position puller screw through flanged end of models except station wagons.
bushing then install Remover Adapter J-21991 1. With tie rod bushing centered over Tool J-7877-2
on threaded end of puller screw. and with tie rod supported horizontally, press or
c. Align tools on carrier ear and center remover drive bushing from rod, using Tools J-7877-1 and
adapter on bushing. Hold head of puller screw J-7079-2 as shown in Figure 38.
and turn 1/2 x 20 nut to withdraw bushing from 2. With tie rod centered over Tool J-7877-2 and rod
carrier ear. Refer to Figure 34 for installed supported horizontally, press or drive bushing into
view of removal tools. arm using Tools J-7877-3 and J-.7079-2 as shown
d. Position Installer J-21474-2 on flanged end of in Figure 38. Tool J-7877-3 should bottom on tie
new bushing and install Driver Handle J-7079-2 rod when bushing is fully installed.
to opposite end of installer.
e. Position bushing in carrier ear and drive bush Installation
ing until it seats against carrier. Bushing is 1. Mount the tie rod to the axle bracket stud. Install
properly seated when shoulder on bushing con
tacts carrier. Refer to Figure 35 for installation.
NOTE: Do not attempt to seat flange of bush
ing against ear of carrier. Bushing is properly
installed when shoulder on bushing seats against
l..._-_----- J-7079-2 -.----_-_
chamfer on carrier ear.
J-7877-3
TIE ROD
J-7877- 1
N TIE ROD
I-
Fig. 37-Rear Suspension Tie Rod Attaching Points Chevrolet Fig. 38-Tie Rod Bushing Replacement Chevrolet
_______
nut and special washer but do not tighten.

NOTE: Bolt may be installed from either
NOTE: On the tie rod used on all models except direction.
station wagons, place flanged portion of bushing
against attaching bracket.
3. Lower vehicle to floor if raised and bounce rear
2. Install the bolt, lock washer and nut to the frame end several times to settle bushings. Tighten af
bracket fig. 37. Do not tighten. fected parts to specifications.
COMPONENT PARTS REPLACEMENT CORVETTE

WHEEL SPINDLE AND SUPPORT Fig. 39 rod mounting shaft. It may be necessary to sup
Removal port spring outer end before disconnecting shock
Remove wheel drive spindle as outlined previously in absorber, as shock absorber has internal rebound
this section under "Wheel Bearing Adjustment". control.
d. Remove cotter pin and nut from strut rod mount
Repairs ing shaft, then pull shaft from support and strut
1. Out of 3/8" square steel bar stock, make bearing rod.
removers and use as shown in Figure 40. e. Spindle support may then be removed and bearing
2. After removing deflector, spindle inner grease seal cups serviced as in Step 2 above.
and inner bearing race, bearing cups may be re 4. To remove drive spindle outer bearing and seal
moved while spindle support is still mounted to the proceed as follows.
torque arm, by inserting remover tool and tapping a. Position Tool J-8331 between chamfered edge of
cup out. New bearing cups are installed using Tool bearing seat and inner race of bearing fig. 42.
J-7817 cup installer and handle J-8092 fig. 41. Clamp Tool J-8331 in a vise and apply pressure
3. To remove spindle support from torque arm, pro to unseat bearing.
ceed as follows.
a. Disconnect parking brake cable from actuating CAUTION: Use extreme caution when position
lever. ing Tool J-8331 against machined surface of
b. Remove four nuts securing support to torque arm spindle. Make sure all tool imperfections such
and withdraw brake backing plate and position it as nicks and burrs are removed from spindle
out of the way. contact area before applying pressure to unseat
c. Disconnect shock absorber lower eye from strut bearing.
b. Position Tool J-8331 and spindle in an arbor
press and press bearing from spindle fig. 43.
c. Remove outer seal and inspect for damage--re
place if necessary. Outer seal must be placed on
SPINDLE spindle before outer bearing inner race and roller
SUPPORT assembly is installed.
BEARING d. Pack outer bearing with a high-melting point
SPACER
wheel bearing lubricant and position on spindle.
INNER
BEARING
DRIVE
FLANGE
BEARING
PRELOAD
SPACER
DEFLECTOR
Fig. 39-Wheel Spindle and Support Cross-Section Corvette Fig. 40-Bearing Cup Removal Corvette
Fig. 43-Removing and Installing Drive Spindle

Outer Bearing Corvette
b. Check bearing adjustment and correct as neces

sary, following adjustment procedures previously
outlined.
DIFFERENTIAL CARRIER SUPPORT

Fig. 41-installing Spindle Bearing Cup Corvette BRACKET REPLACEMENT
1. Place a 1/2" thick block of wood or steel between
Large end of bearing should be toward shoulder
on spindle. nose of differential carrier, and floor pan. This will
prevent carrier from twisting upward when support
e. Press bearing on spindle using a bearing spacer
bracket is disconnected.
and Tool J-9436 as installers, as shown in Fig
2. Remove carrier support-to -crossmembe r attaching
ure 43.
bolt.
5. Pack spindle inner bearing with a high-melting point
3. Remove nuts from both bracket-to-carrier through
wheel bearing lubricant and position bearing in
bolts and remove bolts.
spindle support - small end of bearing should be
4. Assemble carrier support bracket by reversing above
positioned inward.
6. Tap new spindle inner grease seal into seal bore procedure. Torque all bolts to specifications.
and install deflector over support inner end.
SHOCK ABSORBER Fig. 44
Installation
1. Position support over torque arm bolts with strut Removal
rod fork toward center of vehicle and downward. 1. Disconnect shock absorber upper mounting bolt.
Place backing plate over studs and torque nuts to
specifications.
2. Connect parking brake cable to actuating lever.
3. Install drive spindle assembly as outlined previously
in this section under "Wheel Bearing Adjusment".
4. If new spindle support or associated parts are in
stalled, determine correct shim size as follows.
a. Assemble spindle to support, using a .145" shim.
Fig. 42-Unseating Drive Spindle Outer Bearing Corvette Fig. 44-Shock Absorber Installation Corvette
REAR SUSPENSION AND DRIVE LINE 4.19
Fig. 45-Strut Rods Corvette

Fig. 47-Marking Camber Cam and Bracket Corvette
2. Remove lower mounting nut and lock washer. bracket.
3. Slide shock upper eye out of frame bracket and pull 6. Remove cam bolt nut and cam and bolt assembly.
lower eye and rubber grommets off strut rod mount Pull strut down out of bracket and remove bushing
ing shaft. caps.
4. Inspect grommets and shock absorber upper eye for 7. Inspect strut rod bushings for wear and replace
excessive wear. where necessary. Replace strut rod if it is bent or
Installation damaged in any way.
1. Slide upper mounting eye into frame mounting Repairs
bracket and install bolt, lock washer and nut. 1. With strut rod bushing centered over Tool J-7877-2
2. Place rubber grommet, shock lower eye, inboard and with strut rod supported horizontally, press or
grommet, washers and nut over strut rod shaft. drive bushing from rod, using Tools J-7877-1 and
3. Torque nuts to specifications. J-7079-2 as shown in Figure 48.
2. With strut rod end centered over Tool J-7877-2 and
STRUT ROD AND BRACKET Fig. 45 rod supported horizontally, press or drive bushing
Removal into arm using Tools J-7877-3 and J-7079-2 as
1. Raise vehicle enough to provide working clearance. shown in Figure 48. Tool J-7877-3 should bottom
2. Disconnect shock absorber lower eye from strut on strut rod when bushing is fully installed.
rod shaft. Installation
3. Remove strut rod shaft cotter pin and nut. With 1. Place bushing caps over inboard bushing and slide
draw shaft by pulling toward front of vehicle fig. 46. rod into bracket. Install cam and bolt assembly and
4. Mark relative position of camber adjusting cam and adjust cam to line up with mark on bracket, Tighten
bracket, so they may be reassembled in same loca nut but do not torque at this point.
tion fig. 47 2. Raise bracket and assemble to carrier lower mount
5. Loosen camber bolt and nut. Remove four bolts se ing surface. Torque bolts to specifications.
curing strut rod bracket to carrier and lower 3. Raise outboard end of strut rod into spindle support
fork and insert strut rod shaft into fork so that flat
on shaft lines up with corresponding flat in spindle
fork. Install retaining nut, but do not torque.
4. Place shock absorber lower eye and bushing over
Fig. 46-Removing Strut Rod Shaft Corvette Fig. 48-Strut Rod Bushing Rep’acement
SPRING LINK BOLT
CUSHION
RETAINER -SPRING CUSHION
0
CUSHION
RETAINER
PLATE
SPRING
CUSHION
Fig. 49-Spring Mounting Corvette

strut shaft, install washer and nut and torque to
specifications.
5. Lower vehicle to floor and torque camber cam nut
and strut rod shaft nut to specifications. Then in
stall cotter pin through rod bolt.
6. Check rear wheel camber and adjust where
necessary.
SPRING Fig. 49 Fig. 51-Removing Clamp Plate Corvette

Removal
a safe grab hook for this operation. Do not use
1. Raise rear of vehicle and support on frame slightly
rope wire, cable or other method of retaining
forward of torque control arm pivot points. Remove
spring.
wheels and tires.
2. Place floor jack under spring at link bolt, and raise 4. Lower jack to free link bolt and remove link bolt
spring until nearly flat. cotter pin, nut and rubber cushions.
3. Wrap 1/4" or 5/16" chain with grab hook around 5. Support and raise spring end as in Step 2 above,
suspension crossmember and spring and hook chain remove chain when loose.
securely with grab hook. Secure chain to spring with 6. Carefully lower jack until spring tension is com
C clamp to prevent slipping fig. 50. pletely released.
7. Repeat Steps 2-6 on other side.
CAUTION: Use 1/4" or 5/16" chain only with 8. Remove four bolts and washers securing spring
center clamp plate fig. 51.
9. Drop spring and, slide out from under vehicle fig.
52.
Fig. 50-Chain Installation Corvette Fig. 52-Lowering Spring Corvette
Fig. 53-Removing Center Bolt Corvette

Repairs
1. Clamp spring center section in vise and remove
center bolt fig. 53. Fig. 55-Torque Control Arm Corvette
2. Release vise, remove spring and separate leaves.
sert new cotter pin and bend ends around.
3. Replace worn or damaged liners as necessary and
5. Raise spring end with jack under link bolt, and re
replace any broken leaves.
move chain and C clamp when loose.
4. Replace main leaf spring cushion retainers by
6. Carefully lower jack, making sure rubber cushions
chiseling over flared portion until retainer may be
knocked out of leaf. Place new retainers into posi remain indexed in retainers.
7. Remove jack and repeat on opposite side. Install
tion and flare over with a ball peen hammer or other
wheels and tires, remove frame supports and lower
suitable tool.
vehicle to floor.
5. Insert drift into center bolt holes in leaves to align
spring leaves fig. 54. Install center bolt and tighten
securely. TORQUE CONTROL ARM Fig. 55
1. Disconnect spring on side torque arm is to be re
1. Place spring on carrier cover mounting surface,
moved. Follow Steps 1-6, Spring-Removal.
indexing center boithead with hole in cover.
2. Place center clamp plate in position and install four NOTE: If vehicle is so equipped, disconnect
bolts and washers. Tighten bolts and torque to stabilizer shaft from torque arm - refer to
specifications. "Stabilizer Shalt Replacement".
3. Raise spring outer end with floor jack until spring
2. Remove shock absorber lower eye from strut rod
is nearly flat and secure with chain as in Step 3-
shaft.
Removal.
3. Disconnect and remove strut rod shaft and swing
4. Lower jack, align torque control arm with spring
strut rod down.
end and insert link bolt, rubber cushions and re
4. Remove four bolts securing axle drive shaft to
tainers. Install castellated nut on link bolt and
spindle flange and disconnect drive shaft.
tighten until cotter pin hole in bolt is visible. In-
CONTROL ARM
Fig. 54-Aligning Spring Leaves Corvette Fig. 56-Torque Control Arm Bushing Cross-Section Corvette
Fig. 59-Installing Bushings Corvette
3. Remove bushings by spreading them apart with a

chisel and tap out of arm fig. 58.
NOTE: If bushing diameters are s eve rely
rusted in torque arm, and arm tends to spread
during removal, clamp arm in a C-clamp to
prevent spreading.
4. Lightly oil new bushing diameters not rubber por
Fig. 57-Drilling Out Retainer Flare Corvette tion and start bushings squarely in arm.
5. Install Tool J-7055-1 as shown in Figure 59 and
NOTE: It may be necessary to force torque press bushings into place.
arm outboard to provide clearance to drop drive 6. When bushings are fully installed, place special
shaft. plate over flared portion of new bushing retainer
5. Disconnect brake line at caliper and from torque and insert retainer into bushing.
arm. Disconnect parking brake cable. 7. Out of 5/8" thick steel plate 1-1/2" wide make flar
6. Remove torque arm pivot bolt and toe-in shims’ and ing tool support to the dimensions shown in Figure
pull torque arm out of frame. Tape shims together 60 and drill clearance holes as shown for 2 - 1/2"
and identify for correct reinstallation. bolts.
8. Place fabricated back-up plate on flared end of bush
NOTE: For service operations pertaining to ing retainer and assemble Tool 3-8111-23 to plate
the spindle support assembly, refer to service with two 1/2" x 5" bolts. Make sure threaded hole
operations under Wheel Spindle and Support in 3-8111-23 is centered over unflared end of bushing
earlier in this section. retainer and that chamfered retainer plate is cen
Repairs Fig. 56 tered over retainer tube.
1. Using 11/16" drill, drill out flared end of bushing 9. Lightly oil pointed end of J-8880-5 screw and thread
retainer fig. 57. into 3-8111-23 until pointed end contacts bushing
2. Remove special retainer plate and tap retainer out retainer. Continue threading 3-8111-23 until retainer
of bushing. Is flared fig. 61.
Installation
Place torque arm in frame opening.
1. Place toe-in shims in original position on both sides
2.
of torque arm, install pivot bolt and tighten but do
not torque at this point.
3. Raise axle drive shaft into position and install to
drive flange. Torque bolts to specifications.
4. Raise strut rod into position and insert strut rod
Fig. 58-Removing Bushings Corvette Fig. 60-Flaring Tool Back-Up Plate Corvette
BEND OVER TABS AFTER INSTALLATION
Fig. 63-Crossmember Mount Cross-Section Corvette
crossmember fig. 62.

4. Remove bolts securing carrier cover to cross-
member.
5. Inspect rubber isolation mounts for aging and re
place where necessary.
Fig. 61-Flaring Retainer Corvette Repairs-Isolation Mount
shaft so that flat lines up with flat in spindle sup 1. Bend back isolation mount tabs to allow mount re
port fork. Install nut and torque to specifications. moval fig. 63.
5. Install shock absorber lower eye and tighten nut 2. Place crossmember on a suitable support and press
to specifications. mount out of arm using a piece of suitable size pipe
6. Connect spring end as outlined u n d e r Spring- or tubing on outer shell or inner insert.
Installation, Steps 3-6. 3. Place new mount into position on crossmember,
compress outer sleeve and press mount into place
NOTE: If vehicle is so equipped, connect sta until it is fully and squarely seated.
bilizer shaft to torque arm - refer to "Sta
4. After installation, bend over locking tabs.
bilizer Shaft Replacement".
Installation
7. Install brake line at caliper and torque arm. Bleed
brakes 1. Install carrier cover to crossmember and torque
as outlined in Section 5-Brakes. bolts to specifications.
8. Install wheel and tire and lower vehicle. Torque, 2. Raise crossmember into position and install mount
torque arm pivot bolt to specifications.
ing bolts. Torque bolts to specifications.
3. Install differential carrier assembly as outlined
SUSPENSION CROSSMEMBER under Differential Carrier - Installation in th i s
Removal section.
1. Disconnect and remove spring as outlined under 4. Install spring, wheels and tires, remove frame sup
Spring-Removal. ports and lower vehicle.
2. Remove differential carrier assembly as outlined
under Differential Carrier-Removal in this section.
3. Support crossmember, remove bolts . securing
crossmember isolation mounts to frame and lower
Fig. 62-Removing Crossmember Corvette Fig. 64-Stabilizer Shaft Installation Corvette
STABILIZER SHAFT REPLACEMENT spect shaft for bends, breaks or other defects - do
not attempt to straighten shaft - replace parts as
1. Raise rear of vehicle and support at frame side rail deemed necessary.
with stand jacks. 4. Position bushings on shaft and loosely install shaft
2. Disconnect stabilizer shaft at both torque arms fig. to torque arms and at frame brackets.
64. Remove stabilizer shaft brackets from the 5. Align shaft to assume proper placement when bolts
frame and withdraw assembly from vehicle. are torqued, and torque attaching bolts to
3. Inspect bushings for signs of deterioration, and in- specifications.
DRIVE LINE
REAR AXLE
INDEX
Page Page
General Description 4-24 Axle Shaft 4-29
Chevrolet, Chevelle, Camaro and Chevy U 4-24 Removal 4-29
Corvette 4-24 Wheel Bolt Replacement 4-29
Maintenance and Adjustments 4-27 Oil Seal and/or Bearing Replacement 4-29
Lubricant 4-27 Brake Flange Plate Replacement 4-30
Lubricant Leaks 4-27 Installation 4-30
Axle Bolts and Wheel Nuts 4-27 Pinion Flange, Dust Deflector and/or
Rear Axle Noise Diagnosis 4-27 Oil Seal Replacement 4-31
Gear Noise 4-27 Component Parts Replacement Corvette 4-32
Bearing Noise 4-27 Axle Driveshaft 4-32
Drive Line Backlash 4-27 Removal 4-32
Failure Analysis 4-27 Repairs 4-33
Hypoid Gears 4-28 Installation 4-33
Differential Gears 4-28 Pinion Flange, Dust Deflector and/or Oil Seal. 4-33
Bearings 4-28 Removal 4-33
Component Parts Replacement Inspection 4-33
Chevrolet, Chevelle, Camaro and Chevy U 4-29 Installation 4-33
Axle Assembly 4-29 Differential Carrier 4-34
Positraction Differential Unit-On the Vehicle Check 4-35
GENERAL DESCRIPTION
CHEVROLET, CHEVELLE, CHEVY II AND CAMARO The hypoid ring gear is bolted to a one-piece differen
tial case which is supported by two preloaded tapered
The rear axle fig. 65 is a semifloating, fabricated roller bearings.
construction type consisting of a cast carrier with large
bosses on each end into which two welded steel tubes
are fitted. The carrier contains an overhung hypoid CORVETTE
pinion and ring gear. The differential is a two pinion
arrangement. The Corvette rear axle is of the type where the di!
The axle housing is made up of two steel welded tubes ferential carrier housing enclosing the differential and
pressed into the crossbore of the cast carrier - each hypoid gears is supported on a crossmember mounted to
tube is puddle welded at three places to the carrier. the chassis frame. The differential is connected through
Welded-on brackets provide attachment p o I n t s for universal joints to the drive shafts and wheels fig. 66.
Chevelle springs, shock absorbers, and lower control The internal components of the carrier are of conven
arms. Chevrolet models have welded-on brackets for tional design, incorporating a hypoid gear set with an
control arms, tie rod, and shock absorbers. The housing overhung pinion supported on two pre-loaded, tapered
on Chevy II and Camaro has welded brackets for mounting roller bearing assemblies, and a two-pinion differential
lower spring pad and shock absorber. A welded flange is assembly supported on tapered roller bearings. Pinion
provided for brake flange plate attachment. mounting distance adjustments are made through the use
The overhung hypoid drive pinion is supported by two of shims, as are the differential bearing pre-load and
preloaded tapered roller bearings. The pinion shaft is backlash adjustments. The differential side gears drive
sealed by means of a molded, spring loaded, rubber seal. two splined yokes which are retained laterally by snap
The seal is mounted on the pinion shaft flange which is rings located on the yoke splined end. The yokes are sup
splined and bolted to the hypoid pinion shaft. ported on caged needle bearings pressed into the carrier,
adjacent to the differential bearings. A lip seal, pressed center section. The filler plug is located on the right side
in outboard of the bearings, prevents oil leakage and dirt of the cover near the bolting flange.
entry. The carrier cover is bolted to the carrier and All service operations allow carrier removal without
provides accessibility to the internal parts. The cover removing the carrier cover. Cover removal is not nec
incorporates two integral, reinforced mounting pads which essary in any of the service procedures except in the
serve as the carrier attaching point to the suspension case of complete carrier housing replacement, as the
crossmember, and an attaching point for the spring carrier and cover are serviced as an assembly.
ia
iTra1 ! fl, .3
iii[ -5
23 :r ‘
TI
22
IA ut 6
20
19
v,fi1Th, 4qr A
‘ 0
I 4tE±Il
lij
r
a
#gIvIItz --
17 9
i0
16 11
12
% 13
14
15
Fig. 65-Rear Axle Cross-Section Chevrolet, Chevelle, Camaro and Chevy II
1. Companion Flange 7. Differential Case 13. Cover t9. Thrust Washer

2. Deflector 8. Shim 14. Pinion Shaft 20. Differential Pinion
3. Pinion Oil Seal 9. Gasket 15. Ring Gear 21. Shim
4. Pinion Front Bearing 10. Differential Bearing 16. Side Gear 22. Pinion Rear Bearing
5. Pinion Bearing Spacer 11. ‘IC" Lock 17. Bearing Cap 23. Drive Pinion
6. Differential Carrier 12. Pinion Shaft Lock Bolt 18. Axle Shaft
CHEVROLET CHAssIS 5ERVICE MANUAL
18-7
17}I
101112
14
Fig. 66-Rear Axle Cross-Section Corvette
1. Companion Flange 6. Pinion 11. Yoke Bearing 16. Differential Pinion Shaft
2. Pinion Seal 7. Differential Pinion 12. Yoke Bearing Seal 17. Thrust Washer
3. Front Pinion Bearing 8. Differential Side Gear 13. Side Gear Yoke 18. Ring Gear
4. Rear Pinion Bearing 9. Differential Bearing 14. Carrier Cover 19. Pinion Bearing Spacer
5. Pinion Shim 10. Differential Bearing Shim 15. Differential Case

LUBRICANT BEARING NOISE
The lubricant level should be periodically checked and Defective bearings will always produce a whine that is
maintained at level of filler plug with a warm axle. See constant in pitch and varies with vehicle speed. This fact
the lubricatiot’i section of this manual for lubricant will allow you to distinguish between bearing noise and
recommendations. gear noise.
1. Pinion bearing noise resulting from a bearing failure
Lubricant Leaks can be identified by a constant rough sound. Pinion
Lubricant leaks should be checked for at the pinion bearings are rotating at a higher speed than differen
flange oil seal, axle wheel bearing seals, lubricant filler tial side bearings or axle shaft bearings. This
plug, and carrier cover. Correction of these leaks con particular noise can be picked up best by testing the
sists of replacing the defective seals or gaskets involved car on a smooth road black top. However, care
as described in this section. should be taken not to confuse tire noise with bear
ing or gear noise. If any doubt exists, tire treads
AXLE BOLTS AND WHEEL NUTS should be examined for irregularities that would
From a safety standpoint, axle housing to rear spring produce such noise.
bolts, wheel nuts and control arm attaching bolts should 2. Wheel bearing noise may be confused with rear axle
be periodically inspected for secdre installation. noise. To differentiate between wheel bearings and
rear axle, drive the vehicle on a smooth road at
REAR AXLE NOISE DIAGNOSIS medium-low speed. With traffic permitting, turn
the vehicle sharply right and left. If noise is caused
Mechanical failures of the rear axle are relatively by wheel bearings, it will increase in the turns be
simple to locate and correct. Noise in a rear axle is a
cause of the side loading. If noise cannot be isolated
little more difficult to diagnose and repair. One of the to front or rear wheel bearings, inspection will be
most essential parts of rear axle service is proper necessary.
diagnosis. 3. Side bearings will produce a constant rough noise of
All rear axles are noisy to a certain degree. The a slower nature than pinion bearings. Side bearing
action of transmitting the high engine torque through a noise will not fluctuate in the above wheel bearing
90° turn reducing propeller shaft speed produces noise test.
in rear axles. This point establishes the need for a line
between normal and abnormal or unacceptable axle
noises. DRIVE LINE BACKLASH
Slight axle noise heard only at a certain speed or under The following procedure may be used in determining
remote conditions must be considered normal. Axle noise if the amount of backlash is within limits or if the
tends to "peak" at varying speeds and the noise is in no problem may be in the drive shaft or transmission.
way indicative of trouble in the axle. 1. Jack up one rear wheel and support axle tube with
If noise is present in an objectionable form, loud or at a jack stand.
all speeds, an effort should be made to isolate the noise 2. Gently rotate raised wheel clockwise by hand until
as being in one particular unit of the vehicle. Axle noise all axle assembly lash is taken up.
is often confused with other noises such as tire noise 3. From under the vehicle scribe a line across the
transmission noise, propeller shaft vibration and uni brake drum flange and backing plate.
versal joint noise. Isolation of the noise as in any one 4. Gently rotate wheel counter-clockwise until all axle
unit requires skill and experience. An attempt to elimii backlash is taken up.
nate a slight noise may baffle even the best of diagnos
ticians. Such practices as raising tire pressure to CAUTION: ROTATE WH E E L ONLY FAR
eliminate tire noise, listening for the noise at varying ENOUGH AND WITH SUFFICIENT FORCE TO
speeds and on drive, float and coast, and under proper TAKE UP REAR AXLE BACKLASH. DO NOT
highway conditions, turning the steering wheel from left ROTATE WHEEL WITH SUFFICIENT FORCE
to right to detect wheel bea:ring noise, will aid even the TO CAUSE PINION FLANGE TO TURN.
beginner in detecting alleged axle noises. Axle noises
fall into two categories: gear noise and bearing noise. 5. Scribe line on backing plate directly opposite the
line on the brake drum.
GEAR NOISE 6. Measure distance between scribe marks on backing
plate. If distance is less than 11/32" with 9-1/2"
Abnormal gear noise can be recognized since it pro
duces a cycling pitch and will be very pronounced in the brakes or 3/8" with 11" brakes on the standard axle
speed range at which it occurs, appearing under either 10-bolt cover; 1/4" with 9-1/2" brakes or 9/32"
"drive," "float" or "coast" conditions. Gear noise with 11" brakes on heavy-duty axles 12-bolt cover
tends to peak in a narrow speed range or ranges, while axle backlash is within limits.
bearing noise will tend to remain constant in pitch. Ab
normal gear noise is rare and usually originates from FAILURE ANALYSIS
the scoring of the ring gear and pinion teeth as a result The most common types of rear axle failures are
of insufficient or improper luibrication in new assemblies. hypoid gear tooth scoring and fracture, differential gear
Side gears seldom give trouble as they are used only fracture and/or differential bearing failure, and axle
when the rear wheels travel at different speeds. shaft bearing failure.
REAR SUSPENSION AND DRIVE LINE 4-1w
Hypoid Gears
Hypoid gear tooth scoring fig. 67 is caused generally
by improper break-in, incorrect lube, insufficient gear
backlash or improper ring/pinion gear alignment. The
scoring will progressively lead to complete erosion of
the gear tooth, or gear tooth pitting and eventual fracture
with possible attendant damage to bearings, if the initial
scoring condition is not diagnosed in time and corrected.
Hypoid gear scoring is easily recognized by it char
acteristic loud whine in either drive, coast or under both
conditions. Another cause of hypoid tooth fracture fig.
68 is extended overloading of the gear set which will
produce fatigue fracture, or shock loading which will
result in sudden failure.
Differential Gears
Common causes of differential gear failure are shock
loading, extended overloading leading to fatigue failure,
and overheating of gear thrust surfaces resulting from
excessive wheel spin and consequent lubrication break
down. Overheating will lead to seizing of thrust surfaces
or tooth failure fig. 69.
Fig. 67-Scored Hypoid Ring Gear
Bearings
Failure of axle tapered roller bearings is due pri
marily to excessive wear caused by long service or
foreign materials in the oil. The second most common
cause of bearing failure is too tight or too loose pre
load adjustment leading to spalling and eventual failure.
This failure may also lead to hypoid gear scoring due to
the resultant misalignment of the hypoid gear set.
Fig. 68-Cracked Hypoid Ring Gear Fig. 69-Differential Gear Failure

Chevrolet, Chevelle, Chevy II and Camaro
bracket. Torque nut as outlined in Shock Absorber

AXLE ASSEMBLY
Installation procedures.
Removal 9. Install brake hose and brake line retaining bracket
1. Raise vehicle to a height that will permit axle as to carrier and connect wheel cylinder inlet lines.
sembly to hang freely and position supports under Connect parking brake cable to frame bracket and
both frame side rails. at control arm. Adjust parking brake and bleed
2. Disconnect wheel cylinder inlet lines. Disconnect and brakes as outlined in Section 5.
remove brake hose and brake line retaining bracket 10. Reassemble rear universal joint to companion flange.
by removing retaining bolt from carrier cover. 11. Support vehicle at axle and remove supports from
3. Loosen parking brake equalizer adjusting nut and beneath the frame side rails.
disconnect both rear cables at frame bracket and at 12. Remove supports and lower vehicle to floor. Torque
control arms. See Section 5 for detail of parking all affected parts to specifications.
brake cable removal.
4. Remove two trunnion bearing "U" bolts from the AXLE SHAFT
rear yoke and separate rear universal joint. Wire
propeller shaft to frame side rail and tape trunnion Removal
bearing cups. 1. Raise vehicle to desired working height and remove
5. Support and secure axle assembly with an adjustable wheel and tire assembly and brake drum.
lifting device. On Chevrolet and Chevelle models, 2. Clean all dirt from area of carrier cover.
loosen upper and lower control arm attaching bolts 3. Drain lubricant from carrier by removing cover.
at axle housing. On Chevrolet models, disconnect 4. Remove the differential pinion shaft lock screw and
tie rod at axle bracket. the differential pinion shaft fig. 70.
6. Disconnect shock absorbers at axle brackets. Refer 5. Push flanged end of axle shaft toward center of
to Shock Absorber Removal procedures outlined in vehicle and remove "C" lock from button end of
this section. shaft.
7. On Chevrolet and Chevelle models, lower axle as 6. Remove axle shaft from housing, being careful not
sembly until suspension reaches end of travel, then to damage oil seal.
disconnect spring retainers Chevrolet only and with Wheel Bolt Replacement
draw springs from vehicle. Press bolts out of axle shaft flange as illustrated in
8. On Chevy II and Camaro models, remove four nuts Figure 71 and press new bolts into place, making sure
securing lower spring seat to axle housing, then that they are tight and square with flange.
remove spring front eye attaching bracket and swing
spring to rear so that it does not interfere with axle. Oil Seal and/or Bearing Replacement
9. On Chevrolet and Chevelle models, disconnect upper 1. Remove the oil seal by using the button end of the
and lower control arm attaching bolts at axle housing. axle shaft - insert the button end of the shaft behind
10. Lower axle assembly and remove from undervehicle. the steel case of the oil seal, then pry seal out of
bore being careful not to damage housing.
Installation 2. Insert Tool J-8119 into bore and position it behind
1. Place axle assembly under vehicle and raise into bearing so that tangs on tool engage bearing outer
position. race. Remove bearing, using slide hammer as shown
2. On Chevrolet and Chevelle models, install, but do not in Figure 72. Figure 73 shows a detail of axle
tighten, upper and lower control arm attaching bolts housing outer end.
at axle housing. 3. Lubricate new bearing with wheel bearing lubricant,
3. On Chevrolet models, position coil springs in upper
seats so that end of spring is indexed in seat.
4. On Chevrolet models, install lower end of spring on
axle bracket or control arm and secure by installing
retainer and bolt. Install lock washer and retainer
nut.
5. On Chevelle pry lower pigtail of spring over vertical
flange of the axle bracket spring seat.
6. On Chevy II and Camaro models, install spring seat
pads and swing springs up into spring seats on axle
housing, making sure upper seat pads are aligned in
axle housing bracket.
7. Install spring front eye attaching bracket bolt and
tighten, then install s:pring seat lower mounting
bracket and retaining nuts.
8. Raise axle assembly to allow shock absorber and tie
rod installation. Position shock absorber in axle Fig. 70-Differential Pinion Shaft Removal
Fig. 71-Wheel Bolt Replacement
and install bearing so that it bottoms against

shoulder fig. 74. To install bearing use Tool
J-21491 for the Chevelle, Camaro and Chevy II
light-duty axle and Tool J-21051 for all Chevrolet
models and also for Chevelle, Camaro and Chevy II
models with heavy-duty axle.
4. Pack cavity between the seal lips with a high melting
point wheel bearing lubricant; position seal on tool Fig. 73-Axle Housing Detail
Use J-21491 for the Chevelle, Camaro and Chevy II
light-duty axle and J-21051 for all Chevrolet models CAUTION: Excercise care that splines on end
and also for Chevelle, Camaro and Chevy II models of shaft do not damage oil seal and that they
with heavy-duty axle and position seal in axle engage with splines of differential side gear.
housing bore, tap seal into place so that it bottoms
against bearing fig. 74. 2. Install axle shaft "C" lock on button end of axle
shaft and push shaft outward so that shaft lock seats
Brake Flange Plate Replacement in counterbore of differential side gear.
1. Remove brake line at wheel cylinder inlet and dis 3. Position differential pinion shaft through case and
assemble brake components from flange plate. Refer pinions, aligning hole in shaft with lock screw hole.
to Section 5 for brake disassembly procedure. Install lock screw and torque to specifications.
2. Remove 4 nuts securing flange plate to axle housing. 4. Using a new gasket, install carrier cover and torque
3. Install new flange plate to axle housing and torque bolts to specifications.
nuts to specifications.
4. Install brake components on flange and connect CAUTION: Make sure both gasket surfaces on
hydraulic line to wheel cylinder inlet. Seee Section 5 carrier and cover are clean before installing
for brake assembly procedure. new gasket. Torque carrier cover b olts in ,
5. Install axle shaft, brake drum and wheel and tire crosswise pattern to ensure uniform draw on
assembly. cover gasket.
6. Bleed and adjust brakes as outlined in Section 5. 5. Fill axle with lubricant to a level even with bottom
of fillers hole. See Section 0 for proper lubricant.
Installation 6. Install brake drum and wheel and tire assembly.
1. Slide axle shaft into place. 7. Lower vehicle and test operation of axle.
Fig. 72-Wheel Bearing Removal Fig. 74-Wheel Bearing and/or Oil Seal Installation
Fig. 75-Measuring Drive Pinion Bearing Preload
PINION FLANGE, DUST DEFLECTOR

AND/OR OIL SEAL
Replacement
1. Raise rear of vehicle and place stand jacks under Fig. 77-Drive Pinion Flange Removal
frame side rails so that axle hangs freely to allow turning J-8614-3 while holding J-8614-1 fig. 77.
sufficient working room. 7. Pry old seal out of bore, using a screw driver or a
2. Check wheels for freedom of rotation. hammer and chisel.
3. Separate rear universal joint, tape trunnion bearings 8. Inspect pinion flange for smooth oil seal surface,
to joint, position propeller shaft to one side and tie worn drive splines, damaged ears, and for smooth
it to frame side rail. ness of bearing contact surface. Replace if
4. Using Tool J- 5853 with Adapter J- 5810 and a suitable
necessary.
socket on the pinion flange nut, rotate the pinion 9. If deflector requires replacement, remove by tapping
through several complete revolutions and record the from flange, clean up stake points; install new de
torque required to keep the pinion turning fig. 75. flector, and stake deflector at three new equally
If flange is to be reused, mark pinion and flange for spaced positions.
reassembly in the same relative position.
5. Install Tool J-8614-1 on pinion flange and remove NOTE: Staking operation must be performed
pinion flange self-locking washerfaced nut fig. 76. in such a manner that the seal operating surface
Position J-8614-1 on flange so that the four notches is not damaged.
are toward flange. Discard nut and use a new one
10. Pack the cavity between the seal lips of the pinion
upon reassembly.
flange oil seal with a lithium-base extreme pressure
6. Thread pilot end of Tool J-8614-3 into small O.D.
lubricant, position seal in bore and place gauge plate
end of J-8614-2. Then with J-8614-1 installed as
J-22804-2 Light-Duty or J-22804-1 Heavy-Duty
in Step 4, insert J-8614-2 into J-8614-1 and turn over seal and against seal flange. Gauge plate
it 45 degrees to locked position. Remove flange by insures proper seating of seal in carrier bore.
Fig. 78-Drive Pinion Flange Oil Seal

Fig. 76-Drive Pinion Nut Removal Installation Light-Duty
Fig. 79-Drive Pinion Flange Oil Seal

Installation Heavy-Duty
11. Using Tool J-21468 and J-9458 for Light-Duty

Axles fig. 78 or Tool J-21057 for Heavy-Duty
Axles fig. 79, press seal into carrier bore unt. Fig. 80-Drive Pinion Flange Installation
gauge plate is flush with the carrier shoulder and
seal flange. Turn gauge plate 180° from installed onto pinion shaft. To do so will damage ring
position; seal must be square in carrier bore to gear and pinion.
seal properly against pinion flange. 13. Pack the cavity between end of pinion splines and
12. Position and align pinion flange on pinion shaft using pinion flange with a non-hardening sealer such as
Tools J-9458 and J-8614-1. Tool J-9458-1 is Permatex Type A prior to installing washer and
threaded onto pinion shaft and nut tightened against nut on pinion.
J-9458-2 to pull flange on shaft fig. 80. Remove 14. Install a new self-locking washer faced nut on pinion
J-9458 after flange is seated.
shaft. Tighten nut to remove end play and continue
NOTE: The position of the pinion and flange alternately tightening in small increments and check
was previously marked so that reinstallation ing preload with torque wrench until it is the same
may be made with flange and pinion in same as that recorded in Step 4.
relative position. 15. Reassemble the rear universal joint, and torque
"U" bolt nuts to specifications.
CAUTION: Do not attempt to hammer flange 16. Lower vehicle to floor and road test for leaks.
COMPONENT PARTS REPLACEMENT CORVETTE

AXLE DRIVESHAFT-FIGURE 81 3. Pry driveshaft out of outboard drive flange pilot
Removal and remove by withdrawing outboard end first fig.
1. Disconnect inboard driveshaft trunnion from side 82.
gear yoke.
2. Bend bolt lock tabs down and remove four bolts
securing shaft flange to spindle drive flange.
Fig. 81-Axle Driveshaft Fig. 82-Removing Driveshaft
Repairs yokes and assemble "U" bolts. Rotate yokes so that

1. Remove bearing lock ring from trunnion yoke. trunnion seats are phased 90° apart.
2. Support trunnion yoke on a piece of 1-1/4" pipe on 2. Install outboard dirve flange into spindle drive flange
arbor press bed. pilot, position bolt lock over bolt holes and install
3. Using suitable socket or rod, press trunnion down four bolts. Torque bolts to specification and bend
far enough to drive opposite bearing cup from yoke. lock tabs flat against bolt heads.
4. Remove trunnion and press other bearing cup from
yoke, being careful not to drop cup or lose bearing PINION FLANGE, DUST DEFLECTOR
rollers. AND/OR OIL SEAL
5. Remove trunnion and yoke from other joint in a
Removal
similar manner.
1. Raise vehicle and place jackstand under frame to
6. Remove dust seals from trunnion, clean and inspect
allow wheels to hang free.
bearing rollers and tru.nnion. Relubricate bearings
2. Place 1/2" thick block of wood or steel between
with a high-melting point wheel bearing type
lubricant. carrier upper surface to rear of companion flange,
and body floor. This will prevent carrier assembly
NOTE: In addition to packing the bearings, from twisting upward when front support bracket is
make sure that the lubricant reservoir at the disconnected.
end of each truimion is completely filled with 3. Disconnect carrier front mounting bracket bolt from
lubricant. In filling these reservoirs, pack lu frame crossmember.
bricant into the hole so as to fill from the 4. Remove nuts from both bracket-to-carrier through
bottom. This will prevent air pockets and en bolts and remove bolts and mounting bracket.
sure an adequate supply of lubricant. 5. Disconnect propeller shaft at transmission and at
7. Place new dust seals on trunnion, cavity of seal companion flange. Slide transmission yoke foreward,
toward end of trunnion *- then position Tool J-21556 and lower propeller shaft down and out.
6. Mark companion flange nut and pinion relative loca
over end of trunnion and into cavity portion of seal.
Press seal onto trunnion until tool bottoms against tion. This is necessary to reset original pinion
trunnion fig. 83. bearing pre-load during reassembly of companion
flange.
NOTE: Installation of seal is critical to proper 7. Attach J-8614-1 companion flange holder and remove
sealing - use specified tool during installation flange nut and washer fig. 84.
to prevent seal distortion and to assure proper 8. Remove companion flange by driving off with brass
seating of seal on trunnion. drift and hammer fig. 85.
8. Partially install one bearing cup into yoke. Place 9. Using screw driver, pry oil seal out of carrier.
trunnion in yoke and into bearing cup. Install other Inspection
bearing cup and press 10th bearing cups into yoke,
Inspect companion flange splines for excessive wear
being careful to keep trunnion aligned in bearing
or twisting and check deflector for looseness. If de
cups.
flector is loose or damaged, break stake marks and
9. Press bearing cups far enough to install lock rings,
remove. Install new deflector and stake in place.
and install lock rings.
Installation
NOTE: It may be more convenient, if neces 1. Pack cavity between the seal lips of the pinion flange
sary, to use a bench vise for removal and oil seal with a Lithium base extreme pressure
installation, instead of an arbor press. In this
case, proceed with disassembly and assembly
procedure as with an arbor press.
Installation
1. Place driveshaft inboard trunnion into side gear
Fig. 83-"U" Joint Trtinnion Seal Installation Fig. 84-Removing Companion Flange Nut
Fig. 85-Removing Companion Flange
lubricant, position seal in bore and place gauge plate

J-22804-1 over seal and against seal flange. Gauge
plate insures proper seating of seal in carrier bore.
2. Using Tool J-21057 fig. 86, press seal into carrier
bore until gauge plate is flush with the carrier
shoulder and the seal flange. Turn gauge plate 180°
from installed position; seal must be square in car
rier bore to seal properly against pinion flange.
3. Lubricate companion flange splines and tap into Fig. 86-Installing Pinion Oil Seal
place.
DIFFERENTIAL CARRIER
4. Install companion flange washer and nut, and tighten
Removal
nut so that it lines up with mark on pinion.
1. Disconnect spring end link bolts as outlined in
5. Raise propeller shaft into position and connect to
companion flange and transmission yoke. Spring-Removal, in this section.
2. Disconnect axle drive shafts at carrier by removing
6. Place rubber cushion on carrier front mount, and "U" bolts securing trunnion to side gear yoke.
place bracket into position and loosely install rear 3. Disconnect carrier front support bracket at frame
carrier-to-bracket bolt. crossmember.
7. Install front mounting nut and front carrier-to- 4. Disconnect propeller shaft at transmission and at
bracket bolt. Torque all affected parts to specifi companion flange. Slide transmission yoke forward
cations and install cotter pin to carrier bracket into transmission. Drop propeller shaft down and
front bolt. out toward the rear.
Fig. 87-Installing Carrier Assembly
5. Mark camber cam and bolt relative location on strut

rod bracket and loosen cam bolts.
6. Remove four bolts securing bracket to carrier lower
surface and drop bracket. Remove camber cam bolts
and swing strut rods up and out of the way.
7. Remove eight carrier-to-cover bolts. Loosen bolts
gradually to allow lubricant to drain out.
8. With mounting bolts removed, pull carrier partially
out of cover, drop nose to clear crossmember and
gradually work carrier down and out.
Installation
1. Clean inside of carrier cover and liberally grease
gasket surface. Place new gasket on cover.
2. Cut heads off two 1/2"-13 x 1-1/4" bolts and slot
unthreaded end. Install these aligning studs into two
below-center carrier bolt holes, one on each side.
3. Raise carrier into position aligning studs into Fig. 88-Measuring Positraction Rotating Torque
cover fig. 87.
4. Install carrier-to-cover bolts and tighten securely. is installed in the conventional carrier to replace the
5. Connect propeller shaft to companion flange and standard differential unit.
transmission yoke. Service procedures for the Positraction equipped axle
6. Install rubber cushion on bracket and position to are the same as on a conventional axle except for the
frame crossmember. I n stall nut and torque to operations listed below.
specifications.
7. Raise axle drive shafts into position and assemble On the Vehicle Check
inboard trunnion to side gear yokes with "U" bolts.
8. Assemble strut rods to bracket and raise bracket If vehicle is equipped with a manual transmission, shift
into position under carrier. Install four bolts and transmission into neutral.
torque to specifications. Move camber cams to 1. Raise rear of vehicle until wheels are off the ground,
marked location and tighten cam nuts. remove one wheel and tire assembly.
9. Connect spring end link bolts as outlined under 2. Attach Adapter J- 5748 to axle shaft flange and install
Spring--Installation, in this section. a 1/2-13 bolt into adapter fig. 88,
10. Remove filler plug, located on right side of cover,
and fill with hypoid lubricant to level of filler hole. 3. With wheel and tire assembly still on vehicle held
11. Lower vehicle and road test for leaks, noise and firmly to prevent turning, measure torque required
general performance. to rotate opposite axle shaft with a 0-1 50# torque
wrench attached to J-5748. Torque should he 70
POSITRACTION DIFFERENTIAL UNIT ft. lbs. minimum new, and no less than 40 ft. lbs. if
The optionally available Positraction differential unit used.
PROPELLER SHAFT AND UNIVERSAL JOINTS

Page Page
General Description 4-35 Installation 4-37
Component Parts Replacement 4-36 Propeller Shaft Saginaw 4-38
Propeller Shaft Dana 4-36 Removal 4-38
Removal 4-36 Repairs 4-38
Repairs 4-36 Installation 4-39
GENERAL DESCRIPTION
The one-piece, exposed-type, tubular propeller shaft replaced as an assembly to avoid unbalance problems.
is used on all models. The cardon-type universal joints Periodic service is not needed at the spline area, how
are of the extended-life design and do not require period ever, should a driveline "clunk" develop in vehicles
ic maintenance. A splined front yoke on the front end of equipped with a three-speed automatic transmission the
the propeller shaft extends into a splined coupling on the spline should be cleaned and the spline packed with
transmission output shaft. This slip joint permits a slight approximately one tablespoon of chassis lube lithium
lengthening and shortening of the propeller shaft to com soap base. An "0" ring seal which is located in the
pensate for up and down movement of the rear axle transmission output shaft prevents the transmission from
assembly. Two versions of the tubular propeller shaft lubricating this spline.
are used fig. 89 Dana design and fig. 90 Saginaw de Two different methods are used to retain the bearing
sign. A damper is incorporated on both versions for assemblies in the propeller shaft yokes. Conventional
some applications. This damper is not serviced external snap rings are used on all Dana designed pro
separately--the sleeve and damper fig. 91 must be peller shafts. Saginaw designed shafts have the bearing
Fig. 89-Propeller Shaft Cross-Section Dana Design
Fig. 90-Propeller Shaft Cross-Section with Damper Saginaw Design
assembly retained by nylon material which is injected ings for these shafts have a lock ring groove in the
through small holes in the yoke and into an annular bearing housing fig. 103 inboard of the yoke which lock
groove in the yoke and bearing assembly. Service bear- the replacement bearings in place.

PROPELLER SHAFT DANA and lubricate reservoir at end of trunnions with
Removal high-melting point wheel bearing lubricant and
1. Raise vehicle, mark relationship of shaft to com replace the dust seals.
panion ‘flange and disconnect the rear universal joint
by removing trunnion bearing "U" bolts fig. 92.
Tape bearing cups to trunnion to prevent dropping
and loss of bearing rollers.
NOTE: On Corvette models, remove trunnion
"U" bolts at transmission yoke also.
2. Withdraw propeller shaft front yoke from transmis
sion by moving shaft rearward, passing it under the
axle housing. Watch for oil leakage from transmis
sion output shaft housing.
Repairs
NOTE: The universal joints fig. 93 are of
the extended-life design and do not require
periodic inspection or lubrication; however, when
these joints are disassembled, repack bearings Fig. 91-Propeller Shaft Sleeve and Damper Assembly
Fig. 93-Propeller Shaft Trunnion Dana Design
trunnion fig. 95.
Fig. 92-Removing Propeller Shaft from Companion Flange NOTE: Installation of seal is critical to proper
sealing - use specified tool during installation to
1. Remove bearing lock rings from trunnion yoke. prevent seal distortion and to assure proper
2. Support trunnion yoke on a piece of 1-1/4" I.D. pipe seating of seal on trunnion.
on an arbor bed. 6. Partially install one bearing cup into yoke. Place
NOTE: Due to length of the propeller shaft it trunnion in yoke and into bearing cup. Install other
may be more convenient to use a bench vise, bearing cup and press both bearing cups into yoke
for removal and installation, instead of an arbor fig. 96 being careful to keep trunnion aligned in
press. In this case, proceed with disassembly bearing cups.
and assembly procedure as with an arbor press. 7. Press bearing cups far enough to install lock rings,
and install lock rings.
3. Using a suitable socket or rod, press trunnion down
far enough to drive bearing cup from yoke fig. 94. Installation
4. Remove dust seals from trunnion, clean and inspect 1. Inspect yoke seal in the transmission and replace,if
bearing rollers and trunnion. Relubricate bearings necessary, as described in the transmission section.
with a lithium base chassis lubricant. 2. Insert propeller shaft front yoke into transmission.
NOTE: In addition to packing the bearings, NOTE: On Corvette models, install front yoke
make sure that the lubricant reservoir at the into transmission then position propeller shaft
end of each trunnion is completely filled with between yoke and companion flange; install "U"
lubricant. In filling these reservoirs, pack lu bolts to front yoke.
bricant into the hole so as to fill from the
bottom use of squeeze bottle is recommended. 3. Align propeller shaft with companion flange, using
This will prevent air pockets and ensure an reference marks established in "Removal" pro
adequate supply of lubricant. cedure, connect the rear universal joint by installing
"U" bolt clamps over bearing trunnions - carefully
5. Place new dust seals on trunnions - cavity of seal torque nuts to specifications.
toward end of trunnion - then position Tool J-21548
over end of trunnion and into cavity portion of seal. NOTE: Overtorquing may cause early bearing
Press seal onto trunnion until tool bottoms against failure.
Fig. 94-Removing Bearing Cups
Fig. 95-"U" Joint Trunnion Seal Installation
Fig. 97-Removing Propeller Shaft from Companion Flange

PROPELLER SHAFT SAGINAW
Removal bearing from yoke fig. 99.
1. Raise vehicle sufficiently to permit access to propel c. Apply force on yoke around bearing until nylon
ler shaft and mark relationship of rear yoke to retainer breaks. Continue to apply force until the
companion flange. downward movement of the yoke forces the bear
2. Remove trunnion bearing retaining strap attaching ing as far as possible from the yoke fig. 100.
screws from both bearings fig. 97. d. Complete removal of bearing by tapping around
3. Lower rear of propeller shaft, being careful not to circumference of exposed portion with a small
dislodge bearing caps from trunnion, and tape bear hammer fig. 101.
ing caps to trunnion. e. Rotate propeller shaft so that opposite bearing
4. Withdraw propeller shaft front yoke from transmis may be removed in the manner described above.
sion by moving shaft rearward, passing it under the f. Remove trunnion from yoke.
axle housing. Watch for oil leakage from transmis 2. Remove trunnion at transmission end of propeller
sion output shaft housing. shaft using the following procedure:
a. Support spUmed yoke on a press bed and the rear
Repairs of the propeller shaft on a stand so that shaft is
NOTE: Because of the elastic properties of the horizontal. Be sure that weight is evenly dis
nylon retainers, the trunnions must be pressed tributed on each side of the spumed yoke and that
from the yokes. Pressing the trunnions from the the fixed yoke half of the "U" joint is free to
yokes will shear the retainers which renders move downward.
the bearing caps unsuitable for reuse. A service b. Using a piece of pipe or similar tool, with an
kit, which employs a snap ring to retain the inside diameter slightly larger than 1 1/8", press
trunnion, must be used when reassembling the bearing from yoke fig. 99.
propeller shaft fig. 98. c. Apply force on yoke around bearing until nylon
retainer breaks. Continue to apply force until the
1. Remove trunnion at differential end of propeller shaft downward movement of the yoke forces the bear
using the following procedure: ing as far as possible from the yoke fIg. 100.
a. Support trunnion on a press bed so that the d. Complete removal of bearing by tapping around
propeller shaft yoke can be moved downward. circumference of exposed portion with a small
Support front of propeller shaft so that shaft is
in a horizontal position.
b. Using a piece of pipe or similar tool, with an in
side diameter slightly larger than 1 1/8", press
Fig. 96-Installing Bearing Cup and Trunnion Fig. 98-Service Kit Trunnion Saginaw
Fig. 101-Removing Bearing from Propeller Shaft
incorporates two different size bearing caps.

The larger bearing caps with the annular
Fig. 99-Pressing Trunnion Bearing from Propeller Shaft grooves must be mated with the propeller shaft
yoke.
hammer fig. 101.
e. Rotate propeller shaft so that opposite bearing a. Install bearing cap and seal about one-fourth way
may be removed in the manner described above. in on one side of yoke, using a soft-face hammer
f. Remove splined yoke and trunnion from propeller to tap the bearing into position. Check bearing
shaft. cap during installation to ensure that it does not
g. Support exposed trunnion fingers on press bed and become cocked in yoke.
press splined yoke from bearing caps using b. Insert trunnion into yoke fig. 102.
method described above. c. Firmly seat trunnion into bearing cup and press
h. Remove trunnion from splined yoke. bearing cup into yoke until it is flush with yoke.
3. Install trunnion and bearing assembly to the propel d. Install opposite bearing cap and seal making sure
ler shaft yokes using the following procedure: that rollers do not become jammed on trunnion.
Check for free movement of trunnion in yoke.
NOTE: The trunnion and bearing assembly used e. Install bearing retainer snap rings making sure
at the differential end of the propeller shaft that gap in ring is toward yoke fig. 103.
Installation
1. Inspect yoke seal in the transmission extension,
Fig. 100-Bearing Partially Pressed from Propeller Shaft Fig. 102-Installing Trunnion to Propeller Shaft
replace if necessary as described in the transmission

section.
2. Insert propeller shaft front yoke into transmission
extension, making sure that output shaft splines
mate with propeller shaft yoke splines.
3. Align propeller shaft with companion flange using
reference marks established in "Removal" pro
cedure; remove tape used to retain trunnion bearing
caps; connect exposed bearing caps to companion
flange by installing retaining strap and screws-
torque screws to specifications.
Fig. 103-Installing Snap Ring to Retain Trunnion
U 0 3
so =
nbc
7 8
5
Qf
9
0 12
16
0
17
0
18
14 15
19 22
20
Fig. 104-Rear Suspension Special Tools Chevrolet, Camaro, Chevelle and Chevy II
1. J-8614 Companion Flange Remover--Consists of J-8614-1 11. J-21491 Rear Wheel Bearing and Oil Seal Installer--
Holder, J-8614-2 Nut and J-8614-3 Screw. Light Duty Axle--Used with J-8092.
2. J-21057 Drive Pinion Oil Seal Installer--Heavy-Duty Axle. 12. J-2619 Rear Wheel Bearing and Oil Seal Remover
3. J-21468 Drive Pinion Oil Seal Installer--Light Duty Slide Hammer
Axler-Used with J9458. 13. J-8119 Rear Wheel Bearing and Oil Seal Remover--
4. J-5748 Positraction Torque Measuring Adapter. Used with J-2619.
5. J-21830 Upper and Lower Control Arm Bushing Puller-- 14. J-21058 Upper and Lower Control Arm Puller--Consists
Consists of J-21830-2 Adapter, J-21830-4 Receiver, of J-21058-15 Screw and J-21058-8 Nut--Used
J-21830-7 Bridge--Used with J-21058-6 Spacer, with J-21830.
and J-21830-3 Spacer 15. J-8092 Driver Handle--Threaded Type.
6. J-7574 Chevrolet Lower Control Arm Front Bushing 16. J-7079-2 Driver Handle--Insert Type.
Remover/Install er--Consists of J -7574-4 Receiver, 17. J-21548 Propeller Shaft U" Joint Trunnion Seal Installer.
J-7574-1 Remover, J-7574-2 Installer Adapter, 18. J-21991 Chevelle Upper Control Arm Carrier Bushing
J-7574-3 Spacer. Remover Adapter.
7. J-7877 Chevrolet Tie Rod Bushing Remover/Installer--Consists 19. J-5853 Torque Wrench--In. lbs.
of J-7877-1 Remover Adapter, J-7877-2 Bushing 20. J-22804-1-2 Pinion Seal Gauge Plate -1 Heavy Duty
Receiver, J-7877-3 Installer Adapter--Used with -2 Light Duty
J-7079-2 Handle. 21. J-5810 Torque Wrench Adapter 3/4" to 3/8"
8. J-21474 Chevelle Control Arm Bushing Remover--Consists of 22. J-13]3 Torque Wrench--ft. lbs.
J-21474-5 Receiver, J-21474-1 Spacer and J-22553 Rear Spring Front Bushing Remover/Installer
J-21474-2 Adapter. Consists of J-22553-1 Receiver, J-22553-2
9. J-9458 Drive Pinion Oil Seal Installer--Light Duty Installer--Used with J-21978-1 Receiver,
Axle-- Used with J-21468. J-21058-8 Nut and J-21058-15 Puller
10. J-21051 Rear Wheel Bearing and Oil Seal Installer-- Screw.
Heavy Duty Axle--Used with J-7079-2.
3 4
7
Ii ‘10
11
I12 13 14
16
Fig. 105-Rear Suspension Special Tools Corvette
1. J-8111-23 Torque Control Arm Spacer Flaring Tool

2. J-22602 Wheel Drive Spindle Remover
3. J-9436 Wheel Drive Spindle Outer Bearing Installer
4. J-21057 Drive Pinion Oil Seal Installer
5. J-8331 Wheel Drive Spindle Outer Bearing Remover
6. J-7877 Strut Rod Bushing Replacement Set
7. J-7817 Wheel Drive Spindle Bearing Cup Installer
8. J-21548 Propeller Shaft "U" Joint Trunnion Seal Installer
9. J-21556 Axle Drive Shaft U" Joint Trunnion Seal Installer
10. J-22804-1 Pinion Seal Gauge Plate
11. J-5748 Positraction Torque Measuring Adapter
12. J-7079-2 Driver Handle Insert Type
13. J-8001 Dial Indicator Set
14. J-8092 Driver Handle Threaded Type
15. J-7055-1 Torque Control Arm Bushing Installer
16. J-8614 Rear Axle Companion Flange Holder
5-12
5-11
5-23
BRAKES
SECTION 5
Page Page
Duo Servo Brakes 5-1 Power Brakes 5-30
Disc Brakes Special Tools 5-31
DUO-SERVO BRAKES
INDEX
Page Page
General Description 5-1 Center Cable
Maintenance and Adjustments 5-3 Rear Cables
Hydraulic Brake Fluid 5-3 Parking Brake - Corvette
Bleeding Hydraulic System 5-3 Lever Assembly
Pressure Bleeding 5-3 Front Cable
Manual Bleeding 5-4 Rear Cable
Push Rod to Main Cylinder Clearance 5-5 Brake Pedal 5-13
Hydraulic Brake Lines 5-5 Shoes and Linings 5-14
Hydraulic Brake Hose 5-5 Organic 5-14
Hydraulic Brake Tubing 5-6 Metallic 5-15
Brake Adjustment 5-7 Main Cylinder 5-17
Service Brake 5-7 Wheel Cylinders 5-20
Parking Brake 5-7 Anchor Pin 5-20
Component Replacement and Repairs 5-8 Front Wheel 5-20
Parking Brake - Chevrolet, Chevelle, Camaro Rear Wheel 5-21
and Chevy II 5-8 Brake Drums 5-21
Pedal Assembly 5-8 Brake Pipe Distribution and Switch Assembly 5-22
Front Cable 5-10 Camaro Pressure Regulator Valve 5-22
GENERAL DESCRIPTION
All 1968 models are equipped with a new split brake will also be illuminated when the parking brake is
system. The system is designed with separate hydraulic applied.
systems for the front and rear brakes using a dual main On Camaro models equipped with air conditioning, the
cylinder fig. 1. If a wheel cylinder or brake line should rear brake hydraulic line is routed through a pressure
fail at either the front or rear brake system of the regulator valve mounted on the left frame side rail
vehicle, the operator can still bring the vehicle to a fig. 3. The valve controls the hydraulic pressure to
controlled stop. the rear brakes resulting in the correct pressure balance
The design of the main cylinder is similar to that used between the front and rear hydraulic systems.
on the Corvette in that it has two entirely separate The self-adjusting brakes fig. 4, used on both front
reservoirs and outlets in a common body casting. The and rear of all models, are the Duo-Servo single anchor
front reservoir and outlet is connected to the front wheel pin type which utilize the momentum of the vehicle to
brakes, and the rear reservoir and outlet is connected to assist in the brake application. The self-energizing or
the rear wheel brakes. Two pistons within the main cyl self-actuating force is applied to both brake shoes at
inder receive mechanical pressure from the brake pedal each wheel in both forward and reverse motion. The
push rod and transmit it through the brake lines as brake shoe linings are bonded to the shoes.
hydraulic pressure to the wheel cylinders. The filler Wheel cylinders are the double piston type permitting
cap is accessible from inside the engine compartment. even distribution of pressure to each brake shoe. To
A new brake pipe distribution and switch assembly is keep out dust and moisture, both ends of each wheel
mounted below the main cylinder. The front and rear cylinder are sealed with a rubber boot. The wheel
hydraulic brake lines are routed from the main cylinder, cylinders have no adjustments.
through the brake pipe distribution and switch assembly, The Chevrolet, Chevelle, Camaro and Chevy II parking
to the front and rear brakes as shown in Figure 2. The brakes have a foot operated rachet type pedal mounted to
switch is wired electrically to the brake alarm indicator the left of the steering column. A cable assembly con
light on the instrument panel. If a leak in either front or nects the pedal to an intermediate cable by means of an
rear system should occur, the pressure differential 150 equalizer, where the adjustment for the parking brake is
to 250 psi during brake application will cause the piston incorporated. The intermediate cable attaches to the two
to compress the springs and move in the bore until it rear cables which operate the rear service brake.
touches the electrical contact which causes th parking The Corvette is equipped with a ratchet-type parking
brake lamp on the instrument panel to light. This lamp brake lever located behind the console. The parking
BRAKES 5-2
DELCO MORAINE MAIN1 CYLINDER BENDIX MAIN CYLINDER
Fig. 1-Main Cylinder
brake cable runs forward from the lever to a pulley single piece rear cable passes through the equalizer
assembly mounted on a frame crossmember, then back and back to the rear servi ce brakes.
to an equalizer near the rear frame crossmember. A
---CHEVROLET CAMARO
Fig. 2-Brake Pipe Distribution and Switch Assembly
BRAKES 5-3
PRIMARY WIRE LINK

SHOE
/IOVERRIDE
LEVER
I
VERRIDE
PRING
RETURN
SPRING
WHEEL
Fig. 3-Camaro Pressure Regulator Valve Fig. 4-Self-Adjusting Brake

In any service operation it is extremely important that necessary for proper operation, such as a high boiling
absolute cleanliness be observed. Any foreign matter in point to prevent vapor lock and the ability to remain
the hydraulic system will tend to clog the lines, ruin the fluid at low temperatures.
rubber cups of the main and wheel cylinders and cause In the event that improper fluid has entered the system,
inefficient operation or even failure of the braking sys it will be necessary to service the system as follows:
tem. Dirt or grease on a brake lining may cause that 1. Drain the entire system.
brake to grab first on brake application and fade out on 2. Thoroughly flush the system with clean alcohol,
heavy brake application. 188 proof, or a hydraulic system cleaning fluid such
The split system consists basically of two separate as "Declene".
brake systems. When a failure is encountered on either, 3. Replace all rubber parts of the system, including
the other is adequate to stop the vehicle. If one system brake hoses.
is not functioning, it is normal for the brake pedal lash 4. Refill the system.
and pedal effort to substantially increase. This occurs 5. Bleed the system.
because of the design of the master cylinder which
incorporates an actuating piston for each system. When BLEEDING HYDRAULIC SYSTEM
the rear system loses fluid, its piston will bottom against
The hydraulic brake system must be bled whenever,
the front piston. When the front system loses fluid, its any line has been disconnected or air has in some way
piston will bottom on the end of the main cylinders body. entered the system. A "spongy" pedal feeling when the
The pressure differential in one of the systems causes an brakes are applied may indicate presence of air in the
uneven hydraulic pressure balance between the front and system. The system must be absolutely free of air at
rear systems. The brake pipe distribution and switch all times. Bleeding of brake system may be performed
assembly, near the main cylinder, detects the loss of
by one of two methods-either pressure or manual.
pressure and illuminates the brake alarm indicator light
on the instrument panel. The pressure loss is felt at the PRESSURE BLEEDING
brake pedal by an apparent lack of brakes for most of the
brake travel and then, when failed chamber is bottomed, 1. Clean all dirt from top of main cylinder and remove
the pedal will harden. cylinder cover and rubber diaphragm.
If a vehicle displays these symptoms, it is a good 2. Reduce fluid level in main cylinder until reservoirs
indication that one of the systems contains air or has are approximately half full.
failed, and it is necessary to bleed or repair the brakes.
NOTE: Make sure brake fluid in bleeder equip
ment is at operating level and that the equipment
HYDRAULIC BRAKE FLUID is capable of exerting 30 to 50 lbs. hydraulic
Use GM Hydraulic Brake Fluid, Supreme No. 11 or pressure on the brake system.
equivalent when servicing brakes. This brake fluid is 3. Install brake bleeder adapter J-22489 fig. 6 on
satisfactory for any climate and has all the qualities main cylinder. Connect hose from bleeder equipment
BRAKES 5-4
loose end of bleeder hose into the container. Be sure

- I the hose end is submerged in the fluid.
6. Open wheel cylinder bleeder valve by turning Tool
J-21472 counterclockwise approximately 1/3 of a
turn and observe flow of fluid at end of bleeder hose.
7. Close bleeder valve tightly as soon as bubbles stop
and brake fluid flows in a solid stream from the
bleeder hose.
8. Remove brake bleeder wrench and bleeder hose from
wheel cylinder bleeder valve.
9. Repeat Steps 4 through 8 on the remaining wheel
cylinders.
10. Disconnect bleeder equipment from brake bleeder
adapter cover J-22489.
NOTE: The main cylinder on certain passenger
car models is tilted upward. When removing
the bleeder adapter on these models, place a
clean dry cloth behind and below the cylinder
to absorb any fluid spillage as the cover is
removed.
11. Remove bleeder adapter J-22489. Wipe all area dry

of fluid if fluid was spilled during adapter removal.
12. Fill master cylinder reservoirs to within 1/4" of
reservoir rims as shown in Figure 7.
13. Install main cylinder diaphragm and cover.
Fig. 5-Brake Bleeder Adapter Tool J-22489-lnstalled
MANUAL BLEEDING
to bleeder adapter and open release valve on bleeder
1. Clean all dirt from top of main cylinder and remove
equipment.
4. Install brake bleeder wrench, Tool J-21472 on bleed cylinder cover and rubber diaphragm.
2. Fill main cylinder reservoirs and reinstall cover.
er valve at wheel cylinder and install one end of
3. Install brake bleeder wrench, Tool J-21472 on bleed
bleeder hose on bleeder valve fig. 6.
er valve at wheel cylinder and install one end of
5. Pour a sufficient amount of brake fluid into a trans
parent container to insure that end of bleeder hose bleeder hose on bleeder valve fig. 6.
4. Pour a sufficient amount of brake fluid into a trans
will remain submerged during bleeding. Place the
parent container to insure that end of bleeder hose
will remain submerged during bleeding. Place the
loose end of bleeder hose into the container. Be
sure the hose end is submerged in the fluid.
NOTE: Carefully monitor fluid level at main
cylinder during manual bleeding operations. Do
not bleed enough fluid at one time to drain the
reservoir completely. Replenish the reservoirs
with fluid while bleeding to insure a sufficient
amount of fluid is in the main cylinder at all
times. To insure that outside air is not sucked
back into the hydraulic system, the bleeder
valve should be closed before the brake pedal
reaches the floor.
5. Open wheel cylinder bleeder valve by turning Tool
J-21472 counter-clockwise approximately 1/3 of a
turn. Slowly depress brake pedal. Just before brake
pedal reaches the end of its travel, close bleeder
valve and allow brake pedal to return slowly to the
fully released position. Repeat this procedure until
expelled brake fluid flows in a solid stream from the
bleeder hose and no bubbles are present, then close
bleeder valve tightly.
6. Remove brake bleeder wrench and bleeder hose from
wheel cylinder bleeder valve.
7. Repeat Steps 2 through 7 on the remaining wheel
cylinders.
Fig. 6-Bleeding Brakes Using Brake Bleeder 8. Fill the main cylinder to the levels shown in
Wrench Tool J-21472 Figure 7.
BRAKES 5-5
LEVEL CYLINDER TILTED CYLINDER
Fig. 7-Correct Main Cylinder Fluid Level
9. Install main cylinder d:iaphragm and cover. contacts main cylinder pistons must be 1/16" to
1/4" fig. 9.
3. Tighten check nut against clevis, and recheck
PUSH ROD TO MAIN CYLINDER CLEARANCE movement.
The brake pedal has a definite stop which is permanent
and not adjustable. This stop consists of a rubber bumper HYDRAULIC BRAKE LINES
at the release end of pedal travel. Before adjusting push
rod to main cylinder clearance, make sure pedal returns Hydraulic Brake Hose
to the fully released position freely and that the pedal The flexible hoses which carry the hydraulic pressure
retracting spring has not lost its tension, then proceed from the steel lines to the wheel cylinders are carefully
as follows:
1. Loosen check nut on push rod.
2. Turn push rod as required to provide correct ad-
justment. Movement of pedal pad before push rod
Fig. 8-Brake Pedal Free Movement Fig. 9-Brake Line Support Bracket
BRAKES 5-6
Hydraulic Brake Tubing

Hydraulic brake tubing is a double layer annealed
steel terne plate tubing which resists corrosion and has
the physical strength to stand up under the high pres
sures which are developed when applying the brakes. In
making up hydraulic brake pipes, it is important that
the proper flaring tool be used to flare the ends of the
tubing for the compression couplings. Unless the tubing
is properly flared, the connections will leak and the
brakes will become ineffective.
CAUTION: When necessary to r eplace brake
tubing, always use special steel tubing which
is designed to withstand high pressure and re
sist corrosion. Ordinary copper tubing is not
satisfactory and should not be used.
Fig. 10-Hydraulic Brake Lube Double Flaring Tool
This safety steel tubing must be double-lap flared at
designed and constructed to withstand all conditions of the ends in order to produce a strong leak-proof joint.
stress and twist which they encounter during normal The brake tube flaring Tool J- 8051 fig. 10 is used to
vehicle usage. form the double-lap flare.
The hoses require no service other than periodic Figure 11 shows two pieces of tubing, one with single-
inspection for damage from road hazards or other like lap flare "A" and the other with double-lap flare "B".
sources. Should damage occur and replacement become It will be noted that the single-lap flare in "A" split
necessary, the following procedure is to be followed. the tubing while the one shown in "B" is well-formed and
unbroken due to the reinforcement of the double wall.
Removal
The following procedure should be followed in making
1. Separate hose from steel line by turning double
up hydraulic brake pipes.
flare connector out of hose fitting.
2. Remove "U" shaped retainer from hose fitting and
withdraw hose from support bracket. Double Lap Flaring
3. Turn hose fitting out of wheel cylinder inlet.
1. Clamp the tubing in the proper size die blocks with
Replacement the flat ends of the blocks toward the end of the
1. Install new copper gasket on cylinder end of hose tubing to be cut off. Cut the end of the tubing flush
male end. and square. Using a mill file, dress tubing and
2. Moisten threads with brake fluid and install hose in square ends.
wheel cylinder inlet. 2. Remove the tubing from the die block and deburr
3. With weight of car on wheels and suspension in the inside and outside edges.
normal position front wheels straight ahead pass 3. Install compression couplings on tubing and dip end
female end of hose through support bracket, allowing of tubing to be flared in hydraulic fluid. This lubri
hose to seek its own position. Insert hex of hose cation results in better formation of the flare.
fitting into the 12 point hole in support bracket 4. Place one-half of the die blocks in the tool body with
in .position which induces least twist to hose fig. 10. the counterbored ends toward the ram guide. Now
NOTE: Do not twist hose unduly during this lay the tubing in the block with approximately 1/2"
operation as its natural curvature is abso protruding beyond the end.
lutely necessary to maintain proper hose-to- Fit the other half of the block into the tool body,
suspension clearance through full movement of close the latch plate and tighten the nuts "finger
the suspension and steering parts. tight".
5. Select the correct size upset flare punch. One end
4. Install "U" shaped retainer to secure hose in sup of this punch is counterbored or hollowed out to
port bracket. gauge the amount of tubing necessary to form a
5. Inspect by removing weight completely from wheel, double lap flare. Slip the punch into the tool body
turn wheels from lock to lock while oberving hose with the gauge end toward the die blocks. Install the
position. Be sure that hose does not touch other ram; then tap lightly until the punch meets the die
parts at any time during suspension or wheel travel. blocks and they are forced securely against the
If contact does occur, remove hose retainer and stop plate fig. 12.
rotate the female hose end in the support bracket 6. Using the supplied wrench, draw the latch plate
one or two points in appropriate direction, replace nut down tight to prevent the tube from. slipping.
retainer, and re-inspect. Tightening the nuts alternately beginning with the
6. Place steel tube connector in hose fitting and tighten nut at the closed hole in the plate will prevent
securely. distortion of the plate. Remove the punch and the
7. Bleed all brakes as outlined in this section. ram. Now reverse the punch and put it back into the
8. Do not tighten male end wheel cylinder end once tool body. Install the ram and tap it lightly until
the other end is fixed. If necessary to tighten male the face of the upset flare punch contacts the face
end, disconnect hose at opposite end, then reconnect of the die blocks fig. 13. This completes the
following above procedure. first operation. Remove the ram and the punch.
BRAKES 5-7
Fig. 13-Flaring Operation-First Flare
b. Turn the star wheel 1-1/4 turns to retract the

shoes. This will allow sufficient lining-to-drum
clearance so final adjustment may be made as
Fig. 11-Single and Double Lap Flaring
described in Step 4.
3. Install the drum and wheel.
7. To complete the flare, insert the pointed finish
flare punch and the ram into the tool body. Tap the NOTE: 1: If lanced area in brake drum is
ram until a good seat is formed fig. 14. knocked out, be sure all metal has been re
moved from brake compartment. Install new
NOTE: The seat should be inspected at inter
hole cover in drum to prevent contamination
vals during the finishing operation to avoid
of the brakes.
over- seating.
NOTE: 2: Make certain when installing drums
that drums are installed in the same position
BRAKE ADJUSTMENT as when removed with the drum locating tang
in line with the locating hole in the wheel hub
Service Brake fig. 17.
Although the brakes are self-adjusting, a preliminary 4. Make final adjustment by making numerous forward
or initial adjustment may he necessary after the brakes and reverse stops, applying brakes with a firm
have been relined or replaced, or whenever the length pedal effort until a satisfactory brake pedal height
of the adjusting screw has been changed. The final results.
adjustment is made by using the self-adjusting feature.
1. With brake drum off, disengage the actuator from NOTE: Frequent usage of an automatic trans
the star wheel and rotate the star wheel by spinning mission forward range to halt reverse vehicle
or turning with a small screw driver. motion may prevent the automatic adjusters
2. Recommended. from functioning, thereby inducing low pedal
a. Use special Tool J-21177; Drum-to-Brake Shoe heights.
Clearance Gauge, to check the diameter of the
brake drum inner surface fig. 15. Parking Brake
b. Turn the tool to the opposite side and fit over the The rear brake assemblies serve a dual purpose in
brake shoes by turning the star wheel until the that they are utilized both as a hydrauliOally operated
gauge just slides over the linings fig. 16.
c. Rotate the gauge around the brake shoe lining
surface to assure proper clearance.
Alternate
a. Using the brake drum as an adjustment fixture
turn the star wheel until the drum slides over
the brake shoes with a slight drag.
LATCH PLATE
DIE BLOCK
TUBE
STOP
Fig. 12-Flaring Operation-PositIoning Tubing Fig. 14-Flaring Operation-First and Second Flare
BRAKES 5-8
Fig. 15-Using Drum-To-Brake Shoe Clearance

Gauge Tool J-21177
Fig. 17-Aligning Drum Tang with Wheel Hub
service brake and also as a mechanically operated
parking brake. In view of this dual purpose, the service brake adjustment; conversely the parking brake must
brake must be properly adjusted as a base for parking be properly adjusted for the service brake to function
as intended.
Adiustment
1. Place car on hoist.
2. Apply parking brake, two notches from fully re
leased position.
3. Loosen the equalizer forward check nut, and tighten
or loosen the rear nut until a light to moderate drag
is felt when rear wheels are rotated.
4. Tighten check nuts securely.
5. Fully release parking brake and rotate rear wheels;
no drag should be present.
Inspection
If complete release of the parking brake is not ob
tained, unless it is forcibly returned to its released
position, or if application effort is high, check parking
brake assembly for free operation. If operation is sticky
or a bind is experienced, correct as follows:
1. Clean and lubricate brake cables and equalizer.
2. Inspect brake assembly for straightness and align
ment replace if necessary.
FIg. 16-Checking Brake Shoe Lining Clearance 3. Clean and lubricate parking brake assembly.
Using Tool J-21177 4. Check routing of cables for kinks or binding.
COMPONENT REPLACEMENT AND REPAIRS

PARKING BRAKE-CHEVROLET, CHEVELLE, eliminate the possibility of creating short cir
CAMARO AND CHEVY II Figs. 19 and 20 cuits under dash.
1. Place parking brake pedal in released position.
Pedal Assembly 2. Remove equalizer check nut, and separate cable
stud from equalizer.
Removal
3. Remove two attaching nuts from mounting studs
NOTE: Remove positive cable from battery to located in engine compartment.
BRAKES 5-9
CHEVELLE
Fig. 18-Parking Brake System-CheVrolet and Chevelle
BRAKES 5-10
4. Remove front cable ball end from pedal assembly eliminate the possibility of creating short cir
swivel. cuits under dash.
5. Remove pedal assembly to dash brace attaching
screw.
2. Remove equalizer check nut, and separate cable
6. Remove pedal assembly by lowering rear slightly
stud from equalizer.
to avoid scratching dash, and pulling it out of the
3. Remove retainer from cable assembly at inner side
firewall.
of frame rail.
Installation 4. Remove ball end of cable from pedal assembly
1. Place pedal assembly in position with the two mount swivel.
ing studs protruding through the holes provided in 5. Compress expanded conduit locking fingers at toe
the firewall. pan and withdraw cable from car.
2. Install and tighten pedal assembly to dash brace 6. On Chevelle, if necessary, remove rubber tube from
attaching screw. front cable.
3. Position front cable ball end into pedal assembly
swivel. Installation
4. Install and tighten two attaching nuts on mounting 1. On Chevelle, if necessary, replace rubber tube over
studs located in engine compartment. front cable.
5. Place equalizer in position on center cable and 2. Position cable ball and conduit tip through cutout
insert front cable stud through equalizer and secure in firewall. Make sure conduit locking fingers are
with check nut. fully expanded and secured in cutout, then position
6. Adjust parking brake as outlined under Maintenance cable ball into pedal assembly swivel.
and Adjustments in this section. 3. Feed stud end of cable through frame rail and secure
7. Connect positive battery cable. with retainer on inner side of frame.
4. Place one check nut on cable stud and insert stud
Front Cable through equalizer, make sure center cable is in
position, then place second check nut on stud.
Removal 5. Adjust parking brake as outlined in this section.
NOTE: Remove positive cable from battery to 6. Connect positive battery cable.
*
VIEW A
7-
VIEW B
CAMARO AND CHEVY
Fig. 19-Parking Brake System-Camaro and Chevy II
BRAKES 5-1 1
Fig. 20-Parking Brake System-Corvette
Center Cable 6. Remove rear brake shoes as outlined in this section.

7. Remove cable end from parking brake actuating
Removal lever.
8. Compress expanded conduit locking fingers at flange
2. Remove equalizer check nut and remove equalizer plate entry hole and withdraw cable.
from cable.
3. Remove cable from cable guides. Installation
4. Disconnect center cable from r e a r cables at 1. Pass end of cable and conduit tip through flange
connectors. plate entry hole, making sure that conduit locking
fingers all expand fully.
Installation 2. Connect cable end to actuating lever.
1. Install cable ends into rear cable connectors. 3. Install rear brake shoes, drum and wheel as out
2. Place cable through equalizer and install equalizer lined in this section.
on to front cable stud, secure with check nut. Do 4. Pass cable through frame bracket and install
not tighten. retainer.
3. Install cable in cable guides figs. 19 and 20. 5. Install cable end into cable connector.
4. Adjust parking brake as outlined in this section. 6. Position equalizer on center cable and place on
front cable stud, secure with check nut.
Rear Cables 7. Make sure all center cable guides are in place
Removal and adjust parking brake as outlined in this section.
2. Remove equalizer check nut and remove equalizer PARKING BRAKE-CORVETTE Fig. 20
from cable.
3. Remove rear cable from connector. Lever Assembly
4. Remove retainer from rear cable at frame bracket. Removal
Pull cable out of bracket. 1. Place parking brake lever in the fully released
5. Remove rear brake drum as outlined in this section. position.
BRAKES 5-12
Fig. 21-Removing or Installing Cover Lower Mounting Screws
2. Under vehicle, unhook and remove return spring. Fig. 23-Removing or Installing Front Cable
3. Remove rear nut from cable stud at equalizer and
allow front cable to hang down. 5. Insert the end of the trim seal into the slot in the
4. Inside vehicle, remove six screws securing cover cover and slide the cover forward and down into
to underbody. It is necessary to push the seat position.
cushion down as shown in Figure 21 to gain access 6. Place the retainer in position. Secure retainer and
to the lower mounting screw on each side. Remove cover to underbody with six screws. It is necessary
the retainer. Lift the cover upward and to the to push the seat cushion down as shown in Figure 23
rear to allow seal to slide out of cover slot and to gain access to the lower mounting screw hole on
remove cover. each side.
5. Remove trim seal from lever fig. 22. 7. Under vehicle, insert front cable stud through equal
6. Remove screw and washer securing parking brake izer assembly and secure with nut.
alarm switch to side of lever assembly. 8. Install return spring.
7. Remove four bolts securing lever assembly to under 9. Adjust parking brake as outlined under Maintenance
body and lift lever assembly upward. Remove lever and Adjustments in this section.
forward mounting bracket.
8. Remove front cable from lever assembly using long Front Cable
nose pliers as shown in Figure 23. Remove lever Removal
from vehicle. 1. Peform the complete parking brake lever removal
Installation procedure above.
1. Install front cable in lever assembly using long 2. Under vehicle, remove nut, washer, and bolt se
nose pliers as shown in Figure 23. Slide slack curing pulley to pulley bracket fig. 20.
cable through hole and place lever assembly in 3. Remove seal grommet from underbody cable hole.
position. 4. Pull front cable out of vehicle.
2. Place forward mounting bracket in position and Installation
secure plate and lever assembly to underbody with 1. Install seal grommet around front cable.
four mounting bolts. 2. Slide front cable into position through cable hole
3. Secure parking brake alarm switch to side of lever and work seal grommet intO installed position.
assembly with washer and screw fig. 22. 3. Under vehicle, loop front cable around pulley wheel
4. Install trim seal on lever fig. 22. and secure pulley wheel to bracket with bolt, washer,
and nut fig. 20.
4. Perform the complete parking brake lever installa
tion procedure above.
Removal
1. Remove the cable clip retainers on the back side of
the frame rail from each of the rear brake cable
ends.
2. Disconnect the cable at the rear wheel flange plate.
3. Remove the cable ball out of the recess in the brake
lever assembly clevis.
4. Disconnect the cables at the equalizer connector and
remove the cables.
Installation
1. Attach the rear cable balls on the rear cable ends
to the rear wheel recess in the brake lever assembly
Fig. 22-Removing or Installing Trim Seal clevis.
BRAKES 5-13
2. Attach the cable assembly to the rear wheel flange 6. Remove retainer from right side of pedal pivot shaft.
plate. 7. Slide clutch pedal assembly to the left and remove
3. Connect the cable assemblies along the frame rail from support brace.
area. 8. Withdraw brake pedal and all nylon bushings.
4. Insert the cable end through the equalizer and attach Inspection
to the equalizer connector. 1. Clean all metal parts with a good nontoxic cleaning
5. Adjust as outlined u n d e r Maintenance an d solvent.
Adjustments. 2. Wipe nylon bushings clean with a clean cloth.
6. Lubricate the cables and all moving parts for
trouble-free operation- see Lubrication, Section 0. CAUTION: Nylon bushings should not be treated
with cleaning agent of any nature.
Brake Shoes 3. Inspect all nylon bushings for wear and damage.
Refer to parking brake shoe service procedures under 4. Inspect mating surface of bushings for wear and
Disc Brakes in this section. damage-- replace parts as required.
Installation
BRAKE PEDAL Fig. 24 1. Lubricate and install nylon bushings on pedal pivot
Removal shaft, right side of support brace cutout, and through
both ends of brake pedal bore.
NOTE: Refer to Section 1A for removal of 2. Chevrolet, Chevy II, and Corvette: Position brake
air conditioning components if necessary. pedal return spring on pedal arm and place pedal
1. Disconnect clutch pedal return spring manual trans assembly in support brace. Index return spring in
mission models only. support brace cutout.
2. Disconnect clutch push rod at pedal. 3. Chevelle and Camaro: Place pedal assembly in
3. Disconnect brake pedal return spring Chevelle and support brace.
Camaro only. 4. Slide pedal pivot shaft through support brace and
4. Disconnect brake pedal from main cylinder push brake pedal bore.
rod by removing retainer and clevis pin. 5. Install retainer to right side of pedal pivot shaft.
5. Corvette only: 6. Corvette only:
a. Remove steering column from vehicle as outlined a. Install bracket with pedal assemblies to underside
in Section 9. of instrument panel with two screws.
b. Support main cylinder from inside engine com b. Install support plate on bracket with four bolts
partment and remove four support brace nuts. and nuts.
c. Remove four nuts and bolts securing support c. Place main cylinder in position and install four
plate to bracket and remove support plate. bracket and cylinder mounting bolts; secure en
d. Remove two screws securing bracket to under tire assembly with four nuts.
side of instrument panel and lower bracket and d. Install steering column in vehicle as outlined
pedals to floor. in Section 9.
I,
CHEVROLET CHEVELLE
Fig. 24-Brake Pedal Installation
BRAKES 5-14
7. Chevelle and Camaro: Install brake pedal return

spring.
8. On manual transmission models, connect clutch pedal
push rod to pedal bracket and install retainer. In
stall clutch pedal return spring.
9. Adjust brake pedal free travel as outlined in this
section. Adjust stoplight switch as outlined in Section
6Y. Adjust clutch pedal travel as outlined in
Section 7.
SHOES AND LININGS

Organic Linings
NOTE: If brake drums are worn severely, it
may be necessary to retract the adjusting screw.
To gain access to the adjusting screw star
wheel, knock out the lanced area in the web of
the brake drum using a chisel or similar tool.
Release the actuator from the star wheel by
lifting with a small screw driver and back off
the star wheel with a second screw driver press
down on the handle to retract shoes.
CAUTION: After knocking out the metal, be
sure to remove it from the inside of the drum
and clean all metal from the brake compartment.
A new hole cover must be installed when drum
is reinstalled.
Fig. 26-Removing Hold-Down Springs and Pins
Removal
1. Raise car on hoist. 4. Unhook brake shoe pull back springs from anchor
2. Loosen check nuts at parking brake equalizer suffi pin and link end, using Tool J-8049 fig. 25.
ciently to remove all tension from brake cable. 5. Remove the actuator return spring and link.
3. Remove brake drums. 6. Remove hold-down pins and springs fig. 26.
7. Remove the actuator assembly.
NOTE: Since there are wheel cylinder piston
stops to prevent pistons from leaving cylinders, NOTE: The actuator, pivot and override spring
it is not necessary to install wheel cylinder are an assembly. It is not recommended that
clamps when brake shoes are removed; however, they be disassembled for service purposes,
brake pedal must not be depressed while drums unless they are broken. It is much easier to
are removed. assemble and disassemble the brakes by leaving
them intact.
& Separate the brake shoes by removing adjusting
screw and spring.
9. Remove parking brake lever from secondary brake
shoe rear only.
Inspection
1. Clean all dirt out of brake drum using care to avoid
getting dirt into front wheel bearings. Inspect drums
for roughness, scoring or out-of-round. Replace or
recondition drums as required.
2. Inspect wheel bearings and oil seal, and replace any
necessary parts.
3. On Chevrolet only:
Carefully pull lower edges of wheel cylinder boots
away from cylinders and note whether interior is
wet with brake fluid. Excessive fluid at this point
indicates leakage past piston cups and a need for
wheel cylinder overhaul or replacement.
NOTE: A slight amount of fluid is nearly always
present and acts as lubricant for the piston.
4. Check cylinders with internal boots by carefully pull
ing a small part of the boot out of the cylinder.
Note whether interior is wet with brake fluid. Ex
Fig. 25-Unhooking Pull Back Spring cessive fluid at this point indicates leakage past
BRAKES 5-15
piston cups and a need for wheel cylinder overhaul If the lubrication in the adjusting screw assem
or replacement. bly is contaminated or destroyed, the adjust
5. Check all brake flange plate attaching bolts to make ing screw should be thoroughly cleaned and
sure that they are tight. Clean all rust and dirt lubricated.
from shoe contact faces on flange plate fig. 27, 6. Connect brake shoes together with adjusting screw
using fine emery cloth. spring, then place adjusting screw, socket and nut
in position.
Installation
CAUTION: Make sure the proper adjusting
CAUTION: Make certain to install recom screw is used "L" for left side of vehicle,
mended shoe and lining assemblies. Otherwise, "R" for right side of vehicle. The star wheel
serious fade or failure may occur. should only be installed with the star wheel
nearest to the secondary shoe and the adjusting
1. Inspect new linings and make certain there are no screw spring inserted to prevent interference
nicks or burrs on bonding material on shoe edge with the star wheel.
where contact is made with brake flange plate or
on any of the contact surfaces. 7. On rear wheels connect parking brake cable to lever.
8. Secure the primary brake shoe short lining-faces
NOTE: Keep hands clean while handling brake
forward first with the hold-down pin and spring
shoes. Do not permit oil or grease to come in using a pair of pliers. Engages shoes with the wheel
contact with linings.
cylinder connecting links.
2. If working on rear brakes, lubricate parking brake 9. Install and secure the actuator assembly and second
cable. ary brake shoe with the hold-down pin and spring
3. On rear brakes only, lubricate fulcrum end of park using a pair of needle nose pliers. On rear wheels
ing brake lever and the bolt with brake lube, then position parking brake strut and strut spring.
attach. lever to secondary shoe with bolt, spring 10. Install guide plate over anchor pin.
washer, lock washer and nut. Make sure that lever 11. Install the wire link.
moves fre.ely. NOTE: Do not hook the wire link over the
4. Put a light coat of lubriLplate on pads, backing plate anchor pin stud with the regular spring hook
and the threads of the adjusting screw. tool. This may damage the cylinder boot seals.
CAUTION: BE CAREFUL TO KEEP LUBRI Fasten the wire link to the actuator assembly
CANT OFF FACINGS. first, then place over the anchor pin stud by
hand while holding the adjuster assembly in the
5. Before installation make certain the adjusting screw full down position.
is clean and lubricated properly.
12. Install actuator return spring.
NOTE: Loose adjustment may occur from an
adjusting screw that is not properly operating. NOTE: Do not pry actuator lever to install re
turn spring. Ease it in place using the end of a
screw driver or other suitable flat tool.
13. Ii old brake pull back return springs are nicked,
distorted or if strength is doubtful, install new
springs.
14. Hook springs in shoes using Tool J-8049 by in
stalling the primary spring from the shoe over the
anchor pin and then spring from secondary shoe
over the wire link end.
15. After completing installation, make certain the actu
ator lever functions easily by hand operating the
self-adjusting feature fig. 28.
/ 16. Follow the above procedure for all wheels.
17. Adjust the service brakes and parking brake as
outlined under "Maintenance and Adjustments" in
this section.
18. Install drum, wheel and tire and lower vehicle.
Metallic Linings
Metallic brake linings which use special heat resistant
brake springs are available as an option. Service opera
tions are the same as for standard brakes; however,
when new linings are installed, the linings should be
seated as described below.
NOTE: Brake shoes with metallic linings re
quire specially finished brake drums honed to a
Fig. 27-Backing Plate Contact Surfaces 20 micro-inch finish. Metallic linings are not
BRAKES 5-16
recommended for service replacement on ve

hicles with standard brake drums that have not
been honed to specified finish.
Seating Metallic Linings
After the brakes have been adjusted, the following
recommended "lining seating" is as follows:
1. Make six to eight stops from 30 MPH with moderate
pedal pressure to aid in seating and to modulate
any tendency to dive.
2. Make six to eight complete stops from maximum
legal highway speed at approximately one mile inter
vals to fully seat the linings.
Identification of Worn Lining Fig. 29
The metallic shoe assembly incorporates a number of
segmented pads with each pad consisting of two layers of
dissimilar material. The top layer is the braking ma
terial and the lower layer is a metal bonding agent used
to weld the brake facing material to the shoe proper.
During brake inspection, one can be misled easily
since the bonding pad does not appear to be much dif
ferent from the brake facing pad.
Close inspection of the shoes, however, will indicate
the difference between a worn and satisfactory shoe.
When the bonding pad begins to appear through the brake
facing material a bright finish will appear fig. 31.
Fig. 28-Checking Operation of the Actuating Lever To preclude the possibility of excessively worn shoes
damaging the drum, it is recommended that metallic
NORMAL WORN EXCESSIVELY WORN
PAD PART PAD PART PAD PART

OF SHOE OF SHOE OF SHOE
BRAKE BRAKE BRAKE

SHOE SHOE SHOE
MINIMUM
SERVICEABLE
LINING %2
SEC A-A SEC B-I SEC C-C
Fig. 29-Identification of Worn Metallic Brake Lining
BRAKES 5-17
F Main Secondary
Model Source Brake Type I Cylinder I Piston
Code [ Identification
Delco Manual-Drum 2 Rings
Chevrolet AT
Moraine Power -Drum or Grooves
1 Ring or
Bendix Power -Drum AT
2 Grooves
Delco Manual- 1 Ring
Moraine AR
Metallic or Groove
All Passenger Manual- Drum BS

1 Ring
Delco Power -Drum or Groove
Cars except
Moraine 2 Rings or
Chevrolet Manual-
AU
Metallic Grooves
Manual-Disc 5 Rings
DC
Delco Power Disc or Grooves
Corvette Moraine
1 Ring or
Power -Disc PG
Groove
Chevrolet & Delco 2 Rings
Power -Disc SA
Chevelle Moraine or Grooves
6 Rings
Manual-Disc AD
Delco or Grooves
Camaro Moraine
3 Rings
Power -Disc WT
or Grooves
Delco Manual-Disc 6 Rings
Chevy II AD
Moraine Power -Disc or Grooves
Fig. 30-Brake Main Cylinder Identification
brake shoes be replaced whenever segment thickness The primary pistons are of two types. One has a
becomes less than 3/32" measured at the heel or toe deep socket for the push rod and the other a very shallow
of the pad. socket.
It is mandatory that replacement pistons be identical
MAIN CYLINDER to the original piston. This can be verified by checking
the identification marks on the secondary piston and the
DUAL MAIN CYLINDER COMPONENT REPLACEMENT socket contour of the push rod end of the primary piston.
When servicing the Delco Moraine dual master cyl
The dual main cylinder used on 1968 passenger cars inder, follow the rules below when replacing either
is designed and built to satisfy individual brake system complete master cylinder or the component pistons of
displacement requirements for each vehicle line. There the cylinder. It is equally important to use only the
fore, it is necessary that correct parts be used when correct service parts when servicing a main cylinder.
replacing either complete main cylinder assemblies or
the component pistons of these assemblies. 1. The two-letter identification stamp on the end of
There are two sources for dual main cylinders used the master cylinder indicates the displacement capa
on 1968 Chevrolet vehicles: Delco Moraine and Bendix. bilities of that particular cylinder. Master cylinders
The Bendix unit can be readlily identified by a ‘Secondary should only be replaced with another cylinder bearing
Piston Stop’ bolt on the bottom of the casting. Delco the same two- letter identification.
Moraine main cylinders do not have this bolt See 2. The length of the component pistons in the master
Figure 1 located on lower portion of main cylinder. cylinders are critical factors in displacement capa
The displacement capabilities of a particular cyl. bilities of a particular master cylinder. These
inder are specified by the two letters which are stamped pistons are coded, using rings or grooves in the
in the metal on the top of the closed end of the main shank of the piston. It is mandatory that when
cylinder barrel. Main cylinders should only be replaced pistons are replaced, the replacing piston must con
with another cylinder bearing the same two-letter tain the same identification marks and the same
identification See Figure 30. contour at the push rod end as the piston which
The length of the secondary pistons in these main is removed.
cylinders is a critical factor in the displacement capa 3. Delco Moraine dual master cylinders, used with
bilities of a particular main cylinder. These secondary drum-type brakes, contain a rubber check valve and
pistons are coded, using rings or grooves in the shank check valve spring in each outlet boss. When the
or center section of the piston. Refer to the chart car is equipped with disc brakes on the front and
above for proper identification See Figure 30. drum brakes on the rear, the dual master cylinder
BRAKES 5-18
will have a check valve and spring in the outlet 3. Disconnect the push rod from the brake pedal.
boss for the rear brakes. No check valve is required 4. Unbolt and remove the main cylinder from the
for four wheel disc brakes, and, therefore, the outlet firewall.
boss to the front brakes will not contain a check 5. Remove the main cylinder mounting gasket and boot.
valve and spring. 6. Remove the main cylinder cover and dump out the
fluid. Pump the remaining fluid from the cylinder
Removal by depressing the push rod.
1. Wipe main cylinder and lines clean with a clean
cloth. Place dry cloths below main cylinder area to Disassembly Fig. 31
absorb any fluid spillage. 1. Clamp main cylinder in a bench vice.
2. Disconnect hydraulic lines at main cylinder. Cover 2. Remove push rod retainer.
line ends with clean lint-free material to prevent 3. Remove secondary piston stop bolt from bottom of
foreign matter from entering the system. front fluid reservoir.
7
8
9
4
1 2 a
10
211
3
14
5
16
17
8
9
23
Fig. 31-Main Cylinder for Drum Type Brakes-Exploded View
1. Spring 8. Stop Screw 15. Seal 20. Spring Retainer

2. Check Valve 9. Body 16. Seal 21. Seal
3. Valve Seat 10. Spring 17. Piston Extension 22. Seal Protector
4. Bleeder Valve 11. Retainer Screw 23. Secondary Piston
5. Bail Wire 12. Seal 18. Secondary Piston 24. Seal
6. Cover 13. Seal Protector Stop 25. Retaining Ring
7. Diaphragm 14. Primary Piston 19. Spring
BRAKES 5-19
4. Remove the snap ring retainer and primary piston valves over the springs, being careful not to dis
assembly. Remove the secondary piston, piston place the springs from the spring seats.
spring, and retainer by blowing air through the stop 2. Place new brass tube seats in the outlet holes. Be
bolt hole. If no air is available, a piece of wire sure seats are not cocked as this would cause burrs
may be used. Bend approximately 1/4 inch of one to be turned up as the tube seats are pressed in.
end into a right angle, hook the secondary piston Thread a spare brake line tube nut into the outlet
and pull it out. hole and turn the nut down until the tube seat bot
5. Position main cylinder in vice with outlet holes toms. Remove the tube nut and check the outlet hole
facing up. for loose burrs, which might have been turned up
6. Drill a 13/64 inch hole through both check valve when the tube seat was pressed down. Repeat this
seats. process to bottom the second seat.
7. Tap out both seats using a 1/4 - 20 tap. 3. Put new secondary seals in the two grooves in the
8. Install a spare brake line tube nut in the outlet end of the secondary piston assembly. The seal
hole. Place a flat washer on a one inch screw which is nearest the end will have its lips facing
threaded to screw into tapped hole, and thread toward that end. The seal in the second groove
screw into threaded hole in tube seat. Hold the should have its lips facing toward the portion of
screw to keep it from turning and back out the the secondary piston which contains the small com
tube nut. This will remove the tube seat. pensating holes.
9. Repeat Step 8 above on second tube seat. 4. Assemble a new primary seal protector and primary
10. Remove the check valves and springs from the seal over the end of the secondary piston with the
cavities beneath the tube seats. flat side of the seal seats against the seal protector,
11. Remove the primary seal, primary seal protector, and the protector against the flange of the piston
and secondary seals from the secondary piston. which contains the small compensating holes.
Remove the piston extension screw securing the 5. Assemble the new secondary seal into the groove on
primary piston spring to the primary piston. Re the push rod end of the primary piston. The lips of
move the spring retainer, primary seal, primary this seal should face toward the small compensating
seal protector, and secondary seal from the primary holes in the opposite end of the primary piston.
piston. 6. Assemble the new primary seal protector and pri
mary seal on the end of the primary piston with the
Cleaning and Inspection flat side of the seal seated against the seal protector,
1. Remove main cylinder casting from vice and inspect and the protector against the flange on the piston
the bore for corrosion, pits, and foreign matter. which contains the compensating holes.
Be sure that the outlet ports are clean and free of 7. Assemble the spring retainer in one end of the
brass cuttings from the tube seat removal operation. primary piston spring and the secondary piston
2. Inspect the fluid reservoirs for foreign matter. stop in the other end. Place the end of the spring
Check the bypass and compensating ports to the over the end of the primary piston with the spring
cylinder bore to insure that they are not restricted. retainer seats inside of the lips of the primary
Do not use wire to check ports. seal.
NOTE: Before washing parts, hands must be 8. Remove all cleaning liquid from the threaded hole
in the primary piston. Place the piston extension
clean. Do not wash hands in gasoline or oil
screw down through the secondary piston stop and
before cleaning parts. Use soap and water only.
the primary spring retainer and screw it into the
3. Use Declene or equivalent to clean all metal parts primary piston until it bottoms out.
thoroughly. Immerse parts in the cleaning fluid and 9. Coat the bore of the master cylinder with clean
brush with hair brush to remove foreign matter. brake fluid. Coat the primary and secondary seals
Blow out all passages, orifices, and valve holes. Air on the secondary piston with clean brake fluid. Insert
dry the parts and place on clean paper or lint-free the secondary piston spring retainer into the sec
clean cloth. ondary piston spring. Place the retainer and spring
down over the end of the secondary piston until the
NOTE: Be sure to keep parts clean until re retainer locates inside of the lips of the primary
assembly. Rewash parts, if there is any occa cup.
sion to doubt cleanliness. 10. Hold the master cylinder with the open end of the
4. Check pistons for scratches or other visual damage; bore down. Push the secondary piston into the bore
replace if necessary. until the spring seats against the closed end of the
bore.
Assembly Fig. 31 11. Position the master cylinder in a vise with the
Use care when reassembling the main cylinder check open end of the bore up. Coat the primary and
valves. Improper assembly of the check valve seats secondary seal on the primary piston with clean
will result in distortion of the seats. If this occurs, brake fluid. Push the primary piston assembly,
there will be no check valve action and a loss of brake spring end first, into the bore of the master cylinder.
pedal travel will result; the pedal will have to be pumped Hold the piston down and snap the lock ring into
one or more times before actual car braking occurs. position in the small grooves in the I.D. of the bore.
1. Place the main cylinder in a vice with the outlet 12. Push the primary piston down to move the secondary
holes facing up. Place the check valve springs in piston forward far enough to clear the stop screw
the outlet holes. Be sure the springs are seated hole in the bottom of the front fluid reservoir. Install
in the bottom of the holes. Place new rubber check the stop screw.
BRAKES 5-20
13. Install reservoir diaphragm in the reservoir cover 1. Inspect cylinder bore. Check for staining and corro
and install the cover on the main cylinder. Push sion. Discard cylinder if corroded.
ball wire into position to secure the reservoir cover. 2. Polish any discolored or stained area with crocus
cloth by revolving the cylinder on the cloth sup
Installation ported by a finger. Do not slide the cloth in a
1. Assemble the push rod through the push rod retainer, lengthwise manner under pressure.
if it has been disassembled.
2. Push the retainer over the end of the main cylinder. NOTE: Before washing parts, hands must be
Assemble new boot over push rod and press it down clean. Do not wash hands in gasoline or oil
over the push rod retainer. Slide new mounting before cleaning parts. Use soap and water to
gasket into position. clean hands.
3. Secure the main cylinder to the firewall with mount 3. Wash the cylinder and metal parts in Declene or
ing bolts. equivalent.
4. Connect the push rod clevis to the brake pedal with 4. Shake excess cleaning fluid from the cylinder. Do
pin and retainer. not use a rag to dry the cylinder as lint from the rag
5. Connect the brake lines to the main cylinder. cannot be kept from the cylinder bore surfaces.
6. Fill the main cylinder reservoirs to the levels 5. Check piston for scratches or other visual damage;
shown in Figure 7. Bleed the brake system as out replace if necessary.
lined in this section.
7. If necessary, adjust the brake pedal free play as Assembly Fig. 32
outlined in this section. 1. Lubricate the cylinder bore and counterbore with
clean brake fluid and insert spring-expander
WHEEL CYLINDER Fig. 32 assembly.
2. Install new cups with flat surfaces toward outer
The wheel cylinder boots should be removed from a ends of cylinder. Be sure cups are lint and dirt free
cylinder body only when they are visibly damaged or before insertion. Do not lubricate cups prior to
leaking fluid. Wheel cylinders having torn, cut, or heat- assembly.
cracked boots should be completely overhauled. 3. Install new Durex pistons into cylinder with flat
Removal surfaces toward center of cylinder. Do not lubri
1. Place car on hoist. cate pistons before installation.
2. Remove wheel and tire assembly. Back off brake 4. Press new boots into cylinder counterbores by hand.
adjustment, if necessary, and remove drum. Do not lubricate boots prior to installation.
3. Disconnect brake system hydraulic line from Installation
cylinder. 1. Position wheel cylinder to brake flange plate. Install
4. Remove brake shoe pull back springs. screws and tighten securely.
5. Remove screws securing wheel cylinder to flange
plate. Disengage cylinder push rods from brake NOTE: On Chevrolet front wheels, mount front
shoes and remove cylinder. wheel cylinders to the brake flange plate by
installing the threaded anchor pin through the
NOTE: On Chevrolet, it is necessary to re wheel cylinder housing and tighten to 130 ft. lb.
move the anchor pin which holds the front wheel To secure, peen over the flat washer on the
cylinder to flange plate to remove the front anchor pin.
wheel cylinder.
Disassembly 2. Replace all push rods and pull back springs.
3. Connect hose or line to wheel cylinder.
1. Remove boots from cylinder ends with pliers and
discard boots. NOTE: If replacing front wheel cylinder, con
2. Remove and discard pistons and cups. nect hose and inspect installation as outlined in
"Hydraulic Brake Hose Replacement".
Inspection and Cleaning
4. Install drum and wheel.
NOTE: Staining is not to be confused with
5. Bleed brakes as outlined in this section.
corrosion. Corrosion can be identified as pits
or excessive bore roughness. ANCHOR PIN
oa
Front Wheel
2. Remove wheel and drum as outlined in this section.
3. Remove brake shoe pull back springs, link and guide
plate.
4. Disengage anchor pin lock and remove anchor pin by
turning counter- clockwise.
Fig. 32-Chevelle Wheel Cylinder-Exploded View 5. Place new lock plate on anchor pin and pass pin
through the hole in flange plate and screw into tapped
1. Push Rod Boot 4. Housing 7. Piston Cup hole in spindle support.
2. Piston 5. Fluid Inlet 8. Piston 6. Torque pin to 130 ft. lb. and lock by peening over
3. Piston Cup 6. Spring 9. Push Rod Boot washer tabs.
BRAKES 5-21
7. Install brake shoe guide plate, link and pull back A small screw driver or hooked wire may be inserted
springs. to disengage the automatic adjuster actuating lever so
8. Adjust brakes, install drum and wheel as outlined the star wheel may be turned.
in this section and lower vehicle. Test brake
operation. Removal
Rear Wheel 2. Remove wheel and tire assembly, back off brake
adjustment and remove drum.
Two type anchor pins are used in production for the
rear wheels. The riveted type is not serviced and if Inspection and Reconditioning
failure or damage should occur to either the anchor Whenever brake drums are removed they should be
pin or flange plate, both parts will have to be replaced thoroughly cleaned and inspected for cracks, scores,
and the threaded type anchor pin used. deep grooves, and out-of-round. Any of these conditions
must be corrected since they can impair the efficiency
Threaded Type of brake operation and also can cause premature failure
of other parts.
1. Place car on hoist. Smooth up any slight scores by polishing with fine
2. Remove wheel and drum as outlined in this section. emery cloth. Heavy or extensive scoring will cause
3. Remove brake shoe pull back springs, link and guide excessive brake lining wear and it will probably be
plate. necessary to rebore in order to true up the braking
4. Remove anchor pin retaining nut and washer and surface.
remove pin from flange plate. An out-of-round drum makes accurate brake shoe
5. Position anchor pin to flange plate, install lock adjustment impossible and is likely to cause excessive
washer and nut, and torque pin to 80 ft. lb. wear of other parts of brake mechanism due to its
6. Install brake shoe guide plate, link and pull back eccentric action.
springs. A drum that is more than .008" out-of-round on the
7. Adjust brakes and install drum and wheel as outlined diameter will result in rough brake application and
in this section and lower vehicle. should be rebored. Out-of-round, as well as taper and
8. Test brake operation. wear can be accurately measured with an inside microm
eter fitted with proper extension rods.
BRAKE DRUMS if drum is to be rebóred for use with standard size
Front brake drums are the demountable type; that is, brake facings which are worn very little, only enough
they can be removed without removing the hub. Rear metal should be removed to obtain a true smooth braking
brake drums are demountable and may be removed surface.
without removing the axle shaft. If drum has to be rebored more than .020" over the
A lanced "knock out" area fig. 33 is provided in standard diameter, it should be rebored to .060" diameter
the web of the brake drum for servicing purposes in oversize and the brake facing should be replaced with
the event retracting of the brake shoes is required in .030" oversize facings.
order to remove the drum. A brake drum must not be rebored more than .060"
over the maximum standard diameter, since removal
of more metal will effect dissipation of heat and may
cause distortion of drum. Chevrolet brake facing is
not furnished larger than .030" oversize and this will
not work efficiently in drums bored more than .060"
oversize.
Brake drums may be refinished either by turning or
grinding. Best brake performance is obtained by turning
drums with a very fine feed. To insure maximum lining
life, the refinished braking surface must be smooth and
free from chatter or tool marks, and run-out must not
exceed .005" total indicator reading.
Cleaning
New brake drums in parts stock are given a light
coating of rust proofing oil to prevent the formation of
rust on the critical braking surfaces during the time
that the drums are in storage.
This rust proofing oil must be carefully removed
before the drum is placed in service to prevent any
of this oil from getting on the brake shoe facings, which
mighat cause an extreme brake grab condition.
It is recommended that a suitable volatile, non-toxic,
I greaseless type solvent be used to clean the oil from the
braking surface of the new brake drums before they are
placed in service to insure the cleanest possible surface.
Gasoline or kerosene should not be used as there is
Fig. 33-Brake Drum Access Hole danger that a portion of the diluted oil substance may
BRAKES 5-22
be left on the braking surface that may later cause adjustable, non-serviceable valve. If defective
difficulty. it must be replaced.
Installation Removal Fig. 3
1. Make brake adjustment as outlined in this section. 1. Place dry rags below valve to absorb any fluid
2. Install brake drum, aligning tang with wheel hub spilled during removal of valve.
fig. 18. 2. Disconnect hydraulic brake lines from both sides
3. Install wheel and tire assembly and lower vehicle.
of switch. Cover open line ends with clean, lint-free
4. Make final brake adjustment as outlined in this
material to prevent foreign matter from entering
section and check brake operation. the system.
NOTE: The brake pressure differential warn 3. Remove mounting screw and remove switch from
ing switch is non-adjustable, non-serviceable vehicle.
valve. If defective it must be replaced.
Installation
BRAKE PIPE DISTRIBUTION AND SWITCH 1. Make sure new valve is clean and free of dust and
ASSEMBLY Fig. 2 lint. if any doubt exists, wash valve in Declene, or
equivalent, and dry with air.
Removal 2. Place valve in position and secure to frame side
1. Disconnect battery cable. rail with mounting screw.
2. Disconnect electrical lead from switch assembly. 3. Remove protective material from open hydraulic
3. Place dry rags below the switch to absorb any fluid brake lines and connect lines to each side of valve.
spilled during removal of switch. 4. Bleed brake system as outlined in this section.
4. Disconnect four hydraulic lines from connections
at switch. if necessary, loosen line connections at
main cylinder to loosen lines. Cover open line ends BRAKE WARNING LIGHT CHECKING PROCEDURE
with clean, lint-free material to prevent foreign
1. Determine if bulb is functioning by applying and re
matter from entering the system.
leasing parking brake.
5. Remove mounting screw and remove switch from
2. Check to make sure that both master cylinder reser
vehicle.
voirs are full.
Installation 3. Open wheel cylinder bleed screw at one rear wheel.
1. Make sure new switch is clean and free of dust and 4. Depress brake pedal and hold down. The brake
lint. if any doubt exists, wash switch in Declene, warning light should come on due to pressure dif
or equivalent, and dry with air. ference between front and rear systems. Approxi
2. Place switch in position and secure to bracket with mately 150-250 psi differential is needed to operate
mounting screw. brake light.
3. Remove protective material from open hydraulic 5. Close bleed screw, then release brake pedal. Refill
brake lines and connect lines to switch. if necessary, rear reservoir, if needed.
tighten brake line connections at main cylinder.
4. Connect switch electrical lead. NOTE: Caution should be taken to prevent air
5. Connect battery cable. from entering hydraulic system during checks
6. Bleed the brake systems as outlined in this section. on switch.
CAMARO PRESSURE REGULATOR VALVE The recommended checking interval should be 24

months or 24,000 miles, any time major brake work is
AIR CONDITIONED MODELS ONLY done or any time a customer complains of excessive
NOTE: The pressure regulator valve is a non- pedal travel.
BRAKES 5-23
DISC BRAKES
INDEX
Page Page
General Description 5-23 Brake Shoes 5-24
Maintenance and Adjustments 5-23 Brake Caliper 5-26
Bleeding Hydraulic System 5-23 Brake Disc 5-28
Parking Brake Adjustment - Corvette 5-24 Main Cylinder 5-29
Component Replacement and Repairs 5-24 Parking Brake Shoes - Corvette 5-29
GENERAL DESCRIPTION
Four wheel disc brakes are standard equipment on are not included in this section are the same as for
the 1968 Corvette, as in 1967. The Corvette may also the Duo-Servo type brakes.
be equipped with heavy duty disc brakes which include
new front calipers, shoes, linings, and rear pressure
regulator valve. This heavy duty option is used in
conjunction with a vacuum power unit. Front wheel disc
brakes are installed as optional equipment on Chevrolet,
Chevelle, Camaro, and Chevy II models.
The disc brake, figs. 35-36 consists of a fixed
caliper, rotating disc, splash shield, and mounting
bracket. The caliper assembly contains four pistons and
two shoe and lining assemblies with the lining riveted to
the steel shoes. A seal and dust boot are installed on
each piston, with a piston spring in the caliper cylinder
bore beneath each piston. A retaining pin extends through
each caliper half and both shoes to hold the shoes and
linings in position in the caliper. On Corvette heavy
duty disc brakes, two retaining cotter pins are used at
each end of the caliper to secure the shoes and linings.
Machined surfaces within the caliper prevent the shoe
and lining assembly from rotating with the brake disc
when pressure is applied.
The disc, which has a series of air vent louvers to
provide cooling, is mounted on the front wheel-hub.
The caliper straddles the disc and mounts on a mounting
bracket attached to the steering knuckle with two bolts.
The Corvette heavy duty option includes a pressure
regulator valve mounted in the rear brake line just
below the main cylinder. Chevrolet, Chevelle, Camaro,
and Chevy II models with disc brakes have a pressure
regulator valve mounted in the front brake line just
below the main cylinder. The valve meters the hydraulic
pressure to the front brakes resulting in simultaneous
braking balance between the front and rear brake sys
tems. This valve guards against premature lock-up of
front wheels when brakes are applied.
Maintenance, adjustment, and service operations which Fig. 34-Delco Moraine Disc Brake

BLEEDING HYDRAULIC SYSTEM 2. The front calipers contain one bleeder valve. The
rear calipers on Corvette contain two bleeder valves
The operation of bleeding the disc brake hydraulic
system is the same as for Duo-Servo system outlined one inboard and one outboard which necessitates
in the front of this section. Note the exceptions below the removal of the rear wheels for bleeding.
and refer to bleeding procedures under Duo-Servo 3. Tapping the caliper with a rawhide mallet as the
brakes. fluid is flowing out may assist in obtaining a good
1. When pressure bleeding equipment is used, the bleeding job.
correct pressure setting for bleeding disc brakes 4. On Chevrolet, Chevelle, Camaro and Chevy II the
is 10-20 lbs. on Corvette, and 40 lbs. on all other spring loaded end of the pressure regulator valve
models. fig. 36 must be held valve in open position while
BRAKES 5-24
Fig. 35-Disc Brake-Cutaway View
bleeding. This is done by depressing and holding 5. Insert an adjusting tool or screw driver through the
in the plunger in the end of the valve either by hand, hole in the disc and tighten the adjusting screw by
by taping, or by clamping. moving your hand away from the floor on both the
5. Never reuse brake fluid that has been drained from left and right sides fig. 37.
the hydraulic system, when bleeding the brakes. 6. Tighten until the disc will not move, then back off
PARKING BRAKE-CORVETTE six 6 to eight 8 notches.
7. Apply the parking brake two 2 notches from inside
Adjustment the car.
2. Remove rear wheels. 8. Tighten the brake cables at the equalizer to produce
a light drag with the wheels mounted.
3. Loosen brake cables at the equalizer until the park
ing brake levers move freely to the "off" position 9. Fully release the parking brake handle and rotate
with slack in the cables. the rear wheels. No drag should be evident with the
4. Turn the disc until the adjusting screw can be seen handle released.
through the hole in the disc. 10. Lower vehicle.

BRAKE SHOES approximately 1/16 inch of lining thickness. Shoes with
linings retained by rivets should be replaced when the
Shoes with bonded linings should be replaced when the lining is worn to approximately .020" thickness over
groove in the center of the lining is worn off leaving the rivet heads.
BRAKES 5-25
Fig. 36-Pressure Regulator Valve-Chevrolet and Camaro Shown
Removal 8. Repeat above procedure at each wheel where shoes

1. Siphon 2/3 of the brake fluid from the main cylinder are to be replaced.
reservoirs. 9. Refill main cylinder to fluid level shown in Figure
8. If necessary, bleed brake system as outlined in
CAUTION: If fluid is not removed, insertion
this section.
of the new full thickness lining will force the
10. Install wheels and lower vehicle.
pistons back into the housing displacing fluid
into the master cylinder. This will cause the
main cylinder to overflow. Do not drain the CAUTION: Do not move car until a firm pedal
reservoirs completely or air will be pumped is obtained.
into the system.
3. Remove wheels.
4. Remove and discard the cotter pin from the inboard
end of the shoe retaining pin and slide out the re
taining pin. On Corvette with heavy duty disc brakes,
two retaining pins must be removed, one on each
end of the caliper assembly.
5. Remove the inboard shoe by rotating either end of
shoe out of caliper and pulling shoe out.
6. Insert new shoe with lining into position. Use a
putty knife to push each piston back as the shoe is
inserted as shown in Figure 38.
7. Replace the outboard shoe as described above. When
both caliper shoes have been replaced, install the
shoe retaining pin through outboard caliper half,
outboard shoe, inboard shoe, and inboard caliper
half. Insert a new 3/32 x 5/8 plated cotter pin
through the retaining pin and bend back ends of
cotter pin. On Corvette heavy duty front caliper,
install two retaining cotter pins, one at each end of
the caliper. Fig. 37-Adjusting Parking Brake Shoes
CHEVRpLET CHASSIS SERVICE MANUAL
BRAKES 5-26
BRAKE CALIPER
Removal
2. Remove wheel.
3. On front caliper, disconnect the brake hose at brake
line support bracket. On Corvette rear caliper,
disconnect the brake tubing from the inboard caliper.
Tape the open tube or line end to prevent foreign
matter from entering the system.
4. Pull cotter pin from end of shoe assembly retaining
pin. Remove the pin and shoe assembly from the
caliper. Two retaining pins must be removed on
heavy duty Corvette front calipers. Identify the
inboard and outboard shoe if they are to be reused.
5. Remove the end of brake hose at bracket by re
moving U-shaped retainer from the hose fitting and
withdrawing the hose from bracket.
6. Remove the caliper assembly from the mounting
bracket by removing two hex head bolts.
Disassembly Fig. 39
1. Clean exterior of caliper with Declene, or equivalent.
On Chevrolet and Corvette front caliper, remove
Fig. 38-Replacing Shoe and Lining Assembly brake hose.
11N
12
CHEVELLE, CHEVY II AND CAMARO SHOWN
Fig. 39-Caliper Assembly-Exploded View
1. Caliper Belts 4. Piston Spring 7. Piston Boot 10. Caliper Half

2. Bleeder Valve 5. Seal 8. Brake Shoes 11. Retaining Pin
3. Caliper Half 6. Piston 9. "0" Rings 12. Cotter Pin
BRAKES 5-27
Fig. 40-Installing Piston in Caliper Bore Using Tool J-22591 Fig. 41-Installing Boot Seal in Caliper Bore Using Tool J-22592
2. Separate the caliper halves by removing the two Assembly

large hex head bolts. Remove the two small "0" 1. Assemble the seal in the groove in the piston which
rings from the cavities around the fluid transfer is closest to the flat end of the piston. The lip on
holes in the two ends of the caliper halves. the seal must face toward the large end of the
3. To free the piston boots so that the pistons may be piston. Be sure lips are in the piston groove and do
removed, push the piston down into the caliper not extend over the step in the end of the groove.
as far as it will go. Insert a screwdriver blade 2. Place the spring in the bottom of the piston bore.
under the inner edge of the steel ring in the boot, 3. Lubricate the seal with clean brake fluid.
and using the piston as a fulcrum, pry the boot from 4. Install the piston assembly in the bore using appli
its seat in the caliper half. cable piston ring compressor Tool J-22639, 2262
CAUTION: Use care not to puncture seal when or 22591 as shown in Figure 40. Use care not to
removing pistons from caliper. damage the seal lip as piston is pressed past the
edge of the bore.
4. Remove the pistons and piston springs from the 5. Assemble the boot in the groove of the piston closest
caliper half. Remove the boot and seal from their to the concave end of the piston. The fold in the boot
grooves in the piston. must face toward the end of the piston with the seal
Cleaning and Inspection on it.
1. Clean all metal parts using Declene, or equivalent. 6. Depress the pistons and check that they slide
Remove all traces of dirt and grease. Do not use smoothly into the bore until the end of the piston is
mineral base solvents to clean brake parts. flush with the end of the bore. if not, recheck piston
2. Using an air hose, blow out all fluid passages in the assembly and location of the piston spring and the
caliper halves, making sure that there is no dirt seal.
or foreign material blocking any of these passages. 7. Position applicable boot seal installer Tool J-22592,
3. Discard all rubber parts. Boots, seals, and "0" J-22628, or J-22638 over the piston and seat the
*rings should be replaced with new service kit parts. steel boot retaining ring evenly in the coursterbore
4. Carefully inspect the piston bores in the caliper as shown in Figure 41. The boot retaining ring must
halves. They must be free of scores and pits. A be flush or below the machined face of the caliper.
scored or otherwise damaged bore will cause leaks Any distortion or uneven seating could allow con
and unsatisfactory brake operation. Replace the taminating and corrosive elements to enter the bore.
caliper half if eithe:r bore is damaged to the extent 8. Position the "0" rings in the small cavities around
that polishing with very fine crocus cloth will not the brake fluid transfer holes in both ends of the
restore it. outboard caliper halves. Lubricate the hex leaçI
5. Check the fit of the piston in the bore using a feeler bolts with Delco Brake Lube or clip in clean bialê
gauge. Clearance should be as follows: fluid. Fit caliper halves together and secure with
2 1/16 inch Bore .0045 to .010 bolts. Refer to torque specifications in rear of
1 7/8 inch Bore .0045 to .010 manual for correct torque valves.
1 3/8 inch Bore .0035 to .009 Installation
if the bore is not damaged, and the clearance exceeds 1. Carefully mount the assembled caliper over the edge
either of the upper limits, a new piston will be required. of the disc. Use a putty knife to depress pistons so
BRAKES 5-28
that the caliper can be lowered into position on the 9. Install wheels and lower vehicle.
disc fig. 42. Use care to prevent damage to boots
on the edge of the disc as the caliper is mounted. CAUTION: Do not move car until a firm pedal
2. Secure the caliper to the mounting bracket with two is obtained.
hex head bolts. Refer to torque specifications in
rear of manual for correct torque values. BRAKE DISC
CAUTION: if replacing old shoe assemblies, Servicing of the disc brakes is extremely critical
be sure to get the shoes in the same position due to tolerances required in machining of the brake
from which they were removed. New shoe as disc to insure proper brake operation.
semblies have an arrow printed on the back, Manufacturing tolerance for flatness and parallelism
showing the direction of forward disc rotation. of the brake disc is held to .0005" while lateral runout of
the brake disc surfaces cannot exceed .004" total in
3. Install the shoe and lining assemblies as outlined in dication reading. Excessive lateral runout of the brake
this section. disc will cause a "knocking back" of the pistons, which
4. On Chevrolet and Corvette front calipers, place a will create increased pedal travel and vibration when the
new copper gasket on the male end of the front brakes are applied. The finish of the frictional surfaces
wheel brake hose. On all models, install brake hose must be maintained at 30-50 micro inches.
in the calipers. With the wheels straight ahead, In view of the foregoing close tolerances, machining
pass the female end of the brake hose through the of the discs is not recommended.
support bracket. It has been found that, once a wear pattern has been
5. Make sure the tube seat is clean and connect the established, disc brakes are less susceptible to scoring
break line tube nut to the caliper. Tighten securely. problems than are drum brakes. Disc surface scoring
6. Allowing the hose to seek a normal position, without imperfections less than .015 in depth have negligible
twist, insert hex of the hose fitting into the 12-point effect on disc brake operation.
hole in the support bracket and secure it in place When the total disc thickness is less than .965 for the
with the "U"-shaped retainer. Turn the steering 1" thick disc Chevelle, Camaro and Chevy II or 1.215
geometry from lock to lock while observing the hose. for the 1-1/4" thick disc Chevrolet and Corvette, it
Check that the hose does not touch other parts at should be replaced. Disc thickness less than this can
any time during suspension or geometry travel. permit the shoes to come out of contact with the shoe
if contact does occur, remove the "U"-shaped re abutments and cause malfunction.
tainer and rotate the end of the hose in the support
bracket one or two points in a direction which will
Checking Procedure Fig. 43
eliminate hose contact. Reinstall the retainer and
recheck for hose contact. if it is satisfactory, place Front
the steel tube connector in the hose fitting and Tighten the adjusting nut of the wheel bearing until all
tighten securely. play has been removed. It should be just loose enough
7. if rear brake caliper is being serviced, connect to allow the wheel to turn. Clamp a dial indicator to the
brake line to caliper.
8. Bleed brakes as outlined in this section.
Fig. 42-Installing Caliper on Disc Fig. 43-Dial Indicating Disc Runout
BRAKES 5-29
caliper so that its button contacts the disc at a point about

1 inch from the outer edge. When the disc is turned, the
indicator reading should not exceed .002 inches. if runout
exceeds this amount the hub and disc assembly should
be replaced. Due to the close tolerances involved it is
not recommended that the front discs be machined or
serviced separately.
After checking the runout, readjust the wheel bearings
as outlined in Section 3 of this manual.
Rear-Corvette Only
Check the rear wheel bearing end play, as outlined in
Section 4 of this manual. Then dial indiate the disc face.
If lateral runout of the disc exceeds the bearing end play
by .004 inches, the disc should be replaced.
Removal
1. Place car hoist and remove wheel and tire assembly.
2. Remove brake caliper as outlined in this section.
3. Drill out the five rivets attaching the disc to the hub
or spindle.
4. Remove brake disc from vehicle.
5. Complete the removal of the five rivets from the Fig. 44-Exploded View of Parking Brake Shoes
hub or spindle.
When reassembling the disc to the spindle, once the 1. Parking Brake Shoe 6. Backing Plate
2. Hold Down Spring and Cap 7. Parking Plate
five rivets have been removed, it is unnecessary to 8. Hold Down Spring and Cap
3. Hold Down Pin
rerivet the two assemblies,, The lug nuts will supply 4. Actuating Lever 9. Adjusting Screw Spring
ample "hold". It is necessary, however, to install the 5. Retractor Spring 10. Adjusting Screw Assembly
lug nuts less wheel when checking the Runout of the
disc whenever the rivets have been removed. Remove hold down springs on primary and secondary
Installation shoes.
1. Install the disc to the hub or spindle aligning the lug 3. Remove shoes by pulling them away from the anchor
bolts with the holes in the disc. pin.
4. Remove the adjusting screw spring and adjusting
CAUTION: Be sure the emergency brake ad screw from the shoes.
justing holes of the spindle and disc are in
alignment. Installation
1. Put light coat of lubriplate on pads, backing plate,
2. Install the brake caliper and shoes as outlined in and the threads of the adjusting screw.
this section. 2. Attach adjusting screw spring to the bottom hole in
3. Bleed the brakes as outlined in this section. each shoe.
4. Install wheel and tire assembly and lower vehicle. 3. Insert the star wheel between the shoes. On left
CAUTION: Do not move car until a firm pedal hand brakes, the star wheel goes next to the rear
is obtained. shoe; on right hand brakes, the star wheel goes next
to the forward shoe.
MAIN CYLINDER 4. Install the shoes on the backing plate by spreading
them and placing them around the anchor pin.
The service operations fo:r the main cylinder are the 5. Install the hold down springs on the hold down nails.
same as for Duo-Servo main cylinder. Refer to service 6. Install retractor spring on one shoe and stretch to
procedures under Duo-Servo Brakes. other shoe.
CAUTION: Make sure that the lever assembly
PARKING BRAKE SHOES which spreads the shoe is located so that the
Corvette Fig. 44 notches on the lever fit against the shoes.
Removal 7. Install disc and caliper as outlined in this section.
1. Remove tire and wheel assemblies and brake disc 8. Bleed brakes as outlined in this section.
as outlined in this section. 9. Adjust the parking brake as outlined in this section.
2. Remove retractor spring at the top of the shoes. 10. Install wheels and lower vehicle.
BRAKES 5-30
POWER BRAKES
INDEX
Page Page
General Description 5-30 Component Replacement 5-30
Maintenance and Adjustments 5-30 Power Brake Cylinder 5-30
Inspection 5-30 Removal 5-30
Lubrication 5-30 Disassembly and Assembly See Overhaul Manual
Bleeding Instructions 5-30 Installation 5-30
Air Cleaner Service 5-30
GENERAL DESCRIPTION
The Power Brake Unit is a self-contained hydraulic line connections are necessary - one a vacuum connection
and vacuum unit, utilizing manifold vacuum and atmos from manifold to check valve located on front shell; the
phere pressure for its power. other, a hydraulic connection from the main cylinder
This unit permits the use of a low brake pedal as well outlet directly into the hydraulic system. The unit is
as less pedal effort than is required with the conventional mounted on the engine side of the fire wall and directly
nonpower hydraulic brake system. Only two external connected to the brake pedal.

INSPECTIONS needs no further lubrication other than maintaining
normal reservoir fluid level. The reservoir should be
1. Check vacuum line and vacuum line connections as
filled as described in this section.
well as vacuum check valve in front shell of power
unit for possible vacuum loss.
2. Inspect all hydraulic lines and connections at the BLEEDING INSTRUCTIONS
wheel cylinders and main cylinder for possible
hydraulic leaks. The power system may be bled manually or with a
3. Check brake assemblies for scored drums, grease pressure bleeder as outlined in this section. Use only
or brake fluid on linings, worn or glazed linings, GM Supreme 11 Brake Fluid or equivalent. Do not use the
and make necessary adjustments. power assist while bleeding. The engine should not be
4. Check brake fluid level in the hydraulic reser running and the vacuum reserve should be reduced to
voirs. The reservoirs should be filled to the levels zero by applying the brake several times before starting
shown in Figure 8. the bleeding procedure.
5. Check for loose mounting bolts at main cylinder and
at power section.
6. Check air cleaner filter in power piston extension AIR CLEANER SERVICE
and replace filter if necessary. Servicing of the air cleaner is recommended and the
7. Check brake pedal for binding and misalignment element replaced when restriction becomes severe
between pedal and push rod. enough to affect power brake response. At any other
time, if cleaning of the filter is felt necessary, it should
LUBRICATION be shaken free of dirt or washed in soap and water and
The power brake unit is lubricated at assembly and thoroughly dried.
COMPONENT REPLACEMENT
POWER BRAKE CYLINDER Installation
Removal 1. Mount the power brake assembly in place and install
1. Remove vacuum hose from vacuum check valve. the attaching nuts and lock washers.
2. Disconnect hydraulic lines at main cylinder. 2. Attach vacuum line to check valve.
3. Disconnect push rod at brake pedal assembly. 3. Secure hydraulic lines to main cylinder.
4. Remove nuts and lock washers securing power unit 4. Attach push rod to brake pedal assembly, and check
to fire wall, and remove power unit from engine operation. of stop light.
compartment. 5. Bleed brakes as outlined in this section.
Repair procedures for the power cylinder are outlined CAUTION: After replacing the unit on the vehi
in the Brake Section of the Overhaul Manual - for service cle, start the engine and allow vacuum to build
of the main cylinder refer to applicable portion of up before applying the brake.
"Standard Brakes" in this manual.
BRAKES 5-31
SPECIAL TOOLS
U
n
4
5
2
I 7
Fig. 45-Brake Special Tools
1. J-8051 Brake Tool Flaring Tool 4. J-22591, J-22629, J-22639 Piston 7. J-21177 Drum-to-Brake Shoe
2. J-.8049 Brake Spring Remover Ring Compressors Clearance Gauge
and Installer 5. J-21472 Brake Bleeder Wrench 8. J-22592, J-22628, J-22638 Boot Seal
3. J-8113 Brake Tube Cutter 6. J-22489 Pressure Bleeder Adapter InStallers
6-24
6-12
6.-i
SECTION 6
ENGINE
Page Page
Engine Tune Up . Torque Sequence 6-38
Engine Mechanical In Line . Special Tools 6-39
Engine Mechanical V8
ENGINE TUNE UP
INDEX
Page Page
General Description 6-1 Instrument Check-Out 6-7
Mechanical Checks and Adjustments 6-i Instrument Hook-Up 6-7
Spark Plug Removal 6-1 Check and Adjust Dwell 6-7
Test Compression 6-1 Check Dwell Variation 6-7
Service and Install Spark Plugs 6-2 Check and Adjust Timing 6-7
Service Ignition System 6-3 Adjust Idle Speed and Mixture 6-8
Service Battery and Battery Cables 6-5 Additional Checks and Adjustments 6-8
Service Delcotron and Regulator 6-5 Testing Crankcase Ventilation Valve 6-8
Service Fan Belt 6-5 Testing Cranking Voltage 6-8
Service Manifold Heat Valve 6-5 Cylinder Balance Test 6-8
Tighten Manifold 6-5 Battery 6-8
Service Fuel Lines and Fuel Filter 6-6 Ignition 6-8
Service Cooling System 6-6 Carburetor 6-10
Check and Adjust Accelerator Linkage 6-6 Fuel Pump 6-10
Service Crankcase Ventilation 6-6 Cooling System 6-11
Service Air Injection Reactor System 6-6 Cylinder Head Torque and Valve Adjustment 6-11
Choke Adjustment 6-7
GENERAL DESCRIPTION
The engine tune up is important to the modern automo of service equipment available for this purpose. Always
tive engine with its vastly improved power and perform follow the instructions provided by the manufacturer of
ance. The higher compression ratios, improved electri the particular equipment to be used.
cal systems and other advances in design, make today’s Additional checks and adjustments are included in the
engines more sensitive and have a decided effect on latter part of this section for use as required. Many of
power, performance and fuel consumption. these operations can be used to isolate and correct trou
It is seldom advisable to attempt a tune up by correc ble located during the tune up. Where conditions are un
tion of one or two items only. Time will normally be covered requiring major corrective action, refer to the
saved and more lasting results assured if the technician appropriate section of this manual or the Passenger
will follow a definite and thorough procedure of analysis Chassis Overhaul Manual for detailed service informa
and correction of all items affecting power, performance tion.
and economy. Typical illustrations and procedures are used except
The tune up will be performed in two parts. The first where specific illustrations or procedures are necessary
part will consist of visual and mechanical checks and ad to clarify the operation. Illustrations showing bench op
justments; the second part will consist of an instrument erations are used for clarification however all operations
checkout that can be performed with any one of the units can be performed on the vehicle.
MECHANICAL CHECKS AND ADJUSTMENTS

Spark Plug Removal fully. It is essential that improper compression be cor
Remove any foreign matter from around spark plugs by rected before proceeding with the engine tune up.
blowing out with compressed air, then disconnect wires 1. Remove air cleaner and block throttle and choke in
and remove plugs. wide open position.
2. Hook up starter remote control cable and insert
Test Compression Fig. fl compression gauge firmly in spark plug port.
The compression check is important because an engine
with low or uneven compression cannot be tuned success- CAUTION: Whenever the engine is cranked
CHEVROtET CHASSIS SERVICE MANUAL
ENGINE 6-2
remotely at the starter, with a special jumper

cable or other means, the primary distributor
lead must be disconnected from the negative
post on the coil and the ignition switch must be
in the "ON" position. Failure to do this will PORCELAIN
result in a damaged grounding circuit in the INSULATOR
ignition switch. INSULATOR CRACKS
OFTEN OCCUR HERE
3. Crank engine through at least four compression
strokes to obtain highest possible reading. N
4. Check and record compression of each cylinder. HELL
5. If one or more cylinders read low or uneven, inject
about a tablespoon of engine oil on top of pistons
in low reading cylinders through spark plug
port. Crank engine several times and recheck
compression.
* If compression comes up but does not necessarily
reach normal, rings are worn.
* If compression does not improve, valves are f-PROPER GAP
burnt, sticking or not seating properly.
* If two adjacent cylinders indicate low compres
sion and injecting oil does not increase compres CENTER ELECTRODE /
sion, the cause may be a head gasket leak between [FILE FLAT WHEN
the cylinders. Engine coolant and/or oil in cylin IADJUSTING GAP-. SIDE ELECTRODE
[O NOT BEND! BEND TO ADJUST GAP
ders could result from this defect.
NOTE: If a weak cylinder cannot be located
with the compression check, see "Cylinder Bal Fig. 2 - Spark Plug Detail
ance Test" under "Additional Checks and Adjust
ments" in this section.
CAUTION: Never bend the center electrode to
Service and tnstall Spark Plugs Fig. 2 adjust gap. Always adjust by bending ground or
1. Inspect each plug individually for badly worn elec side electrode.
trodes, glazed, broken or blistered porcelains and
replace plugs where necessary. Refer to spark plug 5. If available, test plugs with a spark plug tester.
diagnosis information presented in Section 6Y for an 6. Inspect spark plug hole threads and clean before in
analysis of plug conditions. stalling plugs. Corrosion deposits can be removed
2. Clean serviceable spark plugs thoroughly, using an with a 14 mm. x 1.25 SAE spark plug tap available
abrasive-type cleaner such as sand blast. File the through local jobbers or by using a small wire brush
center electrode flat. in an electric drill. Use grease on tap to catch
3. Inspect each spark plug for make and heat range. All chips.
plugs must be of the same make and number.
4. Adjust spark plug gaps to specifications using a
round feeler gauge.
Fig. 1 - Checking Compression Fig. 3 - Distributor In Line
ENGINE 6-3
LATERAL PROPER
/ROTOR
MISALIGNMENT LATERAL ALIGNMENT
LOCATOR
ROUND
LOCATOR
/ SQUARE
CENTRIFUGAL
ADVANCE
MECHANISM
/,BTOR
f rCORRECT LATERAL MISALIGNMENT BY
U BENDING FIXED CONTACT SUPPORT
LNEvER BREAKER LEVER
CAM
LUBRICATOR Fig. 5 - Point Alignment
REPLACEMENT
Magnetic PulseBreakerless Distributor
There are no moving parts in the ignition pulse ampli
CAUTION!
NEVER OIL fier, and the distributor shaft and bushings have perma
CAM LUBRICATOR- nent type lubrication, therefore no periodic maintenance
REPLACE WICK is required for the magnetic pulse ignition system. Refer
WHEN NECESSARY to Section 6Y for an analysis of problems and/or repair
procedures encountered on the Transistorized Magnetic
JUST SQUARELY Pulse ignition system.
AND JUST
TOUCHING LOBE Standard Breaker Point Distributor Figs. 3 or 4
OF CAM 1. Check the distributor centrifugal advance mechanism
by turning the distributor rotor in a clockwise direc
Fig. 4 - Distributor V8 tion as far as possible, then releasing the rotor to
see if the springs return it to its retarded position.
CAUTION: Use extreme care when using tap to If the rotor does not return readily, the distributor
prevent cross threading. Also crank engine sev must be disassembled and the cause of the trouble
eral times to blow out any material dislodged corrected.
during cleaning operation. 2. Check to see that the vacuum spark control operates
freely by turning the movable breaker plate counter
7. Install spark plugs with new gaskets and torque to clockwise to see if the spring returns to its retarded
specifications. position. Any stiffness in the operation of the spark
control will affect the ignition timing. Correct any
NOTE: The following are some of the interference or binding condition noted.
greatest causes of unsatisfactory spark plug 3. Examine distributor points and clean or replace if
performance. necessary.
* Installation of plugs with insufficient torque to

fully seat the gasket.
* Installation of the plugs using excessive torque
which changes gap settings.
* Installation of plugs on dirty gasket seal.
* Installation of plugs into corroded spark plug hole
threads.
8. Connect spark plug wiring.
Service Ignition System

1. Remove distributor cap, clean cap and inspect for
cracks, carbon tracks and burned or corroded ter
minals. Replace cap where necessary.
2. Clean rotor and inspect for damage or deterioration.
Replace rotor where necessary.
3. Replace brittle, oil soaked or damaged spark plug
wires. Install all wires to proper spark plug. Proper
positioning of spark plug wires in supports is impor
tant to prevent cross-fi:ring.
4. Tighten all ignition system connections.
5. Replace or repair any wires that are frayed, loose or
damaged. Fig. 6 - Testing Specific Gravity of Battery
ENGINE 6-4
* Contact points with an overall gray color and only

slight roughness or pitting need not be replaced.
* Dirty points should be cleaned with a clean point
file.
Use only a few strokes of a clean, fine-cut con
tact file. The file should not be used on other
metals and should not be allowed to become
greasy ordirty. Never use emery cloth or sand
paper to clean contact points since particles will
embed and cause arcing and rapid burning of
points. Do not attempt to remove all roughness
nor dress the point surfaces down smooth.
Merely remove scale or dirt.
* Clean cam lobe with cleaning solvent, lubricate
cam lobe with "Delco Remy Cam and Ball Bearing
Lubricant" or its equivalent and rotate cam lubri
cator wick 1/2 turn.
* Replace points that are burned or badly pitted.
NOTE: Where prematurely burned or badly

pitted points are encountered, the ignition sys
tem and engine should be checked to determine Fig. 8 - Manifold Heat Control Valve In Line
the cause of trouble so it can be eliminated.
Unless the condition causing point burning or point pressure with a spring gauge hooked to
pitting is corrected, new points will provide no breaker lever at the conjact and pull exerted at 90
better service than the old points. Refer to degrees to the breaker lever. The points should
Section 6Y for an analysis of point burning or be closed cam follower between lobes and the
pitting. reading taken just as the points separate. Spring
tension should be 19-23 ounces. If not within
* Check point alignment fig. 5 then, adjust distri limits, replace.
butor contact point gap to .019" new points or Excessive point pressure will cause excessive
.016" used points. Breaker arm rubbing block wear on the points, cam and rubber block. Weak
must be. on high point of lobe during adjustment. point pressure permits bouncing or chattering,
resulting in arcing and burning of the points and
NOTE: If contact points have been in service, an ignition miss at high speed.
they should be cleaned with a point file before 4. Install rotor and distributor cap. Press all wires
adjusting with a feeler gauge. firmly into cap towers.
* Check distributor point spring tension contact
Fig. 7 - Checking Fan Belt Tension Fig. 9 - Manifold Heat Control Valve V8
ENGINE 6-5
Service Battery and Battery Cables are corroded, the cables should be cleaned separately
1. Measure the specific gravity of the electrolyte in with a soda solution and wire brush. After cleaning
each cell fig. 6. If it is below 1.230 corrected to and before installing clamps, apply a thin coating of
80°F. recharge with a slow rate charger, or if de petrolatum to the posts and cable clamps to help
sired, further check battery. retard corrosion.
2. Connect a voltmeter across the battery terminals and If the battery has remained undercharged, check
measure the terminal voltage of the battery during for loose or defective fan belt, defective Delcotron,
cranking disconnect the coil primary lead at the high resistance in the charging circuit, oxidized
negative terminal during this check to prevent engine regulator contact points, or a low voltage setting.
from firing. If the terminal voltage is less than 9.0 If the battery has been using too much water, the
volts at room temperature, approximately 80° voltage output is too high.
± 20° F., the battery should be further checked. See
Section 6Y for further tests. Service Delcotron and Regulator
3. Inspect for signs of corrosion on battery, cables and The Delcotron and regulator tests during tune up con
surrounding area, loose or broken carriers, cracked sist of the above battery tests; the condition of the battery
or bulged cases, dirt and acid, electrolyte leakage indicating further tests and adjustments as outlined in
and low electrolyte level. Fill cells to proper level Section 6Y.
with distilled water or water passed through a
"demineralizer". Service Belts Fig. 7
The top of the battery should be clean and the bat Inspect belt condition.
tery hold-down bolts properly tightened. Particular Check and adjust if necessary for correct tension of
care should be taken to see that the top of the battery belt, as follows:
is kept clean of acid film and dirt. When cleaning * Using a strand tension gauge, check the belt tension.
batteries, wash first with a dilute ammonia or soda * Adjust belt until the specified tension is reached.
solution to neutralize any acid present and then flush See Tune Up Chart.
off with clean water. Keep vent plugs tight so that
the neutralizing solution does not enter the cell. The Service Manifold Heat Valve Figs. 8 or 9
hold-down bolts should be kept tight enough to prevent Check manifold heat control valve for freedom of oper
the battery from shaking around in its holder, but ation. If shaft is sticking, free it up with GM Manifold
they should not be tightened to the point where the Heat Control Solvent or its equivalent.
battery case will be placed under a severe strain.
NOTE: Tap shaft end to end to help free it up.
To insure good contact, the battery cables should
be tight on the battery posts. Oil battery terminal Tighten Manifold
felt washer. If the battery posts or cable terminals Tighten intake manifold bolts to specifications in the
CLOSED POSITIVEIN LINE CLOSED POSITIVE IN LINE CLOSED POSITIVE 396 a 427
302-307-327 & 350
Fig. 10 - Crankcase Ventilation Systems
ENGINE 6-6
ROD IN BOTTOM CHOKE VALVE

OF SLOT CLOSED
CHOKE VALVE
COMPLETELY
CLOSED
PULL
ROD TO
TRAVEL
BEND ROD
TO ADJUST
L6 TYPICAL
Fig. 11-Choke Adjustment
sequence outlined on Torque Sequence Chart. A slight 5. Connect accelerator rod at throttle lever.
leak at the intake manifold destroys engine performance
and economy.
Service Crankcase Ventilation Fig. 10.
Service Fuel Lines and Fuel Filter
All engines have "Closed Positive" ventilation sys
1. Inspect fuel lines for kinks, bends or leaks and cor
tems utilizing manifold vacuum to draw fumes and con
rect any defects found.
2. Inspect filter and replace if plugged. taminating vapors into the combustion chamber where
they are burned. Since it affects every part of the en
NOTE: If a complaint of poor high speed per gine, crankcase ventilation is an important function and
formance exists on the vehicle, fuel pump tests should be understood and serviced properly.
described in Section 6M should be performed. In the "Closed Positive" ventilation system, air is
Service Cooling System drawn through the engine, through a regulating valve
1. Inspect cooling system for leaks, weak hoses, loose into the manifold, drawing crankcase vapors and fumes
hose clamps and correct coolant level, and service with it to be burned. This ventilation system draws the
as required. clean air from the carbureto.r air cleaner and has a
nonvented oil filler cap.
NOTE: A cooling system pressure test, as de 1. Ventilation valve may be checked as outlined under
scribed in "Additional Checks and Adjustments" "Additional Checks and Adjustments".
in this section, may be performed to detect 2. Inspect for deteriorated or plugged hoses.
internal or external leaks within the cooling 3. Inspect all hose connections.
system. 4. On "Closed Positive" ventilation systems, remove
Check and Adjust Accelerator Linkage flame arrestor if equipped and wash in solvent then
1. Disconnect accelerator rod at carburetor throttle dry with compressed air.
lever.
2. Hold carburetor throttle lever in wide position.
Service Air Injection Reactor System
3. Pull accelerator rod to wide open position. On ve
hicles equipped with automatic transmission, pull Inspect air injection reactor system for evidence of
through detent. leaks, deteriorated hoses, cracked air manifolds or tubes
4. Adjust accelerator rod to freely enter hole in carbu and loose hose clamps. Inspect air injection pump belt
retor throttle lever. condition and tension. Make all necessary repairs as
outlined in "Section 6T".
NOTE: Accelerator linkage is outlined in de Because of the relationship between "Engine Tune Up"
tail in Section 6M. and "Unburned Exhaust Gases", the condition of Engine
ENGINE 6-7
Tune Up should be checked whenever the Air Injection with bottom of hole in choke lever.
Reactor System seems to be malfunctioning. Particular On L6 and 390 H.P. 427 cu. in. engines, hold
care should be taken in check:Lng items that affect fuel-air choke valve closed and pull rod upward to end of
ratio such as the crankcase ventilation system, the car travel. The bottom of rod should be even with top of
buretor and the carburetor air cleaner. Carburetors and hole in choke lever.
distributors for engines with the Air Injection Reactor 4. If necessary, adjust rod length by bending rod at off
System and Controlled Combustion System are designed, set. Bend must be such that rod enters choke lever
particularly, for these engines; therefore, they must not hole freely and squarely.
be interchanged with or replaced by a carburetor or dis 5. Connect rod at choke lever and install air cleaner.
tributor designed for different applications.
With Manual Choke
Choke Adjustment Fig. 11 1. Remove air cleaner.
With Remote Choke 2. Push hand choke knob in to within 1/8" of instrument
1. Remove air cleaner and check to see that choke panel.
valve and rod move freely. 3. Loosen choke cable at carburetor bracket and adjust
2. Disconnect choke rod at choke lever. cable through the clip until the choke valve is wide
3. Check choke adjustment as follows: open.
On all engines except L6 and 390 H.P. 427 Cu. in. 4. Tighten cable clamp at carburetor bracket and check
engines, hold choke valve closed and push rod down operation of choke valve to ensure full closed and
ward to contact stop. The top of rod should be even wide open positions.
INSTRUMENT CHECK-OUT
Instrument Hook Up misfire, then turn screw one-half turn in the op
Connect vacuum gauge, dwell meter, tachometer and posite direction to complete adjustment.
timing light as recommended by the manufacturer of the
IN LINES ENGINES
equipment being used.
* Remove distributor cap and recheck point setting.
Check and Adjust Dwell If dwell is still not within specifications check the
1. Start engine then check ignition dwell. distributor as outlined in Section 6Y.
2. If dwell is not within specifications, adjust dwell as
follows: Check Dwell Variation
Slowly accelerate engine to 1500 rpm and note dwell
V8 ENGINES
reading. Return engine to idle and note dwell reading. If
* With engine running at idle, raise the adjustment
screw window and insert an Allen wrench in the dwell variation exceeds specifications, check for worn
socket of the adjusting screw fig. 12. distributor shaft, worn distributor shaft bushing or loose
* Turn the adjusting screw as required until a dwell breaker plate.
reading of 30° is obtained. A 2° variation is al Check and Adjust Ignition Timing Fig. 13
lowable for wear. 1. Disconnect the distributor spark advance hose and
* Close access cover fully to prevent the entry of
dirt into the distributor.
NOTE: If a dwell meter is not available, turn
adjusting screw clockwise until engine starts to
WINDOW
-
"HEX" TYPE
WRENCH
Fig. l2-Setting Point Dwell Fig. l3-Ignition Timing Marks
ENGINE 6-8
plug the vacuum source opening. NOTE: On air conditioning vehicles, turn air
2. Start engine and run at idle speed see tune up chart. conditioning "OFF" except L-4 and L-6 en
3. Aim timing light at timing tab. gines with automatic transmission and 325 H.P.
NOTE: The markings on the tabs are in and 350 H.P. 327 Cu. in. engines manual trans
2°
increments the greatest number of markings on mission where idle speed is set with air con
the "A" side of the "0". The "0" markings is ditioning "ON".
TDC of #1 cylinder and all BTDC settings fall on 3. Adjust idle mixture screw to obtain highest steady
the "A" advance side of the "0". idle speed. Adjust idle speed screw to recommended
4. Adjust the timing by loosening the distributor clamp rpm on "DECAL".
and rotating the distributor body as required, then NOTE: Idle speed adjustment for L-6 engines
tighten the clamp. and powerglide transmissions with idle solenoid
5. Stop engine and remove timing light and reconnect is as follows: Adjust idle speed to 500 rpm by
the spark advance hose. adjusting solenoid plunger hex only. Disconnect
wire at solenoid and observe idle speed. De
energizing the solenoid allows the throttle lever
Adjust Idle Speed and Mixture Fig. 14
to seat against the carburetor idle screw. Adjust
1. As a preliminary adjustment, turn idle mixture
screws lightly to seat and back out 3 turns. the carburetor idle screw as necessary to obtain
400 rpm.
CAUTION: Do not turn idle mixture screw
tightly against seat or damage may result. 4. Adjust mixture screw in to obtain a 20 rpm drop
lean roll.
2. With engine running at operating temperature Air 5. Adjust mixture screw out 1/4 turn.
cleaner installed, pre-heater valve and choke valve 6. Repeat Steps 4 and 5 for second mixture screw if
wide open; adjust idle speed screw to bring idle so equipped.
speed to specified rpm automatic transmission in 7. Readjust speed screw if necessary to specified idle
drive, manual transmission in neutral. rpm.
ADDITIONAL CHECKS AND ADJUSTMENTS

Testing Crankcase Ventilation Valve Fig. 1 5 V8 Firing Order
1. Connect tachometer and vacuum gauge as for idle
1-8-4-3-6-5-7-2 1-8-4-3 = 1-6, 8-5, 4-7, 3-2
=
speed and mixture adjustment.
6-5-7-2
2. Set parking brake, start engine and adjust idle speed
4. Operate engine on each pair of cylinders in turn and
and mixture.
note engine rpm and manifold vacuum for each pair.
3. Disconnect ventilation hose at valve, block opening of A variation of more than 1 inch of vacuum or 40 rpm
valve and read engine rpm change. between pairs of cylinders being tested indicates that
4. A change of less than 50 rpm indicates a plugged the cylinders are off balance.
ventilation valve - replace the valve.
Battery
Cylinder Balance Test Fig. 16 The battery should be checked with special testing
It is often difficult to locate a weak cylinder. A com equipment and to the equipment manufacturers specifica
pression test, for example, will not locate a leaky intake tions. See Section 6Y for complete information on battery
manifold, a valve not opening properly due to a worn tests.
camshaft, or a defective spark plug. Ignition
With the cylinder balance test, the power output of one The following additional ignition checks may be made
cylinder may be checked against another, using a set of with any of several pieces of equipment available for un
grounding leads. When the power output of each cylinder covering the source of engine difficulties. The specific
is not equal, the engine will lose power and run roughly. operating instructions of the equipment manufacturer
Perform a cylinder balance test as follows: should be followed:
1. Connect the tachometer and vacuum gauge. * Cranking voltage
2. Start engine and run at 1500 rpm. * Ignition switch
3. Ground large clip of grounding leads and connect in * Distributor resistance
dividual leads to all spark plugs except the pair being * Secondary resistance
tested. * Ignition output and secondary leakage
Divide the firing order in half and arrange one half
over the other. The cylinders to be tested together ap Cranking Voltage Fig. 17
pear one over the other. 1. Disconnect coil primary lead at the coil negative
L4 Firing Order terminal to prevent engine from firing during
1-3-4-2 = 1-3 1-4, 3-2 cranking.
4-2 2. Connect voltmeter between primary terminal of coil
L6 Firing Order resistance wire side and ground.
1-5-3-6-2-4 = 1-5-3 = 1-6, 5-2, 3-4 3. Operate starting motor.
6-2-4 a. If voltage is 9 volts or more and cranking speed
ENGINE 6-9
ROCHESTER M ROCHESTER MV ROCHESTER 2GV
IDLE
SPEED
IDLE
SPEED
N IDLE
MIXTURE N
IDLE IDLE
MIXTURE
MIXTURE
HOLLEY 2300C PRIMARY HOLLEY 2300 SECONDARY
/
IDLE
MIXTURE
ROCHESTER 4MV HOLLEY 4150
N.
IDLE
IDLE MIXTURE
MIXTURE
APPLICATION a, IN LINE V-8

0 a’
0
‘1 >.. C
CARBURETOR > >
E
a, 327 5C 396 427
a, a,
-C -C .C 0 0
U U U U U 90 140 155 290 20 210 25 VS 50C 325 350 295 325 350375 385 390 400425430435
ROCHM 3 3
ROCHMV 3 4 2312
1 2
ROCH2GV 1 2 3 4 4
ROCH 4MV 1 2 3 4 5 1 2 5 23 5 34 23 1 5
HOLLEY C Prim. 5 , 5 5
2300 Sec 5 - - - -
HOLLEY 4150 5 4 . 23 1 5
Fig. 14-Idle Speed and Mixture Screws
ENGINE 6-10
Fig. 15-Crankcase Ventilation Valve

is satisfactory, the battery, starter, cables,
starter switch and ignition circuit to coil by
passing resistance wire are in good condition.
b. If below 9 volts, check circuit until difficulty is
located.
Meter reading below specification--Weak bat
tery; defective cables, connections, switch or
starter; defective ignition circuit to coil.
Cranking speed below normal--Excessive re
sistance in cables or starting motor; excessive
mechanical drag in engine.
Uneven cranking speed- -Uneven compression,
defective starter or starter drive.
Ignition Switch
With voltmeter connected as described for the Cranking
Voltage Test, turn ignition switch to ON. Voltage should
drop to 5 to 7 volts as current is now passing through
high resistance wire connected between ignition switch Fig. 17-Testing Crankcase Voltage
and + positive terminal of coil. If battery voltage of
12 volts is obtained, the starter solenoid is by-passing * Uniform "normal readings" as specified by manu
the high resistance wire connected between ignition facturer indicate all secondary circuit components
switch and + positive terminal of coil, thus the starter are in good condition.
solenoid is not functioning properly to bypass the ignition * If all readings are "below normal," check for cor
resistance wire or the ignition circuit is incorrectly roded coil tower terminal, poorly connected or
wired. broken coil wire, center cap electrode or rotor tip
Distributor Resistance burned, or an open secondary in coil.
Use equipment as directed by manufacturer. Excessive * If readings are "higher than normal" at two or
resistance in primary circuit must be eliminated before more plugs adjacent in firing order, cross firing is
continuing with test procedure. occurring in distributor cap or between spark plug
cables concerned.
Secondary Resistance * If meter reads off scale to left, the coil polarity is
Use equipment as directed by manufacturer. reversed. Check for reversed coil primary wires,
wrong coil or reversed vehicle battery connections.
Ignition Output and Secondary Leakage
Use equipment as directed by manufacturer.
* GOOD readings indicate both ignition output and
secondary insulation are good.
* If all readings are BAD or if ignition test calibrator
cannot be adjusted to Set Line, check for high re
sistance in primary circuit, defective distributor
points, coil or condenser.
* If readings are BAD when certain plug wires are
lifted off, check for cracks or carbon tracks in dis
tributor cap or defective insulation on those plug
wires being lifted off.
Carburetor
Refer to Section 6M to perform adjustments such as
idle vent, float level, pump rod and secondary valve.
Fuel Pump
Fig. 16-Cylinder Balance Test If the owner has complained of poor high speed per-
ENGINE 6-11
formance, the fuel pump may be at fault. Too low a 2. With the engine running at idle, back off valve rocker
pump pressure or volume will cause a high speed "miss" arm nut until the valve rocker arm starts to clatter.
because of lack of fuel delivered to the carburetor, while 3. Turn rocker arm nut down slowly until the clatter
too high a pressure will cause carburetor flooding. just stops. This is the zero lash position.
Check fuel pump as outlined in Section 6M. 4. Turn nut down 1/4 additional turn and pause 10 sec
Cooling System onds until engine runs smoothly. Repeat additional
The following test may be performed with pressure 1/4 turns, pausing 10 seconds each time, until nut
testing equipment available commercially for this pur has been turned down 1 full turn from the zero lash
pose. This test provides an excellent means of detecting position.
internal or external leaks within the cooling system. NOTE: This 1 turn preload adjustment must be
1. Remove radiator cap. done slowly to allow the lifter to adjust itself to
2. Apply a test pressure of 3 pounds higher than the prevent the possibility of interference, between
radiator cap fig. 18. i.e. 18 pounds for a 15 pound the inlet valve head and top of piston, which
cap. might result in internal damage and/or bent push
3. If the pressure will not hold, there is either an rods. Noisy lifters should be replaced.
internal or external leak in the system.
5. Repeat Steps 2, 3 and 4 to adjust the rest of the
Cylinder Head Torque and Valve Adjustment valves.
Retorquing the cylinder head bolts is not necessary 6. Clean gasket surfaces on cylinder heads and rocker
unless a gasket has been replaced, or a leak is suspected. arm covers with degreaser then install rocker arm
Valve lash must always be adjusted after the head has covers, using new gaskets, and torque bolts to
been torqued. specifications.
Before adjusting the valve lash, it is extremely impor
tant that the engine be thoroughly warmed up to normal Mechanical
ize the expansion of all parts. This is very important 1. Normalize the engine.
because during the warm-up period, the valve clearances 2. Remove rocker arm covers and gaskets.
will change considerably. CAUTION: Do not pry rocker arm cover loose.
Gaskets adhering to cylinder head and rocker
Hydraulic arm cover may be sheared by bumping end of
1. After the engine has been normalized, remove rocker rocker acm cover rearward with palm of hand
arm covers and gaskets. or a rubber mallet.
CAUTION: Do not pry rocker arm cover loose. 3. Use a socket wrench on self-locking rocker arm stud
Gaskets adhering to cylinder head and rocker nut and adjust as needed to obtain valve lash see
arm cover may be sheared by bumping end of tune up chart measured between rocker arm and
rocker arm cover rearward with palm of hand valve stem with a leaf type feeler gauge.
or a rubber mallet. 4. Stop engine, clean gasket surfaces on cylinder heads
and rocker arm covers with degreaser then install
rocker arm covers, using new gaskets, and torque
bolts to specifications.
Fig. 18-Cooling System Pressure Test Fig. 19-Oil Deflector Clips Installed
ENGINE 6-12
ENGINE MECHANICAL
IN-LINE ENGINES
INDEX
Page Page
General Description 6-12 Removal 6-18
Component Replacement and Adjustment 6-12 Installation 6-18
Engine Assembly 6-12 Oil Seal Rear Main 6-18
Removal 6-12 Replacement 6-18
Installation 6-13 Crankshaft Pulley and Hub 6-19
Manifold Assembly 6-14 Removal 6-19
Installation 6-14 Torsional Damper 6-19
Rocker Arm Cover 6-14 Removal 6-19
Installation 6-14 Crankcase Front Cover 6-19
Valve Mechanism 6-14 Removal 6-19
Installation and Adjustment 6-14 Oil Seal Front Cover 6-20
Valve Lifters 6-15 Replacement 6-20
Locating Noisy Lifters 6-15 Camshaft 6-20
Removal 6-15 Measuring Lobe Lift 6-20
Valve Stem Oil Seal and/or Valve Spring 6-16 Installation 6-21
Replacement 6-16 Timing Gears 6-21
Cylinder Head Assembly 6-16 Replacement 6-21
Removal 6-16 Flywheel 6-22
Oil Pan 6-17 Installation 6-22
Removal 6-17 Engine Mounts 6-22
Installation 6-17 Replacement Front 6-22
Oil Pump 6-18 Replacement Rear 6-22
GENERAL DESCRIPTION
The In Line engines fig. 1L covered in this section Because of the interchangeability and similarity of
are the 153 cu. in. L4, the 230 and 250 cu. in. L6, re many engine sub-assemblies and engine parts, regardless
gardless of which passenger vehicle they are used in. of which passenger vehicle they are used in, typical illus
This section covers the removal and installation of en trations and procedures are used except where specific
gine assemblies; the removal, installation and adjustment illustrations or procedures are necessary to clarify the
of some sub-assemblies and replacement of some com operation. Although illustrations showing bench opera
ponents. For service to all components and sub-assem tions are used, most single operations, when not pirt of a
blies after removal and removal of some sub-assem general overhaul, should be performed if practical with
blies, refer to Section 6 of the Chassis Overhaul Manual. the engine in the vehicle.
COMPONENT REPLACEMENT AND ADJUSTMENT

ENGINE ASSEMBLY * Delcotron
* Temperature Switch
Removal * Oil Pressure Switch
1. Drain cooling system and engine oil. * Coil
2. Remove air cleaner and disconnect battery cables at 7. Disconnect:
battery. * Accelerator linkage at manifold bellcrank.
3. Remove hood hinge front bolts, loosen the rear * Exhaust pipe at manifold flange.
bolts. Swing hood up and install Tool J-22382-1. * Fuel line from tank at fuel pump.
4. Remove radiator and radiator shroud as outlined in * Vacuum line to power brake unit at manifold if
Section 13. so equipped.
5. Remove fan blade and pulley as outlined in Section * Power steering pump lines at pump end if so
6K. equipped.
6. Disconnect wires at: 8. Raise vehicle.
* Starter Solenoid 9. Remove propeller shaft.
ENGINE 6-13
14 L6
Fig. 1L- In Line Engines Typical
NOTE: If plug for propeller shaft open pulled away from the engine to prevent damage
ing in transmission is not available, drain to clutch disc.
transmission.
c. Remove starter and clutch housing rear cover.
10. Disconnect: d. Loosen clutch mounting bolts a turn at a time to
* Shift linkage at transmission. prevent distortion of clutch cover until the spring
* Speedometer cable at transmission. pressure is released. Remove all bolts, clutch
11. On synchromesh equipped vehicles, disconnect clutch disc and pressure plate assembly.
linkage at cross-shaft then remove cross-shaft en
gine bracket. Automatic Transmission
12. Remove rocker arm cover as outlined, then attach a. Lower engine, secured by the hoist, and support
engine lifting adapter at the proper cylinder head engine on blocks.
bolt locations. b. Remove starter and converter housing underpan.
13. Remove front mount through bolts. c. Remove flywheel-to-converter attaching bolts.
14. Attach lifting device and raise engine to take weight d. Support transmission on blocks.
off front mounts, then remove rear mount bolts. e. Remove transmission-to- engine mounting bolts.
15. Raise engine to take weight off rear mount, then f. With the hoist attached, remove blocks from the
remove crossmember. engine only and slowly guide the engine from the
NOTE: On Chevrolet vehicles it will be neces transmission.
sary to remove mount from transmission before 18. Mount engine in stand.
crossmember can be removed.
Installation
NOTE: On Camaro vehicles it is not necessary 1. Attach lifting device to engine and remove engine
to completely remove the crossmember. Re from engine stand.
move crossmember bolts and slide back. 2. Install transmission and clutch:
Synchromesh Transmission
16. Remove engine-transmission assembly from vehicle a. Install the clutch on flywheel as outlined in Sec
as a unit. tion 7.
17. Remove transmission and clutch: b. Install clutch housing rear cover and starter.
c. Install transmission and clutch housing as out
Synchromesh Transmission lined in Section 7.
a. Remove clutch hous:ing cover plate screws. d. Install clutch housing cover screws and tighten
b. Remove bolts attaching the clutch housing to en securely.
gine block then remove transmission and clutch
housing as a unit. Automatic Transmission
NOTE: Support the transmission, as the last a. Position engine adjacent to the transmission and
mounting bolt is removed, and as it is being align the converter with the flywheel.
ENGINE 6-14
b. Bolt transmission to engine, then raise engine and Installation

transmission assembly and install flywheel to 1. Clean gasket surfaces on cylinder head and
converter attaching bolts. manifolds.
c. Install converter housing underpan and starter. 2. Position new gasket over manifold end studs on head
3. Tilt and lower engine and transmission assembly into and carefully install the manifold in position making
the chassis as a unit, guiding engine to align front sure the gaskets are in place.
mounts with frame supports. 3. Install bolts and clamps while holding manifold in
4. Install front mount through bolts and torque to place with hand.
specifications. 4. Torque bolts to specifications.
5. Raise engine enough to install rear crossmember, NOTE: On L6 engines center bolt and end bolt
then install crossmember, install rear mount, lower torque differ.
engine and torque bolts to specifications.
6. Remove lifting device and lifting adapter then install 5. Connect exhaust pipe to manifold using a new
rocker arm cover as outlined. packing.
7. On synchromesh equipped vehicles, install clutch 6. Connect crankcase ventilation hose at rocker arm
cross shaft engine bracket, then adjust and connect cover.
clutch as outlined in Section 7. 7. Connect fuel and vacuum lines at carburetor.
8. Connect: 8. On LA engines connect choke cable and adjust as out
* Speedometer cable. lines in Section 6M.
* Shift linkage at transmission. 9. Connect throttle rods at bellcrank and install throttle
9. Install propeller shaft. return spring.
10. Remove jack stands and lower vehicle. 10. Install air cleaner, start engine, check for leaks and
11. Connect: adjust carburetor idle speed and mixture.
* Power steering pump lines if disconnected.
* Vacuum line to power brake unit if disconnected. ROCKER ARM COVER
* Fuel line at fuel pump.
* Exhaust pipe at manifold flange.
Removal
* Accelerator linkage at manifold belicrank.
1. Disconnect crankcase ventilation hoses at rocker
12. Connect wires at:
arm cover.
* Coil
* Oil pressure switch 2. Remove air cleaner.
* Temperature switch 3. Disconnect temperature wire from rocker arm cover
* Delcotron clips.
4. Remove rocker arm cover.
* Starter solenoid
13. Install pulley, fan blade and fan belt as outlined in
Section 6K. Installation
14. Install radiator and shroud as outlined in Section 13. 1. Clean gasket surfaces on cylinder head and rocker
15. Remove hood prop tool and install front hinge bolts. arm cover with degreaser then, using a new gasket,
Adjust hood as outlined in Section 11. install rocker arm cover and torque bolts to
16. Connect battery cables. specifications.
17. Fill with coolant, engine oil and transmission oil, 2. Connect temperature wire at rocker arm cover clips.
then start engine and check for leaks. 3. Install air cleaner.
18. Perform necessary adjustments and install air 4. Connect crankcase ventilation hoses.
cleaner.
MANIFOLD ASSEMBLY VALVE MECHANISM
Removal Removal
1. Remove air cleaner. 1. Remove rocker arm cover as outlined.
2. Disconnect both throttle rods at belicrank and re 2. Remove rocker arm nuts, rocker arm balls, rocker
move throttle return spring. arms and push rods.
3. Disconnect fuel and vacuum lines at carburetor.
Disconnect choke cable on L4 engines. NOTE: Place rocker arms, rocker arm balls
4. Disconnect crankcase ventilation hose at rocker arm and push rods in a rack so they may be rein
cover. stalled in the same location.
5. Disconnect exhaust pipe at manifold flange and dis
card packing.
6. Remove manifold attaching bolts and clamps then Installation and Adjustment
remove manifold assembly and discard gaskets.
7. Check for cracks in manifold castings. Whenever new rocker arms and/or
NOTE:
8. If necessary to replace either intake or exhaust rocker arm balls are being installed, coat bear
manifolds, separate them by removing one bolt and
ing surfaces of rocker arms and rocker arm
two nuts at center of assembly. Reassemble mani
balls with Molykote or its equivalent.
folds using a new gasket. Tighten finger tight and
torque to specifications after assembly to cylinder 1. Install push rods. Be sure push rods seat in lifter
head. Transfer all necessary parts. socket.
ENGINE 6-15
2. Install rocker arms, rocker arm balls and rocker hose approximately four feet in length. Place one end of
arm nuts. Tighten rocker arm nuts until all lash is the hose near the end of each intake and exhaust valve
eliminated. with the other end of the hose to the ear. In this manner,
3. Adjust valves when lifter is on base circle of cam the sound is localized making it easy to determine which
shaft lobe as follows: lifter is at fault.
a. Mark distributor housing, with chalk, at each cyl Another method is to place a finger on the face of the
inder position plug wire then disconnect plug valve spring retainer. If the lifter is not functioning
wires at spark plugs and coil and remove distri properly, a distinct shock will be felt when the valve
butor cap and plug wire assembly if not previ returns to it seat.
ously done. The general types of valve lifter noise are as follows:
b. Crank engine until distributor rotor points to 1. Hard Rapping Noise--Usually caused by the plunger
number one cylinder position and breaker points becoming tight in the bore of the lifter body to such
are open. Both valves on number one cylinder an extent that the return spring can no longer push
may now be adjusted. the plunger back up to working position. Probable
c. Back out adjusting nut until lash is felt at the push causes are:
rod then turn in adjusting nut until all lash is re a. Excessive varnish or carbon deposit causing
moved. This can be determined by checking push abnormal stickiness.
rod side play while turning adjusting nut fig. 2L. b. Galling or "pickup" between plunger and bore of
When play has been removed, turn adjusting nut lifter body, usually caused by an abrasive piece
in one full additional turn to center lifter of dirt or metal wedging between plunger and
plunger. lifter body.
d. Adjust the remaining valves, one cylinder at a 2. Moderate Rapping Noise- - Probable causes are:
time, in the same manner. a. Excessively high leakdown rate.
4. Install distributor cap and spark plug wire assembly. b. Leaky check valve seat.
5. Install rocker arm cover as outlined. c. Improper adjustment.
6. Adjust carburetor idle speed and mixture. 3. General Noise Throughout the Valve Train--This
will, in almost all cases, be a definite indication of
VALVE LIFTERS insufficient oil supply, or improper adjustment.
4. Intermittent Clicking--Probable causes are:
Hydraulic valve lifters very seldom require attention. a. A microscopic piece of dirt momentarily caught
The lifters are extremely simple in design readjustments between ball seat and check valve ball.
are not necessary, and servicing of the lifters requires b. In rare cases, the ball itself may be out-of-
only that care and cleanliness be exercised in the han round or have a flat spot.
dling of parts. c. Improper adjustment.
In most cases where noise exists in one or more lifters
Locating Noisy Lifters all lifter units should be removed, disasssmbled, cleaned
Locate a noisy valve lifter by using a piece of garden in a solvent, reassembled, and reinstalled in the engine.
If dirt, varnish, carbon, etc. is shown to exist in one unit,
it more than likely exists in all the units, thus it would
only be a matter of time before all lifters caused trouble.
Removal
1. Remove valve mechanism as outlined.
2. Mark distributor housing, with chalk, at each cylin
der position plug wire then disconnect plug wires at
spark plugs and coil and remove distributor cap and
plug wire assembly.
3. Crank engine until distributor rotor points to number
one position, then disconnect distributor primary lead
at coil and remove distributor.
4. Remove push rod covers discard gaskets.
5. Remove valve lifters.
NOTE: Place valve lifters in a rack so they
may be reinstalled in the same location.
Installation
1. Install valve lifters.
NOTE: Whenever new valve lifters are being
installed, coat foot of valve lifters with Molykote
or its equivalent.
2. Install push rod covers, using new gaskets, and
torque bolts to specifications.
3. Install distributor, positioning rotor to number one
cylinder position, then connect primary lead at coil.
Fig. 2L - Valve Adjustment 4. Install and adjust valve mechanism as outlined.
ENGINE 6-16
5. Adjust ignition timing and carburetor idle speed and matter and free of nicks or heavy scratches.
mixture. Cylinder bolt threads in the block and threads
on the cylinder head bolt must be cleaned. Dirt
VALVE STEM OIL SEAL AND/OR VALVE SPRING will affect bolt torque. Do not use gasket sealer
on composition steel asbestos gasket.
Replacement
1. Remove rocker arm cover as outlined.
2. Remove spark plug, rocker arm and push rod on the
cylinders to be serviced.
3. Apply compressed air to the spark plug hole to hold
the valves in place.
NOTE: A tool to apply air to the cylinder is
available through local jobbers or may be manu LCUTJ
factured. In manufacturing this Tool a AC-46N
Spark Plug or its equivalent is recommended.
This will make the Tool universal for all L
Chevrolet engines. Chisel the spark plug as
shown, then drive the porcelain out of the plug
by tapping the center electrode against a hard
block. Using a 3/8" pipe tap, cut threads in the
remaining portion of the spark plug and assem
ble as shown fig. 3L.
4. Using Tool J-5892 to compress the valve spring, re Fig. 3L - Air Adapter Tool
move the valve locks, valve cap, valve shield and
valve spring and damper fig. 4L. 1. Place the gasket in position over the dowel pins with
5. Remove the valve stem oil seal. the bead up.
6. To replace, set the valve spring and damper, valve 2. Carefully guide cylinder head into place over dowel
shield and valve cap in place. The close coiled end pins and gasket.
of the spring is installed against the cylinder head. 3. Coat threads of cylinder head bolts with sealing com
Compress the spring with Tool J- 5892 and install oil pound and install finger tight.
seal in the lower groove of the stem, making sure the 4. Tighten cylinder head bolts a little at a time in the
seal is flat and not twisted. sequence shown on the torque sequence chart until
NOTE: the specified torque is reached.
A light coat of oil on the seal will help
prevent twisting. 5. Install coil if removed.
6. Connect upper radiator hose and engine ground strap.
7. Install the valve locks and release the compressor 7. Connect temperature sending unit wires and install
tool, making sure the locks seat properly in the fuel and vacuum lines in clip at water outlet.
upper groove of the valve stem. 8. Fill cooling system.
9. Install manifold assembly as outlined.
NOTE: Grease may be used to hold the locks
10. Install and adjust valve mechanism as outlined.
in place while releasing the compressor tool.
8. Install spark plug, using a new gasket, and torque to
specifications.
CYLINDER HEAD ASSEMBLY

Removal
1. Remove manifold assembly as outlined.
3. Drain cooling system block.
4. Remove fuel and vacuum line from retaining clip at
water outlet then disconnect wires from temperature
sending units.
5. Disconnect upper radiator hose at water outlet hous
ing and battery ground strap at cylinder head.
6. Remove coil L6 engines only.
7. Remove cylinder head bolts, cylinder head and gas
ket. Place cylinder head on two blocks of wood to
prevent damage.
Installation
CAUTION: The gasket surfaces on both the

head and the block must be clean of any foreign Fig. 4L - Compressing Valve Spring
ENGINE 6-17
gine. Do not remove all weight of engine from

engine lift.
3. On vehicles equipped with automatic transmissions
remove converter housing underpan.
4. Remove starter.
5. Remove oil pan and discard gaskets and seals.
Installation
1. Thoroughly clean all gasket sealing surfaces.
NOTE: Use a new pan gasket set. Do not use
sealer.
2. Install rear seal in rear main bearing cap.
3. Install front seal on crankcase front cover pressing
tips into holes provided in cover.
4. Install side gaskets on cylinder block fig. 6L.
5. Complete installation as follows:
Fig. 5L-Engine Blocked for Pan Removal
Chevrolet Camaro and Chevy II
NOTE: Do not install rocker arm cover. a. If crankshaft was rotated while pan was off, place
timing mark at 6:00 o’clock position.
11. Start engine and allow warm up then retorque cylin b. On Chevrolet, install oil pan and torque bolts to
der head as outlined in Step 4 and readjust valves as specifications.
outlined under Engine Tune Up. c. On Camaro and Chevy II, raise oil pump and pan
into position. Install oil pump and pick-up and
OIL PAN torque attaching bolts to specifications. Install
oil pan screws and torque to specifications.
Removal
d. Using a suitable jack and a block of wood to
Chevrolet, Camaro and Chevy II prevent damaging oil pan raise, engine enough to
1. Disconnect battery positive cable. remove 2" x 4" wood blocks, then lower engine.
2. Remove through bolts from engine front mounts. e. On vehicles equipped with automatic transmission
3. Drain radiator, then disconnect upper and lower ra install converter housing underpan, then connect
diator hoses at radiator. transmission cooler lines.
4. Remove fan blade as outlined in Section 6K. f. Install and connect starter.
5. Raise vehicle then drain engine oil. g. Lower vehicle and install fan blades as outlined
6. Disconnect and remove starter. in Section 6K.
7. On vehicles equipped with automatic transmission, h. Connect upper and lower radiator hoses.
disconnect transmission cooler lines at transmission i. Install through bolts in engine front mounts.
and remove converter housing underpan. j. Connect battery positive cable.
8. Disconnect steering rod at idler lever then swing
steering linkage for oil pan clearance.
9. Rotate crankshaft until timing mark on torsional
damper is at 6:00 o’clock position.
10. Using a suitable jack and a block of wood to prevent
damaging oil pan, raise engine enough to insert 2" x
4" wood blocks under engine mounts fig. 5L, then
lower engine onto blocks.
NOTE: If 2" x 4" wood blocks are cut 5-1/2"
long they can be used on all Chevrolet engines.
The 5-1/2" length up for in line engines and the
4" side up for V8 engines.
11. On Chevrolet, remove oil pan and discard gaskets
and seals.
12. On Camaro and Chevy II, remove oil pan retaining
screws and lower pan. Remove the two bolts se
curing the oil pump assembly and the one bolt se
curing the intake pipe and screen to the block.
Remove oil pump and pan and discard gaskets and
seals.
Chevelle
1. Remove engine from vehicle as outlined.
2. Place engine on jack stands, one at each front mount
and one at transmission extension.
CAUTION: Leave eflgine lift attached to en- Fig. 6L-Pan Gaskets and Seals
ENGINE 6-18
k. Fill radiator with coolant and fill engine with oil,

then start engine and check for leaks.
Chevelle
a. Install oil pan and torque bolts to specifications.
b. On vehicles equipped with automatic transmis
sion, install converter housing underpan.
c. Install starter.
d. Install engine as outlined.
OIL PUMP
Removal
1. Remove oil pan as outlined.
2. Remove two flange mounting bolts, pickup pipe bolt,
then remove pump and screen as an assembly.
Installation
1. Align oil pump drive shafts to match with distributor
tang, then install oil pump to block positioning flange
over distributor lower bushing. Use no gasket.
NOTE: Oil pump should slide easily into place,

if not, remove and reposition slot to align with
distributor tang.
2. Install oil pan using new gaskets and seals as

outlined.
OIL SEAL REAR MAIN

Replacement
The rear main bearing oil seal can be replaced both
halves without removal of the crankshaft.
NOTE: Always replace the upper and lower
seal as a unit. Install with the lip facing toward
the front of the engine.
1. With the oil pan and oil pump removed, remove the
rear main bearing cap. Fig. 8L-Removing Oil Seal Upper Half Typical
2. Remove oil seal from the annular tang by prying
from the bottom with a small screw driver fig. 7L.
3. Lubricate the lip of a new seal with engine oil. Keep
oil off the parting line surface as this is treated with
glue. Insert seal in cap and roll it into place with
finger and thumb, using light pressure so seal tangs
at parting line do not cut bead on back of seal.
4. To remove the upper half of the seal, use a small
hammer to tap a brass pin punch on one end of seal
until it protrudes far enough to be removed with
pliers fig. 8L.
NOTE: Always wipe crankshaft surface clean

before installing a new seal.

oil off the parting line surface.
Gradually push with a hammer handle, while
turning crankshaft, until seal is rolled into place.
Similar to installing a main bearing. Be careful
that seal tangs at parting line do not cut bead on back
of seal. Use sealer at parting line on cap half
of seal.
6. Install the rear main bearing cap with new seal and
Fig. 7L-Removing Oil Seal Lower Half Typical torque to specifications.
ENGINE 6-19
CRANKSHAFT PULLEY AND HUB Tool .J-22197 to prevent the inertia weight sec
tion from walking off the hub during installation
Chevy II with L4 Engine of damper.
Removal 2. Attach damper installer Tool J-22197 to damper.
1. Drain radiator and disconnect upper and lower radi Tighten fingers of tool to prevent weight from moving
ator hoses at radiator. fig. 1OL.
2. Remove radiator core as outlined in Section 13. 3. Position damper on crankshaft and drive into posi
3. Remove fan belt. Remove crankshaft pulley from tion, using J-5590, until it bottoms against crankshaft
pulley hub. gear fig. 1OL. Remove installer tool.
4. Install puller Tool J-6978 to pulley hub with two 4. Install faIl belt and adjust using strand tension gauge.
3/8" x 2" and one 5/16" x 2" bolts and remove hub 5. If so equipped, install accessory drive pulley and
then remove puller tool. belt.
Installation 6. Install radiator core as outlined in Section 13.
1. Coat oil seal contact area on hub with engine oil 7. Fill cooling system and check for leaks.
position hub over crankshaft and key and start hub
into position with a mallet. Using Tool J-5590 drive CRANKCASE FRONT COVER
onto crankshaft until it bottoms against crankshaft
Removal
gear.
NOTE: Crankshaft extends slightly through hub 2. Remove crankshaft pulley and hub or torsional
and a tool is necessary to drive hub completely damper as outlined.
into bottomed position. 3. Remove crankcase front cover attaching bolts, re
move cover and gasket.
2. Install pulley onto hub.
Installation
NOTE: There are two 3/8" holes and one 1. Clean gasket surfaces on block and crankcase front
5/16" hole that must be matched on hub in order cover.
to properly position tim:ing mark. 2. Install centering Tool J-966 or Tool J-21742 in
3. Install fan belt and adjust using strand tension gauge. crankcase front cover seal fig. ilL.
4. Install radiator as outlined in Section 13. 3. Coat the gasket with gasket sealer and place in posi
tion on cover, then install crankcase front cover to
block and torque bolts to specifications.
TORSIONAL DAMPER 4. Remove centering tool.
Removal NOTE: It is important that centering tool be
1. Remove radiator core, as outlined in Section 13.
used to align crankcase front cover so that
2. Remove fan belt and if so equipped accessory drive
crankshaft hub or torsional damper installation
pulley and belt.
will not damage seal and to position seal evenly
3. Install Tool J-6978 to damper and turn puller screw
around the balancer or hub surface.
to remove damper fig. 9L. Remove tool.
5. Install crankshaft hub and/or torsional damper as
Installation
outlined.
1. Coat front cover oil seal contact area of damper with
6. Install oil pan with new gaskets and seals as outlined.
engine oil.
CAUTION: It is necessary to use installer
Fig. 9L-Removing Torsional Damper Fig. 1OL-Installing Torsional Damper
ENGINE 6-20
with a large screw driver, being careful not to dam

age the seal surface on the cover.
2. Install new seal so that open end of seal is toward the
inside of cover and drive it into position with Tool
J-8340 fig. 13L.
CAMSHAFT
Measuring Lobe Lift
NOTE: Procedure is similar to that used for
checking valve timing. If improper valve op
eration is indicated, measure the lift of each
push rod in consecutive order and record the
readings.
Fig. 11L-J-21742 Centering Tool in Cover
2. Position indicator with ball socket adapter Tool
J-8520 on push rod fig. i4L.
OIL SEAL FRONT COVER 3. Rotate the crankshaft slowly in the direction of rota
Replacement tion until the lifter is on the heel of the cam lobe.
At this point, the push rod will be in its lowest
With Cover Removal position.
1. With cover removed, pry old seal out of cover from
the front with screw driver being carefuj ot to 4. Set dial indicator on zero, then rotate the crankshaft
distort cover. slowly, or attach an auxiliary starter switch and
2. Install new seal so that open end of the seal is toward "bump" the engine over, until the push rod is in the
the inside of cover and drive it into position with fully raised position.
Tool J-995 fig. i2L. CAUTION: The primary distributor lead must
CAUTION: Support cover at sealing area. Tool be disconnected from the negative post on the
J-971 may be used as support. coil and the ignition switch must be in the ON
position. Failure to do this will result in a
Without Cover Removal damaged grounding circuit in the ignition switch.
1. With crankshaft pulley and hub or torsional damper 5. Compare the total lift recorded from the dial indica
removed, pry old seal out of cover from the front tor with specifications.
6. Continue to rotate the crankshaft until the indicator
reads zero. This will be a check on the accuracy of
the original indicator reading.
Fig. 12L-lnstalling Oil Seal Cover Removed Fig. 13L-lnstalling Oil Seal Cover Installed
ENGINE 6-21
7. Remove the camshaft and gear assembly by pulling it

out through the front of the block.
NOTE:. Support camshaft carefully when re

moving so as not to damage camshaft bearings.
Installation
1. Install the camshaft and gear assembly in the engine
block, being careful not to damage camshaft bearings
or camshaft.
2. Turn crankshaft and camshaft so that the valve tim
ing marks on the gear teeth will line up fig. 15L.
Push camshaft into position. Install camshaft thrust
plate-to-block bolts and torque to specifications.
3. Check camshaft and crankshaft gear run out with a
dial indicator fig. 16L. The camshaft gear run out
should not exceed .004" and the crankshaft gear run
out should not exceed .003".
4. If gear run out is excessive, the gear will have to be
removed and any burrs cleaned from the shaft or the
gear will have to be replaced.
5. Check the backlash between the timing gear teeth
with a dial indicator fig. 17L. The backlash should
not be less than .004" nor more than .006".
6. Install fuel pump as outlined in Section 6M.
Fig. 14L-Measuring Camshaft Lobe Lift 7. Install grille as outlined in Section 13.
8. Install crankcase front cover as outlined.
7. If camshaft readings for all lobes are within specifi
9. Install radiator as outlined in Section 13.
cations, remove dial indicator assembly. 10. Install valve lifters as outlined.
Removal Camaro
1. Remove engine and proceed as outlined in the Chas TIMING GEARS
sis Overhaul Manual.
Replacement
Removal Except Camaro
1. Remove valve lifters as outlined. With camshaft removed, crankshaft gear may be re
2. Remove crankcase front cover as outlined. moved using Tool J-8105 fig. 18L. To install crankshaft
3. Remove radiator as outlined in Section 13. gear use Tool J-5590 fig. 19L. For camshaft gear re
4. Remove grille as outlined in Section 13. placement, refer to Section 6, "Camshaft Disassembly"
5. Remove fuel pump as outlined in Section 6M. of the Overhaul Manual.
6. Align timing gear marks then remove the two cam
shaft thrust plate bolts by working through holes in
the camshaft gear fig. 15L.
Timing Gear Marks Fig. 16L-Checking Camshaft Gear Runout
ENGINE 6-22
Fig. 19L-lnstalling Crankshaft Gear

Front Mount Replacement
Chevrolet, Chevelle, and Camaro
1. Remove nut, washer, spacer then engine mount
through-bolt.
2. Raise engine to release weight from mount.
3. Remove mount, stop bracket and frame bracket as
sembly from crossmember, then remove stop
bracket and mount from frame bracket.
Fig. 17L-Checking Timing Gear Backlash 4. Install stop bracket and new mount on frame bracket,
then install assembly on crossmember.
FLYWHEEL 5. Lower engine, install through-bolt and tighten all
mount bolts to specified torques.
Removal
With transmission and/or clutch housing and clutch re Chevy II
moved from engine, remove the flywheel. 1. Remove nut, washer and engine mount through-bolt.
2. Raise engine to release weight from mount.
Installation 3. Remove bracket-to-mount bolt, then remove mount.
1. Clean the mating surfaces of flywheel and crankshaft 4. Install new mount on bracket.
to make certain there are no burrs. 5. Lower engine, install through-bolt and tighten all
2. Install flywheel on crankshaft and position to align mount bolts to specified torques.
dowel hole of crankshaft flange and flywheel fig.
Rear Mount Replacement
20L.
Chevrolet
NOTE: On Automatic Transmission equipped 1. Remove crossmember-to-mount bolts.
engines, the flywheel must be installed with the 2. Raise transmission to release weight from mount.
flange collar to transmission side fig. 20L. 3. Remove mount-to-transmission bolts, then remove
3. Install bolts and torque to specifications. mount and spacer.
4. Install spacer and new mount on transmission.
5. While lowering transmission, align and st a r t
ENGINE MOUNTS crossmember-to-mount bolts.
Engine mounts fig. 21L are the non-adjustable type 6. Lower transmission and tighten all mounting bolts
and seldom require service. Broken or deteriorated to specified torques.
mounts should be replaced immediately, because of the
added strain placed on other mounts and drive line
components. CONVERTER -RING
BOLT AREA - GEAR
DEPRESSED
WELDS
ENINE TRANS
SYNCHROMESH AUTOMATIC
Fig. 1 8L-Removing Crankshaft Gear Fig. 20L-Flywheel Installation Typical
ENGINE 6-23
FRONT FRONT
CHEVY II
FRONT
CHEVROLET CAMARO
CHEVELLE
L6
REAR L6 REAR REAR
Fig. 21L-Engine Mounts
Chevelle and Camaro Chevy II

1. Remove crossmember-to-mount bolts. 1. Remove crossmember-to-mount bolts.
2. Raise transmission to release weight from mount. 2. Raise transmission to release weight from mount.
3. Remove mount-to -transmission bolts, then remove 3. Remove mount-to-transmission bolts, then remove
mount. mount.
4. Install new mount on transmission. 4. Install new mount on transmission.
5. While lowering transmission a 1 i g n an d s t a r t 5. While lowering transmission a 1 i g n and s tart
crossmember-to-mount bolts. crossmember-to-mount bolts.
6. Lower transmission and tighten all mounting bolts to 6. Lower transmission and tighten all mounting bolts
specified torques. to specified torques.
ENGINE 6-24
ENGINE MECHANICAL
V-8 ENGINES
INDEX
Page Page
General Description . 6-24 Removal 6-30
Component Replacement and Adjustment 6-25 Installation 6-30
Engine Assembly 6-25 Oil Pump 6-31
Removal. 6-25 Removal 6-31
Intake Manifold 6-26 Oil Seal Rear Main 6-31
Removal. 6-26 Replacement 6-31
Installation 6-26 Torsional Damper 6-32
Exhaust Manifold. 6-27 Removal 6-32
Removal . 6-27 Installation 6-32
Installation 6-27 Crankcase Front Cover 6-33
Rocker Arm Cover 6-27 Removal 6-33
Removal. 6-27 Installation 6-33
Installation 6-27 Oil Seal Front Cover 6-33
Valve Mechanism 6-27 Replacement 6-33
Removal 6-27 Timing Chain and/or Sprockets 6.34
Installation and Adjustment 6-27 Replacement 6-34
Valve Lifters 6-28 Camshaft 6-35
Locating Noisy Lifters Hydraulic 6-28 Measuring Lobe Lift 6-35
Valve Stem Oil Seal and/or Valve Spring 6-29 Flywheel 6-37
Replacement 6-29 Removal 6-37
Cylinder Head Assembly 6-30 Installation 6-37
Removal 6-30 Engine Mounts 6-37
Installation 6-30 Replacement Front 6-38
Oil Pan 6-30 Replacement Rear 6-38
GENERAL DESCRIPTION
The V8 engines fig. 1V covered in this section are the gine assemblies; the removal, installation and adjustment
302, 307, 327, 350, 396, and 427 cu. in. engines, regard of some sub-assemblies and replacement of some compo
less of which passenger vehicle they are used in. nents. For service to all components and sub-assemblies
This section covers the removal and installation of en- after removal and removal of some sub-assemblies,
Fig. 1V - V8 Engines lypical
ENGINE 6-25
refer to Section 6 of the Chassis Overhaul Manual. where specific illustrations or procedures are necessary
Because of the interchangeability and similarity of to clarify the operation. Although illustrations showing
many engines, engine sub-assemblies and engine parts, bench operations are used, most single operations, when
regardless of which passenger vehicle they are used in, not part of a general overhaul, should be performed if
typical illustrations and procedures are used except practical with the engine in the vehicle.
COMPONENT REPLACEMENT AND ADJUSTMENT

ENGINE ASSEMBLY move crossmember bolts and slide crossmem
ber back.
Removal
1. Drain cooling system and engine oil. 16. Remove engine-transmission assembly from vehicle
2. Remove air cleaner and disconnect battery cables at as a unit.
battery. 17. Remove transmission and clutch:
3. Remove hood hinge front bolts, loosen the rear
bolts. Swing hood up and install Tool J-22382-l. Synchromesh Transmission
4. Remove radiator and shroud as outlined in Sec a. Remove clutch housing cover plate screws.
tion 13. b. Remove bolts attaching the clutch housing to en
5. Remove fan blade and pulley as outlined in Sec gine block then remove transmission and clutch
tion 6K. housing as a unit.
6. Disconnect wires at:
NOTE: Support the transmission as the last
* Starter solenoid
Delcotron mounting bolt is removed, and as it is being
Temperature switch pulled away from the engine to prevent damage
Oil pressure switch to clutch disc.
* Coil c. Remove starter and clutch housing rear cover
7. Disconnect: plate.
* Accelerator linkage at pedal lever. d. Loosen clutch mounting bolts a turn at a time to
* Exhaust pipes at manifold flanges. prevent distortion of clutch cover until the spring
* Vacuum line to power brake unit at manifold if pressure is released. Remove all bolts, clutch
so equipped. disc and pressure plate assembly.
* Power steering pump lines at pump end if so
equipped. Automatic Transmission
* Fuel line from tank at fuel pump. a. Lower engine, secured by the hoist, and support
* Engine cooler lines if so equipped. engine on blocks.
* Oil pressure gauge line if so equipped. b. Remove starter and converter housing underpan.
8. Raise vehicle and place on jack stands. c. Remove flywheel-to-converter attaching bolts.
9. Remove propeller shaft. d. Support transmission on blocks.
e. Remove transmission-to-engine mounting bolts.
NOTE: If plug for propeller shaft opening f. With the hoist attached, remove blocks from the
in transmission is not available, drain engine only and slowly guide the engine from the
transmission. transmission.
18. Mount engine in stand.
10, Disconnect:
* Shift linkage at transmission. Installation
* Speedometer cable at transmission. 1. Attach lifting device to engine and remove engine
* Transmission cooler Lines if so equipped. from engine stand.
11. On synchromesh equipped vehicles, disconnect clutch 2. Install transmission and clutch:
linkage at cross-shaft then remove cross-shaft en
gine bracket. Synchromesh Transmission
12. Remove rocker arm covers as outlined, then attach a. Install the clutch on flywheel as outlined in Sec
engine lifting adapter at the proper cylinder head bolt tion 7.
locations. b. Install clutch housing rear cover and starter.
13. Remove front mount bolts. c. Install transmission and clutch housing as out
14. Attach lifting device and raise engine to take weight lined in Section 7.
off front mounts, then remove rear mount bolts. d. Install clutch housing cover screws and tighten
15. Raise engine to take weight off rear mount, then re securely.
move crossmember.
Automatic Transmissions
NOTE: On Chevrolets it will be necessary to a. Position engine adjacent to the transmission and
remove mount from transmission before cross- align the converter with the flywheel.
member can be removed. b. Bolt transmission to engine, then raise engine and
transmission assembly and install flywheel to
NOTE: On Camaro models it is not necessary converter attaching bolts.
to completely remove the crossmember. Re- c. Install converter housing underpan and starter.
ENGINE 6-26
3. Tilt and lower engine and transmission assembly into 6. Remove manifold-to-head attaching bolts, then re
the chassis as a unit, guiding engine to align front move manifold with carburetor on from engine and
mounts with frame supports. discard gaskets and seals.
4. Install front mount bolts and torque to specifications. 7. If manifold is to be replaced, transfer:
5. Raise engine enough to install rear crossmember, * Carburetor and carburetor mounting studs.
then install crossmember, install rear mount, lower * Water outlet and thermostat use new gasket.
engine and torque rear mount to specifications. * Heater hose adapter.
6. Remove lifting device and lifting adapter then install * Choke coil.
rocker arm covers as outlined. Installation
7. On synchromesh equipped vehicles, install clutch 1. Clean gasket and seal surfaces of manifold, cylinder
cross-shaft engine bracket, then adjust and connect heads and block.
clutch as outlined in Section 7. 2. Install manifold end seals on block as shown fig.
8. Connect: 2V.
* Speedometer cable. 3. Install side gaskets on cylinder heads using sealing
* Shift linkage at transmission. compound around water passages fig. 2V.
* Transmission cooler lines if so equipped. 4. Install manifold bolts, and torque to specifications in
9. Install propeller shaft. the sequence outlined on the Torque Sequence Chart.
10. Remove jack stands and lower vehicle. 5. Install coil.
11. Connect: 6. Install distributor with the rotor pointing at the chalk
* Power steering pump lines if so equipped. mark, then install distributor cap.
* Vacuum line to power brake unit if so equipped.
* Exhaust pipes at manifold flanges. NOTE: If the crankshaft has been rotated while
* Accelerator linkage at pedal lever. the distributor was removed, time distributor to
* Fuel line at fuel pump. number 1 cylinder as outlined in Section 6Y.
* Engine cooler lines if so equipped. 7. Install Air Injection Reactor pump and hoses. Adjust
* Oil pressure gauge lines if so equipped. belt t e n si on and to r q u e attaching bolts to
12. Connect wires at: specifications.
* Coil
Connect:
* Oil pressure switch
* Temperature switch * Battery cables at battery.
* Delcotron * Upper radiator and heater hose at manifold.
* Starter soleniod * Accelerator linkage at pedal lever.
13. Install pulley, fan blade and fan belt as outlined in * Fuel line at carburetor.
* Wires at temperature sending switch and coil
Section 6K.
both sides.
14. Install radiator and shroud as outlined in Section 13.
* Power brake hose at carburetor base.
15. Remove hood prop tool and install front hinge bolts.
Adjust hood as outlined in Section 11. * Spark advance hose at distributor.
16. Connect battery cables. * Crankcase ventilation hoses as required.
17. Fill with coolant, engine oil and transmission oil,
18. Perform necessary adjustments and install air
cleaner.
INTAKE MANIFOLD
Removal
1. Drain radiator and remove air cleaner.
2. Disconnect:
* Battery cables at battery.
* Upper radiator and heater hose at manifold.
* Accelerator linkage at pedal lever.
* Fuel line at carburetor.
* Wires at temperature sending switch and coil
both sides.
* Power brake hose at carburetor base.
* Spark advance hose at distributor.
* Crankcase ventilation hoses as required.
3. Remove distributor cap and mark rotor position with
chalk. Remove distributor clamp and distributor,
then position distributor cap rearward clear of
manifold.
4. Disconnect Air Injection Reactor hoses. Remove
pump belt adjusting brace bolt, pump body bolt and
remove pump.
5. Remove coil. Fig. 2V-lntake Manifold Gasket and Seal Location
ENGINE 6-27
Fill with coolant, start engine, check for leaks and

arms and push rods.
adjust timing and carbu:retor idle speed and mixture.
NOTE: Place rocker arms, rocker arm balls
and push rods in a rack so they may be rein
EXHAUST MANIFOLD stalled in the same location.
Removal
Installation and Adjustment
NOTE: If equipped with "Air Injection Reactor NOTE: Whenever new rocker arms and/or
System", remove air manifold and tubes as out
rocker arm balls are being installed, coat bear
lined in Section 6T. Remove pre-heater air
ing surfaces of rocker arms and rocker arm
stove.
balls with Molykote or its equivalent.
1. Install push rods. Be sure push rods seat in lifter
2. Disconnect and remove Delcotron as required.
3. On 396 and 427 cu. in. engines, remove spark plugs socket.
2. Install rocker arms, rocker arm balls and rocker
and spark plug shields.
4. Remove exhaust manifold flange nuts, then lower ex arm nuts.
3. Adjust valves when lifter is on base circle or cam
haust pipe assembly hang e:thaust pipe from frame
shaft lobe as follows:
with wire.
5. Remove end bolts then remove center bolts and re With Hydraulic Valve Lifters
move manifold from engine. a. Crank engine until mark on torsional damper
lines up with center or "0" mark on the timing
Installation
tab and the engine is in the number 1 firing posi
1. Clean mating surfaces on manifold and head, then
tion. This may be determined by placing fingers
install manifold in position and install center bolts.
2. Install end bolts with french locks under them. on the number 1 cylinder valve as the mark on the
damper comes near the "0" mark on the front
3. Torque center bolts to specifications, then torque end
cover. If the valves are not moving, the engine is
bolts to specifications, and bend french lock tabs to
in the number 1 firing position. If the valves
lock end bolts.
4. Using a new flange gasket install exhaust pipe to move as the mark comes up to the timing tab, the
manifold flange. engine is in number 6 firing position and crank
5. On 396 and 427 cu. in. engines, clean and install shaft should be rotated one more revolution to
reach the number 1 position.
spark plugs using new gaskets. Torque spark plugs
b. Valve adjustment is made by backing off the ad
to specifications.
justing nut rocker arm stud nut until there is
6. Install and connect Delcotron.
play in the push rod and then tighten nut to just
7. Connect the battery ground cable.
8. Install air cleaner pre-heater. remove all push rod to rocker arm clearance.
9. Start engine and check for leaks. This may be determined by rotating push rod with
fingers as the nut is tightened fig. 3V. When
push rod does not readily move in relation to the
ROCKER ARM COVER
Removal
1. Remove air cleaner.
2. Disconnect crankcase ventilation hoses as required.
3. Disconnect temperature wire from rocker arm cover
clips.
4. Remove rocker arm cover.
CAUTION: DO NOT pry rocker arm cover
loose. Gaskets adheri:ng to cylinder head and
rocker arm cover may be sheared by bumping
end of rocker arm cover rearward with palm of
hand or a rubber mallet.
Installation
1. Clean gasket surfaces on cylinder head and rocker
arm cover with degreaser then, using a new gasket,
install rocker arm cover and torque bolts to
specifications.
2. Connect crankcase ventilation hoses if disconnected.
3. Connect temperature wire at rocker arm cover clips.
4. Install air cleaner.
VALVE MECHANISM
Removal
1. Remove rocker arm covers as outlined.
2. Remove rocker arm nuts, rocker arm balls, rocker Fig. 3V-Valve Adlustment Hydraulic
ENGINE 6-28
rocker arm, the clearance has been eliminated. Locating Noisy Lifters Hydraulic
The adjusting nut should then be tightened an Locate a noisy valve lifter by using a piece of garden
additional 1 turn to place the hydraulic lifter hose approximately four feet in length. Place one end of
plunger in the center of its travel. No other the hose near the end of each intake and exhaust valve
adjustment is required. with the other end of the hose to the ear. In this manner,
c. With the engine in the number 1 firing position the sound is localized making it easy to determine which
as determined above, the following valves may be lifter is at fault.
adjusted. Another method is to place a finger on the face of the
Exhaust - 1, 3, 4, 8 valve spring retainer. If the lifter is not functioning
Intake - 1, 2, 5, 7 properly, a distinct shock will be felt when the valve re
d. Crank the engine one revolution until the pointer turns to its seat.
"0" mark and torsional damper mark are again The general types of valve lifter noise are as follows:
in alignment. This is number 6 firing position. 1. Hard Rapping Noise--Usually caused by the plunger
With the engine in this position the following becoming tight in the bore of the lifter body to such
valve may be adjusted. an extent that the return spring can no longer push
Exhaust - 2, 5, 6, 7 the plunger back up to working position. Probable
Intake - 3, 4, 6, 8 causes are:
a. Excessive varnish or carbon deposit causing ab
With Mechanical Valve Lifters normal stickiness.
a. Crank engine until mark on torsional damper b. Galling or "pick-up" between plunger and bore of
lines up with center or "0" mark on the timing lifter body, usually caused by an abrasive piece of
tab and the engine is in the number 1 firing posi dirt or metal wedging between plunger and lifter
tion. This may be determined by placing fingers body.
on the number 1 cylinder valve as the mark on the 2. Moderate Rapping Noise--Probable causes are:
damper comes near the "0" mark on the front a. Excessively high leakdown rate.
cover. If the valves are not moving, the engine b. Leaky check valve seat.
is in the number 1 firing position. If the valves c. Improper adjustment.
move as the mark comes up to the timing tab, the 3. General Noise Throughout the Valve Train--This
engine is in number 6 firing position and crank will, in almost all cases, be a definite indication of
shaft should be rotated one more revolution to insufficient oil supply, or improper adjustment.
reach the number 1 position. 4. Intermittent Clicking--Probable cases are:
b. With the engine in the number 1 firing position as
determined above, adjust the following valves to
specifications with a feeler gauge fig. 4V.
Exhaust - 4, 8
Intake - 2, 7
c. Turn crankshaft 1/2 revolution 180° clockwise
and adjust the following valve to specifications
with a feeler gauge.
Exhaust - 3, 6
Intake - 1, 8
d. Turn crankshaft 1/2 revolution 180° clockwise
until the pointer "0" mark and torsional damper
mark are again in alignment. This is number 6
firing position. With the engine in this position,
adjust the following valves to specifications with
a feeler gauge.
Exhaust - 5, 7
Intake - 3, 4
e. Turn crankshaft 1/2 revolution 180° clockwise
and adjust the following valves to specifications
with a feeler gauge.
Exhaust - 1, 2
Intake - 5, 6
f. Readjust valves hot and running as outlined
under "Engine Tune Up".
4. Install rocker arm covers as outlined.
5. Adjust carburetor idle speed and mixture.
VALVE LIFTERS
Hydraulic valve lifters very seldom require attention.
The lifters are extremely simple in design, readjust
ments are not necessary, and servicing of the lifters re
quires only that care and cleanliness be exercised in the
handling of parts. Fig. 4V-Valve Adjustment Mechanical
ENGINE 6-29
a. A microscopic piece of dirt momentarily caught 4 Using Tool J-5892 to compress the valve spring, re
between ball seat and check valve ball. move the valve locks, valve cap, and valve spring and
b. In rare cases, the ball itself may be out-of-round damper fig. 6V.
or have a flat spot. 5. Remove valve stem oil seal.
c. Improper adjustment. 6. Remove as follows:
In most cases where noise exists in one or more lifters 302, 307, 327 and 350 Cu. in. Engines
all lifter units should be removed, disassembled, cleaned a. To replace, set the valve spring and damper,
in a solvent, reassembled, and reinstalled in the engine. valve shield and valve cap in place. The close
If dirt, corrosion, carbon, etc. is shown to exist in one coiled end of the spring is installed against the
unit, it more than likely exists in all units, thus it cylinder head.
would only be a matter of time before all lifters caused b. Compress the spring with Tool J-5892 and install
trouble. oil seal in the lower groove of the stem, making
Removal sure the seal is flat and not twisted.
1. Remove intake manifold as outlined. NOTE: A light coat of oil on the seal will help
2. Remove valve mechanism as outlined. prevent twisting.
3. Remove valve lifters.
c. Install the valve locks and release the compres
NOTE: Place valve lifters in a rack so they sor tool making sure the locks seat properly in
may be reinstalled in the same location. the upper groove of the valve stem.
Installation NOTE: Grease may be used to hold the locks

1. Install valve lifters. in place while releasing the compressor tool.
NOTE: Whenever new valve lifters are being 396 and 427 cu in. Engines
installed coat foot of valve lifters with Molykote a. Install new valve stem oil seal coated with oil
or its equivalent. in position over valve guide.
b. Set the valve spring and damper and valve cap in
2. Install intake manifold as outlined. place.
3. Install and adjust valve mechanism as outlined. c. Compress the spring with Tool J-5892 and install
the valve locks, then release the compressor tool,
VALVE STEM OIL SEAL AND/OR VALVE SPRING making sure the locks seat properly in the groove
of the valve stem.
Replacement
1. Remove rocker arm covers as outlined. NOTE: Grease may be used to hold the locks
2. Remove spark plug, rocker arm and push rod on the in place while releasing the compressor tool.
cylinders to be serviced.
3. Apply compressed air to the spark plug hole to hold
the valves in place.
NOTE: A tool to apply air to the cylinder is
available through local jobbers or may be manu
factured. In manufacturing this Tool an AC-46N
Spark Plug or its equ:ivalent is recommended.
This will make the Tool universal for all
Chevrolet engines. Chisel the spark plug as
shown, then drive the porcelain out of the plug
by tapping the center electrode against a hard
block. Using a 3/8" pipe tap, cut threads in the
remaining portion of the spark plug and assem
ble as shown fig. 5V.
CUT
Fig. 5V-Air Adaptor Tool Fig. 6V-Compressing Valve Spring
ENGINE 6-30
7. Install spark plug, using a new gasket, and torque to damaging oil pan, raise engine enough to insert 2" x
specifications. 4" wood blocks under engine mounts fig. 7V, then
8. Install and adjust valve mechanism as outlined. lower engine onto blocks.
NOTE: If 2" x 4" wood blocks are cut 5-1/2"
CYLINDER HEAD ASSEMBLY long they can be used on all Chevrolet engines.
Removal The 5-1/2" length up for In-line engines and the
1. Remove intake manifold as outlined. 4" side up for V8 engines.
2. Remove exhaust manifolds as outlined.. 11. Remove oil pan and discard gaskets and seals.
4. Drain cooling system block. Chevelle
5. Remove cylinder head bolts, cylinder head and gas 1. Remove engine from vehicle as outlined.
ket. Place cylinder head on two blocks of wood to 2. Lower engine onto jack stands, one at each front
prevent damage. mount and one at transmission extension.
Installation CAUTION: Leave engine lift attached to en

gine. Do not remove all weight of engine off
CAUTION: The gasket surfaces on both the engine lift.
head and the block must be clean of any foreign
matter and free of nicks or heavy scratches. 3. Remove starter.
Cylinder bolt threads in the block and threads on 4. On vehicles equipped with automatic transmission
the cylinder head bolt must be cleaned. Dirt remove converter housing underpan.
will affect bolt torque. 5. Remove oil pan and discard gaskets and seals.
1. On engines using a STEEL gasket, coat both sides of Corvette

a new gasket with a good sealer, spread the sealer 1. Disconnect battery positive cable then remove oil
thin and even. One method of applying the sealer that dip stick and tube.
will assure the proper coat is with the use of a paint 2. Raise and support vehicle then drain engine oil.
roller. Too much sealer may hold the beads of the 3. Remove starter and flywheel underpan.
gasket away from the head or block. 4. Disconnect steering linkage idler at frame and lower
the linkage.
CAUTION: Use no sealer on engines using a 5. Remove oil pan and discard gaskets and seals.
composition STEEL ASBESTOS gasket. 6. On Hi-Performance engines, the oil baffle must
2. Place the gasket in position over the dowel pins with be removed before additional operations can be
the bead up. performed.
3. Carefully guide cylinder head into place over dowel Installation
pins and gasket. 1. Thoroughly clean all gasket sealing surfaces.
4. Coat threads of cylinder head bolts with sealing
compound and install finger tight. NOTE: Use a new pan gasket set.
5. Tighten cylinder head bolts a little at a time in the 2. Install side gaskets on pan rails, using gasket sealer
sequence shown on the torque sequence chart until as a retainer.
the specified torque is reached. 3. Install rear oil pan seal in groove in rear main
6. Install the exhaust manifold as outlined. bearing cap with ends fig. 8V butting side gaskets.
7. Install the intake manifold as outlined. 4. Install oil pan front seal in groove in crankcase front
8. Install and adjust the valve mechanism as outlined. cover, with ends butting side gaskets.
5. If crankshaft was rotated while pan was off, place
OIL PAN timing mark at 6:00 o’clock position.
Removal
Chevrolet, Camaro and Chevy II
1. Disconnect battery positive cable.
2. Disconnect distributor cap from distributor to pre
vent breaking distributor cap when engine is raised.
3. Drain radiator, then disconnect lower radiator hose
at water pump and remove oil dip stick and tube
where necessary.
4. Remove fan blade.
5. Raise vehicle then drain engine oil.
6. Remove through bolts from engine front mounts.
Disconnect and remove starter.
7. On vehicles equipped with automatic transmissions,
remove converter housing underpan.
8. Disconnect steering rod at idler lever then swing
steering linkage down for oil pan clearance.
9. Rotate crankshaft until timing mark on torsional
damper is at 6:00 o’clock position.
10. Using a suitable jack, and a block of wood to prevent Fig. 7V-Engine Blocked for Oil Pan Removal
ENGINE 6-3m
c. Fill engine with oil, then start engine and check

for leaks.
OIL PUMP
Removal
2. Remove pump to rear main bearing cap bolt and re
move pump and extension shaft.
Installation
1. Assemble pump and extension shaft to rear main
bearing cap, aligning slot on top end of extension
shaft with drive tang on lower end of distributor
drive shaft.
2. Install pump to rear bearing cap bolt and torque to
specifications.
NOTE: Installed position of oil pump screen
is with bottom edge parallel to oil pan rails.
3. Install oil pan as outlined.
OIL SEAL REAR MAIN

Replacement
The rear main bearing oil seal can be replaced both
halves without removal of the crankshaft.
NOTE: Always replace the upper and lower
seal as a unit. Install with the lip facing toward
the front of the engine.
1. With the oil pan and oil pump removed, remove the
rear main bearing cap.
2. Remove oil seal from the arinulor tang by prying
from the bottom with a small screw driver fig.
9V.
Fig. 8V-Oil Pan Gasket and Seal Location 3. Lubricate
.
the lip
.
of. a new seal with . engine oil. Keep
oil off the parting line surface as this is treated with
6. Install oil pan and torque bolts to specifications, glue. Insert seal in cap and roll it into place with
7. Complete installation as follows: finger and thumb, using light pressure so seal tangs
Chevrolet, Camaro and Chevy II
a. Using a suitable jack and a block of wood to pre
vent damaging oil pan raise engine enough to re
move 2" x 4" wood blocks, then lower engine.
b. On vehicles equipped with automatic transmission
install converter housing underpan.
c. Install through bolts in engine front mounts.
d. Install and connect starter. Connect steering rod
at idler lever.
e. Lower vehicle and install fan blade.
f. Connect lower radiator hose, then install oil dip
stick tube and dip stick.
g. Connect distributor cap and battery positive
cable.
h. Fill radiator with coolant and fill engine with oil,
Chevelle
a. On vehicles equipped with automatic transmission
install converter housing underpan.
b. Install starter.
c. Install engine as outlined.
Corvette
a. Connect steering linkage.
b. Install oil dip stick tube and dip stick then con
nect battery cables. Fig. 9V-Removing Oil Seal Lower Half
ENGINE 6-32
at parting line do not cut bead on back of seal.

4. To remove the upper half of the seal, use a small
hammer to tap a brass pin punch on one end of seal
until it protrudes far enough to be removed with
pliers fig. 1OV.
NOTE: Always wipe crankshaft surface clean
before installing a new seal.
oil off the parting line surface. Gradually push with
a hammer handle, while turning crankshaft, until
seal is rolled into place. Similar to installing a
main bearing. Be careful that seal tangs at parting
line do not cut bear on back of seal. Use sealer at
parting line on cap half of seal.
Fig. 11V-Removing Torsional Damper
6. Install the rear main bearing cap with new seal and
torque to specifications.
Installation
TORSIONAL DAMPER CAUTION: It is necessary to use installer tool
Removal to prevent the inertia weight section from walk
1. Remove fan belt, fan and pulley as outlined in Sec ing off the hub during installation of damper.
tion 6K. 307, 327 and 350 Cu. in. Engines
2. Remove the radiator and shroud as outlined in Sec Except 302 and 327 325 & 350 HP cu. in. Engines
tion 13. 1. Coat front cover seal contact area on torsional
NOTE: If additional operations such as cam damper with engine oil.
shaft removal are not being performed, the radi 2. Attach damper installer Tool J-22197 to damper.
ator will not have to be removed on Chevrolets Tighten fingers of tool to prevent weight from moving
and Corvettes equipped with 396 and 427 cu. in. fig. 12V.
engines. 3. Position damper on crankshaft and drive into position
until it bottoms against crankshaft sprocket fig.
3. On Corvettes equipped with 427 cu. in. engines, re 13V. Remove installer tool.
move engine front mount through-bolts and raise 4. Install accessory drive pulley.
front of engine enough for torsional damper to clear 5. Install radiator and shroud as outlined in Section 13.
frame crossmember. 6. Install fan pulley and fan as outlined in Section 6K.
4. Remove accessory drive pulley, then remove tor 7. Install fan belt and adjust to specifications using
sional damper retaining bolt if so equipped. strand tension gauge.
5. Install Tool J-6978 to torsional damper and turn 8. Fill cooling system, start engine and check for leaks.
puller screw to remove damper from crankshaft
fig. 11V. 396 and 427 cu. in. Engines
6. Remove tool. 1. Coat front cover seal contact area on damper with
engine oil.
Fig. JOV-Removing Oil Seal Upper Half Fig. 12V-lnstalling Torsional Damper 302, 307, 327 and 350
ENGINE 6-33
3. Install cover s c r e w s and to r qu e bolts to

specifications.
4. Install water pump as outlined in Section 6K.
5. Install torsional damper as outlined.
396 and 427 Cu. in. Engines
1. Make certain that cover mounting face and cylinder
block front face are clean and flat.
2. Coat the oil seal with engine oil and install Aligning
Tool J-22102 in oil seal fig. 14V then using a new
cover gasket coated with gasket sealer, install cover
and gasket on cylinder block.
3. Install cover screws and torque bolts to specifica
tions, then remove Aligning Tool J-22102.
4. Install water pump as outlined in Section 6K.
5. Install torsional damper as outlined.
OIL SEAL FRONT COVER

Replacement
With Cover Removal
Fig. ]3/-lnstalling Torsional Damper 396 and 427 1. With cover removed, pry old seal out of cover from
2. Place damper in position over key on crankshaft. the front with a large screw driver.
3. Using Tool J-21058 pull damper onto crankshaft 2. Install new seal so that open end of the seal is toward
fig. 13V. the inside of cover and drive it into position with
Tool J-995 on 302, 307, 327 and 350 cu. in. engines
NOTE: If engine or radiator has not been re
fig. 15V or Tool J-22102 on 396 and 427 cu. in.
moved from the vehicle a 1/2"-20 x 5" bolt and engines fig. 16V.
a 1/2"-20 nut may be used in place of the bolt
and nut of Tool J-21058. CAUTION: Support cover at sealing area to
avoid distorting cover.
CAUTION: Install bolt in crankshaft with suffi
cient thread enae en1Jpin. 1/2". Without Cover Removal
1. With torsional damper removed, pry old seal out of
4. Remove tool from crankshaft. cover from the front with a large screw driver, being
5. Install damper retaining bolt and torque to specifica careful not to damage the surface on the crankshaft.
tions, then install accessory drive pulley.
2. Install new seal so that open end of seal is toward the
6. Install radiator and shroud as outlined in Section 13.
inside of cover and drive it into position with Tool
7. Install fan pulley and fan as outlined in Section 6K.
J-8340 on 302, 307, 327 and 350 cu. in. engines fig.
8. Install fan belt and adjust to specifications using
17V or Tool J-22102 on 396 and 427 cu. in. engines
strand tension gauge.
fig. 18V.
9. On Corvettes, lower engine and install front mount
through-bolts.
10. Fill cooling system, start engine and check for leaks.
302 and 327 325 & 350 HP cu. in. Engines
Install damper as outlined for 396 and 427 cu. in. en
gines, using a 7/16"-20 x 5" bolt and nut in place of the
bolt and nut furnished with J-21058.
CRANKCASE FRONT COVER

Removal
2. Remove torsional damper as outlined.
3. Remove water pump as outlined in Section 6K.
4. Remove crankcase front cover attaching bolts and
remove front cover and gasket, then discard gasket.
Installation
302, 307, 327 and 350 cu. in. Engines
1. Make certain that cover mounting face and cylinder
block front face are clean and flat.
2. Coat the oil seal with engine oil and using a new
cover gasket, coated with gasket sealer, install cover
and gasket over dowel pins and cylinder block. Fig. l4V-Centering Tool in Cover 396 and 427
ENGINE 6-34
Fig. 17V -Installing Oil Seal Cover Installed

302, 307, 327 and 350
NOTE: Sprocket is a light press fit on cam

shaft. To dislodge, tap lightly on lower edge of
camshaft sprocket with a plastic hammer.
5. If crankshaft sprocket is to be replaced, remove
sprocket using Tool J-5825 on 302, 307, 327 and 350
cu. in. engines fig. 20V, or Tool J-1619 on 396 and
427 cu. in. engines fig. 21V. Install new sprocket
Fig. l5V-lnstalling Oil Seal Cover Removed using Tool J-5590 on 302, 307, 327 and 350 Cu. in.
302, 307, 327 and 350 engines fig. 22V or Tool J-21058 on 396 and 427
cu. in. engines fig. 23V.
6. Install timing chain on camshaft sprocket. Hold the
sprocket vertical with the chain hanging below, and
orient to align marks on camshaft and crankshaft
sprockets fig. 19V.
7. Align dowel in camshaft with dowel hole in camshaft
TIMING CHAIN AND/OR SPROCKETS sprocket and install sprocket on camshaft fig. 24V.
Replacement NOTE: Do not attempt to drive cam sprocket
1. Remove torsional damper and crankcase front cover on shaft as welsh plug at rear of engine can be
as outlined. dislodged.
2. Crank engine until marks on camshaft and crankshaft 8. Draw camshaft sprocket onto camshaft, using the
sprockets are in alignment fig. 19V.
3. Remove three camshaft sprocket to camshaft bolts.
4. Remove camshaft sprocket and timing chain together.
Fig. 16V-lnstalling Oil Seal Cover Removed 396 and 427 Fig. l8V-lnstalling Oil Seal Cover Installed 396 and 427
ENGINE 6-35
Fig. 21 V-Removing Crankshaft Sprocket 396 and 427

lobe. At this point, the push rod will be in its lowest
Fig. 19V-Timing Sprocket Marks position.
three mounting bolts. Torque to bolt specifications. 4. Set dial indicator on zero, then rotate the damper
9. Lubricate timing chain with engine oil. slowly, or attach an auxiliary starter switch and
10. Install crankcase front cover and torsional damper "bump" the engine over, until the push rod is in the
as outlined. fully raised position.
CAUTION: The primary distributor lead must
CAMSHAFT be disconnected from the negative post on the
coil and the ignition switch must be in the on
Measuring Lobe Lift
position. Failure to do this will result in a dam
NOTE: Procedure is similar to that used for aged grounding circuit in the ignition switch.
checking valve timing. If improper valve opera
5. Compare the total lift recorded from the dial indica
tion is indicated, measure the lift of each push
tor with specifications.
rod in consecutive order and record the
6. Continue to rotate the crankshaft until the indicator
readings. reads zero. This will be a check on the accuracy of
1. Remove valve mechanism as outlined. the original indicator reading.
2. Position indicator with ball socket adapter Tool 7. If camshaft readings for all lobes are within specifi
*J-8520 on push rod fig. 25V. cations, remove dial indicator assembly.
3. Rotate the crankshaft damper slowly in the direction
of rotation until the lifter is on the heel of the cam
Fig. 20V-Removing Crankshaft Sprocket 302, 307, 327 and 350 Fig. 22V-lnstalling Crankshaft Sprocket 302, 307, 327 and 350
ENGINE 6-36
Fig. 23V-Installing Crankshaft Sprocket 396 and 427

Removal
1. Remove valve lifters as outlined.
2. Remove crankshaft front cover as outlined
3. Remove grille as outlined in Section 13.
4. Remove fuel pump push rod as outlined in Sec
tion 6M.
5. Complete camshaft removal as follows: Fig. 25V-MeasUring Camshaft Lobe Lift
CAUTION: All camshaft journals are the same Remove camshaft sprocket to camshaft bolts then
diameter and care must be used in removing remove sprocket and timing chain together. Sprocket
camshaft to avoid damage to bearings. is a light fit on camshaft. If sprocket does not come
off easily a light blow on the lower edge of the
sprocket with a plastic mallet should dislodge the
sprocket.
Install two 5/16" - 18 x 4" bolts in camshaft bolt
holes then remove camshaft fig. 26V.
Installation
NOTE: Whenever a new camshaft is installed
coat camshaft lobes with Molykote or its
equivalent.
1. Lubricate camshaft journals with engine oil and in-
stall camshaft.
Fig. 24V-lnstalling Timing Chain Fig. 26V-Removing Camshaft
ENGINE 6-37
7. Install grille as outlined in Section 13.

CONVERTER 1RING 8. Install crankcase front cover as outlined.
BOLT AREA GEAR 9. Install valve lifters as outlined.
DEPRESSED
FLYWHEEL
Removal
With transmission and/or clutch housing and clutch
removed from engine, remove the flywheel.
WELDS Installation
1. Clean the mating surfaces of flywheel and crankshaft
!iNE TRANS. to make certain there are no burrs.
2. Install flywheel on crankshaft and position to align
SYNCHROMESH AUTOMATIC dowel hole of crankshaft flange and flywheel fig.
27V.
Fig. 27V-Flywheel Installation Typical
NOTE: On Automatic Transmission equipped
2. Install timing chain on camshaft sprocket. Hold the engines, the flywheel must be installed with the
sprocket vertical with the chain hanging down, and flange collar to transmission side fig. 27V.
orient to align marks on camshaft and crankshaft
sprockets. Refer to Figure 19V.
3. Align dowel in camshaft with dowel in hole in cam ENGINE MOUNTS
shaft sprocket then install sprocket on camshaft.
Refer to Figure 24V. Engine mounts fig. 28V are the non-adjustable type
4. Draw the camshaft sprocket onto camshaft using the and seldom require service. Broken or deteriorated
mounting bolts. Torque to specifications. mounts should be replaced immediately, because of the
5. Lubricate timing chain with engine oil. added strain placed on other mounts and drive line
6. Install fuel pump push rod as outlined in Section 6M. components.
Fig. 28V-Engine Mounts
ENGINE 6-38
Front Mount Replacement 2. Raise transmission to release weight from mount.

1. Remove nut, washer and engine mount through-bolt. 3. Remove mount-to-transmission bolts, then remove
2. Raise engine to release weight from mount. mount and spacer on Chevrolets.
3. Remove mount from engine. 4. Install new mount and spacer on Chevrolets on
4. Install new mount on engine. transmission.
5. Lower engine, install through-bolt and tighten all 5. While lowering transmission, align and start cross-
mount bolts to specified torques. member-to-mount bolts.
6. Lower transmission and tighten all mounting bolts
Rear Mount Replacement to specified torques.
1. Remove crossmembe r-to-mount bolts.
CYLINDER HEAD TORQUE SEQUENCE
i:ri:i
L6 L4
rr 0 0 0 0
000000
V8-302-307-327 & 350 V8-396 & 427
INTAKE MANIFOLD TORQUE SEQUENCE
FRONT
FRONT
V8-302-307-327 a 350 V8-396 a 427

Fig. iT-Torque Sequence
ENGINE 6-39
SPECIAL TOOLS
Fig. 21 - Engine Special Tools

1. J-4536 Engine Lift Kit 15. J-5860 Cylinder Head Bolt Wrench
2. J-1264 0-200 ft. lb. Torque Wrench 16. J-5715 .003" Rocker Arm Stud Reamer
J-8058 0-50 ft. lb. J-6036 .013"
J-5853 0-100 in. lb. 17. J-6880 Rocker Arm Stud Installer
3. J-8087 Indicator Set Cylinder Bore 18. J-5802 Rocker Arm Stud Remover
4. J-8001 Indicator Set Universal 19. J-9534 Distributor Lower Bushing Remover
5. J-7316 Belt Tension Gauge 20. J-9535 Distributor Lower Bushing Installer
6. J-8037 Piston Ring Compressor 21. J-22144 Oil Pick-up Screen Installer
7. J-8020 3 9/16" Piston Ring Expander 22. J-8369 Oil Pick-up Screen Installer
J-8021 3 7/8" 23. J-6098 Cam Bearing Tool
J-8032 4" 24. J-0971 Camshaft Gear Support
J-22249 3 15/16" 25. J-6978 Torsional Damper Puller
J-221 47 4 3/32" 26. J-22197 Torsional Damper Installer
J-22250 4 1/4" 27. J-21058 Torsional Damper and Sprocket Installer
8. J-6994 Piston Pin Assembly Tool 28. J-1619 Crankshaft Sprocket Puller
9. J-9510 Piston Pin Assembly Tool 29. J-5825 Crankshaft Sprocket Puller
10. J-5239 3/8" Connecting Rod Guide Set 30. J-8105 Crankshaft Gear Puller
J-6305 11/32" 31. J-5590 Crankshaft Sprocket or Gear Installer
ii. J-8062 Valve Spring Compressor 32. J-0966 Crankcase Cover Centering Gauge
12. J-8101 Valve Guide Cleaner 33. J-21742 Crankcase Cover Centering Gauge
13. J-5830 11/32" Valve Guide Reamer Set 34. J-22102 Crankcase Cover Tool
J-7049 3/8" 35. J-8340 Crankcase Cover Seal Installer
14. J-8089 Carbon Removing Brush 36. J-996 Crankcase Cover Seal Installer
SECTION 6K
ENGINE COOLING
INDEX
Page Page
6K-i Cylinder Block and Cylinder Head 6K-2
General Description
Hot Water Heater 6K-2
Maintenance and Adjustments 6K-i
6K-i Fan Belt 6K-2
Coolant Level
Adjustment 6K-2
Coolant System Checks 6K-i
6K-2 Thermostat 6K-3
Periodic Maintenance
BK-2 Replacement 6K3
Cleaning
6K-2 Water Pump 6K-3
Reverse Flushing
Radiator 6K-2 Removal 6K-3
Installation 6K-3
GENERAL DESCRIPTION
A pressure cooling system is provided for on all For radiator service, refer to Section 13 of this
models by a pressure type radiator cap fig. 1. The manual. For radiator fan shroud replacement, refer to
pressure type radiator cap used is designed to hold a Section 11.
pressure above atmospheric pressure in the cooling
system. Excessive pressure is relieved by a valve within
the cap that opens to radiator overflow.
The water pump is a ball bearing, centrifugal vane
impeller type. It requires no care other than to make
certain the air vent at the top of the housing and the drain
holes in the bottom do not become plugged with dirt or
grease. Removal and installation of the water pump is
I
covered in this section. For overhaul procedures of the
water pump refer to Section 6K of the Passenger Chassis
Overhaul Manual. Hg. 1-Pressure Radiator Cap

Coolant Level normal boiling point of water are in no way objectionable
The radiator coolant level should only be checked when so long as the coolant level is satisfactory when the
the engine is cool, particularly on cars equipped with air engine is cool.
conditioning. If the radiator cap is removed from a hot Upon repeated coolant loss, the pressure radiator cap
cooling system, serious personal injury may result. and seat should be checked for sealing ability. Also, the
The cooling system fluid level should be maintained cooling system should be checked for loose hose con
one inch below the bottom of the filler neck of the down- nections, defective hoses, gasket leaks, etc.
flow radiator when cooling system is cold, or at the
bottom of the filler neck when the system is warm. Coolant System Checks
Coolant level in crossflow radiators should be main
tained three inches below the bottom of the filler neck 1. Test for restriction in the radiator, by warming the
engine up and then turning the engine off and feeling
when the system is cold. It is very important that the
the radiator. The radiator should be hot at the top
correct fluid level be maintained. The sealing ability of
and warm at the bottom, with an even temperature
the radiator cap is affected when the cooling level is
rise from bottom to top. Cold spots in the radiator
too high.
indicate clogged sections.
All passenger car cooling systems are pressurized
2. Water pump operation may be checked by running the
with a 15 pressure cap which permits safe engine opera
engine while squeezing the upper radiator hose. A
tion at cooling temperatures of up to 247°F.
pressure surge should be felt. Check for a plugged
When the radiator cap is removed or loosened, the
vent-hole in pump.
system pressure drops to atmospheric, and the heat
which had caused water temperature to be higher than NOTE: A defective head gasket may allow ex
2 12°F, will be dissipated by conversion of water to haust gases to leak into the cooling system.
steam. Inasmuch as the steam may form in the engine This is particularly damaging to the cooling
water passages, it will blow coolant out of the radiator system as the gases combine with the water to
upper hose and top tank, necessitating coolant replace form acids which are particularly harmful to
ment. Engine operating temperatures higher than the the radiator and engine.
ENGINE COOLING 6K-2
3. To check for exhaust leaks into the cooling system, 7. While the engine is still running, add the powder
drain the system until the water level stands just portion No. 2 of the cooling system cleaner and
above the top of the cylinder head, then disconnect continue to run the engine for 10 minutes.
the upper radiator hose and remove the thermostat 8. At the end of this time, stop the engine, wait a few
and fan belt. Start the engine and quickly accelerate minutes and then open the drain cocks or remove
several times. At the same time note any appreci pipe plugs. Also remove lower hose connection.
able water rise or the appearance of bubbles which
are indicative of exhaust gases leaking into the cool CAUTION: Be careful not to scald your hands.
ing system. NOTE: Dirt and bugs may be cleaned out of
the radiator air passages by blowing out with air
Periodic Maintenance pressure from the back of the core. Do not
bend radiator fins.
It is the owner’s responsibility to keep the freeze pro
tection at a level commensurate with the area in which Reverse Flushing
the vehicle will be operated. Regardless of climate, Reverse flushing should always be accomplished after
system protection should be maintained at least to 0°F., the system is thoroughly cleaned as outlined above.
to provide adequate corrosion protection. When adding Flushing is accomplished through the system in a direc
solution due to loss of coolant for any reason or in areas tion opposite to the normal flow. This action causes the
where temperatures lower than -20°F. may occur, a water to get behind the corrosion deposits and force
sufficient amount of an ethylene glycol base coolant that them out.
meets GM Specification 1899-M should be used. Radiator
Every two years the cooling system should be serviced
1. Remove the upper and lower radiator hoses and re
by flushing with plain water, then completely refilled
place the radiator cap.
with a fresh solution of water and a high-quality, in
2. Attach a lead-away hose at the top of the radiator.
hibited permanent-type glycol base coolant meeting GM
3. Attach a new piece of hose to the radiator outlet
Specification 1899-M and providing freezing protection
connection and insert the flushing gun in this hose.
at least to 0°F. At this time, also add GM Cooling System
4. Connect the water hose of the flushing gun to a water
Inhibitor and Sealer or equivalent. In addition, Cooling
outlet and the air hose to an air line.
System Inhibitor and Sealer should be added every fall
5. Turn on the water and when the radiator is full, turn
thereafter. GM Cooling System Inhibitor retards the
on the air in short blasts, allowing the radiator to
formation of rust or scale and is compatible with alumi fill between blasts of air.
num components.
CAUTION Apply air gradually as a clogged
NOTE: Alcohol or methanol base coolants or radiator will stand only a limited pressure.
plain water are not recommended for your en
gine at any time. 6. Continue this flushing until the water from the lead-
away hose runs clear.
Two common causes of corrosion are: 1 air suction--
Air may be drawn into the system due to low liquid level Cylinder Block and Cylinder Head
in the radiator, leaky water pump or loose hose con 1. With the thermostat removed, attach a lead-away
nections; 2 exhaust gas leakage--Exhaust gas may be hose to the water pump inlet and a length of new hose
blown into the cooling system past the cylinder head to the water outlet connection at the top of the engine.
gasket or through cracks in the cylinder head and block.
NOTE: Disconnect the heater hose and cap
connections at engine when reverse flushing
Cleaning
engine.
A good cleaning solution should be used to loosen the
rust and scale before reverse flushing the cooling sys 2. Insert the flushing gun in the new hose.
tem. There are a number of cleaning solutions available 3. Turn on the water and when the engine water jacket
and the manufacturer’s instructions with the particular is full, turn on the air in short blasts.
cleaner being used should always be followed. 4. Continue this flushing until the water from the lead-
An excellent preparation to use for this purpose is GM away hose runs clear.
Cooling System Cleaner. The following directions for Hot Water Heater
cleaning the system applies only when this type cleaner 1. Remove water outlet hose from heater core pipe.
is used. 2. Remove inlet hose from engine connection.
1. Drain the cooling system including the cylinder block 3. Insert flushing gun and flush heater core. Care must
and then close both drain plugs. be taken when applying air pressure to prevent
2. Remove thermostat and replace thermostat housing. damage to the core.
3. Add the liquid portion No. 1 of the cooling system
cleaner. Fan Belt
4. Fill the cooling system with water to a level of about
3 inches below the top of the overflow pipe. Adjustment
5. Cover the radiator and run the engine at moderate 1. Loosen bolts at Delcotron mounting.
speed until engine coolant temperature reaches 180 2. Pull Delcotron away from engine until desired ten
degrees. sion reading is obtained with a strand tension gauge.
6. Remove cover from radiator and continue to run the Refer to Engine Tune-Up Specifications.
engine for 20 minutes. Avoid boiling. 3. Tighten all Delcotron bolts securely.
CHEVROlET CHASSIS SERVICE MANUAL
ENGINE COOLING 6K-3
Thermostat
The 195° thermostat consists of a restriction valve

actuated by a thermostatic element. This is mounted in
the housing at the cylinder head water outlet above the
water pump. Thermostats are designed to open and close
at predetermined temperatures and if not operating prop
erly should be removed and tested as follows.
Replacement
1. Remove radiator to water outlet hose.
2. Remove thermostat housing bolts and remove water
outlet and gasket from thermostat housing fig. 2.
3. Inspect thermostat valve to make sure it is in good
condition.
4. Place thermostat in hot water 250 above the temper
ature stamped on the thermostat valve.
5. Submerge the valve completely and agitate the water
thoroughly. Under this condition the valve should
open fully.
6. Remove the thermostat and place in water 10° below
temperature indicated on the valve.
7. With valve completely submerged and water agitated
thoroughly, the valve should close completely.
8. If thermostat checks satisfactorily, re-install, using Fig. 2-Replacing Thermostat
a new housing gasket.
9. Refill cooling system.
NOTE: On in line engines, pull the pump
straight out of the block first, to avoid damage
Water Pump to impeller.
Installation
Removal 1. Install pump assembly on cylinder block then, using
1. Drain radiator and break loose the fan pulley bolts. a new sealer-coated pump-to-block gasket, tighten
2. Disconnect heater hose, lower radiator hose and bolts securely.
by pass hose as required at water pump. 2. Install pump pulley and fan on pump hub and tighten
3. Loosen Delcotron and remove fan belt then remove bolts securely.
fan bolts, fan and pulley.
NOTE: A guide stud 5/16"-24 x 1-1/2" bolt
NOTE: Thermostatic fan clutches must be kept with the head removed installed in one hole of
in an "in-car" position. When removed from the fan hub will aid in aligning hub, pulley and
the car the assembly should be supported so fan. Remove stud after starting the remaining
that the clutch disc remains in a vertical plane three bolts.
to prevent silicone fluid leakage.
3. Connect hoses and fill cooling system.
4. Remove pump to cylinder block bolts and remove 4. Install fan belt and adjust as previously outlined.
pump and old gasket from engine. 5. Start engine and check for leaks.
SECTION 6M
ENGINE FUEL
Page Page
Carburetors GM-i Fuel Pumps GM-15
Air Cleaners GM-li Special Tools GM-i?
CARBURETORS
INDEX
Page Page
General Description GM-i Additional Adjustments . 6M-4

Service Procedures GM-i Removal GM-4
Preliminary Checks GM-i Test Before Installation GM-4
Idle Speed and Mixture Adjustment GM-i Installation GM-4
Fast Idle Adjustment 6M-3 Fuel Filter Maintenance GM-4
Choke Adjustment 6M-3 Choke Coil Replacement 6M-5
Float Adjustment 6M-3 Throttle Linkage Adjustment GM-6
GENERAL DESCRIPTION
Various carburetors fig. ic are used with Chevrolet, procedures are necessary to clarify the operation.
Chevelle, Chevy II, Camaro and Corvette passenger This section covers removal, installation and adjust
vehicles. These carburetors are designed to meet the ments on engine of carburetors. Also covered in this
particular requirements of engines, transmissions and section are maintenance procedures for choke coils,
vehicles. Therefore, carburetors that look alike are not throttle linkage and fuel filters. For carburetor over
always interchangeable. Refer to carburetor part num haul procedures and additional adjustments bench, re
ber and/or specifications. fer to Section 6M of the Overhaul Manual under the
Because many service procedures for the various carburetor being serviced.
carburetors are similar, typical illustrations and pro Specifications for carburetors are located in the back
cedures are used except where specific illustrations or of this manual.
SERVICE PROCEDURES
Preliminary Checks conditioning "OFF" except L-4 and L- 6 engines
1. Thoroughly warm-up engine. If the engine is cold, with automatic transmission and 325 H.P. and
allow to run for at least 15 minutes. 350 H.P. 327 cu. in. engines manual transmis
2. Inspect torque of carburetor to intake manifold bolts sion where idle speed is set with air con
and intake manifold to cylinder head bolts to exclude ditioning "ON".
the possibility of air leaks.
3. Inspect manifold heat control valve if used for free 3. Adjust idle mixture screw to obtain highest steady
dom of action and correct spring tension. idle speed. Adjust idle speed screw to recommended
rpm on "Decal".
Ad1ust Idle Speed and Mixture Fig. 1 c NOTE: Idle speed adjustment for L- 6 engines
1. As a preliminary adjustment, turn idle mixture and powerglide transmissions with idle solenoid
screw slightly to seat and back out 3 turns. is as follows: adjust idle speed to 500 rpm by
adjusting solenoid plunger hex only. Disconnect
CAUTION: Do not turn idle mixture screw wire at solenoid and observe idle speed. De
tightly against seat or damage may result. energizing the solenoid allows the throttle lever
2. With engine running at operating temperature air to seat against the carburetor idle screw. Ad
cleaner installed, pre-heater valve and choke valve just the carburetor idle screw as necessary to
wide open; adjust idle speed screw to bring idle obtain 400 rpm.
speed to specified rpm automatic transmission in
4. Adjust mixture screw in to obtain a 20 rpm drop
drive, manual transmission in neutral.
lean roll.
NOTE: On air conditioned vehicles, turn air 5. Adjust mixture screw out 1/4 turn.
ENGINE FUEL 6M-2
ROCHESTER M ROCHESTER MV ROCHESTER 2GV
‘-... IDLE
SPEED
IDLE
SPEED
IDLE
MIXTURE
IDLE IDLE
/
MIXTURE
MIXTURE
HOLLEY 2300C PRIMARY HOLLEY 2300 SECONDARY
IDLE
/
MIXTURE
ROCHESTER 4MV HOLLEY 4150
IDLE
IDLE MIXTURE
MIXTURE
APPLICATION = IN LINE V-8

- G, 0 a>
CARBURETOR >
a >
w >
a>
0
E 30; 327 350 396 427
_c c - 0 0
U U L U U 90 140 155 290 20 21 0 25 275 30C 325 350 295 325 35 375 385 390 0O 425 430 435
ROCHM 3 3
2312
ROCHMV 1 2 3 4
ROCH2GV 1 2 4 12
3
1 2 4 1 2 12 2 3
ROCH 4MV 3 5 5 23 5 1 5
C Prim. 5 5 5
HOLLEY
2300
Sec. 55
HOLLEY 4150 5 4 23 1 5
Fig. iC-Carburetors
ENGINE FUEL 6M-3
6. Repeat Steps 4 and 5 for second mixture screw if With Manual Choke Rochester M
so equipped. 1. Remove air cleaner.
7. Readjust speed screw if necessary to specified idle 2. Push hand choke knob in to within 1/8" of instru
rpm. ment panel.
3. Loosen choke cable clamp at carburetor bracket and
Fast Idle Adjustment adjust cable through the clip until the choke valve
Rochester M, 4MV and Holley is wide open.
With fast idle lever on high step of cam and choke valve 4. Tighten cable clamp at carburetor bracket and check
open engine warm set fast idle to give specified engine operation of choke valve to ensure full closed and
rpm. Adjust screw on Rochester 4MV and bend fast wide open positions.
idle lever on Rochester M and Holley. 5. Install air cleaner.
Choke Adjustment Float Adjustment

With Remote Choke Fig. 2c HolleyModel 4150 Center Inlet & Model 2300
1. Remove air cleaner then remove the fuel level sight
1. Remove air cleaner and check to see that choke
plugs fig. 3c.
valve and rod move freely.
2. With parking brake on, and transmission in neutral,
2. Disconnect choke rod at choke lever.
3. Check choke adjustment as follows: start the engine and allow it to idle.
3. With the car on a level surface, the fuel level should
On all engines except L6 and 390 H.P. 427 cu. in.
be on a level with the threads at the bottom of the
engines, hold choke valve closed and push rod down
sight plug port plus or minus 1/32 inch.
ward to contact stop. The top of rod should be even
with bottom of hole in choke lever. NOTE: No float drop adjustment is required
On L6 and 390 H.P. 427 cu. in. engines, hold choke on this carburetor.
valve closed and pull rod upward to end of travel.
4. If necessary to adjust either or both bowls, loosen
The bottom of rod should be even with top of hole in
inlet needle lock screw and turn the adjusting nut
choke lever.
clockwise to lower or counter-clockwise to raise
4. If necessary, adjust rod length by bending rod at
fuel level, then tighten lock screw.
offset bend. Bend must be such that rod enters
choke lever hole freely and squarely. NOTE: 1/6 turn of adjusting nut equals ap
5. Connect rod at choke lever and install air cleaner. proximately 1/16" fuel level change.
ROD IN BOTTOM CHOKE VALVE

CLOSED
CHOKE VALVE
COMPLETELY
CLOSED
PULL
ROD
TRAVEL
BEND ROD
TO ADJUST
L6 TYPICAL
Fig. 2C-Remote Choke Adjustment
ENGINE FUEL 6M-4
* Choke Vacuum Break

* Choke Unloader
* Secondary Throttle Lockout
* Secondary Opening
* Secondary Closing
Holley2300 and 4150
* Float
* Air Vent Valve
* Accelerator Pump
* Choke Unloader
Removal
Flooding, stumble on acceleration and other perform
ance complaints are, in many instances, caused by the
presence of dirt, water, or other foreign matter in the
carburetor. To aid in diagnosing the cause of the com
plaint, the carburetor should be carefully removed from
the engine without draining the fuel from the bowl.
The contents of the fuel bowl may then be examined for
contamination as the carburetor is disassembled.
.1. Remove air cleaner and gasket.
2. Disconnect fuel and vacuum lines from carburetor.
3. Disconnect choke rod or choke cable.
4. Disconnect accelerator linkage.
Fig. 3C-Fuel Level Sight Plug 5. If equipped with Automatic transmission, discon
nect TV linkage.
6. Remove carburetor attaching nuts and/or bolts and
5. Allow a minute for fuel level to stabilize, and re remove carburetor.
check the level at sight plug.
Test Before Installation
6. Readjust, if necessary, until proper level is obtained,
and install sight plug and air cleaner. It is good shop practice to fill the carburetor bowl
before installing the carburetor. This reduces the strain
NOTE: To assure proper secondary float level on the starting motor and battery and reduces the pos
setting it is advisable to accelerate primary sibility of backfiring while attempting to start the engine.
throttles slightly and hand operate secondary A fuel pump clamped to the bench, a small supply of fuel
throttle. This assures a stabilized secondary and the necessary fittings enable the carburetor to be
fuel level. filled and the operation of the float and intake needle and
seat to be checked. Operate the throttle several times
Additional Adjustments and check the discharge from the pump jets before in
The following adjustments may be made without re stalling the carburetor.
moving the carburetor from the engine. For procedure
refer to Section 6M of the Overhaul Manual under the Installation
carburetor being serviced. 1. Be certain throttle body and intake manifold sealing
surfaces are clean.
Rochester MV
2. Install new carburetor to manifold flange gasket if
. Float
required.
. Idle Vent
3. Install carburetor over manifold studs.
* Choke Rod Fast Idle
4. Start vacuum and fuel lines at carburetor.
5. Install attaching nuts and/or bolts and tighten
* Choke Unloader
securely.
Rochester 2GV 6. Tighten fuel and vacuum lines.
. Float 7. Connect and adjust accelerator and TV linkage.
* Accelerator Pump 8. Connect choke rod.
* Idle Vent 9. Install air cleaner, adjust idle speed and mixture
* Choke Rod Fast Idle per decal.
* Choke Unloader Fuel Filter Maintenance
1. Disconnect fuel line connection at inlet fuel filter nut.
* Secondary Throttle Opening
2. Remove inlet fuel filter nut from carburetor with a
* Secondary Throttle Lockout
1" box wrench or socket.
Rochester 4MV 3. Remove filter element and spring fig. 4c and fig.
* Float 5c.
* Accelerator Pump 4. Check bronze element for restriction by blowing on
* Idle Vent cone end; element should allow air to pass freely.
* Air Valve 5. Check paper element by blowing on fuel inlet end.
* Choke Rod If filter does not allow air to pass freely, replace
ENGINE FUEL 6M-5
Fig. 4C-Fuel Filter Bronze Type

Fig. 6C-Choke Coil - L6 Engine
element. No attempt should be made to clean filters.
8. Install fuel line and tighten connector.
NOTE: Element should be replaced if plugged
or if flooding occurs. A plugged filter will re NOTE: Filter element should be replaced every
sult in a loss of engine power or rough pulsat 12 months or 12,000 miles, whichever occurs
ing engine feel, especially at high engine speeds. first.
6. Install element spring, and install element in carbur Choke Coil Replacement
retor. Bronze filters must have small section of L6 Engines Fig. 6c
cone facing out. 1. Remove air cleaner and disconnect choke rod upper
7. Install new gasket on inlet fitting nut and install nut clip.
in carburetor and tighten securely. 2. Remove bolts attaching choke coil to manifold, and
remove choke coil and choke rod as an assembly.
3. Disconnect choke rod from choke coil.
4. Connect choke rod to new choke coil and install as
sembly on manifold.
5. Install bolts and tighten securely.
6. Adjust and connect choke rod as outlined.
7. Start and warm-up the engine then check operation
of choke and install air cleaner.
V8 Engines Fig. 7c
1. Remove air cleaner and disconnect choke rod upper
clip.
2. Remove choke coil as follows:
WITH ROCHESTER 2GV CARBURETOR
* Remove the choke coil shield by prying with a
screw driver in the cut out provided and then re
move the choke rod.
* Remove bracket and choke coil assembly.
WITH ROCHESTER 4MV AND
HOLLEY CARBURETORS
* Remove the choke coil shield by prying with a
screw driver in the cut out provided then lift
shield carefully over rod.
* Remove choke rod, bracket screw and choke coil
assembly.
3. Install a new choke coil assembly being sure the
locating tab is in the forward hole of the intake
Fig. 5C-Fuel FiIter Paper Type manifold and install mounting screw.
ENGINE FUEL 6M-6
CHEVY 11 307 CU. IN. CAMARO 327 CU. IN.
Fig. 7C-Choke Coil - V8 Engine T

-
CHEVY IL 327 £ 350 CU. IN. CAMARO 327. 350 a 396 CU. IN.
4. Complete installation as follows:

WITH ROCHESTER 2GV CARBURETOR
* Check that the choke rod eye of the coil is
below the stop tab on the bracket and install
the choke rod and adjust if necessary.
* Install the choke coil shield over the choke coil
and move shield to best fit along manifold.
WITH ROCHESTER 4MV AND
HOLLEY CARBURETORS
* Install the choke rod and adjust as necessary
without choke coil shield installed.
* Disconnect choke rod upper end and lower choke
coil shield over choke rod and install over choke
coil.
* Move shield to best fit along manifold and con
nect upper end of choke rod.
5. Be sure choke valve moves freely from full open
to full closed position.
6. Start and warm up the engine and check operation
of the choke. Fig. 8C-Throttle Linkage - Chevy II and Camaro V8
7. Install the air cleaner.
3. On automatic transmission equipped vehicles dis
Throttle Linkage Adjustment connect TV rod at throttle lever.
1. Disconnect throttle rod swivel at throttle lever on 4. Hold carburetor throttle in wide open position, push
carburetor. throttle rod rearward to position accelerator pedal
at the floor mat and adjust swivel to just enter hole
NOTE: Cable controls do not require adjust
in throttle lever.
ment except Corvette. TV controls used with
5. Connect swivel to throttle lever and install accelera
cable throttle linkages are adjusted same as
tor return spring.
Step 5.
6. On vehicles equipped with automatic transmission
2. Corvette only: hold accelerator pedal to floor against hole throttle lever in full open position, pull TV
stop. Move carburetor throttle lever to wide open rod to full detent position and adjust TV rod to just
position. Tighten cable clamp bolt to 45 in. lbs. of enter hole on throttle lever, and connect TV rod at
torque. throttle lever.
VIEW A
CHEVELLE, CHEVY 11 & CAMARO
VIEW D
CHEVELLE & CAMARO
D
VIEW B
CAMARO & CHEVY K
VIEW D
VIEW C CHEVY ii:
CHEVY II
0 VIEW C
0
CHEVELLE & CAMARO
0 m
z
0
z
m
‘1
0 C
Ill
z 0
Fig. 9C-Throttle Linkage - Chevelle, Chevy II and Camaro L-6 N
ENGINE FUEL 6M-8
‘VIEW111
/ 396 ENGINE
lvii*El 307 & 327 ENGINE
Fig. 1OC-Throttle Linkage Chevelle V8
V-8 ENGINE 396-427 ACCELERATOR CONTROLS
A
L-6 ENGINE
V-8 ENGINE EXCEPT 396 & 427 CU. IN.
0
I
3
0
I 2
U,
z
FRI
‘I
C
VIEWA VIEW B I!
0’
z
C I
Fig. 11C-Throttle Linkage Chevrolet ‘0
ENGINE FUEL 6M- 10
VIEW B
427 CU. IN. WITH 3x2
LEFT HAND SHOWN

RIGHT HAND OPPOSITE
VIEW
VIEW C
327 & 427 ‘CU. IN. EXCEPT 3x2
Fig. 1 2C-Throttle Linkage Corvette
ENGINE FUEL 6M-1 1
AIR CLEANERS
INDEX
Page Page
General Description 6M-11 Maintenance 6M-13
Service Proceduies 6M-11 Thermostatically Controlled Air Cleaner 6M-14
Polyurethane Element 6M-11 Testing 6M-14
Maintenance 6M-11 Replacement 6M-15
Oil Wetted Paper Element .. 6M-13
GENERAL DESCRIPTION
Air cleaners on all models operate primarily to re and/or cooler air from the engine compartment.
move dust and dirt from the air that is taken into the The oiled paper filters used in most air cleaner as
carburetor and engine. The air cleaner is also effective semblies have both ends of the paper element bonded with
in reducing engine air inlet noise. plastisol sealing material. Oil on the paper causes the
Three basic types of air cleaners are used on 1968 element to become discolored by a small amount of dirt
Chevrolet vehicles. They are the oiled paper, oiled paper that does not necessarily indicate that the element is
with polyurethane band, and th wire mesh with poly plugged or reduced in efficiency. It is advisable to rotate
urethane band. the air cleaner element 180° at 12,000 miles and to re
On most automatic transmission equipped vehicles an place the air cleaner element every 24,000 miles. The
automatic air inlet temperature control device is used. preceding maintenance operations should be performed
Air temperature is automatically controlled by a thermo more often when subject to dusty or otherwise adverse
static valve which selects warmed air from the heat stove driving conditions.
SERVICE PROCEDURES
POLYURETHANE ELEMENT 4. Remove support screen from element and wash

element in kerosene or mineral spirits; then squeeze
Maintenance out excess solvent fig. 3A.
1. Remove cover wing nut, cover and filter element.
2. Visibly check the element for tears or rips and re NOTE: Never use a hot degreaser or any sol
place if necessary. vent containing acetone or similar solvent.
3. Clean all accumulated dirt and grime from air
cleaner bottom and cover. Discard air horn to air 5. Dip element into light engine oil and squeeze out
cleaner gaskets. excess oil.
BOTTOM COVER
BOTTOM
SUPPORT ELEMENT
Fig. lA-Polyurethane Element Air Cleaner Fig. 2A-Paper Element Air Cleaner
ENGINE FUEL 6M-12
Fig. 4A-Polyurethane Support
7. Using new gaskets, replace air cleaner body over

carburetor air horns.
Fig. 3A-Cleaning Polyurethane Element
8. Replace the element in the air cleaner. Care must
be taken that the lower lip of the element is properly
NOTE: Never shake, swing or wring the ele placed in the assembly and that the filter material
ment to remove excess oil or solvent as this is not folded or creased in any manner that would
may tear the polyurethane material. Instead, cause an imperfect seal. Take the same precautions
"squeeze" the excess from the element. when replacing the cover that the upper lip of the
6. Install element on screen support fig. 4A. element is in proper position.
AIR CLEANER ASSY TEMP SENSING SPRING
MOTOR
LINKAGE
& PIPES
SNORKEL TUBE
Fig. 5A-ThermostatiCally Controlled Air Cleaner
ENGINE FUEL 6M-1 3
9. Replace cover and wing nut.
OIL WETTED PAPER ELEMENT AIR BLEED VALVE TEMP SENSING SPRING
CLOSED
Replacement
1. Remove wing nut, washer and cover.
2. Remove paper element and discard.
3. Remove bottom section of air cleaner and gasket SNORKEL TUBE
on air horn of carburetor. Discard air horn gasket.
4. Clean bottom section of air cleaner and cover pieces
INL LINKAGE APHRAGM
thoroughly, to remove dust and grime.
NOTE: Do not submerge bottom section of HOT AIR PIPE
CONTROL DAMPER ASSM.
thermostatic air cleaners in solvent.
HOT AIR DELIVERY MODE
5. Check bottom section air cleaner seal for tears or TEMP. SENSING SPRING
cracks.
6. Install a new gasket on carburetor air horn and set AIR BLEED VALVE
bottom section of air cleaner on carburetor. VACUUM CHAMBER DIAPHRAGM SPRING
7. Install new paper element on bottom section of air
SNORKEL
cleaner with either end up.
NOTE: Plastisol seal is the same material on
both ends. INLET AGE
8. Install cover, washer and wing nut.

CONTROL DAMPER ASSM. H- HOT
Cleaning REGULATING MODE
1. Remove air cleaner element as previously outlined.
2. Inspect top and bottom seals for deformation or AIR BLEED VALVE OPEN
cracking. These surfaces must be smooth and
VACUUM CHAMBER DIAPHRAGM SPRING
uniform.
3. Inspect element for punctures or splits by looking SNORKEL TUBE
through the element towa:rds a light bulb.
4. Tap element on smooth flat surface to dislodge dirt
INLET INKAGE DIAPHRA
particles being careful not to damage element. Com
pressed air can be used to clean element if done
very gently and opposite the flow of air to the CONTROL DAMPER ASSM.
/ HOT AIR PIPE
carburetor.
5. Internal portions of air cleaner cover and bottom COLD AIR DELIVERY MODE
should be clean. If washed with solvent surfaces
should be dried thoroughly.
NOTE: Do not submerge bottom section of Fig. 6A-Operafional Diagrams
thermostatic air cleaners in solvent.
2. Check for kinked or deteriorated hoses. Repair or
6. Install air cleaner element as previously outlined.
replace as required.
THERMOSTATICALLY CONTROLLED Operational
AIR CLEANER 1. Remove air cleaner cover and install temperature
This system is designed to improve carburetor opera gauge as close as possible to sensor.
tion and engine warm-up characteristics. It achieves this 2. If engine has been in recent operation allow it to cool
by keeping the air entering the carburetor at a tempera to below 85°F. Replace air cleaner cover without
ture of at least 100°F or more. wing nut.
The thermostatic air cleaner system includes a tem
perature sensor, a vacuum motor and control damper CAUTION IF INSPECTION OF CONTROL
assembly mounted in the air cleaner, vacuum control DAMPER ASSEMBLY IS DIFFICULT DUE TO
hoses, manifold heat stove and connecting pipes. The SNORKLE TUBE POSITION, THE USE OFA
vacuum motor is controlled by the temperature sensor. MIRROR IS RECOMMENDED.
The vacuum motor operates the air control damper as 3. Start and idle engine. When control damper assem
sembly to regulate the flow of hot air and under hood air bly begins to open, remove air cleaner cover and
to carburetor. The hot air is obtained from the heat observe temperature reading. Open temperature
stove on the exhuast manifold. must be between 85° and 115°F.
4. II damper assembly does not open at the correct
Inspection temperature, continue with the following vacuum
Visual motor and sensor checks.
1. Check for proper, secure connections of heat pipe 5. With the engine off, the position of the control damper
and hoses. assembly should be in the cold air delivery mode.
ENGINE FUEL 6M-14
SPOTWELDS
RETAINING STRAP INSTALL REPLACEMENT

/
SENSOR ASSM IN SAME
POSITION AS ORIGINAL ASSM
Fig. 7A-Component Replacement
6. To determine if the vacuum motor is operable apply Replacement

at least nine 9 inches of vacuum either from the 1. Drill 7/64" hole in snorkie tube at center of vacuum
engine or an independent source to the fitting on the motor retaining strap fig. 7A.
vacuum motor. 2. Connect vacuum motor linkage to damper door.
7. The control damper should close the cold air passage Fasten retaining strap to air cleaner with sheet
as long as vacuum is applied the hot air pipe will be metal screw.
open. 3. Replace air cleaner on engine and check operation of
8. if the vacuum motor fails to operate the control vacuum motor and control damper assembly.
damper assembly with the direct application of vac Temperature Sensor Replacement
uum, check to determine if the vacuum motor link Removal
age is properly connected to the door of if a bind is 1. Remove air cleaner from engine and disconnect vac
present. uum hoses at sensor.
9. If the linkage is found satisfactory, then motor re 2. Pry up tabs of sensor retaining clip.
placement is indicated. If the vacuum motor check is NOTE: Observe position of sensor, new sensor
found to be satisfactory, then sensor replacement is must be installed in this same position.
indicated.
3. Remove clip and sensor from air cleaner.
Replacement
Vacuum Motor Replacement 1. Install sensor and gasket assembly in air cleaner in
Removal position as noted above.
1. Remove air cleaner from engine. 2. Press retaining clip on sensor. Support the sensor
2. Drill out spot welds fastening vacuum motor retain on its sides to prevent damage to the control mecha
ing strap to snorkel tube. nism in the center.
3. Remove vacuum motor by lifting and unhooking 3. Install air cleaner on engine and connect vacuum
linkage rod from damper door. hoses.
ENGINE FUEL 6M-15
FUEL PUMP
INDEX
Page Page
General Description 6M-15 Test 6M-15

Service Procedures 6M-15 Removal 6M-16
Inspection 6M-15 Installation. 6M-16
GENERAL DESCRIPTION
The fuel pump fig. 1P used on all Chevrolet vehicles rocker arm. On V-8 engines, a push rod located be
covered in this manual are of the diaphragm type. The tween the camshaft eccentric and fuel pump actuates the
pumps are actuated by an eccentric located on the engine pump rocker arm. Because of design, this pump is
camshaft. On in-line engines, the eccentric actuates the serviced as an assembly only.
SERVICE PROCEDURES
c. If pump is operating properly the pressure will
Inspection be within specifications and will remain constant
The fuel pump should be checked to make sure the at speeds between 450-1,000 rpm. If pressure
mounting bolts and inlet and outlet connections are tight. is too low, too high, or varies significantly at
different speeds, the pump should be replaced.
Test
Always test pump while it is mounted on the engine and Removal
be sure there is gasoline in the tank. 1. Disconnect fuel inlet and outlet pipes at fuel pump.
The line from the tank to the pump is the suction side 2. Remove fuel pump mounting bolts and remove pump
of the system and the line from the pump to the carburet and gasket.
or is the pressure side of the system. A leak on the 3. On V8 engines, if push rod is to be removed, remove
pressure side, therefore, would be made apparent by pipe plug and push rod 396 and 427 cu. in. engines,
dripping fuel, but a leak on the suction would not be ap and fuel pump adapter and gasket and push rod 302,
parent except for its effect of reducing volume of fuel on 307, 327 and 350 Cu. lfl. engines.
the pressure side.
1. Tighten any loose line connections and look for bends Installation
or kinks in lines. 1. On V8 engines, if fuel pump push rod has been re
2. Disconnect fuel pipe at carburetor. Disconnect dis moved, install push rod and pipe fitting or fuel pump
tributor to coil primary wire so that engine can be adapter using gasket sealer on gasket or pipe fitting.
cranked without firing. Place suitable container at
end of pipe and crank engine a few revolutions. If
little or no gasoline flows from open end of pipe then
fuel pipe is clogged or pump is inoperative. Before
removing pump disconnect fuel pipe at gas tank and
outlet pipe and blow through them with an air hose
to make sure they are clear. Reconnect pipes and
retest while cranking engine.
CAUTION: Whenever the engine is cranked re
motely at the starter, with a special jumper
cable or other means, the primary distributor
lead must be disconnected from the negative
post on the coil and the ignition switch must be
in the "ON" position. Failure to do this will
result in a damaged grounding circuit in the
ignition switch.
3. If fuel flows from pump in good volume from pipe
at carburetor, check fuel delivery pressure to be
certain that pump is operating within specified limits
as follows:
a. Attach a fuel pump pressure test gauge to dis
connect end of pump to carburetor pipe.
b. Run engine at approximately 450- 1,000 rpm on
gasoline in carburetor bowl and note reading on
pressure gauge. Fig. 1P-Fuel Pump Non-Serviceable
ENGINE FUEL 6M-1 6
2. Install fuel pump using a new gasket and tighten

securely. Use sealer on fuel pump mounting bolt
threads.
NOTE: On V8 engines, a pair of mechanical
fingers or heavy grease may be used to hold
fuel pump push rod up while installing fuel pump
fig. 2P.
3. Connect fuel pipes to pump.
4. Start engine and check for leaks.
Fig. 2P-Installing 302, 307, 327, 350 V8 Engine Fuel Pumps
ENGINE FUEL 6M- 7
SPECIAL TOOLS
J - 22973
J-9789
J - 10176
LiiL1
J--1137
J_4552[
i-6058A
J8328
M J-6556
J5496:
BENDING TOOLS
Fig. 11-Engine Fuel Special Tools
SECTION 6T
AIR INJECTION REACTOR SYSTEM
INDEX
Page Page
General Description 6T-l Check Valves 6T-4

Maintenance Procedures 6T-2 Inspection 6T-4
Drive Belt 6T-2 Replacement. . . . 6T-4
Inspection 6T-2 Diverter Valve 6T-4
Adjustment 6T-2 Inspection 6T-4
Replacement 6T-2 Replacement 6T-4
Drive Pulley 6T-2 Air Injection Tube 6T-4
Replacement 6T-2 Inspection 6T-4
Pump Pulley 6T-3 Replacement 6T-5
Replacement 6T-3 Air Injection Pump 6T-5
Air Manifold, Hose and Tube 6T-4 Inspection 6T-5
Inspection 6T-4 Pressure Relief Valve Replacement 6T-5
Replacement 6T-4 Special Tools 6T-6
GENERAL DESCRIPTION
The Air Injection Reactor A.I.R. System fig. 1, used placed by a carburetor or distributor designed for en
on Chevrolet passenger car engines consists of: the air gines without the A.I.R. System.
injection pump with necessary brackets and drive at The air injection pump fig. 2 with an integral filter,
tachments, air injection tubes one for each cylinder, compresses the air and injects it through the air mani
an air diverter valve, check valves one for in-line en folds, hoses and injection tubes into the exhaust system
gines, two for V8 engines and air manifold assemblies, in the area of the exhaust valves. The fresh air ignites
tubes and hoses necessary to connect the various compo and burns the unburned portion of the exhaust gases in
nents. the exhaust system, thus minimizing exhaust contamina
Carburetors and distributors for engines with the A.I.R.
System are designed, particularly, for these engines;
therefore they should not be interchanged with or re
tions.
The diverter valve fig. 3 when triggered by a sharp
increase in manifold vacuum, shuts off the injected air
1
DIVERTER VALVE
CHECK VALVE.
IN LINE V8
Fig. 1-Air Inlection Reactor System
CHEVROLET CHASS%S SEW4CE
AIR INJECTOR REACTOR SYSTEM 6T-2
OUTLET
, RELIEF VALVE
/ PRESSURE SETTING
REAR COVER .-.-.i - PLUG
VENT HOLE
,-DO NOT OIL
ROTOR SHAFT
FILTER FAN
DRIVE HUB / -
VALVE IN OPEN POSITION

Fig. 2-Air Inlection Pump
to the exhaust port areas and prevents backfiring during

this richer period. Fig. 3-Diverter Valve Typical
On engine overrun the total air supply is dumped
through the muffler on the diverter valve. At high engine malfunction, the exhaust emissions might be Increased.
speeds the excess air is dumped through the pressure Because of the relationship between "Engine Tune Up"
relief valve when the pressure relief valve is part of the and "Unburned Exhaust Gases", the condition of the En
air pump and through the diverter valve when the pres gine Tune Up should be checked whenever the A.I.R. Sys
sure relief valve is part of the diverter valve. tem seems to be malfunctioning. Particular care should
The check valves prevent exhaust gases from entering be taken in checking items that affect fuel-air ratio such
and damaging the air injection pump, as back flow can as the crankcase ventilation system, the carburetor and
occur even under normal operating conditions. the carburetor air cleaner.
When properly installed and maintained, the A.I.R. Because of the similarity of many parts, typical illus
System will effectively reduce exhaust emissions. How trations and procedures are used except where specific
ever, if any A.I.R. component or any engine component illustrations or procedures are necessary to clarify the
that operates in conjunction with the A.I.R. System should operation.
MAINTENANCE PROCEDURES
DRIVE BELT CAUTION: Do not pry on the pump housing.
Distortion of the housing will result in exten
Inspection sive damage to the Air Injection Pump.
* Inspect drive belt for wear, cracks or deterioration Replacement
and replace if required.
* Loosen pump mounting bolt and pump adjustment
* Inspect belt tension and adjust if below 50 lbs. using
bracket bolt then swing pump until drive belt may be
a strand tension gauge.
removed.
* Install a new drive belt and adjust as outlined above.
Adjustment
DRIVE PULLEY
* Loosen pump mounting bolt and pump adjustment
bracket bolt. Replacement
* Move pump until belt is tight 55 ± 5 lb. used belt or * Remove drive belt as outlined above then replace
75 ± 5 lb. new belt using a strand tension gauge then drive pulley.
tighten adjustment bracket bolt and mounting bolt. * Install and adjust drive belt as outlined above.
PUMP PRESSURE
DIVERTER VALVE
OUTLET
Fig. 5-Air Inlection Tube Typical
* Install the new filter by drawing it on with the pulley

and pulley bolts fig. 7. Do not attempt to install a
filter by hammering it on or pressing it on.
* Draw the filter down evenly by alternately torquing
the bolts. Make certain that the outer edge of the
filter slips into the housing. The slight amount of
interference with the housing bore is normal.
Fig. 4-Air Manifold, Hose and Tube Routing
PUMP PULLEY
Replacement
* Hold pump pulley from. turning by compressing drive
belt then loosen pump pulley bolts.
* Remove drive belt as outlined above then remove
pump pulley.
* Install pump pulley with retaining bolts hand tight.
* Install and adjust drive belt as outlined above.
* Hold pump pulley from turning by compressing drive
belt then torque pump pulley bolts to 25 ft. lbs.
* Recheck drive belt tension and adjust if required.
PUMP FILTER
Replacement
* Remove drive belt and pump pulley as previously
outlined.
* Pry loose outer disc of filter fan.
* Pull remaining portion of filter off with pliers fig. 6.
NOTE: Care should be taken to prevent I rag
ments from entering the air intake hole. Fig. 6-Removing Centrifugal Filter
-I CHECK VALVE
Inspection
* The check valve should be inspected whenever the
hose is disconnected from the check valve or when
ever check valve failure is suspected. A pump that
had become inoperative and had shown indications of
having exhaust gases in the pump would indicate
check valve failure.
* Orally blow through the check valve toward air
manifold then attempt to suck back through check
valve. Flow should only be in one direction toward
the air manifold.
Replacement
* Disconnect pump outlet hose at check valve. Re
move check valve from air manifold, being careful
not to bend or twist air manifold.
DIVERTER VALVE
Inspection
1 * Check condition and routing of all lines especially

the signal line. All lines must be secure, without
crimps and not leaking.
Fig. 7-Installing Centrifugal Filter * Disconnect signal line at valve. A vacuum signal
must be available with engine running.
NOTE: A new filter may squeal upon initial * With engine stabilized at idle speed, no air should be
operation until its O.D. sealing lip has worn in. escaping through the muffler. Manually open and
quickly close the throttle, a momentary blast of air
AIR MANIFOLD, HOSE AND TUBE should discharge through muffler for at least one
second.
Inspection Fig. 4 * Defective valves should be replaced.
* Inspect all hoses for deterioration or holes. CAUTION: Diverter valves although some
* Inspect all tubes for cracks or holes. times similar in appearance are designed to
* Check all hose and tube connections. meet particular requirements of various en
* Check all tube and hose routing. Interference may gines, therefore, be sure to install the correct
cause wear. valve.
* If leak is suspected on the pressure side of the sys
tem or any tubes and/or hoses have been discon Replacement
nectd on the pressure side, the connections should
be checked for leaks with a soapy water solution. * Disconnect vacuum signal line. Disconnect valve
With the pump running, bubbles will form if a leak exhaust hoses.
exists. * Remove diverter valve from pump. Remove muffler
from valve assembly noting angle of attachment.
Replacement * Install muffler to new valve at angle previously noted.
* Install diverter valve to pump or bracket with new
* To replace any hose and/or tube, note routing then gasket. Torque valve attaching screws to 85 in. lbs.
remove hoses and/or tubes as required.
* Install outlet and vacuum signal lines and check sys
CAUTION: The 1/4" pipe threads at the cylin tem for leaks.
der head In Line or exhau st manifold V8 are
a straight pipe thread. Do not use a 1/4" ta AIR INJECTION TUBE
pered pipe tap. The hoses of the A.I.R. System
are a special material to withstand high tern-
Inspection Fig. 5
perâture. No other type hose should be substi
tuted. * There is no periodic service or inspection for the
Install new hoses and/or tubes, routing them as air injection tubes, yet on In Line engines whenever
*
when removed. the cylinder head is removed or on V8 engines when
ever the exhaust manifolds are removed, inspect the
* Tighten all connections.
air injection tubes for carbon build up and warped or
NOTE: Use anti seize compound on threads of burnt tubes.
tne air manifold to exhaust manifold or cylinder * Remove any carbon build up with a wire brush.
head connections. * Warped or burnt tubes must be replaced.
AIR INJECTOR REACTOR SYSTEM 61-5
Fig. 8-Removing Pressure Relief Vczlve Fig. 9-Installing Pressure Relief Valve
Replacement * Check hoses, tubes, air manifolds and all connections

for leaks and proper routing.
* On In Line engines remove carbon from tubes and * Check air injection pump for proper mounting.
using penetrating oil, work tubes out of cylinder * If none of the above conditions exist and the air in
head. jection pump has excessive noise remove and re
* On V8 engines clamp exhaust manifold in a vise, place pump unit.
remove carbon from tubes and using penetrating oil,
work tubes out of manifo]Ld. Replacement
* Install new tubes in cylinder head or manifold.
* Disconnect the hoses at the pump.
* Remove pump pulley as outlined.
AIR INJECTION PUMP * Remove pump mounting bolts and remove pump.
* Install pump with mounting bolts loose.
Inspection * Install pump pulley as outlined.
Accelerate engine to approximately 1500 RPM and ob * Install and adjust belt as outlined
serve air flow from hoses. If air flow increases as * Connect the hoses at the pump.
engine is accelerated, pump is operating satisfactorily. * Tighten mounting bolts securely.
If air flow does not increase or is not present, proceed
as follows: Pressure Relief Valve Replacement
* Check for proper drive belt tension.
NOTE: When the pressure relief valve is in
* Check for a leaky pressure relief valve. Air may be
corporated in the diverter valve the complete
heard leaking with the pump running.
unit must be replaced.
NOTE: The A.I.R. System is not completely
1. Using J-7055-5 and J-6585 pull relief valve from
noiseless. Under normal conditions noise rises
housing fig. 8.
in pitch as engine speed increases. To deter
2. Using a 15/16" socket tap the relief valve into hous
mine if excessive noise is the fault of the Air ing until the valve shoulders on the housing fig. 9.
Injection Reactor System, operate the engine
with the pump drive belt removed. If excessive CAUTION: Use extreme care to avoid distort
noise does not exist with the belt removed pro ing housing.
ceed as follows:
NOTE: Various length pressure setting plugs
* Check for a seized Air Injection Pump. designed for the particular requirements of
Fig. 10-Removing Exhaust Tube Fig. 11-Installing Exhaust Tube
vehicle - engine combinations, determine the suitable pair of pliers and pulling out using a twist
pressure required to open the relief valve. For ing motion fig. 10.
identification, the pressure setting plugs are * Insert new tube and tap in place using a plate to
color coded. To remove the pressure setting protect end of tube. Tap down until approximately
plug, carefully unlock legs from inside surface 7/8" of tube extends above cover.
of relief valve with a small screw driver. To
NOTE: Support pump as shown in Figure 11
install the pressure setting plug, carefully push
do not clamp when tapping tube in place.
into relief valve until legs lock. If a pressure
setting plug is to be reused be sure leg angles
are sufficient for the pressure setting plug to Bolt On Type
lock in place. * Remove two attaching bolts remove elbow and gasket.
* Install new elbow with new gasket and torque retain
PUMP EXHAUST TUBE ing bolts to 20 ft. lbs.
Replacement
Tube Type
* Remove exhaust tube by grasping tube in vise or with
SPECIAL TOOLS
J-7055-5
J-6585
6Y-3
6Y-2
6Y-l
SECTION 6Y
ENGINE ELECTRICAL
Page Page
Battery 6Y-1 Starting System 6Y-29

Charging System 6Y-7 6Y-32
Special Tools
Ignition System 6Y-17
BATTERY
INDEX
Page Page
General Description Carrier and Hoiddown 6Y-4
Types of Batteries Safety Precautions 6Y-4
Dry Charged Batteries 6Y-2 Charging Procedures 6Y-4
Activating Dry Charged Batteries 6Y-2 Slow Charging 6Y-4
Wet Charged Batteries 6Y-3 Fast Charging 6Y-4
Periodic Service 6Y-3 Emergency Boost Charging 6Y-4
Common Causes of Failure 6Y-3 Test Procedures 6Y-5
Level Indicator Visual Inspection 6Y-5
Electrolyte Level 6Y-3 Instrument 6Y-5
Water Usage 6Y-4 Full Charge Hydrometer Test 6Y-5
Cleaning 6Y-4 Specific Gravity Readings 6Y-5
Cables 6Y-4 Installing Battery 6Y-7
GENERAL DESCRIPTION
The battery fig. ib is made up of a number of separ
ate elements, each located in an individual cell in a hard
rubber case. Each element consists of an assembly of
positive plates and negative plates containing dissimilar ONE PIECE
active materials and kept apart by separators. The ele CELL COVER ELECTROLYTE LEVEL
ments are immersed in an electrolyte composed of dilute INDICATOR
sulfuric acid. Plate straps located on the top of each ele
ment connect all the positive plates and all the negative
plates into groups. The elements are connected in series
electrically by connectors that pass directly through the
case partitions between cells. The battery top is a one-
piece cover of hard rubber construction. The cell con
nectors, by-passing through the cell partitions, connect
the elements along the shortest practical path fig. 2b.
With the length of the electrical circuit inside the
Battery reduced to a minimum, the internal voltage drop
is decreased resulting in improved performance, par
ticularly during engine cranking at low temperatures.
The hard, smooth one-piece cover greatly reduces the
tendency for corrosion to form on the top of the battery.
The cover is bonded to the case with sealing compound
that forms an air tight seal between the cover and case.
Protection for the Battery charging circuit 10 gauge
wire is provided by a pigtail lead which is a fusible link
off the battery positive cable 14 gauge wire. This lead is
an integral part of the Battery cable assembly and serv
icing requires replacing the complete cable assembly.
A battery generally has two classifications of ratings: HOLD-DOWN SLOT
1 a 20 hour rating at 80 F and, 2 a cold rating at 0 F
which indicates the cranking load capacity. The Ampere-
Hour rating found on batteries was based on the 20 hour
rating. That is, a battery capable of furnishing three 3 Fig. lb-Energizer
ENGINE-ELECTRICAL 6Y-2
PARTITION PLATE
STRAP
CONNECTOR
Fig. 3b-Vent Well Construction
Each vent well in a "dry charge" Battery has an inte

gral hard rubber seal to prevent the entrance of air and
moisture which would oxidize the negative active mate
rials and reduce the freshness of the Battery fig. 3b.
The integral hard rubber seals and the sealing compound
between the case and one-piece cell cover make possible
a vacuum sealed assembly which can be stored for very
long periods of time without detrimental effects.
Before activating the "dry charge" Battery, the inte
gral hard rubber seals may be broken simply by pushing
the Delco Eye down into each vent well. The seals drop
into the cells, and can remain there since they are not
Fig. 2b-lnternol View of Energizer
chemically active and will cause no harm. The Delco
Eye is a special type of vent plug that is described in the
amperes for 20 hours while maintaining a specified section entitled "Periodic Servicing".
average individual cell voltage would be classified as a 60
ampere hour battery e.g. 3 amperes x 20 hours = 60 ACTIVATING DRY CHARGED BATTERIES
A.H. a PWR Peak Watt Rating has been developed as a
measure of the Energizer’s cold cranking ability. The A "dry charge" Battery is activated by filling each
numerical rating is embossed on each case at the base of cell with electrolyte, which is a dilute solution of sulfuric
the Energizer. This value is determined by multiplying acid having s specific gravity of 1.265 at 80°F. The cells
the max. current by the max. voltage. The PWR should are properly filled when the electrolyte level reaches
should not be confused with the ampere hour rating since the bottom of the "split vent" at the bottom of the vent
two batteries with the same ampere hour rating can have well. The split vent is a visual level fill feature designed
quite different watt ratings. For battery replacement, a into the cell cover of Delco Batteries fig. 4b. The
unit of at least equal power rating must be selected.
TYPES OF BATTERIES
There are two types of Batteries-the "dry charge"
type and the "wet charge" type. The difference in types
depends on the method of manufacture.
DRY CHARGED BATTERIES

A "dry charge" Battery contains fully charged ele ELECTROLYTE ELECTROLYTE
ments which have been thoroughly washed and dried. This LEVEL TOO AT CORRECT
LOW LEVEL
type of battery contains no electrolyte until it is activated
for service in the field and, therefore, leaves the factory
in a dry state. Consequently, it is called a "dry-charge"
Battery. Fig. 4b-View Inside Vent Well Showing Electrolyte
electrolyte surface will appear distorted when it contacts After electrolyte has been added to a "dry charge"
the split vent. Battery, it then becomes a wet charged Battery and
The electrolyte level of each cell should be checked should be maintained in the same manner as any other
after filling the Battery initially. If the level has fallen "wet" Battery.
below the split vent, additional electrolyte should be
added. NEVER ADD WATER TO THE ELECTROLYTE WET CHARGED BATTERIES
WHEN ACTIVATING BATTERY.
Long and trouble-free service can be anticipated only Wet charged Batteries contain fully charged elements
if the Battery is properly activated. Improper activation and are filled with electrolyte before being shipped from
results in poor performance and short Battery life. the factory.
PERIODIC SERVICING
Since the Battery is a perishable item which requires trolyte is at the proper level, the lower tip of the rod is
periodic servicing, a good maintenance program will immersed, and the exposed top of the rod will appear
insure the longest possible Battery life. very dark; when the level falls below the tip of the rod,
the top will glow.
COMMON CAUSES OF FAILURE The indicator reveals at a glance if water is needed,
without the necessity of removing the vent plugs fig. 6b.
If the Battery tests good but fails to perform satis The Level Indicator is used in only one cell second
factorily in service for no apparent reason, the following
cell cap from positive Battery post because when the
are some of the more important factors that may point to
electrolyte level is low in one cell, it is normally low in
the cause of the trouble.
all cells. Thus when the indicator shows water is needed,
1. Vehicle accessories inadvertently left on overnight to check the level in all six cells.
cause a discharged condition. An alternate method of checking the electrolyte level is
2. Slow speed driving of short duration, to cause an to remove the vent plug and visually observe the electro
undercharged condition. lyte level in the vent well. The bottom of the vent well
3. A vehicle electrical lclad exceeding the generator
features a split vent which will cause the surface of the
capacity. electrolyte to appear distorted when it makes contact.
4. Defect in the charging system such as high resist The electrolyte level is correct when the distortion first
ance, slipping fan belt, faulty generator or voltage appears at the bottom of the split vent fig. 4b.
regulator.
5. Battery abuse, including failure to keep the Battery
top clean, cable clamps and posts clean and tight, ELECTROLYTE LEVEL
and improper addition of water to the cells. The electrolyte level in the Battery should be checked
regularly. In hot weather, particularly during trip driv
LEVEL INDICATOR ing, checking should be more frequent because of more
The Battery features an electrolyte level indicator, rapid loss of water. If the electrolyte level is found to be
which is a specially designed vent plug with a transparent low, then colorless, odorless, drinking water should be
rod extending through the center fig. Sb. When the elec added to each cell until the liquid level rises to the split
INDICATOR INDICATOR
ELECTROLYTE LEVEL ELECTROLYTE LEVEL

CORRECT LOW
Fig. 5b-Electrolyte at Proper Level Fig. 6b-Electrolyte at Low Level
vent located in the bottom of the vent well. DO NOT 1. Do not smoke near Batteries being charged or which
OVERFILL because this will cause loss of electrolyte have been very recently charged.
resulting in poor performance, short life, and excessive 2. Do not break live circuits at the terminals of Bat
corrosion. teries because a spark usually occurs at the point
where a live circuit is broken. Care must always be
CAUTION: During service only water should be taken when connecting or disconnecting booster leads
added to the Battery, not electrolyte.
or cable clamps on fast chargers. Poor connections
The liquid level in the cells should never be allowed to are a common cause of electrical arcs which cause
drop below the top of the plates, as the portion of the explosions.
plates exposed to air may be permanently damaged with a
resulting loss in performance. BATTERY CHARGING PROCEDURES
There are three methods of recharging Batteries.
WATER USAGE
They differ basically in the length of time the battery is
Excessive usage of water indicates the Battery is being charged and the rate at which charging current is sup
overcharged. The most common causes of overcharge plied. One is the Slow Charge method, the second is the
are high Battery operating temperatures, too high a volt Fast Charge method, and the third is the Emergency
age regulator setting, poor regulator ground wire con Boost Charge method.
nection. Normal Battery water usage is approximately Before recharging a Battery by any method, the elec
one to two ounces per month per battery. trolyte level must be checked and adjusted if necessary.
CLEANING
The external condition of the Battery should be checked SLOW CHARGING
periodically for damage or for the presence of dirt and The Slow Charge method supplies the Battery with a
corrosion. The top of the Battery should be kept clean. relatively low current flow for a relatively long period of
An accumulation of acid film and dirt may permit current time. This is the only method that will bring the Battery
to flow between the terminals, which will slowly dis to a full state of charge.
charge the Battery. For best results when cleaning the The Slow Charge method consists of charging at ap-.
top of Batteries, wash first with a diluted ammonia or a proximately a 4 ampere rate for 24 hours or more if
soda solution to neutralize any acid present; then flush necessary to bring the Battery to full charge. A fully
with clean water. Care must be taken to keep vent plugs charged condition is reached when the cells are gassing
tight, so that the neutralizing solution does not enter the freely and three corrected specific gravity readings
cells. taken at hourly intervals show no increase.
CABLES FAST CHARGING
To insure good electrical contact, the cables should be The Fast Charge method supplies current to the Bat
clean and tight on the Energizer posts. If the posts or tery at a 40 to 50 ampere rate for a 1-1/2 hour period of
cable terminals are corroded, the cables should be dis time. If the electrolyte temperature reaches 125°F before
connected and the terminals and clamps cleaned sepa the 1 1/2 hour period is completed, the Battery must be
rately with a soda solution and a wire brush. After taken off charge temporarily, or the charging rate re
cleaning and installing clamps, apply a thin coating of duced to avoid damage to the Battery.
petroleum jelly on the cable clamps to retard corrosion. Although a Battery cannot be brought to a fully charged
condition during Fast Charge, it can be substantially
CARRIER AND HOLD-DOWN recharged or "boosted". In order to bring the Battery to
The Battery carrier and hold-down should be clean and a fully charged condition, the charging cycle must be
free from corrosion before installing the Battery. The finished by the Slow Charge method.
carrier should be in a sound mechanical condition so that
it will support the Battery securely and keep it level. EMERGENCY BOOST CHARGING
To prevent the Battery from shaking in its carrier, the
In cases where the Battery is not sufficiently charged
hold-down bolts should be tight 60-80 in. lbs.. However,
to crank the engine, an emergency boost charge may be
the bolts should not be tightened to the point where the
applied as a temporary expedient in order to crank the
Battery case or cover will be placed under a severe
engine. The Emergency Boost Charge method consists of
strain.
charging at a 40 to 50 ampere rate for a period of one-
half hour.
BATTERY SAFETY PRECAUTIONS It should be particularly noted that the Emergency
When Batteries are being charged, an explosive gas Boost Charge will not necessarily restore the Battery to
mixture forms in each cell. Part of this gas escapes a useful state of charge for continued service. After an
through the holes in the vent plugs and may form an emergency boost charge, failure to charge the Battery
explosive atmosphere arOund the Battery itself if ventila further, either by a long uninterrupted driving period or
tion is poor. This explosive gas may remain in or around by the Fast Charge or Slow Charge method, may result
the Battery for several hours after it has been charged. in failure to crank the engine the next time cranking is
Sparks or flames can ignite this gas causing an internal attempted. A Battery should never be condemned on the
explosion which may shatter the Battery. basis of failure to crank the engine after an emergency
The following precautions should be observed to pre boost charge. Although an emergency boost charge may
vent an explosion: put enough energy into the Battery to crank the engine
once, further charging usually is necessary in order to Energizers discharged to this degree cannot be
create a sufficient reserve to crank a second and third accurately tested using equipment requiring load
time. capability comparison tests.
3. FULL CHARGE HYDROMETER TEST

12 VOLT BATTERY SUGGESTED This test should be used only on Batteries which test
CHARGING RATES good with testing equipment or "Specific Gravity Cell
Comparison Test" but which subsequently fail in service.
100 Amp-hr of Less Capacity * Remove the Battery from the vehicle, and adjust the
electrolyte level as necessary, by adding colorless,
TYPE OF LENGTH CHARGING odorless, drinking water.
CHARGE OF TIME RATE * Fully charge the Battery at the Slow Charging rate
as covered in the s e c t ion entitled "Battery
Boost Charge for Charging".
20 Minutes 50 Amps * Measure the specific gravity of the electrolyte in
Light Load Test
each cell and interpret as follows:
Slow Charge 24 Hours 4 Amps Hydrometer Reading Less Than 1.230-Full charge
Fast Charge 1-1/2 Hours 40-50 Amps hydrometer readings less than 1.230 corrected for
temperature indicate the Battery is defective and
Quick Boost 30 Minutes 40-50 Amps
should be replaced.
Dry Charge 10 Minutes 15 Amps Hydrometer Readings Above 1.310-Full charge
Warm-up Boost hydrometer readings above 1.310 corrected for tem
perature indicate that the cells have been improperly
filled activation or improperly serviced. Poor
BATTERY TESTING PROCEDURES service and short Battery life will result.
Testing procedures are used to determine whether the SPECIFIC GRAVITY READINGS
Battery is 1 good and usabLe, 2 requires recharging or A hydrometer can be used to measure the specific
3 should be replaced. Analysis of Battery conditions can gravity of the electrolyte in each cell.
be accomplished by performing a visual inspection,
The hydrometer measures the percentage of sulphuric
Instrument Test and the full charge hydrometer test.
acid in the battery electrolyte in terms of specific
gravity. As a battery drops from a charged to a dis
1. VISUAL INSPECTION charged condition, the acid leaves the solution and enters
The first step in testing the Battery should be a visual the plates, causing a decrease in specific gravity of
inspection, which very often will save time and expense electrolyte. An indication of the concentration of the
in determining Battery condition. electrolyte is obtained with a hydrometer.
* Check the outside of the Battery for a broken or When using a hydrometer, observe the following points:
cracked case or a broken or cracked cover. If any 1. Hydrometer must be clean, inside and out, to insure
damage is evident, the Battery should be replaced. an accurate reading.
* Note the electrolyte level. Levels that are too low or 2. Hydrometer readings must never be taken immedi
too high may cause poor performance, as covered in ately after water has been added. The water must be
the section entitled "Periodic Servicing". thoroughly mixed with the electrolyte by charging for
* Check for loose cable connections, and for evidence at least 15 minutes at a rate high enough to cause
of corrosion as covered in section entitled "Periodic vigorous gassing.
Servicing". Correct as required before proceeding 3. If hydrometer has built-in thermometer, draw liquid
with tests. into it several times to insure correct temperature
before taking reading.
2. INSTRUMENT TEST 4. Hold hydrometer vertically and draw in just enough
A number of suppliers have approved testing equipment liquid from battery cell so that float is free floating.
available. These testers have a programmed test proce Hold hydrometer at eye level so that float is vertical
dure consisting of a series of timed discharge and and free of outer tube, then take reading at surface of
charge events, requiring approximately 2 to 3 minutes, liquid. Disregard the curvature where the liquid
that will determine the condition of the Battery with a rises against float stem due to surface tension.
high degree of accuracy. When using these testers, the 5. Avoid dropping battery fluid on car or clothing as it
procedure recommended by the tester manufacturer is extremely corrosive. Any fluid that drops should
should be followed. Batteries should not be charged prior be washed off immediately with baking soda solution.
to testing as doing so may alter the test results. If a The specific gravity of the electrolyte varies not only
tester is not available for testing, the "Specific Gravity with the percentage of acid in the liquid but also with
Cell Comparison Test" may be used or an alternate temperature. As temperature increases, the electrolyte
method, but with a sacrifice in testing accuracy. expands so that the specific gravity is reduced. As
temperature drops, the electrolyte contracts so that the
NOTE: New energizers which have become specific gravity increases. Unless these variations in
completely discharged over a relatively long specific gravity are taken into account, the specific
period of time, such as during vehicle storage, gravity obtained by the hydrometer may not give a true
should be tested by the hydrometer method. indication of the concentration of acid in the electrolyte.
A fully charged Battery will have a specific gravity

reading of approximately 1.270 at an electrolyte temper
ature of 80°F. If the electrolyte temperature is above or
below 80°F, additions or subtractions must be made in
order to obtain a hydrometer reading corrected to the
80°F standard. For every 10° above 80°F, add four
specific gravity points .004 to the hydrometer reading.
Example: A hydrometer reading of 1.260 at 110°F would
be 1.272 corrected to 80°F, indicating a fully charged
Battery. For every 10° below 80°F, subtract four points
.004 from the reading. Example: A hydrometer reading
of 1.272 at 0°F would be 1.240 corrected to 80°F, indi
cating a partially charged Battery.
Specific Gravity Cell Comparison Test-This test may
be used when an instrumental tester is not available. To
perform this test measure the specific gravity of each
cell, regardless of state of charge, and interpret the
results as follows:
* If specific gravity readings show a difference be
tween the highest and lowest cell of .050 50 points
or more, the Battery is defective and should be
replaced.
Fig. 7b-Checking Specific Gravity
ICAUTIONI WHEN ASSEMBLING BATTERY

CABLE TERMINALS TO BATTERY, DO NOT
OPEN BEYOND POSITION SHOWN OR
PERMANENT SET AND LOOSE CONNECTION
WILL RESULT.
WITH TERMINAL FULLY OPEN,
PUSH ON TO BATTERY POST AS FAR AS
POSSIBLE, AT LEAST FLUSH WITH OR BELOW
TOP OF POST.
DO NOT DRIVE TERMINAL ONTO
POST WITH HAMMER OR ANY OTHER TOOL.
VIEW B
VIEW A
Fig. Bb-Battery Installation - Corvette
INSTALLING BATTERIES terminal clamps are clean and tight. Make sure the
To install a Battery properly, it is important to ob ground cable is clean and tight at engine block or
serve the following precautions: frame.
* Connect grounded terminal of Battery last to avoid * Check polarity to be sure the Battery is not reversed
with respect to the generating system.
short circuits which may damage the electrical
system.
* Be sure there are not foreign objects in the carrier, CAUTION: When assembling battery cable
so that the new Battery will rest properly in the terminals to battery, do not open beyond posi
bottom of the carrier. tion shown or permanent set and loose connec
* Tighten the hold-down evenly until snug 60-80 in. tion will result. With terminal fully open, push
lbs.. Do not draw down tight enough to distort or on to battery post as far as possible, at least
crack the case or cover. flush with or below top of post. Do not drive
* Be sure the cables are in good condition and the terminal onto post.
CHARGING SYSTEM
INDEX
Page Page
General Description 6Y-7 Field Circuit Resistance Wire Checks 6Y-14

Maintenance and Adjustments 6Y-1O Field Relay Checks and Adjustment 6Y-14
Static Checks 6Y-lO Other Harness Checks 6Y-15
System Condition Test 6Y-lO Service Operations 6Y-15
Adjusting Regulator Voltage 6Y-11 Generator GY-15
Delcotron Output Test 6Y-12 Removal and Installation 6Y-15
Delcotron Diode and Field Test 6Y-12 Pulley Replacement 6Y-15
Indicator Lamp-Initial Field Excitation Brush Replacement 6" Delcotron 6Y-15
Circuit Tests GY-13 Double Contact Regulator 6Y-16
GENERAL DESCRIPTION
The charging system includes the battery, generator, equipment, although there are various capacities avail
regulator, telltale light, and necessary wiring to connect able on all models.
these components. The Delcotron is offered as standard The Delcotron continuous output A.C. generator figs.
"BATT"
RELAY
TERMINAL "F" TERMINAL
"BAT" I
TERMINA
/ / GRD;’ TERMINAL
L LIGHT
RELAY
5.5" SERIES 1 D DELCOTRON 6.2" SE RIES 2D, TYPE 150 DELCOTRON
Fig. lc-Delcotron - Full View
____________
SLIP RING DRIVE END

END FRAME FRAME
BRUSH AND
TERMINAL DIODE BEARING
ASSEMBLY
SHIELD
SLIP RING BEARING
BEARING /
GREASE
RESERVOIR
BRUSH
DIODES ASSEMBLY
T STATOR
ASSEMBLY
5.5" SERIES 1 D DELCOTRON 6.2" SERIES 2D TYPE 150 DELCOTRON
Fig. 2c-Delcotron - Cross Section View
lc and 2c consists of two major parts, a stator and a Diodes are mounted in heat sinks to provide adequate
rotor. The stator is composed of a large number of heat dissipation. The six diodes replace the separately
windings assembled on the inside of a laminated core that mounted rectifier as used in other types of application.
is attached to the generator frame. The rotor revolves The diodes change the Delcotron A.C. current to D.C.
within the stator on bearings located in each end frame. current.
Two brushes are required to carry current through the Two regulators fig. 3c are available on the 1967 ve
two slip rings to the field coils wound concentric with the hicles, a double contact two unit type and a transistor
shaft of the rotor. Six rectifier diodes are mounted in the regulator. The function of these regulators in the charg
slip ring end frame and are joined to the stator windings ing system is to limit the generator voltage to a pre-set
at three internally located terminals. value by controlling the generator field current. Both
ACCESS PLUG TO
VOLTAGE ADJUSTMENT
"LATCH"
"F" TERMINAL
NO. 2 TERMINAL
NO. 3 TERMINAL
NO. 4 TERMINAL
Fig. 3c-Voltage Regulator Assemblies
EATTERY
DOUBLE CONTACT
Fig. 4c-Voltage Regulator Assemblies Exc. Corvette
regulators have an internal field relay unit. The relay voltage regulating unit in combination with a conventional
unit allows the telltale lamp to light as a bulb check vibrating type field relay.
with the ignition key on and engine not running. When the The transistor is an electrical device which limits the
engine is started and the generator begins to charge, the generator voltage to a preset value by controlling the
indicator light goes out indicating that the system is op generator field current. The diodes, capacitor and re
erating normally. sistors act together to aid the transistors in controlling
The double-contact regulator assembly fig. 2c con the generator voltage. This is the only function that the
sists of a double contact voltage regulator unit and a field regulator performs in the c ha r gin g circuit. The
relay unit. This unit uses two sets of contact points on thermistor provides a temperature-compensated voltage
the voltage regulator unit to obtain desired field excita setting. Wiring diagrams of the transistor regulator are
tion under variable conditions. Internal circuit wiring shown in Figures 4c and 5c.
diagrams of the double contact regulator are shown in The voltage at which the generator operates is deter-
Figures 4c and 5c. minted by the regulator adjustment. The regulator voltage
The transistor regulator fig. 3c is an assembly com setting can be adjusted externally by removing a pipe plug
posed principally of transistors, diodes, resistors, a in the cover fig. 3c and turning the adjusting arm inside
capacitor, and a thermistor to form a completely static the regulator. This procedure is explained in the follow-
Fig. 5c-Voltage Regulator Assemblies Corvette
ENGINE-ELECTRICAL 6Y-1 0
ing section, and permits regulator adjustments without 2. A 16 gauge black fusible link is located at the horn
removing the cover. relay to protect all unfused wiring of 12 gauge or
Engine compartment wiring harness incorporates sev larger. It is installed as a molded splice and serv
eral fusible links. Each link is identified with its gauge icing requires splicing in a new link.
size. A fusible link is a length of special wire normally
3. The generator warning light and field circuitry 16
four wire gauges smaller than the circuit it is protecting
gauge wire is protected by a fusible link 20 gauge
used In wiring circuits that are not normally fused, such
orange wire used in the "battery feed to voltage
as the ignition circuit. The same size wire with a hypalon
regulator #3 terminal" wire. The link is installed as
insulation must be used when replacing a fusible link.
a molded splice in the generator and forward lamp
The links are:
harness and is serviced by splicing in a new 20 gauge
1. The pigtail lead at the battery positive cable except
wire as required.
Corvette is a 14 gauge, brown fusible link protecting
the 10 gauge battery charging circuit. This wire is an 4. The ammeter circuit on all models is protected by
integral part of the battery cable assembly and serv two orange, 20 gauge wire fusible links installed as
icing requires replacing the complete battery cable molded splices in the circuit at the junction block or
assembly. On Corvette models this link is installed the solenoid "Bat" terminal Corvette only and at
as a molded splice at the solenoid "Bat" terminal the horn relay. Each link is serviced by splicing in a
and servicing requires splicing in a new link. new 20 gauge wire as required.

At regular intervals, inspect the terminals for cor STATIC CHECKS
rosion and loose connections, and the wiring for frayed
insulation. Check mounting bolts for tightness. Check the Before making any electrical checks, perform the
drive belt for alignment, proper tension and wear. Be following static checks:
cause of the higher inertia and load capacity of the rotor 1. Check for loose fan belt.
used in A.C. generators, PROPER BELT TENSION is 2. Check for defective battery. Refer to Battery.
more critical than on D.C. generators. 3. Inspect all connections, including the slip-on con-
Since the Delcotron and its companion regulator are nectors at the regulator and Delcotron.
designed for use on negative polarity systems only, the NOTE: Do not short field to ground to check if
following precautions must be observed. Failure to ob generator is charging since this will seriously
serve these precautions may result in serious damage to damage the charging system.
the charging system.
1. When installing a battery, always make absolutely
SYSTEM CONDITION TEST
sure the ground polarity of the battery, generator and
regulator is the same. This test is used to indicate the overall condition of the
2. When connecting a booster battery, make certain to charging system both good and defective and to isolate
connect the correct battery terminals together. the malfunctioning unit if the system is defective.
3. When connecting a charger to the battery, connect the
NOTE: On Corvette models difficulty may be
correct charger leads to the battery terminals.
4. Never operate the generator on an uncontrolled open encountered when attempting to make the re
circuit. Make absolutely certain all connections in quired test connections at the voltage regulator.
It is advisable to remove the regulator from its
the circuit are secure.
5. Do not short across or ground any of the terminals
on the generator or regulator.
6. Do not attempt to polarize the generator. TO SOLENOID
7. Do not disconnect lead at generator without first dis
connecting battery ground cable.
Trouble in the A.C. charging system will usually be
indicated by one or more of the following conditions:
1. Faulty indicator lamp or ammeter operation.
2. An undercharged battery usually evidenced by slow
cranking speeds.
3. An overcharged battery usually evidenced by exces
sive battery water usage.
4. Excessive generator noise or vibration.
Described below are a series of on-the-vehicle quick
checks which are designed to assist the service tech
nician in locating troubles within the various components
of the engine electrical system. Additional checks, ad
justments and overhaul procedures of these components
are also described in the "Charging Systems-Service
Operations Section" and should be r e f e r r e d to as
necessary. Fig. óc-Typical Wiring Diagram Showing
mounting location to perform the necessary con a few minutes generally, unless the battery Is
nections at the regulator for the following tests severely discharged or is hot.
but make sure unit is grounded.
If reading is:
1. With ignition off, perform the prescribed Static a. 12-1/2 volts or more, turn off electrical loads,
Checks outlined in this section. Then set hand brake stop engine and proceed to Step 7.
and shift transmission into neutral. b. Less than 12-1/2 volts, perform "Delcotron Out
2. Connect a voltmeter from junction block relay to put Test-Ammeter Method."
ground at regulator base. 1 Delcotron tests bad-refer to "Service Op
CAUTION: Be sure meter clip does not touch a erations" and repair Delcotron, then repeat
resistor or terminal extension under regulator. Step 6.
2 Delcotron tests good - disconnect regulator
3. Connect a tachometer on engine. connector, remove regulator cover and recon
4. Models equipped with indicator Lamp: Turn ignition nect the connector. Then repeat Step 6 and
switch on "ON" position and check indicator lamp. turn voltage adjusting screw fig. 7c to raise
If lamp fails to glow, perform appropriate tests and setting to 12-1/2 volts. On transistor regula
corrections Indicator Lamp Circuit Tests before tor remove pipe plug fig. 7c, insert screw
continuing. driver into slot and turn clockwise one or two
Models equipped with Ammeter: Turn ignition notches to increase setting. Turning counter-
switch to "ACC" with an accessory on and check clockwise decreases setting. For each notch
ammeter. If ammeter fails to read discharge, check moved, the voltage setting will change ap
ammeter circuit before continuing. proximately .3 volt. Turn off loads, stop en
5. Models equipped with Indicator Lamp: If lamp glows, gine and proceed to Step 7. If 12-1/2 volts
start the engine and run it at 1500 rpm or above. cannot be obtained, install a new regulator and
Check indicator lamp. If lamp fails to go out, per repeat Step 6.
form appropriate test and corrections Indicator
Lamp Circuit Test before continuing.
Models equipped with Ammeter: If ammeter reads ADJUSTING REGULATOR VOLTAGE
discharge, start the engine and observe ammeter.
7. Connect a 1/4 ohm-25 watt fixed resistor purchased
If meter fails to move toward charge from original
commercially into the charging circuit at the junc
position, perform appropriate test and corrections
Field Circuit Tests before continuing. tion block as shown in Figure 8c.
NOTE: Between both leads and the terminal.
NOTE: At this point a field circuit has been
established and any other problem will lie in 8. Run engine at 1500 rpm or above for at least 15
generator or regulator. minutes of warm-up, then cycle regulator voltage
control by disconnecting and re-connecting regulator
6. Turn on high-beam headlights and heater blower connector and read voltage.
motor to high speed, run engine at or above 1500 If voltage is 13.5 to 15.2, the regulator is okay.
rpm for a few minutes, if necessary and read the If voltage is not within 13.5 to 15.2 volts, leave en
voltage on meter. gine running at 1500 rpm or above and:
NOTE: Voltage will not greatly exceed 12-1/2 a. Disconnect four terminal connector and remove
volts until the battery develops a surface charge, regulator cover. Then re-connect four terminal
AIR GAP
ADJUSTING NUT
ONLY
ADJUSTING SCREW
Turn To Adjust
Voltage Setting
Fig. 7c-Adusting Voltage Setting
Fig. 8c-Voltage Setting Test Connections
connector and adjust voltage to 14.2 to 14.6. 11. If the Delcotron meets the test specifications, the
Refer to Step 6 and fig 7c. problem is not in the generator.
b. Disconnect four terminal connector and reinstall 12. If the Delcotron fails to meet the test specifications,
regulator cover, then reinstall connector. remove it and perform bench tests and make repair
c. Continue running engine at 1500 rpm for 5-10 needed.
minutes to re-establish regulator internal
temperature. DELCOTRON DIODE AND FIELD TEST Fig. lOc
d. Cycle regulator voltage by disconnecting and re
connecting regulator connector. Read voltage. A NOTE: These tests will indicate good, shorted
reading between 13.5 and 15.2 indicates a good or open field or shorted diode but will not indi
cate a failed open diode. If output was low and
regulator.
following tests show good, refer to service op
CAUTION: Be sure four terminal regulator erations to determine cause and repair.
connector is disconnected when removing or in
stalling cover. This is to prevent regulator 1. Disconnect battery ground cable at battery.
2. Positive diodes Test A connect an ohmmeter be
damage by short circuits.
tween "R" terminal and "BAT" terminal and note
reading, then reverse the leads at same terminals
DELCOTRON OUTPUT TEST
Ammeter Method Fig. 9c

1. Disconnect the battery ground cable at the battery.
2. Disconnect the red wire at Delcotron battery termi
nal and connect an ammeter in series between the
wire and terminal.
3. Connect a voltmeter from battery terminal to a good
ground on the generator.
4. Disconnect the F-R terminal connector at the
Delcotron.
5. Connect the jumper wire between Delcotron "F" and
battery terminals.
6. Connect the battery ground cables at the battery.
7. Connect an adjustable carbon pile across the battery
posts.
8. Start the engine and slowly bring the speed to 1500
RPM and at the same time adjust the carbon pile
load to hold the voltage at 14 volts.
9. Read the amperage and compare with a specifications
chart.
10. Turn off ignition, disconnect battery ground cable,
and remove all test equipment. Fig. 9c-Ammeter Method Test Connections
b. If meter reads zero or excessively high resist

ance, the Delcotron is faulty.
5. If above tests indicate a defective Delcotron, remove
and completely check Delcotron as outlined under
"Service Operations".
INDICATOR LAMP/INITIAL FIELD

EXCITATION CIRCUIT TESTS Fig. 1 ic
On standard models the indicator lamp circuit provides
initial field excitation causing lamp to glow. The light
is cancelled by closing the field relay which applies bat
tery voltage to both sides of bulb bulb goes out.
The indicator light should glow when ignition switch is
"ON" and go out almost immediately when engine starts.
Ammeter equipped vehicles use the same initial field
excitation and control circuits as the indicator lamp ex
cept the lamp is omitted. The continuity tests on both
type vehicles can be made as follows:
If Lamp Fails to Glow or Ammeter Fails to
Function the Possible Causes are:
Fig. 1OC-DelCotron Diode and Field Test 1. Faulty bulb or bulb socket.
2. Faulty ammeter.
and note this reading. Meter should read high re 3. An open circuit in wiring, regulator, or field.
sistance in one direction and low in the other. 4. A shorted positive diode-may also cause glow with
3. Negative diodes Test B connect ohmmeter between ignition switch "OFF".
"R" terminal and "GRD" and note reading, then
reverse the leads and note this reading. Meter TEST AS FOLLOWS:
should read high in one direction and low in the 1. Disconnect connector from regulator and turn ig
other. nition switch to "ON". Connect a test lamp from
connector terminal "4" to ground fig. lic Step 1
NOTE: A high or low reading in both directions and note test lamp.
indicates a defective diode.
a. Lamp fails to glow-check for faulty bulb, socket
4. Open Field Check: or open circuit between switch and regulator con
a. Connect an ohmmeter from "F" terminal to nector. Repair as needed.
"GRD" terminal stud and note reading on the b. Light goes on-failure is in regulator, Delcotron,
lowest range scale. Meter should read 7 to or wire between "F" terminals on regulator and
20 ohms. Delcotron. Go to Step 2.
STEP STEP STEP

II III
Fig. lic-Initial Field Excitation Circuit Tests
REGULATOR
VARIABLE
RESISTOR
VOLTMETER
VO LTM ETE
Fig. 13c-Held Relay Closing Voltage Test

WIRING HARNESS
CONNECTOR
FIELD CIRCUIT RESISTANCE
Fig. ]2c-Testing Field Relay WIRE CHECKS
The resistance wire is an integral part of the ignition
2. Disconnect lamp lead at ground end and connect be harness. However, the resistance wire is not solderable;
tween connector "F" and "4" terminals fig lic, it must be spliced with a crimp-type connector. It is
Step 2, and note lamp: rated at 10 ohms, 6.25 watts minimum.
a. Test Lamp glows-problem is in regulator. An The check for an open resistor or field excitation wire
open circuit in regulator or relay is stuck closed. connected to the ignition switch "ACC" terminal is as
See "Service Operations" for repair. follows:
b. Fails to glow-problem is in wire between "F" 1. Connect a test lamp from the wiring harness con
terminals on generator and regulator or in field nector terminal "4" to ground as shown in Figure
windings. Go to Step 3. lie Step 1.
3. Disconnect test lamp at connector "F" terminal and 2. Turn the ignition switch to the "ON" position and
connect to "F" terminal on Delcontron fig. lie, note test bulb.
Step 3, and note lamp: a. Test lamp glows-resistance is O.K.
a. Lamp glows-an open circuit in wire between "F" b. Test lamp does not glow-the resistor is open
terminals-correct as needed. circuited-note also that dash lamp does not glow
b. Fails to glow-Delcotron field has open circuit, during this test because series resistance of the
see "Service Operations" to repair. 2 bulbs causes amperage to be too low.
If Lamp Fails to Go Out, or if Ammeter Shows FIELD RELAY CHECKS AND ADJUSTMENT
Discharge the Possible Causes are: To check for a faulty relay proceed as follows:
1. Loose drive belt-adjust as necessary. 1. Connect a voltmeter into the system at the regulator
2. Faulty field relay-see relay test and adjustment. No. 2 terminal to ground fig. 12c.
3. Defective Delcotron-see Delcotron output test. 2. Operate the engine at fast idle 1500 to 2000 rpm and
4. At normal idle-parallel resistance wire open see observe voltmeter reading.
Resistance test. On ammeter models the initial 3. If voltmeter shows zero voltage at regulator, check
field excitation wire to "ACC" terminal is open. circuit between No. 2 terminal on regulator to "R"
5. Switch off-positive diode shorted see Diode test. terminal on Delcotron.
4. If voltage at regulator exceeds closing voltage spec

ification and light remains on, regulator field relay
is faulty Refer to specifications. Check and adjust
regulator as follows:
CLOSING VOLTAGE ADJUSTMENT

1. Make connections as shown in Figure 13c using a 50
ohm variable resistor.
NOTE: This gives us a variable resistance in
series from a hot lead to the relay coil.
2. Turn resistor to "open" position.
3. Turn ignition switch off.
4. Slowly decrease resistance and note closing voltage
of the relay. Adjust by bending heel iron in the man
ner illustrated in Figure 14c.
OTHER HARNESS CHECKS

Other wires in the charging system harness need be
checked for continuity by use of an ohmmeter or a test
light 12 Volt. Connect the test so the wire in question is Fig. 14c-AdUSting Field Relay Closing Voltage
in series in the test circuit.
SERVICE OPERATIONS
Service Procedures described in this section are for Pulley Replacement
the 5.5" aluminum and 6.2" :perforated stator Delcotrons.
Where important differences are encountered separate 5.5" Delcotron
mention is made of the two generators. Single Groove Pulley
1. Place 15/16" box wrench on retaining nut and insert
GENERATOR a 5/16" allen wrench into shaft to hold shaft while
removing nut fig. l5c.
Removal and Installation 2. Remove washer and slide pulley, fan and spacer
1. Disconnect the battery ground strap at battery to from shaft.
prevent damaging diodes. 3. Reverse Steps 1 and 2 to install, use a torque wrench
2. Disconnect wiring leads at Delcotron. with a crow-foot adapter instead of box wrench and
3. Remove generator brace bolt, if power steering torque the nut to 50 ft. lbs. fig. 16c.
equipped, loosen pump brace and mount nuts then
detach drive belt belts. Double Groove Pulley
4. Support the generator and remove generator mount 1. Place a 15/16" socket with wrench flats on the drive
bolt 6.2" Delcotron uses 2 mount bolts and remove end or use Adapter J-2l50l and a box wrench on re
from vehicle. taining nut, insert a 5/16" allen wrench through
5. Reverse the removal procedure to install then adjust socket and adapter into hex on shaft to hold the shaft
drive belt. while removing the nut.
2. Remove washer and slide pulley, fan and spacer
from shaft.
3. To install, slide spacer, fan, pulley and washer on
shaft and start the nut.
4. Use the socket and adapter with a torque wrench and
tighten nut to 50 ft. lbs. torque.
Brush Replacement
6.2" Delcotron
1. Remove two nuts retaining the blade connectors
and remove the connectors fig. 17c. Slide the in
dicator light relay wire from the terminal post.
2. Remove two screws retaining the capacitor and
brush holder to rear end frame. Remove brush
holder.
NOTE: Capacitor lead is connected inside the
generator. Allow capacitor to remain with the
Fig. 15c-Pulley Removal generator to avoid undue strain on the lead wire.
3. Inspect brushes for wear. If they are worn halfway,

replace. Inspect brush springs for distortion or
weakening. If brushes appear satisfactory and move
freely in brush holder, springs may be reused.
4. To install brushes, push brushes into holder and
install pin to keep the brushes in holder.
5. Attach brush assembly and condenser to the end
frame with hex-head stud on the left side only.
6. Rearrange leads as shown in Figure 18c with right-
hand brush lead connected under the right hand
hex-head stud.
7. Attach terminal cover with two screws, making sure
leads are not caught underneath the cover.
DOUBLE CONTACT REGULATOR

While most regular adjustments are made on the vehi
cle as outlined under "Maintenance and Adjustments",
the regulator may be removed for field relay point and
air gap adjustment. However, voltage regulating contacts
should never be cleaned as they are made of special
material that may be destroyed by cleaning with any
abrasive material. LEAD
I
NOTE: A sooty or discolored condition of the BRUSH HOLDER GROUND CONDENSER
contacts is normal after a relatively short MOUNTING SCREW STUD LEAD 1-2958
period of operation.
Fig. 17c-Delcotron Brush Holder Assembly
To remove the regulator assembly, disconnect the bat
tery ground cable and the wiring harness connector at the Mechanical Adjustments
regulator, then remove the screws securing the regulator
NOTE: Only an approximate voltage regulator
to the vehicle.
air gap setting should be made by the "feeler
Electrical settings must be checked and adjusted after gauge" method.
making mechanical adjustments. Before installing regu
lator cover, make sure the rubber gasket is in place on
the regulator base. Field Relay Adjustment
1. Point Opening: The point opening is checked as il
lustrated in Figure 19c. If adjustment is necessary,
carefully bend the armature stop.
2. Air Gap: Check the air gap with the points just
touching fig. 20c. The air gap normally need not be
adjusted. If the point opening and closing voltages
Fig. lóc-TorqUing Pulley NUt Fig. 18c-Lead Arrangement After Assembly
POINT OPENINGJ
Fig. 20c-Checking Field Relay Air Gap
are within specifications, the relay will operate

satisfactorily even though the air gap may not be
Fig. 19c-Checking Field Relay Point Opening
exactly according to specifications. If adjustment is
necessary, bend the flat contact spring.
IGNITION SYSTEMS
INDEX
Page Page
General Description 6Y-17 Disassembly 6Y-22

Maintenance and Adjustments 6Y-18 Cleaning and Inspection 6Y-23
Breaker Point System 6Y-18 Assembly 6Y-24
Breakerless System 6Y-18 Installation 6Y-25
Ignition Coil Check 6Y-19 Breakerless 6Y-26
Spark Plugs 6Y-19 Removal 6Y26
Service Operations 6Y-19 Disassembly 6Y-26
Distributor Contact Points 6Y-19 installation 6Y-27
Cleaning 6Y19 Off-Engine Test 6Y-27
Replacement 6Y-19 Coil Replacement 6Y27
Setting Dwell Angle 6Y-20 Pulse Amplifier 6Y27
Distributor Condenser 6Y-22 Disassembly 6Y-27
Performance Diagnosis 6Y-22 Component Checks 6Y-27
Replacement 6Y-22 Assembly 6Y-29
Distributor Spark Plugs 6Y29
Breaker Point Type 6Y-22 Cleaning and Regapping 6Y-29
Removal 6Y-22 Installation 6Y29
GENERAL DESCRIPTION
There are two ignition systems available on 1968 tributor and control unit ignition pulse amplifier are
vehicles. The breaker point type which is continued as shown in Figure 11 and 2i.
the regular production system and the optional Corvette Although the external appearance of the distributor
only transistor controlled breakerless ignition system resemb’s a standard distributor, the internal construc
magnetic pulse type. The transistor ignition system tion is quite different. As shown in the exploded view
features a specially designed distributor, control unit fig. l6i an iron timer core replaces the conventional
ignition pulse amplifier, and a special coil. Two resist breaker cam. The timer core has the same number of
ance wires are also used in the circuit; one as a ballast equally-spaced projections, or vanes as engine cylinders.
between the coil negative terminal and ground, while the The timer core rotates inside a magnetic pickup as
other resistance wire provides a voltage drop for the sembly, which replaces the conventional breaker plate,
engine run circuit and is by-passed at cranking. The contact point set, and condenser assembly. The magnetic
other units in the system the ignition switch, spark pickup assembly consists of a ceramic permanent mag
plugs, and battery are of standard design. The dis net, a pole piece, and a pickup coil. The pole piece is a
ENGINE-ELECTRICAL 6Y- 8
Fig. 2i-Ignition Pulse Amplifier Unit
The magnetic pickup assembly is mounted over the

main bearing of the distributor housing, and is made to
rotate by the vacuum control unit, thus providing vacuum
Fig. li-Magnetic Pulse Distributor advance. The timer core is made to rotate about the shaft
steel plate having equally spaced internal teeth, one tooth by conventional advance weights, thus providing centrifu
for each cylinder of the engine. gal advance.

PERIODIC MAINTENANCE cavity next to the upper bushing contains a supply of
lubricant which will last between overhaul periods. At
BREAKER POINT SYSTEM time of overhaul, the upper bushing may be lubricated
by removing the plastic seal and then adding SAE 20 oil
The distributor breaker points and spark plugs are the to the packing in the cavity. A new plastic seal will be
only ignition system components that require periodic required since the old one will be damaged during
service. The remainder of the ignition system requires
removal.
only periodic inspection to check operation of the units, Tachometer readings for test purposes can be made on
tightness of the electrical connections, and condition of the primary circuit of the breakerless ignition system in
the wiring. When checking the coil, test with a reputable
tester.
Breaker type distributors are equipped with cam lubri
cator and should have the wick replaced at the same time
contact point set is replaced. It is not necessary to
lubricate the breaker cam when using a cam lubricator.
Do not attempt to lubricate the wick - Replace when
necessary. When installing a new wick, adjust its posi
tion so the end of the wick just touches the lobe of the
breaker cam.
Distributor shaft lubrication is accomplished by a
reservoir of lube around the mainshaft in the distributor
body.
BREAKERLESS SYSTEM
Since there are no moving parts in the ignition pulse
amplifier unit mounted forward of the radiator bulkhead,
and the distributor shaft and bushings have permanent
type lubrication, no periodic maintenance is therefore
required for the breakerless ignition system. The dis
tributor lower bushing is lubricated by engine oil through
a splash hole in the distributor housing, and a housing Fig. 3i-Breakerless Ighition System
the same manner as on the conventional ignition system, to either primary terminal. To obtain a reliable reading,
however before attempting to connect a test tachometer a scale on the ohmmeter having the 20,000 ohm value
into the primary circuit check with your instrument within, or nearly within, the middle third of the scale
supplier to insure that satisfactory readings can be should be used. Secondary resistance at 75°F. should be
obtained and the breakerless system will not be damaged between 8,000 and 12,500 ohms. If the reading is infinite,
by the tachometer that is to be used. the coil secondary winding is open.
A number of different types of coil testers are avail
able from various test equipment manufacturers. When
IGNITION COIL CHECK BREAKERLESS using these testers, follow the procedure recommended
The ignition coil primary can be checked for an open by the tester manufacturer.
condition by connecting an ohmmeter across the two
NOTE: Make sure the tester will properly
primary terminals with the battery disconnected. Pri
check this special coil.
mary resistance at 75°F. should be between .35 and .55
ohm. An infinite reading indicates the primary is open.
SPARK PLUGS
For the engine to run but miss at times, the primary
open may be of the intermittent type. Should be removed, inspected cleaned and regapped at
The coil secondary can be checked for an open by con tune-up. Defective plugs should be replaced, see Servic
necting an ohmmeter from the high tension center tower ing of Units Off the Vehicle.
SERVICE OPERATIONS
DISTRIBUTOR CONTACT POINTS 7. Connect primary and condenser lead wires to quick
disconnect terminal on contact point set.
CLEANING 8. Check and adjust points for proper alignment and
breaker arm spring tension fig. 5i. Use an aligning
Dirty contact points should be dressed with a few tool to bend stationary contact support if points need
strokes of a clean, fine-cut contact file. The file should alignment.
not be used for other metals and should not be allowed to
become greasy or dirty. Never use emery cloth to clean NOTE: The contact point pressure must fall
contact points. Contact surfaces, after considerable use, within specified limits. Weak tension will cause
may not appear bright and smooth, but this is not neces chatter resulting in arcing and burning of the
sarily an indication that they are not functioning satis points and an ignition miss at high speed, while
factorily. Do not attempt to remove all roughness nor excessive tension will cause undue wear of the
dress the point surfaces down smooth; merely remove 1
scale or dirt.
Badly burned or pitted contact points should be re
placed and the cause of trouble determined so it can be
eliminated. High resistance or loose connections in the
condenser circuit, oil or foreign materials on the contact
surfaces, improper point adjustment or high voltages may LUBRICATOR
cause oxidized contact points. Check for these conditions CONTACT SET
where burned contacts are experienced. An out-of- ATtACHING
balance condition in the ignition system, often the result SCREW
of too much or too little condenser capacity, is indicated
where point pitting is encountered.
REPLACEMENT
Four and Six Cylinder Engine Distributor
1. Release distributor cap hold-down screws, remove
cap and place it out of work area.
2. Remove rotor.
3. Pull primary and condenser lead wires from contact
point quick disconnect terminal fig. 4i. QUICK
4. Remove contact set attaching screw, lift contact point DISCONNECT
set from breaker plate. TERMINAL
5. Clean breaker plate of oil smudge and dirt.
6. Place new contact point assembly in position on
breaker plate, install attaching screw.
CAUTION: Carefully wipe protective film from
BREAKER PLATE
point set prior to installation.
ATtACHING SCREWS
NOTE: Pilot on contact set must engage match
ing hole in breaker plate. Fig. 4i-Breaker Plate and Attaching Parts
Fig. 5i-Checking Breaker Arm Spring Tension
contact points, cam and rubbing block. Breaker

arm spring tension should be 19-23 ounces. The
Fig. ói-Distributor Lead Arrangements
contact poing pressure should be checked with a
spring gauge. The scale should be hooked to the too hard against cam surface. A correctly ad
breaker lever and the pull exerted at 90 degrees justed cam lubricator wick will provide adequate
to the breaker lever as shown in Figure Si. The lubrication for cam. Do not apply additional
reading should be taken just as the points sepa grease to cam surface.
rate. The pressure can be adjusted by bending 7. Start engine and check point dwell and ignition
the breaker lever spring. If the pressure is ex timing.
cessive, it can be decreased by pinching the
spring carefully. To increase pressure, the Setting Dwell Angle
lever must be removed from the distributor so Four and Six Cylinder Engine Distributors
the spring can be bent away from the lever. The point opening of new points can be checked with a
Avoid excessive spring distortion. feeler gauge, but the use of a feeler gauge on rough or
9. Set point opening .019" for new points.
10. Reinstall rotor, position and lock distributor cap to
housing. /.ROTOR
11. Start engine and test dwell and ignition timing.
Eight Cylinder Engine Distributor
1. The contact point set is replaced as one complete
assembly and only dwell angle requires adjustment
after replacement. Breaker lever spring tension and LOCATOR
point alignment are factory set.
2. Remove the distributor cap by placing a screw driver
/ SQUARE
in the slot head of the latch, press down and turn 1/4
turn in either direction.
3. Remove the two attaching screws which hold the base
CENTRIFUGAL
ADVANCE
/ BRKATOR
of the contact set assembly in place. MECHANISM

4. Remove the primary and condenser leads from their
nylon insulated connection fig. 6i in contact set.
5. Reverse Steps 2, 3 and 4 to install new contact set. CAM
LUBRICATOR
CAUTION: Install the primary and condenser REPLACEMENT
leads as shown in Figure 6i. Improper installa
tion will cause lead interference between the
CAUTION!
cap, weight base and breaker advance plate. NEVER OIL
CAM LUBRICATOR-
6. If car has 20,000 to 25,000 miles or sooner if REPLACE WICK
desired the cam lubricator wick fig. 7i should be WHEN NECESSARY
changed. Using long nosed pliers squeeze assembly
together at base and lift out. Remove all old lubri ADJUST SQUARELY
cant from cam surface. Replace in same manner. AND JUST
TOUCHING LOBE
NOTE: End of cam lubricant wick should be
OF CAM
adjusted to just touch cam lobes. Over lubrica
tion of cam resulting in grease on contact points
can be caused by cam lubrication wick bearing Fig. 7i-Top View of Distributor
-+- ACTUAL POINT OPENING .021

I I t
/ 4 .016 FEELER GAUGE
Fig. lOi-Setting Point Opening
Fig. 8i-Inaccurate Gauging of Rough Points 2. Turn or crank the distributor shaft until the breaker
arm rubbing block is on the high point of the cam
uncleaned used points is not recommended since accurate lobe. This will provide maximum point opening.
mechanical gauging cannot be done on such points fig. 8i. 3. Loosen the contact support lock screw.
Contact points must be set to the proper opening. 4. Use a screw driver fig. iOi to move the point sup
Points set too close may tend to burn and pit rapidly. port to obtain .019" opening for new points and a
Points with excessive separation tend to cause a weak
.016" opening for used points.
spark at high speed. Proper point setting for all models
5. Tighten the contact support lock screw and recheck
are: the point opening.
.019" for new points 6. After checking and adjusting the contact point open
.016" for used points ing to specifications, the cam angle or dwell should
be checked with a dwell angle meter if such equip
New points must be set to the larger opening as the
ment is available see Specifications for proper dwell
rubbing block will wear down slightly while seating to the
angle. If the cam angle is less than the specified
cam. Contact points should be cleaned before adjusting if
minimum, check for defective or misaligned contact
they have been in service.
points or worn distributor cam lobes. The variation
To adjust contact point opening:
in cam angle readings between idle speed and 1750
1. If necessary, align points fig. 9i by bending the engine rpm should not exceed 3°. Excessive varia
fixed contact support. Do not bend the breaker lever. tion in this speed range indicates wear in the
Do not attempt to align used points; replace them distributor.
where serious misalignment is observed. Use an
aligning tool if available. NOTE: Cam angle readings taken at speeds
above 1750 engine rpm may prove unreliable
LATERAL PROPER on some cam angle meters.
MISALIGNMENT LATERAL ALIGNMENT
On the Vehicle
With the engine running at idle and operating tempera
tures normalized, the dwell is adjusted by first raising
the window provided in the cap and inserting a "Hex"
type wrench into the adjusting screw head fig. lii.
1. Preferred Method - Turn the adjusting screw until
the specified dwell angle is obtained as measured in
RORRECT LATERAL MISALIGNMENT BY degrees 28° to 32°, 30° preferred by a dwell angle
H BENDING FIXED CONTACT SUPPORT meter.
LNEVER 8END BREAKER LEVER 2. Alternate Method - Turn adjusting screw in clock
wise until the engine begins to misfire, then turn
screw 1/2 turn in the opposite direction counter
Fig. 9i-Alignment of Points clockwise. This will give the approximate dwell
test equipment. Condenser capacity should be 18-:23

microfarads.
Replacement
Four and Six Cylinder Engine Distributor Fig. 4i
1. Release distributor cap hold-down screws, remove
cap and place it out of the work area.
2. Remove rotor.
3. Disconnect condenser lead wire from contact point
quick-disconnect terminal.
4. Remove condenser attaching screw, lift condenser
from breaker plate and wipe breaker plate clean.
5. Install new condenser using reverse of procedure
outlined above.
1. Remove distributor cap.
2. Loosen condenser lead attaching screw fig. 6i and
lift out condenser lead clip.
Fg. 111-Adjusting Dwell Angle 3. Remove screw holding condenser bracket to breaker
plate and slide condenser from bracket.
angle required. Use only when meter is not 4. To replace condenser reverse the above procedure.
available.
NOTE: Make sure that new condenser lead is
Off the Vehicle installed in proper position fig. 6i.
1. Distributor Test Method:
a. With the distributor mounted on a distributor DISTRIBUTOR BREAKER POINT TYPE
testing machine, connect the dwell meter to the
Removal
distributor primary lead.
b. Turn the adjusting screw fig. lii to set the dwell 1. On radio equipped Corvettes, remove ignition shield
angle to 30 degrees. from over distributor and coil. One bolt is acces
2. Test Light Method: sible from top of shield, the other two are at rear of
a. With the distributor mounted in a vise, connect a shield, facing firewall.
testing lamp to the primary lead. 2. Release the distributor cap hold-down screws, re
b. Rotate the shaft until one of the circuit breaker move the cap and place it clear of the work area.
cam lobes is under the center of the rubbing block
NOTE: If necessary, remove secondary leads
of the breaker lever.
from the distributor cap after first marking the
c. Turn the adjusting screw clockwise fig. lii until
cap tower for the lead to No. 1 cylinder. This
the lamp lights, then give the wrench 1/2 turn in
will aid in the reinstallation of leads in the cap.
the opposite direction counter-clockwise to on
tam the proper dwell angle. 3. Disconnect the distributor primary lead from the coil
terminal.
DISTRIBUTOR CONDENSER 4. Scribe a realignment mark on the distributor bowl
and engine in line with the rotor segment.
Performance Diagnosis 5. Disconnect vacuum line to distributor and tachometer
The following four factors affect condenser perform drive cable Corvette. Remove the distributor hold-
ance and, each factor must be considered in making any down bolt and clamp and remove the distributor from
condenser test. the engine. Note position of vacuum advance mecha
1. Breakdown - A failure of the insulating material. A nism relative to the engine.
direct short between the metallic elements of the CAUTION: Avoid rotating the engine with the
condenser. This prevents any condenser action. distributor removed as the ignition timing will
2. Low Insulating Resistance Leakage - Low insula be upset.
tion resistance prevents the condenser from holding
a charge. All condensers are subject to leakage Disassembly
which, up to a certain limit, is not objectionable. It is advisable to place the distributor in a distributor
3. High Series Resistance - Excessive resistance in
testing machine or synchroscope prior to disassembly
the condenser circuit due to broken strands in the When mounting distributors for tests, first secure the
condenser leak or to a defective connection. This gear in the test drive mechanism, then push the distribu
will cause burned points and ignition failure upon tor housing downward toward the gear to take up any end
initial starts and at high speeds. play between the gear and the housing.
4. Capacity - Capacity is determined by the area of
the metallic elements and the insulating and im NOTE: When testing distributors that have
pregnating materials. their lower shaft support bushing located in the
For a complete check of the condenser, use a tester engine block 6 cylinder engines, a special
which will check for all of the above conditions. Follow adapter should be used to insure the shaft will
the instructions given by the manufacturer of the run true in its housing.
cHEVROLET CHASSI5 SERVICE MANUAL
Test the distributor for variation of spark, correct

centrifugal and vacuum advance and condition of contacts.
This test will give valuable information on distributor
condition and indicate parts replacement which may be
necessary. Check the area on the breaker plate just
beneath the contact points. A smudgy line indicates that
oil or crankcase vapors have been present between the
points.
Four and Six Cylinder Engines
Refer to Figure 12i.
1. Remove the rotor. O
2. Remove the vacuum control assembly retaining
screws, detach the unit from the distributor housing.
3. Disconnect the primary and condenser leads from the
contact point quick disconnect terminal, remove the
contact point set attaching screw, condenser attach
ing screw. Remove the point set and condenser from
11
the breaker plate.
4. Remove the breaker plate attaching screws, remove
the breaker plate from the distributor housing fig.
12i.
13
NOTE: Do not disassemble breaker plate any
further.
4
5. Remove the roll pin retaining the driven gear to the
mainshaft, slide the gear from the shaft.
6. Slide the cam and mainshaft from the distributor
housing.
7. Remove the weight cover and stop plate screws, re
move the cover, weight springs, weights and slide
cam assembly from the mainshaft.
V-8 Engines
Refer to Figure 13i.
1. Remove the rotor. 7
2. Remove both weight springs and advance weights.
3. Remove roll pin retaining driven gear to distributor
shaft, slide the gear and spacers from the shaft.
Remove tachometer dr:ive gear on Corvette models.
4. Before sliding the distributor shaft from the hous
ing, check for and remove any burrs on the shaft.
This will prevent damage to the seals and bushing
still positioned in the housing.
5. Slide the distributor mainshaft and cam-weight base
assembly from the housing.
6. Remove vacuum advance mechanism retaining
screws, remove the vacuum advance assembly.
7. Remove the spring retainer, remove the breaker
plate assembly from the distributor housing. Re
move the contact point and condenser from the Fig. 12i-L-6 Distributor-Exploded View
breaker plate. Remove the felt washer and plastic
seal located beneath the breaker plate. 1. Breake Plate Attaching 10. Contact Point
Screws Attaching Screw
Cleaning and Inspection 2. Condenser Attaching 11. Contact Point Assembly
Screws 12. Weight Cover
1. Wash all parts in cleaning solvent except cap, rotor, 3. Condenser Attaching Screws
condenser, breaker plate assembly and vacuum con 4. Breaker Plate Assembly 13. Weight Cover
4a. Cam Lubricator 14. Weight Springs
trol unit. Degreasing compounds may damage insula 5. Vacuum Control Assembly 15. Advance Weights
tion of these parts or saturate the lubricating felt in 6. Vacuum Control 16. Cam Assembly
the case of the breaker plate assembly. Attaching Screws 17. Main Shaft Assembly
2. Inspect the breaker plate assembly for damage or 7. Housing 18. Roll Pin
wear and replace if necessary. 8. Cap 19. Drive Gear
9. Rotor
3. Inspect the shaft for wear and check its fit in the
bushings in the distributor body. If the shaft or bush- alignment with a dial gauge. The run-out should not
ings are worn, the parts should be replaced. exceed .002".
4. Mount the shaft in "V" blocks and check the shaft 5. Inspect the advance weights for wear or burrs and
10
5
3
14
Fig. 13i-V-8 Distributor Typical - Exploded View
1. Condenser 5. Felt Washer 8. Shim Washer 13. Weight Springs

2. Contact Point Assembly 5a. Plastic Seal 9. Drive Gear Pin 14. MainShaft
2a. Cam Lubricator 6. Vacuum Advance 10. Drive Gear 15. Advance Weights
3. Retaining Ring Unit 11. Cap 16. Cam Weight
4. Breaker Plate 7. Housing 12. Rotor Base Assembly
free fit on their pivot pins. 2. Install governor weights on their pivot pins, replace
6. Inspect the cam for wear or roughness. Then check weight springs. Install weight cover and stop plate
its fit on the end of the shaft. It should be absolutely 3. Lubricate mainshaft and install it in distributor
free without any roughness. housing.
7. Inspect the condition of the distributor points. Dirty 4. Install distributor driven gear to mainshaft and in
points should be cleaned and badly pitted points sert attaching roll pin. Check to see that shaft turns
should be replaced. See Distributor Contact Points. freely.
8. Test the condenser for series resistance, micro- 5. Install breaker plate assembly in the distributor body
farad capacity .18 to .23 and leakage or breakdown, and attach retaining screws.
following the instructions given by the manufacturer 6. Attach condenser and contact point set in proper lo
of the test equipment used. cation with appropriate attaching screws.
9. Inspect the distributor cap and spark plug wires for
damage and replace if necessary. NOTE: Contact point set pilot must engage
matching hole in breaker plate. Connect primary
Assembly and condenser leads to contact set quick-
disconnect terminal.
Four and Six Cylinder Engine
Refer to Figure 12i for Exploded View of Distributor. 7. Attach vacuum control assembly to distributor
1. Replace cam assembly to mainshaft. housing.
8. Check and adjust contact point opening and align
NOTE: Lubricate top end of shaft with Delco ment See setting and alignment of points.
cam and ball bearing grease or equivalent prior 9. Check breaker lever spring tension which should
to replacing. be 19-23 ounces. See contact point replacement.
V-S Assembly-Fig. 13i NOTE: It is important that the spark plug wires
1. Fill housing lubricating cavity with proper compound, be installed in their proper location in the
press in new plastic seal and install felt washer. supports.
2. Replace the vacuum advance unit, install the breaker
plate in housing and install the spring retainer on 4. Time ignition as previously described under Tune
the upper bushing. Up in Section 6.
3. Lubricate and slide weight cam over mainshaft and
install weights and spring fig. 14i. Installation-Engine Disturbed All Models
4. Insert mainshalt into housing, indexing it with drive
gear and washers. Install tachometer drive gear on 1. Locate No. 1 piston in firing position by either of two
Corvette models. methods described below.
5. Slide distributor drive gear shims and gear over a. Remove No. I spark plug and, with finger on plug
shaft and install new pin. Tap new pin through gear hole, crank engine until compression is felt in the
and mainshaft. Check shaft for free rotation. No. 1 cylinder. Continue cranking until timing
mark on crankshaft pulley lines up with timing
NOTE: Mainshaft end clearance should be tab attached to engine front cover.
.002"- .007". Add or remove shims as necessary. b. Remove rocker cover left bank on V-8 engines
6. Install contact point set and condenser to breaker and crank engine until No. 1 intake valve closes
plate. Connect leads as shown in Figure 6i. and continue to crank slowly about 1/3 turn until
timing mark on pulley lines up with timing tab.
NOTE: Contact point spring tension is factory- 2. Position distributor to opening in block in normal
set above specifications to assure ease of final installed attitude fig. 15i, noting position of vacuum
adjustment. Correct tension is 19-23 oz. control unit.
7. Install rotor to cam assembly, indexing round and 3. Position rotor to point toward front of engine with
square pilot holes. distributor housing held in installed attitude, then
turn rotor counter-clockwise approximately 1/8 turn
more toward left cylinder bank and push distributor
Installation-Engine Not Disturbed down to engine camshaft. It may be necessary to ro
All Models tate rotor slightly until camshaft engagement is felt.
4. While pressing firmly down on distributor housing,
1. Turn the rotor about 1/8 turn in a clockwise direc
kick starter over a few times to make sure oil pump
tion past the mark previously placed on the distribu
shaft is engaged. Install hold-down clamp and bolt
tor housing to locate rotor.
and snug up bolt.
2. Push the distributor down into position in the block
with the housing in a normal "installed" position 5. Turn distributor body slightly until points just open
fig. 15i. and tighten distributor clamp bolt.
6. Place distributor cap in position and check to see
NOTE: It may be necessary to move rotor that rotor lines up with terminal for No. 1 spark
slightly to start gear into mesh with camshaft plug.
gear, but rotor should line up with the mark
when distributor is down in place.
3. Tighten the distributor clamp bolt snugly and con
nect vacuum line. Cosmect primary wire to coil
terminal and install cap. Also install spark plug and
high tension wires if removed.
Fig. 14i-Advance Weights Installed Fig. 15i-Six Cylinder Engine Distributor
7. Install cap, check all high tension wire connections

and connect spark plug wires if they have been re
moved. It is important that the wires be installed in
their location in the supports.
NOTE: The brackets are numbered to show the
correct installation. Wires must be installed as
indicated to prevent cross firing.
8. Connect vacuum line to distributor and distributor
primary wire to coil terminal.
9. Start engine and set timing as described under Tune CENTRIFUGAL
Up in Section 6. ADVANCE
DISTRIBUTOR BREAKERLESS MAGNETIC PULSE
Removal Corvette
1. If vehicle is equipped with radio, remove three bolts
securing ignition shield over distributor and coil. ROTATING
One bolt is accessible from the top of shield, the POLE PIECE
other two are at rear of shield, facing firewall.
2. Disconnect tachometer drive cables from distributor
housing.
3. Disconnect pickup coil leads at connector.
STATIONARY
4. Remove distributor cap.
5. Crank engine so rotor is in position to fire No. 1
cylinder and timing mark on harmonic balancer is
indexed with pointer.
6. Remove vacuum line from distributor.
7. Remove distributor clamping screw and hold-down
clamp. MAGNETIC
8. Remove distributor and distributor-to-block gasket. PICKUP
It will be noted that the rotor will rotate as the ASSEMBLY
distributor is pulled out of the block. Mark the re
lationship of the rotor and the distributor housing
after removal so that the rotor can be set in the
same position when the distributor is being installed.
Disassembly Fig. 16i

NOTE: If a distributor is being disassembled
for replacement of the stationary magnetic pick
:
up assembly only, it will be necessary to per
form only Steps 3, 4, 5, 7, 8, 9, and 12 of the
service procedure listed below. VACUUM
ADVANCE
1. Remove screws securing rotor and remove rotor.
2. Remove centrifugal weight springs and weights.
3. Remove the tachometer drive gear from the distribu
tor Corvette only.
4. Remove roll pin, then remove distributor drive gear DISTRIBUTOR
and washer. HOUSING
CAUTION: To prevent damage to the permanent
magnet, support drive gear when driving out roll
pin.
5. Remove drive shaft assembly.
6. Remove centrifugal weight support and timer core DRIVE E
from drive shaft.
7. Remove connector from pickup coil leads. GEAR
8. Remove retaining ring which secures magnetic core
support plate to distributor shaft bushing in
housing.
9. As a unit, remove the entire magnetic pickup assem
bly from the distributor housing.
10. Remove brass washer and felt pad.
11. Remove vacuum advance unit. Fig. 16i-Magnetic Pulse Distributor Components
12. To reassemble distributor, perform the above steps 2. To aid in reassembly, note the locations of the lead
in reverse order. connections to the panel board.
3. Remove the three panel board attaching screws, and
Installation Corvette lift the assembly from the housing.
1. Check to see that the engine is at firing position for 4. To aid in reassembly, note any identifying markings
on the two transistors and their respective locations
No. 1 cylinder timing mark on harmonic balancer
indexed with pointer. on the panel board and heat sink assembly.
2. Position a new distributor-to-block gasket on the 5. Note the insulators between the transistors and the
block. heat sink, and the insulators separating the heat sink
3. Before installing distributor, index rotor with hous from the panel board.
ing as noted when distributor was removed. Install 6. Remove the transistor attaching screws, and sepa
distributor in block so that vacuum diaphragm faces rate the two transistors and heat sink from the panel
approximately 45° forward on the right side of the board.
engine and the rotor points toward contact in cap for 7. Carefully examine the panel board for evidence of
No. 1 cylinder. damage.
4. Replace distributor clamp leaving screw loose
enough to allow distributor to be turned for timing Component Checks Figs. 17i and 18i
adjustment. With the two transistors separated from the assembly,
5. Install spark plug wires in distributor cap. Place an ohmmeter may be used to check the transistors and
wire for No. 1 cylinder in tower marked on old cap components on the panel board for defects. An ohmmeter
during assembly then install remaining wires clock having a 1-1/2 volt cell, which is the type usually found
wise around the cap according to the firing order in service stations, is recommended. The low range
1-8-4-3-6-5-7-2. scale on the ohmmeter should be used except where
6. Attach distributor to coil primary wires. specified otherwise.
7. Replace distributor cap. A 25 watt soldering gun is recommended, and a 60% tin
8. Adjust timing and then fully tighten distributor clamp 40% lead solder should be used when re-soldering. Avoid
screw. excessive heat which may damage the panel board. Clip
9. Attach vacuum line to distributor. away any epoxy involved, and apply new epoxy which is
10. Connect tachometer drive cables to distributor body. commercially available.
11. Replace ignition shields. In order to check the panel board assembly, it is
necessary to unsolder at the locations indicated in Fig-
DISTRIBUTOR OFF-ENGINE TEST ure 18i the two capacitors C2 and C3. In all of the fol
lowing checks, connect the ohmmeter as shown and then
The distributor’s centrifugal and vacuum advance can
be checked in a distributor testing machine or synchro reverse the ohmmeter leads to obtain two readings. The
amplifier circuitry is shown in Figure 19i.
scope specially adapted or designed to accommodate this
type distributor. However, since this involves removing
the distributor from the engine, this test may be post
poned until other system checks have been made. A dwell MOUNTING
reading cannot be obtained on this distributor and it is not
RESISTOR R5 DIODE Dl
likely that the centrifugal or vacuum advance will be a
cause of trouble. TRANSISTOR TR2 TRANSISTOR TR1
UNDERNEATH UNDERNEATH
COIL REPLACEMENT
1. Disconnect ignition switch and distributor leads from
terminals on coil. On Corvettes equipped with radio,
remove bolts securing ignition shield over distribu
tor and coil.
2. Pull high tension wire from center terminal of coil.
3. Remove the two coil support mounting bolts or loosen
friction clamp screw and remove coil.
4. Place new coil in position and install attaching bolts
or tighten clamp screw.
5. Place high tension lead securely in center terminal
of coil and connect ignition switch and distributor
primary leads to terminals on coil. Replace ignition
shield on Corvettes.
6. Start engine and test coil operation.
SCREW
IGNITION PULSE AMPLIFIER CAPACITOR Cl RESISTOR Rl
MOUNTING CAPACITOR C3
Disassembly SCREW RESISTOR R6
CAPACITOR C2
To check the amplifier for defective components, pro- TRANSISTOR TR3
ceed as follows:
1. Remove the bottom plate from the amplifier. Fig. l7i-Ignition Pulse Amplifier Panel Board
CHECKING CHECKING CHECKING CHECKING CHECKING

DIODE Di RESISTOR R3 RESISTOR R4 RESISTOR R5 RESISTOR R2
CHECKING
RESISTOR Ri /
/ CHECKING TRIGGER
TRANSISTOR TR3
CHECKING
CAPACITOR Cl
UNSOLDER]
Fig. 18i-Pulse Amplifier Component Checks
1. Transistors TR1 and TR2: Check each transistor by

referring to Figure 20i. If both readings in Step 1 Fig. 20i-Transistor Checks
are zero, the transistor is shorted. If both readings
in Step 2 are zero, the transistor is shorted; and if 2. Trigger Transistor TR3: if both readings in Step 1
both readings are infinite, the transistor is open. are zero, the transistor is shorted. if both readings
Interpret Step 3 the same as Step 2. in Step 2 are zero, the transistor is shorted; and if
both readings are infinite, the transistor is open.
Interpret Step 3 the same as Step 2.
IGNITION PULSE AMPLIFIER 3. Diode Dl: if both readings are zero, the diode is
shorted; and if both readings are infinite, the diode
is open.
4. Capacitor Cl: If both readings are zero, the capaci
tor is shorted.
5. Capacitors C2 and C3: Connect the ohmmeter across
each capacitor not illustrated. The capacitor is
shorted if both readings are zero.
6. Resistor Ri: The resistor is open if both readings
are infinite.
7. Resistor R2: Use an ohmmeter scale on which the
1800 ohm value is within, or nearly within, the
middle third of the scale. If both readings are infi
nite, the resistor is open.
8. Resistor R3: Use an ohmmeter scale on which the
680 ohm value is within, or nearly within, the middle
third of the scale. if both readings are infinite, the
resistor is open.
9. Resistor R4: Select an ohmmeter scale on which the
15000 ohm value is within, or nearly within, the
middle third of the scale. If either reading is infi
nite, the resistor is open.
10. Resistor R5: Use the lowest range ohmmeter scale.
The resistor is open if either reading is infinite.
NOTE: This resistor on some applications may
be located in the vehicle wiring harness, and not
Fig. 1 9i-Ignition Pulse Amplifier Internal Circuitry on the panel board.
11. Resistor R6: An ohmmeter scale on which the 150

ohm value is within or nearly within, the middle
third of the scale should be used. If both readings
are infinite, the resistor is open.
Reassembly
During assembly, coat with silicone grease both sides
of the flat insulators used between the transistors and
heat sink, and also the heat sink on the side on which the
transistors are mounted. The silicone grease, which is
available commercially, conducts heat and thereby pro
vides better cooling.
SPARK PLUGS
Cleaning and Regapping

Clean the spark plugs thoroughly, using an abrasive
type cleaner. If the porcelains are badly glazed or
blistered, the spark plugs should be replaced. All spark
plugs must be of the same make and number or heat
range. Use a round feeler gauge to adjust the spark plug
gap to specifications fig. 211.
CAUTION: Before adjusting gap, file center
electrode flat. In adjusting the spark plug gap,
never bend the center electrode which extends Fig. 21i-Checking Spark Plug Gap
through the porcelain center. Always make ad
justment by bending the ground or side electrode.
available, tighten plugs finger tight and 1/2 turn more.
Installation Plugs are of a 14 millimeter size and care must be
Install the spark plugs in the engine with new gaskets exercised when installing or the gap setting may be
and tighten to specifications, if torque wrench is not changed.
STARTER CIRCUIT
INDEX
Page Page
General Description 6Y-29 Service Operations 6Y-31

Maintenance and Adjustments 6Y-29 Starter Motor 6Y-31
Resistance Checks 6Y-29 Removal and Installation 6Y-3 1
Starting Motor and Solenoid Check GY-30
GENERAL DESCRIPTION
The function of the starting system, composed of the fields, connected with the armature. The aluminum drive
starting motor, solenoid and battery, is to crank the end housing is extended to enclose the entire shift lever
engine. The battery supplies the electrical energy, the and plunger mechanism, protecting them from dirt,
solenoid completes the circuit to the starting motor, and splash, and icing. The flange mounted solenoid switch
the motor then does the actual work of cranking the operates the overrunning clutch drive by means of a
engine. linkage to the shaft lever.
The starting motor fig. is consists primarily of the The V-8 wiring harness differs from the in-line engine
drive mechanism, frame, armature, brushes, and field in that the ignition lead to the coil from the switch is at
windings. The starting motor is a pad mounted 12-volt tached at the coil instead of the starter solenoid fig.
extruded frame type, having four pole shoes and four 2s.

No periodic lubrication of the starting motor sole RESISTANCE CHECKS
noid is required. Since the starting motor and brushes
cannot be inspected without disassembling the unit, no Although the starting motor cannot be checked against
service is required on these units between overhaul specifications on the car, a check can be made for exces
periods. sive resistance in the starting circuit. Place a volt-
ENGINE-ELECTRICAL-6Y-30
CONTACT SOLENOID
FINGER PLUNGER RETURN SPRING
1
L
ARMATURE
GROUNDED BRUSH HOLDER
Fig. is-Starting Motor Cross Section Typical
meter across points in the cranking circuit as oultined warm, it will require a somewhat higher voltage to
below and observe the reading with the starting switch pull in.
closed and the motor cranking distributor primary lead
grounded to prevent engine firing. STARTING MOTOR AND SOLENOID CHECK
1. From battery positive post To solenoid battery
The following checks may be made if the specific
terminal.
2. From battery negative post To starting motor gravity of the battery is 1.215 or higher.
1. If the solenoid does not pull in, measure the voltage
housing.
3. From solenoid battery terminal To solenoid motor between the switchS terminal of the solenoid and
ground with the starting switch closed.
terminal.
if voltage drop in any of above check exceeds 0.2 volts, CAUTION: if the solenoid feels warm, allow to
excessive resistance is indicated in that portion of start cool before checking.
ing circuit and the cause of the excessive resistance
if the voltage is less than 7.7 volts, check for ex
should be located and corrected in order to obtain maxi
cessive resistance in the solenoid control circuit.
mum efficiency in the circuit.
CAUTION: Do not operate the starting motor
continuously for more than 30 seconds in order
to avoid overheating. +
When the solenoid fails to pull in, the trouble may be

due to excessive voltage drop in the solenoid control cir
cuit. To check for this condition, close the starting
switch and measure the voltage drop between the BAT
TERY terminal of the solenoid and the SWITCHS termi
r4 6dflJ
nal of the solenoid.
1. if this voltage drop exceeds 3.5 volts, excessive re
ETI:on
sistance in the solenoid control circuit is indicated
and should be corrected.
2. If the voltage drop does not exceed 3.5 volts and the
solenoid does not pull in, measure the voltage availa
ble at the SWITCH terminal of the solenoid.
3. if the solenoid does not feel warm, it should pull in
Jii7 V-8 ENGINE
whenever the voltage available at the SWITCH termi

nal is 7.7 volts or more. When the solenoid feels Fig. 2s-V-8 Starting Circuit Diagram
if the voltage exceeds 7.7 volts, remove the starting solenoid, always check starting m ot o r pinion
motor and check 1 solenoid current draw, 2 clearance.
starting motor pinion clearance, and 3 freedom of 3. if motor engages but does not crank or cranks
shift lever linkage. slowly, check for excessive resistance in the ex
2. if the solenoid "chatters" but does not hold in, ternal starting circuit, trouble within the starting
check the solenoid for an open "hold-in" winding. motor, or excessive engine resistance to cranking.
Whenever it is necessary to replace a starting motor
SERVICE OPERATIONS
STARTING MOTOR
Removal and Installation Fig. 3s

The following procedure is a general guide for all
vehicles and will vary slightly depending on series and
model.
1. Disconnect battery ground cable at battery.
2. Raise vehicle to a good working height.
3. Disconnect all wires at solenoid terminals.
NOTE: Reinstall the nuts as each wire is dis
connected as thread size is different but may be
mixed and stripped.
4. Loosen starter front bracket nut on V-8 and bolt on
L-6 then remove two mount bolts.
5. Remove the front bracket bolt or nut and rotate Fig. 3s-Starter Mounting and Solenoid Connections
bracket clear of work area then lower starter from
vehicle by lowering front end first - - hold starter the mount bolts to 25-35 ft. lbs. first, then torque
against bell housing and sort of roll end-over-end. brace bolt.
6. Reverse the removal procedure to install. Torque 7. Check operation of starter on vehicle.
SPECIAL TOOLS
J-96OO2 J-21 501

J-971 7-2 J-971 7-1 PULL’V’
SHOULDERED
SUPPORT PRESS ADAPTER
INSTALLER
TOOL TOOL
i-S 184
CHECKING J-21600
SCALE HARNESS ADAPTER
Fig. 4s-Special Tools
SECTION 7
CLUTCH AND TRANSMISSIONS
Page Page
Clutch 7-1 Special Tools Clutch and Manual Transmission . 7-20
Three-Speed Transmissions 7-6 Powerglide 7-22
Overdrive 7-11 Turbo Hydra-Matic 7-33
Four-Speed Transmissions 7-15 Special Tools Automatic Transmission 7-42
CLUTCH
INDEX
Page Page
General Description 7-1 Installation in Vehicle 7-2
Maintenance and Adjustments 7-1 Clutch Pedal 7-3
Linkage Inspection 7-1 Clutch Cross Shaft 7-3
Clutch Linkage Adjustment 7-1 Removal 7-3
Component Parts Replacement 7-2 Repairs 7-3
Clutch Assembly 7-2 Installation 7-3
Removal from Vehicle 7-2
GENERAL DESCRIPTION
A diaphragm spring- type clutch assembly is used with signed for maximum speed conditions.
manual transmissions. The clutch release bearing fig. 4, used with the bent
The clutch assembly is enclosed in a 360° bell housing finger diaphragm clutch, has an overall length of approxi
which must be removed to gain access to the clutch. mately 1-1/4". The longer bearing, used with the straight
V-8 engines equipped with a 4 speed transmission use diphragm, will cause inability to obtain free pedal
a bent-finger, centrifugal diaphragm type clutch as travel, especially as the clutch wears, resulting in slip
sembly. All its integral release fingers are bent back to page and rapid wear. DO NOT INTERCHANGE:
gain a centrifugal boost and to insure quick reengagement The clutch is operated by conventional linkage consist
at high engine speeds. ing of two groups, upper linkage and lower linkage.
This type of clutch has the advantages of increasing The return spring pre-loads clutch linkage, removing
pressure plate load as the driven plate wears, and of low looseness due to wear. The clutch free pedal travel,
pedal effort with high plate loads without requiring over- therefore, will increase with linkage wear and decrease
center booster springs on the clutch linkage. with driven disc wear, and free travel felt at pedal is
The pressure plate is a high tensile strength iron de throwout bearing lash.

LINKAGE INSPECTION 4. Check for bent, cracked or damaged cross shaft
There are several things which affect good clutch op levers or support bracket.
erations. Therefore, it is necessary, before performing 5. Loose or damaged engine mounts may allow the en
any major clutch operations, to make preliminary in gine to shift its position causing a bind on clutch
spections to determine whether trouble is actually in the linkage at the cross shaft. Check to be sure there is
clutch.
Check the clutch linkage to be sure the clutch releases
fully as follows: CLUTCH LINKAGE ADJUSTMENT
1. With engine running, hold the clutch pedal approxi
mately 1/2" from floor mat and move shift lever be There is one linkage adjustment clutch fork push rod
tween first and reverse several times. If this can be or pedal push rod to compensate for all normal clutch
done smoothly, the clutch is fully releasing. If shift wear.
is not smooth, clutch is not fully releasing and ad The clutch pedal should have free travel measured
justment is necessary. at clutch pedal pad before the throwout bearing engages
2. Check clutch pedal bushings for sticking or excessive the clutch diaphragm spring levers. Lash is required
wear. to prevent clutch slippage which would occur if the
3. Check fork for proper installation on ball stud. Lack bearing was held against the fingers or to prevent the
of lubrication on fork can cause fork to be pulled off bearing from running continually until failure. A clutch
the ball. that has been slipping prior to free play adjustment may
CLUTCH AND TRANSMISSIONS 7-2
V8 ENGINE L4 - L6 ENGINE - CHEVY II & CAMARO

CAMARO & CHEVY II ONLY L6-V8 ENGINE - CHEVELLE
Fig. 2-ChitCh Pedal Free Travel Adjustment
the clutch fork until the release bearing contacts the

pressure plate fingers lightly.
3. Rotate upper nut B against swivel and back off
4-1/2 turns. Tighten lower nut A to lock swivel
Fig. 1-Chevrolet Clutch Pedal Free Travel Adjustment
against nut B.
4. Install return spring E and check clutch pedal free
still slip right after the new adjustment due to previous travel. Pedal free travel should be:
heat damage. The vehicle should be returned to the a. Chevrolet - 1" to 1-1/2"
Dealership the next day at least 12 hours to give clutch b. Corvette STD - 1-1/4" to 2"
time to cool to normal temperatures. Any slippage c. Corvette HVY DTY - 2" to 2-1/2"
should then be evaluated as follows:
1. Drive in high gear at 20-25 MPH. Chevelle, Chevy II and Camaro Fig. 2
2. Depress clutch pedal to the floor and rev engine to 1. Disconnect return spring at clutch fork.
2500-3500 rpm. 2. With clutch pedal against stop: loosen locknut C
3. Engage clutch quickly snap foot off pedal and press sufficiently to allow the adjusting rod to be turned
accelerator to full throttle. out of swivel and against clutch fork until the release
Engine speed should drop noticeably then accelerate bearing contacts pressure plate fingers lightly.
with vehicle. If clutch is bad, the engine speed will 3. Rotate push rod into swivel 3 turns and tighten
increase. locknut.
NOTE: Do not repeat more than once or clutch NOTE: Chevy II and Camaro V- 8 engine models
will overheat. use a two piece push rod. Turn adjusting rod
portion of push rod 3 turns into rod end then
Chevrolet and Corvette Fig.1 tighten locknut.
1. Disconnect spring E between clutch push rod and 4. Reinstall return spring and check pedal free travel.
cross shaft lever. Pedal free travel should be:
2. With clutch pedal against stop: loosen jam nuts a. Chevelle - 1-1/8" to 1-3/4"
sufficiently to allow the adjusting rod to move against . Chevy II and Camaro - 1" to 1-1/8"

CLUTCH ASSEMBLY clutch cover. If "X" mark is not evident, prick
punch marks on flywheel and clutch cover for
Removal From Vehicle indexing purposes during installation.
1. Support engine and remove transmission as outlined
6. Loosen the clutch-to-flywheel attaching bolts evenly
in transmission section.
1 turn at a time until spring pressure is released,
2. Disconnect clutch fork push rod and spring.
3. Remove flywheel housing. then remove the bolts, and remove clutch assembly.
4. Slide clutch fork from ball stud and remove fork Installation to Vehicle
from dust boot. Clean pressure plate and flywheel face. They should
be free of oil, grease, metal deposits or burned spots.
NOTE: Ball stud is threaded into clutch hous 1. Position the clutch disc and pressure plate in rela
ing and is easily replaced, if necessary. tive installed position and support them with align
5 Install Tool J- 5824 to support the clutch assembly m.ent Tool J-5824.
iuring removal. NOTE: The driven disc is installed with the
NOTE: Look for "X" mark on flywheel and on damper springs to the transmission side. THE
ing collar and the throwout fork groove with a light

coat of graphite grease fig. 3. On Corvette models
use Moly Grease.
7. Install clutch fork and dust boot into clutch housing
and install throwout bearing to the throwout fork,
then install flywheel housing.
8. Install transmission as outlined in transmission
section.
9. Connect fork push rod and spring.
10. Adjust shift linkage as outlined in transmission
section.
11. Perform linkage adjustment for pedal free play and
check clutch release position.
COAT CLUTCH PEDAL Fig. 4

THIS PACK THIS RfCESS
GROOVE The clutch pedal is the pendant-type hung from a sup
port brace common to the brake pedal and must be
removed to remove brake pedal. Refer to Section 5 for
brake and clutch pedal service procedure.
CLUTCH CROSS SHAFT Fig. 5

Removal
1. Remove linkage return and lower linkage springs and
disconnect clutch pedal and fork push rods from re
spective cross shaft levers.
Fig. 3-Release Bearing Lubrication and Comparison 2. Loosen outboard ball stud nut and slide stud out of
bracket slot.
GREASE SLINGER IS ALWAYS ON THE TRANS
3. Move cross shaft outboard, and as required to clear
MISSION SIDE.
inboard ball stud, then merely lift out to remove
2. Turn clutch assembly until "X" mark on cover lines from vehicle.
up with "X" mark on flywheel, then align cover bolt
holes to nearest flywheel holes. Repairs
3. Install a bolt in every hole and tighten down evenly The cross shaft has nylon ball stud seats which should
and gradually until tight to avoid possible clutch be inspected for wear or damage. Also check condition
distortion. of engine bracket ball stud assembly and special anti-
rattle "0" ring. Figures show component parts of cross
NOTE: Cover loads are as high as 1-1/4 tons.
shaft. Replace parts as necessary based on wear or
4. Remove pilot tool. damage. Lubricate ball studs and seats with graphite
5. Unhook clutch fork and lubricate ball socket and fork grease before reassembly.
fingers at release bearing end with a high melting
point grease such as graphite and reinstall fork on Installation
ball stud. On Corvette models use Moly Grease. 1. Reverse removal procedure to install.
6. Lubricate the recess on the inside of throwout bear- 2. Adjust clutch linkage as previously outlined.
CHEVROLET
CORVETTE
CHEVY II & CAMARO CHEVELLE
Fig. 4-Clutch Pedal Unkoge-Composite
&
CHEVROLET
1-4 & 1-6
C
-4
A
I
I
z
0 0
-4
n
I
z
CHEVELLE CHEVY II & CAMARO I,

‘I,
0
z
zC N
Fig. 5-Lower Linkage Details-Composite
>
UI
THREE-SPEED TRANSMISSIONS
SAGINAW AND WARNER
INDEX
Page Page
General Description 7-6 Replacement
Maintenance and Adjustments . 7-6 Transmission Side Cover 7-9
Shift Linkage 7-6 Removal 7-9
Adjustment 7-6 Disassembly 7-9
Shift Control Lever and Bracket Assembly 7-7 Assembly 7-9
Replacement 7-7 Installation 7-9
Speedometer Driven Gear and Seal 7-8 Transmission Replacement 7-10
Replacement Removal 7-10
Extension Oil Seal 7-8 Installation 7-10
GENERAL DESCRIPTION
The Saginaw three speed fully synchronized all for- at high speeds with neither excessive heat generation nor
gears transmission incorporates helical drive gears excessive frictional losses. Shafts, bearings, high ca
throughout. pacity clutches and other precision parts are held to
The main drive gear is supported by a ball bearing at close limits providing proper clearances necessary for
the front end of the transmission case and is piloted at durability during extended heavy usage.
its front end in an oil impregnated bushing mounted in the The main drive gear is supported by a heavy duty ball
engine crankshaft. The front end of the mainshaft is bearing at the front end of the transmission case and is
piloted in a row of roller bearings set into the hollow end piloted at its front end in an oil impregnated bushing
of the main drive gear and the rear end is carried by a mounted in the engine crankshaft. The front end of the
ball bearing mounted in the front of the extension housing. mainshaft is piloted in a row of roller bearings set into
The countergear is carried on a single row of rollers the hollow end of the main drive gear and the rear end
at both ends while thrust is taken on thrust washers is carried by a heavy duty ball bearing mounted in the
located between the ends of the gear and the thrust bosses front of the extension housing.
in the case. An anti- rattle plate assembly at the front of The countergear is carried on a double row of rollers
the countergear provides a constant spring tension be at both ends while thrust is taken on thrust washers lo
tween the counter and clutch gears to reduce torsional cated between the ends of the gear and the thrust bosses
vibrations. The reverse idler gear is carried on a bush in the case. An anti-rattle plate assembly at the front
ing finish bored in place, and rotates on a short idler of the countergear provides a constant spring tension be
shaft. Forward movement is stopped by a snap ring on tween the counter and clutch gears to reduce torsional
the idler shaft. vibrations. The reverse idler gear is carried on 25
Gear shifting is manual through shift control rods to roller bearings while thrust is taken on thrust washers
the rearward shift lever of the side cover assembly for located between the ends of the gear and the thrust bosses
first and reverse gear; and through a cross shaft assem of the case.
bly Chevrolet models attached to the forward side cover Gear shifting is manual through shift control rods from
lever for second and third gear. All three forward gears the shifter tube in the mast jacket to the rearward shift
are fully synchronized. The synchronizer assemblies lever of the side cover assembly for first and reverse
consist of a clutch hub, clutch sleeve, two clutch key gear; and through a cross shaft assembly attached to the
springs and three energizer clutch keys and are retained forward side cover lever for second and third gear. All
as an assembly on the main shaft by a snap ring. three forward gears are fully synchronized. The syn
The transmission may be used as an aid in deceleration chronizer assemblies consist of a clutch hub, clutch
by downshifting in sequence without double-clutching or sleeve, two clutch key springs and three energizer clutch
any gear clashing. Reverse is not synchronized, how keys and are retained as an assembly on the main shaft
ever, it is a helical gear to insure quiet operation. by a snap ring. The transmission may be used as an aid
The Borg-Warner heavy duty three speed fully syn in deceleration by downshifting in sequence without
chronized all forward gears transmission incorporates double-clutching or any gear clashing. Reverse is not
helical gears throughout specially designed to provide synchronized, however, it is a helical gear to insure
high torque capacity, and gear teeth proportion to operate quiet operation.

SHIFT LINKAGE ADJUSTMENT proper shift linkage adjustment when equipped with col
umn shift 3-speed transmission.
Column Shift-Chevrolet, Chevelle, Chevy II, When shift linkage adjustment is necessary out of
Camaro Fig.
adjustment, steering column realignment, transmission
An alignment bracket is on Chevrolet, Chevelle, Chevy removal, etc. on vehicles incorporating this alignment
II and Camaro steering column mast jackets to facilitate bracket, use the following procedure.
2ND & 3RD

ROD
VIEW A
ALIGNMENT TOOL
FARRICATE TOOL FROM 3Ao"
ROUND STEEL STOCK
TO DIMENSIONS SHOWN
I- 2" -+.j
______
3’io" ROD
[ji"
1ST & REV.
ROD
Fig. 6-Three-Speed Column Shift Linkage Adjustment Fig. 7-Three-Speed Transmission Linkage Adjustment-Corvette
1. Loosen swivel locking clamps on both shift rods. 2. Set shift lever within car in neutral and install lo
Shift rods must pass freely through swivels. cating gauge into control lever bracket assembly.
2. Place shift lever handle within the car in neutral. NOTE: Gauge is serviced part.
Insert fabricated "L" shaped tool fig. 6 through
1/H lever, the relay [ever, and the 2/3 lever and 3. Manually place transmission shift levers in neutral.
then into the hole in the alignment plate bolted to the 4. Run 1st/Reverse shift rod nut G against swivel and
mast jacket See Figure 6. tighten locknut E against swivel.
3. Manually, place transmission shift levers in neutral 5. Run 2nd/3rd shift rod nut K against swivel then
position. tighten nut H against swivel.
4. Tighten both swivel locking clamp nuts on the rods, 6. Remove locating gauge and discard. Check shifting
supporting the swivels with one hand while tightening to insure proper operation.
to insure against any movement of the swivels or
rods. Shift Control Lever and Bracket Assembly
5. Remove the alignment tool from the levers. Shift the Replacement Corvette Fig. 9
transmission through its ranges; return to neutral.
Reinsert tool, if the tool does not pass relatively 1. Remove shift control lever knob inside vehicle.
freely through the alignment holes and the bracket, 2. Remove console trim plate and seat assembly.
loosen clamps and readjust linkage. 3. Disconnect transmission control rods from shift
Figure 1 depicts the Camaro and Chevrolet linkage and control levers.
adjustment provision. Chevelle and Chevy II use align 4. Remove shift control to support bracket retaining
ment holes in the lower side of the levers, however, the bolts.
5. Remove support bracket to crossmember retaining
above procedure is still applicable.
bolts.
Floor Shift-Corvette Fig.. 7 6. Remove support assembly from vehicle, then pull
down on control assembly to remove from console
1. Loosen swivel lock nuts on both shift rods. Shift boot and vehicle.
rods must pass freely through swivel.
2. Place shift lever control within car in neutral. NOTE: if disassembly of this control lever
Insert locating gauge 41/64 in. in notch of lever and and bracket assembly is necessary refer to
bracket assembly. Figure 9 for parts breakdown and relative po
sitioning for assembly.
3. Manually place transmission shift levers in neutral
position. 7. To install, reverse removal procedure.
4. With 1st/Reverse rod and lever against locating
gauge, tighten locknut against swivel. Shift Control Lever Assembly Replacement-
5. With 2nd/3rd rod and lever against locating gauge, Chevelle, Camaro and Chevy II Fig. 10
run forward nut against swivel then tighten aft nut
against swivel. NOTE: This procedure for 3 or 4 speed levei
6. Remove locating gauge and check shifts. Return to assembly.
neutral position and reinsert locating gauge. If gauge 1. Remove shifter knob from control lever.
does not freely enter bracket assembly, readjust
linkage. NOTE: Tool J-9138 or other suitable snap ring
pliers may be used to remove lower half of two-
Floor Shift-Chevelle, Camaro, Chevy II Fig. 8 piece knob assembly.
1. Loosen locknuts at swivels on both shift rods. Shift 2. Remove console or floor trim iate assembly.
rods should pass freely through swivels. 3. Raise vehicle on hoist.
10. Disassemble control assembly from support bracket.

SPEEDOMETER DRIVEN GEAR

Disconnect speedometer cable, remove lock plate to
extension bolt and lock washer and remove lock plate.
Insert screw driver in lock plate slot in fitting and pry
fitting gear and shaft from extension. Pry "0" ring from
groove in fitting.
Install new "0" ring in groove in fitting. Coat "0"
ring and driven gear shaft with transmission lubricant
and insert shaft.
Hold the assembly so slot in fitting is toward lock plate
KH boss on extension and install in extension. Push fitting
into extension until lock plate can be inserted in groove
and attach to extension.
Fig. 8-Three-Speed Transmission Linkage Adjustment-

Chevelle, Camaro, Chevy II EXTENSION OIL SEAL REPLACEMENT
4. Remove bracket stabilizer retaining nut and discon 1. Remove propeller shaft as outlined in Section 4 and
nect stabilizer rods at control lever. disconnect any necessary items to obtain clearance.
5. Disconnect transmission shift rods at side cover. 2. Pry seal out of extension.
6. Remove crossmember to control support bracket 3. Wash counterbore with cleaning solvent and inspect
attaching bolts. for damage.
7. Remove transmission rear mount attaching bolts. 4. Prelubricate between sealing lips and coat new seal
8. Remove crossmember to frame attaching bolts. Sup O.D. with Permatex or equivalent and start straight
port transmission and remove crossmember from in bore in case extension. Using Tool J-5154, tap
vehicle or slide to rear. seal into counterbore until flange bottoms against
9. Pull control lever and support down and to rear to extension.
disengage lever from floor seal and remove assem 5. Reinstall propeller shaft and any items removed to
bly from vehicle. obtain clearance.
VIEW A VIEW B
Fig. 9-Three-Speed Control Lever and Bracket Assembly-Corvette
DETENT CAM
DETENT SPRING
CAM
2-3 SHIFT
FORK
7 DETENT CAM’S
/
"p PIVOT PIN
1ST & REV. 1ST & REV. ‘
2-3 SHIFTER SHAFT
SHIFTER SHAFT SHIFT FORK
DETENT CAM
RETAINER RING
1-1g. Il-Transmission Side Cover-Saginaw
the first and reverse shifter shaft cover hole install

the 2nd and 3rd detent cam.
2. Install detent cam retaining "C" ring to pivot shaft,
and hook spring into detent cam notches.
3. Install both shifter shaft assemblies in cover being
careful not to damage seals. Install both shift forks
to shifter shaft assemblies, lifting up on detent cam
to allow forks to fully seat into position.
4. Install outer shifter levers, flat washers, lock wash
ers and bolts.
Installation
1. Shift shifter levers into neutral detent center posi
tion. Position cover gasket on case.
CAMARO - CHEVY II 2. Carefully position side cover into place making sure
the shift forks are aligned with their respective
Fig. 10-Floor Shift Control Assemblies mainshaft clutch sliding sleeves.
3. Install cover attaching bolts and tighten evenly to
specified torque.
TRANSMISSION SIDE COVER-SAGINAW 4. Remove filler plug and add lubricant specified in
Secion 0, to level of filler plug hole.
Removal
1. Disconnect control rods from levers; remove 2-3 SIDE COVER ASSEMBLY-WARNER
cross shaft Chevrolet.
2. Shift transmission into neutral detent positions be Removal
fore removing cover. 1. Drain transmission and disconnect control rod and
3. Remove cover assembly from transmission case cross shaft from side cover levers.
carefully and allow oil to drain. 2. Remove nine cap screws securing the transmission
side cover assembly to transmission case and re
Disassembly Fig. 11 move cover assembly, shifting forks and gasket.
1. Remove the outer shifter levers.
2. Remove both shift forks from shifter shaft assem Disassembly Fig. 12
blies. Remove both shifter shaft assemblies from 1. Remove shifting forks from shift lever assemblies.
cover. "0" ring seals around shifter shaft may now 2. Remove nut and lock washer from each shift lever
be pryed out if replacement is required because of shaft.
damage. 3. Remove outer shift levers and lightly tap shift lever
3. Remove detent cam spring and pivot retainer "C" shafts from assembly.
ring. Remove both detent cams. 4. Remove two steel balls, poppet spring, interlock pin
4. Replace damaged parts.. and interlock sleeve from cover.
5. Remove "0" ring seals from shift lever shafts.
Assembly Fig. 11
1. With detent spring tang projecting up over the 2nd Assembly Fig. 12
and 3rd shifter shaft cover opening install the first 1. Install new "0" ring seals to shift lever shafts.
and reverse detent cam onto the detent cam pivot 2. Install low and reverse shifter shaft and plate as
pin. With the detent spring tang projecting up over sembly to cover.
TRANSMISSION
Removal-Chevrolet, Chevelle, Chevy II and Camaro
1. Support vehicle on hoist.
2. Disconnect speedometer cable at transmission and
on floor shift models disconnect back-up lamp
switch.
3. Remove propeller shaft assembly.
NOTE: On Camaro models, disconnect exhaust
pipe at manifold.
4. Remove crossmember to frame attaching bolts.
NOTE: On floor shift models fig. 10, remove
crossmember to control lever support attaching
bolts. On Chevelle models also remove control
lever brace to crossmember attaching bolt.
5. Remove bolts retaining transmission mount to cross-
member.
6. Support engine and raise slightly until crossmember
may be slid rearward or removed.
7. Remove shift levers at transmission side cover.
NOTE: On floor shift models, remove stabi
lizer to control lever assembly retaining nut.
Push bolt toward transmission until stabilizer
Fig. 12-Transmission Side Cover-Warner rod may be disconnected.
8. Remove transmission to clutch housing upper re
1. Side Cover 6. Interlock Pin
2. Poppet 7. 2nd and 3rd Shifting taining bolts and install guide pins in holes then
3. 1sf and Reverse Shifter Fork remove lower bolts.
Lever and Shaft 8. Interlock Sleeve 9. Slide transmission rearward and remove from
4. Poppet Spring 9. 2nd and 3rd Shifter vehicle.
5. lst and Reverse Shifter Lever and Shaft
Fork 10. ‘O" Ring Seal Installation-Chevrolet, Chevelle, Chevy II
and Camaro
1. Raise transmission into position and slide forward,
3. Place shifter shaft and plate assembly in neutral po piloting clutch gear retainer into clutch housing.
sition, middle detent, and install interlock sleeve, 2. Install transmission to clutch housing retaining bolts
ball, poppet spring and interlock pin. and lock washers. Torque to specifications.
4. Install remaining poppet ball and then install second 3. Install shift levers at transmission side cover.
and third shifter shaft and plate assembly. NOTE: On floor shift models, install stabilizer
NOTE: Installation is easiest if shifter shaft rod to the control lever assembly.
and plate assembly passes over ball in its neu 4. Support engine and raise slightly until crossmember
tral position. may be repositioned. Install retaining bolts and
5. Check clearance between end of interlock sleeve and torque to specifications. Remove engine support.
shifter shaft and plate cams when one plate is in 5. Install transmission crossmember to mount re
neutral and the other is shifted into gear position. taining bolts.
Clearance should be .002 to .008. Interlock sleeves NOTE: On floor shift models, install cross-
are available in four sizes to give the proper member to contr.ol lever support attaching bolts
clearance. and control lever brace to crossmember attach
6. Install outer shifter levers to shafts with lock wash ing bolts Chevelle only.
ers and nuts. Tighten securely.
7. Install shifting forks to shift levers 1st and reverse 6. Install propeller shaft assembly.
fork "hump" towards bottom. NOTE: On Camaro models, connect exhaust
Installation pipe to manifold.
1. Install new side cover gasket to transmission case, 7. Connect speedometer assembly.
install cover and secure with lock washers and cap
screws. NOTE: On floor shift models, connect backing
lamp switch wiring.
NOTE: The two rear side cover to case attach
ing bolts have a special oil sealing spline and 8. Fill transmission with lubricant and lower vehicle
must be used at these two "through" hole and check operation of transmission.
locations. Removal-Corvette
2. Connect control rod and cross shaft to control 1. Disconnect battery ground cable.
levers. 2. From inside vehicle, remove shifter ball.
3. Remove console trim plate. Refer to Corvette Body, 11. Remove transmission mount bracket to crossmember
Section 1A, Passenger Service Manual. bolts and remove mount bracket. Remove bolts re
4. Raise vehicle on hoist. taining rear mount cushion and exhaust pipe yoke.
5. Completely remove right and left exhaust pipes from 12. Remove transmission-to-clutch housing retaining
vehicle. In order to remove the exhaust pipes on bolts and extension bottom bolt.
vehicles equipped with 396 or 427 cu. in. engines, it 13. Pull transmission rearward and rotate clockwise
is necessary to remove the forward stud on each until it is clear of clutch housing. To allow room for
manifold. transmission removal slowly lower the rear of en
6. Disconnect propshaft at transmission slip yoke. gine until the tachometer drive cable at the dis
Lower front of propshaft. Remove slip yoke from tributor just clears the horizontal ledge across the
transmission. front of dash.
7. Remove bolts attaching rear mount to rear mount
CAUTION: THE TACHOMETER CABLE CAN
bracket. Raise engine lifting transmission off mount
BE EASILY DAMAGED BY HEAVY CON
bracket.
TACT WITH THE DASH. SLIDE TRANSMIS
8. Remove the bolts retaining transmission linkage
SION REARWARD OUT OF THE CLUTCH, THEN
mechanism mounting bracket to frame.
TIP FRONT END OF TRANSMISSION DOWN
9. Remove bolts attaching gearshift assembly to mount
ing bracket and remove mounting bracket. Remove WARD AND LOWER THE ASSEMBLY FROM
shifter mechanism with rods attached. VEHICLE.
10. Disconnect shifter levers at transmission. Discon 14. Reinstall transmission assembly by performing
nect speedometer cable.. above steps in reverse order.
TRANSMISSION OVERDRIVE
INDEX
Page Page
General Description 7-11 Air Gap 7-12
Maintenance and Adjustments 7-11 Point Opening 7-12
Governor Switch and Pinion 7-12 Closing Voltage 7-12
Sun Gear Solenoid Oil Seal and Control Solenoid 7-13
Cable Bracket 7-12 Closing Coil . . . . . 7-13
Case Rear Oil Seal 7-12 Engaging Spring 7-13
Removal 7-12 Ignition Grounding Contact 7-13
Installation 7-12 Governor Switch 7-13
Control Shaft Lever and Oil Seal 7-12 Kickdown Switch 7-13
Speedometer Driven Gear 7-12 Diagnosis - Overdrive 7-13
Electrical Unit Checks 7-12 Mechanical 7-13
Overdrive Relay 7-12 Electrical 7-13
GENERAL DESCRIPTION
The overdrive unit is essentially a two-speed planetary SERVICING THE OVERDRIVE
transmission attached to the rear of a conventional three- With the overdrive assembly removed from the
speed transmission. In overdrive, engine speed is ap transmission, service operations on the transmission
proximately 30 per cent slower at a given road speed proper are the same as for the standard three-speed
since the drive train includes planetary gears which pro transmission.
vide a lower overall gear ratio than that obtained in high Repairs to the overdrive housing, output shaft, ring
gear with the conventional transmission. gear assembly, clutch cam, roller retainer, pinion cage,
The electrical equipment which controls the automatic sun gear, shift rail, sun gear control plate, output shaft
action of the mechanical portion of the overdrive unit bearing, oil seal, speedometer drive gear, solenoid pawl
consists of a solenoid, a speed-sensitive governor switch, and interlock plunger may be performed underneath the
a relay and a kickdown switch. The circuit including this car, if so desired, by removing the overdrive housing
equipment makes it possible to operate in overdrive without disturbing the transmission. Refer to Overhaul
above a pre-set cut-in speed, or in conventional drive at Manual for Service Procedure.
any speed. if the transmission mainsha.ft, overdrive adapter or
With the overdrive unit engaged, the transmission transmission rear bearing which is retained in adapter
should not be left in any forward gear with intent of lock require replacement, the entire transmission and over
ing the drive-line as the overrunning clutch is a free drive assembly should be removed and overhauled on the
wheeling condition. bench.

Servicing of the overdrive governor switch and pinion, speedometer driven gear may be accomplished without
the sun gear solenoid, oil seal and cable bracket, the out removing the overdrive from the vehicle, as discussed
put shaft rear oil seal, the control shaft lever, and the in the following paragraphs:
GOVERNOR SWITCH AND PINION

To remove governor switch, disconnect wires at gover
nor switch and screw governor out of housing, using Tool
J-4653 on the flat hexagonal surface of governor case.
The pinion may be separated from the governor by re
moving the snap ring on the shaft.
SUN GEAR SOLENOID, OIL SEAL AND

CONTROL CABLE BRACKET
Remove the solenoid by taking out the two mounting
bolts and lock washers, removing the cable bracket with
the lower bolt. Turn the solenoid 1/4 turn and pull sole
noid plunger out of adapter. The oil seal may be pried
out of the adapter.
CASE REAR OIL SEAL

Removal
1. Remove propeller shaft as outlined in Section 4.
2. Using a punch against seal in housing, pry out seal
from housing.
Installation Fig. 13-Checking Relay Air Gap
1. Prelubricate between sealing lips and coat outside of
new oil seal with a suitable sealant, then start seal Air Gap
into bore in overdrive housing. The air gap should not normally require adjustment
2. Using Tool J-5154 drive oil seal into counterbore. unless the relay has been misadjusted. Check the air gap
3. Install propeller shaft as outlined in Section 4. with the points barely touching and adjust if necessary by
bending the lower point support fig. 13.
CONTROL SHAFT LEVER AND/OR "0" RING Point Opening
OIL SEALS Check the contact point opening and adjust by bending
To remove the control shaft, disconnect the control the upper armature stop fig. 14.
cable, remove tapered pin and pull lever out. Replace
Closing Voltage
the two "0" ring seals on the control shaft. Insert shaft
To check the relay closing voltage, connect a potenti
and new "0" ring seals into housing and install tapered
ometer or variable resistance of sufficient value not less
pin. Connect control wire to lever.
than 50 ohms in series with the "KD" terminal, connect
SPEEDOMETER DRIVEN GEAR a voltmeter to the "IGN" and "KD" terminals. With the
ignition switch on, slowly decrease the amount of resist
Disconnect speedometer cable, remove lock plate to ance in order to check the relay closing voltage the
housing bolt and lock washer and remove lock plate. In overdrive solenoid and relay should click when the relay
sert screw driver in lock plate slot in fitting and pry closes. Adjust the closing voltage by bending the arma
fitting, gear and shaft from housing. Pry "0" ring from ture spring post fig. 15. Bend down to increase the
groove in guide. closing voltage and bend up to decrease the closing
Install new "0" ring in groove in fitting and insert voltage.
shaft. To check the sealing voltage, increase the voltage after
Hold the assembly so slot in fitting is toward lock plate the relay closes until the armature seals against the
boss on housing and install in housing. Push fitting into core. Decrease the sealing voltage by reducing the relay
housing until lock plate can be inserted in groove and air gap.
attached to housing.
ELECTRICAL UNIT CHECKS
Overdrive Relay
Specifications and checking procedures for this relay
are as follows:
Specifications
Air Gap 011 inch minimum
Point Opening 025 inch
Closing Voltage 8.3-10.2 volts
Armature Sealing Voltage . . . . 11.2 volts maximum
Three checks and adjustments are required on the
overdrive relay; air gap, point opening and closing volt
age. The air gap contact point opening checks and adjust
ments should be made with the battery disconnected. Fig. 14-Adjusting Relay Point Opening
Solenoid
Closing Coil
Remove solenoid from transmission, connect a jumper
wire between negative terminal of battery and mounting
flange of solenoid. Connect a second jumper wire be
tween the battery positive terminal and solenoid terminal
No. 4; this should cause the solenoid pawl to move out.
If soleno.id chatters, Hold-In Coil is defective.
Engaging Spring
With jumper wire connected as in paragraph above,
solenoid energized, plunger extended place ball end of
solenoid against bench. Push down on solenoid. The
pawl rod should move in 3/8" under a load of not less
than 8 lbs. nor more than 12. Pawl should move out to
extended position when load is removed.
Ignition Grounding Contact
Place a test lamp between negative battery terminal
and solenoid terminal No. 6. Lamp should light when this
connection is made. Remove jumper from between nega
tive battery terminal and solenoid terminal No. 4. Pawl
rod should snap "in" and test lamp should go out.
Fig. 15-Adjusting Relay Closing Voltage
Governor Switch
Remove overdrive wire at governor and connect test 1. Connect test lamp between "SW" terminal and posi
lamp between governor overdrive terminal and positive tive terminal of battery; with switch in normal posi
terminal of battery. Drive car on road or raise on jacks. tion, lamp should light when "REL" terminal is
The lamp should light at a car speed of between 26 to 30 grounded but should not light when "IGN" or "SOL"
MPH. Upon decreasing speed, the lamp should go out at terminals or switch case is grounded.
between 28 and 23.5 MPH. The car speed differential 2. Connect test lamp between "IGN" terminal and posi
between light "on" and light "off" should be 2 or 3 MPH. tive terminal of battery; with switch stem pushed in,
Kickdown Switch lamp should light when "SOL" terminal is grounded,
but should not light when "SW" or "REL" terminals
Disconnect the 4 wires at kickdown switch. or switch case is grounded.
DIAGNOSIS-OVERDRIVE
MECHANICAL overdrive dash control wire is connected to the
lockup lever on the left side of the overdrive
Any one of the following general complaints may be due housing in such a manner as to move the lever
to non-standard mechanical conditions in the overdrive all the way back when the dash control knob is
unit: pushed in, it may hold the shift rail in such a po
1. Does not drive unless locked up manually. sition as to interlock the pawl against full engage
2. Does not engage, or lock-up does not release. ment resulting in a buzzing noise when overdrive
3. Engages with a severe jolt, or noise. engagement is attempted.
4. Free-wheels at speeds over 30 MPH. To correctly make this connection, loosen bind
These troubles may be diagnosed and remedied as de ing post at lever, pull dash control knob out 1/4",
scribed in the following paragraphs. move lever all the way to the rear, and tighten
1. Does not drive unless locked up manually. binding post.
a. Occasionally, the un:it may not drive the car for b. Transmission and overdrive improperly aligned-
ward in direct drive, unless locked up by pulling The same symptoms as above may also result
the dash control. This may be caused by one or from misalignment, at assembly, of the overdrive
more broken rollers in the roller clutch, the housing to the transmission case, resulting in
remedy for which is the replacement of the entire binding of the overdrive shift rail, so that the re
set of rollers. tractor spring cannot move the rail fully forward,
b. This may also be caused by sticking of the roller when the dash control knob is pushed in, and the
retainer upon the cam. This retainer must move transmission is not in reverse. Under such con
freely to push the rollers into engaging position, ditions, the unit may remain fully locked up.
under the pressure of the two actuating springs. To test for this, be sure that the transmission
c. Sometimes this is due to slight indentations, worn is not in reverse; disconnect the dash control
in the cam faces by the rollers spinning, reme wire from the lockup lever, and feel the lever for
died by replacement of the cam. free forward movement. If the lever can be
2. Does not engage, or lock-up does not release. moved forward more than 1/4", it indicates that
a. Dash control impro:perly connected-- Unless the misalignment probably exists. To correct this,
loosen the capscrews between the overdrive hous

ing and transmission case, and tap the adapter
plate and overdrive housing until a position is
found where the rail shifts freely; tighten cap-
screws.
c. Kickdown switch improperly adjusted-The posi
tion of the kickdown switch should be adjusted,
by means of the two large nuts which clamp the
switch shaak, so the switch plunger travels 3/16"
before the throttle lever touches its stop.
Occasionally the large nuts which clamp the
switch through the switch bracket are tightened
sufficiently to bend the switch shank, thus pre
venting free motion of the switch stem. This may
usually be remedied by loosening the upper of the
two nuts.
d. Improper installation of solenoid-If car cannot
be rolled backward under any circumstances and
there is no relay click when the ignition is turned
on, it probably indicates that the solenoid has
been installed directly, without twisting into the
bayonet lock between solenoid stem and pawl, thus
jamming the pawl permanently into overdrive en
Fig. 16-Overdrive Electrical Circuit Wiring Diagram
gagement. If the car will occasionally roll back
wards, but not always, and there is no relay click
plate. Check the fit and tension of the ring as de
when the ignition switch is turned on it may indi
scribed under "Cleaning and Inspection"
cate that, upon installation, the bayonet lock was 4. Free-wheels at speeds over 30 MPH.
caught, and the solenoid forcibly twisted into
If cam roller retainer spring tension is weak the unit
alignment with the attaching flange, thus shearing
will free wheel at all times. Check spring action as
off the internal keying of the solenoid. Under
described under "Cleaning and Inspection".
these circumstances, the end of the solenoid stem
may not catch in the pawl, and upon release of the
ELECTRICAL
solenoid, the pawl will not be withdrawn promptly
from engagement, but simply drift out. If the Any one of the following general complaints may be due
solenoid stem end has its two flats exactly facing to electrical trouble in the overdrive circuit.
the two solenoid flange holes, it will not withdraw 1. Does not engage.
the pawl properly. if the stem can be rotated 2. Does not release.
when grasped by a pair of pliers, it indicates that 3. Does not kickdown from overdrive.
the internal keying has been sheared. These troubles may be traced and remedied as de
e. Improper positioning of blocker ring-Occasion scribed in the following paragraphs.
ally, either in assembly at the factory, or in 1. Does not engage
service operations in the field, the internal parts a. With the ignition switch on, ground the "KID" ter
of the overdrive unit may have been rotated with minal of the solenoid relay with a jumper lead.
the solenoid pawl removed, causing the blocker if the solenoid clicks, the relay and soleno.id cir
ring to rotate, so that its two lugs are not located cuits are in operating condition. If no click is
with respect to the pawl as shown in Figure 12B. heard in the relay, check the fuse and replace if
In other words, the solid portion of the blocker defective.
ring may be in alignment with the pawl, which will b. if the fuse is good, use a second jumper lead to
prevent full engagement of the pawl with the sun connect the "SOL" and "BAT" terminals of the
gear control plate. relay. if a click is now heard in the solenoid, the
To test for this condition, remove solenoid relay is probably at fault and should be repaired
cover, pull dash control knob out, roll car 2 ft. or replaced.
forward. Push dash control in, turn ignition c. If the solenoid does not click in Step b, check the
switch on. Then ground the "KD" terminal of wiring to. the No. 4 terminal of the solenoid and
relay, and watch movement of center stem of replace if necessary. if the wiring is not defec
solenoid. It should not move more than 1/8" when tive, the trouble is probably in the solenoid. Re
the solenoid clicks. Then, with the relay terminal move the solenoid cover, examine the solenoid
still grounded, shift into low gear, and roll car contacts in series with the pull-in winding and
forward by hand. Solenoid stem should then move clean if necessary. Test again for clicks, as in
an additional 3/8", as the pawl engages fully. Step b, after replacing solenoid cover and lead
These two tests indicate proper blocker action. wires. Replace the solenoid if trouble has not
Unless both tests are met, the blocker ring is been corrected.
probably not in the correct position. d. if the relay and solenoid circuits are in good con
3. Engages with a severe jolt or noise. dition as determined in Step a, leave the ignition
Insufficient blocker ring friction may cause the ring switch on and make sure the manual control knob
to lose its grip on the hub of the sun gear control is in the overdrive position. Ground one and then
the other of the two terminals next to the stem of b. if the engine does not stop in Step a, ground one
the kickdown switch identified as "SW" and and then the other of the two terminals identified
"REL". If the solenoid clicks when one terminal as "IGN" and "SOL" farthest from the stem of
is grounded but not the other, replace the switch. the kickdown switch. The engine should stop when
if the solenoid does not click when either of the one of the two terminals IGN is grounded. If
terminals is grounded, check the wiring between the engine does not stop when the terminal is
the relay and the kickdown switch and replace if grounded, the wiring or connections to the switch
defective. between the switch and coil are defective. When
e. if the solenoid clicks as each terminal is the other terminal SOL is grounded, the engine
grounded in Step d, ground the governor switch should stop when the kickdown switch is operated.
terminal. if the solenoid clicks, the governor if the engine does not stop when the kickdown
switch may be defective. if the solenoid does not switch is operated with the second terminal
click, check the wiring between the kickdown and grounded, the kickdown switch is defective, if
governor switches and replace if necessary. the trouble is in the kickdown switch, adjust the
2. Does not release linkage to give more travel of the switch rod.
a. Remove the connection to the "KD" terminal of if this does not correct the trouble, replace the
the relay. If this release overdrive, look for a kickdown switch.
grounded control circuit between the relay and If the kickdown switch operates as it should,
governor switch. check for an open circuit in the wiring between
b. If the overdrive is not released in Step a, dis the kickdown switch and the No. 6 terminal of the
connect the lead to the "SOL" terminal of relay. solenoid.
if this releases the overdrive, replace the relay. c. If the trouble is not located by the above checks,
3. Does not kickdown from overdrive the upper contacts of the kickdown switch may not
a. With the engine running, connect a jumper lead be opening. To check for this condition, ground
between the No. 6 terminal of the solenoid and the overdrive control circuit at the governor
ground. Operate the kickdown switch by hand. switch. This should cause the solenoid to click.
This should stop the engine, if it does, the sole Operate the kickdown switch by hand. This should
noid is probably defective and it should be cause a second click as the solenoid releases.
checked for dirty gound-out contacts or other de If there is no second click, adjust the linkage to
fects within the ground-out circuit of the solenoid give more travel of the switch rod. If this does
fig. 16. Clean the contacts or replace the con not correct the trouble, replace the kickdown
tact plate as required. switch.
FOUR-SPEED TRANSMISSION MUNCIE & SAGINAW

INDEX
Page Page
General Description 7-15 Transmission Side Cover 7-17
Maintenance and Adjustments 7-16 Removal 7-17
Shift Linkage Adjustment 7-16 Disassembly 7-17
Gearshift Lever Reverse Blocker Cable 7-16 Assembly 7-17
Replacement 7-16 Installation 7-j-
Adjustment 7-16 Extension Oil Seal 7-19
Shift Control Lever and Bracket 7-16 Replacement 7-19
Removal Transmission Replacement 7-19
Installation Removal from Vehicle 7-19
Speedometer Driven Gear and Oil Seal 7-16 Installation in Vehicle 7-19
Replacement 7-16
GENERAL DESCRIPTION
The Muncie four-speed synchromesh transmission in the hollow end of the main drive gear and the rear end
corporates helical gears throughout specially designed to is carried by a heavy-duty ball bearing mounted at the
provide high torque capacity without additional weight, and rear end of the transmission case in a retainer casing.
gear teeth proportioned to operate at high speeds with The counter gear is carried on a double row of rollers
neither excessive heat generation nor excessive fric at both ends while thrust is taken on thrust washers lo
tional losses. Shafts, bearings, high capacity clutches cated between the ends of the gear and the thrust bosses
and other precision parts are held to close limits, pro in the case.
viding proper clearances necessary for durability during The two-piece reverse idler gear is carried on bronze
extended heavy usage. bushings while thrust is taken on thrust washers located
The main drive gear is supported by a heavy-duty ball between the front of the gear and the back of the reverse
bearing at the front end of the transmission case and is idler thrust boss and between the rear of the gear and the
piloted at its front end in an oil impregnated bushing reverse idler shaft boss in the case extension.
mounted in the engine crankshaft. The front end of the Gearshifting is manual through shift control rods to the
mainshaft is piloted in a row of roller bearings set into transmission cover shifter levers for first through fourth
gears, and to the reverse lever located in the case ex bored in place and rotates on a short idler shaft retainer
tension. The shifter lever to the rear of the transmis by a Woodruff key.
sion cover controls first and second gears while the The synchronizer assemblies consist of a clutch hub,
lever to the front controls third and fourth gears. All clutch sleeve, two clutch key springs and three energizer
four forward gears are fully synchronized. The trans clutch keys and are retained as an assembly on the main
mission may he used as an aid in deceleration by down- shaft by a snap ring.
shifting in sequence without double clutching. Reverse is A great deal of similarity and interchangeability
not synchronized, however, it is a helical gear to insure now exists between the new 3 and 4-speed Saginaw
quiet operation. transmissions.
The Saginaw four- speed fully synchronized all forward However, the synchronizer assembly at the front of the
gears transmission incorporates helical drive gears
mainshaft is used for the third and fourth rather than the
throughout.
second and third shift. The synchronizer assembly at
The main drive gear is supported by a ball bearing at the rear of the mainshaft is used for the first and second
the front end of the transmission case and is piloted at its rather than the first and reverse shift. Gear teeth cut
front end in an oil impregnated bushing mounted in the in the first and second synchronizer sleeve reverse
engine crankshaft. The front end of the mainshaft is
gear distinguish it from the third and fourth synchro
piloted in a row of roller bearings set into the hollow end
nizer sleeve.
of the main drive gear and the rear end is carried by a
ball bearing mounted in the front of the extension housing. Starting from the front, gears on the mainshaft are
The countergear is carried on a single row of rollers third, second and first rather than second, first and re
at both ends while thrust is taken on thrust washers lo verse. A fourth blocker ring is used between the 1-2
cated between the ends of the gear and the thrust bosses synchronizer assembly and first gear on the four- speed
in the case. An anti-rattle plate assembly at the front of transmissions.
the countergear provides a constant spring tension be The cover on the new four-speed transmission is lo
tween the counter and clutch gears to reduce torsional cated on the left-hand side of the case. It is similar to
vibrations. the three-speed cover with the addition of a reverse
The reverse idler gear is held in constant mesh with shifter shaft assembly, detent ball and detent spring.
the 1st and 2nd synchronizer gear regardless of its po Disassembly and assembly procedures are covered in
sition. The idler gear is carried on a bushing finish this section.

SHIFT LINKAGE ADJUSTMENTS Figs. 17 & 18 5. Reverse Steps 1, 2 and 3 to install.
1. Loosen swivel locknuts on shift rods. Rods should Figure 19 shows the adjustment and lubrication proce
pass freely through swivels. dure for the mechanism.
2. Set transmission shift levers L, M and N in neutral Adjustment
detent position. 1. With set screw loose, assemble cable through hole
3. Move shift control lever A to neutral detent position in cylindrical retainer above handle.
and insert locating gauge B, into control lever 2. With handle in full down position-adjust cable to ac
bracket assembly. quire dimension shown, be certain that cable is
4. Tighten reverse lever E swivel locknuts. pulled taut.
5. Repeat step four for 1st and 2nd shift control rod D 3. Tighten set screw to 15-20 in. lbs.
and 3rd and 4th control rod E. 4. Bend excess wire and cut - be certain that wire does
6. Remove locating gauge and discard. After removing not interfere with I.D. of lever or threads of shifter
locating gauge on Camaro only with Muncie trans knob.
mission, readjust rod by shortening the rod three
turns by use of the jam nuts. Check shift for proper NOTE: Handle must return freely from any
operation. Readjust if necessary. position.
SHIFT CONTROL LEVER AND BRACKET ASSEMBLY
GEAR SHIFT LEVER REVERSE BLOCKER CABLE Refer to replacement procedures for three-speed
Fig. 19 transmission control lever and bracket assemblies de
Replacement scribed under 3-Speed Transmissions.
In the event replacement is necessary use the following
SPEEDOMETER DRIVEN GEAR AND OIL SEAL
procedure.
1. Remove seat separator console assembly. Replacement
2. Remove shift lever seal retainer and slide seal up Disconnect speedometer cable, remove retainer to
on lever. housing bolt and lock washer and remove retainer. In
3. Remove shift lever knob, and the 2 lever to bracket sert screw driver in slot in fitting and pry fitting, gear
retaining bolts and remove the lever assembly. and shaft from housing. Pry "0" ring in groove in fitting.
4. Replace blocker cable - thread new cable up through Install new "0" ring in groove and insert shaft. Hold
lever and "T" handle and install cable retainer the assembly so slot in fitting is toward boss on housing
through access slot. Adjust retainer to hold blocker and install in housing. Push fitting into housing until re
end .010/.020" above lever bracket surface, then lock tainer can be inserted in groove and install retainer lock
and cut off excess cable. washer and bolt.
____________________________________________
CHEVELLE
Fig. 18-4-Speed Linkage Assembly-Corvette
2. Install detent cam retaining "C" ring to pivot shaft,

and hook spring into detent cam notches.
3. Install both shifter shaft assemblies in cover being
careful not to damage lip seals. Install both shift
forks to detent plates, lifting up on detent cam to
allow forks to fully seat into position.
4. Install outer shifter levers, flat washers, lock wash
ers and nuts.
CAMARO & CHEVY II
Fig. 17-4-Speed Linkage Assembly-Cheve lIe, Camaro,

and Chevy II
TRANSMISSION SIDE COVER Muncie
Removal
1. Disconnect control rods from levers.
2. Shift transmission into second speed before removing
cover, by moving 1-2 Rear Cover shifter lever into
forward detent position.
3. Remove cover assembly from transmission case
carefully and allow oil to drain.
Disassembly Fig. 20
1. Remove the outer shifter lever nuts, lock washers
and flat washers. Pull levers from shafts.
2. Remove both shift forks from shifter shaft and detent
plate assemblies. Remove both shifter shaft assem
blies from cover. Lip seals in side cover may now
be pryed out if replacement is required because of
damage.
CAUTION: Components should be marked so
they may be reinstalled with same relationship.
3. Remove detent cam spring and pivot retainer "C"
ring. Remove both detent cams.
4. Replace necessary parts.
Assembly Fig. 20
1. Install 1-2 detent cam to cover pivot pin first, then
install 3-4 detent cam so the detent spring notches
are offset or opposite each other. Detent cam
notches must be facing downward. Fig. 19-Gearshift Lever Assembly and Adjustment
Disassembly Fig. 22
1. Remove the outer shifter levers.
1-2 DETENT CAM DETENT SPRING 3-4 DETENT CAM 2. Remove both shift forks from shifter shaft assem
blies. Remove all three shifter shaft assemblies
from cover. "0" ring seals around shifter shaft
may now be pryed out if required because of damage.
Remove reverse shifter shaft detent ball and spring.
3. Remove detent cam spring and pivot retainer "C"
ring. Mark to identify for reassembly, then remove
1-2 SHIFTER SHAFT 3-4 SHIFT both detent cams.
FORK
4. Replace damaged parts.
Assembly Fig. 22
1-2 SHIFT
1. With detent spring tang projecting up over the 3rd
DETENT CAM 3-4 SHIFTER SHAFT and 4th shifter shaft cover opening install the first
RETAINER RING
and second detent cam onto the detent cam pivot pin.
DETENT CAM PIVOT PIN With the detent spring tang projecting up over the
first and second shifter shaft cover hole install the
3rd and 4th detent cam.
Fig. 20-Transmission Side Cover-Muncie NOTE: The 1-2 detent cam has .090" greater
contour on the inside detent notch.
Installation Fig. 21 2. Install detent cam retaining "C" ring to pivot shaft,
1. Shift 1-2 shifter lever into second speed forward and hook spring into detent cam notches.
position. Position cover gasket on case. 3. Install 1-2 and 3-4 shifter shaft assemblies in cover
2. Carefully position side cover into place making sure being careful not to damage seals. Install both shift
the shift forks are aligned with their respective forks to shifter shaft assemblies, lifting up on detent
mainshaft clutch sliding sleeves. cam to allow forks to fully seat into position.
3. Install cover attaching bolts and tighten evenly to 4. Install reverse detent ball and spring to cover, then
15-20 ft. lbs. torque. install reverse shifter shaft assembly to cover.
4. Remove filler plug and add lubricant specified in 5. Install outer shifter levers, flat washers, lock wash
Section 0, to level of filler plug hole. ers and bolts.
TRANSMISSION SIDE COVER Saginaw

Installation
Removal
1. Shift shifter levers into neutral detent center posi
1. Disconnect control rods from levers. tion. Position cover gasket on case.
2. Shift transmission into neutral detent positions be 2. Carefully position side cover into place making sure
fore removing cover. the shift forks are aligned with their respective
3. Remove cover assembly from transmission case mainshaft clutch sliding sleeves.
carefully and allow to drain. 3. Install cover attaching bolts and tighten evenly to
specified torque.
4. Remove filler plug and add lubricant specified in
Section 0, to level of filler plug hole.
PIVOT PIN
1.2 DETENT
CAM DETENT 3-4 DETENT
CAM
SPRING
3.4
LL/ SHIFT FORK
1.2 SHIFTER
SHAFT ASSY.
RE VERSE
SHIFTER SHAFT
ASSY.
L. 3-4 SHIFTER
SHAFT ASSY.
DETENT - -, RETAINER
& BALL UNDERNEATH 1-2 SHIFTER RING
FORK
Fig. 21-Installing Side Cover Assembly Fig. 22-Transmission Side Cover, Assembly-Saginaw
EXTENSION OIL SEAL NOTE: Connect exhaust pipe to exhaust mani

Replacement fold on Camaro models.
1. Remove propeller shaft. 6. Install propeller shaft assembly.
2. Pry out the extension oil seal.
3. Prelubricate between sealing lips and press new oil CAUTION: Prelube bushing extension.
seal carefully into place in extension using J- 5154 or 7. Connect speedometer assembly and connect backing
similar tool. lamp switch wiring.
8. Fill transmission with lubricant and lower vehicle
CAUTION: Do not excessively force the seal
against the seat in the extension. and check operation of transmission.
TRANSMISSION Remova I-Corvette

Removal-Chevrolet, Chevelle, Chevy II and Camaro 2. From inside vehicle remove shifter ball and "T"
1. Support vehicle on hoist. handle..
2. Disconnect speedometer cable at transmission and 3. Remove console trim plate. Refer to Corvette Body,
back-up lamp switch wiring. Secion 1A, Passenger Service Manual.
3. Remove propeller shaft assembly. 4. Raise vehicle on hoist.
NOTE: On Camaro models, disconnect exhaust 5. Completely remove right and left exhaust pipes from
pipe at manifold. vehicle. In order to remove the exhaust pipes on
vehicles equipped with 396 or 427 cu. in. engine, it
4. Remove crossmember to frame attaching bolts and is necessary to remove the forward stud on each
crossmember to control lever support attaching manifold.
bolts. On Chevelle models also remove control lever 6. Disconnect propshaft at transmission slip
brace to crossmember attaching bolt. yoke. Lower propshaft. Remove slip yoke from
NOTE: Complete removal of the control lever transmission.
support bracket will provide greater clearance 7. Remove bolts attaching rear mount to rear mount
for moving transmission rearward. bracket. Raise engine lifting transmission off mount
bracket.
5. Remove bolts retaining transmission mount to 8. Remove the bolts retaining transmission linkage
c rossmember. mechanism mounting bracket to frame.
6. Support engine and raise slightly until crossmember 9. Remove bolts attaching gearshift assembly to mount
may be slid rearward or removed. ing bracket and remove mounting bracket. Remove
7. Remove shift levers at transmission side cover. Re shifter mechanism with rods attached.
move stabilizer to control lever assembly retaining 10. Disconnect shifter levers at transmission. Discon
nut. Push bolt toward transmission until stabilizer nect speedometer cable.
rod may be disconnected. 11. Remove transmission mount bracket to crossmem
8. Remove transmission to clutch housing upper re ber bolts and remove mount bracket. Remove bolts
taining bolts and install guide pins in holes then retaining rear mount cushion and exhaust pipe yoke.
remove lower bolts. 12. Remove transmission-to-clutch housing retaining
9. Slide transmission rearward and remove from bolts and lower left extension bolt.
vehicle. 13. Pull transmission rearward until it is clear of
Installation-Chevrolet, Chevelle, Chevy II and Camaro clutch housing. Rotate clockwise while pulling to
1. Raise transmission into position and slide forward, rear. To allow room for transmission removal
piloting clutch gear retainer into clutch housing. slowly lower the rear of engine until the tachometer
2. Install transmission to clutch housing retaining bolts drive cable at the distributor just clears the hori
and lock washers. Torque to specifications. zontal ledge across the front of dash.
3. Install shift levers at t:ransmission side cover and
CAUTION: THE TACHOMETER CABLE CAN
stabilizer rod to the control lever assembly.
BE EASILY DAMAGED BY HEAVY CONTACT
4. Support engine and raise slightly until crossmember
may be repositioned. Install retaining bolts and WITH THE DASH. SLIDE TRANSMISSION REAR
WARD OUT OF THE CLUTCH, THEN TIP
torque to specifications. Remove engine support.
FRONT END OF TRANSMISSION DOWNWARD
5. Install transmission crossmember to mount re
taining bolts, crossmember to control lever support AND LOWER THE ASSEMBLY FROM VEHICLE.
attaching bolts and control lever brace to cross- 14. Reinstall transmission assembly by performing
member attaching bolts Chevelle only. above steps in reverse order.
SPECIAL TOOLS
1 2
Fig. 23-Clutch-Special Tools
1. J-1522 Pilot Bearing Driver 2. J-5824 Clutch Pilot Tool 3. J-1448 Pilot Bearing Puller
SPECIAL TOOLS
g2g
3
p2
4 5 11
10 1
Fig. 24-Manual Transmission Special Tools
1. J-0933 Clutch Gear Bearing Retainer Wrench 8. J-5814-15 Speedometer Drive Gear Remover
2. J-1 126 Transmission Guide Pins 9. J-1453-01 Speedometer Drive Gear Press Plates
3. J-8059 Retainer Snap Ring Pliers J-9771 Press Plates Not Illustrated
4. J-21629 Countergear Loading Tool J-358-1 Press Plate Holder
5. J-22246 Countergear Loading Tool 10. J-4653 Overdrive Governor Wrench
6. J-5778 Extension Housing Bushing Remover and Installer 11. J-5590 Clutch Gear Bearing Installer
7. J-5154 Extension Housing Seal Installer 12. J-7785 Clutch Gear Retainer Lip Seal Installer
ALUMINUM POWERGLIDE
INDEX
Page Page
General Description 7-22 Diagnosis 7-30
Maintenance and Adjustments 7-22 Warming Up Transmission 7-30
Oil Level Check . 7-22 Shop Warm Up 7-30
Periodic Oil Change 7-23 Road Warm Up 7-30
Periodic Low Band Adjustment 7-23 Checking Fluid Level and Condition 7-30
Manual Shift Linkage Check and Adjust 7-25 Manual Linkage 7-30
Floor Shift Linkage 7-26 Oil Leaks 7-30
Throttle Valve Linkage 7-27 Basic Pressure Checks 7-30
Neutral Safety Switch 7-27 Wide Open Throttle Upshift Pressure Check. 7-31
Throttle Return Check Valve Dashpot 7-27 Idle Pressure in Drive Range 7-31
Floor Mounted Shift Control Lever 7-26 Manual "Low" Range Pressure Check 7-31
Component Parts Replacement 7-27 Drive Range Overrun Coast Pressure 7-31
Transmission Replacement 7-27 Powerglide Shift Points 7-32
Other Service Operations 7-29
GENERAL DESCRIPTION
The case and converter housing of the two speed alumi ernor which requires a hole through the output shaft. The
num Powerglide Transmission is a single case aluminum reverse clutch assembly is a multiple disc type clutch.
unit. When the manual control is p’laced in the drive po The steel plates are splined directly to the case while the
sition, the transmission automatically shifts to low gear face plates are splined to the internal or ring gear. The
for initial vehicle movement. As the car gains speed and clutch piston operates within the rear portion of the case.
depending on load and throttle position, an automatic shift The internal diameter of the piston is sealed to an inte
is made to high gear. A forced downshift feature pro gral hub portion of the case rear bulkhead. The outside
vides a passing gear by returning the transmission to low diameter is sealed to a machined portion of the case. The
range. piston is hydraulically applied and is released by sepa
The oil pump assembly is a conventional gear type and rate coil springs. The valve body assembly is bolted to
the oil pump housing is of the large diameter type acting the bottom of the transmission case and is accessible for
as the front bulkhead of the transmission. The torque service by removing the oil pan assembly. The valve
converter is a conventional three element welded design body consists of an upper and lower body located on
bolted to the engine flywheel which drives through a two- either side of a transfer plate. The vacuum modulator
speed planetary gearset. The high clutch assembly is is located on the left rear face of the transmission case.
typical of the designs used in this type transmission. The The modulator valve bore is located in the upper valve
aluminum Powerglide uses an output shaft mounted gov. body.
MAINTENANCE AND ADJUSTMENT

OIL LEVEL CHECK
The transmission oil level should be checked period
ically as recommended in Section 0. Oil should be added
only when level is on or below the "ADD" mark on the
dip stick with oil hot or at operating temperature. The oil
level dip stick is located at the right rear of the engine
compartment. Fill with oil specified in Section 0.
In order to check oil level accurately, the engine should
be idled with the transmission oil hot and the control
lever in neutral N position.
It is important that the oil level be maintained no
higher than the "FULL" mark on the transmission oil
level gauge. DO NOT OVERFILL, for when the oil level
is at the full mark on the dip stick, it is just slightly be
low the planetary gear unit. If additional oil is added,
bringing the oil level above the full mark, the planetary
unit will run in the oil, foaming and aerating the oil. This
aerated oil carried through the various oil pressure pas
sages low servo, reverse servo, clutch apply, converter,
etc. may cause malfunction of the transmission assem
bly, resulting in cavitation noise in the converter and
improper band or clutch application. Overheating may
also occur.
If the transmission is found consistently low on oil, a
thorough inspection should be made to find and correct
all external oil leaks. Fig. 1PG-Adjusting Low Band Using J-2184.8
PERIODIC OIL CHANGE at 12,000 mile intervals, or sooner, as necessary if op

erating performance indicates low band slippage.
The transmission oil should be changed periodically as
recommended in Section 0, and whenever transmission is 1. Raise vehicle and place selector lever in neutral.
to be removed from the vehicle for repairs. 2. Remove protective cap from transmission adjusting
screw.
1. Run engine for one minute in neutral prior to
3. On Chevelle Models: To gain clearance between
changing.
2. Be sure vehicle is level or raise from the rear only. underbody and transmission, it may be necessary
to remove rear mount bolts from crossmember,
3. Remove the oil pan drain plug and allow oil to drain
thoroughly into a pan or can. and move transmission slightly toward passenger
4. Replace drain plug and refill with approximately two side of vehicle.
4. Loosen adjusting screw locknut 1/4 turn and hold in
quarts of oil specified in Section 0.
this position with wrench.
NOTE: To refill the transmission, remove dip 5. Using Special Tool J-21848 adjust band to 70 in. lbs.
stick from oil filler tube and refill transmission and back off four 4 complete turns for a band which
with oil specified in Section 0 using filler tube has been in operation for 6,000 miles or more, or
and funnel J-4264. Then, after shifting into all three 3 turns for one in use less than 6,000 miles.
ranges at idle speed to fill all oil passages, the
CAUTION: Be sure to hold the adjusting screw
engine should be run at 800-1000 rpm with the
locknut at 1/4 turn loose with a wrench during
transmission in Neutral until the oil warms up,
then add oil as required to raise the fluid level the adjusting procedure.
to the full mark on the dip stick, Refill capacity 6. Tighten the adjusting screw locknut to specified
is approximately 2 qts. torque.
PERIODIC LOW BAND ADJUSTMENT Fig. 1PG CAUTION: The amount of back-off is not an
Low band adjustment should be periodically performed approximate figure, it must be exact.
IVItWEI
Fig. 2PG-Chevrolet Shift Linkage Adlustments - Column
Fig. 3PG-Chevelle Shift Linkage Adjustments - Column
wE1
Fig. 4PG-Chevy II, Camaro Shift Linkage Adjustments - Column
MANUAL SHIFT LINKAGE CHECK & ADJUST 5. Release the selector lever. The lever should now
Column Type be inhibited from engaging reverse range unless the
lever is lifted.
1. The shift tube and lever assembly must be free in the 6. A properly adjusted linkage will prevent the selector
mast jacket. See Section 9 for alignment of steering lever from moving beyond both the neutral detent, and
column assembly if necessary. the drive detent unless the lever is lifted to pass
2. To check for proper shift linkage adjustment, lift over the mechanical stop in the steering column.
the transmission selector lever towards the steering 7. In the event that an adjustment is required, place
wheel. Allow the selector lever to be positioned in the selector lever in drive D position as determined
drive D by the transmission detent. by the transmission detent. See Steps 2 and 3.
8. Loosen the adjustment swivel at the cross-shaft, and
NOTE: Do not use the indicator pointer as a rotate the transmission lever so that it contacts the
reference to position the selected lever. When drive stop in the steering column.
performing linkage adjustment, pointer is ad 9. Tighten the swivel and recheck the adjustment. See
justed last. Steps 2 and 6.
10. Readjust indicator needle if necessary to agree with
3. Release the selector lever. The lever should be in the transmission detent positions. See Section 9.
hibited from engaging low range unless the lever is 11. Readjust neutral safety switch if necessary to pro
lifted. vide the correct relationship to the transmission
4. Lift the selector lever towards the steering wheel, detent positions. See Section 12.
and allow the lever to be positioned in neutral N by CAUTION: Any inaccuracies in the above ad
the transmission detent. justment may result in premature failure of the
.02
.07 DETENT
BUTTON
HANDLE
ASSEMBLY
VIEW A
DIM. E
PAWL
ROD
A B
Fig. 5PG-Chevrolet Floor Shift Linkage Adjustments
transmission due to operation without controls Bolt B; after adjustments are made tighten Bolts C
in full detent. Such operation results in reduced and D.
oil pressure and in turn partial engagement of 6. Check operation of shift lever.
the affected clutches. Partial engagement of the
clutches with sufficient pressure to cause ap Chevy II Linkage Adjustment Rod Type Fig. 7PG
parent normal operation of the vehicle will
result in failure of the clutches or other in 1. Loosely assemble nuts A and B on Lower Rod C.
ternal parts after only a few miles of operation. 2. Set Transmission Lever D in "DRIVE" position.
NOTE: Obtain "DRIVE" position by moving
CHEVROLET Trans. Lever Counter-clockwise to "LOW" de
tent, then clockwise one detent position to
Floor Shift Linkage-Cable Type Refer to Fig. 5PG "DRIVE."
1. Loosely assemble bolts A, B, C, D. 3. Set Control Pawl Rod E in the "NEUTRAL or
2. Place handle assembly in Reverse position. DRIVE" notch of Detent F. See View A.
3. Squeeze button and adjust detent to obtain clearance 4. Apply load in direction of Arrow Y on Actuating
shown in View A. Tighten Bolt A. Lever G until pawl Rod comes in contact with
4. Place handle assembly in Drive position. Detent at Contact Point Z. See View A and B.
5. Place a .094" Spacer H between Nut A and Swivel
NOTE: Obtain drive position by moving Trans J, run Nut A until it touches Spacer. Tighten Nut
mission Lever counter-clockwise to low detent, B against Swivel and lock Swivel between Nuts A
then clockwise one detent position to drive. and B. See View B.
5. With handle assembly in Drive position as shown in The foregoing procedure will provide a .050" over
View B adjust lever to obtain dimension E. Tighten travel gap in the notches of Detent F.
CABLE ASSEMBLY 5.5"

5.5
CABLE
ASSEMBLY
PIN
PLACE TRANSMISSION LEVER
IN DRIVE. ADJUST PIN TO
PIN
5.5" BEFORE INSTALLING
CABLE ASSEMBLY
/
VIEW C VIEW B
VIEW A
CHEVELLE
Fig. 6PG-Chevelle, Camaro Floor Shift Linkage Adjustments
Throttle Valve Linkage Adjustment 1-4 and 1-6 Models Throttle Return Check Valve
Dashpot Adjustment
With accelerator pedal depressed, Bell Crank on L-4
and L-6 models must be at wide open throttle position. The adjustment of the throttle return check valve is
Dash Lever must be 1/64"-1/16" off Lever Stop and described in Section 6M for each carburetor installation.
Transmission Lever must be against transmission inter Floor Mounted Shift Control Lever Refer to Fig. 8PG
nal stop.
Disassembly-Control Lever
1. Remove neutral safety back-up switch.
V-S Models-With Uni-Directional Linkage 2. Remove 2 pivot bolts. Place punch in shaft hole to
1. Remove air cleaner. keep shaft from rotating.
2. Disconnect accelerator linkage at carburetor. 3. Remove cable drive lever.
3. Disconnect accelerator return and TV rod return 4. Spread lever handle to remove lever strap and button
springs. mechanism.
4. With right hand, pull TV upper rod forward until 5. Spread control lever strap to remove pawl and dis
transmission is through detent. With left hand, open assemble button mechanism.
carburetor to wide open throttle position. Carburet 6. Remove screws to disassemble handle from lever.
or must reach wide open throttle position at the
Control Lever Cover
same time the ball stud contacts end of slot in upper
To replace handle cover, drill attaching points with
TV rod. suitable size drill. Place new cover on handle and secure
5. Adjust swivel on end of upper TV rod to obtain set to handle by applying heat soldering iron to retaining
ting described in Step 4. Allowable tolerance is tabs. Be sure cover is securely assembled to handle.
approximately 1/32’. Detent
6. Connect and adjust accelerator linkage as described To remove detent from mounting bracket, remove at
in Section 6. taching bolt and rivet. Replace rivet with suitable bolt at
7. Check for throttle linkage freedom.
assembly.
Assembly-Control Lever
Neutral Safety Switch Adjustment Use reverse of disassembly procedure. Place handle in
The adjustment at the neutral safety switch is de Drive position when installing neutral safety-back-up
scribed in the Electrical Section 12. switch. See Section 12 for adjustment.

TRANSMISSION REPLACEMENT 8. Support engine at the oil pan rail with a jack or other
suitable brace capable of supporting the engine
weight when the transmission is removed.
Removal
1. Place car on hoist and remove oil pan drain plug
to drain oil.
NOTE: If desired, the oil may be drained after
transmission removal.
2. Disconnect the oil cooler lines external cooled ACTUATING LEVER F POINT OF
models, vacuum modulator line and the speedometer
drive cable fitting at the transmission. Tie lines out LOAD 1J
of the way.
ROD C LOAD H DETENT K
3. Disconnect manual and TV control lever rods from
transmission.
4. Disconnect propeller shaft from transmission. NUT E
5. Install suitable transmission lift equipment to jack
or other lifting device and attach on transmission. .09
6. Disconnect engine rear mount on transmission ex SWIVEL’
tension, then disconnect the transmission support VIEW A
crossmember and slide rearward. Remove cross-
DETENT K
member on Camaro models.
7. Remove converter underpan, scribe flywheel.-
converter relationship for assembly, then remove the
flywheel-to-converter attaching bolts.
NOTE: The "light" side of the converter is
denoted by a "blue" stripe painted across the
ends of the converter cover and housing. This
marking should be aligned as closely as possible
with the "white" stripe painted on the engine
side of the flywheel outer rim heavy side of
engine to maintain balance. Fig. 7PG-Chevy II Floor Shift Linkage Adjustments
CI4EVROLrT CHASSIS SERV1C! MANUAL
9. Lower the rear of the transmission slightly so that not to lower rear of transmission too far as the
the upper transmission housing-to-engine attaching distributor housing may be forced against the
bolts can be reached using a universal socket and, a dash causing damage to the distributor. It is
long extension. Remove upper bolts. best to have an assistant observe clearance of
all upper engine components while the trans
CAUTION: On V-8 engines, care must be taken mission rear end Is being lowered.
BUTTON
COVER
TRANSMISSION
CONTROL LEVER
LEVER
SPRING RETAINER
CONTROL LEVER
BUTTON
BACK.UP
NEUTRAL
SWITCH
PAWL
MOUNTING
BRACKET
I ATTACHING RIVET
Fig. 8PG-Transmission Floor Mounted Shift Control Lever
structed as shown in Figure 9PG, or, in an

emergency, a length of strong wire may be used
immediately after removal from the engine.
Installation
NOTE: The "light" side of the converter is
denoted by a "blue" stripe painted across the
ends of the converter cover and housing. This
marking should be aligned as closely as possible
with the "white" stripe painted on the engine
side of the flywheel outer rim, denoting the
"heavy" side of the engine.
1. Mount transmission on transmission lifting equip
ment installed on jack or other lifting device.
2. Remove converter holding tool.
CAUTION: Do not permit converter to move
forward after removal of holding tool.
3. Raise transmission into place at rear of engine and
install transmission case to engine upper mounting
bolts, then install remainder of the mounting bolts.
Torque bolts to 35 ft. lbs.
4. Remove support from beneath engine, then raise
rear of transmission to final position.
5. Through flywheel cover opening align as closely as
possible the "white" flywheel balance mark stripe
and the "blue" painted stripe on the end of converter
cover and housing. If scribed during removal, align
scribe’ marks on flywheel and converter cover. In
stall converter to flywheel attaching bolts. Torque
bolts to 30-35 ft. lbs.
6. Install converter under pan.
Fig. 9PG-Converter Holding Tool 7. Reinstall transmission support crossmember to
transmission and frame.
10. Remove remainder of transmission housing-to- 8. Remove transmission lift equipment.
engine attaching bolts. 9. Connect propeller shaft to transmission.
11. Remove the transmission by moving it slightly to the 10. Connect manual and TV control lever rods to
rear and downward, then remove from beneath the transmission.
car and transfer to a work bench. 11. Connect oil cooler lines if so equipped, vacuum
modulator line, and speedometer drive cable to
NOTE: Observe converter when moving the transmission.
transmission rearward. If it does not move 12. Refill transmission through filler tube, using Funnel
with the transmission, pry it free of flywheel J-4264 and following the recommended procedure
before proceeding. provided earlier in this section.
CAUTION: Keep front of transmission upward 13. Check transmission for proper operation and for
to prevent the converter from falling out. Install leakage. Check and, if necessary, adjust linkage.
converter Tool J-9549 or a similar tool con- 14. Remove car from hoist.
OTHER SERVICE OPERATIONS

Although certain operations, such as oil pan gasket or Powerglide; their service procedure is covered in
manual levers and oil seal replacement, valve body, gov the Passenger Overhaul Manual and is not repeated
ernor, filler pipe "0" ring, speedometer drive gear, here. Refer to the Powerglide Section of the Passenger
case extension "0" ring and rear oil seal, vacuum mod Overhaul Manual for all other service operations not
ulator, and servo cover or gasket service may be per covered here.
formed from underneath the vehicle without removing the
DIAGNOSIS
Proper operation of the Powerglide transmision may MANUAL LINKAGE
be affected by a number of factors, all of which must be
considered when trouble in the unit is diagnosed. Manual linkage adjustment and the associated neutral
Proper trouble diagnosis can only be accomplished safety switch are important from a safety standpoint.
when performed in *a thorough step by step procedure. The neutral safety switch should be adjusted so that the
The following proceaure has been devised and tested and engine will start in the Park and Neutral positions only.
is recommended for all trouble diagnosis complaints and With the selector lever in the Park position, the park
if the service man will follow this checking procedure, ing pawl should freely engage and prevent the vehicle
accurate and dependable diagnosis may be accomplished. from rolling. The pointer on the indicator quadrant
This will result in a savings of time, not only to the should line up properly with the range indicators in all
service man, but to the customer as well. ranges.
WARMING UP TRANSMISSION OIL LEAKS

Before attempting to correct an oil leak, the actual
Before attempting to check and/or correct any com
plaints on the Powerglide transmission it is absolutely source of the leak must be determined. In many cases
essential that the oil level be checked and corrected if the source of the leak can be deceiving due to "wind flow"
necessary. An oil level which is either too high or too around the engine and transmission.
low can be the cause of a number of 3bnormal conditions The suspected area should be wiped clean of all oil
from excessive noise to slippage in all ranges. before inspecting for the source of the leak. Red dye is
It must be remembered that cold oil will slow up the used in the transmission oil at the assembly plant and
action of the hydraulic controls in the transmission. For will indicate if the oil leak is from the transmission.
this reason a trouble or oil leak diagnosis should not be The use of a "black light" to identify the oil at the
attempted until the transmission has been warmed up by source of leak is also helpful. Comparing the oil from
either of the following procedures: the leak to that on the engine or transmission dip stick
when viewed by black light will determine the source
of the leak.
Shop Warm Up Oil leaks around the engine and transmission are gen
1. erally carried toward the rear of the car by the air
Connect tachometer to engine.
2. Set parking brake tight and start engine. stream. For example, a transmission "oil filter tube
to case leak" will sometimes appear as a leak at the
3. Place selector lever in "D" drive range.
rear of the transmission. In determining the source of
4. Adjust carburetor idle speed adjusting screw to run
an oil leak it is most helpful to keep the engine running.
engine at approximately 750 rpm and operate in this The mating surfaces of servo cover, converter housing,
manner for two minutes. At the end of two minutes
of operation, the transmission will be sufficiently transmission case and transmission case extension
warmed up for diagnosis purposes. should be carefully examined for signs of leakage. The
vacuum modulator must also be checked to insure that
NOTE: At this point, readjust the engine idle the diaphragm has not ruptured as this would allow trans
speed to 450-475 rpm in "D" range. mission oil to be drawn into the intake manifold. Us
ually, the exhaust will be excessively smoky if the
Road Warm Up diaphragm ruptures due to the transmissionoil added to
the combustion. The transmission case extension rear
Drive the car approximately 5 miles with frequent oil seal should also be checked. All test plugs should be
starts and stops. checked to make sure that they are tight and that there
NOTE: At this point, make sure the engine idle is no sign of leakage at these points. The converter
speed is set to 450-475 rpm in "D" range. underpan should also be removed. Any ‘appreciable quan
tity of oil in this area would indicate leakage at the pump
square seal ring, pump seal assembly, or pump bolt
CHECKING FLUID LEVEL AND CONDITION sealing washers.
After transmission has been warmed up, check the
fluid level with the engine idling, parking brake set and BASIC PRESSURE CHECKS
control lever in "N" neutral. If the fluid level is low,
add fluid to bring level up to the full mark on gauge rod. Four basic pressure checks are used for diagnosis and
operational checks for the Aluminum Powerglide trans
CAUTION: If fluid level is too high, fluid may mission. All checks should be made only after thoroughly
be aerated by the planet carrier. Aerated fluid warming up the transmission.
will cause turbulence in the converter which will
result in lost power, lower stall speed and lower * Wide Open Throttle Upshift Pressure.
pressures in control circuits. Lower fluid level * Idle Pressure in "Drive" Range.
to full mark, then shut off engine to allow air * Manual "Low" Range Pressure.
bubbles to work out of fluid. * "Drive" Range Overrun Coast Pressure.
When checking oil level, a burned smell and discolora
tion indicate burned clutches or bands and the transmis * A "Black Light" testing unit may be obtained from
sion will have to be removed. several different service tool suppliers.
points as indicated on the lower servo apply main line

gauge.
* Idle Pressure in "Drive" Range
In addition to the oil pressure gauges, a vacuum gauge

is needed for this check.
With the parking brake applied and the shift selector
lever in "Drive", low servo apply main line pressure
should be as shown on the pressure check chart.
If pressures are not within these ranges, the following
items should be checked for oil circuit leakage:
1. Pressure regulator valve stuck.
2. Vacuum modulator valve stuck.
3. Hydraulic modulator valve stuck.
4. Leak at low servo piston ring between ring and
bore.
5. Leak at low servo piston rod between rod and bore.
6. Leak at valve body to case gasket.
7. Leak at valve body gaskets.
8. Oil pump clearances.
9. Check passages in transmission case for porosity.
* Manual "Low" Range Pressure Check

Connect a tachometei’, apply the parking brake, place
the selector lever in "Low" range, and adjust the engine
speed to 1000 rpm with the car stationary.
Low servo apply main line pressure should be as
Fig. 1OPG-Pressure Test Plug shown on the pressure check chart.
Pressures not within this range can indicate the fol
lowing possibilities:
1. Partially plugged oil suction screen.
It is not recommended that stall tests be conducted 2. Broken or damaged ring low servo.
which would result in engine vacuum falling below 10" Hg. 3. Pressure regulator valve stuck.
Pressure gauge hose connections should be made at 4. Leak at valve body to case gasket.
the low servo apply main line test point fig. 9PG. 5. Leak between valve body gaskets.
Run the gauge line into the driving compartment by 6. Leak at servo center.
pushing aside the mast jacket seal. The line out of the 7. Oil pump clearances.
way of the drivers feet and connect to pressure gauge * Drive Range Overrun Coast Pressure
J-21867.
With the vehicle coasting in "Drive" range at 20-25
* Wide Open Throttle Upshift Pressure Check MPH with engine vacuum at approximately 20" Hg., low
servo apply main line pressure should be as shown on
Refer to the pressure check chart for upshift pressure the pressure check chart.
POWERGLIDE BASIC PRESSURE MAINLINE CHECK CHART
L-4 - 153 86 - 101 105 - 117 48 - 53

L-6 - 230 94 - 113 125 - 138 48 - 53
L-6 - 250
Pass. 88 - 106 105 - 117 48 - 53
V-8 - 307 88 - 106 115 - 128 48 - 53
V-8-3272BBL Camaro 89 - 108 125 - 138 48 - 53
V-8 - 327 102 - 120 125 - 138 48 - 53
V-8 - 396 102 - .120 125 - 138 48 - 53
V-8 - 350 89 - 107 125 - 138 48 - 53
*partially open throttle until vacuum reads 10" Hg.
Detent p..
Chevelle Models MPH

V-307 Base V-307 Base
L-230 Base L-250 L-22 V-327 L-30 V-396 L-35 V-396 L-35
Engine Sm. Gear Set Lg. Gear Set
3.08 Axle 7.35-14 Tire 3.08 Axle 7.35-14 Tire 3.08 Axle 7.35-14 Tire 3.07 Axle 7.75-14 Tire 3.31 Axle 7.75-14 Tire
3.08 Axle 7.35-14 Tire 3.08 Axle 7.35-14 Tire
Throttle Up Down Up Down Up Down Up Down Up Down Up Down Up Down

Position
Closed 14.0-17.4 13.9-15.4 14.0-17.4 13.9-15.4 14.0-17.4 12.8-16.4 14.0-17.4 12.8-16.4 15.5-16.7 14.3-15.7 16.2-17.5 15.0-16.5 15.2-16.4 13.6-14.9
Detent
42.5-52.5 30.3-39.3 42.5-52.5 32.2-39.4 47.3-55.3 26.6-37.6 46.8-56.9 30.4-39.0 53.4-60.9 17.2-25.6 57.9-66.9 18.0-21.0 59.1-68.7 16.4-27.6
Touch
Full
51.4-58.8 49.0-53.4 51.4-58.8 49.3-53.7 54.0-61.5 50.8-58.7 56.5-63.5 52.8-60.3 65.2-68.5 61.0-65.1 72.4-76.3 67.0-72.2 74.1-78.0 65.6-70.1
Detent
Chevy II Models MPH
L-153 Base L-230 Base V-307 Base V-307 Base V-327 L-30 V-350 L-48
Engine L-250 L-22 V-307 Base
3.08 Axle 6.95-14 Tire 2.73 Axle 6.95-14 Tire 2.73 Axle 6.95-14 Tire 2.73 Axle 6.95-14 Tire Sm. Gear Set Lg. Gear Set
Throttle
Up Down Up Down Up Down Up Down Up Down Up Down Up Down Up Down
Position
Closed 14.9-16.2 13.7-15.1 15.4-19.2 15.3-17.0 15.4-19.2 15.3-17.0 15.4-19.2 14.1-18.1 15.4-19.2 14.1-18.1 15.4-19.2 14.1-18.1 17.4-18.8 16.1-17.7 15.8-17.0 14.5-16.0
Detent
41.7-48.5 23.8-32.8 46.8-57.8 33.4-43.4 46.8-57.8 35.5-43.5 51.6-62.8 33.5-43.2 52.2-60.9 29.3-41.5 51.6-62.8 33.5-43.2 60.2-68.7 19.4-28.8 56.2-64.9 17.6-21.4
Touch
Full 50.6-54.2 46.9-51.1 56.7-64.9 54.0-59.9 56.7-64.9 54.4-59.2 62.3-70.0 58.3-66.5 59.6-67.9 56.2-64.7 62.3-70.0 58.3-66.5 73.5-77.2 68.7-73.4 70.3-74.0 65.6_70J
Detent
A
I
Camaro Models MPH
0
L-230 Base L-250 L-22 V-327 Base V-327 L-30 V-350 L-48
E *ne
A 2.73 Axle 7.35-14 Tire 2.73 Axle 7.35-14 Tire 2.73 Axle 7.35-14 Tire 2.73 Axle 7.35-14 Tire 3.07 Axle D70-14 Tire
I
.
Throle
Up Down Up Down Up Down Up Down Up Down
A Closed 15.8-19.6 15.7-17.4 15.8-19.6 15.7-17.4 17.2-18.7 15.8-17.4 17.4-18.8 16.1-17.7 15.3-16.5 14.1-15.5
Detent 48.0-59.3 34.2-44.4 48.0-59.3 34.2-44.4 56.3-64.8 32.7-44.2 60.2-68.7 19.4-28.8 54.5-62.9 17.1-20.7
Touch
Full 58.1-66.5 55.4-60.4 58.1-66.5 55.4-60.4 69.1-74.5 65.1-69.5 73.5-77.2 68.7-73.4 68.1-71.8 63.6-68.4
Detç
TURBO HYDRA-MATIC TRANSMISSION

INDEX
Page Page
General Description 7-33 Rear Seal 7-38

Maintenance and Adjustments 7-34 Other Service Operations 7-38
Transmission Fluid 7-34 Transmission Replacement 7-38
Fluid Checking Procedure 7-34 Turbo Hydra-Matic Diagnosis Procedure 7-39
Fluid Level Indicator 7-36 Sequence 7-39
Shift Control Linkage Adjustment 7-36 011 Level and Condition Check 7-39
Detent Switch Adjustment 7-37 Manual Linkage 7-39
Neutral Safety Switch Adjustment 7-37 Oil Leaks 7-39
Draining and Refilling Transmission 7-37 Case Porosity - Repair 7-40
Pressure Regulator Valve 7-37 Oil Pressure Check 7-40
Control Valve Body 7-37 Vacuum Modulator Assembly 7-40
Governor 7-37 Transmission Shift Points 7-41
Modulator and Modulator Valve 7-38 Special Tools 7-42
Parking Linkage 7-38
GENERAL DESCRIPTION
The Turbo Hydra-Matic transmission is a fully auto External control connections to transmission are:
matic unit consisting primarily of a 3-element hydraulic
torque converter and a compound planetary gear set. Manual Linkage - To select the desired op
Three multiple-disc clutches, one sprag unit, one roller erating range.
clutch and two bands provide the friction elements re Engine Vacuum - To operate a vacuum mod
quired to obtain the desired function of the compound ulator unit.
12 Volt Electrical - To operate an electrical
planetary gear set.
Signal detent solenoid.
The torque converter couples the engine to the plane
tary gears through oil and provides hydraulic torque
multiplication when required. The compound planetary A vacuum modulator is used to automatically sense
gear set produces three forward speeds and reverse. any change in the torque input to the transmission. The
The 3-element torque converter consists of a pump or vacuum modulator transmits this signal to the pressure
driving member, a turbine or driven member, and a regulator for line pressure control, to the 1-2 accumula
stator assembly. The stator is mounted on a one-way tor valve, and to the shift valves so that all torque re
roller clutch which will allow the stator to turn clock quirements of the transmission are met and smooth
wise but not counter-clockwise. shifts are obtained at all throttle openings.
The torque converter housing is filled with oil and The detent solenoid is activated by an electric switch
is attached to the engine crankshaft by a flex plate and on the carburetor. When the throttle is fully opened, the
always rotates at engine speed. The converter pump is switch on the carburetor is closed, activating the detent
an integral part of the converter housing, therefore the solenoid and causing the transmission to downshift at
pump blades, rotating at engine speed, set the oil within speeds below approximately 70 MPH.
the converter into motion and direct it to the turbine, The selector quadrant has six selector positions: P,R,
causing the turbine to rotate. N,D,L2,L1. P,R,N,3,2,1
As the oil passes through the turbine it is traveling in P. - Park position positively locks the output shaft to
such a direction that if it were’ not re-directed by the the transmission case by means of a locking
stator it would hit the rear of the converter pump blades pawl to prevent the vehicle from rolling in either
and impede its pumping action. So at low turbine speeds, direction. The engine may be started in Park
the oil is re-directed by the stator to the converter pump position.
in such a manner that it actually assists the converter R. - Reverse enables the vehicle to be operated in a
pump to deliver power or multiply engine torque. reverse direction.
As turbine speed increases, the direction of the oil N. - Neutral position enables the engine to be started
leaving the turbine changes and flows against the rear and run without driving the vehicle.
side of the stator vanes in a clockwise direction. Since 3-D. - Drive Range is used for all normal driving con
the stator is now impeding the smooth flow of oil, its ditions and maximum economy. Drive Range has
roller clutch releases and it revolves freely on its shaft. three gear ratios, from the starting ratio to
Once the stator becomes inactive, there is no further direct drive. Detent downshifts are available by
multiplication of engine torque within the converter. At depressing the accelerator to the floor.
this point, the converter is merely acting as a fluid 2-L2. - L2 Range has the same starting ratio as Drive
coupling as both the converter pump and turbine are Range, but prevents the transmission from shift
being driven at approximately the same speed - or at a ing above second speed to retain second speed
one-to-one ratio. acceleration when extra performance is desired.
A hydraulic system pressurized by a gear type pump L2 Range can also be used for engine braking.
provides the working pressure required to operate the L2 Range can be selected at any vehicle speed,
friction elements and automatic controls. and the transmission will shift to second gear
and remain in second until the vehicle speed or axle ratio. Li Range position prevents the trans
the throttle are changed to obtain first gear mission from shifting out of first gear.
operation in the same manner as in D Range. It is very important that any communication concerning
1-Li. - Li Range can be selected at any vehicle speed, the Turbo Hydra-Matic always contain the transmission
and the transmission will shift to second gear serial and Vehicle Identification number and that all
and remain in second until vehicle speed is re transmission parts returned to Chevrolet Motor Division
duced to approximately 40 MPH, depending on always be tagged with the transmission serial number.

TRANSMISSION FLUID FLUID CHECKING PROCEDURE
To determine proper fluid level, proceed as follows:
Transmission fluid level should be checked with trans
mission warm and selector lever in "P" Park position, CAUTION: The full mark on the dipstick is an
every time engine oil level is checked or as specified in indication of transmission fluid at normal oper
Section 0 when engine oil is changed. ating temperature of 180F. This temperature
Transmission fluid should be changed as specified in is only obtained after at least 15 miles of ex
Section 0. pressway driving or equivalent of city driving
After properly adjusting carburetor 1. Align hole in driver with hole

linkage see section 6M, place carburetor in switch. Insert a .092 pin
lever in wide open position and automatic to a depth of .10" to hold driver
choke in off position, fully depress switch in place.
plunger. Adjust switch to obtain dim. A 2. Place accelerator lever in wide
between plunger and lever paddle. open throttle position make sure
Tighten switch attaching parts. accelerator linkage is properly
Check linkage. adjusted.
3. Loosely install switch to bracket
and slide switch toward lever until
driver contacts lever.
THROTTLE LEVER 4. Tighten bolt to secure switch to
bracket and remove pin.
PLUNGER BRACKET
DRIVER
DIM. A
THROTTLE
POSITION .092" PIN
SERIES ENGINE DIM. A
CHEVROLET 307,327 .20 ACCELERATOR
396,427 .05 LEVER
CHEVELLE ALL .05 CORVETTE
CAMARO ALL .20
Fig. iT-Detent Switch Adjustment
1. With manual control lever Park position start en gine. DO NOT RACE ENGINE. Move manual control
gine. DO NOT RACE ENGINE. Move manual control lever through each range.
lever through each range. 2. Immediately check fluid level with selector lever in
2. Immediately check fluid level with selector lever in Park, engine running, and vehicle on LEVEL surface.
Park, engine running, and vehicle on LEVEL At this point, when a reading is made, fluid level on
surface. the dipstick should be 1/4" below the "ADD" mark.
At this point, when a reading is made, fluid level on
the dipstick should be at the "FULL" mark.
CAUTION:, Do Not Overfill, as foaming and loss
of fluid through the vent pipe might occur as
3. If additional fluid is required, add fluid to the
"FULL" mark on the dipstick. fluid heats up. If fluid is too low, especially
If vehicle is not driven 15 expressway miles or equiva when Cold, complete loss of drive may result
lent, and it becomes necessary to check fluid level, the which can cause transmission failure.
transmission fluid must be at room temperature 70°F. NOTE: If transmission fluid level is correctly
With fluid at room temperature 70°F follow Steps i, established at 70°F it will appear at the "FULL"
2 and 3 below. mark on the dipstick when the transmission
1. With manual control lever Park position start en- reaches normal operating temperature 180°F.
Fig. 2T-Shift Linkage Adjustment Column - Typical
The fluid level is set 1/4" below the "ADD" wheel. Allow the selector lever to be positioned in
mark on the dipstick to allow for expansion of drive D by the transmission detent. Rotate selec
the fluid which occurs as transmission tem tor lever counter-clockwise to low detent then clock
peratures rise to normal operating temperature wise two positions for drive.
of 180°F.
NOTE: Do not use the indicator pointer as a
FLUID LEVEL INDICATOR reference to position the selector lever. When
performing linkage adjustment, pointer is ad
The fluid level indicator is located in the filler pipe at justed last.
the right rear corner of the engine. To bring the fluid
level from the add mark to the full mark add 1 pint. 3. Release the selector lever. The lever should be in
Fluid level should be to the full mark with transmission hibited from engaging low range unless the lever is
at normal operating temperature. With cold fluid the lifted.
level should be approximately 1/4" below the add mark. 4. Lift the selector lever towards the steering wheel,
and allow the lever to be positioned in neutral N by
SHIFT CONTROL LINKAGE ADJUSTMENT the transmission detent.
NOTE: See Figure 4T for Corvette adjustment. 5. Release the selector lever. The lever should now be
inhibited from engaging reverse range unless the
Adjust linkage as shown below Column and in Figure
lever is lifted.
3T Console.
6. A properly adjusted linkage will prevent the selector
1. The shift tube and lever assembly must be free in the lever from moving beyond both the neutral detent,
mast jacket. See Section 9 for alignment of steering and the drive detent unless the lever is lifted to pass
column assembly if necessary. over the mechanical stop in the steering column.
2. To check for proper shift linkage adjustment, lift the 7. In the event that an adjustment is required, place the
transmission selector lever towards the steering selector lever in drive D position as determined by
TRANSMISSION GEAR SHIFT & CONTROL ADJUSTMENT
Same as Powerglide for obtaining DRIVE position

CHEVROLET Obtain DRIVE position by moving transmission
lever counterclockwise to low detent, then clockwise
two positions for drive.
HANDLE ASM.
TRANSMISSION
LEVER
PIN NUT
SPRING
CABLE ASM.
Fig. 3T-Shift Linkage Adjustment Console Typical
the transmission detent. See Steps 2 and 3. "0" ring seal from intake pipe and discard the
8. Loosen the adjustment swivel at the cross-shaft, and strainer and "0" ring.
rotate the transmission lever so that it contacts the 3. Install new "0" ring seal on intake pipe and install
drive stop in the steering column. new strainer on pipe assembly.
9. Tighten the swivel and recheck the adjustment. See 4. Thoroughly clean bottom pan.
Steps 2 and 6. 5. Affix new gasket to bottom pan with petroleum jelly.
10. Readjust indicator needle if nedessary to agree with 6. Install bottom pan with attaching screws and torque
the transmission detent positions. See Section 9, to specifications.
11. Readjust neutral safety switch if necessary to pro 7. If only the pan has been removed, pour approximately
vide the correct relationship to the transmission de 7-1/2 pints of fluid into the transmission. If the
tent positions. See Section 12. valve body has also been removed use 9-1/2 pints.
12. When properly adjusted the following conditions must After a complete overhaul approximately 19 pints
be met by manual operation of the steering column are required. Be sure container, spout, or funnel is
shift lever: clean.
a. From reverse to drive position travel, the trans 8. Start engine and let idle carburetor off fast idle
mission detent feel must be noted and related to step. Place selector lever in P position and apply
indicated position on dial. hand brake.
b. When in drive and reverse positions, pull lever 9. With transmission warm approximately 180°F, add
rearward towards steering wheel and then re fluid to bring level to full mark on indicator. With
lease. It must drop back into position with no transmission at room temperature approximately
restrictions. 70°F, add fluid to 1/4" below the add mark.
CAUTION: Do not overfill. Foaming will result.
DETENT SWITCH ADJUSTMENT
Adjust switch as shown in Figure iT PRESSURE REGULATOR VALVE
NEUTRAL SAFETY SWITCH ADJUSTMENT Removal
The neutral safety switch must be adjusted so that the 1. Remove bottom pan and strainer.
car will start in the park or neutral position, but will not 2. Compress regulator boost valve bushing against
start in the other positions. For replacement refer to pressure regulator spring and remove snap ring,
Section 12 of this Manual. using J-5403 pliers.
3. Remove regulator boost valve bushing and valve.
DRAINING AND REFILLING TRANSMISSION 4. Remove pressure regulator spring.
Drain oil immediately after operation before it has had 5. Remove regulator valve, spring retainer, and spac
an opportunity to cool. ers if present.
To drain oil proceed as follows: Installation
1. Remove bottom pan attaching screws, pan, and Installation of the pressure regulator valve is the re
gasket. Discard gasket. verse of the removal. Adjust oil level.
2. Remove oil strainer, retainer bolt, oil strainer and
CONTROL VALVE BODY
Removal
1. Remove bottom pan and strainer.
2. Disconnect solenoid lead from connector terminal.
3. Remove control valve body attaching screws and de
tent roller spring assembly.
NOTE: Do not remove solenoid attaching
screws.
4. Remove control valve body assembly and governor
pipes. If care is taken in removing control, valve
body the six 6 check balls will stay in place above
the spacer plate.
VIEW A
CAUTION: Do not drop manual valve.
PLACE TRANSMISSION CONTROL
LEVER IN DRIVE POSITION,
INSTALL CABLE - SECURE WITH
5. Remove the governor pipes and manual valve from
RETAINING CLIP AND COTTER
PIN AS SHOWN IN VIEW A.
control valve body.
Installation
Installation of the control valve body is the reverse of
the removal. Adjust oil level.
GOVERNOR
Removal
1. Remove governor cover attaching screws, cover, and
gasket.
Fig. 4T-Shift Linkage Adjustment Console - Corvette 2. Discard gasket.
3. Withdraw governor assembly from case. NOTE: DO NOT remove manual shaft seal un
less replacement is required.
Installation
Installation of the governor assembly is the reverse of 5. Remove parking actuator rod and detent lever
the removal. Use a new gasket under the governor assembly.
cover. Adjust oil level. 6. Remove parking pawl bracket attaching screws and
bracket.
MODULATOR AND MODULATOR VALVE 7. Remove parking pawl return spring.
Removal NOTE: The following steps should not be com
1. Remove modulator assembly attaching screw and pleted unless part replacement is required.
retainer.
2. Remove modulator assembly from case. Discard 8. Remove parking pawl shaft retainer.
"0" ring seal. 9. Remove parking pawl shaft, cup plug, parking pawl
3. Remove modulator valve from case. shaft, and parking pawl.
Installation Installation
Installation of the modulator assembly and modulator Installation of the parking linkage is the reverse of the
valve is the reverse of the removal. Use a new "0" ring removal. Use new seal and cup plug, if removed, and
seal on the modulator assembly. Adjust oil level. new bottom pan gasket. Adjust oil level.
REAR SEAL
PARKING LINKAGE
Removal
Removal
1. Remove propeller shaft.
1. Remove bottom pan and oil strainer. 2. Pry seal out with screw driver or small chisel.
2. Unthread jam nut holding detent lever to manual
shaft. Installation
3. Remove manual shaft retaining pin from case. 1. Using Tool J-21359 ‘install new seal.
4. Remove manual shaft and jam nut from case. 2. Re-install propeller shaft.
OTHER SERVICE WITH TRANSMISSION IN VEHICLE

The following operations when done as single opera c. Down shift solenoid or connector.
tions and not as part of a general overhaul should, as a d. Valve body spacer plate, gasket and check balls.
practical matter, be performed with the transmission in e. Front accumulator piston.
the vehicle. Refer to the "Transmission Disassembly f. Rear servo and rear accumulator assembly.
and Reassembly" section of the Overhaul Manual for g. Rear band apply checking with Tool J-21370.
service procedures. h. Front servo assembly.
i. Speedo driven gear.
a. Oil filler pipe and "0" ring seal. j. Case extension or gasket.
b. Oil pan and gasket. k. Strainer and "0" ring.
TRANSMISSION REPLACEMENT
Before raising the car, disconnect the negative battery speedo cable, and detent solenoid connector wire at
cable and release the parking brake. transmission.
9. Remove converter under pan.
1. Place car on hoist. 10. Remove converter to flywheel bolts.
Camaro models only: 11. Loosen exhaust pipe to manifold bolts approximately
a. Disconnect parking brake cables. 1/4 inch Chevrolet and Chevelle. Lower trans
b. Remove underbody reinforcement plate. convert mission until jack is barely supporting it.
ible 12. Remove transmission to engine mounting bolts and
c. Disconnect left exhaust pipe from manifold for remove oil filler tube at transmission.
clearance. 13. Raise transmission to its normal position, support
On Corvette models, remove both exhaust pipes. engine with jack and slide transmission rearward
2. Remove propeller shaft. from engine and lower it away from vehicle.
3. Disconnect speedometer cable, electrical lead to
case connector, vacuum line modulator, and oil
CAUTION: Use converter holding Tool J-5384
cooler pipes.
when lowering transmission or keep rear of
4. Disconnect shift control linkage.
transmission lower than front so as not to lose
5. Support transmission with suitable transmission jack. converter.
6. Disconnect rear mount from frame crossmember.
7. Remove two bolts at each end of frame crossmember The installation of the transmission is the reverse of
plus through bolt at inside of frame and the removal with the following added step. Before in
parking brake pulley on Corvette models. Re stalling the Flex Plate to converter bolts, make certain
move crossmember. that the weld nuts on the converter are flush with the flex
8. Remove oil cooler lines, vacuum modulator line, plate and the converter rotates freely by hand in this
position. Then, hand start all three bolts and tighten NOTE: After installation of transmission, re
finger tight before torqueing to specification. This will move car from hoist. Check linkage for proper
insure proper converter alignment. adjustment.
TURBO HYDRA-MATIC DIAGNOSIS PROCEDURE

Accurate diagnosis of transmission problems begins OIL LEAKS
with a thorough understanding of normal transmission
Before attampting to correct an oil leak, the actual
operation. In particular, knowing which units are in source of the leak must be determined. In many cases,
volved in the various speeds or shifts so that the specific the source of the leak can be deceiving due to "wind flow"
units or circuits involved in the problem can be isolated around the engine and transmission.
and investigated further. Analytical diagnosis will pro The suspected area should be wiped clean of all oil be
tect the technician from come backs and certainly will fore inspecting for the source of the leak. Red dye is
improve owner satisfaction. used in the transmission oil at the assembly plant and
An important and often overlooked aspect of diagnosis will indicate if the oil leak is from the transmission.
is finding out specific customer complaints. For this
The use of a "black light" to identify the oil at the
purpose a short ride with the customer will often prove source of leak is also helpful. Comparing the oil from
beneficial. It may be found that the condition the custom
the leak to that on the engine or transmission dip stick
er wants corrected is standard and should not be altered. when viewed by black light will determine the source
The following sequence, based on field experience, pro of the leak.
vides the desired information quickly and in most cases Oil leaks around the engine and transmission are gen
actually corrects the malfunction without requiring the erally carried toward the rear of the car by the air
removal of the transmission. Details of the items listed stream. For example, a transmission "oil filler tube to
in this sequence are covered further in the text. case leak" will sometimes appear as a leak at the rear
of the transmission. In determining the source of an oil
SEQUENCE FOR TURBO HYDRA-MATIC leak it is most helpful to keep the engine running.
DIAGNOSIS PROCEDURE
POSSIBLE POINTS OF OIL LEAKS
1. Check oil level and condition.
1. TRANSMISSION OIL PAN LEAK
2. Check and correct detent switch.
a. Attaching bolts not correctly torqued.
3. Check and correct vacuum line and fittings.
4. Check and correct manual linkage. b, Improperly installed or damaged pan gasket.
C. Oil pan gasket mounting face not flat.
2. REAR EXTENSION LEAK
OIL LEVEL AND CONDITION CHECK a. Attaching bolts not correctly torqued.
Always check the oil level before road testing. Oil b. Rear seal assembly - damaged or improperly
must be visible on dip stick prior to operating the ve installed.
hicle. Erratic shifting, pump noise, or other malfunc c. Gasket seal - extension to case damaged or
tions can in some cases be traced to improper oil level. improperly installed.
Oil level should be checked with the selector lever in d. Porous casting.
the Park P position, engine running, and the vehicle on 3. CASE LEAK
level pavement. a. Filler pipe "0" ring seal damaged or missing;
Fluid level should be to the FULL mark with the trans misposition of filler pipe bracket to engine -
mission at normal operating temperature 170°-190°F.. "loading" one side of "0" ring.
With warm fluid room temperature, the level should be b. Modulator assembly "0" ring seal - damaged or
at or slightly below the ADD mark. improperly installed.
If oil level was low, refer to Oil Leaks. c. Governor cover, gasket and bolts - damaged,
The condition of the oil is often an indication of whether loose; case face leak.
the transmission should be removed from the vehicle, or d. Speedo gear - "0" ring damaged.
to make further tests. When checking oil level, a burned e. Manual shaft seal - damaged, improperly installed.
smell and discoloration indicate burned clutches or bands f. Line pressure tap plug - stripped, shy sealer
and the transmission will have to be removed. compound.
g. Parking pawl shaft cup plug - damaged, improp
MANUAL LINKAGE erly installed.
h. Vent pipe refer to Item 5.
Manual linkage adjustment and the associated neutral i. Porous case.
safety switch are important from a safety standpoint. 4. FRONT END LEAK
The neutral safety switch should be adjusted so that the a. Front seal damaged check converter neck for
engine will start in the Park and Neutral positions only. nicks, etc., also for pump bushing moved for
With the selector lever in the Park position, the park ward; garter spring missing from pump to con
ing pawl should freely engage and prevent the vehicle verter seal.
from rolling. The pointer on the indicator quadrant b. Pump attaching bolts and seals - damaged, miss
should line up properly with the range indicators in all ing, bolts loose.
ranges. c. Converter - leak in weld.
d. Pump "0" ring seal - damaged. Also check 1 or 2

pump groove and case bore. Drive, Neutral, Park Li or L2 Reverse
e. Porous casting pump or case. 60 150 107
5. OIL COMES OUT VENT PIPE
a. Transmission over-filled. VACUUM MODULATOR ASSEMBLY
b. Water in oil.
c. Pump to case gasket mispositioned. After thorough investigation of field returned modulator
d. Foreign material between pump and case, or be assemblies, it has been found that over 50% of the parts
tween pump cover and body. returned as defective were good. For this reason, the
e. Case - porous, pump face improperly machined. following procedure is recommended for checking Turbo
f. Pump - shy of stock on mounting faces, porous Hydra-Matic modulator assemblies in the field before
casting. replacement is accomplished.
CASE POROSITY-REPAIR THREADED SCREW SEAL
Transmission leaks caused by aluminum case porosity

have been successfully repaired with the transmission in
the vehicle by using the following procedure.
1. Road test and bring the transmission to operating
temperature.
2. Raise the car and, with the engine running, locate the /cRIMPED UPPER TO LOWER
source of the oil leak. Check for leaks in all operat VACUUM CONNECTOR HOUSING SEAM
ing positions.
Fig. 5T-Vacuum Modulator Assembly
NOTE: The use of a mirror will be helpful in
finding leaks. 1. Vacuum Diaphragm Leak Check
3. Shut off engine and thoroughly clean area with a sol Insert a pipe cleaner into the vacuum connector pipe
vent and air dry. as far as possible and check for the presence of trans
4. Using the instruction of the manufacturer, mix a suf mission oil. If oil is found, replace the modulator.
ficient amount of epoxy cement, part #1360016, to NOTE: Gasoline or water vapor may settle in
make the repair. the vacuum side of the modulator. If this is
5. While the transmission is still hot, apply the epoxy found without the presence of oil, the modulator
to the area, making certain that the area is fully should not be changed.
covered.
6. Allow epoxy cement to dry for three hours and re 2. Atmospheric Leak Check
test for leaks, as outlined in Steps 1 and 2. Apply a liberal coating of soap bubble solution to the
vacuum connector pipe seam, the crimped upper to lower
OIL PRESSURE CHECK housing seam, and the threaded screw seal Fig. 7.
Using a short piece of rubber tubing, apply air pressure
With Car Stationary to the vacuum pipe by blowing into the tube and
Transmission oil pressure gauge and engine tachome observe for leak bubbles. If bubbles appear, replace
ter should be connected and the oil pressures should the modulator.
check as follows:
NOTE: Do not use any method other than human
1. Pressures indicated below are at 0 output speed with
lung power for applying air pressure, as pres
the vacuum modulator tube disconnected and with en
sures over 6 psi may damage the modulator.
gine at 1200 rpm.
3. Bellows Comparison Check
Approximate Drive Li Using a comparison gauge, as shown in Fig. 8, com
Altitude of Check Neutral or pare the load of a known good Hydra-Matic modulator
Reverse
Ft. above sea level Park L2 with the assembly in question.
0 150 150 244 ENDS TO BE SQUARE

WITHIN 1
2,000 150 150 233
4,000 145 150 222
6,000 138 150 212
13/32" TO 3/8"
8,000
10,000
132
126
150
150
203
194
SCRIBED LINE l ‘I i]i ROUND OR FLAT STOCK
12,000 121 150 186 -
14,000 116 150 178
Fig. 6T-Bellows Comparison Gauge
2. Pressures indicated below are with the vacuum tube
connected for normal modulator operation, and with A. Install the modulator that is known to be acceptable
the engine at approx. 600-800 rpm. on either end of the gauge.
B. Install the modulator in question on the opposite end
NOTE: Pressures are not significantly affected of the gauge.
by altitude or barometric pressure when the C. Holding the modulators in a horizontal position,
vacuum tube is connected. bring them together under pressure until either
modulator sleeve end just touches the line in the and observe the sleeve for concentricity to the can. If
center of the gauge. The gap between the opposite the sleeve is concentric and the plunger is free, the
modulator sleeve end and the gauge line should then modulator is acceptable.
be 1/16" or less. If the distance is greater than this Once the modulator assembly passes all of the above
amount, the modulator in question should be replaced. tests, it is an acceptable part and should be re-used.
4. Sleeve Alignment Check
Roll the main body of the modulator on a flat surface
TURBO HYDRA-MATIC SHIFT POINTS
Chevrolet Models MPH

V-307 Base V-327 L30
E ngine
Throttle Position 1-2 up 2-i dn. 2-3 up 3-2 dn. 1-2 up 2-1 dn. 2-3 up 3-2 dn.
Closed 7.7-11.5 10.9- 6.9 17.5-22.6 19.5-14.6 7.8-11.5 11.0- 6.9 17.6-22.8 19.6-14.7
Thru Detent 36.4-50.1 43.3-26.7 74.8-91.4 85.1-67.6 36.6-50.5 43.6-26.8 75.3-92.0 85.7-68.1
Chevrolet Models MPH
E ngine V-396 L35 V-427 L36

2.56 Axle 8.25-14 Tire 2.73 Axle
Throttle Position 1-2 up 2-1 dn. 2-3 up 3-2 dn. 1-2 up 2-1 dn. 2-3 up 3-2 dn.
Closed 9.2-13.5 12.0- 7.1 18.8-24.3 20.3-15.4 7.7-11.5 10.9- 6.9 17.5-22.6 19.5-14.6
Thru Detent 41.2-56.6 48.0-28.3 80.3-98.1 91. 1-72.0 36.4-50.1 43.3-26.7 74.8-91.4 85.1-67.6
Chevelle or Camaro Models MPH
. V-396 L35 V-396 L341

Engine 2.73 Axle F70-14 Tire 3.07 Axle
Closed 8.3 16.1- 6.4 17.2-25.0 13.6-13.9 7.4-11.1 10.1- 5.9 15.3-22.2 17.3-12.8
Thru Detent 41.1-56.3 43.0-21.1 79.9-98.8 91.9-71.9 36.5-50.1 38.5-19.0 71.1-87.9 82.0-64.2
Corvette Models MPH
V-327 Base V-427 L36 or L68

E ngine 3.09 Axle F70-15 Tire 3.08 Axle
Closed 6.8-10.1 9.6- 6.1 15.5-20.0 17.2-12.9 7.7-11.5 10.5- 6.1 15.8-23.0 17.9-13.3
Thru Detent 32.2-44.4 38.3-23.6 66.1-80.8 75.3-59.8 41.8-55.4 39.8-19.6 73.5-90.8 84.7-66.3
16111
4 5
Ito I
III:IE.
18 19
Fig. 7T-Aluminum Powerglide Special Tools

Y 23
1. J-9506 Holding Fixture Adapters 15. J-7079 Handle

2. J-3289-O1 Holding Fixture Use with J-3289-20 Base 16. J-6582 Governor Support Bushing Installer
3. J-9549 Converter Safety Strap 17. J-9543 Vacuum Modulator Wrench
4. J-21867 Transmission Pressure Gauge and Hose 18. J-5778 Extension Bushing Remover and Installer
5. J-4264 Oil Filler Tube and Funnel 19. J-5154 Extension Oil Seal Installer
6. J-3387 Pilot Stud Set 20. J-5403 Snap Ring Pliers
7. J-9539 Oil Pump Puller Bolts Use with 21. J-5853 Torque Wrench
weights from Slide Hammers J-6585 22. J-8039 Snap Ring Pliers
8. J-6839 Oil Pump Seal Driver 23. J-21848 Low Band Adjusting Tool
9. J-9546 Clutch Drum Bushing Remover and Installer J -8001 Dial Indicator Not Illustrated
10. J-7782 Clutch Spring Compressor Adapter Plate J-5492 Dial Indicator Support Strap
11. J-5133 Clutch Spring Compressor Not Illustrated
12. J-4599 Planet Pinion Assembly Tool Set J-6585 Slide Hammers Not Illustrated
13. J-9542 Reverse Piston Spring Compressor J-6585-3 Slide Hammer Adapters Not Illustrated
14. J-9557 Transmission Case Rear Bushing Remover and J-9534 Bushing Remover Not Illustrated
Installer and Rear Governor Support Bushing Remover
-1
15
Fig. 8T-Turbo Hydra-Matic Special Tools
1. J-8763 Transmission Holding Fixture 9. J-21363 Seal Protector - Intermediate Clutch - Inner
2. J-3289-14 Holding Fixture Base 10. J-21409 Seal Protector - Forward Clutch - Outer
3. J-21427-1 Speedo Gear Remover 11. J-21664 Clutch Spring Compressor Adapter Ring
4. J-9539 Slide Hammer Bolts 3/8" - 16 Threads 12. J-4670 Clutch Spring Compressor
5. J-8105 Speedo Gear Remover Puller 13. J-8059 Snap Ring Pliers
6. J-21885 Accumulator Piston Installer 14. J-5586 Snap Ring Pliers
7. J-21369 Converter Pressure Check Fixture 15. J-5403 Snap Ring Pliers
8. J-21362 Seal Protector - Forward & Direct Clutch - Inner 16. J-1313 Torque Wrench 0-140 Ft. Lbs.
aoa21
I
2
0
16
Q
12
-8
Fig. 9T-Turbo Hydra-Matic Special Tools
1. J-6116-01 Rear Unit Holding Fixture 15. J-5384 Converter Holding Strap
2. J-8092 Driver Handle 16. J-21465-01 Bushing Tool Set
3. J-21359 Pump Oil Seal Installer 17. J-21465-5 Part of Bushing Tool Set
4. J-21364 Holding Fixture Adapter Used with 18. J-21465-3 Part of Bushing Tool Set
J-6116-O1 Fixture 19. J-21465-2 Part of Bushing Tool Set
5. J-2619 Slide Hammer Used with 2619-4 Adapter 20. J-21465-1 Part of Bushing Tool Set
and Remover Tools J-21465-01 21. J-21465-17 Part of Bushing Tool Set
6. J-5154 Extension Oil Seal Installer 22. J-21465-8 Part of Bushing Tool Set
7. J-6585 Slide Hammer Weights 23. J-21465-13 Part of Bushing Tool Set
8. J-9539 Slide Hammer Bolts 3/8" - 16 Threads 24. J-21465-6 Part of Bushing Tool Set
9. J-5590 Speedo Gear Installer 25. J-21465-15 Part of Bushing Tool Set
10. J-21867 Pressure Gauge and Hose 26. J-21465-16 Part of Bushing Tool Set
11. J-21370-6 Rear Band Apply Fixture 27. J-21465-9 Part of Bushing Tool Set
12. J-21370-5 Rear Band Apply Pin 28. J-21465-10 Part of Bushing Tool Set
13. J-21795-1 Gear Unit Assembly Holding Tool 29. J-22182 Extension Bushing Remover &
14. J-21795-2 Part of Above Holding Tool Installer Not Illustrated
8-5
8-4
8-5
8-8
SECTION 8
FUEL TANK AND EXHAUST SYSTEMS
Subject Page
Fuel Tanks . ,. 8-i

Exhaust Systems 8-8
FUEL TANKS
INDEX
Page Page
General Description 8-i Metering Units Gauge Sending Unit
Component Part Replacement 8-i Fuel Tank Vent Lines
Draining Fuel Tank 8-i Fuel Lines
Fuel Tank 8-2 Fuel Line Retainer Clip
GENERAL DESCRIPTION
All fuel tanks are of steel construction. All tanks, except Corvette. The Corvette gauge is located on the
except Station Wagons, are mounted between the frame lower side of the tank. The metering unit cannot be
rails and behind the rear axle. Station Wagon tanks are serviced on any model except Corvette without first
side-mounted and located rear of the left rear quarter removing the fuel tank assembly.
wheelhouse. Sedan and pickup tanks, except Corvette are held in
All fuel tanks are vented to the atmosphere. Chev place by two metal straps, hinged at either the front or
rolet and Chevelle sedan tanks incorporate external rear end with a bolt through the hinge and secured at
vent hoses. All other models use a vented, anti-surge the opposite end with a bolt and nut assembly. Corvette
type filler cap, conforming to SAE standards. tank straps are hinged at the tank support and attached
Filler neck assemblies are similar in design to pre at the rear end with bolts. Station Wagon tanks are
vious models. secured with two metal straps located at the front and
The fuel pickup pipe is built integrally with the tank lower sides of tank.
gauge which is located on the upper side of all tanks
COMPONENT PART REPLACEMENT

DRAINING FUEL TANK
The absence of a drain plug in the gas tank makes it
necessary to siphon fuel from the tank when draining is
needed. The following procedure is recommended:
- FUEL FLOW
1. Obtain approximately 10 feet of 3/8" I.D. hose and
cut a flap-type slit 18’ from one end. Make this
cut in the direction of the shorter end of hose See
Figure 1.
2. Insert a small pipe nipple slightly larger O.D. than
SLIT HOSE AS SHOWN
the hose I.D. into the opposite end of hose.
3. Insert the nipple end of siphon hose into the fuel
tank filler neck with the natural curl of the hose
pointed down. Insert until the hose is heard to
strike the bottom of the tank.
4. With the opposite end of the hose in a suitable con 10 FEET APPROX.
tainer, insert an air hose in the downward direction
in the flap-type slit and trigger the flow of fuel.
CAUTION: Before starting draining procedure
be sure that the fuel tank gauge unit wire or Fig. 1-Siphon Construction
FUEL TANK AND EXHAUST SYSTEMS 8-2
CHEVROLET
VIEW A VIEW B
CHEVY II
Fig. 3-Chevelle Fuel Tanks
battery negative cable is disconnected.

Always drain gasoline from complete fuel sys
tem including carburetor, fuel pump, all fuel
lines and fuel tank if the vehicle is to be stored
for any appreciable length of time. This pre
caution will prevent accumulation of gum forma
tion and resultant poor engine performance.
FUEL TANK
Chevelle Pickup and all Sedans except Corvette
Figs. 2 and 3
CAMARO 1. Disconnect meter wire at rear wiring harness con
nector. On sedan models, push out grommet and
thread meter wire through hole in trunk compartment
Fig. 2-Chevrolet, Chevy II and Camaro Fuel Tanks floorpan.
Fig. 4-Station Wagon Fuel Tanks
Station Wagons - Fig. 4

2. Raise car on hoist.
3. Drain fuel tank. Removal and Installation
4. Disconnect fuel line hose at gauge unit pickup line. 1. Raise car on hoist.
5. Remove gauge ground wire screw at underbody floor- 2. Chevelle-- Place rear of vehicle on jack stands and
pan. then lower rear axle into full rebound. Remove left
6. Chevrolet-- Remove vent hose at tank. rear wheel and tire assembly.
Chevelle Sedan- - Remove vent hoses from floorpan 3. Disconnect meter wire at rear wiring harness.
retainer clip. 4. Drain fuel tank.
7. Chevelle Pickup--Remove tank filler neck bolt. 5. Remove gas tank front shield.
Camaro-- Loosen filler neck inlet hose clamp and 6. Remove gauge ground wire at rear quarter inner
slide hose up off tank lower neck. panel.
8. Remove tank strap bolts and lower tank carefully. 7. Disconnect fuel line hose and gauge wires at gauge
9. To install, reverse Steps :1 through 8. unit.
8. Remove tank strap bolts and lower tank carefully.
END OF HOSE
FLUSH TO Y2 INCH
BACK FROMEDGE
OF BUMPERETrE.
Fig. 5-Corvette Fuel Tank Fig. 6-Corvette Fuel Tank Filler Neck
Fig. 7-Spare Tire Carrier Installed
Fig. 8-Meter Assembly Removal Using Tool J-22554
Corvette - Fig. 5
4. Clean strainer screen by blowing out with corn-
Removal and Installation pressed air.
1. Remove battery ground cable. 5. Reverse removal procedure to install.
2. Remove gas cap, filler neck boot from top of tank
and disconnect drain line fig. 6. CAUTION: When installing cam lock, it may be
3. Raise vehicle on hoist. necessary to compress gasket slightly by press-
4. Remove the spare tire from tire carrier fig. 7. ing down on Gauge Tool. On ce cam lock is
5. Remove spare tire carrier bolted attachments and started under retaining tangs, pressure may be
remove carrier. released.
6. Loosen "U" clamps and separate exhaust systems at Always use a new gasket when replacing or in
transmission support. stalling a new gauge unit.
7. Remove rear muffler brackets at frame and slide
exhaust systems rearward.
8. Remove fuel tank retaining strap bolts.
9. Remove tank gauge unit wires and fuel lines and
drain fuel tank.
10. Remove tank support to frame bolts and remove
support.
11. Lower tank, rotating toward front of vehicle.
METERING UNITS GAUGE SENDING UNIT

Fig. 10
All Models Except Corvette

1. Follow tank removal procedure.
2. Use Tool J-22554 fig. 8 to remove cam lock on
Chevrolet Sedan tanks: Use Tool J- 8950 on all other
models fig. 9.
3. Remove unit and gasket.
CAUTION: REMOVE UNIT CAREFULLY TO
AVOID DAMAGE TO SCREEN AT END Oi
PICKUP PIPE. Fig. 9-Metering Unit Removal Using Tool J-8950
Corvette
It has been reported that some technicians have been

checking the operation of the Corvette fuel gauge unit by
reaching through the large filler neck opening with a
metal rod to operate the float arm. Although this method
provides a usable test for full range operation it is not
in line with good safety practices. There is the possi
bility of sparking between the metal rod and the lip of
the gas tank as a result of friction and/or an open circuit
with the gauge unit grounding through the rod.
A far safer method is to remove the leads from the
installed tank unit and connect them to a known good
tank unit, outside the tank.
1. Remove spare tire from carrier.
2. Remove spare tire carrier bolted attachments and
carrier.
3. Disconnect tank gauge wires.
4. Drain fuel tank.
5. Disconnect fuel lines at gauge unit.
6. Use Tool J- 8950 to remove cam lock.
7. Remove unit and rubber gasket.
CAUTION: REMOVE UNIT CAREFULLY TO
AVOID DAMAGE TO SCREEN AT END OF
PICKUP PIPE.
8. Clean strainer by blowing out with compressed air.
9. Reverse removal procedure to install.
NOTE: Always use a new gasket when re
placing or installing a new gauge unit.
FUEL TANK VENT LINES

The Chevrolet Sedan vent line is connected by a rubber
hose, with two clamps, to the gauge pickup line fig. 2.
A rubber grommet around the vent pipe acts as a seal
to prevent gasoline fumes from entering the passenger
compartment.
Chevelle sedan models are vented with two rubber vent
hoses at the right forward edge of tank. Hoses are at
tached to the tank with clamps and to the underbody as
shown in Figure 3.
IMPORTANT: It is important to note that the

above gas tanks use non-vented filler neck caps;
therefore, it is necessary to be assured that the
vent hoses and lines are free from dirt and
foreign material and that they are open at all
times.
The larger 1/2" vent hose on Chevelle sedan models
incorporates a restrictor which should be checked oc
casionally, and if plugged, cleaned in gasoline and then
reinserted flush with end of vent hose fig. 3.
All other vehicles use a vented, anti-surge type filler
neck cap, complying to SAE standards.
FUEL LINES
The fuel lines, extending from the fuel tank to fuel
pump, are routed along the right frame rail on all
models. Fuel lines are secured to the frame or under
body with clamp and screw assemblies or with riveted
clips. Flexible hoses are located at the fuel tank pickup
and at the fuel pump fig. 11-14. Fig. 10-Metering Units - Typical
VIEW C VIEW D
STATION WAGONS
V-8
VIEW B VIEW A
Fig. 11-Chevrolet Fuel Lines
NVERTIBLE’
STATION WAGONS
VIEW A VIEW B VIEW C
Fig. 12-Chevelle Fuel Lines
VIEW D
CHEVY ONLY
VIEW
fr=
CAMARO ONLY
VIEW C VIEW B VIEW A
Fig. 13-Chevy II and Camaro Fuel Lines
FUEL VAPOR
RETURN LINE
FUEL FEED
LINE
VIEW A
FUEL FEED
LINE
A FUEL VAPOR
RETURN LINE
Fig. 14-Corvette Fuel Lines
8-8
The fuel lines should be inspected occasionally for

leaks, kinks or dents. If evidence of dirt is found in the
carburetor, fuel pump or on a disassembly, the lines
should be disconnected and blown out. Check the fuel
strainer in the tank for damage or omission.
FUEL LINE RETAINER CLIP
If fuel line riveted retainer clips are removed, Tool

J-7777 should be used to install new clips fig. 15.
After removing the old clip from the frame, position the
new clip in the location of the old clip, index the "blind
rivet" and press hard hand pressure should do to expand
the rivet. Fig. 15-Installing Fuel Line Retainer Clip
EXHAUST SYSTEMS
INDEX
Page Page
General Description Chevy U and Camaro . 8-13
Component Part Replacement Muffler and Tail Pipe Assembly. . . . . 8-13
Chevrolet Resonator Assemblies Dual Exhaust 8-13
Muffler Assembly 8-8 Exhaust Pipe Single Exhaust 8-15
Exhaust Pipe Crossunder With V-8 Engine Front Exhaust Pipe Dual Exhaust 8-15
Single Exhaust 8-11 Rear Exhaust Pipe Dual Exhaust 8-15
Tail Pipe and/or Resonator 8-11 Left Tail Pipe Dual Exhaust 8-15
Chevelle 8-11 Corvette 8-15
Muffler 8-11 Muffler Assembly. . . . . 8-15
Exhaust Pipe Crossunder With V-8 Engine Front Exhaust Pipes 8-15
Single Exhaust 811 Special Tools 8-16
Tail Pipe and/or Resonator - . 8-13
GENERAL DESCRIPTION
All exhaust systems used on the 1968 Chevrolet are of rest of the system.
the split system in which all components exhaust pipes, Dual exhaust systems are available as regular produc
mufflers, resonators and tail pipes can be separated by tion or optional equipment on all models. Chevrolet and
removing clamps. All other models have at least two Camaro offer an optional "Deep Tone" system which
components that cannot be separated by merely removing eliminates the resonators.
a clamp. All exhaust systems are suspended on insulated brack
All V-8 single exhaust systems incorporate a "cross- ets for rattle free operation. System components are
under" exhaust pipe in which either the left or right ex attached to the brackets or to one another with "U" bolt
haust pipe crosses under the engine oil pan to join the clamps.

CHEVROLET Fig. 16-17 2. Remove "U" bolt clamp at forward end of muffler
pipe.
3. Disengage muffler at exhaust and tail pipe connec
MUFFLER ASSEMBLY tions.
4. Three-fourths inch clearance should be allowed be
Remove and Replace tween the muffler bracket hanger and crossmember
at installation.
1. Remove "U" bolt clamp at center mounting. 5. Install unit with the flat side of the muffler showing.
V-8
1.02 1ST GEAR VIEW C
VIEW A VIEW B
.88
L-6
1
C
m
I-
-l
z
n m
I
0
C
C-’
x
.<
m
Ri,
V-8 ‘0
Fig. 16-Chevrolet Single Exhaust Systems
RI,
TRANS. SUPPORT
M40 0
.49
1.00 VIEW D
C-’
x
C-’ E
I
STATION WAGON
VIEW E
C-’
z
Fig. 17-Chevrolet Dual Exhaust Systems
EXHAUST PIPE CROSSUNDER WITH CHEVELLE Fig. 18-19

V-8 ENGINE SINGLE EXHAUST MUFFLER ASSEMBLY
Remove and Replace Replacement
1. Remove exhaust pipe to manifold nuts, extension and 1. Cut the exhaust pipe near the muffler to allow suf
packing-- separate pipe from manifold. ficient pipe for muffler replacement:
2. Remove muffler and/or exhaust pipe clamps and re
move pipe. CAUTION: Before cutting the exhaust pipe,
3. Attach pipe to muffler, then secure to manifold using measure service muffler exhaust pipe extension
new nuts and packings. Do not secure attachments and make certain to allow 1-1/2" for engage
until clearances for the standard and automatic ment of exhaust pipe into muffler extension.
control linkages, underbody and crossmember have 2. Remove "U" bolt clamp at center mounting and dis
been checked. Contact of exhaust pipe to engine engage muffler from tail pipe.
panrail is permissible. 3. Install new muffler and secure with new "U" bolt
NOTE: Clean manifold stud threads with wire clamps.
brush and use new nuts to secure exhaust pipe 4. Realign and check clearances before finally tighten
to manifold. ing all hardware.
4. Tighten nuts uniformly. NOTE: If bracket mounting insulators tire
carcass mountings are fatigued, replace to
insure a secure exhaust system.
TAIL PIPE AND/OR RESONATOR
EXHAUST PIPE CROSSUNDER WITH V-8 ENGINE
Remove and Replace
SINGLE EXHAUST
1. Remove "U" clamp attachment at muffler.
2. Remove screw attachment at tail pipe rear hanger Replacement
assembly. On L-6 single and V-8 dual exhaust systems, it will be
3. Remove tail pipe and/or resonator assembly. necessary to replace both the exhaust pipe and muffler
4. Replace tail pipe at muffler, then install at hanger. with service replacement parts.
Do not secure attachments until clearances have 1. Remove nuts attaching exhaust pipe to manifold.
been checked. Check position of hanger so that 2. Remove muffler and exhaust pipe clamps and remove
interplates are parallel. muffler and exhaust pipe assembly.
VIEW B
Fig. 18-Chevelle Single Exhaust
VIEW A
AND SUPER SPORT
AUTO.
VIEW B VIEW C VIEW D
RPO M40 AUTO.
STATION WAGON
SUPER SPORT
Fig. 19-Chevelle Dual Exhaust Systems

NOTE: Realign and check all clearances be NOTE: Be sure to check clearances before
fore finally tightening all clamps. If bracket tightening attachments.
mounting insulators tire carcass mountings
are fatigued, replace to insure a secure exhaust
system. CORVETTE Fig. 22
EXHAUST PIPE SINGLE EXHAUST
MUFFLER ASSEMBLY
Remove and Replace
1. Remove exhaust pipe to manifold nuts, extensions Replacement Also Rear Exhaust and Tail Pipes
and packings and separate pipes from manifold. 1. Remove "U" bolt attachments at both rear tail pipes
2. Remove "U" bolt clamp at muffler and remove and remove tail pipes.
exhaust pipe. 2. Separate the exhaust system at the crossmember
3. To install new pipe, attach pipe to muffler and then tube by loosening the "U" bolt nuts.
secure to manifold using new packings and nuts. 3. Remove rear muffler bracket screws and slide the
muffler system rearward.
NOTE: Clean manifold stud threads before
installing new nuts. After checking clearances, CAUTION: Before cutting the rear exhaust
tighten nuts uniformly. pipe, measure service muffler exhaust pipe end
and make certain to allow 1-1/2" for engage
FRONT EXHAUST PIPE DUAL EXHAUST ment of the rear exhaust pipe into service muf
fler pipe.
Remove and Replace
1. Remove exhaust pipe to manifold nuts, extensions 4. Cut the exhaust pipe near the muffler see caution
and packings and separate pipes from manifolds. above to allow sufficient pipe for muffler replace
2. Remove "U" bolt clamps at resonator outlet and m ent.
remove exhaust pipe and resonator assemblies. 5. Replace muffler and secure with new clamps.
3. To install new pipes, connect resonator to rear NOTE: Clamps must be assembled with nuts
exhaust pipe and then attach pipe to manifold using attached toward the rear of the vehicle - ref
new packings and nuts. Be sure to clean manifold erence 90c to sawcuts in service muffler pipe.
stud threads and check system clearances before
tightening nuts and clamps. 6. Reverse procedure for installation.
NOTE: If bracket mounting insulators tire
REAR EXHAUST PIPE DUAL EXHAUST carcass mountings are fatigued, replace to in
Remove and Replace sure a secure exhaust system.
1. Remove "U" bolt clamps at muffler inlet and at 7. In the event the tail pipe bezel has been damaged and
resonator outlet connections.
replacement is required, remove three screws and
2. Disconnect pipe at muffler and then at resonator
replace the bezel.
outlet.
3. To install new rear exhaust pipe, connect to reso FRONT EXHAUST PIPES
nator outlet and then to muffler.
4. Install "U" bolt clamps and tighten after checking Replacement
system clearances. 1. Remove exhaust pipe to manifold nuts, extensions
and packings.
LEFT TAIL PIPE DUAL EXHAUST 2. Remove clamps just forward of transmission cross-
member and remove front exhaust pipe.
Remove and Replace
3. To install, connect front pipe to rear pipe and then
1. Remove "U" bolt clamp at muffler.
install at manifold using new packings and nuts,
2. Remove screw attachment at tail pipe rear hanger
and remove tail pipe. NOTE: Clean manifold stud threads before in
3. Install new tail pipe to muffler, then install at rear stalling new nuts. Check exhaust system clear.
hanger. ances before tightening nuts and clamps.
SPECIAL TOOLS
I
TAPER
TO 1/2"
1. J-8950 Fuel Tank Gauge Unit Spanner

2. J-7777 Fuel Line Clip Installer
3. J-22554 Fuel Tank Gauge Unit Spanner Chevrolet
SECTION 9
STEERING
CONTENTS OF THiS SECTiON
Page
Standard Steering 9-1

Power Steering 9-32
Special Tools 9-39
STANDARD STEERING
INDEX
Page Page
General Description 9-1 Assembly--Syncromesh Column 9-12

Maintenance and Adjustments 9-1 Disassembly--Column Mounted Powerglide
Adjustments 9-2 Lever or Floor Shift Column 9-14
Steering Gear 9-2 Assembly--Column Mounted Powerglide Lever
Steering Wheel Alignment and High or Floor Shift Column 9-16
Point Centering 9-4 Disassembly--Tilt Column 9-17
Toe-in Adjustment 9-4 Assembly--Tilt Column 9-21
Corvette Steering Ratio 9-4 Disassembly--Standard Corvette Column 9-23
Component Replacement and Repairs 9-4 Assembly--Standard Corvette Column 9-24
Steering Wheel 9-4 Disassembly--Corvette Telescoping Column . 9-24
Regular Production 9-4 Assembly--Corvette Telescoping Column 9-25
Deluxe Installation 9-26
Tilt 9-6 Steering Column Alignment 9-28
Simulated Wood 9-6 Steering Linkage 9-29
Corvette Telescoping Tie Rods 9-29
Steering Coupling
9:9 Relay Rod 9-30
Steering Gear
Sector Shaft Seal Replacement Idler Arm 9-31
Steering Column 9-9 Pitman Arm 9-31
Inspection 9-10 Steering Arms 9-31
Removal 9-10 Steering Damper 9-32
Disassembly--Synchromesh Column 9-11
GENERAL DESCRIPTION
The regular production steering gear is the recirculat force the driver continues its forward direction. A
ing ball type. This gear provides for ease of handling by severe collision generally involves these two forces- -
transmitting forces from worm to sector gear through the primary and secondary forces. The secondary im
ball bearings. The steering linkage is of the relay type, pact occurs when the driver is thrust forward into the
and extended interval lubrication design, with the pitman steering wheel and column.
arm connected to one end of the relay rod. The outer end The Energy Absorbing Column Is designed to absorb
of the relay rod is connected to an idler arm which is these primary and secondary forces to the extent that
connected to the frame side rail opposite the steering the severity of the secondary impact is reduced. During
gear. Two adjustable tie rods connect the relay rod to a collision the steering column compresses, thereby
the steering arms. reducing its tendency to move rearward into the driver’s
All passenger cars for 1968 are equipped with Energy compartment. A split second later when the driver is
Absorbing Steering Columns. The mast jacket, shift tube, thrown forward the secondary impact his energy is also
and steering shaft are designed to collapse under various partially absorbed by the compression characteristics o.
front impact conditions. When an automobile is involved the column. See Figure 1.
in a frontal collision, the primary force forward move All new columns are of this design, including the tilt
ment of the car is suddenly halted, while the secondary option and telescope option.

The manual steering gear is filled at the factory with a made using a water resistant EP chassis lubricant.
water resistant grease. Seasonal change of this lubrica Check and fill steering gear as follows:
tion is unnecessary and the housing should not be drained. 1. Remove lower and outboard cover retaining screws
The steering gear lubricant level should be checked every fig. 2.
36,000 miles. Whenever required, additions should be 2. Insert filling device in lower screw hole.
STEERING 9-2
Fig. 2-Cover Attaching Bolts TypiCal
a torque wrench with a 3/4 inch socket on the

steering wheel nut fig. 5.
NOTE: Do not use torque wrench having max

imum torque reading of more than 100 pounds
inch.
Fig. 1-Reaction of Forces in Two Stages of a Collision b. On vehicles with Tilt Steering Columns, it will be
necessary to disconnect the steering coupling to
3. Inject lubricant until it appears in outboard screw obtain a torque reading of the steering column.
hole; gear is now filled to correct level. This reading should then be subtracted from any
The steering linkage should be lubricated with water reading taken on the gear.
resistant EP chassis lubricant every 6,000 miles or six c. On vehicles with Simulated Wood Steering Wheels,
months, whichever occurs first. Lubrication points and it will be necessary to remove contact ring to
additional information on the chassis lubricant to be used gain access to the steering wheel nut.
can be found in Section 0 - - General Information and d. On vehicles with Telescopic Steering Columns,
Lubrication. check preload by removing the horn button and
applying torque wrench, with a phillips-head
adapter socket, on the star-headed screw in center
ADJUSTMENTS of steering wheel.
Steering Gear NOTE: Apply a light vertical pressure to torque
wrench end to keep phillips-head engaged in
Before any adjustments are made to the steering gear
in an attempt to correct such conditions as shimmy, screw.
loose or hard steering etc., a careful check should be
made of front end alignment, shock absorbers, wheel
balance and tire pressure for possible cause.
Correct adjustment of the steering gear is very im
portant. Perform adjustments following the sequence
listed below.
1. Remove pitman arm nut and mark relation of pitman
arm position to sector shaft. Remove pitman arm
with Tool 3-6632 as shown in Figure 3.
2. Loosen the pitman shaft lash adjuster screw locknut
and turn the adjuster screw a few turns in a counter
clockwise direction fig. 4. This removes the load
imposed on the worm bearings by the close meshing
of rack and sector teeth. Turn steering wheel gently
in one direction until stopped by gear, then back away
about one turn.
CAUTION: Do not turn steering wheel hard
against stops when steering relay rod is discon
nected as damage to ball guides may result.
3. a. On vehicles with regular steering, check preload
by removing horn button or shroud and applying Fig. 3-Removing Pitman Arm
STEERING 9.3
Fig, 4-Steering Gear Adlustment Points
e. if torque does not lie within limits given in speci marks made during disassembly. Refer to torque
fications at rear of manual, adjustment is nec
specifications at rear of manual for correct torque
essary. value.
4. To adjust worm bearings, loosen worm bearing ad
juster locknut and turn worm bearing adjuster shown 8. Install horn cap or shroud and connect steering col
in Figure 4 until there is no perceptible end play in umn harness at chassis connector.
worm. Check pull at steering wheel, readjusting if
necessary to obtain proper pull. Tighten locknut and
recheck pull, if the gear feels "lumpy" after adjust
ment of worm bearings, there is probably damage in
the bearings due to severe impact or to improper
adjustment and the gear must be disassembled for
replacement of damaged parts.
5. After proper adjustment of worm is obtained and all
mounting bolts securely tightened, adjust lash ad
juster screw. First turn the steering wheel gently
from one stop all the way to the other, carefully
counting the total number of turns. Then turn wheel
back exactly half way, to center position. Turn lash
adjuster screw clockwise to take out all lash In gear
teeth, and tighten locknut. Check pull at steering
wheel taking highest reading as wheel is turned
through center position. See specifications in rear of
manual for proper sector lash adjustment. Readjust
if necessary to obtain proper pull.
NOTE: if maximum specification is exceeded,
turn lash adjuster screw counter-clockwise, then
come up on adjustment by turning the adjuster
In a clockwise motion.
6. Tighten locknut then recheck pull, as it must lie be
tween specified readings.
7, Reassemble pitman arm to sector shaft, lining up
Fig. 5-Checking Wheel Pull
STEERING 9-4
Fig. 6-Steering Wheel Alignment
Steering Wheel Alignment and High Point Centering

1, Set front wheels in straight ahead position. This can
be checked by driving vehicle a short distance on a
flat surface to determine steering wheel position at
which vehicle follows a straight path.
2. With front wheels set straight ahead, check position
of mark on wormshaft designating steering gear high
point. This mark should be at the top side of the
shaft at 12 o’clock position and lined up with the
mark in the coupling lower clamp. Fig. 7-Adjusting Steering Ratio-Corvette
3. II gear has been moved off high point when setting
wheels in straight ahead position, loosen adjusting Toe-In Adjustment
sleeve clamps on both left and right hand tie rods, Adjust the steering linkage for proper toe-in setting as
then turn both sleeves an equal number of turns in
outlined in Section 3.
the same direction to bring gear back on high point.
CAUTION: Turning the sleeves an unequal Corvette Steering Ratio Fig. 7
number of turns or in differential directions
will disturb the toe-in setting of the wheels. The Corvette steering ratio may be changed as follows:
CAUTION: Do not use the rearward hole in the
4. Readjust toe-in as outlined in Section 3 if neces
steering arm with power steering equipment or
sary.
interference may result.
5. With wheels in a straight ahead position and the
steering gear on highpoint, check the steering wheel 1. Remove tie rod ball stud nut at steering arm and
alignment by measuring the distance from each hori disconnect tie rod from steering arm.
zontal spoke to the horizontal centerline of the 2. Move tie rod end to forward hole for 17.6:1 ratio
steering wheel fig. 6. if the horizontal spokes are fast ratio or rear hole for 20.2:1 ratio standard
over 1-1/8 inches from the horizontal position the ratio.
wheel should be removed and centered. See steering 3. Install tie rod stud nut and tighten securely. Repeat
wheel removal in this section. operation on opposite steering arm.

STEERING WHEEL 3. Pull out horn button cap or center ornament and
retainer.
Regular Production Fig. 8 4. Remove three screws from the receiving cup.
Removal 5. Remove the receiving cup, belleville spring, bushing,
1. Disconnect battery ground cable. and pivot ring.
2. Disconnect steering column harness from chassis 6. Remove the steering wheel nut and washer.
wiring harness at connector fig. 9 using Tool 7. Using Tool 3-2927, install centering adapter on
3-22727. steering shaft, thread puller anchor screws into
STEERING 9.
Fig. 9-Steering Column Wiring Connector and

Removing Electric Terminals Using Tool J-22727
Fig. 8-Steering Wheel and Horn Attachments
3. Remove three attaching screws on underside of

threaded holes provided in steering wheel. Turn steering wheel.
center bolt of tool clockwise to remove steering 4. Disconiiect four attaching screws securing both horn
wheel fig. 10. blowing buttons. This will permit wires to hang
Installation loose.
5. Remove steering wheel shroud.
CAUTION: Direction signal control assembly 6. Remove steering wheel nut and washer.
must be in neutral position when assembling 7. Using Tool J-2927, install centering adapter on
steering wKéei to prevent damage t6 cancelling steering shaft, thread puller anchor screws into
cam and control assembly.
threaded bolts provided in steering wheel. Turn
1 * With directional cancelling cam and horn contact as center bolt *f tool clockwise to remove steering
sembly in place, set wheel onto steering shaft. wheel fig. 10.
Secure with washer and nut. Refer to torque speci
fications at rear of manual for correct torque values.
Assembly
2. Install belleville spring with dish of spring up, pivot 1. With directional cancelling cam and horn contact in
ring, bushing and receiving cup with screws.
place, set wheel onto steering shaft. Secure with
3. Install retainer and horn button cap or center orna
washer and nut. Refer to torque specifications at
ment.
rear of manual for correct torque values.
4. Connect steering column harness to chassis wiring
2. Install steering wheel shroud.
connector.
3. Connect four attaching screws to horn blowing
5. Connect battery ground cable. buttons.
Deluxe Steering Wheel Fig. 8 4. Position shroud on steering wheel.
5. Install three attaching screws on underside of steer
Removal ing wheel.
1. Disconnect battery ground cable. 6. Connect steering column harness to chassis wiring
2. Disconnect steering column harness from chassis connector.
wiring harness at connector fig. 9. 7. Connect battery ground cable.
Fig. 12-Simulated Wood Steering Wheel and Attaching Ports
NOTE: if steering wheel only is to be replaced,

perform step 4. if directional signal cancelling
cam is to be replaced, omit step 4 and proceed
with steps 5 and 6.
5. Remove remaining screws from steering wheel and
remove wheel from hub assembly.
Fig. 10-Removing Steering Wheel with J-2927 6. Remove steering wheel nut and washer.
7. Using Tool J-2927, install centering adapter on
steering shaft, thread puller anchor screws into
Tilt Type threaded holes provided in hub assembly. Turn
On vehicles with Tilt Steering columns, it will be center bolt of tool clockwise to remove hub assembly.
necessary to install steering upper bearing preload spring Installation
prior to the cancelling cam as in fig. 11. This differs
from all other steering upper bearing preload springs as CAUTION: Directional signal control assembly
they are installed after the cancelling cam. must be in neutral position when assembling hub
assembly to prevent damage to cancelling cam
Simulated Wood Fig. 12 and control assembly.
Removal 1. With directional cancelling cam and horn contact In

1. Disconnect steering column harness from chassis place, install hub assembly on steering shaft. Secure
wiring harness at connector. with washer and nut. Refer to torque specifications
2. Disconnect battery ground cable. at rear of manual for correct torque value.
3. Remove horn cap assembly by pulling up. 2. Attach steering wheel to hub assembly using the six
4. Remove contact assembly attaching screws and re attaching screws and tighten securely.
move contact assembly. 3. Place horn contact on steering wheel and attach with
three screws. Tighten securely.
4. Snap horn button in place.
5. Connect steering column harness to chassis wiring
connector.
6. Connect battery ground cable.
Corvette Telescoping Fig. 13

Removal
1. Disconnect steering column harness at wiring
connector.
3. Pry off horn button cap.
4. Remove three screws securing horn contact to spacer
and hub.
5. Remove two screws securing lock screw to lock
knob, and remove lock screw, lock knob, and spacer.
NOTE: If steering wheel only is to be replaced,
perform Step 5 below only, if directional signal
cancelling cam is to be replaced, omit Step 5
and proceed with Steps 6 and 7.
6. Remove six screws securing steering wheel to hub
Fig. 11-Tilt Steering Upper Bearing Preload Spring and removewheel.
STEERING 9-7
Fig. 13-Corvette Telescoping Wheel Option
7. Remove nut and washer from shaft and using steering 9. Remove three screws holding spacer. Attach horn
wheel puller Tool J-2927, remove steering wheel and contact to spacer and steering wheel with three
hub from vehicle. screws.
8. Slide cancelling cam and spring off shaft. 10. Install horn button cap.
11. Connect steering column harness at chassis plug.
Installation 12. Connect battery ground cable.
NOTE: Refer to torque specifications at rear of
manual for correct torque values.
Steering Coupling
1. if necessary, slide cancelling cam and spring on end
of shaft. Removal
2. If hub was removed from steering wheel, attach hub 1. Disconnect battery ground cable.
to steering wheel with screws removed during dis 2. Disconnect steering column harness and back-up
assembly. lamp/neutral safety switch at connector plugs fig. 9.
3. Place steering wheel and hub assembly in position 3. Camaro and Chevy II only:
and secure to column with washer and nut. a. Remove lower mast jack cover fig. 16.
4. Position spacer on steering wheel. b. If vehicle is equipped with automatic, remove
5. Position lock knob on steering wheel. indicator pointer wire by removing screw from
6. Install lock screw through lock knob, turn into shaft, six o’clock position at bottom of mast jacket fig.
and adjust to lock position. 15. Work indicator wire out of position and
7. Attach spacer to wheel with three screws. remove.
8. Place lock knob in lock position and attach to lock 4. Chevrolet and Chevelle.
screw with two screws. a. Remove upper and lower mast jacket covers.
STEERING 9-8
one in the driver’s seat and one at engine com

partment.
6. Lift steering column upward enough to permit re
moval of steering coupling from steering gear.
Mechanic at engine compartment can pilot column
shift levers, if so equipped, through dash panel open
ing as column is listed, if it is necessary to leave
the vehicle at this point, place steering column in
correct mounted position and loosely install instru
ment panel mounting bracket to support column.
7. Remove steering coupling from vehicle.
Installation
1. Lift steering column enough to provide clearance and
loosely install steering coupling on steering gear
shaft. Be sure column is supported in its normal
mounted position at all times when not moving for
clearance. Mechanic at engine compartment can
pilot column shift levers through dash panel opening
as column is moved.
2. Slide steering coupling into correct installed position
and install clamp bolt.
3. Secure steering coupling to flanged end of steering
column with washers and nuts. Maintain coupling
adjustment shown in Figure 17.
4. Install instrument panel column mounting bracket.
Fig. 14-Steering Column-Corvette Refer to torque specifications at rear of manual for
correct torque values.
b. if vehicle is equipped with automatic, remove 5. Chevrolet and Chevelle only:
indicator cable. a. If vehicle is equipped with Automatic, work shift
5. Remove instrument panel column mounting bracket indicator pointer wire into position on column and
attaching hardware and remove bracket. secure with screw at six o’clock position at
bottom of mast jacket fig. 16.
CAUTION: Do not allow steering column to
hang down from dash panel area or distortion to b. Install mast jacket lower cover fig. 16.
column will result. When instrument panel 6. Connect steering column harness at connector plug.
mounting bracket is removed, be sure column is Connect back-up lamp/neutral safety switch plug, if
so equipped.
supported in its normal position.
7. Inside vehicle, install seal, protective covers, and
NOTE: The following step requires two men, trim cover or boot fig. 14. On Corvette models the
Fig. 15-Automatic Indicator Connection-Chevrolet, Chevelle and Chevy II
STEERING 9.9
CENTER LINE OF
STEERING GEAR
FLEXIBLE COUPLING SETTING
End of top pin at 12 o’clock
position must be flush with
II -v
"
3_
1/4"
TO rear flange surface.
CENTER LINE OF
STEERING SHAFT
COUPLING PINS -
WITH RUBBER STEERING

PROTECTORS COLUMN
REMOVED TO STEERING
CHEVROLET GEAR
CHE YE LIE
CORVETTE CHEVY U CAMARO
Fig. 16-Steering Coupling Clearance Adjustment
covers are installed in the enine compartment side. 4. Pull sector shaft seal from gear housing using
8. Connect transmission controls to shift levers at hooked tool or pliers.
bottom of column if so equipped. 5. Coat new seal with chassis grease and position in
9. Connect battery ground cable. sector shaft bore.
8. Place a socket or piece of pipe of suitable diameter
Steering Gear-Chevrolet, Chevelle, Camaro, on top of seal and drive seal into bore by tapping
Chevy II and Corvette Fig. 12 pipe or socket with soft hammer.
Removal 7. Install sector shaft side cover assembly, being care
1. Remove retaining nuts, lock washers, and bolts at ful not to damage new seal with splines on end of
steering coupling. shaft; splines may be wrapped with a few turns of
2. Remove pitman arm nut and washer from sector tape to prevent this.
shaft and mark relation of arm position to shaft. 8. Install new side cover gasket and align side cover on
3. Remove pitman arm with Tool J-6632 as shown in gear housing and install cap screw.
Figure 3. 9. Perform steering gear adjustment and install pitman
arm as outlined under Maintenance and Adjustments.
NOTE: On Camaro models, use care not to
bend or fracture brake pipe when removing
steering gear.
4. Remove screws securing steering gear to frame and
STEERING COLUMN
remove gear from vehicle. AU models are equipped with new energy absorbing
Installation steering columns. The columns are of five basic designs
1, Place gear into position so that steering coupling as follows:
mounts properly to flanged end of steering shaft. 1. Syncromesh. The syncromesh column is 4sed on
Secure gear to frame with washers and bolts. On models with standard, column mounted, conventional
Corvette models, install gear with bolts, washers, shift levers. The shift tube, within the outer mast
and nuts. Maintain coupling adjustment shown In jacket, includes two lower shift levers for connection
Figure 16. to the transmission control linkage.
2. Install pitman arm aligning marks made during re 2. Automatic and floor shift. This column is used on
moval and secure with washer and retaining nut. models equipped with column mounted powerglide
3. Secure steering coupling to flanged end of steering shift levers, or models with floor shift. If the
column with lock washers, and nuts. vehicle has the column mounted powerglide shift
control, the inner shift tube has a single lower shift
Sector Shaft Seal Replacement lever for connection to the transmission control
A faulty seal may be replaced without removal of linkage. On floor shift models, no lower shift levers
steering gear from car by removing pitman arm as out are present on the shift tube.
lined under Maintenance and Adjustments-Steering Gear 3. Tilt wheel option. The upper end and steering shaft
Adjustments and proceed as follows: of this column is specially designed to accommodate
1. Loose lash adjuster lock nut and turn lash adjuster the optional tilt steering wheel.
screw several turns counterclockwise. 4. Standard Corvette Column. The standard Corvette
2. Remove three cap screws holding side cover to gear column is similar in design to the Automatic and
bushing. Floor Shift column used on other models, except no
3. Pull side cover and sector shaft from gear housing shift tube is used. Other differences are pointed out
as a unit, Do not separate side cover from sector in the disassembly and assembly procedures for
shaft. Standard Corvette column.
STEERING 9-10
5. Telescopic wheel option Corvette. The upper end usually result in collapsing of the mesh section of the
and steering shaft of this column is specially de steering column.
signed to accommodate the optional telescoping
Column
steering wheel.
To perform service procedures on steering column Inspect mesh section of column for bulged sections
and/or bends.
upper end components, it is not necessary to remove the
column from the vehicle. The steering wheel, horn com Shifter Shaft
ponents, turn signal switch, upper housing with bearing, Separation of the shifter shaft sections will be internal
shift control lever, hazard warning knob, and upper shift and cannot be visually identified. Hold lower end of the
bowl may all be removed with the column remaining in "shifter shaft" and move "shift lever" on column through
the vehicle. When servicing the above components, omit its ranges and up and down. if there is little or no move
the removal procedure and proceed with the applicable ment of the "shifter shaft", the plastic joints are sheared.
disassembly procedures. Because of the numerous dif
ferences in steering column types, be sure to refer to the Steering Shaft
set of instructions below which apply to the exact column Hold steering shaft at coupling and rotate steering
wheel back and forth, no lash should be evident. Lash
to be serviced:
will indicate that the plastic pins have sheared. It should
CAUTION: The outer mast jacket, shift tube, be noted that if the steering shaft pins are sheared due to
steering shaft, and instrument panel column minor collision with no appreciable damage to other com
mounting bracket are designed as energy ab ponents, that the vehicle can be safely steered, however,
sorbing units. Because of the design of these steering shaft replacement is recommended.
components, it is absolutely necessary to handle
the column with care when performing any serv
ice operation required. Avoid hammering, jar Removal
ring, dropping, or leaning on any portion of the 1. Disconnect steering column harness at connector.
column. Disconnect neutral safety switch and back-up lamp
switch connectors if so equipped.
Inspection 2. Remove steering wheel as outlined in this section.
To determine if the energy absorbing steering column 3, Remove nuts and washers securing flanged end of
components are functioning as designed, or if repairs are column to steering gear.
required, a close inspection should be made. An inspec 4. Disconnect transmission control linkage, if so
tion is called for in all cases where damage is evident or equipped, from lower column shift tube levers.
whenever the vehicle is being repaired due to a front end 5. Chevrolet only: Remove screws attaching upper and
collision. Whenever a force has been exerted on the lower mast jacket covers together. Remove screws
steering wheel or steering column, or its components, attaching lower cover to instrument panel fig. 15.
inspection should also be made. if damage is evident, the Remove lower cover.
affected parts must be replaced. 6. Chevelle only: Remove screws securing mast jacket
The inspection procedure for the various steering trim cover to instrument panel and remove cover.
column components on all 1968 Passenger Cars is as 7, Remove screws securing upper and lower covers
follows: together and remove covers.
Column Support Bracket 8. Chevrolet only fig. 18:
Damage in this area will be indicated by separation of a. Remove screws securing cover trim to dash panel
the mounting capsules from the bracket. The bracket will and remove cover trim.
have moved forward toward engine compartment and will b. Remove clamp screw and loosen clamp.
I,
Fig. 17-Steering Column to Dash Panel-Chevelle Fig. 18-Steering Column to Dash Panel-Chevrolet
STEERING 9-1 1
Fig. 20-Steering Column to Dash Panel-Corvette
J-22573 is not used, frequently check position

of column in vise jaws to insure column is not
working free of jaws.
Fig. 19-Steering Column to Dash Panel-Camaro and Chevy Il
2. Clamp column in a bench vise as shown in Figure 23.
3. Slide upper bearing preload spring and cancelling
c. Remove screws securing cover and seal to dash
cam off end of shaft fig. 23.
panel. 4. Remove turn signal lever retaining screw and re
9. Chevelle only fig. 19: move lever. Push hazard warning switch in, un
a. Remove screws securing cover trim to dash panel screw and remove knob.
and remove cover trim. 5. Drive out shift control lever retaining pin and re
b. Remove screws securing inner cover to outer move shift lever.
cover. 6. Remove "C" retaining ring from upper steering shaft
c. Remove screws and washers securing inner using snap ring remover Tool J-22569 as shown in
cover, outer cover, and seal to dash panel and
Figure 25.
remove covers. 7. Slide thrust washer and wave washer off upper steer
10. Camaro and Chevy II fig. 19:
ing shaft fig. 25.
a. Fold grommet back on column.
8. Loosen three turn signal switch mounting screws
b, Remove screws securing lower cover to upper until the switch cover can be rotated counter-clock
cover. wise. It may be necessary to push on top of screws
c. Remove screws securing upper cover, lower
to loosen the cover assembly.
cover, and seal to dash panel and remove covers.
11. Corvette only fig. 20: NOTE: Do not remove the three turn signal
a. Remove clamp bolt and washer from support as switch screws completely unless it is necessary
sembly on engine side of dash panel. to replace the turn signal switch, lockplate, or
b. Remove screws securing support assembly and upper bearing housing and bearing.
seal to engine side of dash panel.
9. Rotate turn signal switch cover counter-clockwise
12. Support column and remove screws, nuts, and bolts and pull cover off top of jacket fig. 26.
securing instrument panel mounting bracket to un 10. Remove shift lever bowl from top of jacket.
derside of instrument panel. On Chevrolet, Chevelle, 11. If necessary, pry upper shift lever spring fig. 27
Camaro, and Chevy II models, remove and retain from bowl and discard spring. Remove bowl washer
wedge shims. On Chevrolet models, remove re fig. 27.
tainers. 12. If necessary to service components within the signal
13. Move front seat back as far as possible to provide switch cover, remove the three signal switch mount
maximum clearance, and carefully lift column up out ing screws completely from engagement with the
of position and remove from vehicle, if column is lockplate. Use care to control three springs as
equipped with lower shift levers, mechanic at engine screws are removed.
compartment can pilot levers through dash panel 13. Remove turn signal switch and upper bearing housing
opening as column is lifted. assembly from cover.
Disassembly-Syncromesh Column Fig. 21 14. Carefully pull steering shaft assembly from bottom
1. Unsnap and remove wiring protector fig. 22. of column.
15, Remove screws securing back-up lamp switch to
CAUTION: Secure column in bench vise for column and remove switch. Retain these mounting
service one of two ways shown in Figure 23. screws.
Clamping column in vise in any other manner 16. Remove three bolts securing reinforcing ring to
will damage the column, if support fixture adapter just above the lower gearshift levers. It is
_ ______
STEERING 9-12
16 15 14 13 12’’
17
//
I I
18
19
1.
1 - . .1 1V 1. 1
26 25 24 /3
396 ENGINE ONLY
WV
Fig. 21-Syncromesh Steering Column-Exploded View-,Cheve lIe
1. Steering Wheel Nut 10. Lock Ring 19. Shift Tube Assembly
2. Screw 11. Thrust Washer 20. Adapter
3. Retaining Ring 12. Shift Lever Spring 21. Bolt
4. Thrust Washer 13. Shift Bowl 22. Reinforcing Ring
5. Wave Washer 14. Shroud 23. Steering Shaft
6. Turn Signal Switch 15. Bearing 24. Bearing
7. Upper Bearing and 16. Mast Jacket 25. Tolerance Ring Kit
Housing Assembly 17. Flange Plate 26. Pot Joint
8. Cover 18. Wiring Protector 27. Flange
9. Spring
very important to retain these bolts for reassembly. bearing out. This bearing may be reused in this
Use of the wrong size bolts during reassembly would column or discarded. It may not be used as a re
result in damage to the column. placement part in another column.
1’?. Remove reinforcing ring, adapter with bearing, first 20. If necessary, remove and discard lower bearing.
and reverse shift lever, and spacer from lower end. 21. if necessary, unwrap mesh cover from jacket.
18. Withdraw shift tube assembly from lower end.
19. Remove the lower bowl bearing from the top end of Assembly-Syncromesh Column Fig. 21
the jacket by inserting a suitable length of pipe or 1. Apply a thin coating of lithium soap grease to all
wooden rod through the lower end and tapping the friction surfaces.
STEERING 9-13
Fig. 24-Upper Bearing Preload Spring and Cancelling Cam
5. Assemble the lever spacer, first and reverse lever,

adapter with bearing, and reinforcing ring. Place
this assembly into position on the lower end of the
jacket and loosely secure using the three bolts ré
moved during disassembly.
6. Place a 0.005 maximum shim on each side of the
shaft, between either one of the shift levers and the
spacer fig. 28.
7. Using spanner wrench J-22658 installed in spanner
holes in adapter, rotate the adapter clockwise until
the shift levers are bottomed out fig. 29. Bottom
the adapter against the jacket while rotating to re
Fig. 22-Removing Wiring Protector move end play.
8. Tighten the three adapter bolts. Remove the two
2. If lower bearing was removed, press a new lower 0.005 shims.
bearing into the adapter. 9. Insert the steering shaft assembly into position
3. if lower shift bowl bearing was removed from jacket, through the lower end of the jacket.
press bowl bearing into top end of jacket.
4. Insert the shift tube assembly into the lower end of
the jacket.
NOTE: Be sure friction surfaces of lower
levers and mating bearing surfaces are greased
before performing the next step.
Fig. 23-Column Secured in Bench Vice Fig.25-Removing or Installing "C" Ring Retainer Using Tool J-22569
STEERING 9.14
Fig. 26-Removing Turn Signal Switch Cover from Column
10. Attach the back-up lamp switch loosely to the jacket

using the same screws removed during disassembly.
Install these screws loosely, switch will be tightened
to the jacket when column is installed in vehicle and
shift levers are aligned.
11. If upper shift lever spring was removed, press a new Fig. 28-Bottoming Shift Levers Using Spanner Wrench J-22568
upper shift lever spring into bowl pocket. Be sure
14. Slide three springs onto screw ends at rear of cover
spring is seated in bowl pocket. Install bowl washer
and place lockplate in position over screws and
fig. 27.
springs. Turn screws three turns into lockplate.
12. Insert the upper bearing housing assembly and the 15, Feed switch wire through the shift lever bowl and
turn signal switch assembly into the cover, feeding
place upper end assembly on top of bowl.
the signal switch wires through the back of the cover, 16. Place the shift lever bowl and signal switch cover
13. Align the signal switch and bearing housing holes assembly on top of jacket, aligning the tangs on the
with the holes in the cover. Install three mounting LD. of the lockplate with the slots in the top of the
screws through the holes,
jacket. Shift tube key should align in bowl keyway as
bowl is pushed on.
17. Lock upper end assembly into position by pushing
down on the cover assembly and rotating assembly
fully clockwise. Tangs of lockplate must engage
slots in jacket.
18. Tighten three turn signal switch mounting screws in
a gradual criss-cross sequence to avoid cocking the
lockplate.
19. Slide wave washer and thrust washer over steering
shaft and against upper bearing housing.
20. Start "C" retaining ring over steering shaft taper.
Complete installation of retaining ring using snap
ring installer J-22659 as shown in Figure 25. Be
sure "C" retaining ring is completely seated into
steering shaft groove.
21. Place turn signal switch lever in position and secure
with screw. Screw hazard warning knob into posi
tion.
22. Remove column from vise and pull wires flat against
jacket. Snap wire protector into place.
23. if mesh cover was removed, wrap mesh cover around
jacket and secure with electricians or friction tape.
SHIFT LEVER 24. Slide cancelling cam and upper bearing preload
spring onto end of shaft.
Disassembly-Column Mounted Automatic Lever or
Floor Shift Column Fig. 29
Fig. 27-Upper Shift Lever Spring and Bowl Washer NOTE: In this procedure, automatic refers to
_-_ _______
STEERING 9-1 5
10 9 8 43 2
14 -- 13 - - 12 ii"
20 16
22
.-,-------==‘- _.
Fig. 29-Column Mounted Automatic Lever or Floor Shift Column-Exploded View-Chevrolet
Steering Wheel Nut 7. Upper Bearing Assembly 13. Bearing 18. Spring
2. Screw 8. Cover 14. Mast Jacket 19. Bearing
3. Retaining Ring 9. Spring 15. Wiring Protector 20. Retainer
4. Thrust Washer 10. Lock Plate 16. Shift Tube 2]. Steering Shaft
5. Wave Washer 11. Shift Lever Spring 17. Washer 22. Tolerance Ring Kit
6. Turn Signal Switch 12. Bowl
a column with a column mounted, Powerglide column in vise jaws to insure column is not
shifting lever. Floor shift refers to a column working free of jaws.
with floor shift controls.
2. Clamp column in a bench vise as shown in Figure 23.
1. Unsnap and remove wiring protector and wiring clip. 3. Slide upper bearing preload spring and cancelling
cam off end of shaft.
CAUTION: Secure column in bench vise for 4. On automatic columns removed from Chevy U or
service one of two ways shown in Figure 23. Camaro, remove screws securing dial retainer to
Clamping column in vise in any other manner column and remove retainer and dial fig. 30. Slide
will damage the column, If support fixture indicator out of shift bowl and remove indicator.
J-22573 is not used, frequently check position of Remove cap and bulb from turn signal switch housing.
STEERING 9-16
5. Remove turn signal lever retaining screw and re

move lever. Push hazard warning knob in; unscrew
STEERING SHAFT
and remove knob.
6. On automatic columns, drive out shift control lever
retaining pin and remove shift lever.
7. Remove "C" retaining ring from upper steering, shaft
using snap ring remover Tool J-22569 fig. 25.
8. Slide thrust washer and wave washer off upper steer
fIJUM
SHIFT TUBE
ing shaft fig. 25.
9. Loosen three turn signal switch mounting screws
until the switch cover can be rotated counter-clock Fig. 31-Shift Tube and Steering Shaft
wise. It may be necessary to push on top of screws
to loosen the cover assembly. spring. On automatic columns, remove spring thrust
NOTE: Do not remove the three turn signal washer fig. 30.
switch screws completely unless it is necessary 19. if necessary, press bearing out of bearing adapter.
to replace the turn signal switch, lockplate, or 20. Withdraw shift tube assembly from lower end.
upper bearing housing and bearing. 21. Remove the lower bowl bearing from the top end of
the jacket by inserting a suitable length of pipe or
10. Rotate turn signal switch cover counter-clockwise wooden rod through the lower end and tapping the
and pull cover off top of jacket fig. 26. bearing out, This bearing may be reused in this
11. if necessary, pry upper shift lever spring fig. 27 column or discarded. It may not be used as a re
from bowl and discard spring. placement part in another column.
12. Remove shift lever bowl from top of jacket. 22. Slide steering shaft lower bearing spring, plunger,
13. if necessary to service components within the signal tolerance ring and sleeve assembly, and thrust
switch cover, remove the three signal switch mount washer off upper end of shaft.
ing screws completely from engagement with the 23. if necessary, unwrap mesh cover from jacket.
lockplate. Use care to control three springs as 24. Remove flange clamp bolt and flange at bottom of
screws are removed. steering shaft, if so equipped.
14. Remove turn signal switch and upper bearing housing
Assembly-Column Mounted Powerglide Lever or
assembly from cover.
Floor Shift Column Fig. 29
[5. Carefully pull steering shaft assembly from bottom
of column. 1. Apply a thin coating of lithium soap grease to all
16. Remove securing back-up lamp/neutral start switch friction surfaces.
to column, if so equipped, and remove switch. Re 2. if lower shift bowl bearing was removed from jacket,
tain these mounting screws. press bowl bearing into top end of jacket.
17. Remove bearing adapter clip fig. 32. 3. if lower bearing was removed from adapter, press
18. Remove bearing adapter with bearing, and shift tube lower bearing into adapter.
4. On automatic columns, install spring thrust washer
on end of shift tube against lower shift lever.
Fig. 30-Automatic Dial Indicator Assembly-Camaro Fig. 32-Tolerance Ring Kit First Adjustment
STEERING 9-17
5. Install shift tube spring and adapter on end of shift

tube and secure with bearing adapter clip fig. 31.
6. Slide shift tube into position through lower end of
jacket.
7. Attach the back-up lamp/neutral start switch, if so
equipped, to the jacket using the same screws re
moved duriug disassembly. Install these screws
loosely; the switch must be adjusted after column is
installed in the vehicle.
NOTE: If the steering shaft assembly mast
jacket, upper bearing housing assembly, or lower
bearing assembly has been replaced, the com
ponent stack-up in the column will be different.
Replace the lower plastic injected tolerance ring
and bearing preload spring with the necessary
tolerance ring kit as described below.
8. Slide thrust washer, tolerance ring kit, plunger, and
kit spring into position from top of steering shaft.
9. Slide steering shaft assembly into position through
lower end of jacket.
10. On automatic columns, if upper shift lever spring
was removed, press a new upper shift lever spring
into shift lever bowl. Be sure spring is seated in
bowl pocket.
11. Insert the upper bearing housing assembly and the Fig. 33-Tolerance Ring Kit- Final Adjustment
turn signal switch assembly into the cover, feeding
the signal switch wires through the back of the cover. 23. Place turn signal switch lever in position and secure
12. Align the signal switch and bearing housing holes with screw. Screw hazard warning knob into posi
with the holes in the cover. Install three mounting tion.
screws through the holes. 24. if column is automatic and to be installed in a Chevy
13. Slide three springs onto screw ends at rear of cover U or Camaro, install the bulb and cap fig. 30. Slide
and place lockplate in position over screws and the indicator into the shift bowl. Install dial and re
springs. Turn screws three turns into lockplate. tainer with screws removed during disassembly.
14. Feed switch wire through the shift lever bowl and 25. Install flange and clamp bolt at bottom of steering
place upper end assembly on top of bowl. shaft, if so equipped.
15. Place the shift lever bowl and signal switch cover 26. Remove column from vise and pull wires flat against
assembly on top of jacket, aligning the tangs on the bottom of jacket. Snap wire protector and clip into
I.D. of the lockplate with the slots in the top of the place.
jacket. 27. If mesh cover was removed, wrap mesh cover around
16. Lock upper end assembly into position by pushing jacket and secure with electricians or friction tape.
down on the cover assembly and rotating assembly 28. Slide cancelling cam and upper bearing preload
fully clockwise. Tangs on lockplate must engage spring onto end of shaft.
slots in jacket. Disassembly-Tilt Column Fig. 34
17. Tighten three turn signal switch mounting screws in
a gradual criss-cross sequence to avoid cocking the NOTE: This procedure covers disassembly
lockplate. and assembly instructions for all tilt columns.
18. Screw tolerance ring kit sections together leaving Automatic refers to a tilt column with a column
enough inner edge exposed for later adjustment as mounted, Powerglide shifting lever. Floor shift
shown in Figure 32. refers to a tilt column taken from a vehicle with
19. Slide wave washer and thrust washer over steering conventional or Powerglide floor shift controls.
shaft against upper bearing housing. 1. Unsnap and remove wiring protector.
20. Start "C" retaining ring over steering shaft taper.
Complete installation of retaining ring using snap CAUTION: Secure column in bench vise for
ring installer J-22659 as shown in Figure 25. Be service one of two ways shown in Figure 23.
sure "C" retaining ring is completely seated into Clamping column in vise in any other manner
steering shaft groove. will damage the column. If support fixture
J-22573 is not used, frequently check position
21. Remove any remaining looseness from internal col
of column in vise jaws to insure column is not
umn stack-up by unscrewing inner tolerance kit ring
working free of jaws.
section; then screw inner kit ring section back in 1/8
to 1/4 turn fig. 33. 2. Clamp column in a bench vise as shown in Figure 23.
22. Touch the outer surface of the tolerance ring kit at 3. Slide upper bearing preload spring and cancelling
several locations with a hot soldering iron to melt cam off end of shaft.
the threads of the inner and outer ring sections 4. On automatic cclumns removed from a Camaro, re
together. move screws securing dial retainer to column and
STEERING 9-18
Fig. 34-Tilt Steering Column-Exploded View-Cheve lIe
1. Cover 14. Shoe Springs 26. Support 38. Dash Seal

2. Steering Wheel Nut 15. Spring 27. Lock Shoe Guide Pin 39. Shift Tube Assembly
3. Nut 16. Release Lever Pivot Pin 28. Stop Plate 40. Adapter
4. Seat 17. Release Lever 29. Screw 41. Bearing
5. Race 18. Bearing 30. Retainer 42. Clamp Bolt and Nut
6. Screw 19. Upper Shaft 31. Thrust Washer 43. Retainer Clip
7. Turn Signal Switch 20. Spring 32. Lock Plate 44. Spring Clip
8. Bearing Assembly 21. Sphere 33. Wave Washer 45. Bearings
9. Spring Retainer 22. Wave Washer 34. Shift Lever Spring 46. Pin
10. Lock Shoe Pin 23. Lower Shaft 35. Shift Bowl 47. Seal
11. Shoe 24. Tilt Spring 36. Shroud 48. Lower Steering Shaft
12. Bearing Housing 25. Screw 37. Mast Jacket 49. Flange
13. Pivot Pin
remove retainer and dial fig. 30. Slide pointer out knob.
of bowl and remove pointer. Remove cap and bulb 6. On Automatic columns, drive out shift control lever
from turn signal switch housing. retaining pin and remove shift lever.
5. Remove turn signal lever retaining screw and re 7. Assemble Tool J-22708 inside turn signal cover and
move lever. Unscrew and remove tilt release lever. push in until tangs on tool lock in place. Using a
Push hazard warning knob in, unscrew and remove wrench, turn clockwise until cover is removed.
STEERING 9-19
Fig. 35-Removing Turn Signal Housing Cover on

Tilt Steering Wheels Using J-22708
8. Remove three turn signal switch mounting screws.

Note short length of screw removed from top posi
tion.
9. Lift signal switch assembly off bearing housing and
allow to hang by the wires. On some columns, the
switch and wires can be removed at this time; re
move switch and wires if possible. if switch and
wires cannot be removed, allow assembly to hang
by wires.
10. Install tilt release lever and place column in full up
position. Remove tilt spring retainer using screw
driver blade that just fits into slot opening. Insert
screw driver in slot, press in approximately 3/16-
inch; rotate retainer approximately 1/8 turn clock Fig. 36-Removing Steering Shaft Bearing Lock Nut
wise until ears align with grooves in housing, and Using Lock Nut Wrench J-22599
remove retainer and spring. Use care when remov
ing spring, it is tightly compressed. 15. Remove retaining ring, washers, adjuster assembly
11. Remove steering shaft bearing lock nut using lock nut and spring from lower end of shaft.
wrench Tool J-22599 fig. 36. Remove inner race 16. Slide steering shaft out of top end of jacket.
seat and inner race. 17. if necessary to disassemble steering shaft, proceed
12. Remove two pivot pins from bearing housing using as follows:
pivot pin remover Tool J-21854 fig. 37. a. Turn upper shaft slightly from center line of
13. Pull up on tilt release lever to disengage lock shoes. lower shaft.
Remove bearing housing and hang with signal switch, b. Using a narrow blade screw driver, work preload
if present, until further disassembly. If signal switch spring out of upper shaft and remove spring
and wires were removed earlier, bearing housing fig. 38.
may be completely removed. Remove tilt release c. Turn upper shaft 90° from center line of lower
lever. shaft and remove shaft.
14. Remove steering shaft flange bolt and flange from d. Rotate centering spheres and remove spheres and
lower end of shaft. wave washer from lower shaft.
Fig. 37-Removing Pivot Pins Using Pivot Pin Removal Tool J-21854
STEERING 9-20
Fig. 38-Removing Pre load Spring from Centering Spheres
18. Remove screws securing the support assembly to the

lockplate and mast jacket and remove support.
19. Remove shift tube retaining ring with a screw driver.
Remove thrust washer fig. 39. rig. 39-Shift Tube Retaining Ring and Lower Bushing
20. Remove lower bearing adapter from bottom of shift
tube by raising plastic fingers, one at a time, and
pulling adapter out. 23. Remove lockplate fig. 41 by sliding out of jacket
21. Remove nuts securing back-up lamp, neutral start notches. Tip plate down toward bowl hub and slide
switch to column, if so equipped, and remove switch. out from under top edge of jacket opening. Remove
Retain these mounting screws. wave washer.
22. Remove shift tube assembly from bowl using shift 24. Remove bowl from mast jacket. Remove signal
tube remover Tool J-22551 fig. 40. Insert the switch and bearing housing if not previously re
hooked end of the tool into the notch of the shift tube moved.
below the bowl key. Pilot sleeve into upper end of 25. On automatic column, remove shift lever spring from
shift tube. Force shift tube out of bowl by turning bowl by winding spring up with pliers and pulling out.
nut on tool. If the shift tube is not completely free 26. On automatic column, remove screws securing shift
when tool is removed, complete removal by hand. stop plate to support, if necessary.
As shift tube is removed from automatic columns, 27. Remove upper bearings from upper bearing housing,
use care as lower shift lever is lowered through if necessary.
bottom of mast jacket. Do not hammer or force 28. Remove lower bearing from lower bearing adapter,
shift tube during removal from mast jacket. if necessary.
Fig. 40-Removing Shift Tube Using Shift Tube Remover J-22551
STEERING 9-21
Assembly-Tilt Column Fig. 34

1. Apply a thin coating of lithium soap grease to all
friction surfaces.
2. Assemble bearing housing components as follows:
NOTE: With tilt lever opening on the left side,
shoes facing up, position the four slot shoe on
the left.
a. Place lock shoe springs and lock shoes in position
in bearing housing. Line up shoes for pin instal
lation using Tool J-22635 fig. 42. Install shoe
pin flush with housing face on shoe release lever
pin side.
b. Hold the shoe springs in compression by rocking
lock shoes in. Insert pin through release lever
and install pin and lever.
3. Ii lower bearings were removed, press upper bearing
into adapter.
4. If upper bearing was removed, press upper bearing
into race on to of bearing housing.
Fig. 41-Lockplote Installed 5. On automatic columns, install stop plate on support
with screws, if plate was removed during disassem
29. Service lock shoes, release springs, or shoe release
bly.
if necessary, as follows:
6. On automatic columns, press a new shift lever spring
a. Drive the lock shoe retaining pin out of the hous into bowl, if original spring was removed.
ing using release lever pivot remover Tool 7. Insert the signal switch wire harness and connector
J-22635 fig. 42, View A. through the bearing housing and bowl. Retain the
b. Hold the shoe springs in compression by rocking housing and bowl together during remaining assem
lock shoes in with a wedge to relieve the load on bly. On columns where signal switch connector can
the shoe release lever; drive out shoe release be inserted through bowl, it is not necessary to re
lever pin using Tool J-22635 fig. 42, View B. tain bearing housing and bowl together.
Remove shoe release lever and release lever 8. Slide bowl into top of mast jacket.
spring. 9. Place wave washer and lockplate into position. Work
c. Remove lock shoes and lock shoe springs. lockplate into notches in jacket by tipping lockplate
30. if necessary, remove seals from lower end of shift toward bowl hub under the top edge of the jacket.
tube and discard seals. 10. if seals were removed from lower end of shift tube,
31. Unwrap mesh cover from jacket, if necessary. cement new seals into place.
Fig. 42-Removing Lock Shoe Retaining Pin Using Tool J-22635
STEERING 9-22
Fig. 44-Installating Spherical Joint Spring
17. Install shaft in shift tube from upper end. Carefully

guide shaft through shift tube, taking care not to tear
or push out foam seal cemented inside lower end of
shift tube.
Fig. 43-Installing Shift Tube Using Shift Tube Installer Tool J-22549 18. Install tilt control lever and, holding lock shoes in
11. Carefully install shift tube in lower end of mast disengaged position, assemble bearing housing on
jacket. On automatic columns, align keyway in tube the shaft over the support until pivot pin holes line
with key in bowl. Complete installation of shift tube up.
19. Secure bearing housing in position by pressing in the
using shift tube installer Tool J-22549 as shown in
Figure 43. Do not hammer or force tube when in pivot pins.
stalling in jacket. 20. Place housing in full up position and install tilt
12. Pull up on bowl to compress wave washer and install spring, tapered end first. Install tilt spring re
thrust washer and shift tube retaining ring. tainer using screw driver in retainer slot.
13. Insert support into jacket by aligning "V" in support 21. Install turn signal switch with three mounting screws.
with "V" notch in jacket. Insert mounting screws Place short length screw in top position above lock
through support into lockplate and tighten screws. shoes.
14. Align fingers of lower bearing adapter with holes in NOTE: if the steering shaft, adapter, mast
jacket and pilot adapter over shift tube. Snap adapter jacket, support or bearing housing has been
into place. replaced, the component stack-up in the column
15. Install back-up lamp/neutral start switch on column, will be different. Replace the lower plastic
if so equipped, using the same mounting nuts re tolerance ring and the lower bearing preload
moved during disassembly. Installthe switch loosely, spring with the necessary tolerance ring kit as
it is to be adjusted when column is installed in the described below.
vehicle.
16. Assemble the steering shaft as follows: 22. Slide kit spring, tolerance ring kit, washers, and
a. Clamp the lower portion of the steering shaft in a retaining ring on steering shaft from lower end.
vise with the socket facing upward. Seat retaining ring in steering shaft groove.
b. Apply front wheel bearing lube to the centering 23. Screw tolerance ring kit sections together leaving
spheres and the steering shaft sockets. Assem enough inner edge exposed for later adjustment as
ble the spheres, with the wave washer in between, shown in Figure 32.
and place the spheres in the upper shaft socket. 24. Install inner race, inner race seat, and bearing lock
c. Turn the spheres so the lower shaft may be in nut on end of steering shaft, using locknut wrench
stalled over the grooves. Tool J-22599 fig. 36.
25. Remove any remaining looseness from internal col
NOTE: The locating marking on the end of the umn stack-up by unscrewing inner tolerance kit ring
upper shaft should be on the same side as the section; then screw inner ring section back in 1/8 to
flat on the lower shaft. 1/4 turn fig. 33.
d. Install the upper shaft with spheres into the lower 26. Tighten bearing locknut installed in Step 24 above
shaft. until the torque required to rotate the steering’ shaft,
e. Insert the joint preload springthrough the spheres with the housing in the mid position, is 23 lb. in.
into the lower shaft. Using the upper shaft to 27. Touch the outer surface of the tolerance ring kit at
hold the spring in place, carefully feed the spring several locations with a hot soldering iron to melt
into the upper shaft joint with a narrow bladed the threads of the inner and outer sections together.
screw driver fig. 44. 28. Check to insure hazard warning switch is pushed in.
_ _____
__
StEERING 9-23
31. On automatic columns to be installed in a Camaro,

insert the bulb and cap into the turn signal switch
housing fig. 30. Slide pointer into position in bowl.
Install dial and dial retainer with mounting screws
removed during disassembly.
32. Install steering shaft flange on bottom of shaft and
secure with flange bolt.
33. Remove column from vise. Pull wires back against
column leaving a small amount of slack. Snap wir
ing protector into position. Be sure enough slack re
mains in wires to allow column head to tilt to full
up position.
34. if mesh cover was removed, wrap mesh cover around
mesh portion of jacket and secure with friction or
electricians tape.
35. Slide cancelling cam and cancelling cam spring on
upper end of shaft.
Fig. 45-Installing Turn Signal Switch Cover Using
Signal Switch Installer Tool J-21853 Disassembly-Standard Corvette Column Fig. 46
1. Place column on a suitable work bench.
Remove tilt release control lever and install turn 2. Remove upper bearing preload spring and cancelling
signal switch cover using turn signal cover installer cam from end of column.
Tool J-21853 fig. 45. Be sure key in the cover is 3. Remove turn signal lever retaining screw and re
aligned with keyway in bearing housing. move lever. Push hazard warning knob in; unscrew
29. Place turn signal control lever in position and se and remove knob.
cure with mounting screw. Screw tilt release con 4, Remove "C" retaining ring from upper steering
trol lever in. Screw hazard warning knob in. shaft using snap ring remove Tool J-22569 fig. 47.
30. On automatic columns, place transmission shift con Remove thrust washer and wave washer.
trol lever in position and insert lever retaining pin. 5. Remove three upper flange mounting bolts.
I
10 11 12 13 14 15 16 17 18
1/I /
:1’ 0 0
Fig. 46-Standard Corvette Column-Exploded View
1. Upper Flange 6. Signal Switch Screws 11. Upper Bearing Preload Spring 16. Spring
2. Retaining Screws 7. Turn Signal Switch 12. Cancelling Cam 17. Parking Seal
3. Most Jacket 8. Upper Bearing Housing 13. Retaining Ring 18. Spacer
4. Wiring Protector 9. Signal Switch Cover 14. Thrust Washer 19. Clamp Bolt and Nut
5. Bearing 10. Steering Wheel Nut 15. Wave Washer 20. Steering Shaft
STEERING 9-24
SIGNAL SWITCH
BEARING HOUSING
.COVER
UPPER FLANGE
Fig. 48-Assembling Upper End
8. Feed turn signal switch wires through upper as

Fig. 47-Removing "C" Ring Retainer Using Tool J-22569 sembly.
9. Secure upper flange to column with three mounting
6. Slide upper end assembly with covers off end of bolts.
column. 10. Slide wave washer, thrust washer, and "C" retaining
7. if necessary to service upper end components, re ring loosely into place at top of shaft.
move the turn signal switch mounting screws. Re 11, Complete installation of "C" retaining ring using
move the switch and upper bearing housing from snap ring installer Tool J-22659 as shown in Figure
cover. 47. Be sure retaining ring is completely seated into
8. Carefully slide steering shaft assembly out of lower steering shaft groove.
end of mast jacket. 12. Place turn signal switch lever in position and secure
9. If necessary, remove lower bearing assembly from with screw. Screw hazard warning knob into position.
lower end of mast jacket and discard bearing 13. Pull signal switch wires flat against column, install
assembly. wiring protector, and slide covers into position.
10. Remove flange bolt and flange from steering shaft. 14. if mesh cover was removed, wrap mesh cover around
11. Slide lower bearing spring, plunger, and sleeve mesh portion of mast jacket and secure with friction
assembly, and thrust washer off shaft. or electricians tape.
12. If necessary, remove two seals from lower end I.D. 15. Install spring and cancelling cam on end of shaft.
of jacket.
13. if necessary, unwrap mesh cover from jacket. Disassembly-Corvette Telescoping Column Fig. 49
1. Place column on a suitable work bench.
Assembly-Standard Corvette Column Fig. 46 2. Remove upper bearing preload spring and cancelling
1. Apply a thin coating of lithium soap grease to all cam from end of shaft.
friction surfaces. 3. Remove turn signal lever retaining screw and re
2. if seals were removed from lower end I.D. of jacket, move lever. Push hazard warning knob in; unscrew
cement two new seals into position. and remove knob.
3. if lower bearing assembly was removed, press new 4. Remove upper spiral retaining ring from upper
lower bearing into position at lower end of mast steering shaft using a screw driver fig. 50. Remove
jacket. thrust washer and wave washer.
4. Slide thrust washer, Wave Washer, packing seal, 5. Remove three screws from the lower bearing
spacer, clamp bolt and nut, plunger, and spring into retainer.
position from top of steering shaft. 6. Carefully slide steering shaft assembly out of lower
5. Install flange and flange bolt on lower end of steering end of mast jacket.
shaft. 7. Remove flange bolt and flange from lower end of
6. Carefully slide steering shaft into lower end of mast shaft.
jacket. 8. Scribe clamp so it may be reinstalled In same radial
7. Assemble upper bearing housing and turn signal and axial position. if necessary, unwrap mesh cover
switch into cover and secure entire assembly to mast from mast jacket.
jacket upper flange with three signal switch mounting 9. Remove clamp, bolt, nut, spacer, spring, washer,
screws as shown in Figure 48. packing washer and bearing. A notched groove is
STEERING 9-25
C!2
/
8 9 10
U
1819 i
12 13 14 15 16 17 ,0
JLó tf c/dc! J
26
2/ I
27 28
Fig. 49-Corvette Telescoping Column-Exploded View
1. Wiring Protector 8. Bumper 15. Spiral Retaining Ring 22. Retaining Rihg
2. Screws 9. Key 16. Thrust Washer 23. Spacer
3. Screws 10. Bumper 17. Wave Washer 24. Clamp, Bolt and Nut
4. Turn Signal Switch 11. Bumper Key Strap 18. Bearing 25. Lower Steering Shaft
5. Upper Bearing Housing 12. Steering Wheel Nut 19. Bearing Retainer 26. Upper Steering Shaft
6. Signal Switch Cover 13. Upper Bearing Preload Spring 20. Spring 27. Locking Rod
7. Mast Jacket 14. Cancelling Cam 21. Washer 28. Wedge
located on shaft for removal of bearing with a 15. If necessary, remove seals from I.D. of mast jacket.
screw driver. 16. If necessary, unwrap mesh cover from jacket.
10. Remove upper shaft section from lower section. If
Assembly-Corvette Telescoping Column Fig. 50
necessary, replace locking wedge and locking rod at
this time. 1. Apply a thin coating of lithium soap grease to all
11. Remove bumper key strap fig. 52. Remove keys friction surfaces.
and bumper assembly. 2. if seals were removed from I.D. of mast jacket,
12. Remove screws securing bottom of wiring protector cement new seals in positions where old seals were
to column. removed.
13. Slide inner jacket section, switch cover, switch, 3. Place locking wedge and locking rod into upper shaft
upper bearing housing and wiring protector off top and slide upper shaft into lower shaft.
end of jacket. 4. Install bearing, spring, spacer, clamp, bolt and nut.
14. if necessary, remove three turn signal switch mount Install clamp to original location and tighten nut to
ing screws and remove switch and upper bearing 30 ft. lbs.
housing. 5. Install spring clip, seal, washer, bearing, spring
STEERING 9-26
TWO WINDING SPIRAL
Fig. 50-Telescopic Column Shaft Upper Retaining Ring
clip, spring, coupling and retainer clip on bottom of

steering shaft.
6. Carefully slide steering shaft into lower end of mast
jacket.
7. Install bearing retainer over lower end of shaft and
lower end of jacket. Secure retainer with three
screws.
8. Install flange and flange bolt on lower end of steering
shaft.
9. Feed wires of turn signal switch through turn signal
switch cover and place switch and upper bearing
housing in cover. Secure switch to cover with three
mounting screws.
Fig. 52-Removing Bumper Key Strap
10. Place wiring protector inside.
11. Start escutcheon and wiring protector, with signal
switch wires, over end of outer jacket. 16. Slide wave washer, thrust washer, and upper retain
12. Slide inner jacket section into outer jacket section. ing ring into place at top of shaft. Seat retaining
13. Secure switch cover to flange of inner jacket section ring in steering shaft groove with a screw driver.
by tightening the signal switch mounting screws. 17. Place turn signal switch lever in position and secure
14. Secure the bottom of the wiring protector to the col with screw. Screw hazard warning knob into position.
umn with two screws.
15. Assemble keys and bumper and place the entire as 18. if mesh cover was removed, wrap mesh cover around
sembly in position in the jacket. Install bumper mesh section of jacket and secure with electricians
key strap. or friction tape.
19. Slide cancelling cam and upper bearing preload
spring over top end of shaft.
Installation
NOTE: Before placing column in position in
vehicle, refer to figures 17 through 20 and slide
dash panel seals, covers, plates, and clamps
loosely into position on column for later in
stallation.
1. Move front seat back as far as possible to provide
maximum clearance. Carefully work column into
position in vehicle and at steering gear. if column
is equipped with lower shift levers, mechanic at
engine can pilot levers through dash panel opening
as column is lowered into position.
NOTE: Install instrument panel column mount
ing bracket loosely as instructed in applicable
step below. Bracket is not to be tightened se
Fig. 51-Removing Lower Bearing Retaining Ring curely until after steering coupling is connected.
STEERING 9-27
Fig. 53-Instrument Panel Mounting Bracket-Chevrolet Fig. 55-Instrument Panel Mounting Bracket-Camaro and Chevy II
2. Chevrolet only fig. 53: Loosely install bracket using bracket to column
Lay retainers and wedge shims in position on in mounting bolts, bracket nuts, and bracket to instru
strument panel column mounting bracket and place ment panel washer and bolt as shown in Figure 54.
bracket in correct position on underside of instru 4. Camaro and Chevy II only fig. 55:
ment panel. Loosely install bracket using bracket Lay wedge shim in position on instrument panel
to column mounting screws and bracket nuts. column mounting bracket and place bracket in cor
3. Chevelle only fig. 54: rect position on underside of instrument panel.
Lay wedge shim in position on instrument panel Loosely install bracket using bracket to column
column mounting bracket and place bracket in cor mounting screws, nuts, and washer and bolt as shown
rect position on underside of instrument panel. in Figure 55.
5. Corvette only fig. 56:
Loosely secure column mounting bracket to sup
port plate and instrument panel with washers and
bolts.
6. Secure flanged end of column to steering coupling
with lock washers and nuts. On Corvette, slide steer
ing shaft flange into lower coupling half, and install
upper clamp bolt loosely; also secure support, seal
and clamp loosely at dash on engine side.
‘7. Tighten instrument panel mounting bracket bolts and
nuts. Refer to torque specifications at rear of
manual for correct torque values.
8. Chevrolet only fig. 15:
Place upper and lower mast jacket covers in po
sition and secure covers together and to instrument
panel using nuts and screws as shown in Figure 15.
9. Chevelle only fig. 15:
Place mast jacket trim cover in position over col
umn on underside of instrument panel and secure
with screws.
10. Corvette only fig. 14:
Slide upper and lower covers into position at
instrument panel and secure with screws. Place
upper end lower covers in position and secure with
screws.
11. On Chevrolet and Chevelle models with column
Fig. 54-Instrument Panel Mounting Bracket-Chevelle mounted automatic controls, secure transmission
STEERING 9-28
Alignment
A slow steering recovery on turns, a noise, an irreg
ular feel as the steering wheel is turned, or flexible
coupling distortion, are conditions which indicate the need
for the steering column to be readjusted and realigned.
It is also necessary to realign the column whenever the
assembly has been completely freed or removed from the
vehicle.
In service, the 1968 Chevrolet, Camaro, Chevelle,
Chevy II and Corvette should be realigned in accordance
with the following procedures.
RAG JOINT
FLANGE
The realignment procedures should be performed with
the vehicle on the ground. All four wheels of the vehicle
GEAR should be supporting vehicle weight.
Chevrolet Only Fig. 55
1. Remove steering column trim cover attached to the
lower side of dash.
2. Loosen, but g remove, nuts F and G - four
nuts total.
3. Remove steering column toe pan trim cover and
insulation material to expose the steering column
VIEW A toe pan attachment plate A and seal B.
4. Loosen, but g remove, screws K - five screws
total.
5. Remove screw J and pull toe pan attachment plate
A and seal B away from the toe pan.
Fig. 56-Instrument Panel Mounting Bracket and 6. Check steering column to ensure that the column is
Support Plate-Corvette loose and can be moved in all directions.
7. Align steering column with steering gear shaft,
shift indicator pointer into position with set screw
move column in or out setting flexible coupling
fig. 15.
clearance to dimension X. See Figure 16 and tighten
12. Chevrolet only fig. 17:
two nuts F to 20 ft. lbs. torque.
a. Secure seal and cover to dash panel with screws. 8. Insert two wedges C to the position required to fill
b. Place clamp assembly in position and install the gap - do not force wedges beyond this point.
clamp screw.
c. Install dash panel trim cover with mounting Holding wedges in position torque two 2 nuts G
to 20 ft. lbs.
screws.
13. Chevelle only fig. 18: 9. Push steering column toe pan attachment plate A to
the toe pan and position the lip of the plate against
a. Secure seal and inner and outer covers to dash
panel with screws. the column.
10. Holding the plate A in position against the dash and
b. Secure inner and outer covers together with
column, tighten the two screws K*, position the
screws.
clamp H as shown, tighten screw J to 90 in. lbs.
c. Install trim cover to dash panel with two re
tainers. torque.
11. Loosen two screws K* and shake column in area
14. Camaro and Chevy II only fig. 19:
a. Secure seal, upper cover, and lower cover to immediately above cover, so as to make certain the
dash panel with screws. column position is not affected by the column to
b. Secure upper and lower cover together with dash cover attachment. Tighten five screws K to
35 in. lbs. torque, install insulation material and
screws.
toe pan trim cover.
c. Fold rubber boot over securely against dash panel 12. Install steering column trim cover attached to lower
to conceal covers.
15. Corvette only fig. 20: side of dash.
a. Secure seal and support assembly to dash panel Chevelle Only Fig. 56
on engine compartment side. 1. Loosen, but remove two nuts F and one bolt
b. Tighten clamp, washer, and clamp bolt on engine H.
compartment side. 2. Remove steering column toe pan trim and insulation
16. Connect transmission linkage to lower shift tube material around the column to expose the steering
levers in engine compartment, if column is so column toe pan attachment plates A and B and seal
equipped. Adjust levers as outlined in Section 7. D.
17. Install steering wheel as outlined in this section. 3. Loosen, but remove toe pan attachment plate
18. Connect directional signal, horn, back-up lamp, and screws - three screws Q* and two screws J.
neutral start switch at wiring harness plugs. Ad 4. Loosen two screws C so that cover assembly is
just back-up lamp, neutral start switch as outlined snug on the column, but still will move with respect
in Section 12. to the column.
19. Adjust steering gear and align and center steering 5. Check the steering column to ensure that the column
wheel as outlined in this section. is loose and can be moved in all directions.
STEERING 9-29
6. Align steering column with steering gear shaft. modate height differential of instrument panel to
Setting flexible coupling clearance - See Figure 16. bracket B. With column position now defined,
7. Push steering toe pan attachment plate A and B to tighten screw assemblies H to 20 ft. lbs. torque.
the toe pan. Seal D must be in position in View Then tighten nuts F to 20 ft. lbs. torque.
"B". Holding the lip on plate A and B against 6. Maintaining a rag joint spacing of 1/4" to 3/8", see
the column, start outer cover screw Q. Install Figure 16, torque upper flange pinch bolt to 30 ft.
screw L and tighten to 35 in. lbs. torque. Tighten lbs. torque.
screw Q to 35 in. lbs. torque and install and 7. Secure steering column lower plate to front of dash
tighten screw R to 35 in. lbs. torque. by installing screws K and tightening to 150 in. lbs.
8. Tighten two clamp screws C to 35 in. lb. torque. torque.
9. Install two outer screws G and tighten to 35 in. lb. 8. Install upper and lower extension covers.
10. Tighten two nuts F to 20 ft. lbs. torque. 9. Install upper and lower outer covers.
11. Insert wedge G to the position required to fill the
gap. Do not force wedge beyond this point. Holding
wedge in position, install forward mast jacket bracket STEERING LINKAGE Fig. 57
bolt H and tighten to 20 ft. lbs. torque.
12. Pot joint operating angle must not exceed 5°. Tie Rods
13. Rag joint must not be distorted due to pot joint
bottoming in either direction. There are two tie rod assemblies used on all models.
Each assembly is of three piece construction, consisting
Camaro and Chevy II Only Fig. 57 of a sleeve and two tie rod ends. The ends are threaded
1. Remove steering column trim cover attached to the into the sleeve and locked with clamps. Right and left
lower side of the column under the dash. hand threads are provided to facilitate toe-in adjustment
2. Loosen, but do remove two nuts H and nut K. and steering gear centering.
3. Remove steering column toe pan trim and insulation The tie rod ends are self-adjusting for wear and re
material around the column to expose the steering quire no attention in service other than periodic lubrica
column toe pan attachment plates A and B and tion and occasional inspection to see that ball studs are
seal D. tight. Replacement of tie rod ends should be made when
4. Loosen, but g remove, three screws J. excessive up and down motion is evident or if any lost
5. Loosen two screws C and pull toe pan attachment motion or end play at ball end of stud exists.
plate A away from the toe pan.
6. Check steering column to ensure column is loose and
can be moved in all directions. Removal
7. Align steering column with steering gear shaft, move 1. Remove cotter pins from ball studs and remove
column in or out, setting flexible coupling clearance castellated nuts.
to dimension X. See Figure 16. Tighten two nuts 2. To remove outer ball stud, tap on steering arm at
H to 20 ft. lbs. torque. tie rod end with a hammer while using a heavy
8. Insert wedge E to the position required to fill the hammer or similar tool as a backing Fig. 58. If
gap - do not force the wedge beyond this point. necessary pull downward on tie rod to remove from
Holding the wedge in this position, tighten one nut steering arm.
K to 20 ft. lbs. torque. 3. Remove inner ball stud from relay rod using same
9. Push steering column toe pan attachment plates procedure as described in Step 2.
A and B to the toe pan. Seal D must be in position 4. To remove tie rod ends from tie rods loosen clamp
shown in View "B". Move the lip on plate A and bolts and unscrew end assemblies.
plate B against the column and tighten two screws
J*. Tighten two screws C to 35 in. lbs. torque. Installation
10. Loosen the two screws J* and shake the column in 1. If the tie rod ends were removed, lubricate the tie
the area immediately above the cover so as to make rod threads with EP Chassis lube and install ends on
certain the column position is not affected by the tie rod making sure both ends are threaded an equal
column-to-dash cover attachment. Tighten three distance from the tie rod.
screws .J* to 35 in. lbs. torque and reinstall steer 2. Make sure that threads on ball stud and in ball stud
ing column toe pan trim and insulation material nuts are perfectly clean and smooth. Install neoprene
around the column. seals on ball studs.
11. Reinstall steering column trim cover to lower side
NOTE: If threads are not clean and smooth,
of column under the dash. ball studs may turn in tie rod ends when at
Corvette Only Fig. 58 tempting to tighten nut.
1. Remove upper and lower outer covers. 3. Install ball studs in steering arms and relay rod.
2. Remove upper and lower extension covers. 4. Install ball stud nut, and install cotter pins. Lubri
3. Loosen but remove attachment screws F, cate tie rod ends.
H and J. 5. Adjust toe-in as described in Section 3.
4. Loosen four nuts F, three screws H, two screws
K and rag joint flange bolt J. NOTE: Before locking clamp bolts on the rods,
5. Maintaining a gap of .30 ± .05 between mast jacket make sure that the tie rod ends are in alignment
and inside semi-circular surface of instrument panel, with their ball studs each ball joint is in the
hold steering column lower plate tight against front center of its travel. If the tie rod is not in
of dash and pull support D rearward to accom alignment with the studs, binding will result.
STEERING 9-30
CORVEITE CAMARO AND CHEVY II
Fig. 57-Steering Linkage
Relay Rod-All Models Except Corvette Relay Rod-Corvette

Removal Removal
1. lemove inner ends of tie rods from relay rod as 1. Remove steering damper from relay rod as outlined
described under Tie Rod - Removal. under Steering Damper-Removal. Remove anchor
2. Remove cotter pin and nut from relay rod ball stud bracket from relay rod by disconnecting two mount
attachment at pitman arm. ing bolts.
3. Detach relay rod from pitman arm. Shift steering 2. Remove inner ends of tie rods from relay rod as
linkage as required to free pitman arm from relay described under Tie Rod-Removal.
rod. 3. Remove cotter pin from end of relay rod at pitman
4. Remove cotter pin and nut from idler arm and re arm ball stud attachment, and remove stud nut.
move relay rod from idler arm. 4. Tap ball stud out of pitman arm and lower relay rod.
5. Remove cotter key and nut from idler arm and re
Installation move relay rod from idler arm. Remove washer and
1. Install relay rod to idler arm, making certain idler seal from idler arm.
stud seal is in place, then install and tighten nut.
Advance nut just enough to align castellation with Installation
cotter pin hole and install pin. 1. Place relay rod on idler arm stud, making certain
2. Raise end of rod and install on pitman arm. Secure idler stud seal and washer are in place, then install
with nut and cotter pin. and tighten nut. Advance nut just enough to align
3. Install tie rod ends to relay rod as previously castellation with cotter pin hole and install pin.
described under Tie Rods. Lubricate tie rod ends. 2. Install new seal and clamp over ball at end of pitman
4. Adjust toe-in see Section 3 and align steering wheel arm.
as described previously in this section under Steer 3. Install inner spring seat and spring to relay rod.
ing Wheel Alignment and High Point Centering. 4. Raise end of rod and install on pitman arm.
STEERING 9-31
5. Refer to torque specifications at rear of manual for

correct torque values.
Pitman Arm
Removal
1. Remove cotter pin from pitman arm ball stud and
remove nut.
2. Remove relay rod from pitman arm by tapping on
side of rod or arm in which the stud mounts with a
hammer while using a heavy hammer or similar tool
as a backing. Pull down on relay rod to remove
from stud.
3. Remove pitman arm nut from sector shaft and mark
relation of arm position to shaft.
4. Remove pitman arm with Tool J-6632 as shown in
Figure 3.
Installation
1. Install pitman arm on sector shaft, lining up the
marks made upon removal.
2. Install sector shaft nut.
3. Position relay rod on to pitman arm. Install nut.
Continue to tighten arm enough to align castellation
with hole in stud and install cotter pin.
Fig. 58-Freeing Bell Stud
Steering Arm
5. Install spring seat, spring, and end plug.
6. Tighten end plug until springs are compressed and If, through collision or other damage, it becomes nec
plug bottoms, then back off 3/4 turn plug amount essary to remove and replace either steering arm, pro
necessary to insert cotter pin. Insert cotter pin to ceed as follows:
lock adjustment.
7. Install tie rod ends to relay rod as previously de Removal
scribed under Tie Rods. 1. Remove tie rod from steering arm as outlined in this.
8. Lubricate tie rod ends and pitman arm to relay rod section.
ball joint. 2. Remove front wheel, hub and brake drum as a unit
9. Install steering damper bracket and tighten bolts. by removing hub cap and dust cap, cotter pin from
Install damper as outlined under Steering Damper- spindle nut and the spindle nut. Pull assembly to
Installation. ward outside of vehicle. If removal is difficult, it
10. Adjust toe-in and align steering wheel as described may be necessary to back off brake adjustment to
previously in this section. increase brake shoe-to-drum clearance; see Hy
draulic Brake Adjustment, Section 5. On models
with disc brakes, remove caliper and disc.
Idler Arm 3. With wheel and drum assembly or caliper and disc
removed, steering arm retaining bolt heads are ac
Chevrolet, Chevelle, Camaro, Chevy II and Corvette cessible and removal of steering arm from vehicle
Fig. 57 may be accomplished by removing retaining nuts.
Removal
1. Remove idler arm to frame nut, washer, and bolt. Installation
No washer is used on Corvette. 1. Place steering arm in position on vehicle and install
2. Remove cotter pin and nut from idler arm to relay retaining bolts.
rod ball stud. 2. Install nuts. Use only the special locknut listed for
3. Remove relay rod from idler arm by tapping relay this use in the Chevrolet Parts Catalog.
rod with a hammer using a heavy hammer as a 3. Pack wheel bearings using a high quality wheel
backing. bearing lubricant. Install bearings and wheel-hub-
4. Remove idler arm. brake drum assembly removed previously. On disc
brake models, install disc and caliper.
Installation 4. Install keyed washer and spindle nut. Proceed as out
1. On Chevrolet, place seal in position on idler arm lined under "Front Wheel Bearing Adjustment" in
stud; position stud up through frame, and secure with Section 3.
lock washer and nut. 5. Install tie rod ball stud in steering arm. Be sure that
2. On Chevelle, Camaro, Chevy H and Corvette, position the dust cover is in place on ball stud.
idler arm on frame and install mounting bolts, 6. Install castellated nut on ball stud, tighten securely
washers and nuts. No washer is used on Corvette. and install cotter pin.
3. Install relay rod to idler arm, making certain seal 7. Following directions given in Section 3 to check cor
is on stud. Install and tighten nut. nering wheel relationship and toe-in; correct as
4. Install cotter pin. required.
STEERING 9-32
Steering Damper-Corvette damaged or excessively worn.

Removal Installation
1. Remove bolt from damper pivot bracket at relay rod. 1. Place piston rod end into frame bracket and install
2. Remove nut from damper pivot at frame bracket and retainers, bushings, and nut.
withdraw damper assembly. 2. Insert cylinder end pivot into relay rod bracket and
3. Damper is serviced as a unit. Replace damper if install through bolt.
POWER STEERING
INDEX
Page Page
General Description 9-32 Component Replacement and Repairs 9-34

Maintenance and Adjustments 9-32 Power Steering Pump. 9-34
Bleeding Hydraulic System 9-32 Power Steering Gear 9-35
Fluid Level 9-33 Control Valve and Adapter Assembly 9-35
Adjustments 9-33 Valve Balancing 9-35
Power Steering Gear 9-33 Power Cylinder 9-36
Pump Belt Tension 9-33 Power Steering Hoses 9-37
Hydraulic System Checks 9-33 Special Tools 9-39
GENERAL DESCRIPTION
Two types of power steering are used for 1968. One is pressure and return hoses.
the conventional linkage type for Corvette and the other is The steering gear for 1968 is basically the same as
the integral gear type for Chevrolet, Chevelle, Camaro, 1967 except the Camaro and Chevy II have a snap ring
and Chevy II. For both types the hydraulic pressure is or rings located at the upper end of the housing which
provided by an engine-driven vane-type pump. serves as a stop for the rack piston assembly. This
On the Corvette linkage type power steering, hydraulic prevents additional pressure from being applied to the
pressure is delivered through a hose from the pump to a linkage after the wheel stops have been reached.
valve which senses the requirement for power assistance
and supplies the power cylinder accordingly. The steer The steering gear is a recirculating ball system in
ing gear used with this power steering is the same basic which steel balls act as a rolling thread between the
unit used on manually steered vehicles; it is serviced as steering worm and rack-piston nut. The rack-piston nut
outlined in the manual steering part of this section except is all one piece and is geared to the sector of the piston
for adjustment, which is covered in the following pages. shaft. The valve is contained in the gear housing elimi
The steering linkage also is serviced the same as nating the need of bolts or seals to attach a separate
manual counterparts. valve housing.
The Chevrolet, Chevelle, Camaro, and Chevy II integral The valve is an open-center, rotary-type three way
gear type power steering has the hydraulic pressure valve. The spool is held in neutral position by means of a
delivered from the pump through two hoses to the steer torsion bar. The spool is attached by means of the stub
ing gear. In the power steering gear the steering shaft, shaft to one end of the torsion bar and to the valve body
hydraulic valve, worm, and rack-piston nut are all in on the other end. Twisting of the torsion bar allows the
line making a compact and space saving assembly. All spool to move in relation to the valve body thereby oper
oil passages are internal within the gear except the ating the valve.

BLEEDING HYDRAULIC SYSTEM 6. Increase engine speed to approximately 1500 rpm.
7. Turn the wheels off ground right and left, lightly
1. Fill oil reservoir to proper level and let oil remain contacting the wheel stops.
undisturbed for at least two minutes. 8. Add oil if necessary.
2. Start engine and run only for about two seconds. 9. Lower the car and turn wheels right and left on the
3. Add oil if necessary. ground.
4. Repeat above procedure until oil level remains con 10. Check oil level and refill as required.
stant after running engine. 11. If oil is extremely foamy, allow vehicle to stand a
5. Raise front end of vehicle so that wheels are off the few minutes with engine off and repeat above pro
ground. cedure.
STEERING 9-33
a. Check belt tightness and check for a bent or loose

pulley. Pulley should not wobble with engine
running.
b. Check to make sure hoses are not touching any
other parts of the car, particularly sheet metal
and exhaust manifold.
c. Check oil level, filling to proper level if neces
sary, f9llowing operations 1 through 10. This
step and Step "D" are extremely important as
low oil level and/or air in the oil are the most
frequent causes of objectionable pump noise.
d. Check the presence of air in the oil. If air is
present, attempt to bleed system as described in
operations 1 through 10. If it becomes obvious
that the pump will not bleed after a few trials,
proceed as outlined under Hydraulic System
Checks.
FLUID LEVEL
1. Check oil level in the reservoir by checking the dip
stick when oil is at oper’ating temperature. On
Chevelle models equipped with remote reservoir,
the reservoir should be maintained approximately
3/4 full when oil is at operating temperature.
2. Fill, if necessary, to proper level with GM Power
Steering Fluid or, if this is not available, automatic Fig. 59-Over Center Adjustment
transmission fluid "Type A" bearing the mark
"AQ-ATF" followed by a number and the suffix Corvette
letter "A". The steering gear used with power steering is adjusted
in the same manner as the manual steering gear.
ADJUSTMENTS
Power Steering Gear Pump Belt Tension

Chevrolet, Chevelle, Camaro, and Chevy II 1. Loosen nut on pivot bolt and pump brace adjusting
The over-center adjustment fig. is the only power nut.
steering gear adjustment which can be made on the car.
However, in order to make this adjustment, it is also CAUTION: Do not move pump by prying against
necessary to check the combined ball and thrust bearing reservoir or by pulling on filler neck.
p reload. 2. Move pump, with belt in place until belt is tensioned
If the vehicle is equipped with a tilt column it will be to specifications as indicated by Tool 3-7316 Fig.
necesary to disconnect the steering coupling to obtain a
torque reading of the column. This torque should then be 3. Tighten pump brace adjusting nut. Then tighten pivot
subtracted from any reading taken on the gear. bolt nut.
1. Disconnect the pitman arm from the relay rod.
2. Loosen the pitman shaft adjusting screw locknut and
thread the adjusting screw out to the limit of its HYDRAULIC SYSTEM CHECKS
travel through the side cover.
3. Disconnect steering column harness at chassis wir The following procedure outlines methods to identify
ing connector plug. and isolate power steering hydraulic circuit difficulties.
This test is divided into two parts. Test number one
4. Remove horn button.
provides means of determining whether power steering
5. Turn the steering wheel through its full travel, then
locate the wheel at its center of travel. system hydraulic parts are actually faulty. If test number
6. Check the combined ball and thrust bearing preload one results in readings indicating faulty hydraulic opera
with an inch-pound torque wrench on the steering tion, test number two will identify the faulty part. Before
shaft nut by rotating through the center of travel performing hydraulic circuit test, carefully check belt
approximately 1/4 turn in each direction. Note the tension and condition of driving pulley. Strand tension
highest reading. of belt should be 125 lbs. on new belts and 75 lbs. on old
belts, as indicated by Tool 3-73 16 Fig.
7. Tighten the pitman shaft adjusting screw and check .
torque at steering shaft nut until over center preload

and total steering gear preload falls within speci
Test Number One-Oil Circuit Open
fications. Refer to torque specifications at rear of
manual for correct torque values. Engine must be at normal operating temperature. In
8. Install horn button. Connect steering column harness flate front tires to correct pressure. All tests are made
at wiring connector plug. with engine idling, so adjust engine idle speed to correct
STEERING 9-34
Fig. 61-Power Steering Diagnosis

Fig. 60-Checking Belt Tension with Tool J-7316
specifications listed in Section 6 and proceed as follows: sure is below specifications see specifications at
a. With engine not running, disconnect flexible pres end of manual, a faulty hydraulic circuit is indi
sure line from pump and install Tool J-5176 as cated. To determine which part is faulty, pro
shown in Figure . Gauge must be between shut ceed with test number two.
off valve and pump. Open shut-off valve.
b. Remove filler cap from pump reservoir and check
fluid level. Fill pump reservoir to full mark on Test Number Two-Oil Circuit Closed
dip stick. Start engine and, holding steering
a. Slowly turn shut-off valve on 3-5176 to closed
wheel against stop, check connections at Tool
position and read pressure indicated on gauge.
J-5176 for leakage. Bleed system as outlined
Quickly reopen valve to avoid pump damage. If
under Maintenance and Adjustments. Insert ther
indicated pressure is less than specification,
mometer Tool J-5421 in reservoir filler open
pump output is below requirement and pump may
ing. Move steering wheel from stop to stop
be considered faulty. If pressure indicated is
several times until thermometer indicates that
within specifications, it may be safely assumed
hydraulic fluid in reservoir has reached tempera
that the external hoses, connections, valve and
ture of 150° to 170°F.
adapter or steering gear is at fault.
CAUTION: To prevent scrubbing flat spots on
NOTE: If pump proves faulty in test number
tires, do not turn steering wheel more than five
two, test should be repeated after pump is re
times without rolling car to change tire-to-floor
paired and installed in vehicle. This will pro
contact area.
vide a means of checking the repairs made to the
c. Hold steering wheel against a stop momentarily pump and the condition of the steering gear or
and read pressure gauge. If the maximum pres valve and adapter which may also be faulty.
COMPONENENT REPLACEMENT AND REPAIRS

Power Steering Pump
reservoir to pump hose before removing the
Removal Fig. 62 pump. Hold a 1 qt. container under the reservoir
1. Disconnect hoses at pump. When hoses are discon when the hose is removed to catch the fluid.
nected, secure ends in raised position to prevent
2. Install two caps at pump fittings to prevent drainage
drainage of oil. Cap or tape the ends of the hoses to
prevent entrance of dirt. of oil from pump.
3. Remove pump belt.
NOTE: Chevelle with 396 engine uses a remote 4. On Corvette with 427 engine, loosen alternator ad
reservoir. It is necessary to disconnect the justment and remove pump to alternator belt.
STEERING 9-35
5. Remove pump from attaching parts and remove pump

from vehicle.
NOTE: On Chevrolet and Chevy Ilequippedwith
307 and 327 engine it may be necessary to re
move pump brace.
6. Remove drive pulley attaching nut.
7. Remove pulley from shaft with Tool J-21239 for
stamped pulleys or Tool J-8433-1 with J-8433-2
adapter for cast iron pulleys. Do not hammer
pulley off shaft as this will damage the pump.
Installation
1. Install pump pulley.
CAUTION: Do not hammer on pump shaft. Use
pulley nut to pull pulley on to shaft.
2. Position pump assembly on vehicle Fig. 62 and in
stall attaching parts loosely.
3. Connect and tighten hose fittings.
4. Fill reservoir. Bleed pump by turning pulley back
ward counterclockwise as viewed from front until
air bubbles cease to appear.
5. Install pump belt over pulley.
6. Tension belt as outlined under "Pump Belt Tension
Adjustment" in this section.
7. Bleed as outlined under "Maintenance and Adjust Fig. 62-Power Steering Pump Mounting
ments."
2. Remove the relay rod to control valve clamp bolt.
3. Disconnect the two pump to control valve hose con
Power Steering GearFig. 63 nections and allow fluid to drain into a container,
Chevrolet, Chevelle, Camaro, and Chevy II then disconnect the two remaining valve to power
Replacement procedures for the power steering gear cylinder hoses.
are the same as for the manual type steering gear. Refer 4. Remove the retaining nut from the ball stud to pitman
to steering gear procedures near the beginning of this arm connection and disconnect the control valve
section under "Component Replacement and Repairs". from the pitman arm.
In addition, disconnect pressure and return hoses from 5. Turn the pitman arm to the right clear of the control
the steering gear housing. Cap both hoses and steering valve and unscrew the control valve from the relay
gear outlets to prevent foreign material from entering rod.
the system. After service is performed and steering 6. Remove the control valve from the vehicle.
gear is installed, connect the pressure and return hoses Installation
to the steering gear housing. Bleed system as outlined 1. Install the control valve on the vehicle by reversing
under Maintenance and Adjustment in this section. Refer the removal procedure.
to torque specifications at rear of manual for correct 2. Reconnect the hydraulic lines, fill the system with
torque values. fluid and bleed out air using the procedure outlined
under "Maintenance and Adjustments." Grease ball
joint.
Control Valve and Adapter Assembly
Corvette Valve Balancing
The control valve must be adjusted, after being dis
Ball Stud Seal Replacement Fig. 64
assembled, as outlined in the following procedure. The
A ball stud seal is used on the power steering control
valve. To replace the seal: same procedure may be followed to correct a complaint
1. Remove the pitman arm as outlined under "Steering of harder steering effort required in one direction than
the other. See Figure 66.
Linkage" in this section.
2. Remove clamp by removing nut, bolt and spacer or, 1. Install valve in vehicle. Connect all hoses and fill
the pump reservoir with oil. Do not connect the
if crimped type clamp is used, straighten clamp end
piston rod to the frame bracket. If the vehicle is
and pull clamp and seal off end of stud.
already in operation, it will be necessary to de
3. Install new seal and clamp over stud so lips on seal
mate with clamp. A nut and bolt attachment type tach the piston rod from the frame bracket.
clamp replaces the crimped type for service. 2. With the car on a hoist, start the engine. One of
4. Center the ball stud, seal and clamp at opening in the following two conditions will exist:
adapter housing, then install spacer, bolt and nut. a. If the piston rod remains retracted, turn the
adjusting nut clockwise until the rod begins to
Removal move out.
1. Raise the front of the vehicle off the floor and place Then turn the nut counter- clockwise until the
it on stands. rod just begins to move in. Now turn the nut
STEERING 9-36
Fig. 63-Power Steering Gear-Chevrolet Shown
clockwise to exactly one-half the rotation needed Power Cylinder Fig. 65

to change the direction of the piston rod move
ment. Corvette
If the rod extends upon starting the pump, move Removal
the nut counter- clockwise until the rod begins to 1. Disconnect the two hydraulic lines connected to the
power cylinder and drain fluid into a container. Do
retract, then clockwise until the rod begins to
not reuse.
move out again. Now position the rod to exactly
2. Remove cotter pin, nut, retainer and grommet from
one-half the rotation needed to change the direc
tion of the piston rod movement. power cylinder rod attached to the frame bracket.
3. Also remove grommet and retainer from bracket if
CAUTION: Do not turn the nut back and forth replacement parts are required.
more than is absolutely necessary to balance the 4. Remove cotter pin, nut and ball stud at relay rod.
valve, as this is a special friction nut. 5. Remove the power cylinder from the vehicle.
3. With the valve balanced, it should be possible to
move the rod in and out manually. Inspection
4. Turn off the engine and connect the cylinder rod 1. Inspect the seals for leaks; if leaks are present,
to the frame bracket. replace the seals using the procedure outlined under
5. Restart the engine. If the front wheels still on the "Disassembly."
hoist do not turn in either direction from center 2. Examine the brass fitted hose connection seats for
the valve has been properly balanced. Correct the cracks or damage and replace if necessary.
valve adjustment if necessary. 3. For service other than ball seat or seal replacement
6. When the valve is properly adjusted, grease end of and ball stud removal, replace the power cylinder.
valve and install the dust cap. 4. Check the frame bracket parts for wear.
STEERING 9-37
4. Remove the snap ring retaining the end plug with the
lube fitting.
5. Push on the end of the ball stud and remove the end
plug, spring, spring seat and ball stud.
6. Remove the "0" ring seal from the top lip of the
power cylinder ball stud opening.
7. If the ball seat is to be replaced, it must be pressed
out using Tool 3- 8937.
Assembly
1. Reassemble the piston rod seal components by re
versing the disassembly procedure. Apply a thin
coat of Lubriplate or equivalent on the inner sur
faces of the seal and scraper before assembly.
2. Reverse the disassembly procedure when reassem
bling the ball stud.
3. In each case be sure that the snap ring is securely
seated in the ring groove.
Installation
Fig. 64-Control Valve Ball Stud Seal Replacement Service Type
1. Install the power cylinder on the vehicle by reversing
the removal procedure.
Disassembly 2. Reconnect the two hydraulic lines, fill the system
1. To remove the piston rod seal remove the snap ring; with fluid and bleed out air using the procedure out
then pull out on the rod, being careful not to spray lined under "Maintenance and Adjustments." Grease
oil. ball joint.
2. Remove the piston rod scraper and scraper element,
back up washer and piston rod seal from the rod. Power Steering Hoses
3. At the ball stud end of the cylinder, remove the ball When servicing the power steering hoses be sure to
stud seal. align the hoses in their correct position as shown in
Fig. 65-Power Cylinder- Exploded View
Snap Ring 6. Ball Stud 11. Backup Washer

2. End Plug and Lube Fitting 7. BaIl Seat 12. Scraper Element
3. ‘0" Ring 8. Ball Stud Seal 13. Piston Rod Scraper
4. Spring 9. Piston Body 14. Snap Ring
5. Spring Seat 10. Piston Rod Seal 15. Piston Rod
STEERING 9-38
Figure 67. On Chevelle models with 396 engine, install

the upper hose so that there is at least .6 inch clearance
between the hose and the Delcotron or the inner fender
skirt.
It is important that the power steering hoses be in
stalled correctly. Hoses installed out of position may be
subjected to chafing or other abuses during sharp turns.
Always make hose installations on Corvette with front
wheels in straight ahead position. Do not twist hoses
unnecessarily during installation.
CAUTION: Do not start engine with any power
steering hose disconnected.
Fig. 66-Balancing Valve
Fig. 67-Power Steering Hose Installation
STEERING 9.39
SPECIAL TOOLS
I A3
p
9
7
I
*
13
9
J2
a 16
17
4
14
IL
1
I 20
21 22 23
1. J-22572 Steering Column Bearing 10. J-22549

Shift Tube Installer 16. J-21853 Actuator Cover Installer
Installer 11. J-22551
Shift Tube Remover 17. J-22568 Spanner Wrench
2. J-8937 Power Piston Ball Seat 12. J-5421Thermometer 18. J-22670 Pump Main Shaft Seal
Installer 13. J-22635
Locking Shoe Guide Pin Installer
3. J-6632 Pitman Arm Puller and Release Lever Pin 19. J-22686 End Play Gauge
4. J22727 Electric Terminal Remover Remover and Installer 20. J-8433 Pump Pulley Remover
5. J-2927 Steering Wheel Puller 14. J-7754 Inch Pound Torque 21. J-21239 Pump Pulley Remover
6. J-22708 Turn Signal Housing Remover Installer 22. J-22573 Column Support Fixture
7. J-6219 Pitman Shaft Oil Seal Installer 15. J-22569 Snap Ring Remover and 23. J-7316 Belt Tension Gauge
8. J-22599 Lock Nut Wrench Installer 24. J-5176 Pressure Gauge
9. J-21854 Pivot Pin Remover
SECTION 10
WHEELS AND TIRES
INDEX
Page Page
General Description 10-1 Valve Assembly 10-5

Maintenance and Adjustments 10-1 Balancing Wheels 10-5
Tires 10-1 Static Balancing w/Tire 10-5
Pressures 10-1 Dynamic Balancing w/Tire 10-6
Inspection 10-1 Run Out w/o Tire 10-6
Wear 10-1 Tire Wear Indicators 10-6
Rotation 10-4 Cleaning
Noise 10-4 Service Operations 10-6
Cleaning 10-4 Tires 10-6
Change w/Wheels 10-4 Removal 10-6
Repair 10-4 Installation 10-7
Wheels 10-5 Rim 10-7
GENERAL DESCRIPTION
WHEELS ommended in the tire inflation pressure table they have
Chevrolet, Chevelle, Camaro, Chevy II, and Corvette the load carrying capacity to operate satisfactorily at all
are base equipped with welded steel wheels. Five studs loads up to and including the specified full rated load at
with nuts fasten each wheel to the front hub or rear axle all normal highway speeds.
flange. Disc brake equipped vehicles except Chevrolet In addition, for those owners who may prefer the ut
and Corvette require special 14 inch diameter wheels most in comfort, optional tire inflation pressures may be
with a revised design for clearance. Chevrolet disc brake used with reduced loads specified in the Recommended
equipped vehicles have 15 in. diameter wheels as do all Tire Inflation Pressure T a b 1 e See specifications,
Corvettes. Section 10.
Chevrolet station wagons, Chevelle Super Sport 396
Optional 8-Ply Rating Tires
and Camaro Super Sport 350 are base equipped with 6 in.
Optional tires if listed in the tables in Specifications,
width wheels. All other vehicles have 5 in. width wheels,
Section 10 are not necessary on passenger cars for
except Corvette models, which have 7 in. width wheels.
normal requirements. However, an extra margin of tire
Do not install 6 inch width wheels or snow chains on
service is available when these options are used at loads
Chevrolets equipped with rear fender skirts. Also, do not
up to and including full rated load.
use tire chains on the rear wheels on Corvette or Camaro On some models example-- Station Wagon, space limi
"SS" models. Clearance between tire and wheelhouse is tations do not permit the use of a larger size tire; hence,
insufficient to permit operation with chains installed.
the 8-ply rating tire is an available option. In either
case, these tires are applicable to trailer towing or when
an extra margin of tire service is desired. Use of a
TIRES larger tire or an 8-ply rating tire should not be con
The factory installed tires on Chevrolet passenger cars strued as permitting an increase in the full rated vehi
are selected to provide the best all around tire perfor cle load over that specified in the tire inflation pressure
mance for all normal operation. When inflated as rec table.

TIRES should be checked for sharp objects or stones in the
tread. If tire is punctured, it should be repaired using
Inflation Pressures one of several repair kits available through tire manu
To ensure the proper tire inflation pressure for the facturers’ outlets.
owners particular requirements follow the recommenda
tions in the Vehicle Capacity Rating and Recommended Wear
Tire Inflation Pressures Table see Specifications. Keep Misalignment
tires properly inflated, and check inflation pressures This is wear due to excessive toe-in or toe-out. In
periodically. This will ensure the best tire life and riding either case, tires will revolve with a side motion and
comfort, over the full range of driving conditions. scrape the tread rubber off. If misalignment is severe,
the rubber will be scraped off of both tires or all four
Inspection tires if front toe is not correct; if slight, only one will
Every few thousand miles and at each lubrication, tires be affected.
WHEELS AND TIRES 10-2
excessive use of brakes. The best remedy, in addition

to cautioning the owner of his driving habits is to inter
change tires regularly.
Fig. i-Toe In or Toe OUt Misalignment Wear
The scraping action against the face of the tire causes

a small feather edge of rubber to appear on one side of
the tread and this feather edge is certain indication of
misalignment fig. 1. The remedy is readjusting toe-in
within specifications, or rechecking the entire front end
alignment if necessary.
Heel and Toe
This is a saw-toothed effect where one end of each
tread block is worn more than the other.
The end that wears is the one that first grips the road
when the brakes are applied.
Heel and toe wear is less noticeable on rear tires than
on front tires, because the propelling action of the rear
wheels creates a force which tends to wear the opposite
end of the tread blocks. The two forces, propelling and
braking, make for more even wear of the rear tires,
whereas only the braking forces act on the front wheels,
and the saw-tooth effect is more noticeable.
A certain amount of heel and toe wear is normal.
Excessive wear is usually due to high speed driving and Fig. 2-Over and Under Inflation Wear
Side Cornering
This may be caused by incorrect wheel camber, under- Since the introduction of independent spring front and
inflation, high cambered roads or taking corners at too rear wheels, improvements in spring suspension have
high a rate of speed. enabled drivers to negotiate curves at higher rates of
The first two causes are the most common. Camber speed with the same feeling of security that they had
wear can be readily identified because it occurs only on with the older cars at lower speeds. Consequently,
one side of the, treads, whereas underinflation causes curves are being taken at higher speeds with the result
wear on both sicjes fig. 2. that a type of tire wear called "Cornering Wear" fig.
There is, of course, no correction for high cambered 4, frequently appears.
roads. Cornering wear is discussed further on. When a car makes an extremely fast turn, the weight
is shifted from a normal loading on all four wheels to an
Center abnormal load on the tires on the outside of the curve
This is caused primarily by overinflation of the tire and a very light load on the inside tires due to centrifugal
fig. 2. Invisible fabric damage can also be caused by force. This unequal loading may have two unfavorable
overinflation. results.
Uneven First, the rear tire on the inside of the curve may be
Uneven or spotty wear fig. 3 is due to such irregu relieved of so much load that it is no longer geared to
larities as unequal caster or camber, bent front or rear the road and it slips, grinding off the tread on the inside
suspension parts, out-of-balance wheels, brake drums half of the tire at an excessive rate. This type of tire
out-of-round, brakes out-of-adjustment, or other me shows much the same appearance of tread wear as tire
chanical conditions. The remedy in each case consists of wear caused by negative camber.
locating the mechanical defect and correcting it.
Fig. 3-Spot Wear Fig. 4-Cornering Wear
Second, the transfer of weight may also over-load the noise complained of is relatively simple. The car should
outside tires so much that they are laterally distorted be driven at various speeds and note taken of part
resulting in excessive wear on the outside half of the throttle, and sudden acceleration and deceleration. Axle
tire producing a type of wear like that caused by ex and exhaust noises show definite variations under these
cessive positive camber. conditions, while tire noise will remain constant. Tire
Cornering wear can be most easily distinguished from noise is, however, most pronounced at speeds of approx
abnormal camber wear by the rounding of the outside imately twenty or thirty miles per hour.
shoulder or edge .of the tire and by the roughening of the The tires may be further checked by driving the car
tread surface which denotes abrasion. over smooth pavement with the tires at normal pressure
Cornering wear often produces a fin or raised portion and again over the same stretch of pavement when the
along the inside edge of each row in the tread pattern. tires have been inflated to fifty pounds pressure. Reduce
In some cases this fin is almost as pronounced as a the tires to normal pressure one at a time to determine
toe-in fin, and in others, it tapers into a row of tread the faulty tire or tires. This high inflation pressure
blocks to such an extent that the tire has a definite step should immediately be reduced to normal after test. If
wear appearance. the noise for which the test is being made is caused by
The only remedy for cornering wear is proper driving tires, it will noticeably decrease when the tire pressure
habits. is increased, whereas axle noise should show no change
Rotation in volume.
To minimize the possibility of tire noise and to equal If, on inspection, the tires on the front wheels are
ize tire wear, it is recommended that tires be inter found to be creating most of the noise the alignment of
changed every 6000 miles as showp in Figure 5 or more the front wheels should be checked. Excessive tire noise
frequently in the case of extremely heavy wear. usually results from lower than recommended tire pres
sure, incorrect alignment, uneven tire wear, or defective
NOTE: Rotate Corvette tires at 4000 miles or thumper tire.
sooner.
Cleaning
Interchanging tires will effectively prevent undue wear A great deal of ordinary road dirt which collects on
on any particular tire, If tire interchanging is followed red or white sidewall tires may be sponged off with clear
as recommended above, all tires will have the same water or a mild soap solution.
number of miles in each wheel position at the end of the A good brand of whitewall tire cleaner, however, is
fourth change. When interchanging tires, inspect for a quicker and more effective cleaner for removing dirt
signs of abnormal wear, bulging, etc., stones, glass, and and stains from whitewall tires and in many cases it
nails should be removed before reinstallation. Also, tire will remove stains and discoloration that the simpler
pressure must be adjusted Front and Rear in accord method fo soap and water will not remove.
ance with recommendations in the tire inflation table in Under no circumstances should gasoline, kerosene or
Specifications, Section 10. any cleaning fluid containing a solvent derived from oil
Noise be used to clean whitewall tires. Oil in any form is
Noise caused by the normal action of tire treads on detrimental to tire rubber and a cleaner with an oil base
various road surfaces is often confused with rear axle will discolor or injure whitewall tires.
gears or other noises in the car.
Change W/Wheels
The determination of whether tires are causing the
To change the road wheels using the jack that comes
with the car, observe the following procedure:
1. Set hand brake and block front wheels if rear wheel
is being changed.
2. Remove hub cap or wheel disc and break wheel
x
U mounting nuts loose.
3. Place the jack as directed under, General Informa
tion, Section 0 and raise car until wheel clears
ground.
4. Remove wheel mounting nuts and remove wheel from
hub or drum.
5. To replace road wheel, reverse the above instruc
tions. Proper torque on nuts is 55-75 ft. lbs.
H torque.
CAUTION: On models equipped with discs, in
dex the pilot hole in the disc on the valve stem.
To insure that the anti- rotation notches in wheel
disc register on lugs in wheel rim.
Repair
5 WHEELS 4 WHEELS When a tire loses all or most of its air pressure,
particularly when driving at high legal speeds on today’s
super’highways, recommended procedure is to remove it
from the wheel for complete inspection to be sure no
Fig. 5-Tire Rotation tire damage has occurred. Punctured tires should be
removed from the wheel and permanently repaired from an attempt to seat the tire bead is a DANGEROUS PRAC
the inside. TICE which can result in a broken tire bead, and serious
Externally applied plug type repairs should be con injury to the serviceman.
sidered temporary and the tire should be permanently 1. Make sure that rim flanges and bead ledge espe
repaired as soon as possible. cially hump and radius areas are smooth and clean.
Remove any oxidized rubber, dried soap solution,
HotPatch Method ruse, heavy paint, etc. with a wire brush, or, in ex
It is essential to thoroughly clean and remove all treme cases, a file.
foreign matter from the hole left by the puncturing object 2. Lubricate tire beads, rim flanges, and bead ledge
without enlarging the injury and then follow the manu areas with a liberal amount of thin vegetable oil
facturer’s instructions for vulcanizing the patch. soap solution, or approved rubber lubricant.
Rubber Plug Methods 3. Insure that air pressure build-up during the bead
There are several types of rubber plugs- - some are seating process is not allowed to exceed 40 pounds
inserted from the inside of the tire; others are inserted pressure. If beads have not seated by the time pres
from the outside of the tire without demounting the tire sure reaches 40 pounds, assembly should be deflated,
from the rim. re-positioned on rim, re-lubricated and re-inflated.
When using the plug method be sure to clean and 4. Make sure valve core is inserted in valve stem
lubricate the hole with repair cement before inserting prior to inflating.
the plug. Your tire supplier has available complete kits 5. Use an extension gauge with clip on chuck so air
containing materials, tools and detailed instructions for pressure build-up can be closely watched and so
making repairs with plugs. Follow instructions in the kit that you can stand well back from the assembly
you use. during the bead seating process.
Cold Patch Method Self Vulcanizing Type WHEELS

In this method it is essential to thoroughly clean and
remove all foreign matter from the hole left by the Valve Assembly
puncturing object without enlarging the injury; also on Replace
the inside of the tire, buff an area large enough for the
patch. Follow the manufacturer’s instructions for appli NOTE: Always use new valve assembly when
cation of the special cement and self-vulcanizing cold replacing.
patch. 1. Cut or drive old valve assembly out of rim.
Pressure Gun Method 2. Clean valve hole and surrounding area on inside of
Several types of pressure guns are available. Consult flange with steel wool.
your tire supplier for materials and instructions.
BALANCING WHEELS
Tire Installation Safety Precautions
The wheel and tire assembly should be removed from
When tires are mounted on dirty or corroded rims, or
vehicles equipped with disc brakes to properly perform
when they are not properly centered on rims, the tire
balancing operations. This is necessary due to drag of
bead may "bind" on the rim, and refuse to seat. Allowing
the spring loaded brake shoes on the disc.
pressure to continue to build up within the assembly in
Static Balancing W/Tire
Static Balance still balance is the equal distribution
of weight of the wheel and tire assembly about the axis
Fig. 6-Installing Valve Fig. 7-Rim Inspection
of rotation so that the assembly has no tendency to rotate

by itself. Static unbalance causes the pounding action of
the front wheels that is called "tramp".
To correct static unbalance front and rear: The
quickest and best methods to correct static unbalance
are through the use of wheel balancers which are com TREAD TREAD
mercially available. Refer to the Information and in
structions included with these balancers.
STILL GOOD WORN OUT
Dynamic Balancing W/Tire
Dynamic Balance running balance requires the wheel
to be not only in static balance, but balanced and running
smoothly while turning on an axis which runs through the
centerline of the wheel and tire perpendicular to the axis
of rotation.
The quickest and best methods of testing and correcting
dynamic unbalance are by the use of dynamic wheel
balancers which are commercailly available. These bal
ancers include all necessary information on where and
how the balancing weights should be placed. The follow
ing information, however, will help in the correction of
dynamic balance.
NOTE: Before attempting to balance the wheels,
check to be certain that no foreign matter has
been trapped in the wheel ventilation slots or in
the accessory wheel discs. This is especially
important if the vehicle has been run in soft mud
and then parked in freezing weather.
When a wheel that is statically unbalanced is dynam

Fig. 8-Tread Wear Indicators
ically in balance the dynamic balance can be retained
while correcting the static balance by installing the cor
The wheels should also run concentric with the steering
rective weights so that half of the weight required is
knuckle spindle within 1/16 inch as measured on the tire
placed on the inner edge of the rim and the other half
bead seat of the rim with the tire removed.
on the outer edge of the rim.
Wheel run-out, eccentricity and balance are closely
Dyanmic unbalance can be corrected without destroying
static balance by installing weights so half of weight associated with steering and front wheel alignment.
required for dynamic balance is placed on the rim op Further information on these subjects will be found under
posite the heavy point, while the other half is placed 180° "Suspension"
away and on the opposite side of the rim. Tire Wear Indicators
NOTE: Vehicles with wire wheel covers should
A decrease in driving, cornering and braking traction
have the wheels balanced with the wire wheel
occurs under inclement weather conditions as tires be
covers installed on the wheels.
come worn out. Moreover, worn tires have lessened re
sistance to road hazards. The original equipment tires on
Run Out W/O Tire Chevrolet vehicles incorporate built-in tread wear in
The wheels should not run out wobble more than 1/16" dicators fig. 8 to assist you in determining when tires
as measured on the side of the rim at the base of the tire. have been worn to the point of needing replacement. These
Excessive run-out is the result of a bent wheel, an im indicators are molded into the bottom of the tread grooves
properly mounted wheel, worn knuckle bearings or steer and will appear as 1/2-inch wide bands when the tire
ing connections. These parts should be checked for tread depth becomes 1/16 of an inch. When the indicators
correct adjustment, proper alignment and wear whenever appear in two or more adjacent grooves, tire replacement
excessive run-out is encountered. due to tread wear is recommended.
SERVICE OPERATIONS
TIRES Use bead loosening tool or if regular tire irons are
used, take particular care not to injure or tear the
Removal sealing ribs on the bead.
Dismounting tubeless tires presents no problems if the
correct procedures are used and the following precau CAUTION: Never use tire irons with sharp
tions observed. edges or corners.
1. Remove the valve cap and valve core. Let out all the
air. 3. Using tire irons on the opposite side, remove bead,
2. Press the inner side of the tire into the rim well. taking small "bites" around the rim.
4. Turn the tire over, and use two tire irons, one be- accomplished by applying to the circumference
tween the rim flange and the bead to pry the rim of the tire a tire mounting band or heavy sash
upward, the other iron to pry outward between the cord and tightening with the use of a tire iron.
bead seat and the bead. On tire mounting machines, bouncing the tire
assembly is not required. The tire should be
Installation lifted on the rim to force the top tire bead
Extreme care must be exercised to prevent injury to against the top rim flange. The weight of the
the sealing bead and circumferential bead when forcing tire will seat the bottom bead.
tire over rim. 4. Coat O.D. of new valve assembly liberally with the
1. Apply a light film of Ruglyde or other suitable rubber
mounting compound.
lubricant to sealing bead of tire. .
5. Insert assembly through rim .
from inside fig. 7.
NOTE: The use of excessive lubrication may Snap into place, using a pair of slip-joint pliers
lead to rim slippage and subsequent breaking of with one jaw on rim and one jaw on base of valve
air seal. assembly.
2. Carefully mount the outer bead in usual manner by Rim
using tire irons, taking small "bites" around rim,
being careful not to injure the tire bead. Repair
1. Straighten the rim if it is bent or dented.
CAUTION: DO NOT use a hammer, as damage 2. Clean rim flange thoroughly with small piece of steel
to the bead will result. wool or sand paper.
3. Install the inner bead in the same manner. 3. Inspect the butt-weld in the rim flange area to make
certain there is no groove or high spot fig. 8.
NOTE: If a seal cannot be effected in the fore- 4. If air loss occurs at valve it can be corrected by
going manner with the rush of air it can be replacing valve core or valve assembly.
SECTION 1 1
CHASSIS SHEET METAL
Page
Chevrolet and Chevelle 11-1

Chevy II 11-10
Camaro 11-16
Corvette See Section 1B
Special Tools 11-21
CHEVROLET AND CHEVELLE

INDEX
Page Page
General Description 11-1 Radiator Support 11-3
Maintenance and Adjustments 11-1 Fender Assembly. 11-4
Hood Adjustment 11-1 Skirt 11-4
Hinges 11-1 Trim 11-4
Bumpers 11-1 Hood Assembly . 11-4
Catch Assembly and Lock 11-1 Lock and Catch. 11-4
Sheet Metal Adjustments 11-1 Trim and Insulation 11-5
Fenders 11-1 Rear Wheel Cover 11-5
Component Part Replacement 11-3 Simulated Wood Grain Moulding 11-6
Battery Tray 11-3
GENERAL DESCRIPTION
The new front end appearance of the 1967 Chevrolet 14 for Bumpers, and Section 1A for Heater and Air Con
and Chevelle passenger cars affects the servicing and ditioning. Figures 1, 2 and 3 illustrate the Chevrolet and
replacement of the chassis sheet metal. Refer to Section Chevelle sheet metal components.
13 for Radiator and Grille service procedures, Section

HOOD ADJUSTMENT HOOD BUMPERS
Adjust hood bumpers so that hood top surface is flush
The alignment of the hood is controlled by the position with the fender and grille top surfaces, Refer to Figures
of the hood hinges and the height of the two bumpers lo 5 and 6 for correct sheet metal adjustment dimensions.
cated one at each side of the radiator support. The ad
justment at the hood lock must be made after the hinges HOOD CATCH AND LOCK
and bumpers are properly adjusted. To align the hood
and lock proceed as follows: The hood catch assembly figs. 8, 9 and 10 mounting
holes are slotted to provide adjustment for the hood lock
bolt. Adjust the hood lock bolt until hood engages securely
HOOD HINGE Fig. 4 when closed and hood bumpers are slightly compressed.
NOTE: The body mounted portion of the hood SHEET METAL ADJUSTMENTS
hinges are slotted to provide up and down move
ment. The hood mounted end is slotted to pro For proper operation of doors and hood, and for pre
sentable appearance, adjust front sheet metal shown in
vide forward and rearward movement.
Figures 5 and 6.
1. Scribe a line around the entire hinge plate to be
repositioned. FENDERS
2. Loosen the appropriate screws and shift the position Fenders are adjustable with shims at the cowl and
of the hood into correct alignment using the scribe rocker panel. To add or remove shims, loosen bolts at
marks to check amount of movement. Check align shim locations fig. 11 and carefully apply force with pry
ment by tightening screws and closing the hood. bar to provide clearance for shim removal or installation.
CHASSIS SHEET METAL 11.2
Fig. 1-Front End Sheet Metal-Chevrolet
Fig. 2-Front End Sheet Metal Replacement-Chevrolet
CHASSIS SHEET METAL 11-3
Fig. 3-Front End Sheet Metal-Chevelle

NOTE: When replacing sheet metal compo RADIATOR SUPPORT
nents on Chevrolet or Chevelle, note position and
attachment of all seals and dust shielding and Removal
replace as necessary.
NOTE: Remove battery ground cable.
BATIERY TRAY
1. Remove front bumper Section 14.
Removal 2. Remove grille and related components See Section
1. Disconnect battery cables. 13.
2. Remove screw retaining battery hold down clamp and 3. Remove battery tray as outlined.
remove battery from vehicle.
4. Remove all electrical components and connections
3. Remove screws retaining battery tray to fender skirt from radiator support.
and radiator support.
5. Detach shroud or radiator from radiator support.
4. On Chevrolet, remove headlamp bezel and remove 6. Remove screws and bolts securing the support to
screw retaining tray to radiator support. fender braces, extensions, skirts, fenders and frame
5. Remove battery tray from vehicle. horns figs. 12, 13, 14 and 15.
Installation 7. Spread fenders apart sufficient to allow support
Reverse removal procedure. removal.
CHASSIS SHEET METAL -4
FENDER SKIRT
Removal
1. Remove fender as outlined above.
2. Jack up front end of vehicle and remove wheel.
3. Remove all wires, hoses, accessories, etc. attached
to skirt; also remove bolt attaching battery tray
bracket to skirt. Remove battery.
4. Remove battery tray bolt attachment.
5. Remove screws securing brace to skirt and dash
panel and remove brace.
6. Remove skirt attaching screws and remove skirt
from vehicle.
Installation
Install skirt and fender following the removal pro
cedure in reverse order. Refer to torque specifications
in rear of manual for correct torque values.
FENDER TRIM
On Chevelle, to gain access to spear molding and em
blem retaining nuts, remove skirt to fender flange screws
top center rearward and pry skirt forward several
inches. Wedge skirt in this position with a wood block
Fig. 4-Hood Hinge-Chevrolet and remove nuts from inside fender retaining molding
to fender. Emblem attaching hardware is accessible from
Installation inside engine compartment.
1. Position the radiator support in vehicle, aligning On Chevrolet, open front door and rear inside door
mounting screw and bolt holes with drift punch. hinge pillar for access to trim retaining nuts. Remain
2. Replace all parts removed following removal pro ing trim retaining nuts, and emblem retaining nuts are
cedure in reverse order. accessible from inside engine compartment.
3. Install screws and bolts loosely until all are started.
HOOD ASSEMBLY Fig. 16
4. Refer to torque specifications in rear of manual for
correct torque values. Hood may be removed either with or without hinges.
5. Aim headlamps as outlined in Section 12. To shorten aligning time, scribe a mark on hood around
the hinge plate. See adjustment procedures in this sec
FENDER ASSEMBLY tion for hood adjustment. Hood hinge springs may be
easily and safely removed and installed using Tool J-9559
Removal
as follows:
NOTE: Remove battery ground cable. 1. Remove bolt from Tool J-9559. Open hood far
enough to allow passage of tool between hood and
1. Remove bumper See Section 14. fender and insert ends of tool between coils of spring
2. Remove hood with hinges from vehicle as outlined until barrel of tool contacts outer diameter of spring.
in this section. 2. Open hood full while holding spring with tool in
3. Remove header panel. stalled in hand; when hood is in opened position,
4. Remove front upper molding and front trim plate remove spring as shown in Figure 17.
See Section 13. 3. When spring is removed, insert long bolt supplied
5. Remove headlamp bezels and headlamps. with J-9559 through holes in ends of tool, passing it
6. Disconnect wiring harness clips from fender to be through spring, and install nut on bolt.
removed. Spring may be removed from J-9559, or J-9559 may
7. If applicable, remove radio antenna. be installed in a new spring by the following method:
8. Remove fender brace. 1. Place a closed 6 or 8 inch "C" clamp in a vise or
9. Remove screws retaining fender to radiator support, fasten it to a heavy bench top bench should be fas
skirt, cowl, filler panel including filler panel ex tened to floor.
tensions -- Chevelle models, tie bar, and rocker 2. Hook one end of spring in clamp and the other end
panel. Note number and location of shims removed in hook of hoist as shown in Figure 18.
from locations shown in Figure 11. 3. Stretch the spring enough to allow insertion of
10. Remove fender from vehicle. J-9559. Install bolt if spring is not to be installed
Installation on hinge at once.
Refer to disassembly procedure for location of screws HOOD CATCH AND LOCK Figs. 8, 9 & 10
and install screws loosely. Install the shimmed screws
at rocker panel and cowl and adjust fender figs. 5 and 6 Removal
before tightening other screws. Always start adjustment 1. Remove catch plate assembly by removing screws
with original amount of shims, then add or remove shims retaining catch to radiator support, center support,
as required. and tie bar.
Fig. 5-Sheet Metal Adlustments-Chevrolet
2. Remove lock plate by removing screws retaining lock for Chevelle hood grille and grille emblem.
plate to. hood and remove lock plate.
REAR WHEEL COVER CAPRICE, AND OPTIONAL
Installation ON OTHER CHEVROLET MODELS EXCEPT
1. Install lock and catch plate following the removal STATION WAGONS
procedure in reverse order. Refer to torque Speci
fications In rear of manual for correct torque values. Removal and Installation
2. Adjust lock and catch plate as outlined under adjust Lift the skirt fig. 21 retaining lever at the bottom
ment procedure in this section. inside skirt flange over the lip of the flange and pull it
downward. Pull the skirt downward and out of the open
HOOD TRIM AND INSULATION Fig. 19 ing. To install the skirt: position it inside the opening,
insert the rod into the slot, lift the skirt and attach the
Figure 19 shows the Chevrolet installation details of hook to the wheel opening flange. Hold the skirt from
both the hood ornamentation and insulating pads. The below and behind to assure proper hook attachment then
hood emblem and molding retaining nuts may be reached lift the retaining lever up and into the skirt lip. Check
from the underside of the hood panel. Refer to Fig. 20 to insure cover is firmly engaged to fender.
Fig. 6-Sheet Metal Adlustments-Chevelle
SIMULATED WOOD GRAIN MOULDING Removal

STATION WAGONS ONLY Remove the moldings from the affected panel. Remove
The wood grain transfer film is a vinyl material with the transfer film by lifting an edge and peeling the ma
a pressure sensitive adhesive backing. The transfers terial from the painted surface. Exercise care so as not
are serviced in pre-cut panels. The shelf life of this to damage the paint.
material is 90 days at a maximum temperature of 105°F NOTE: Application of heat to the transfer and
panel with a heat gun or heat lamp will aid in the
removal.
Installation
Preparation of the surface to which the transfer will
be applied is very important. In cases where body metal
repair has been made it is necessary to prime and color
coat these areas . to blend with the undamaged surface.
Apply the transfer film to color coated panels only, never
to bare metal or primer. The surface must be free of
any imperfections that may high-light through the film.
Remove dirt nibs and other foreign material in the paint
by light sanding with 600 grit sandpaper.
The temperature of the body must be maintained at a
moderate level between apprdximately 65 and 90 de
grees. Too warm a body will cause the wood grain film
Fig. 7-Sheet Metal Removal to stick prematurely while too cool a body will reduce
HOOD
NOTE:
HOOD BUMPERS MUST BE
ADJUSTED UNTIL HOOD &
FENDER LINE UP. SEE SHEET
METAL CHECKING. ADJUST
HOOD LOCK BOLT TO OBTAIN
A LOAD ON EACH BUMPER
AFTER HOOD IS FIRMLY
SLAMMED.
HOOD CATCH
Fig. 8-Hood Catch and Lock Plate-Chevelle SUPPORT
the adhesion of the wood grain film. Cool the body panel
with cool water when too warm and heat the body panel
with a heat gun or a heat lamp when too cold. Just prior
to application of the transfer film clean the painted sur
face with a non-petroleum base volatile cleaner and allow
to dry.
Follow the steps below for easy application of the film.
1. Cut the tape backing the entire width of the transfer Fig. 10-Hood Catch and Lock Plate Components
at the approximate centerline of the film exercising paper backing to the lower edge of the pierced mold
care not to damage the transfer film. ing holes making sure that the transfer is centered
2. Peel the paper backing from one half of the film. on the panel.
3. Align the upper edge of the half of the film with the
4. Starting at the center of the transfer and using a
water dampened rag, press that half of the transfer
with the backing removed on to the panel. Work
Fig. 9-Hood Catch, Lock Plate and Bumper ComponentS-Chevelle Fig. 11-Fender to Cowl and Rocker Panel Shimming
Fig. 12-Chevrolet Radiator Support to Frame, Fenders and Skirts Fig. 14-Chevelle Radiator Support to Frame and Fenders
outboard from the middle to the edges. Remove all

air bubbles.
NOTE: The transfer can be pulled back from
the panel and reinstalled if large air pockets
develop. Exercise care not to stretch the ma
terial. Small air bubbles may be removed by
piercing the film at the bubble with a pin and
pressing the bubble down.
5. Remove the backing from the other half of the trans
fer. Apply this half in the same manner working FILLER
from the center to the end and from the middle to SUPPORT
the upper and lower edges.
6. Fold the transfer over the door or quarter edges and
Fig. 15-Header to Fender and Grille-Chevelle
Fig. 13-Chevrolet Fender Skirt Extension to Filler Panel and Skirt Fig. 16-Hood Replacement
Fig. 19-Hood, Insulator and Molding-Chevrolet
press to the hemming flanges. Application of heat

Fig. 17-Removing Spring with J-9559 with a heat lamp or heat gun will aid in folding the
transfer over the edge.
NOTE: If the transfer film will not adhere to
the flange, brush a clear vinyl adhesive to the
back edge of the film and reapply.
7. Install the moldings.
VIEW A
Fig. 18-Installing J-9559 in New Spring Fig. 20-Hood Grille and Grille Emblem-Chevelle
Fig. 21-Removing Rear Wheel Cover
CHEVY H
INDEX
Page Page
General Description 11-10 Component Part Replacement 11-12
Maintenance and Adjustments 11-10 Battery Tray 11-12
Hood 11-10 Radiator Support 11-12
Hinge 11-10 Fender Assembly . . 11-12
Bumpers 11-11 Trim 11-13
Catch Assembly 11-11 Skirt
Lock 11-11 Hood Assembly 11-14
Fenders 11-11 Catch Assembly and Lock 11-15
Sheet Metal 11-11 Trim
Front End Assembly
GENERAL DESCRIPTION
Bolt-on front end sheet metal construction fig. 22 is ber biscuit mounts are used to attach the radiator sup
similar to that of the Camaro, including "bathtub" type port to the frame horns.
fender skirts which give corrosion protection to outer Conventional front fenders, grille, bumper and brackets
fender inner surfaces. Fenders and fender skirts are all bolt on to the unit front end structure. The hood is
bolted together, and in combination are bolted to the connected to the front end with hinges that are attached
body at the dash and to the radiator support panel. Rub- to the fender skirts.

HOOD ADJUSTMENT HOOD HINGE Fig. 24
The alignment of the hood in relation to other sheet
metal parts is controlled by the position of the hood 1. Note that the mounting holes in the body-mounted
hinges and the height of the two bumpers, located one at end of the hinge are slotted to provide up and down
each end of the radiator support. The adjustments at movement of the hood assembly while the hood
the hood latch must be made after the hinges and bumpers mounted end is slotted to provide fore and aft
are positioned to yield the dimensions shown in Figure movement.
23. Latch adjustments are made so that effort required 2. Scribe a mark around the entire hinge plate which
to open and close the hood is reasonable, and hood align will be involved in the adjustment.
ment obtained by hinge and bumper adjustment is main 3. Loosen the appropriate screws and shift the position
tained when the hood is closed. Note that the hood latch of the hood on the hinge plate the approximate amount
is not designed or intended to correct basic hood align to correct misalignment, using the scribed marks to
ment faults. check amount of movement. Check condition of ad
To align the hood and lock, proceed as follows: justment by tightening cap screws and closing hood.
Fig. 22-Front End Sheet Metal-Chevy II
HOOD BUMPERS required to release the hood catch is reasonable.
Hood bumpers must be adjusted until hood and fender SHEET METAL ADJUSTMENTS
line up as shown in Figure 23.
For proper operation of doors and hood, and for pre
sentable appearance, adjust front sheet metal to the tol
HOOD CATCH AND LOCK Fig. 25 erances shown in Figure 23.
Hood lock plate mounting holes are slotted to provide
fore and alt adjustment of the hood lock bolt. The hood FENDERS
lock bolt itself is adjustable for up and down positioning
of the lock bolt head so that its proper engagement in the Fenders are adjustable with shims at the cowl and
latch assembly may be provided for. The distance that rocker panel. To add or remove shims, loosen bolts at
the lock bolt protrudes out of the lock plate should be shim locations fig. 26 and carefully apply force with
adjusted so that the hood bumpers are slightly com pry bar to provide clearance for shim removal or
pressed by the fully latched hood and so that the effort installation.
Fig. 23-Sheet Metal Adjustment-Chevy II Typical

BATTERY TRAY Fig.27 4. Remove screws retaining tray assembly to fender
Removal skirt and support, and remove tray from vehicle.
1. Disconnect battery cables. Installation
2. Remove screw retaining battery hold down clamp. Reverse removal procedure.
3. Remove battery from vehicle.
RADIATOR SUPPORT Fig. 28
Removal
1. Raise hood, disconnect battery cables, and remove
battery.
2. Remove front bumper Section 14.
3. Remove grille and related components Section 13.
Fig. 24-Hood Hinge-Chevy II Fig. 25-Hood Lock, Catch and Support-Chevy II
Fig. 26-Front Fender Shimming
4. Disconnect horns, horn relay, voltage regulator, FENDER AND SKIRT ASSEMBLY
wiring harness, and washer bottle from radiator
support. Removal
5. Remove screw connecting battery tray to radiator
support. 1. Remove front bumper Section 14.
6. Remove shroud from vehicle if so equipped. 2. Remove hood and hood hinges two men.
7. Remove shroud and radiator Section 13. 3. Remove bolts securing brace to skirt and dash panel
8. Remove screws securing support to frame, skirts, and remove brace fig. 22.
and fenders. 4. Disconnect any components attached to fender and
9. Remove radiator support from vehicle. skirt such as cruise control, hoses, electrical har
ness etc.
Installation 5. Remove screws securing radiator support to fender
Install radiator support following the removal pro and skirt.
cedure in reverse order. Refer to torque specifications 6. Remove headlamp bezel and headlamp.
in rear of manual for correct torque values for radiator 7. Remove screws securing fender and skirt assembly
support, grille, and bumper. to header panel, headlamp housing and valance panel.
CHASSIS SHEET METAL 11.14
Remove screw securing fender extension to valance

panel.
8. Remove screws securing fender and skirt assembly
to vehicle and remove fender and skirt assembly.
9. If necessary, remove screws attaching fender ex
tension and bumper bracket to fender and remove
extension and bracket. Replace fender trim if
necessary.
Installation
Install fender and skirt assembly following the removal
procedure in reverse order. Refer to torque specifica
tions in rear of manual for correct torque values.
HOOD TRIM AND INSULATION Fig. 26

Figure 26 shows the installation details of the hood
ornament and insulation pad. The insulation and ornament
retainers and nuts are accessible from under the raised
hood.
COWL VENT GRILLE

Removal
1. Raise hood.
2. Remove windshield wiper arms and disconnect
washer hoses from tubes. Remove screws securing
washer tubes to cowl vent grille. Pull tubes out Fig. 26-Radiator Support to Fender and Fender Skirt
from under rubber molding and remove.
3. Remove cowl vent grille retaining screws.
BATT 4. Leaving rubber molding in place, remove cowl vent
grille from vehicle.
Installation
Install cowl vent grille following removal procedure in
reverse order. Refer to Figure 17 for correct sheet
metal adjustments.
iöiI1 LIP OF CLAMP
MUST FIT IN SLOT OF
BATTERY.
Fig. 27-Battery Tray Fig. 29-Fender to Fender Skirt
3. As soon as spring is removed, insert long bolt sup a. Remove screws retaining catch assembly to radi
plied with J-9559 through holes in end of tool, pass ator support.
ing it through spring, and install nut on bolt. b. Remove screws retaining catch assembly to catch
Spring may be removed from J-9559 or J-9559 may be support assembly.
installed in a new spring by the following method: c. Remove screws retaining catch assembly to grille
1. Place a closed 6 or 8 inch "C" clamp in a vise or upper bar.
fasten it to a heavy bench top bench should be fas 2. Before removing hood lock plate from hood, locate
tened to floor. position on hood by scribing around base of lock
2. Hook one end of spring in clamp and the other end plate. Remove screws retaining lock plate to hood
in hook of a hoist as shown in Figure 28. and remove lock plate from vehicle.
3. Stretch the spring enough to allow insertion of
J-9559. Install through bolt if spring is not to be Installation
installed on hinge at once.
1. Install both catch and lock assemblies in reverse
HOOD CATCH AND LOCK Fig. 25 order of removal procedure.
Removal 2. Align as outlined under Maintenance and Adjust-
1. Remove catch assembly as follows: ments - Hood Catch.
CAMARO
INDEX
Page Page
General Description 11-16 Component Part Replacement 11-17
Maintenance and Adjustments 11-17 Battery Tray 11-17
Hood 11-17 Radiator Support 11-17
Hinge 11-17 Fender and Skirt Assembly 11-18
Bumpers 11-17 Hood Assembly 11-19
Catch Assembly 11-17 Lock and Catch Assembly 11-19
Lock 11-17 Trim and Insulation 11-19
Fenders 11-17 Cowl Vent Grille 11-19
Sheet Metal 11-17
GENERAL DESCRIPTION
The Camaro sheet metal components are much the by removing the fender and skirt as an assembly. Refer
same as other Chevrolet passenger models as shown in to Section 14 for bumper service procedures, Section 13
Figure 35. The front end design is such that servicing for radiator and grille, and Section 1A for air condition
of the fenders and skirts is most efficiently performed ing components.

HOOD ADJUSTMENT HOOD BUMPERS
The Camaro hood is adjusted in the conventional man Adjust hood bumpers so that hood top surface is flush
ner, by adjustment of the hood bumpers and hinges. The with fender and header panel top surfaces. See Figure
two hood bumpers are located on each side at the top of 34 for correct sheet metal adjustment dimensions.
the radiator support. Do not attempt hood latch adjust HOOD CATCH AND LOCK Fig. 38
ments until the hinges and bumpers are correctly ad
justed. Latch adjustments are made so that effort re Adjust hood lock bolt so that top surface of hood is
quired to open and close the hood is reasonable, and flush with top surface of header panel. The distance that
hood alignment obtained by hinge and bumper adjust the lock bolt protrudes out of the lock plate should be
ment is maintained when the hood is closed. Note that adjusted so that the hood bumpers are slightly com
the hood latch is not designed to correct basic hood pressed by the fully latched hood, and effort required
to release the hood catch is reasonable. Close the hood
misalignment.
and insure catch engages securely.
HOOD HINGE Fig. 36
FENDERS
NOTE: The body mounted portion of the hood
Fenders are adjustable with shims at the cowl and
hinges are slotted to provide up and down move rocker panel. To add or remove shims, loosen bolts
ment. The hood mounted end is slotted to pro
at shim locations fig. 39 and carefully apply force with
vide forward and rearward movement. pry bar to provide clearance for shim removal or
1. Scribe a line around the entire hinge plate to be installation.
repositioned.
SHEET METAL
2. Loosen the appropriate screws and shift the position
of the hood into correct alignment using the scribe For proper operation of doors and hood, and for pre
marks to check amount of movement. Check align sentable appearance, adjust front sheet metal to the
ment by tightening screws and closing the hood. dimensions shown in Figure 37.
Fig. 33-Hood Spring Removal
HOOD ASSEMBLY
Hood may be removed either with or without hinges.
To shorted aligning time, hood hinge plates may be lo
cated by scribing a mark on hood and/or body which
Fig. 30-Front End Filler Panel, Reinforcement and Brace
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 passage of
mechanic’s arm between hood and fender, insert
ends of J-9559 through bolt removed between coils
of spring until barrel of tool contacts outer diameter
of spring.
2. Open hood fully while still holding spring with tool
installed in hand; when hood is near fully opened
position, spring may be removed as shown in Fig
ure 27.
Fig. 32-Hood Insulator, Molding and Emblem Fig. 34-Installing Tool J-9559 in New Spring
Fig. 35-Front End Sheet Metal-Camaro
1. Fender 5. Trim 9. Valance Panel 13. Shroud 16. Bracket V-8 Engine Only 19. Skirt
2. Hood Hinge 6. Molding 10. Header Panel 14. Hood Lock 17. Hood Catch 20. Seal
3. Hood 7. Fender Extension 11. Radiator Support 15. Radiator Cap 18. Brace 21. Battery Tray
4. Cowl Vent Grille 8. Bumper Bracket 12. Radiator

NOTE: When replacing sheet metal compo RADIATOR SUPPORT
nents on Camaro, note position and attachment
of all seals and dust shielding and replace if Removal
necessary. 1. Raise hood, disconnect battery cables, and remove
battery.
BATTERY TRAY 2. Remove front bumper Section 14.
3. Remove grille and related components Section 13.
Removal
4. Disconnect horns, horn relay, voltage regulator,
1. Disconnect battery cables and remove battery from wiring harness, and washer bottle from radiator
vehicle. support.
2. Remove screws securing battery tray to fender skirt 5. Remove screw connecting battery tray to radiator
and radiator support.
support.
3. Remove battery tray from vehicle. 6. Remove shroud from vehicle if so equipped.
Installation 7. Remove shroud and radiator Section 13.
Install battery tray following removal procedure in 8. Remove screws securing support to frame, skirts,
reverse order. and fenders.
8. Remove screws securing fender and skirt assembly

to vehicle and remove fender and skirt assembly.
9. If necessary, remove screws attaching fender ex
tension and bumper bracket to fender and remove
extension and bracket. Replace fender trim if
necessary.
Installation
Install fender and skirt assembly following the removal
procedure in reverse order. Refer to torque specifica
tions in rear of manual for correct torque values.
HOOD ASSEMBLY
Procedures for hood removal and installation for
Camaro are the same as for Chevrolet and Chevelle.
Refer to Chevrolet and Chevelle hood removal and in
stallation procedures, Figure 38 for Camaro hood catch,
support, and lock plate.
HOOD CATCH AND LOCK Fig. 38

Removal
1. Remove catch plate assembly by removing screws
retaining catch to header panel, center support, and
radiator support.
NOTE: Before removing hood lock plate from
hood, locate position on hood by scribing around
base of lock plate.
2. Remove lock plate by removing screws retaining lock
plate to hood and remove lock plate.
Installation
Fig. 36-Hood Hinge-Camaro Install lock and catch plate following the removal pro
9. Remove radiator support from vehicle. in rear of manual for correct torque values. Adjust lock
and catch plate as outlined under adjustment procedure
Installation in this section.
Install radiator support following the removal pro
in rear of manual for correct torque values for radiator
HOOD TRIM AND INSULATION
support, grille, and bumper. The insulation and ornament retainers and nuts are
accessible from under the raised hood.
FENDER AND SKIRT ASSEMBLY
Removal COWL VENT GRILLE
1. Remove front bumper Section 14. Removal
2. Remove hood and hood hinges two men. 1. Raise hood.
3. Remove bolts securing brace to skirt and dash panel 2. Remove windshield wiper arms and disconnect
and remove brace fig. 35. washer hoses from tubes. Remove screws securing
4. Disconnect any components attached to fender and washer tubes to cowl vent grille. Pull tubes out
skirt such as cruise control, hoses, electrical har from under rubber molding and remove.
ness etc. 3. Remove cowl vent grille retaining screws.
5. Remove screws securing radiator support to fender 4. Leaving rubber molding in place, remove cowl vent
and skirt.
grille from vehicle.
6. Remove headlamp bezel and headlamp.
7. Remove screws securing fender and skirt assembly Installation
to header panel, headlamp housing and valance panel. Install cowl vent grille following removal procedure in
Remove screw securing fender extension to valance reverse order. Refer to Figure 32 for correct sheet
panel. metal adjustments.
FENDER TO W/SHIELD
MOLDING .06 ± .06
FENDER FLUSH TO .060

OUTBOARD OF NORMAL
DOOR AT FENDER
CENTER PEAK LINE.
NORMAL DOOR SURFACE

TO BE MEASURED 2" REAR
WARD OF DOOR EDGE
TO FENDER EDGE.
r-HOOD TO BE FLUSH JSURFACE

TO + .06 TO HEADER
. / jTYPICAL ON
/ SURFACE FLUSH
‘%.J CONDITION DESIRED
VIEW A
H iN
TYPICAL SECTION
Fig. 3:7-Sheet Metal Adjustments-Camaro
Fig. 38-Hood Catch, Support and Lock Plate-Camaro
SHIM
SHIM
SHIM.
VIEW A VIEW B
Fig. 39-Fender to Cowl and Rocker Panel Shimming-Camaro
SPECIAL TOOLS
The only special tool required for 1968 chassis sheet
metal servicing is the hood spring removal and installa
tion Tool J-9559. See Figure 40.
Fig. 40-Special Tools-All Models-J-9559 Hood Spring
SECTION 12
ELECTRICAL-BODY AND CHASSIS

Page
Lighting System 12-1

Instruments and Gauges 12-23
Directional Signal * 12-40
Windshield Wipers and Washers * 12-43
Concealed Wiper Door - Corvette * 12-54
Theft Deterrent System 12-56
Wiring Diagrams * 12-57
LIGHTING SYSTEM
INDEX
Page Page
General Description 12-1 Tail Stop, Directional and Backup Lamps 12-11
Maintenance and Adjustments 12-3 Bulb Replacement--All 12-11
Headlamp Adjustment--T-3 Headilamps 12-3 Lamp Housing Replacement 12-12
Headlamp Panel Adjustments 12-5 License Lamps--All 12-12
Chevrolet 12-5 Automatic Trazsmission Quadrant Lamp 12-12
Camaro 12-5 Chevrolet and Chevelle 12-12
Corvette 12-5 Chevy H and Camaro 12-15
Service Operations 12-7 Seat Separator Compartment 12-15
Front Lighting 12-7 Lamp Replacement 12-15
Headlamp Replacement All Vehicles 12-7 Courtesy Lamp Replacement 12-15
Parking Lamp Replacement 12-7 Ignition Switch 12-16
Marker Lamp Replacement 12-8 Lighting Switch Replacement 12-16
Fender Lamp Replacement 12-8 Wiper Switch Replacement 12-17
Vacuum Operated Headlamp Service 12-8 Stoplight Switch Replacement 12-17
Chevrolet 12-8 Dimmer Switch Replacement 12-18
Headlamp Door Panel Camaro 12-10 Backing Lamp Switch Replacement 12-18
Corvette 12-10 Mast Jacket Mounted 12-18
Actuator Assembly 12-10 Transmission Mounted 12-18
Chevrolet 12-10 Neutral Safety Switch Replacement 12-19
Camaro 12-10 Column Shift 12-19
Corvette 12-10 Floor Shift 12-19
Relay Assembly--All 12-11 Corvette 12-19
Vacuum Tank 12-11 Parking Brake Alarm Switch Replacement 12-19
Chevrolet 12-11 Instrument Panel Compartment Lamp Switch
Camaro 12-11 Replacement 12-20
Corvette 12-11 Cigarette Lighter Replacement 12-20
Vacuum Hose Routing 12-11 Chevrolet, Camaro and Chevy II 12-20
Rear Lighting 12-11 Chevelle 12-20
Corvette 12-21
GENERAL DESCRIPTION
The lighting system includes the main lighting switch, New for 1968 are the vacuum actuated headlamp covers
stop light, dimmer and back lamp switches, headlamps, standard on Corvettes and optionally offered on Chevro
parking, side marker, stop, tail and directional lamps. lets and Camaros.
It also includes instrument illumination, indicator lamps Also new for 1968 are the side marker lamps, amber
and the necessary wiring to complete the circuits. Vac bulbs in the front fenders and clear bulbs with red lenses
uum system components for headlamp operation are now in the quarter panels on all Chevrolet passenger cars,
included. A fuse panel provides convenient power taps except Chevelle sedans. In addition the parking and
and fuse clips for the appropriate circuits fig. 1. marker lamps will operate in the headlamp switch "park"
ELECTRJCAL-BODY AND CHASSIS 12-2
Fig. 1-Fuse Panel Assembly
or "headlights" position the same as license and tail The fiber optic monitoring system is standard on
lamps. C orvettes and optionally available on Camaros, Chevelles,
and Chevrolets in 1968.
NOTE: It is recommended that the battery be
disconnected before performing any electrical
The fiber optic conductors are attached to light *source
service other than bulb or fuse replacement.
housings remotely located from the viewing lens.
Corvette, Chevelle, Chevrolet and Chevy II headlamp The monitoring lens will glow when the EXTERIOR
housings are new due to revised front end styling. lights are lit. Backup and marker lamps are not moni
Camaro front end styling is basically carryover. tored.
Front fender lamps are standard on the Caprice model The fiber optic conductors are multi strand coated
and optional on other Chevrolets. plastic bundles, of a precision length having a crimped
Camaro and Chevy II continue to use dual filament ferrule on each end.
single headlamps. The Camaro Rally Sport headlamps In addition to fuses, the wiring harness incorporates
are concealed by a retractable extension of the grille fusible links to protect the wiring. Links are used rather
when the lamps are not used. The grille section covering than a fuse in wiring circuits that are not normally fused,
the headlamps slides rearward when the lamps are turned such as the ignition circuit. Fusible links in the Chevro
on; the headlamps are stationary. The covering is re let wiring are four gauge sizes smaller than the cable it
tracted by a vacuum operated actuator mounted to the is designed to protect. The links are marked on the
headlamp housing. If the vacuum circuit becomes inop insulation with wire gauge size because of the heavy insu
erative, the lamps can be uncovered manually. lation which makes the link appear a heavier gauge than
The new marker lamps are part of the front and rear it actually is.
lighting harnesses.
Engine compartment wiring harnesses incorporate sev
Power windows can be opened or closed with the igni eral fusible links. The same size wire with special
tion switch in the "ACC", accessory, position or the "ON" hypalon insulation must be used when replacing a fusible
position. link.
ELECTRICAL-BODY AND CHASSIS 12-3
The links are: a molded splice in the generator and forward lamp
1. The pigtail lead at the battery positive cable except harness and is serviced by splicing in a new 20 gauge
Corvette is a 14 gauge, brown fusible link protecting wire as required.
the 10 gauge battery charging circuit. This wire is 4. The ammeter circuit on all models is protected by
an integral part of the battery cable assembly and two orange, 20 gauge wire fusible links installed as
servicing requires replacing the complete battery molded splices in the circuit at the junction block or
cable assembly. On Corvette models this link is the solenoid "Bat" terminal Corvette only and at the
installed as a molded splice at the solenoid "Bat" horn relay. Each link is serviced by splicing in a
terminal and servicing requires splicing in a new new 20 gauge wire as required.
link. The wiring harnesses use a standarized color code
2. A 16 gauge black fusible link is located at horn relay common to all Chevrolet vehicles. Under the color code,
to protect all unfused wiring of 12 gauge or larger. the color of the wire designates a particular circuit. The
It is a serviceable piece with an in-line connector harness title indicates the type of harness, single or mul
and is not integral with the wiring harness. tiple wire, and also describe the location of the harness.
3. The generator warning light and field circuitry 16 The body harness is routed through the vehicle near the
gauge wire is protected by a fusible link 20 gauge center of the body. Composite wiring diagrams figs. 89
orange wire used in the "battery feed to voltage thru 110 are included at the end of this section.
regulator #3 terminal" wire. The link is installed as

Maintenance of the lighting units and wiring system
consists of an occasional check to see that all wiring
connections are tight and clean, that the lighting units are
tightly mounted to provide good ground and that the head-
lamps are properly adjusted. Loose or corroded con
nections may cause a discharged battery, difficult start
ing, dim lights, and possible damage to generator and
regulator. Wire harnesses must be replaced if insulation
becomes burned, cracked, or deteriorated. Whenever it
is necessary to splice a wire or repair one that is bro
ken, always use solder to bond the splice. Always use
rosin flux solder on electrical connections. Use insulat
ing tape to cover all splices or bare wires.
When replacing wires, it is important that the correct
size be used. Never replace a wire with one of a smaller
gauge size. Fig. 2-1-3 Safety Aimer
Each harness and wire must be held securely in place
by clips or other holding devices to prevent chafing or
wearing away the insulation due to vibration. 3. Mount the T-3 Aimers on either the No. 1 or No. 2
By referring to the wiring diagrams, circuits may be pair of headlamps so that the points of the headlamps
tested for continuous circuit or shorts with a conventional engage the smooth inner ring of the aimers.
test lamp or low reading volt meter.
NOTE: In the dual headlamp installation, the
inboard unit is designated No. 1 and the outboard
HEADLAMP ADJUSTMENT- T-3 HEADLAMPS unit is designated No. 2.
CAUTION: Check and tighten radiator support
grille retaining bolts prior to attempting head 4. Secure the aimers to the headlamp units by firmly
pressing knob at center of each aimer fig. 3. Ro
lamp aiming. Distorted grille or supports in
tate crossarms inboard to approximate horizontal
this area will hinder proper aiming of head-
lamps. On Corvette models make sure head position.
lamp panel is adjusted properly - refer to NOTE: Moisten suction cups slightly to obtain
"Headlamp Panel Travel Adjustment". maximum holding force.
When aiming headlamps, vehicle should be filled to ca 5. With both aimers in place, knot both ends of elastic
pacity with gas, oil, and water but no load. Tires should string and, using slots provided, fasten string across
be inflated to recommended pressures. horizontal crossarms of each aimer.
The T-3 Safety Aimer-Type B fig. 2, is used for the 6. Rotate both aimers so that the string just clears the
headlamp aiming description that follows. An adapter is points on the crossarms.
required with the Type B T-3 Aimer when adjusting the 7
inch headlamp used on the Chevy II and Camaros. HORIZONTAL ADJUSTMENT
1. Drive vehicle onto selected aiming area. Bounce
vehicle several times and allow to settle. 7. a. Turn horizontal aiming screw, Figure 4, on left
2. Remove headlamp bezels, if necessary. hand lamp until the string is position over the
Fig. 3-Installing Aimer on Headlamp Unit Headlamp Vertical Adjustment

Fig. 5 -
the inner end of the glass tube. Then turn screw

clockwise until bubble is centered in tube.
c. Repeat this procedure on right-hand headlamp
unit to complete vertical adjustment of lamps.
I
HORIZONTAL
AIMING
9. Recheck the string at the ends of each crossarm for
correct setting and the bubble on each aimer for
centered position.
10. Remove the aimers by pulling on the suction cup tabs
SCREW through the openings in the aimers fig. 6.
11. With headlamps properly aimed, replace headlamp
bezels.
STRING OVER
"2R" ON AIMER ARM
Fig. 4-Headlamp Horizontal Adjustment
crossarm centerline. Turn the screw clockwise

in making the final adjustment to take up play in
the headlamp mechanism.
b. Repeat the above procedure on the right-hand
lamp to complete the horizontal adjustment of the
headlamps.
VERTICAL ADJUSTMENT
Fig. 6-Removing Aimer from Headlamp
8. a. Numeral "2" fig. 5 should appear in the "down"
window of each aimer. If not, loosen knob at HOW TO SELECT A LEVEL AIMING AREA
underside of aimer arm and slide back and forth
until the numeral does appear. 1. Select area you believe to be level.
2. Remove headlamp bezels if necessary and install
NOTE: This setting will give a 2" drop of the Aimers on each headlamp fig. 3 making sure aiming
headlamp high beam spot centerline on a screen lugs engage smooth inner ring of the Aimer. To in
placed 25 feet forward of the vehicle. Check stall Aimer, press firmly on the knob extending ou
state laws for proper vertical setting. from the center of the Aimer base. This forces th
suction cup into place on the Sealed Beam unit.
b. Turn headlamp vertical aim screw fig. 5 on left- 3. Loosen the slider knob beneath the aimer arm and
hand unit counter- clockwise until the bubble is at set the numeral "2" in the DOWN view window fig.
Fig. 7-Selecting Level Aiming Area
7. Back vertical lamp adjustment out on each lamp

until bubble is outside of black line of vial, then cen
ter bubble in between black line of vial by turning
clockwise.
4. After both bubbles are centered, turn the car around
end for end, making sure the tires are in the spots
made on the floor before the car was moved.
5. If the bubbles are still within the two outside black
marks on the vials, the floor is level enough to use Fig. 8-Turning Level Adjusting Screw to Calibrate Aimer
the Aimer as it comes from the factory.
NOTE: A quick level check can be made .by 6. The T-3 Aimers are now calibrated for the selected
using the T-3 Safety-Aimer as a level. Use area. All future aiming must be done in the same
with a true eight to ten foot two by four as an area and with the car pointed in the same direction.
extension. Make sure pads on base of Aimer Mark the tire spots on the floor so that other vehi
are used. Place the board where you expect the cles can be located in the same position.
wheels to be and take readings as outlined above.
6. If either bubble moves outside the black lines of the HEADLAMP PANEL ADJUSTMENT
vial there is too much slant to the floor. Try driving Chevrolet Fig. 9
the car in at different angles onto the aiming area.
If bubbles can not be centered follow procedure under Lower Vacuum Door
"How to Compensate for Unlevel Floor." 1. Actuate lower door shut and check alignment of door
NOTE: When level portion of floor is obtained, bottom edge to sheet metal.
mark tire spots on floor so spots can be used 2. Actuate door open and turn adjustment screw clock
next time without calibrating Aimer. wise after loosening locknut to move lower edge
of door inward. Recheck alignment after closing
TO COMPENSATE FOR UNLEVEL FLOORS lower door.
If your floor is not level within the limits specified, the Camaro Fig. 10
T-3 Aimer can be calibrated to compensate for the error
in the floor. Follow this procedure with both aimers. Cover may be aligned with radiator grille through
1. Drive the car onto the area for which you wish to captured floating nuts on back of plate assembly See
compensate the aimers, and install the aimers in Figure 10.
place on the headlamps.
2. Loosen knob beneath the aimer arm and move the Corvette
slider until the bubble is centered. Headlamp Housing Fig. 11
3. Record the numeral in the view window. This nu
meral is to be used only for recalibration. Alignment Procedure
4. Move the slider to a position halfway between this 1. "In-out" loosen screws fastening slotted bracket to
recorded numeral and the numeral "2" in the DOWN underside of headlamp housing assembly.
window. This numeral is used only in recalibration 2. "Down" lamp cover top to opening; by turning hex
and not for headlamp aiming. head screw fastened to top of pivot link.
5. Recalibrate aimers by turning screw shown in Figure 3. "Open" fully extended actuator with rod.
8 until the bubble is centered. a. Remove spring from actuator rod pin.
LOWER DOOR UPPER DOOR
Fig. 9-Headlamp Panel Adjustment Chevrolet
CAPTURED NUTS
ON BACK
Fig. 10-Headlamp Panel Adjustment Camaro Fig. 11-Headlamp Panel Adjustment Corvette
b. Remove cotter pin from rod pin. 4. "Up" bezel to opening alignment by loosening jamb
c. Turn actuator rod until bushing hole aligns to nut and turning bumper covered screw up or down to
forward end of slot in connecting link extended touch then up 1-1/2 turns more.
position, with engine idling for vacuum.
d. Shut off engine, retract actuator rod and unscrew NOTE: The headlamp housing must be prop
rod 1/2 turn to preload actuator rod in link. erly aligned before headlamps are aimed.
SERVICE OPERATIONS
FRONT LIGHTING NOTE: In the dual headlamp installation the
inboard unit No. 1 takes a double connector
plug, the outboard unit No. 2 takes a triple
HEADLAMP REPLACEMENT Figs. 12 and 13 connector plug.
1. On Corvette, Chevrolet and Camaro Rally Sport 6. Position retaining ring into place and install the re
models, open the headlamp panel to the open position. taining ring attaching screws and spring.
2. Remove headlamp bezel retaining screws and remove 7. Check operation of unit and install the headlamp
bezel. bezel.
3. Disengage spring from the retaining ring and remove
two attaching screws. PARKING LAMP REPLACEMENT
4. Remove retaining ring, disconnect sealed beam unit
at wiring connector and remove the unit. Bulb
5. Attach connector to replacement unit and position
unit in place making sure the number molded into the 1. Remove two lens retaining screws and disengage lens
lens face is at the top. from housing.
Fig. 12-Headlamp Assembly Except Corvette
3. Disconnect lamp wiring plug from front wiring har

ness.
4. Transfer lens and bulb to new lamp housing.
5. Install lamp assembly in the grille and secure with
two nuts.
6. Connect lamp wiring harness.
7. Install grille.
MARKER LAMP REPLACEMENT Fig. 14

1. On Corvettes remove four screws holding grille to
body and swing grille to one side to gain access to
marker lamp retaining nuts.
2. Remove retaining nuts inside fender panel.
3. Pull assembly out from fender and disconnect plug
at lamp.
4. Install plug into lamp and install lamp and bezel into
fender.
5. Install nuts retaining bezel to fender.
6. On Corvettes install four screws securing grille to
body.
Bulb Replacement-Except Corvette Front

Turn connector plug counter-clockwise 1/4 turn to re
move plug containing bulb from lamp assembly.
Fig. 13-Headlamp Assembly Corvette NOTE: Some A/C equipped cars will need the
battery removed for access to the right front
marker lamp connector plug.
2. Replace bulb, check operation of lamp, reinstall lens
and retaining screws. Corvette Front
1. Remove screws securing radiator grille and swing
Lamp Housing grille to one side.
Chevrolet, Chevelle and Chevy II 2. Reach through grille opening and turn plug connector
1/4 turn counter-clockwise to remove and replace
1. Disconnect lamp wire assembly in-line connector
bulb inset in plug connector.
from wiring harness.
2. Remove two bolts retaining housing assembly in
FENDER LAMP SERVICE Fig. 1 5
bumper and remove housing.
3. Remove lens retaining screws, lens and bulb from Chevrolet
housing assembly and transfer to new housing unit.
4. Connect lamp wiring assembly to harness assembly, 1. Disconnect parking lamp wiring from forward har
housing and check operation of lamp. ness connector.
5. Position lamp assembly in place and install retaining 2. Remove two screws retaining lens to the lamp as
bolts. sembly and remove lens unit.
3. Replace bulb, lens or housing as required and posi
Camaro tion assembly to fender opening.
4. Remove two nuts retaining lamp assembly to front
1. Raise hood.
sheet metal.
2. Disconnect wiring harness at rear of lamp socket.
5. Transfer bulb and lens to new lamp assembly and
3. Remove attaching nut and disconnect ground wire at
plug in connector to forward wiring harness.
sheet metal connection.
6. Position lamp assembly to fender and secure with
4. Remove retaining nuts and housing from grille open
retaining nuts.
ing.
5. Transfer lens and bulb to new unit.
VACUUM OPERATED HEADLAMP SERVICE
6. To install, position lamp housing to grille opening
and install retaining nuts. Headlamp Door Fig. 9
7. Connect ground wire to attaching point and install
retaining nut.
Chevrolet
8. Connect wiring harness to lamp socket and check
operation of lamp. Replacement
1. Actuate headlamp doors open by sliding valve inboard
Corvette on top of vacuum relay.
1. Remove four screws securing radiator grille to body. NOTE: With care, pull and tape yellow stripped
2. Lift out grille and remove two nuts fastening lamp vacuum hose from center connector of vacuum
assembly to grille. relay.
Fig. 14-Marker Lamp Installation
Fig. 15-Fender Lamp Chevrolet Fig. 16-Actuator Assembly Chevrolet
2. Remove three 3 screws at top of upper lid. 4. Remove front pivot pin retaining washers and pivot
3. Remove one 1 outboard shouldered bolt attaching pin.
upper door to link and lift upper door off car. 5. Remove actuator rear pivot pin retainer with pin and
4. Remove actuator front retainer, washers and pin. lift actuator out of vehicle.
5. Remove lower door pivot pin retainers and pins. 6. Replace actuator and install removed components in
the reverse order of disassembly.
NOTE: Headlamps maybe removed for access. 7. Check out operation of actuator with applied vacuum.
6. Slide lower door assembly out opening. Actuator Assembly

7. Reverse procedure for door assembly.
Corvette Fig. 11
Headlamp Door Fig. 10 Replacement
1. Remove radiator decorative radiator grille and
Camaro screws.
Replacement 2. Actuate headlamps partially open and remove long
1. With door closed, remove four 4 screws securing spring on either side of pivot link pin.
cover-to-plate assembly and lift cover off. 3. Remove two 2 vacuum hoses attached to actuator.
2. Partially open door plate assembly and reach inside 4. Remove cotter pin and slide out pivot pin, freeing
of opening to remove bolts attaching cover to hinge actuator rod.
and lift off door plate. 5. Remove four 4 nuts from actuator studs and slide
NOTE: actuator down and out grille opening.
Spacer installation between hinge and
6. Reverse removal procedure when replacing actuator.
plate assembly.
3. Install cover and plate assembly in the reverse order Actuator Assembly
of removal.
NOTE: Cover may be aligned with radiator
Camaro-RaIIy Sport Fig. 17
grille through captured floating nuts on back of Replacement
plate assembly. 1. Place vehicle on hoist.
2. From underside, forward of front fender skirt re
Headlamp Door Fig. 11 move actuator shield.
3. Remove vacuum hoses from actuator and tag hoses
Corvette as to placement on actuator ie. front, rear.
Replacement 4. Remove pin retainer and pin at front of actuator.
5. Remove actuator attaching side bolts and lower ac
1. Actuate door open.
2. Remove radiator decorative grille and attaching tuator assembly from beneath vehicle.
screws. 6. Install replacement actuator in reverse order of re
3. Remove headlamp bezel and apply protective tape to moval procedure and test operation with applied
vacuum.
headlamp door opening.
4. Remove headlamp assemblies inner and outer by re
moving springs with a hooked wire or small vise
giips.
5. Remove front screw and bushing attaching headlamp
housing to support assembly link.
6. Remove "J" bar from side of headlamp housing ex
tending downward.
7. Reaching in through grille opening, remove three 3
cap screws retaining bearing and headlamp housing
assemblies to support assembly. ACTUATOR
8. Lift headlamp door assembly forward and out of
opening.
9. Transfer remaining door attachments to new door
assembly and install assembly in the reverse order
of removal.
Actuator Assembly
Chevrolet Fig. 16
Replacement
1. Actuate doors open by lifting upper cover lid up and
back, then lifting lower cover up and back.
2. Remove battery for right side actuator, or remove
washer jar and bracket for left side actuator re
moval.
3. Remove front and rear hoses on actuator. Fig. 17-Actuator Assembly Camaro
Vacuum Relay-All Fig. 18 3. Remove vacuum hoses attached to tank.

Replacement 4. Place vehicle on hoist.
1. Raise hood. 5. From underside of left fender skirt remove two 2
2. Gently remove four 4 hoses from relay. attaching bolts and lift off tank.
3. Remove two 2 screws attaching vacuum relay and 6. Install new tank in reverse order of removal proce
lift relay from engine compartment. dure and check out operation of headlamp covers,
4. Install vacuum relay in reverse order of removal with applied vacuum and engine off.
and check operation of headlamp covers with applied
vacuum. Corvette
NOTE: Reinstall color coded hoses on proper Replacement

fittings. Fittings will be noted as R-Y-G letters 1. Raise hood.
on Chevrolet and Camaro. Corvette connectors 2. Remove power brake booster and master cylinder.
have molded R-Y-G letters and color striped See Section 5.
3. Remove vacuum hoses from tank noting color stripe
hoses.
and location of hoses. Tape hose ends to keep out
contaminents.
4. From underside of left fender skirt remove screw
assemblies retaining vacuum tank.
5. Reaching inside engine compartment, lift out tank
with integral brackets.
INSTRUMENT 6. Install tank in the reverse order of removal proce
dure.
Vacuum Hose Routing Fig. 19

The vacuum hose routing is similar on all three ve
hicles Corvette, Camaro Rally Sport and RPO Chev
rolet.
Many vacuum hoses are color stripped and bundeled on
Corvettes for ease of assembly. Replacement hoses
must not be pinched in routing. Actuator to relay valve
VALVE hoses are an exact length for each side.
ACTUATOR
Vacuum hoses connect the following headlamp system
components: manifold vacuum to check valve, check valve
to vacuum tank, check valve to headlamp switch, head
lamp switch to relay valve, vacuum tank to relay valve,
ACTUATOR relay valve to closed side of actuator, relay valve to open
side of actuator and manual control valve to relay valve- -
Corvette.
REAR LIGHTING
Fig. 18-Vacuum Relay Installation Typical
TAIL, STOP, DIRECTIONAL AND BACKUP LAMPS
Vacuum Tank Bulb Replacement Figs. 20 and 21
Chevrolet 1. Remove lens retaining screws and disengage lens
from lamp.
Replacement 2. Replace bulb and check operation of unit.
1. Raise hood. 3. Install lens and retaining screws.
2. Remove vacuum hoses from tank.
Chevrolet-Except Station Wagon Fig. 20
NOTE: Record hose strip color and location
on tank. Housing Replacement
1. Open trunk and disconnect pigtail connectors of lamps
3. Remove two 2 bolts from outside radiator shroud just inside.
and lift vacuum tank from engine compartment. 2. Poke sealing grommets and lamp connectors through
4. Replace vacuum tank and components in the reverse trunk floor pan.
order of removal. 3. Remove lamp lens from bumpc" face.
5. Operate headlamp covers by vacuum. 4. Lower rear bumper. See Section 14.
5. From underside of bumper remove screws retaining
Camaro lamp to be removed.
6. Lift out lamp assembly and transfer needed compo
Replacement nents to new lamp housing before installation.
1. Raise hood and remove washer jar and bracket. 7. Reverse removal procedure when installing replace
2. Remove 2 screws attaching vacuum relay to tank. ment lamp housing.
TO INTAKE
LIGHT SWITCH
LEGEND
RED
GREEN fr
YELLOW VA
WHITE 8&
NONE I
Fig. 19-Vacuum Hose Routing Typical
Chevelle, Camaro, Chevy II, Corvette and 5. Position assembly and install retaining screws. On
Chevrolet Wagon Corvette models make sure ground wire is properly
See Figure 21 for detailed description of removal and installed.
installation of the rear lamp housings. 6. Check operation of lamp assembly.
Bulb Replacement
LICENSE PLATE LAMP SERVICE 1. Remove lens retaining screws and lens.
Lamp Housing NOTE: On Camaro models loosen housing re

taining screws.
1. Remove the lamp assembly retaining screws and re
move lamp assembly from mounting location rear 2. Remove and replace bulb.
bumper center face bar most models. 3. Position lens and install retaining screws.
2. Disconnect lamp wiring from chassis harness con
nector inside trunk on some models. AUTOMATIC TRANSMISSION
3. Force grommet and wiring down through body open QUADRANT LAMP REPLACEMENT
ing where applicable and remove assembly from
vehicle. Chevrolet and Chevelle
4. To install replacement unit, insert grommet and wir The quadrant is a part of the instrument panel, and the
ing through body opening where applicable and con illumination bulb is serviced with other instrument panel
nect wiring to chassis harness. illumination bulbs.
Fig. 20-Rear Lighting Assembly-Chevrolet Except Wagon
CORVETTE
I -
r
CHEVROLET WAGON
CHEVELLE SEDAN
CHEVY II
Fig. 21-Rear Light Assemblies Except Chevrolet
Chevy II and Camaro Fig. 22

1. Remove two screws attaching retainer and dial to
directional signal housing; remove retainer and dial
face from housing.
2. Remove cap and bulb.
3. Replace bulb and cap, then position dial and retainer
to housing and install attaching screws.
SEAT SEPARATOR CONSOLE LAMPS

Compartment Lamp Replacement Fig. 23
1. Remove pry up switch assembly from console
opening in the instrument compartment.
2. Remove bulb from the socket.
3. Replace bulb and install switch assembly in console
opening.
Courtesy Lamp Replacement Fig. 23

1. Remove two screws and lens at rear of console.
2. Remove bulb from retainer.
3. Replace the bulb, position the lens and install attach-
ing screws.
Quadrant Lamp Replacement Fig. 23

1. Remove Dial Quadrant Trim plate retaining screws
and lift trim plate assembly from console opening. Fig. 22-Dial Quadrant Assembly Typical
Fig. 23-Seat Separator Wiring Chevelle
2. Disconnect lamp socket from the retainer and re

move bulb from the socket.
3. To install, insert bulb into the socket and snap the
socket assembly into the retainer.
4. Position the trim plate assembly into the console
opening and install the retaining screws.
IGNITION SWITCH REPLACEMENT Figs. 24 and 25

Chevrolet, Chevelle, Camaro
1. Raise hood and disconnect the ground cable from the
battery.
2. Chevelle only:
a. Remove ash tray and retainer.
b. Remove radio knobs, nuts, connectors, bracket
and radio.
3. Remove lock cylinder by positioning switch in "ACC"
position and inserting wire in cylinder face small
hole. Push in on wire to depress plunger and con
tinue turning key counter-clockwise until lock cyl
inder can be removed. Fig. 25-Back of Ignition Switch
4. Remove the ignition switch bezel nut and pull the
ignition switch out from under the dash.
5. Using a screw driver unsnap the "theft resistant"
2. Remove screws securing "CORVETTE" cover plate
locking tangs on the connector from the position on
in top center of cluster assembly.
the switch shown in Figure 24. Unplug the connector.
6. Snap the connector into the new ignition switch. NOTE: Steps 2 through 8 of other ignition
7. Place the switch into position from behind the in switch replacement apply to Corvette.
strument panel and install the ignition switch bezel
3. Complete installation of the ignition switch in the re
nut from the front.
verse order of removal and connect ground cable to
8. Install the lock cylinder.
battery.
NOTE: Reinstall radio, ash tray and retainer
in Chevelle. LIGHTING SWITCH REPLACEMENT Fig. 26
9. Install the ground cable on the battery and lower the
hood.
NOTE: Factory Air Conditioned Chevy II’s re
Corvette quire the removal of the parking brake and air
conditioning control head before proceeding fur
1. Tip driver’s seat back forward, open battery stowage
ther.
compartment and disconnect ground cable from the
battery. 2. Pull control knob of headlamps to "ON" position.
Fig. 24-Unlocking Ignition Switch Connector Fig. 26-Shaft Retainer
NOTE: Corvette only. . . remove screws at 4. Remove retaining nut and withdraw wiper switch
top and left sides of instrument panel and pull from behind console.
panel forward for access to light switch. 5. To install, reverse removal procedure and check
3. Reach up under instrument panel and depress the operation of wipers.
switch shaft retainer, then remove knob and shaft
assembly. Corvette
4. Remove ferrule nut and switch assembly from in 1. Disconnect battery ground cable.
strument panel. 2. Remove screws from upper portion of center console
NOTE: Remove vacuum hoses from Corvette; labeled "Corvette".
also Camaro and Chevrolet optional headlamp 3. Remove wiring connector from switch.
switches. Tag location of hoses for assembly. 4. Remove switch and plate from center console.
5. Grasping the switch arm with a small pair of lock
5. Disconnect the multi- contact connector from the pliers, gently pry the knob off switch then remove
lighting switch. A screw driver may be inserted in screws securing the switch.
the side of the switch to pry the connector from the 6. The first step in replacing the switch is to insert a
switch. small rod in the switch arm before attempting to
6. Connect the multi-contact connector to the replace push the knob on the arm outside of the trim plate,
ment switch. Connect vacuum hoses to headlamp then follow Steps 1 through 5 in the reverse order
switches and complete switch replacement in the re of removal.
verse order of removal.
STOP SWITCH REPLACEMENT Figs. 28, 29 and 30
WIPER SWITCH REPLACEMENT Fig. 27
1. Disconnect wiring harness connector at switch.
Chevrolet, Camaro and Chevy II 2. Remove retaining nut, if so equipped, and unscrew
switch from bracket.
Chevy II NOTE: On Corvettes remove screw holding
a. Remove parking brake assembly, see Section 5. switch bracket to brake pedal housing.
b. Remove heater control assembly, see Section lÀ. 3. Switch installation.
c. On air conditioned models it is necessary to re a. Chevelle models; depress brake pedal and push
move left air conditioning outlet duct for accessi new switch into clip until shoulder bottoms out
bility to rear of switch. fig. 28.
Chevelle b. Corvettes; align switch bracket on brake pedal
a. On air conditioned models it is necessary to re housing and install screw fig. 29.
move left air conditioning outlet duct for accessi c. All other models; install inboard adjusting nut,
bility to rear of switch. install switch through bracket and install retain
2. Remove connector plug from rear of switch. ing nut.
3. Loosen set screw and pull knob from switch shaft. 4. Plug connector onto switch fig. 30.
BEZEL
A
KNOB
.38-.64"
VIEW A
Fig. 27-Wiper Switch Replacement Typical Fig. 28-Stoplight Switch Chevel Ic
Fig. 29-Stoplight Switch Corvette Fig. 31-Dimmer Switch Typical
2. Remove two screws retaining dimmer switch to toe

pan.
3. Connect multi-plug connector to new switch and
check operation. Install new switch to toe pan with
two screws. Replace floor mat.
BACKING LAMP SWITCH REPLACEMENT

Located on Mast Jacket Fig. 32
1. Disconnect wiring connector at switch terminals.
2. Remove switch attaching screws and switch from
mast jacket.
3. Position new switch to mast jacket, install the re
taining screws and connect wire connector to switch.
NOTE: Position gear shift in neutral before

assembling switch to mast jacket.
4. Check operation of switch.
Located on Transmission Fig. 33
1. Place vehicle on hoist.

2. Disconnect switch wiring from harness wiring at
in- line connector.
3. Remove bolt retaining wiring attaching clip to trans
Fig. 30-Stoplight Switch Chevrolet, Camaro, Chevy II mission.
4. Remove wire clip retaining reverse lever rod to
5. Check switch for proper operation. Electrical con switch.
tact should be made when the brake pedal is de 5. Remove screws retaining switch and shield assembly
pressed 3/8" to 5/8" from fully released position. to transmission, remove switch.
DIMMER SWITCH REPLACEMENT Fig. 31 NOTE: Do not remove transmission-to-bracket

retaining bolts.
1. Fold back upper left corner of front floor mat, dis
engage connector lock fingers, and disconnect multi- 6. To install, reverse removal procedure and check
plug connector from dimmer switch. switch for operation in transmission reverse range.
TO BACK UP
LAMP SWITCH
TO STOP LAMP.
SWITCH
Fig. 32-Backup Lamp Switch on Mast Jacket Chevelle Fig. 33-Backup Switch Automatic Transmission Installation
NEUTRAL SAFETY SWITCH REPLACEMENT 6. Remove clamp and pin, connect wiring and check op
eration of switch.
Column Shift Fig. 34 7. Install indicator lamps, housing, lens, ash tray and
trim plate assembly.
1. Disconnect wiring harness connectors at switch ter
minals. Corvette Fig. 35
2. Remove switch retaining screws and switch from
mast jacket. 1. Disconnect shift control lever arm from the control
3. To install, position shift lever in drive and locate rod.
lever tang against transmission selector plate. 2. Remove the shift control knob.
4. Align slot in contact support with hole in switch and 3. Remove Trim Plate retaining screws and trim plate
insert pin 3/32" dia. to hold support in place. assembly.
Switch is now in drive position. 4. Remove control assembly retaining screws See
5. Place contact support drive slot over shifter tube Section 1.
drive tang and tighten screws. Remove clamp and 5. Remove control assembly from the seal.
pin. 6. Remove switch retaining nuts and switch from the
6. Connect wiring harness to switch terminals and control assembly.
check operation of switch. 7. To install, position gearshift in "Drive" position
align hole in contact support with hole in switch and
Floor Shift insert pin 3/32" dia. to hold support in place.
8. Place the contact support drive slot over the drive
Chevrolet, Chevelle, Chevy II and Camaro Fig. 34 tang and tighten switch mounting screws.
9. Connect wiring harness to switch wiring.
1. Position shift lever in drive position. Remove ash 10. Install trim plate assembly and shift lever control
tray, trim plate assembly, and indicator lens and knob.
housing from console. 11. Connect shift lever arm to the transmission control
2. Disconnect bulbs from housing. Disconnect multiple rod.
connector at switch terminals or on Camaro models
from the wiring harness at the in-line connector. PARKING BRAKE ALARM SWITCH REPLACEMENT
3. Remove switch retaining nuts and switch.
4. To install new switch, clamp pawl rod against contact Corvette Fig. 36
point of detent and align slot in contact support with
drive hole in switch and insert a pin 3/32" dia. to 1. Remove seat belt retainer and parking brake cover
hold in place. Switch is now in drive position. assembly from rear center console.
5. Position switch to lever and bracket assembly with 2. Disconnect wire from brake alarm switch.
lever engaged in contact support and install retain 3. Remove retaining screw and switch from reinforce
ing nuts. m ent.
MODELS
CONTACT SUPPORT
DRIVE SLOT IN LINE
VIEW A WITH HOLE IN SWITCH
LEVER
NEUTRAL
SWITCH LEVER FLOOR SHIFT
Fig. 34-Neutral Safety Switches
4. Position new switch to reinforcement and install re 4. Insert wire and terminal into new switch.
taming screw. 5. Push switch into place and install bulb by setting it
5. Connect switch wire and check operation of switch. in place, depressing and turning it clockwise.
6. Install cover assembly.
Chevrolet, Chevelle, Chevy II and Camaro CIGARETTE LIGHTER REPLACEMENT
Figs. 37 & 38 Chevrolet, Camaro and Chevy II Fig. 39
1. Disconnect wiring connector at switch terminal.
2. Remove nut and lock washer or retaining bolt and 1. Disconnect ground cable from battery under hood.
disengage switch from brace. Chevy II
3. To install, reverse removal procedure. a. Remove radio knobs, bezels, nuts, aerial, elec
trical connections and rear brace, then slip radio
INSTRUMENT PANEL COMPARTMENT out.
2. Remove connector from rear of lighter housing.
LAMP/SWITCH REPLACEMENT 3. Unscrew retainer from rear of housing assembly and
1. Disconnectbattery ground cable. disengage lighter unit from panel.
2. Reach into glove box, depress bulb in end of switch 4. To install, reverse removal procedure.
and turn counter- clockwise to remove bulb.
3. Remove switch from socket. Carefully detach wire Chevelle
and terminal from switch.
1. Disconnect ground cable from battery under hood.
NOTE: On some model switches, the wire and 2. Remove ash tray and retainer.
terminal cannot be detached from the switch 3. Remove radio knobs, bezels, brace, aerial, connec
making it necessary to cut and splice the switch tor and receiver.
wire. 4. Remove air conditioning control head.
A - PART OF LEVER
BRACKET ASM.
Fig. 35-Corvette Neutral Safety Switch Fig. 36-Parking Brake Alarm Switch Corvette
Fig. 37-Parking Brake Alarm Chevrolet, Camaro and Chevy II
Fig. 38-Parking Brake Alarm Chevelle

5. Disconnect automatic transmission steering column
mounted control cable fastener, see Section 9. Corvette Fig. 40
6. Lower steering column per Section 9 and protect
surface with clean cloth. 1. Disconnect ground cable from battery.
7. Remove instrument panel attaching screws, including 2. Remove vent control set screws and gear shift trim
underside of panel, then tilt panel out from top plate secured by screws.
enough to gain access to lighter connector and re 3. Compress clip for lighter lamp and unplug connector
tainer. from beneath lighter housing.
8. Unscrew retainer from rear of housing assembly and 4. Unscrew retainer from rear of housing assembly and
disengage lighter unit from panel. disengage lighter unit from trim plate.
9. To install, reverse removal procedure. 5. To install, reverse removal procedure.
Fig. 39-Cigarette Lighter Installation Typical Fig. 40-Cigarette Lighter Corvette
CHEVROLET INSTRUMENTS AND GAUGES

INDEX
Page Page
General Description 12-23 Tachometer 12-24
Service Operations 12-23 Clock 12-24
Instrument Cluster 12-23 Ammeter 12-25
Instrument Cluster Lamps 12-23 Temperature Gauge 12-25
Printed Circuit 12-23 Oil Pressure Gauge 12-25
Speedometer . 12-24 Oil Pressure Indicator 12-25
Speedometer Cable 12-24 Generator Indicator 12-26
Fuel Gauge 12-24 Temperature Indicator 12-26
GENERAL DESCRIPTION
The new cluster contains three rectangular housings, The brake warning light serves a dual purpose. It
including fuel gauge, speedometer and electric clock. The functions as an indicator when the parking brake is ap
clock is standard equipment for Caprice models only. A plied and also warns if a malfunction loss of hydraulic
new medallion is provided in the accessory clock housing pressure should occur in the brake system. The two
for Biscayne, Bel Air and Impala Series. Green lettering separate switches, which provide the signal to operate the
on black background identifies the instruments. Instru indicator, are located at the parking brake support and in
ment pointers are orange except the green sweep hand of the hydraulic brake line at the master cylinder. Service
the clock. Tell-tale lamps for oil, generator, brake and of the brake pressure differential switch unit at the
hot indicators are located below the speedometer housing master cylinder is described in Section 5 of this manual.
with silhouetted lettering in red lens. All indicator and cluster illuminating lamps may be
An optionally available instrument cluster provides replaced without removing the cluster from the vehicle.
special instrumentation available for all V-8 ‘engine The bulbs are installed in plastic holders which lock into
equipped vehicles. The cluster arrangement, similar in the cluster housing and make contact with the printed
appearance to the standard cluster, contains oil, temper circuit.
ature, fuel and battery gauges located in the speedometer Regular maintenance is not required on the instrument
housing. Tell-tales for L.H. & R.H. turn, brake, bright cluster or its components other than maintaining clean,
and battery are below the speedometer gauge housing. tight electrical connections, replacing defective parts and
The tachometer utilizes the fuel gauge housing of the keeping the speedometer cable properly lubricated.
standard cluster. The clock remains in the R.H. housing.
SERVICE OPERATIONS
INSTRUMENT CLUSTER 8. After all disconnects are made, tip cluster top for
ward and remove from vehicle.
Removal and Installation Fig. 41
9. Reverse removal procedure for installation.
2. Unplug forward wiring harness connector from fuse Instrument Cluster Lamp Replacement
panel under hood.
3. Remove fuse panel from firewall. Figs. 43 and 44
4. Remove eight screws retaining instrument cluster to
1. Rotate socket counter-clockwise to remove from
instrument panel.
rear of cluster housing.
5. Remove screw retaining column mounted automatic
2. To remove bulb, if socket is black color, pull bulb
transmission pointer cable from mast jacket, see
straight out. If socket is gray color, depress and
Section 9.
rotate bulb, then pull out.
6. Protect mast jacket to prevent scratching when re
3. Install replacement bulb in socket, pressing inward
moving cluster assembly.
to lock in place.
7. Reaching behind cluster disconnect speedometer ca
4. Insert socket into housing, with lugs entering notches
ble, chassis harness connector, clock, speed warning
in case, and rotate clockwise to lock in place.
device connections, defogger, convertible top or tail
gate switches and vacuum hose connections, if so
Printed Circuit Replacement Figs. 43 and 44
equipped.
NOTE: On models with gauge pack, disconnect 1. Remove instrument cluster as previously described
oil pressure line also. in this section.
BUZZER
CABLE
ASSY.
CONTROL
KNOB
ASSY.
Fig. 41-Instrument Cluster Installation Fig. 42-Speed Warning Device Typical
2. Remove all cluster illuminating and inaicator lights NOTE: If old cable is broken it may be nec
from cluster housing. essary to remove lower piece from transmis
3. Remove fuel gauge and clock terminal nuts securing sion end of conduit.
printed circuit housing.
4. Remove hex head screws retaining printed circuit to 2. Lubricate the lower 3/4 of cable with speedometer
the cluster housing and remove the printed circuit. cable lubricant and push the cable into the conduit.
5. To install, reverse removal procedure. Connect the upper end to the speedometer head and
CAUTION: The retaining screws and terminal road test vehicle for proper speedometer operation.
DO NOT KINK CABLE HOUSING
nuts are part of the grounding circuit and must
be installed to proyide the proper ground con- Fuel Gauge or Tachometer Replacement
nections for the printed circuit.
NOTE: The tachometer is a self- contained, all
transistor unit requiring very little service
Speedometer Replacement other than keeping the terminal nuts clean and
tight. The unit is not serviceable and must be
1. Remove instrument cluster as previously described
in this section. replaced, if defective.
2. Remove screws retaining rear cover to the cluster 1. Remove cluster lamps from gauge cover plate and
assembly. remove terminal nuts attaching circuit to gauge.
3. Remove screws retaining speedometer to the housing 2. Carefully move printed circuit away from gauge and
and remove speedometer from rear cover. remove screws retaining gauge assembly to the
NOTE: Speedometer assembly servicing should cluster housing.
be performed by an authorized AC Speedometer 3. Remove gauge assembly from cluster housing and
Service Station. remove terminal nuts attaching gauge to the cover
plate.
4. To install, reverse the removal procedure. DO NOT
KINK CABLE HOUSING. NOTE: Observe carefully the stack up of the
internal parts of the fuel gauge assembly.
Speedometer Cable 4. To install, reverse removal procedure.
Replacement or Lubrication Clock Replacement

1. Remove clock set shaft knob at front of console.
1. Disconnect the speedometer cable from the speed 2. Remove cluster lamps from cover, circuit attaching
ometer head. Remove the old cable by pulling it out screws, and terminal nuts at circuit to gauge attach
from speedometer end of conduit. ing points.
Fig. 43-Instrument C luster Connections
5. Fuel Gauge 9. "Bright" Indicator

1. Clock Knob Assembly
2. Instrument Cluster Lamps 6. L.H. Directional 10. "Oil Press" Indicator
Indicator 11. Clock Cover
3. R.H. Directional
Indicator 7. "Hot" Indicator 12. Clock Assembly
8. "Brake" Indicator 13. Instrument Panel Connector
4. "Gen" Indicator
3. Move printed circuit away from gauge and remove 3. Remove gauge assembly backing plate retaining
screws retaining gauge or clock to the cluster screws and, remove gauge assembly from cluster
housing. housing.
4. Remove unit from housing and cover plate from 4. Remove terminal nuts and/or screws retaining gauge
gauge unit. to the backing plate and separate plate from the
5. To install, reverse removal procedure. gauge.
Ammeter,Temperature and Oil Pressure
Oil Pressure Indicator
Gauges Replacement
If the light does not come on when the ignition switch is
1. Remove instrument cluster as previously described turned on, or if the light comes on and remains on alter
in this section. the engine is started, one or more of the following condi
2. Remove instrument lamps, attaching screws or nuts tions is indicated:
and wiring connections as required. . Low oil pressure
10
2
2 6 2
Fig. 44-Optional Gauge Cluster
1. Temperature Gauge 4. Ammeter Gauge 7. Tachometer 10. Oil Pressure Fitting

2. Instrument Cluster Lamp 5. Fuel Gauge 8. "Brake" Indicator 11. Chassis Harness Connector
3. R. H. Directional Indicator 6. L. H. Directional Indicator 9. "Bright" Indicator 12. Printed Circuit
* High engine temperature If indicator light does not go out at engine idle speed,
* Defective wiring or switch refer to Charging Systems under Engine Electrical, Sec
tion 6Y.
Sending Unit Replacement
1. Disconnect wiring harness connector from sender Temperature Cooling System Indicator
unit terminal located in block above starter on L- 6
The temperature indicator circuit consists of two re
engines and at left front of distributor on V-8 en
zu otely located units, indicator gauge and engine sender
gines.
unit. The indicator gauge, located in the instrument
2. Remove sender unit using Tool J-21757 or 12 point
panel, consists of a red light which will indicate an over
socket, replace with new unit and check operation.
heated engine condition.
Generator Indicator Engine Sender Unit Replacement
1. Ignition on, Engine not Running and Telltale Light 1. Relieve coolant system pressure by loosening radia
Off. tor cap.
* Indicator bulb burned out, replace bulb. 2. Remove sender unit locatpd in the left cylinder head
* Open circuit or loose connection in the telltale light on V-8 engines, and in the cylinder head near an ex
circuit. haust port on L-6 engines. Replace with new unit.
2. Telltale Light Stays on after Engine is Started. 3. Check coolant system level and operation of unit.
CHEVELLE INSTRUMENTS AND GAUGES

INDEX
Page Page
General Description 12-27 Speedometer Cable 12-28
Service Operations 12-27 Tachometer 12-30
Instrument Panel 12-27 Indicator Lights 12-30
Instrument Cluster 12-27 Oil Pressure Indicator 12-30
Fuel Gauge, Ammeter, Temp and Clock 12-27 Generator Indicator 12-30
Speedometer 12-28 Temperature Indicator 12-30
GENERAL DESCRIPTION
The Chevelle instrument panel and gauge cluster are transmissions and column mounted shift controls, the
new for 1968 with the cluster contoured in an unusual shift quadrant is mounted in the cluster housing, just
shallow concave "V" for good visibility and accessibility. above the steering column.
Instruments and tell-tale lights are housed in two large An instrument cluster gauge package is available on
rectangular recesses symmetrically arranged over and to SS 396, Custom El Camino, and Malibu Sport Coupe and
either side of the steering column. Recessed controls Convertible models with V-8 engines. The option re
are located high on the cluster face plate. Radio pro places the standard tell-tale lights with oil and tempera
vision, heater controls, and ash tray are stacked at the ture gauges and an ammeter. In addition a tachometer
right side of the cluster within convenient reach of the is mounted between the instrument cluster bezels.
driver. For vehicles equipped with optional automatic
SERVICE OPERATIONS
INSTRUMENT PANEL ASSEMBLY 2. Install all connectors at back of cluster and clips
holding harness wire to top of cluster housing, then
Instrument Cluster Figs 45 and 46 connect oil pressure pipe fitting to rear of oil pres
sure gauge if so equipped.
Removal
3. Lift instrument panel onto dash and reaching behind
1. Disconnect ground cable from battery.
instrument panel, connect speedometer housing nut.
2. Remove ash tray and retainer.
4. Align instrument panel in dash and fasten with screws
3. Remove radio knobs, nuts, electrical connections,
at top, bottom and sides.
aerial plug and radio rear support then lift radio out.
5. Attach speedminder, defogger or tail gate control
4. Remove heater control screws then push control head
switches, if so equipped, to underside of instrument
out of instrument panel.
panel.
5. Lowering steering column, see Section 9. Note re
6. Attach steering column in place, see Section 9. Note
moval of automatic transmission indicator cable lo the attachment of the automatic transmission indica
cated on steering column, if so equipped. tor cable located on the steering column, if so
6. Protect steering column top surface with a cloth. equipped.
7. Remove instrument panel retaining screws at top,
7. Install heater control in place and attach with screws.
sides and bottom of panel, also remove any attach 8. Install radio and support bracket, aerial plug elec
ments to underside of panel such as speedminder trical connections. Attach radio to instrument panel
stem, defogger or tail gate control switch.
with nuts and install knobs.
8. Lift loosened instrument panel up and back slightly,
9. Install ash tray retainer and tray.
reach behind cluster and remove speedometer cable
housing retaining nut, then support instrument panel 10. Connect the ground cable to the battery and lower
on protected steering column. hood.
9. Remove clips at top of instrument cluster rear cover
and remove all connectors at back of cover and oil
pressure pipe fitting from rear of oil pressure gauge Clock, Fuel, Oil, Temperature, and Ammeter Gauges
if so equipped.
10. Remove five screws securing twin window cluster See Figure 46
to back of instrument panel and remove cluster from
instrument panel. Replacement
Installation 1. Remove instrument cluster assembly as previously
1. Install instrument cluster on back of instrument panel outlined in this section.
and secure with five screws. 2. Remove clock stem set knob from lens.
CHEVROLET CHAS5I5 SERVICE MANUAL
Fig. 45-Instrument Cluster Removal
3. Remove screws retaining right rear cover to in- 5. To install, reverse removal procedure. DO NOT
strument cluster rear housing. KINK CABLE HOUSING.
4. Remove clock or gauge attachment and replace clock
or gauge as necessary. Speedometer Cable
Speedometer Replacement Replacement or Lubrication

1. Disconnect battery ground cable. 1. Disconnect the speedometer cable from the speed
2. Remove instrument cluster assembly as previously ometer head. Remove the old cable by pulling it out
outlined in this section. from speedometer end of conduit.
3. Remove screws 8 attaching cover to rear of cluster
NOTE: If old cable is broken it may be neces
housing. sary to remove lower piece from transmission
4. Remove two screws attaching speedometer assembly
end of conduit.
to cluster cover and carefully remove speedometer
head. 2. Lubricate the lower 3/4 of cable with speedometer
cable lubricant and push the cable into the conduit.
NOTE: Servicing of the speedometer assembly Connect the upper end to the speedometer head and
should be performed by an authorized AC speed road test vehicle for proper speedometer operation.
ometer service station. DO NOT KINK CABLE HOUSING.
Fig. 46-Instrument Cluster Assembly

13. Clock Assembly
1. R.H. Directional Indicator 5. "Temp" Indicator 9. "Batt" Gauge Connector 14. Clock Connector
2. Instrument Cluster Lamp 6. "Oil" Indicator 10. Brake Alarm Indicator 15. Cover
3. "Bright" Indicator 7. L.H. Directional Indicator 11. "Temp’ Gauge Connector 16. Plate
"Gen" Indicator 8. Fuel Guage Connector 12. Oil Pressure Gauge Fitting 17. Tach Conn.
4.
Tachometer Replacement Sending Unit Replacement

1. Disconnect wiring harness connector from sender
NOTE: The tachometer is a self-contained, all
unit terminal located in block above starter on L- 6
transistor unit requiring very little service
engines and at left front of distributor on V- 8 en
other than keeping the terminal nuts clean and
gines.
tight. The unit is not serviceable and must be
2. Remove sender unit using Tool J-21757 or 12 point
replaced, if defective.
socket, replace with new unit and check operation.
in this section. Generator Indicator
2. Remove electrical plug from rear of tachometer.
3. Remove screws retaining tachometer assembly to 1. Ignition on, Engine not running and Telltale Light Off.
cluster rear cover and remove assembly. * Indicator bulb burned out, replace bulb.
4. To install, reverse removal procedure. * Open circuit or loose connection in the telltale light
circuit.
Indicator Light Replacement 2. Telltale Light Stays on alter Engine is Started.
If indicator light does not go out at engine idle speed,
To replace indicator or cluster bulb, unsnap the proper refer to Charging Systems under Engine Electrical, Sec
socket from rear of instrument cluster, remove and re tion BY.
place bulb, and reinsert unit into rear of cluster housing.
NOTE: Instrument panel illumination bulbs lo Temperature Cooling System Indicator
cated directly above the steering column will The temperature indicator circuit consists of two re
necessitate a partial removal of the instrument motely located units, indicator gauge and engine sender
panel as previously outlined in this section. unit. The indicator gauge, located in the instrument
panel, consists of a red light which will indicate an over
Oil Pressure Indicator heated engine condition.
If the light does not come on when the ignition switch is Engine Sender Unit Replacement
turned on, or if the light comes on and remains on alter 1. Relieve coolant system pressure by loosening radia
the engine is started; one or more of the following condi tor cap.
tions is indicated: 2. Remove sender unit located in the left cylinder head
* Low oil pressure on V-8 engines, and in the cylinder head near an ex
* High engine temperature haust port on L- 6 engines. Replace with new unit.
* Defective wiring or switch 3. Check coolant system level and operation of unit.
CORVETTE INSTRUMENTS AND GAUGES

INDEX
Page Page
General Description 12-31 Temperature Gauge 12-32
Service Operations 12-31 Ammeter/Oil Pressure Gauges 12-32
Instrument Clusters 12-31 Clock 12-32
Speedometer/Tachometer Service 12-32 Seat Belt and Door Ajar Indicators 12-32
Fuel Gauge 12-32
GENERAL DESCRIPTION
The instrument panel for the 1968 Corvette continues The recessed center instrument cluster contains small
the advanced design theme. Instruments are arranged in circular housings for fuel, ammeter, oil pressure and
the center panel and floor console areas. Two large oval temperature gauges. Radio and windshield wiper con
housings in the left-hand panel facing the driver contain trols are also located in the curved cluster.
160 mph speedometer and 7000 rpm tachometer. The floor center console houses the ash tray, heater,
Ignition and lighting switches are also located on the lamp monitoring transmission and optional power window
driver’s side. controls.
SERVICE OPERATIONS
Instrument Clusters 4. Unclip and remove floor console forward trim panel.
5. Pull cluster assembly slightly forward to obtain
Left Hand Side Fig. 47 clearance for removal of speedometer cable housing
nut, tachometer cable housing nut, headlamp and
ignition switch connectors and panel illuminating
Removal and Installation lamps.
1. Disconnect ground cable from battery. 6. Install by reversing removal procedure, being care
2. Lower steering column, see Section 9. ful not to kink the speedometer or tachometer cable
3. Remove screws and washers securing left instrument housings.
panel to door opening, top of dash and left- side of
center instrument panel. Center Instrument Cluster Fig. 48
Removal
1. Disconnect ground cable from battery.
2. Remove screws from right side dash pad per Section
lB.
3. Remove clipped in center floor console forward trim
pads.
4. Remove radio knobs, bezel retaining nuts from the
front.
5. Reaching behind radio, remove aerial, speaker and
electrical connections.
6. Remove rear support from radio and slide receiver
out right side.
7. Remove upper center console trim plate screws and
tip trim plate forward for access to remove wind
shield wiper switch connector. Lift trim plate out
until reassembly.
8. Remove screws at left side of center console.
9. Remove nuts attached to underside of console studs.
See Figure 48.
10. Tilt center console forward and remove oil and
electrical connectors and lamps from rear of con
sole.
11. Lift center console up and forward for removal.
12. Carefully place console on bench for further service
operations.
13. To install the center console in the dash, reverse the
Fig. 47-Instrument Cluster Left Hand Side removal procedure.
duit. Connect the upper end to the speedometer or

tachometer head and road test vehicle for proper
operation. DO NOT KINK CABLE HOUSINGS.
NOTE: It will be necessary to remove the

center instrument panel as previously outlined
before further proceeding with instrument re
movals.
Fuel Gauge
The gasoline fuel gauge circuit consists of an electrical
indicator in the instrument cluster and a float-controlled
rheostat in the fuel tank.
Since the fuel gauge consists of two remotely located
units and connecting wires, it is sometimes difficult to
determine which unit is at fault when the gauge fails to
operate properly. Center gauge pack removal is nec
essary to replace the fuel, gauge.
NOTE: Be sure to check gas gauge fuse in fuse

panel before attempting to trouble shoot for in
operative gauge or tank sending unit.
Temperature Gauge
Fig. 48-Center Instrument Cluster The temperature indicator requires very little service
other than testing for malfunctioning and replacing de
fective units. Cluster must be removed to service tem
Speedometer and/or Tachometer perature gauge.
Do not attempt to repair either the engine unit or the
Removal and Installation gauge. When installing new engine unit, do not use thread
The left-hand cluster must be removed from the ve compound on unit threads, as this will increase electrical
hicle to service the speedometer or tachometer head as resistance of unit and causefaulty reading on gauge.
sembly. With the cluster removed from the vehicle:
1. Remove odometer reset connector and speedminder Ammeter or Oil Pressure Gauge
connector from rear of speedometer head.
2. Remove the three screws fastening the speedometer The ammeter or oil pressure gauge requires very
or tachometer head to back of cluster and carefully little attention other than keeping ammeter terminals
remove speedometer or tachometer head. clean and tight. If the oil pressure control line should
3. Transfer wiper solenoid to rear of tachometer and or become restricted it should be blown out or replaced.
speedminder buzzer to the rear speedometer head The cluster must be removed to service these gauges.
and fasten appropriate head to cluster bezel.
4. Connect odometer and/or speedminder reset cable to Clock
rear of speedometer head.
5. Connect the left-hand cluster as previously described Replacement
in this section. 1. Remove clock set shaft knob retaining screw and knob
from set shaft.
Cable Replacement or Lubrication 2. Remove screws attaching clock to rear of housing
1. Disconnect th cable from the speedometer or ta and remove clock from rear of cluster housing.
chometer head. Remove the old cable by pulling it 3. InstaU clock in the reverse order of removal.
out from speedometer end of conduit.
Seat Belt and Door Ajar Indicators
NOTE: If old cable is broken it may be nec
essary to remove lower piece from transmission Seat belt indicator is a thermal switch with a push re
or distributor end of conduit as applicable. set. The switch is powered from the fuel gauge terminal.
The switch is replaced as a unit.
2. Lubricate the lower 3/4 of cable with AC speedom Door ajar indicator is a bulb with a remote door jamb
eter cable lubricant and push the cable into the con- switch located on the lock pillar.
CAMARO INSTRUMENTS AND GAUGES

INDEX
Page Page
General Descriptkrn 12-33 Fuel Gauge 12-34
Service Operations 12-33 Ammeter 12-34
Instrument Cluster 12-33 Temperature Gauge 12-34
Instrument Lamps 12-33 Oil Pressure Gauge 12-34
Printed Circuit 12-33 Fuel Warning Unit 12-34
Speedometer 12-34 Oil Pressure Indicator 12-34
Fuel Gauge 12-34 Generator Indicator 12-35
Tachometer - Clock 12-34 Temperature Indicator 12-35
Seat Separator Instrument Console 12-34
GENERAL DESCRIPTION
The standard Camaro instrument cluster assembly con the upper brace rod anchor plate. The bulbs are in
sists of two circular units which house the speedometer stalled in plastic sockets which lock into the cluster
and fuel gauge assemblies. The oil pressure, left-hand housing and make contact with the printed circuit.
directional and brake warning indicators are located in A low level fuel warning system is a special feature
the face of the speedometer bezel while generator, tem available with the floor console gauge pack. This sys
perature and right-hand directional indicators are grouped tem includes an indicator lamp in the dash cluster and a
with the fuel gauge unit. The high beam indicator is lo semi-conductor unit senses the change in electrical re
cated between the cluster bezels. sistance of the fuel system circuitry as variations in’ fuel
A special instrumentation package is available with the level occur. The sensing device is replaced as a unit if
eight-cylinder engine and center floor console combina found defective.
tion. The special cluster includes: coolant temperature, The brake warning light serves a dual purpose. It
oil pressure, fuel and ammeter gauges, mounted forward functions as an indicator when the parking brake is ap
on the seat separator console; an integrated tachometer- plied and also if there is a malfunction loss of hydraulic
clock unit in the right circular housing of the dash in pressure in the brake system. Switches which provide
strument cluster; and a low fuel level indicator replacing the signal to operate the light are located at the parking
the oil pressure indicator lamp in the instrument cluster. brake assembly and at the brake master cylinder in the
The instruments and gauges, may be serviced only hydraulic lines. Service of the brake pressure differen
after the instrument cluster is removed from the vehicle. tial switch unit is covered in Section 5 of this manual.
Indicator and cluster lamps except for the high beam Regular maintenance is not required on the instrument
indicator may be replaced without removing the cluster cluster or its components other than maintaining clean,
assembly. Partial cluster removal is necessary when tight electrical connections, replacing defective parts and
replacing the high beam indicator due to its proximity to keeping the speedometer cable properly lubricated.
SERVICE OPERATIONS
Instrument Cluster Figs. 49 and 50 7. To install, reverse removal procedure.
Removal and Installation Instrument Cluster Lamp Replacement

2. Remove mast jacket lower support screws at toe pan. 1. Turn bulb holder counter-clockwise and pull out to
3. Remove mast jacket upper support bolts and allow remove from the cluster housing.
steering wheel to rest on seat cushion. 2. Pull bulb straight out to remove from socket.
CAUTION: Both supports must be detached to 3. Press replacement bulb inward to lock in socket.
prevent distortion of mast jacket. 4. Insert lamp assembly into housing, with lugs on
holder entering notches in housing, and turn clock
4. Remove cluster attaching screws from face 11 panel wise to lock in place.
and partially remove assembly from console opening.
5. Reaching behind cluster assembly, disconnect speed Printed Circuit Replacement
ometer cable, speed warning device if so equipped -
fig. 42 and chassis harness connector at rear of 1. Remove instrument cluster as previously described
panel. in this section.
6. Remove assembly from console opening to a suitable 2. Remove all cluster illuminating and indicator lamps
bench area for required service operations. from housing.
NOTE: If old cable is broken it may be neces

sary to remove lower piece from transmission
end of conduit.
2. Lubricate the lower 3/4 of cable with speedometer
Connect the upper end to the speedometer head and
road test vehicle for proper speedometer operation.
Fuel Gauge Replacement
1. Remove instrument cluster assembly as previously
described.
2. Remove cluster lamps from gauge cover plate,
ground screw and terminal nuts attaching printed
circuit to fuel gauge.
3. Remove three screws retaining gauge assembly to
cluster housing.
4. Carefully move printed circuit away from gauge and
remove gauge assembly from cluster housing.
5. Remove terminal nuts securing gauge to cover plate
and detach gauge unit.
Tachometer-Clock Unit
NOTE: The tachometer-clock is a self con
tained, all transistor unjt requiring very little
service other than keeping the terminal nuts
Fig. 49-Instrument Cluster Removal clean and tight. The unit is not serviceable and
must be replaced, if defective.
in this section.
3. Remove fuel gauge terminal nuts or tachometer re 2. Remove cluster lamps from rear of gauge cover and
taining nuts securing printed circuit to housing. disconnect harness wiring connections from gauge
4. Remove four hex head screws retaining printed cir terminals.
cuit to the cluster housing and remove circuit from 3. Remove three screws retaining gauge to cluster
housing. housing.
5. To install, reverse removal procedure. 4. Move printed circuit away from gauge area and re
move gauge unit from housing.
CAUTION: The retaining screws are part of
5. Remove terminal nuts securing gauge to cover and
the grounding circuit and must be installed to
detach unit.
provide proper connections for the printed cir
cuit.
Seat Separator Instrument Console Fig. 51
Speedometer Replacement
Fuel, Ammeter, Temperature, Oil Pressure Gauges,
Low Fuel Warning Unit
in this section.
2. Remove clock set shalt knob. 2. Remove cover retaining screws 3 and cover from
cluster assembly.
3. Remove eight screws securing cluster housing to
3. Remove three screws retaining each gauge mounting
bezel trim panel. Separate parts carefully observing
stack up of parts. plate to cluster housing.
4. Remove two screws securing speedometer head to 4. Carefully disengage gauge plate from housing and
rear of cluster housing. disconnect oil pipe and all electrical connections at
rear of gauges.
NOTE: Servicing of the speedometer head
NOTE: At this point, with gauge package re
should be performed by an authorized AC Speed
moved from housing all gauges including the low
ometer Service Station.
fuel warning system may easily be serviced.
5. To install, reverse the removal procedure. DO NOT 6. To install assembly, reverse removal procedure.
KINK CABLE HOUSING.
Speedometer Cable If the light does not come on when the ignition switch is
Replacement or Lubrication turned on, or if the light comes on and remains on after
the engine is started, one or more of the following condi
1. Disconnect the speedometer cable from the speed tions is indicated.
ometer head. Remove the old cable by pulling it out * Low oil pressure
from speedometer end of conduit. * Defective wiring or switch
Fg. 50-Instrument C luster Assembly

1. Cluster Lamp 5. Generator Indicator 8. Printed Circuit
2. ‘Bright" indicator 6. R.H. Directional Indicator 9. Chassis Harness Connector
3. Oil Pressure Indicator 7. Temperature Indicator 10. Brake" Indicator
4. L.H. Directional Indicator
Sending Unit Replacement Temperature Cooling System Indicator

1. Disconnect wiring harness connector from sender
unit terminal located in block above starter on L-6 The temperature indicator circuit consists of two re
engines and at left front of distributor on V-8 en motely located units, indicator lamp and sending unit.
gines. The indicator lamp, located in the instrument cluster
2. Remove sender unit. consists of a single red light which will indicate an over
3. Replace with new unit and check operation. heated engine condition.
Generator Indicator
Engine Sender Unit Replacement t
1. Ignition on, engine not running and indicator light off: 1. Relieve coolant system pressure by loosening radia
* Indicator bulb is burned out, replace bulb. tor cap.
* Open circuit or loose connection in the indicator 2. Remove sender unit located in the left cylinder head
light circuit. on V-8 engines, and in the cylinder head near an ex
2. Indicator light stays on after engine is started: haust port on L-6 engines. Replace with new
* If indicator light does not go out at engine idle unit.
speed, refer to Charging System Tests in Section 3. Check coolant system level and operation
6Y, Engine Electrical. of unit.
Fig. 51-Seat Separator Instrument Console
1. Cluster Lamps 4. Ground Wire

2. Ammeter Conn. 5. Oil Gauge Conn.
3. Temp Gauge Conn. 6. Fuel Gauge Conn.
12-39
CHEVY II INSTRUMENTS AND GAUGES

INDEX
Page Page
General Description 1237 Oil Pressure Indicator 12-38

Service Operations 12-37 Generator Indicator 12-38
Instrument Panel 12-37 Temperature Indicator 12-39
Instrument Cluster 12-37 Seat Separator Instrument Console 12-39
Fuel Gauge 12-37 Fuel Gauge
Clock 12-37 Ammeter
Speedometer 12-38 Temperature Gauge
Speedometer Cable 12-38 Oil Pressure Gauge
Instrument Panel Bulbs 12-38 Fuel Warning Unit
Printed Circuit 12-38
GENERAL DESCRIPTION
The Chevy II instrument cluster assembly consists of a and tight electrical connections, replacing defective parts
speedometer, fuel gauge also temperature, generator and and keeping the speedometer cable properly lubricated.
oil pressure indicator lamps. Optionally a clock may be A special instrumentation package is available with the
located to the right of the speedometer head and a ta V-8 engine and floor console combination. The special
chometer to the left of the speedometer. cluster includes coolant temperature, oil pressure, fuel
In addition to the instrument indicator lamps, a brake and ammeter gauges mounted forward on the floor mini
warning lamp is included in the cluster as standard console. A tachometer replaces the fuel gauge on the left
equipment. The indicator is connected to the parking side of the speedometer.
brake and brake pressure differential switches and serves All indicator and cluster illuminating lamps, except the
a dual function. It lights when the parking brake is ap center top bulb above the high beam indicator, may be
plied and also when the brake pedal is applied, if a mal replaced without removing the cluster from the vehicle.
function should occur in the brake system due to a loss of The bulbs are installed in plastic holders which twist-
hydraulic pressure. Servicing of the hydraulic pressure lock into the cluster housing and make contact with the
differential switch is covered in Section 5 of this manual. printed circuit.
Regular maintenance is not required on the instrument
cluster or its components other than maintaining clean
SERVICE OPERATIONS
INSTRUMENT PANEL 7. For installation, reverse removal procedure. DO
NOT KINK CABLE HOUSING.
Instrument Cluster Figures 52 and 53 Fuel Gauge -Optional Tachometer Replacement
in this section.
2. Remove cluster lamps from gauge cover plate and
2. Lower steering column refer to Steering, Section 9,
remove terminal nuts attaching circuit to gauge.
for complete procedure for lowering jacket. 3. Carefully move printed circuit away from gauge and
NOTE: Apply protective material to the mast remove screws retaining gauge assembly to the
jacket to prevent damage to the painted sur cluster housing.
faces. 4. Remove gauge assembly from cluster housing and
remove three terminal nuts attaching gauge to the
3. Remove two screws above front of heater control
cover plate.
securing it to instrument cluster.
4. Remove radio control knobs, washers, bezel nuts and NOTE: Observe carefully, the stack up of the
front support at lower edge of instrument cluster. internal parts of the fuel gauge assembly.
This will allow the radio to remain in the instrument 5. To install, reverse removal procedure.
panel.
5. Remove screws at top, bottom and sides of instru
Clock Replacement
ment cluster securing it to the instrument panel.
6. Tilt console forward and reach behind to disconnect Due to space limitations at the rear of the instrument
speedometer cable, speedminder, electrical plug con cluster clock replacement will require the removal of the
nectors and lift instrument console out of instrument cluster.
panel. 1. Remove ground cable from battery.
12-38 ELECTRICAL-BODY AND CHASSIS
3. Lubricate the lower 3/4 of cable with speedometer

Connect the upper end to the speedometer head and
road test vehicle for proper speedometer operation.
DO NOT KINK CABLE HOUSING.
Instrument Panel Bulbs
Left of Steering Column
1. Remove ground cable from battery.
2. Remove heater control assembly for bulb access,
See Section 1A.
3. Replace bulb in twist socket holder and install heater
control, then emergency brake in the reverse order
of removal.
Right of Steering Column
1. Remove ground cable from the battery.
2. Remove radio, as outlined under clock replacement,
for access to right hand bulbs.
NOTE: All bulbs are accessible except the
center top bulb above the hi-beam indicator bulb.
For this bulb it will be necessary to remove and
replace the instrument cluster.
Printed Circuit Replacement Fig. 53

Fig. 52-Instrument Cluster Removal in this section.
2. Remove all cluster illuminating and indicator lights
from cluster housing.
3. Remove fuel gauge and clock terminal nuts securing
2. Remove instrument cluster as previously described. printed circuit to housing.
3. Remove clock stem set knob at front of cluster. 4. Remove four hex head screws retaining printed cir
4. Remove cluster lamps from rear cluster cover and cuit to the cluster housing and remove the printed
circuit attaching screws from clock area. circuit.
5. Move printed circuit away from clock and remove 5. To install, reverse removal procedure.
screws retaining clock to cluster housing.
CAUTION: The retaining screws and terminal
6. Remove clock from rear of cluster housing.
nuts are part of the grounding circuit and must
be installed to provide the proper ground con:
nections for the printed circuit.
Speedometer Replacement
1. Remove instrument cluster as previously described Oil Pressure Indicator
in this section.
If the light does not come on when the ignition switch
2. Remove screws retaining rear cover to the cluster
is turned on, or if the light comes on and remains on
assembly. Bend ground strap away from cover and after the ‘engine is started, one or more of the following
remove cover. conditions is indicated.
3. Remove screws retaining speedometer to the housing * Low oil pressure
and remove speedometer from rear cover.
* Defective wiring or switch
NOTE: Servicing of the speedometer assembly Sending Unit Replacement
should be performed by an authorized AC Speed 1. Disconnect wiring harness connector from sender
ometer Service Station. unit terminal located in block above starter on L-6
4. To install, reverse the removal procedure. DO NOT engines and at left front of distributor on V-8 en
KINK CABLE HOUSING. gines.
2. Remove sender unit.
Speedometer Cable 3. Replace with new unit and check operation.
Replacement or Lubrication
Generator Indicator
1. Remove radio as previously outlined under clock 1. Ignition on, engine not running and indicator light off:
replacement.
* Indicator bulb is burned out, replace bulb.
2. Disconnect the speedometer cable from the speed
* Open circuit or loose connection in the indicator
ometer head. Remove the old cable by pulling it out
light circuit.
from speedometer end of conduit. 2. Indicator light stays on after engine is started:
NOTE: If old cable is broken it may be neces * If indicator light does not go out at engine idle
sary to remove lower piece from transmission speed, refer to Charging System Tests in Section
end of conduit. 6Y, Engine Electrical.
Fig. 53-Instrument Cluster
Temperature Cooling System Indicator Seat Separator Instrument Console Fig. 51

The temperature indicator circuit consists of two re Fuel, Ammeter, Temperature, Oil Pressure Gauges,
motely located units, indicator lamp and sending unit. Low Fuel Warning Unit
The indicator lamp, located in the instrument cluster is 1. Disconnect battery ground cable.
a single red light, which will indicate an overheated en 2. Remove cover retaining screws 3 and cover from
gine condition. cluster assembly.
3. Remove three screws retaining each gauge mounting
Engine Sender Unit Replacement plate to cluster housing.
1. Relieve coolant system pressure by loosening radia 4. Carefully disengage gauge plate from housing and
tor cap. disconnect oil pipe and all electrical connections at
2. Remove sender unit located in the left cylinder head rear of gauges.
on V-8 engines, and in the cylinder near an ex
NOTE: At this point, with gauge package re
haust port on L-6 engines. Replace with new
moved from housing all gauges including the low
unit.
3. check coolant fuel warning system may easily be serviced.
system level and operation of
unit. 5. To install assembly, reverse removal procedure.
DIRECTIONAL SIGNAL
Directional signal assemblies provide as standard pro Directional Signal Switch Replacement
duction equipment a lane changing feature and hazard
warning system on all model applications. Two different All steering columns except tilt and telescoping.
design switches are used as shown in Figure 54. Major
difference between the two units is that one type has can Chevrolet, Chevelle, Chevy II and Camaro Fig. 55
celling and detent springs which are serviceable, other 1. Disconnect battery ground cable.
wise both units are not repairable and must be replaced 2. Disconnect signal switch wiring from chassis har
as an assembly in service. ness at multiple connector under instrument panel.
Due to the integral design relationship of the signal 3. Remove steering wheel assembly as outlined in Sec
switch and the energy absorbing steering column, refer tion 9, Steering.
ence should be made to Steering, Section 9 of this manual 4. Remove shift lever roll pin and shift lever from
whenever any service operations are performed on the column if applicable.
steering column. The directional signal switch replace 5. Push in hazard warning switch knob and unscrew
ment procedures covered in this section are intended to knob. Remove switch lever arm.
supplement the detail service operations outlined in Sec 6. On Chevy II and Camaro models equipped with auto
tion 9. matic transmission remove column mounted dial in
Special note should be taken of the fact that different dicator housing and lamp assembly if applicable.
signal flasher units are used in Chevrolet models depend 7. Remove mast jacket lower trim cover retaining
ent on the number of lamps to be operated. The hazard screws and remove trim covers.
warning unit, even though an integral component of the 8. On Chevrolet and Chevelle models equipped with the
directional switch assembly, requires the installation of column mounted automatic transmission quadrant,
an additional flasher unit in the fuse panel capable of op remove dial pointer attachment.
erating six lamps simultaneously depending upon vehicle 9. Remove retaining "C" ring from upper steering shalt
series and model. using snap ring remover Tool J-22659 Refer to
A
HAZARD WARNING CANCELLING
STNGS
DETENT
SPRINGS
Fig. 54-Directional Signal Switches
21. Tighten 3 turn signal mounting screws.

22. Remove mast jacket support clamp, position wiring
and install wiring cover and clip, then reinstall mast
jacket mounting bracket assembly.
23. Install "C" ring over steering shaft using snap ring
installer J-22659 refer to Section 9.
NOTE: Be sure retaining ring is completely
seated into groove.
24. Install dial pointer cable on Chevrolet and Chevelle
models equipped with column shift automatic trans
mission if applicable.
25. Install thai indicator and lamp assembly on Camaro
and Chevy II models equipped with column shift auto
matic transmission.
26. Install mast jacket lower trim covers if applicable.
27. Install hazard warning knob and turn signal lever.
28. Install shift lever if applicable.
29. Install steering wheel.
Fig. 55-Standard Steering Column 30. Install multiple connector to switch wiring using old
harness for wire color guide and connect to body
harness connector.
Steering, Section 9. Slide thrust and wave washers 31. Connect battery ground cable and check operation of
from steering shaft. assembly.
10. Loosen three signal switch mounting screws until
Tilt Steering Column Fig. 56
assembly can be rotated counter-clockwise.
Chevrolet, Chevelle and Camaro
NOTE: Do not remove three screws from as
sembly until unit is on the bench. 1. Disconnect battery ground cable.
2. Disconnect directional switch wiring harness from
11. Rotate switch assembly counter- clockwise and pull body harness at multiple connector under instrument
unit from top of mast jacket. Allow unit to hang panel.
from end of column. 3. Remove steering wheel assembly refer to Steering,
12. Remove upper support bracket bolts and bracket Section 9.
assembly. See Section 9 4. Remove preload spring and cancelling cam from end
of shaft.
CAUTION: Do not suspend column by lower
5. Remove shift lever pin and lever from steering col
reinforcement only.
umn except floor shift.
Reinforce column and remove wiring harness pro 6. Remove directional lever screw and lever.
tector and clip, then position bracket and reinstall 7. Push in hazard warning knob and unscrew knob.
bolts finger tight. 8. On Camaro and Chevy II models equipped with auto
13. Remove shift lever bowl from mast jacket and dis matic transmission, remove quadrant dial and lamp
engage from wiring harness. assembly from column.
14. Remove three mounting screws from engagement 9. Remove mast jacket trim covers.
with lockplate. Use care not to lose 3 springs as 10. On Chevrolet and Chevelle models with automatic
screws are removed. transmission, remove quadrant dial pointer attach
15. Disassemble switch and upper bearing housing from ment.
switch cover. 11. Assemble slide hammer Tool J- 6585-1 to turn signal
cover remover Tool J-21486. Place cover remover
NOTE: Directional switch is not repairable
over turn signal cover, tighten clamp, and pull cover
and must be replaced.
from end of column with slide hammer Refer to
16. Insert the upper bearing housing assembly and signal Steering, Section 9.
switch assembly into the cover, feeding the signal 12. Remove three switch mounting screws, noting short
switch wires through the cover. length of top screw.
17. Align signal switch and bearing housing holes with 13. Remove multiple connector terminals using Tool
holes in the cover. Install three mounting screws J-22727 from switch wiring and slide switch from
through the holes. end of column. Note colors of wire insulation in
18. Slide three springs on to screws and place lockplate connector cavities.
in position over screws and springs. Tighten screws 14. To install new switch, feed wiring through the bear
three turns into lockplate. ing housing, around support, and through shift bowl
19. Feed switch wire through the shift lever bowl and and shroud.
place upper end assembly on top of bowl. 15. Feed through wiring protector. If clearance is not
20. Place shift lever bowl and signal switch assembly sufficient loosen mast jacket bracket retaining bolts.
on top of jacket, aligning the tangs on the I.D. of the 16. Insert switch wiring terminals in multiple connector.
lockplate with slots in jacket. Lock upper end of Use old connector and wiring for color guide.
assembly into position by pushing down on cover 17. Position switch and install three mounting screws
assembly and rotating fully clockwise. with short screw in top position.
_
‘
0
-....
‘U a -"‘
*
Fig. 56-Tilt Steering Column
18. Be sure hazard warning switch is pushed in, then Standard and Telescoping Steering Column
install turn signal cover usiqg special Tool J- 21853.
On automatic columns align key in cover with keyway Corvette Fig. 57
in bearing housing. 1. Disconnect battery ground cable.
19. Install turn signal lever, hazard warning knob and 2. Disconnect signal switch harness wiring from chas
tilt lever. sis wiring harness at multiple connector under in
20. Install shift lever and roll pin where applicable. strument panel.
21. Install dial pointer attachment on Chevrolet and 3. Remove steering wheel assembly as outlined in
Chevelle. On Camaro and Chevy II install dial Steering, Section 9.
indicator and lamp assembly. 4. Remove preload spring and cancelling cam.
22. Install trim covers and retaining screws. 5. Remove directional signal lever screw and lever.
23. Install cancelling cam and preload spring. 6. Push in hazard warning knob, unscrew and remove
24. Install steering wheel Refer to Section 9. knob.
25. Connect switch wiring to body harness under instru 7. Remove lower trim cover retaining screws and
ment panel. cover.
26. Connect battery ground cable and check operation of 8. Remove retaining ring, thrust and wave washers
unit. from upper end of shalt.
Fig. 57-Telescoping Column
9. Cut wiring above connector. 13. Install thrust and wave washers and snap lock ring
10. Remove three switch mounting screws, slide switch, in place.
cover and upper bearing housing from column, pull 14, Install turn signal lever and hazard warning knob.
ing wire through protector and escutcheon. 15. Install cancelling cam and upper bearing preload
11. To install replacement switch remove provided spring on steering shaft.
wiring harness connector from switch wiring, as 16. Install steering wheel assembly.
semble upper bearing housing and turn signal switch
into switch cover, then feed wiring through escutcheon NOTE: Be sure directional signal switch is in
and protector until switch can be positioned on mast neutral position before installing wheel.
jacket.
12. With switch positioned on mast jacket, install three 17. Install connector on directional signal wiring har
switch mounting screws. ness and connect to body harness connector.
WINDSHIELD WIPERS AND WASHERS

INDEX
Page Page
Wiper Transmission Assembly 1243 Washer Pump Unit 12-46

Removal and Installation 12-43 Removal and Installation 12-47
Wiper Motor Assembly 1243 Disassembly and Assembly 12-47
Removal and Installation 12-43 Depressed Park 2-Speed Wiper - Chevrolet -
Non-Depressed Park Wiper 12-43 Chevelle - Corvette 12-48

Wiper Motor Assembly 12-44 Motor Section 12-48
Disassembly 12-45 Gear Box Section 12-50
Inspection 1245 Washer Pump Unit 12-53
Assembly 12-45 Corvette Wiper Cover Panel System 12-54
WIPER TRANSMISSION ASSEMBLY 4. Remove plenum chamber grille or access cover then
loosen nuts retaining drive rod ball stud to crank
Removal and Installation Fig. 58 arm.
1. Make sure wiper motor is in Park position. 5. Remove three motor retaining screw assemblies or
2. Open hood. nuts and motor.
NOTE: 6. Check sealing gaskets at motor and retaining screws;
On Corvettes only-- Remove rubber
replace if necessary.
plug from front of wiper door actuator then in
7. Position motor assembly to cowl and install retaining
sert a screw driver, pushing internal piston
screws or nuts.
rearward to actuate wiper door open.
3. Remove wiper arm and blade assemblies from the CAUTION: WIPER MOTOR MUST BE IN THE
transmission. On articulated left-hand arm assem PARK POSITION PRIOR TO INSTALLATION ON
blies, remove carburetor type clip retaining pinned THE COWL. DO NOT INSTALL A MOTOR
arm to blade arm. WHICH WAS DROPPED OR HUNG BY THE
4. Remove plenum chamber air intake grille, or screen, DRIVE LINK.
if so equipped.
5. Loosen nuts retaining drive rod ball stud to crank 8. Connect wiring and washer hoses to assembly.
arm and detach drive rod from crank arm. 9. Install plenum chamber grille or access cover.
6. Remove transmission retaining screws, or nuts, then
lower and drive rod assemblies into plenum chamber. NON-DEPRESSED PARK WIPER
7. Remove transmission and linkage from plenum cham
ber through cowl opening. Chevelle, Chevrolet and Corvette
8. To install, reverse removal procedure. Make sure
wiper blade assemblies are installed in the Park The Type "E" two- speed electric windshield wiper
position ± 3/8" from stop of reveal moulding on assembly fig. 59 incorporates a non-depressed type
recessed wiper arms. blades park approximately 2" above windshield molding
motor and gear train. The rectangular, 12 volt, com
WIPER MOTOR ASSEMBLY pound wound motor is coupled to a train consisting of a
helical drive gear at the end of the motor armature shalt,
Removal and Installation an intermediate gear and pinion assembly, and an output
1. Make sure wiper motor is in Park position. gear and shaft assembly. The crank arm is attached to
2. Open hood. the output gear shaft.
3. Disconnect washer hoses and electrical connectors Two switches, connected in parallel, control the start
from assembly. ing, stopping and parking of the Type "E" wiper motor.
Fig. 58-Wiper and Motor Linkage
The manually operated start, stop switch is located on 4. Remove crank arm, seal cap, Tnt-Arc retaining
the instrument panel, while the cam operated park switch ring, and end-play washers.
is located in ‘the wiper gear box.
NOTE: Seal cap should be cleaned and re
WIPER MOTOR ASSEMBLY packed with a water-proof type grease before
reassembly.
Disassembly 5. Drill out gear box cover staking tabs with a 9/32"
Gear Box Fig. 60 drill, then remove cover with loosened tabs from
1. For wipers equipped with a washer pump, remove gear train.
the two washer pump mounting screws fig. 61 and
NOTE: Screws, nuts and lock washers for re
lift pump off washer.
assembling cover to wiper are contained in a
2. Remove washer pump drive cam as required fig.
service repair package.
62. The cam is pressed on the shaft but can be
wedged off by using two screw drivers between cam
6. Remove output gear and shaft assembly, then slide
and plate.
intermediate gear and pinion assembly off shaft.
3. Clamp crank arm in a vise and remove crank arm
7. If necessary, remove terminal board and park switch
retaining nut.
assembly as follows:
CAUTION: Failure to clamp crank arm may a. Unsolder motor leads from terminals. Code mo
result in stripping of wiper gearsl tor leads for reassembly purposes.
sembly are included with the replacement as

sembly.
Motor Fig. 60
1. Follow Steps 1 through 7b under gear box disas
sembly.
2. Remove motor through bolts, tap motor frame
lightly, and remove motor from mounting plate.
3. Remove brush spring tension fig. 63, slide arma
ture and end plate from motor frame. Pull end
plate from armature.
NOTE: Thrust plug located between armature
shaft and end plate.
4. Remove end play adjusting washers from armature,
noting arrangement for proper reinstallation.
Inspection
Check and inspect all parts for serviceability, replace
as necessary. All parts can be replaced individually
except motor frame and field, which is serviced as an
assembly. Service kits also provide screws, nuts and
washers to replace gear cover and terminal board rivets.
Assembly
Refer to Figure 60 for exploded view of motor and gear

Fig. 59-Non-Depressed Park Wiper train.
Motor
b. Drill out rivets securing terminal board and park
Reassemble motor using reverse of disassembly
switch ground strap to mounting plate.
procedures.
NOTE: Screws, nuts and washers for attaching NOTE: Armature end play is controlled by end
a replacement terminal board-park switch as- play washers. See Figure 64 for proper assem
Tt’
REMOVE BRUSH SPRING FROM SLOT

AND PLACE IT IN GROOVE
AS SHOWN
Fig. 60-Wiper Motor and Gear Box Assembly
1. Nut 7. Output Gear and 11. Brush Plate Assembly and 15. Armature
2. Crank Arm Shaft Assembly Mounting Brackets 16. Thrust Plug
3. Seal Cap 8. Intermediate Gear 12. Brushes 17. Frame and Field
4. Retaining Ring 9. Wave Washer 13. Wove Washers 18. End Plate
5. Washer 10. Gear Box Housing 14. Flat Washers 19. Tie Bolts Two Required
6. Gear Box Cover
BRUSH HOLDER
AND PLACE IT IN GROOVE AS SHOWN
Fig. 63-Releasing Brush Spring Tension
Fig. 61-Washer Pump - Attach Screws
Fig. 64-End Play Wave Washer Installation
2. Place wiper in park position fig. 65 and install

crank arm on output shaft, rotate crank so alignment
Fig. 62-Washer Pump Drive Cam marks line up with those on cover.
3. Replace retaining nut, place crank arm in vise,
tighten retaining nut.
bly of end play washers. Lubricate armature
shalt bushings with light machine oil. WiNDSHIELD WASHER PUMP
Gear Box
1. Assemble gear box using reverse of disassembly The windshield washer pump used on the 2-speed Type
procedure. "E" wiper motor assembly is a positive displacement
type pump employing a small bellows, bellows spring
NOTE: Lubricate gear teeth with Delco Cam and valve arrangement. The pumping mechanism is ac
and Ball Bearing lubricant or equivalent. Be tuated by a four lobe cam and driven directly by the wiper
sure cover is properly located over dowel pins motor fig. 66. Thus, when the wiper is operated, this
and be sure to reinstall ground strap. cam is always turning with the gear. Programming is
Disassembly-Assembly
Refer to Figure
1. Remove washer pump cover.
2. Relay
a. To remove relay unsolder coil leads from ter
minal s.
NOTE: No coil polarity is necessary when re

soldering coil leads.
b, Remove coil retainer clip and slip coil assembly

out of mounting bracket.
3. Ratchet Pawl
Squeeze slotted end of post together and slide ratchet
pawl off the post.
CAUTION: Be sure spring is properly assem

bled before replacing washer pump cover.
4. Terminal Board
a. Remove ratchet dog fig. 67 and lift terminal
board off washer base.
5. Ratchet Wheel
a. Remove terminal board assembly Step 4.
Fig. 65-Wiper Crank Arm in Park Position b. Remove lock ring from shalt.
c. Slide ratchet wheel from shaft.
6. Valve Assembly
a. To remove valve assembly remove screws that
secure valve assembly to bellows housing.
BELLOWS AND COIL AND POLE

WASHER PUMP SPRING HOUSING ASSEMBLY
ACTUATOR
VALVE
NYLON ASSEMBLY
-I
SLIDER
4 LOBE
RATCHET
WHEEL ACTUATOR
/ PLUNGER ARM
ACTUATOR PIN
CAM
Fig. 67-Washer Pump Mechanism
CAUTION: It may be necessary to carefully

pry bellows lip out of the valve body groove.
Fig. 66-Wash Pump Drive Cam and Actuator 7. Bellows

a. To remove bellows first remove valve assembly.
b. Manually rotate ratchet wheel counter- clockwise
accomplished electrically and mechanically by a relay
assembly and ratchet wheel arrangement. to release pump from "lock-out" position fig.
68.
Removal and Installation c. Hold bellows plunger arm from moving, then push
Removal of the washer pump from the wiper motor in against bottom of bellows with thumb and twist
consists of: bellows 90° to rotate it from plunger arm.
1. Disconnect wiring harness and washer hoses from 8. Nylon Slider
washer. Disconnect nylon slider spring and slip the slider
2. Remove the two pump-to-wiper retaining screws and assembly off the washer base.
remove washer from wiper fig. 61. 9. Assemble washer pump in the reverse order of
3. Reverse removal procedure to install assembly. disassembly.
CHEVROLET cHASI5 SERVICE MANUAL
HOLDING CONTACTS OPEN
Fig. 68-Releasing Pump from Lockout Position
DEPRESSED PARK 2-SPEED WIPER

Chevelle, Chevrolet and Corvette Fig. 69-Depressed Park 2-Speed Wiper
The Type "C" two speed electric wiper assembly fig.
74 incorporates a depressed park type blades park
against windshield lower molding when the motor is PUMP
turned off motor and gear train. The wiper has a com ASSEMBLY
pound wound 12 volt motor and a gear box section con
taining the gear mechanism and relay control. The motor r- CAM SLOT
armature is fitted with a worm gear which drives the ROTOR
main gear assembly and crank arm. CAM
The relay control, consisting of a relay coil, relay
armature and switch assembly, is located in the gear box
section and controls the starting and stopping of the wiper DRIVE PLATE AND
through a latching mechanism fig. 70. ASSEMBLY
An electric washer pump is mounted on the gear box
section of the wiper and is driven by the wiper unit gear
assembly fig. 70.
The overhaul procedures for the wiper are broken down
into three majQr areas: The motor section, gear box
section and washer pump section. Each section may be
serviced independently of the other. "WASHER PUMP
RELAY SWITCH. DRIVE PIN
ASSEMBLY
WIPER MOTOR ASSEMBLY
Disassembly
NOTE: Motor section may be disassembled
independently of the gear box. Fig. 70-Wiper and Washer Pump Mechanism
Brush Plate and Circuit Breaker Removal
1. Scribe a reference line along the side of the casting
and end cap to insure proper re-assembly. 6. Install "U" shaped brush retainer clip over brush
2. Remove the two motor thru bolts. holder that has brush lead attached to circuit breaker
3. Feed exposed excess length of motor leads thru the fig. 73.
casting 7. Holding the opposite brush from that retained in Step
grommet and carefully back the case and
field assembly plus the armature away from the 6, carefully lift the brush holder off the mounting
casting fig. 71. tabs far enough to clear the armature commutator
fig. 73.
NOTE: It may be necessary to remove the 8. Allow the brush, held in Step 7, to move out of its
armature end play adjusting screw and insert a holder. Remove the brush spring and lift the brush
rod thru the opening in order to apply pressure holder off the armature shaft.
against the end of the armature.
Armature Removal
4. Unsolder the black lead from circuit breaker fig. 1. Follow Steps 1 thru 8’ under brush plate removal.
72. ‘3. Lift armature out of case and field assembly.
5. Straighten out the 4 tabs that secure the brush plate 3. Remove thrust ball from end of armature shalt as
to the field coil retainers fig. 72. required and save for reassembly.
CAUTION: Be careful not to break any of the NOTE: Thrust ball may be easily removed
retainer tabs. with a magnet.
Fig. 73-Removing Brush Holder
Fig. fl-Wiper Motor Separation
CUT MOTOR LEADS

I
BRUSH PLATE ASSEMBLY
RETAINER TAB
"U" BRUSH
RETAINER CLIP
ii
BLACK LE4
CIRCUIT -
* SPLIC NOTES:
1-SOLID BLACK TO Fig. 74-Drive Pawl in Full Park Position
CIRCUIT SHUNT FIELD COIL
BRE/.:. 2-SERIES FIELD COIL Case and Field Assembly Removal
TO BLACK WITH PINK 1. Remove brush plate and armature.
S’ LEAD
2. The end case and field assembly is serviced as a
unit. To free the field and case assembly, cut the
solid black and black with pink stripe leads in a lo
cation convenient for splicing - preferably near the
wiper terminal board. Refer to Figure 71.
3. Remove steel thrust plate and rubber disc from case
Fig. 72-Circuit Breaker bearing as required.
Assembly 10. Maintaining the armature in its assembled position

in the case, start the armature worm shaft through
1. If new field and case assembly is being installed,
the field and housing bearing until it starts to mesh
splice the black and black with pink stripe leads of
with the worm gear. At the same time carefully pull
the new field with the corresponding leads of the
the excess black and black with pink stripe leads
wiper.
thru the housing grommet.
2. Install the rubber thrust disc, steel thrust disc and
felt lubricating washer in the case assembly bearing
CAUTION: It may be necessary at this point to
in the order indicated.
rotate armature slightly before the armature
3. Lubricate end of armature shaft that fits in case
worm will engage with worm gear teeth.
bearing. Next, install thrust ball in end of shaft.
4. Assembly armature in the case and field assembly.
11. Rotate the case as required to align the bolt holes in
5. Position the partially assembled brush plate over the
armature shaft far enough to allow re-assembly of the case with those in the housing.
the remaining brush in its brush holder; then position 12. Secure the case to the housing with the two tie bolts.
the brush plate assembly on the mounting tabs in the 13. Adjust armature end play.
position shown in Figure 73.
NOTE: Circuit breaker ground lead will not Gear Box Section
reach circuit breaker terminal if brush plate is
positioned wrong. The gear box section is subdivided into two areas, A
the relay control and latching mechanism and B the
6. Center the brush plate mQunting holes over the drive gear mechanism.
mounting tabs and bend the tabs toward the brush
holders as required to secure the brush plate in A-Relay Switch and Latch Assembly-
position. Terminal Board Removal
CAUTION: Be sure tabs are centered in brush 1. Remove screws retaining washer pump assembly to
plate mounting holes. wiper unit.
2. If wiper pawl is in full park position drive pawl lo
7. Remove brush retainer clips and resolder circuit cated in magnetic switch assembly slot, fig. 74, it
breaker ground lead to circuit breaker. Refer to becomes necessary to remove gear assembly first
Figure see Gear Assembly Removal.
8. If new case and field assembly is used, scribe a line If wiper gear mechanism is not in park position
on it in the same location as the one scribed on the drive pawl away from latch arm, fig. 76, proceed
old case. This will insure proper alignment of the to Step 3.
new case with the scribed line made on the housing 3. Remove relay-switch attaching screw fig. 76 and
Step 1 under Brush Plate Removal. carefully lift the relay-switch assembly out of the
9. Position armature worm shaft inside the housing and, gear box. Unsolder leads from switch terminals as
using the scribed reference marks, line up as near required. Refer to figure 77 when resoldering leads.
as possible the case and field assembly with the 4. To remove terminal board assembly simply slide it
housing. out of housing and unsolder leads as required.
-GEAR ROTATION
r
DRIVE PAWL
ENGAGING
LATCH ARM
RELAY
L&TCH ARM
Fig. 75-Relay Assembly Fig. 76-Drive Gear not in Pork Position
ELECTRICAL-BODy AND CHASSIS 12-51
Relay Switch-Latch and Terminal Board Assembly

TERMINAL BOARD 1. Resolder leads to wiper terminal board as required
fig. 77.
123 2. Slide terminal board into wiper housing being careful
RELAY LEADS RED

SOLDER TO NO. 1 TERMINAL I to position the terminal board resistor lead as shown
in Figure 78.
3. Resolder leads to relay switch assembly as required
RELAY COIL-RED
F fig. ‘77.
4. Position relay- switch assembly in housing.
- TERMINAL
TAN -SOLDER TO
SAME RELAY SWITCH TERMINAL WITH RED COIL LEAD
I
BLACK WITH PINK STRIPE
Fig. 77-Relay Assembly Wiring Fig. 78-Terminal Board Resistor
Fig. 79-Drive Gear Mechanism Assembly
1. Drive Gear Shaft 5. Drive Gear 8. Shield 11. Snap Ring

2. Drive Pawl 6. Relay Assembly 9. Seal 12. Crank Arm
3. Lock Pawl 7. Spacer 10. Washer 13. Nut
4. Coil Spring
CAUTION: Be very careful to route leads in 5. Install relay- switch mounting screw.
such a manner as to avoid having them pinched 6. Assemble gear box cover and washer pump assembly
between relay and wiper housing. to wiper being careful that the ground strap is prop
erly connected. Refer to Figure 70 for assembly of
washer pump to gear housing.
B-Drive Gear Disassembly Fig. 79
NOTE: VIEW SHOWS RELAY SWITCH ASSEMBLY AND 1. Remove washer pump assembly.
TERMINAL BOARD REMOVED. GEAR MAY BE REMOVED 2. Remove crank arm retaining nut, crank arm, rubber
WITHOUT DISTURBING RELAY SWITCH OR TERMINAL seal cap, retaining ring, shim washers, shield and
BOARD IF GEAR IS NOT IN PARK POSITION SHOWN IN spacer washer in the order indicated.
FIGURE 73. 3. Slide gear assembly out of housing fig. 80.
4. Slide drive plate and shaft out of gear and remove the
drive pawl, lock pawl and coil spring as required.
Drive Gear-Assembly
1. Position drive pawl on drive plate as shown in Fig
ure 81.
2. Assemble lock pawl over drive pawl as shown in
Figure 81.
3. Slide gear and tube over the drive shalt fig. 82.
Move drive and lock pawls as required to allow their
respective pins to fit in the gear guide channel,
fig. 83.
Fig. 80-Removing Gear Assembly
Fig. 81-Lock and Drive PawI Assembly Fig. 82-Drive Gear and Shaft Assembly
DRIVE AND LOCK PAWL

PINS IN GEAR POCKETS
Fig. 84-Washer Pump Assembly
6. Assemble inner spacer washer over gear shaft and

assemble gear mechanism in housing so that it is
positioned with respect to the housing in the approxi
mate location shown in Figure 80.
Fig. 83-Drive and Lock Pawl Guide Pins in Pockets 7. Reassemble the outer spacer washer, shield, shim
washers as required to obtain .005" max. end play,
snap ring and rubber seal cap in the order indicated.
4. Holding the gear, manually rotate the drive plate Refer to Figure 79.
until the drive and lock pawl guide pins snap into 8. Operate wiper to "park" or "off" position and install
their respective pockets in the gear fig. 83. crank arm.
5. Reinstall coil spring between lock and drive pawls 9. Reassemble washer pump to wiper fig. 70.
fig. 83.
Washer Pump Unit
IMPORTANT: Be very careful to maintain lock
and drive pawl guide pins in their respective The washer pump and/or valve assembly may be re
pockets during Step 6. moved from the wiper assembly as a unit; therefore, it is
PISTON
SPRING
EXPANDED
INTAKE
VALVE
CLOSED
DIRECTION OF TRAVEL
TO PLATE
NOZZLES
EXHAUST
VALVES
OPEN
Fig. 85-Cross Section of Windshield Washer Pump Valve
not necessary to remove the wiper assembly from the to adjust underside of cover panel at reveal
vehicle if only the washer pump and/or valve assembly moulding clip to a .060" gap at the windshield
required service. center. The adjustment stop screws seat against
When the pump is removed from the wiper assembly, plastic pads mounted on top of the plenum.
all working parts are readily accessible and may easily b. The grille panel has elongated screw holes allow
be serviced as necessary fig. 84. An exploded view of ing fore and aft adjustment.
the washer pump is shown in Figure 85. c. Up and down alignment of the entire control as
sembly with vent grille and cover panel attached
Removal of Pump Assembly is possible at the firewall mounting of the control
1. Raise vehicle hood. assembly nuts "E".
2. Disconnect washer hoses and electrical connections
from assembly. Wiper Cover Panel Bumpers
3. Remove 3 screws securing washer pump and cover Replacement
to wiper assembly. Remove pump from wiper gear
1. Remove eight screws securing vent grille and lift
box. grille off. Note washer hose location.
2. Reaching beneath wiper cover panel, with an offset
CORVETTE WIPER COVER phillips head screw driver, remove and replace soft
PANEL SYSTEM Fig. 86 bumpers if less than 3/16" thick.
The windshield wiper cover panel is operated by a 3. Install and align vent grille, properly positioning
vacuum actuator attached to a control assembly which washer hoses.
pivots the cover panel up and forward. The same vacuum Actuator Assembly View C
source is used to open the headlamp covers.
The wiper cover panel actuator is signaled through a Replacement
relay by a vacuum solenoid attached to the rear of the ta 1. Remove vacuum hoses from the actuator assembly.
chometer housing. Sliding the center console mounted 2. Loosen locking nut from turnbuckle rod nut.
wiper switch electrically activates the vacuum solenoid. 3. Remove two 2 nuts, bolts, washers, and bushings
The wiper niotor is prevented from operating until a attaching actuator assembly to bracket.
limit switch is energized by full open travel of the wiper 4. Rotate actuator assembly to remove from engine
cover panel. compartment.
5. Reverse removal procedure for installation.
Vent Grille and Windshield Wiper Cover Panel
Limit Switch View B
Removal
1. Raise hood then remove ground cable from battery Replacement
behind driver’ s seat. 1. Remove eight screws located in the vent grille and
2. Remove eight screws located in the vent grille. lift off grille.
3. Move the vent grille forward and up to remove. 2. Remove bolt and bushing from rod.
4. If vacuum is present in system, open cover panel by 3. Remove two bolts retaining bracket-to-plenum panel
pulling downward wiper cover panel switch. If panels and remove assembly.
do not open, remove plug at front of vacuum actuator 4. Remove bolt retaining switch to assembly and re
and insert a screw driver into the hole. Press in on move switch.
actuator piston until cover panel raises to the opened 5. Reverse procedure for installation.
position.
Control Assembly
NOTE: The actuator rubber plug is functional Replacement
in the vacuum system. It must be replaced 1. Remove eight screws securing vent grille and lift
immediately. grille off.
2. Remove screw and bushings View B securing limit
5. Remove four bolts with bushings retaining cover switch link to control assembly.
panel to control assembly arms and lift panel from 3. Remove wiper cover panel actuator as previously
vehicle. described.
4. Remove four nuts and reinforcements from outboard
Installation studs on control assembly mounted to firewall.
1. With actuator rod in the EXTENDED position place 5. Rotate entire control assembly, including wiper cover
cover panel over actuator arms and install bushings panel, forward and up for removal and further bench
and bolts. disassembly.
2. With actuator in the closed position align vent grille 6. Reverse removal procedure for installation.
to the mounting brackets and install screws retaining 7. Vent grille and cover panel vertical alignment to
vent to the brackets. Connect ground cable to battery. fenders is possible at nuts "E". Cover panel to
3. Actuate system and check both panels for alignment windshield gap of .060" is adjusted at screws "D".
as follows:
a. The cover panel to windshield adjustment is made Vacuum Relay View A
at two stop screws "D" located on the rear out Replacement
board links of the control assembly under the 1. Remove screws securing wiper vacuum relay to
cover panel. Loosen locking nuts and turn screws inner fender panel.
Fig. 86-Corvette Wiper Cover Panel System
2. Transfer four hoses from removed relay to new re

lay. Note hose color stripe and match letter on pipe HORN RELAY-BUZZER IGNITION
of relay G-Green, Y-Yellow, R-Red. SWITCH
Manual Overide Vacuum Switch
For opening wiper cover panel located beneath left in

strument console, far right of controls.
Replacement
1. Remove screw retaining switch and push switch
rearward to release from bracket.
2. Transfer vacuum hoses to new switch.
3. Place new switch in position and secure with screw.
HORN RELAY-BUZZER Figs. 87, 88 fLRNlTO

Theft Deterrent System
The horn relay-buzzer is constructed to incorporate

both the horn relay and reminder buzzer into one as ;fEORNSr@ TO
sembly. A typical assembly is shown in Figure 87. DOME
LIGHT
Buzzer Operation
DOOR
The horn relay-buzzer operates when the driver’s door ENERGIZER SWITCH
is opened to remind the vehicle driver that the ignition
key has been left in the switch. A typical circuit is
shown in Figure 88. The operation is explained as follows: Fig. 88-Wiring Schematic - Horn Relay-Buzzer
With the key fully inserted into the ignition switch, the
No. 4 terminal on the horn relay-buzzer is connected to is opened. Current then flows from the battery through
ground through the door switch when the driver’s door the coil winding, the buzzer contacts, the ignition switch,
and door switch to ground. The winding magnetism
causes the buzzer contacts to open, which opens the wind
ing circuit, and the contacts then re-close. This cycle
then repeats many times per second to give the buzzing
sound. Closing the door, or removing the key, will stop
the buzzer action.
Horn Operation
When the horn switch is closed, the coil winding is
connected to ground, and the armature moves toward the
core to close the horn relay contacts. The horns are
then connected to the battery, and operate accordingly.
With the horn switch closed, the buzzer contacts remain
separated. The horn relay-buzzer can be checked.
BUZZER
CONTACTS Although the terminal type and location may vary be
tween models, the numerical designation on all models is
standardized. When making electrical checks for im
proper operation, proceed as follows:
Buzzer Check:
1. Insure that the key is fully inserted into the ignition
switch.
2. Open the driver’s door, and observe the dome lamp.
3. If both the dome lamp and buzzer fail to operate,
check the door switch for defects.
4. If the dome lamp is on, but the buzzer fails to oper
ate, remove the horn relay-buzzer from its mounting
// and identify the No. 1 and No. 4 terminals.
5. Connect a jumper lead from the No. 4 terminal to
TERMI NALS ground. Slide a prod into the wiring harness con
nector to make contact if the terminals are of the
Fig. 87-Horn Relay-Buzzer slip-on type.
6. II now the buzzer operates, check the ignition switch 2. Connect a jumper from the No. 2 terminal to ground.
wiring and ignition switch for defects. Slide a prod into the wiring harness connector to
7. If the buzzer does not operate, connect a voltmeter make contact if the terminals are of the slip-on type.
from the No. 1 terminal to ground. 3. If the horns operate, check the No. 2 terminal wire
8. If the reading is zero, the circuit is open between and horn switch for defects.
this point and the battery. 4. If the horns do not operate, leave the No. 2 terminal
9. If a voltage reading is obtained, replace the horn connected to ground, and connect a voltmeter from
relay-buzzer. the No. 3 terminal to ground.
5. If a reading is obtained, check the horn wiring and
Horn Relay Check: horns for defects.
1. Remove the horn relay-buzzer from its mounting, 6. If no reading is obtained, replace the horn relay-
and identify the No. 2 and No. 3 terminals. buzzer.
L.H. FENDER2O B--Ii
LAMP L.H. MARKER LP
Fig. 12-89-Front Lighting & Engine Comportment-Chevrolet
BULKHEAD
CONNECTOR
Eli I!.L.
t.4
DIR SIG
FLASHER
20 LBL
20 P
16 BRN
20 LG
20P
20 T/DLB-B -
14 LBL
18 OR
20 Y
20 DG
20 LG
20 DBL/DLB-W
20 DG
12R -
20 DG
12 OR/B
20 DG
12 OR/B
20 T/DLB-B
Rg. 12-90-Fuse Panel-Chevrolet
0W
20W ‘<iii R, H. DOOR JAMB SW
INST PANEL COMPT LAMP 155-15600-16000
.20 ALL EXCEPT 15300-400
18
14 HTR
18
SW
18 OR
14 OR HEATER
CONTROL LP
20Y RADIO CONN
CIG LGT
CLOCK CONN
12 R
12
12
12 P SW
20B IGN SW LIGHT INSTRUMENT

18 B CLUSTER
18 DBL
18 LBL
16 OR - ILLUM
- ILLUM
- ILLUM
20 GY - OIL PRESS.
20 DBL - R.H. SIG LAMP
GEN
- ILLUM
- ILLUM
- ILLUM
- ILLUM
- HIGH BEAM
- ILLUM
- ILLUM
ILLUM
- PARK.BRAKE
- ALARM & BRAKE

- WARN. LIGHT
-L.H. SIG LAMP
- ILLUM
-ENG TEMP
- ILLUM
20 FUEL GAGE
20 P
ILLUM
16
20
20 20
20
14
18 OR
20 20
20 DG 20
20 LG 20
20: 20
20 DO 12 GY......-..67 MODEL
12 R
ONLY
20 DG 12 PPL
121
20 DO
12
20 - _oR/BJT
14 R/W
20 BRN
L.H. CTSY LP 20 WTH. DOOR JAMB TAILGATE WINDOW SW
67 MODELS & & KEY WARN SW 45 MODELS ONLY
16600 ONLY
Fig. 12-91-Instrument Panel-Chevrolet
::.
RH. RR
r -
DR JAMB SW 18 11W BRN -‘ F:: R. H. TAIL,
18639 ONLY STOP&DIR
‘I
IL
R.H, MARKER
LAMP r-2° BRN SIG LP ALL
I
R.H. MODELS
18 OR
RAIL LAMP 18HWB .. OUTBOARD
I ,.18W
MODELS ONLY R.H. BACK
0
ING LP ALL
0 LEGEND MODELS
CHEVROLET WRG INBOARD
0 FISHER BODY WRO
-- - CHEVROLET RPO WRG R.H. TAIL,
STOP & DIR
II SIG LAMP
16000 ONLY
INBOARD
I:.: II REAR COMPT

z LAMP
0
C..’
IIF-©J
LICENSE
II
rr
I III
LAMPS
ALL MODELS
I I I I I
U J.’-18HWT
DOME LAMP
RAIL EXCEPT
O 00 39, 47 67, 87
18W U MODELS FUEL

MTR
L.H. TAIL
STOP & DIR
18TAN --
SIG LAMP
2OBRN --
16000 ONLY
INBOARD
L, H. BACK
LII ING LP ALL

MODELS
INBOARD
LL
L,H. TAIL,
STOP & DIR
L.H. SIG LP ALL
67 MOD
ONLY
ig:. RAIL LAMP
39,47 & 87
MODELS ONLY L.H. MARKER
18 HW
MODELS
OUTBOARD
LAMP
L.H. RR
DR JAMB SW.
16639 ONLY
Fig. 12-92-Body &. Rear Lighting Exc. Wagon-Chevrolet
R. H. MARKER LAMP
R.H. RR
DR JAMB SW R.H. TAIL,
STOP & DIR
SIG LP ALL
MODELS
OUTBOARD
R.H. BACK
ING LP ALL
I LEGEND MODELS
I CHEVROLET WRG INBOARD
I -- FISHER BODY WRG II
L--- CHEVROLET RPO WRG R.H. TAIL,
STOP & DIR
SIG LAMP
16000 ONLY
INBOARD
TAILGATE
r
WINDOW MTR 0
0
14 LBL 0
U,
14 OR/B
0
14 T C.’
14 T/W 0
0
0
iO
z
*14 W/DGHI’
KEY T/GATE Co
OPERATED CUTOUT LICENSE
r WINDOW SW 11W BRN-j LAMP

SWITCH
ALL MODELS
III II
III DOME
LAMP
L.H. TAIL,
18 W STOP & DIR
SIG LAMP
16000 ONLY
INBOARD
L.H. BACK
ING LP ALL
MODELS
:©Q
- -si -: 18 BRN
INBOARD
18 BRN L.H. TAIL,
18 BRN16000
- 18BRN15000 STOP & DIR
SIG U’ ALL
MODELS
OUTBOARD
III
12
b+-
L-...
12 OR/B L.H. RR
12 LBL DR JAMB SW
L. H. MARKER LAMP
Fig. 12-93-Body & Rear Lighting Wagon-Chevrolet
2 4 6
.1 I ñ
DT
V.8 ENG
DASH
U U
7
PANEL
S
iif_.14 DG1
EXC 13 100-200
BRAKE FLUID
WARNING SW
F’
L. H. MARKER LP.
Fig. 12-94-Front Lighting and Engine Compartment-Chevelle
* NEU. SYIY. SW. NEU. SFTY. SW.

RPO M35 EXC D55 RPO M35 WITH D55
I f% -
0 0 0
Fig. 12-95-Fuse Panel-Chevelle
_______
,, INST. PNL.
HEATER SW. 20 0 R
COMPT. LP.
-14 BRN ,4?fIjl 13500-600
,,.-18 Y OR uLu’iJ
IATER 700-800
RESISTOR 18 LBL
GY ‘!‘ CIG. LGT.
18 OR INST. CL. LP.
LH.COURTLP. g.uu.uu’2OW ®i20W
GY - INST. CL. LP.
R. H. DOOR JAMB SW.
18 EXC. 13100-200
18 OR
--12 PPL/W PPL/W.. _-_..
-12 BRN
-24 BRN/W
PPL
-20 DO
-20 20 DO:
12 P
-20 12R
16 OR HEATER LP.
20 .2OGY 13500-600
20P
20 T 3 700-800
FUEL GAGE
* ONLY WIRES 0 DBL OIL PRESS

20P LP.
PERTINENT
TO PRODUCTION
SIG. OR NEUTRAL BRK. IND. LP.
SAFETY SW
RAVE BEEN
SHOWN. 2ODBL R.H. TURN LP.
20 P III GEN. LP.

16 BRN
HORN
CONTACT 0 DO
0P TEMP. LP.
20 GY_ INST. CL. LP.

-
2OGY INST. CL. LP.
-14
-18 2OLG H/BEAM LP.
-12
20 20 LBL -iiJ L.H. TURN LP.
-20
- 18 2OGY INST. CL. LP.
20
20 GY INST. CL. LP.
18 B
-20 DBL WIPER SW.
14 LBL g
-12
- 16 BRN OR
20 Y
RN__
-20 LG
20 T
20
Cr- 20 W 20 B
-18 OE EXC 13 100-200
L.H. COURTLP 20WR20W
20 DG
CONV. ONLY L. H. DOOR JAMB & "- CONN
KEY WARN SW.
Fig.. 12-96-Instrument Panel-Chevelle
LI
C*EVROLET WRG
PBHER BODY WRO
CYBOLIT *PO WBO
ALL EXC STA. WAG. PICK-UP 13300-400 SEDAN

& 13300-400 SEDAN
r 2OBRN:
R. H. TAIL STOP [ R. H. TAIL, STOP
& DIR. 51G. LP. I , &.DIL.SIG.II LP.
GROMMET
II
2OLGi18LG_u
II I II
r
I
2oLG____E::4:
HIll. BACK-UP LP.
20 BRN
II III
LIC. LP, LIC. .LP.
1!
FUEL
MTR.
B=I BII
II
FUEL MTR.
GROMMET
II III
18LG
L.H. BACK-UP LP.
LII. BACK-UP LP.
i 20
20
Y
BRN
pl:
L.H. TAIL, STOP

& DIR. 510. LP.
-
-
.20Y
20
I
0 BRN:
L. H. TAIL, STOP
& DIR. 51G. LP
- 20
- 20
- 2ODG
Fig. 12-97-Body & Rear Lighting Exc. P.U. & Wagon-Chevelle
__ ___
______ _
__-__
STATION WAGON R. H. MARKER LP.
II LEGEND
CHEVROLET WRG
R. H. MARKER LP.
I -- FISHER BODY WRG

L--’- CHEVROLET RPO WRG
: =g BRN-
20DG=___
R.H. TAIL, STOP R.H. TAIL, STOP

& DIR. SIG, LP. & DIR. SIG. LP.
DOME LP.
EXC. PICK-UP
-
R.H. BACK-UP LP. R.H. BACK-UP LP.

I I II 18BRN BRN
ffl18BRNu_j BRN
[_1 -
I I LIC. LP. LIC. LP.
art
II
1oO’20T--
.:::::: FUEL
T-
- 7.::::. FUEL
lull IIl-.48B MTR. II-S"-18 MTR.
LG®
L. H. BACK-UP LP.
L.H, BACK-UP LP.
B--Ia -20 B --$I
111111111
11111119
z
L.H. TAIL, STOP L. H. TAIL, STOP

000Co00 01 &DIR.SIG.LP. - & DIR. SIG. LP.
C..’ C.’ 14 - ‘‘ C.’ c.’
20 BRN-
L.H. MARKER LP. L.H. MARKER LP.
LoJj
20DG - 20 DG-.--
Fig. 12-98--Body & Rear Lighting P.U. & Wagon-Chevelte
lE 1234
I
L4NG H
Fig. 12-99-Front Lighting & Engine Compartment-Chevy II
18 OR-
18 Y
18 LBL
PPL
P-
BRN -
Y
OR
Fig. l2-100-Fuse Panel-Chevy II
ELECTRICAL-BODY AND CHASSIS 12.70
18 OR 18 OR
-18 Y 18 Y
-18 LBL 10
-14 PPL DIR. SIG.

12 P 12 FLASHER
-14 BRN 14
-20 Y HEATER SW.
20
-18 OR
HORN HAZARD
CONTACT WARNING * RADIO CONNI
ONLY WIRES PERTINENT
1t
TO PRODUCTION OR NEUTRAL
F
SAFETY SWITCH HAVE BEEN
SHOWN.
TO TURN SIG.
-12
-12
12
20
20
20
-18
20 P
ILLUM
18 BRAKE ALARM
LII. SIC LAMP
20 GEN. WARN LAMP
20 ILLUM
ILLUM
FUEL CAGE
OIL PRESS WARN.
18 L. H. SIC LAMP
-18 ENG TEMP WARN LP.
-18 ILLUM
-20
-20
-20
20
-12
-20
-20
-24
-16
-20
-20
-20
-20
-20 Y
-14 LBL
Fig. 12-101 -Instrument Panel-Chevy II
R. H. CRT LP. R.H. MARKER

LP.
II
2OBRN
2OBRN
LEGEND
.Hfl CHEVROLET WRG
--- FISHER BODY WRG
R.H. TAIL, STOP
--- CHEVROLET RPO WRG
& DIR. SIC. LP.
2OLC
H. H. BK-UP LP.
// I
DOME LP.
B
U
GROMME 0
BRNE:
LIC. LP.
F’
0
C.’
L. H. DR. JAM
& KEY WN. SW.
L. H. CRT LP.
U .2OLG
L. H. BK-UP LP.
:j.:
LII. TAIL, STOP

& DIR. 81G. LP.
L.H. MARKER
LP.
Fig. 12-102-Body & Rear Lighting-Chevy II
RH. MARKER LP.
LH. PARK&
DIR. SIG. LP.
W
18LBL
18 18BRN
$1
LBL
I18
L. H. PARK &
DIR. SIG.
L. H. MARKER LP.
Fig. 12-103-Front Lighting & Engine Compartment-Corvette
BULKHEAD
CONN
Fig. 12-104-Fuse Panel-Corvette
PARK BRK
T -OS ALARISW
GY..-C0 CONSOLE LP
CT -- CONSOLE LP
WATER TEMP
GAUGE
GY-_- CIG LP
OR -me 4J CIG LOT
oy’O HEATER LP
CT
14B RADIO
20 Y
20 CT - CONSOLE LP
FUEL GAUGE
CT ll CONSOLE LP
OR CLOCK
CT : CONSOLE LP
DOOR AJAR LP
20 LBL
- 18 20 CT
12 B IGN SW LP
B- - TACHGRD
18
12
:PARK SHE LP
18 BRN .20 GY- CLUSTER LP
18 DBL 20 GY-C CLUSTER LP
LL TURNLP
20
20 GY -C :CLUSTER LP
12 CT -C : CLUSTER LP
12 LO -C
20 * H/BEAM LP
-18 .20 GY-C CLUSTER LP
16 20 GY-.-.C CLUSTER LP.
LBL L.H. TURN LP
20
20 20 CT CLUSTER LP
18
20
14 B - SPEEDO GED
14 .20 GYa..- CLUSTER LP
12 INST.. PANEL CLUSTER
12
20 Wa
20 OR
20
20 BRN.
16 LBL’
-18 1.0 ao LC
20 DO DO
20 --
20 Y
- 2
2B
Fig. 12-105-Instrument Panel-Corvette
H. H. MARKER LP.
flLEGEND -
C:
I - CHEVROLET WRG
CHEVROLET RPOWRG
LL TAIL, STOP & rm.
81G. LP. OUTBOARD
HIH. DOOR
AJAR
WARNING
BRN.::.!!:
SW.
HIL DOME R.H. TAIL, STOP& DIR.

LP. EXC. CONy. 81G. LP. INBOARD
18 BRN ....h:..:
18DG
GLOVE COMPT.
LP. & SW.
eo
ta
H. H. BACK-UP LP.
LICENSE
FUEL MTR *18
B *4’
L. H. BACK-UP LP.
18Y
L. H. TAIL, STOP & DIR.

SIC. LP. INBOARD
18BRN i:.
18Y
16 B
16 B
L.H. TAIL, STOP & DIR.
51G. LP. OUTBOARD
0 L. H. MARKER LP.
Fig. 12-106-Body & Rear Lighting-Corvette
iji. MARKER
Fig. 12-107-Front Lighting & Engine Compartment-Camaro
01
. 4 14
20
Ill
El
"l
z
0- 1-18
1 14
LEl
0
0
Fig. l2-108-Fuse Panel-Camaro
CHEVROLET CHASS1S SERVICE MANUAL
HEATER CONN.
SW.
ILLUM LP
BRAKE ALARM
R.H. SIC. LP.
GEN. WARN. LP.
ILLUM LP.
ILLUM LP.
FUEL GAGE
OIL PRESS. WARN.
L. H. SIC. LP.
ENG. TEMP. WN.LP.
ILLUM LP.
HI BEAM
IND LP.
L.H. DOORJAMB
& KEY WN. SW.
Fig. 12-109-Instrument Panel-Camaro
R.H. MARKER
LP.
LEGEND
CUEVROLET WRG
--- FISHER BODY WHO -__2OBRN’Q
-- - CHEVROLET RPO WRG
2ODG R.H. TAIL,

R.H. CORNER 2OBRN STOP &
LAMP-CONV ONLY DIR. SIC.
LAMP
RH. COMP.
LAMP
c11 - 2OLG
R. H.
BACK-UP
LAMP
0
18 W
OR-
1 GROMMET
BRN-U LICENSE
DOME LLAMP
LAMP
-20 BRN
LC J BACK-UP
‘V LAMP
r i1 Y
20 BRN
.. 4.
L.H. TAIL,
DIR. SIC.
I
LAMP
BRNJ
I L. H. CORNER
,J.....MP-CoNv. ONLY
BODY 1. L.H, MARKER

HARNESS / LAMP
Fig. 12-110-Body & Rear Lighting-Camaro
SECTION 13
RADIATOR AND GRILLE
Page
Radiator 13-1
Grille 13-6
RADIATOR
INDEX
Page Page
General Description 13-1 Radiator-Vehicles With Fan Shroud

Component Part Replacement 13-1 Except Corvette 13-1
Radiator-Vehicles With No Fan Shroud Aluminum Radiator-Corvette 13-2
Except Corvette 13-1 Copper Radiator-Corvette 13-2
Engine Fan Shroud All Vehicles 13-2
GENERAL DESCRIPTION
Radiator assemblies are of copper-brass core construc With the exception of the Chevrolet L-6 with RPO C60,
tion with the exception of the Corvette 427 L88 V-8 en C75 or VOl and Corvette models without C60 steel
gine and all 327 V-8 engines with manual transmission, shrouds, all fan shrouds are of the plastic design. Fan
which incorporate an aluminum core. All Chevrolet shrouds are attached to the radiator, radiator support
models, plus the Chevy II 4-cylinder use downflow radia panel or radiator support brackets by cap screws and/or
tors. All other models incorporate the crossflow design clips.
radiator. All radiators will incorporate a drain cock, With the conventional downflow design radiator, coolant
replacing the drain plug. Radiator assemblies are at level should be one inch below the bottom of filler neck
tached to the radiator support or radiator mounting box when cold. With the crossflow design, coolant level should
by cap screws and/or brackets. be three inches below the bottom of the filler neck when
cold.

RADIATOR-VEHICLES WITH NO FAN SHROUDS verse removal procedures, fill cooling system
and check for leaks.
EXCEPT CORVETTE
Removal RADIATOR-VEHICLES WITH FAN SHROUDS
1. Raise hood and drain radiator. EXCEPT CORVETTE
2. Disconnect radiator inlet and outlet hoses and Power- Removal
glide coolant lines, if so equipped. 1. Raise hood and drain radiator.
3. Chevrolet--Remove radiator to radiator support or 2. Disconnect radiator inlet and outlet hoses and Power-
radiator to radiator mounting box screws and re glide coolant lines, if so equipped
move radiator from vehicle. 3. Chevrolet- - Remove shroud to radiator screws and
Chevelle and Chevy II L-6--Remove radiator mount hang shroud over engine fan. Remove radiator to
ing panel to radiator support screws and remove radiator support or radiator to radiator mounting
panel. Lift radiator up out of vehicle. box screws and lift radiator up out of vehicle.
Chevy U L-4- - Remove radiator to radiator mounting Chevelle and Chevy U- -Remove radiator mounting
box screws and lift radiator out of vehicle. panel screws to radiator support and fan shroud and
Camaro- - Remove radiator fan guard to radiator sup remove panel; lift shroud out of lower radiator clips
port screws and remove guard. Remove radiator and hang shroud over engine fan. Lift radiator up out
to radiator support screws. Lift radiator up out of of vehicle.
vehicle. Camaro- - Remove shroud to radiator support bracket
screw. Lift shroud up out of lower radiator clips
Installation
and hang shroud over engine fan. Remove radi
NOTE: Refer to Figures 1 through 4 for radia ator to radiator support screws and remove ra
tor assembled positions for each vehicle. Re- diator.
RADIATOR AND GRILLE 13-2
Installation COPPER RADIATOR-CORVETTE

NOTE: Refer to Figures 1 through 4 for radia Removal Fig. 5
tor assembled positions for each vehicle. Re- 1. Raise hood and drain radiator install a bolt in hole
verse removal procedures, fill cooling system of hood support bracket for safety purposes.
and check for leaks. 2. Remove radiator inlet and outlet hoses at radiator
ALUMINUM RADIATOR-CORVETTE connection and transmission coolant lines, if so
equipped.
Removal Fig. 5 3. Remove shroud to radiator support bracket screws.
1. Raise hood and drain radiator install a bolt in hole of Remove shroud to radiator baffle bracket screws or
hood support bracket for safety purposes. radiator support and rest shroud on engine fan.
2. Remove radiator inlet and outlet hoses and supply 4. Remove radiator upper support bracket screws and
tank hose at radiator connection. remove brackets and insulators, carefully lift ra
3. Remove shroud to radiator support bracket screws diator up out of vehicle.
the L-88, 427 engine does not incorporate a fan
shroud. Installation
4. Remove shroud to radiator baffle bracket screws. Refer to Figure 5 for radiator assembled position. Re
verse removal procedures, fill cooling system and check
Rest shroud on engine fan.
5. Remove radiator upper support bracket screws and for leaks.
carefully lift radiator from vehicle. ENGINE FAN SHROUD ALL VEHICLES
Installation Replacement
Refer to Figure 5 for radiator assembled position. 1. In most instances, it will be necessary to remove the
Reverse removal procedures, fill cooling system and engine fan before clearance can be obtained to re
check for leaks. move the fan shroud.
Fig. 1-Radiator and Shroud - Chevrolet
Fig. 2-Radiator and Shroud - Chevelle Fig. 3-Radiator and Shroud - Chevy II
2. All vehicles except Corvette- - Remove engine fan

shroud to radiator or radiator mounting panel
screws. If vehicle is so equipped, lift shroud out of
lower radiator clips and remove from vehicle.
Corvette-- Remove radiator as outlined under "Ra
diator- - Corvette". Shroud can then be removed by
tilting rearward, then lifting up to clear fan blades.
Fig. 4-Radiator and Shroud - Camaro
GRILLE
INDEX
Page Page
Component Part Replacement 13-6 Grille Assembly-Camaro Standard
Grille Assembly-Chevrolet 13-7 Headlamps 13-9
Grifie Assembly-Chevelle. 13-8 Grille Assembly-Camaro Retractable
Grille Assembly-Chevy U 13-8 Headlamps 13-9
Grille Assembly-Corvette 13-10
Fig. 6-Chevrolet Grille Assembly
2.O’H
327 V-B ENGINE WITHOUT C 60 L-88 427 V-B ENGINE
n U
I
-I
0 0
zU
0
327 V-B ENGINE WITH C 60 I
I
427 V-B ENGINE EXCEPT L-88 WITHOUT C 60 ni
‘a
U,
Fig. 5-Radiator and Shroud - Corvette
GRILLE ASSEMBLY-CHEVROLET 8. If necessary, remove nuts attaching name plate to

grille and replace name plate.
9. If grille reinforcement removal is desired, remove
Removal Fig. 6 screws at radiator support.
1. Raise hood and disconnect battery leads. NOTE: If vehicle incorporates headlamp doors,
2. Remove bumper See Section 14. remove doors prior to reinforcement removal
3. Remove bolts securing hood catch assembly to ra See Section 12 for door removal.
diator support, hood catch support and header panel
10. Remove parking lamp assemblies See Section 12.
and remove hood catch from vehicle. 11. Remove bumper brace to lower valance panel attach
4. Remove screws attaching headlamp bezels to header
ing bolts and remove lower grille and valance panel
panel and upper grille and remove from vehicle.
assembly.
5. Remove screws attaching hood lock support to radia
12. Remove rivets securing lower grille to valance panel.
tor support, header panel and upper grille and re
move from vehicle. Repair
6. Remove screws attaching header panel to fenders, If header panel, hood catch support or any other com
header panel to grille reinforcements, filler panel to ponents removed are undamaged, they may be used for
grille reinforcement, grille to fender and fender ex the new grille installation. Where rivets were removed,
tension to fender and skirt and remove upper grille, new attachments can be made using screws and nuts,
header panel and filler panel from vehicle as an patent clips or rivets.
assembly. Installation
7. Remove rivets securing header and filler panels to Install grille and related components following the re
upper grille assembly. moval procedure in reverse order.
HEADER HOOD CATCH
HOOD CATCH SUPPORT
GRILLE
FENDER
GRILLE EXTENSION FILLER PANEL
VIEW A HEADLAMP BEZELS
Fig. 7-Chevelle Grille Assembly
GRILLE ASSEMBLY-CHEVELLE 12. Remove left and right front fender braces.
Removal Fig. 7 13. Remove screws attaching filler panel to fenders and
1. Raise hood, disconnect battery leads and remove bat skirts and remove filler panel from vehicle.
tery. Repair
2. Remove screws attaching hood catch assembly to If any components removed were undamaged, they may
header panel, radiator support and hood catch support be used for the new grille installation. Where rivets
bracket and remove hood catch from vehicle. were removed, new attachments can be made using
3. Remove rivets attaching grille to catch support. screws, patent clips or rivets.
4. Remove catch support to header panel screws.
5. Remove screws attaching grille extensions to fenders Installation
and remove from vehicle. Install grille and related components following the re
6. Remove screws from each headlamp bezel and re moval procedure in reverse order.
move bezels from vehicle.
7. Remove the outer headlamp assemblies and then re GRILLE ASSEMBLY-CHEVY II
move the outer grille to filler panel screws and Removal Fig. 8
spacers. 1. Raise hood, disconnect battery cables and remove
8. Remove screws attaching the outer grille reinforce battery assembly.
ments to the radiator support, filler panel and header 2. Remove screws attaching hood lock catch to radiator
panel and rotate reinforcements inward on grille support, grille and hood catch support and remove
rivets. catch from vehicle.
9. Remove header panel to fender screws and remove 3. Remove front bumper See Section 14.
header panel, grille and grille reinforcements as a 4. Remove hood lock support to filler panel screws.
unit. Remove rivets attaching grille to related parts. 5. Remove headlamp bezel screws and remove bezels
10. If filler panel removal is desired, remove front from vehicle.
bumper assembly See Section 14. 6. Remove filler panel to fender screws.
11. Remove filler panel to hood lock support screw and 7. Remove grille outer support to radiator support
rivet. screws and remove grille, grille supports, filler
HOOD LOCK CATCH
HOOD CATCH RADIATOR SUPPORT
GRILLE REINFORCEMENT
FILLER PANEL
GRILLE SUPPORT
FILLER PANEL HEADLAMP

REINFORCEMENT
HEADLAMP HOUSING
FENDER BRACE
Fig. 8-Chevy Il Grille Assembly
RADiATOR AND GRILLE 13-9
panel and filler panel support as an assembly. 9. Remove screws attaching valance panel to fender
8. Damaged components can be replaced by removing extensions and lock support and remove valance
screws and rivets. panel from vehicle.
10. If header panel removal is desired, remove hood
Repair lock catch screws to radiator support, grille support
If any components removed are undamaged, they may and header panel and remove catch from vehicle.
be used for the new grille installation. Where rivets 11. Remove header panel to hood lock support screws.
were removed, new attachments can be made using 12. Remove screws securing header panel to left and
screws, patent clips or rivets. right fenders and remove header panel from vehicle.
Installation Repair
Install grille and related components following the If any components removed were undamaged, they may
removal procedure in reverse order. be used at reinstallation. Where rivets were removed,
new attachments can be made using screws, patent clips
GRILLE ASSEMBLY-CAMARO or rivets.
STANDARD HEADLAMPS Installation
Removal Fig. 9 Install grille and related components following the
1. Disconnect battery ground cable. removal procedure in reverse order. Refer to the
2. Remove headlamp bezel screws and remove both Torque Specifications section of manual for correct
bezels from vehicle. torque values.
3. Remove nuts securing upper grille to header panel
and remove upper grille.
4. Remove nuts securing lower grille to the center GRILLE ASSEMBLY-CAMARO
grille and remove lower grille. RETRACTABLE HEADLAMPS
5. Remove parking lamp assemblies See Section 12.
6. With a chisel, remove rivets securing center grille Removal Fig. 10
to valance panel. 1. Raise hood and disconnect battery leads and remove
7. Remove screws attaching center grille bracket to battery.
headlamp support bracket and remove center grille 2. Remove bumper Section 14.
from vehicle. 3. Remove screws securing hood catch assembly to
8. If valance panel removal is desired, remove front grille header panel, catch support bracket, and
bumper assembly See Section 14. radiator support and remove hood catch.
HEADER
HOOD LOCK
CATCH
CENTER
GRILLE
UPPER
GRILLE
LOWER
GRILLE
FENDER
HEADLAMP
HOUSING
HEADLAMP
HEADLAMP MOLDING
PANEL
Fig. 9-Camaro Grille Assembly Standard Headlamps
HOOD LOCK
CATCH
HEADER
RADIATOR
‘PANEL
SUPPORT
VALANCE
PANEL
UPPER
GRILLE
HEADLAMP
LOWER CENTER PLATE
GRILLE GRILLE
EMBLEM HEADLAMP
MOLDING
HEADLAMP
COVER
Fig. 10-Camaro Grille Assembly Retractable Headlamps
4. Remove screws from each headlamp bezel and re be used for the new grille installation. Where rivets were
move bezels from vehicle. Remove headlamps See removed, make new attachments using screws and nuts,
Section 12. patent clips, or rivets.
5. Remove hardware attaching hood catch support to
radiator support, valance panel, and lower grille Installation
and remove catch support from vehicle. Install grille and related components following the
6. Disconnect parking lamps. Remove rivets securing removal procedure in reverse order.
center grille to upper and lower grilles and remove
center grille from vehicle. If necessary, replace
name plate. GRILLE ASSEMBLY-CORVETTE
7. Remove screws and rivets securing grille header
panel to fenders and upper grille and remove header Removal Fig. 11
panel. 1. Remove left and right hand parking lamps.
8. Remove hardware attaching upper and lower grilles 2. Remove screws attaching left and right grilles and
to vehicle and remove upper and lower grilles. remove grilles from vehicle.
9. Remove screws attaching valance panel to fenders 3. Remove license plate bracket.
and fender extensions and retractable headlamp door 4. Remove four screws securing center grille assembly
assemblies, and remove valance panel from vehicle. and remove grille from vehicle.
10. If necessary to remove retractable headlamp covers,
refer to Section 12. Installation
Repairs Install grilles and related components following the
If any components removed are undamaged, they may removal procedure in reverse order.
HEATER AND ACCESSORIES 13-1 ‘I
Fig. 11-Corvette Grille Assembly
SECTION 14
BUMPERS
INDEX
Page Page
Chevrolet Disassembly 14-5
Service Operations 14-1 Assembly 14-5
Front Bumper Assembly 14-1 Installation 14-5
Removal 14-1 Rear Bumper Assembly 14-5
Disassembly 14-1 Removal 14-5
Assembly 14-1 Disassembly 14-6
Installation 14-1 Assembly 14-6
Rear Bumper Assembly All Except Wagon 14-1 Installation 14-6
Removal 14-1 Corvette
Disassembly 14-2 Service Operations 14-6
Assembly 14-2 Front Bumper Assembly 14-6
Rear Bumper-Wagon 14-2 Installation 14-8
Chevelle Rear Bumper Assembly 14-8
Service Operations 14-4 Removal 14-8
Front Bumper Assembly . . 14-4 Installation 14-8
Removal 14-4 Camaro
Disassembly 14-4 Service Operations 14-8
Assembly 14-4 Front Bumper Assembly 14-8
Rear Bumper Assembly 14-4 Disassembly 14-8
Removal 14-4 Assembly 14-8
Disassembly 14-4 Installation 14-8
Assembly 14-4 Rear Bumper Assembly 14-9
Chevy U Disassembly 14-9
Service Operations . . . . 14-5 Assembly 14-9
Front Bumper Assembly . 14-5 Installation 14-9
Removal 14-5
CHEVROLET
SERVICE OPERATIONS
Front Bumper Fig. 1 Installation
1. Position bumper assembly on frame horns, aligning
Removal bracket and frame holes.
1. Raise hood and disconnect parking lamp wiring, push
2. Connect fiber optic and wiring for parking lamps.
connector and grommet down through sheet metal.
3. Align bumper assembly and tighten bolts to frame.
4. Remove vehicle from hoist.
3. Disconnect fiber optic lead to parking lamp housing.
4. Remove bolts attaching bumper brackets and braces
to frame. Rear Bumper Assembly-AU Except Station Wagon
5. Remove front bumper assembly from vehicle. Fig. 2
Removal
Disassembly
1. Disconnect lamp wiring in trunk and poke grommets
1. Remove bolts attaching brackets and braces to
with connector through trunk floor.
bumper assembly.
2. Separate bumper ends from center face bars.
3. Remove license plate-filler door.
3. Remove rivets fastening lower grille to bumper
assembly center lower face bar.
Assembly
1. Attach lower grille to lower center face bar with
4. Remove rear valance panel attached at quarter
panels, bumper, bracket.
5. Remove center reinforcement attaching face bar to
frame assembly.
I
rivets, screws and nuts, or patent clips. 6. Loosen bolt assembly, each side, holding bumper
2. Bolt upper and lower center face bars to face bar assembly, brace and bracket to frame assembly.
ends. ‘7. Now swivel entire rear bumper down with caution-
3. Attach bumper brackets and braces to face bar electrical wiring or fiber optic connection may be
assembly. snagged.
BUMPERS 14-2
Fig. 1-Front Bumper-Chevrolet
8. Lower hoist and remove remaining bumper attaching Rear Bumper-Chevrolet Wagon Fig. 3
bolts holding bumper.
Removal
Disassembly 1. Place wagon on hoist.
1. Remove license lamps. 2. Disconnect rear license lamp wiring and fiber optic
2. Remove back-up and stop lamps. conductor.
3. Remove bracket assemblies. 3. Remove center face bar to bumper reinforcement
4. Remove remaining bolts fastening bumper pieces- attaching bolts.
inspect rubber spacers for deterioration. 4. Remove bolts attaching bumper brackets to each
side of frame assembly and lift bumper off.
Assembly
Assemble the rear bumper in the reverse order of the Disassembly
disassembly procedure. Tighten all bolts and screws. 1. Remove license plate lamp.
2. Remove bolts retaining braces and brackets to
Installation bumper.
1. Position bumper assembly on vehicle loosely bolting 3. Separate sections of bumper face bars.
brackets and braces to slotted holes in frame
assembly. Assembly
Assemble the rear bumper following the disassembly
NOTE: Toothed face of adjustment washers procedure in reverse order. Attach all bolts loosely; do
must face frame and brackets. not tighten any bolts until all bolts are installed.
2. Pivot bumper assembly partially into position-then
feed lamp connectors and grommets up through trunk Installation
floor connect fiber optics at this time. 1. Position bumper assembly with brackets and braces
3. Install and align center rear reinforcement bar, attached, on wagon aligning holes in frame with those
lower to bumper and frame. in brackets.
4. Tighten bumper bracket adjustment bolts. 2. Loosely install bolts, lock washers and nuts including
5. Install license-filler door. center face bar to reinforeement attachment.
6. Install rear valance panel to underside of bumper 3. Align and tighten all mounting bolts, connect license
face bar. plate lamp wiring and fiber optic conductor.
‘7. Remove vehicle from hoist. 4. Remove wagon from hoist.
BUMPERS 14-3
Fig. 2-Rear Bumper-Chevrolet EXC. Wagon
WASHER
Fig. 3-Rear Bumper-Chevrolet Wagon Fig. 4-Front Bumper-Chevelle
BUMPERS 14-4
CHEVELLE
SERVICE OPERATIONS
Front Bumper Assembly Fig. 4 screws firmly. Assemble the front bumper parts by
following the disassembly procedure in reverse order.
Removal Do not tighten any bolts until all bolts, washers and nuts
1. Disconnect parking lamp wiring from inside engine are installed. Install electrical horns.
compartment.
2. Place vehicle on hoist. Installation
3. Remove bolts retaining bumper brackets and braces 1. Position the front bumper assembly on frame horns,
to the frame. aligning holes in brackets and braces with those in
4. Remove fiber optic connector to parking lamp hous the frame.
ing, and horn plug. 2. Connect parking lamp wiring, horn wiring, and fiber
5. Remove bumper assembly from vehicle. optics before loosely installing all bolts, toothed
washers and nuts.
Disassembly 3. Align bumper assembly to front end sheet metal and
1. Remove parking lamp assemblies secured by 2 tighten attachments.
screws each. 4. Remove vehicle from hoist.
2. Remove bolts attaching braces and brackets to
bumper.
3. Remove electrical horn assemblies. Rear Bumper Assembly Fig. 5
Assembly Removal
Attach both parking lamp assemblies and tighten 1. Disconnect bumper lamp wiring and push sealing
grommets with pigtail connectors through trunk floor
pan on coupes and sedans.
3. Remove bolts located behind license plate door,
attaching face bar reinforcement to frame.
4. Remove fiber optic connector from lamp housing.
5. Remove bolts retaining bumper brackets and braces
to frame.
6. Remove bumper assembly from vehicle.
Disassembly
1. Remove back-up and license lamps from bumper.
2. Remove license plate door.
3. Remove brackets and braces.
Assembly
Attach back-up and license lamp assemblies securely
to bumper. Assemble rear bumper brackets, braces and
reinforcement loosely if slotted. Tighten all bolts not
entering slotted holes.
Fig. 5-Rear Bumper-Chevelle Fig. 6-Front Bumper-Chevy Il
BUMPERS 14-5
Installation 3. Connect fiber optic conductor to lamp housing.

1. Position bumper assembly on frame aligning holes 4. Loosely install bolts, toothed washers and nuts until
in frame with those in brackets, braces and bumper is aligned with sheet metal.
reinforcement. 5. Tighten all mounting bolts securely and remove
2. Push bumper lamp wiring connectors up through vehicle from hoist.
trunk floor pan on ëoupes and sedans. 6. Connect bumper lamp wiring in trunk.
CHEVY II
SERVICE OPERATIONS
Front Bumper Assembly Fig. 6 Installation
1. Position the front bumper on the frame assembly,
Removal aligning holes in brackets and braces with those in
1. Lift hood, disconnect park lamp wiring and pass the frame.
grommet with wiring through sheet metal. 2. Connect parking lamp fiber optic conductor and
2. Place vehicle on hoist. wiring before loosely installing all bolts, washers
3. Remove bolts retaining brackets and braces to and nuts.
frame. 3. Align bumper assembly to front end sheet metal and
4. Disconnect fiber optic conductor to parking lamp. tighten attachments.
5. Remove bumper assembly from vehicle. 4. Remove vehicle from hoist.
Disassembly Rear Bumper Assembly Fig. 7

1. Remove screws securing parking lamp assemblies
to bumper. Removal
2. Remove brackets and braces bolted to bumper face. 1. Disconnect license lamp wiring inside trunk and
push grommet with connector through floor pan.
Assembly 2. Place vehicle on hoist.
Attach parking lamp assemblies and tighten screws 3. Remove bolts fastening bumper brackets to frame
firmly. Assemble the front bumper brackets and braces side rails.
loosely. Tighten nuts, washers and bolts securely alter 4. Remove fiber optic conductor from license lamp
all bolts are installed. housing.
A
Fig. 7-Rear Bumper-Chevy II
BUMPERS 14-6
5. Remove bumper assembly from vehicle. Installation

1. Position rear bumper assembly to frame side rail.
Disassembly 2. Push bumper lamp wiring connector and grommet
1. Remove license lamp from bumper. up through trunk floor pan.
2. Remove door assembly from bumper. 3. Connect fiber optic conductor to lamp housing.
3. Remove brackets anl braces. 4. Loosely install bolts into bracket assemblies until
bumper is aligned with sheet metal.
Assembly 5. Tighten all mounting bolts securely and remove
Attach license lamp and door assemblies securely to vehicle from hoist.
face bar. Bolt brackets to bumper firmly. 6. Connect bumper lamp wiring inside trunk.
CORVETTE
SERVICE OPERATIONS
Front Bumper Assembly Fig. 8 2. Remove both decorative radiator grills.
3. Remove bolts attaching face bar to brackets and
The face bar and bumper guards may be removed,
braces.
without the brace, bracket or license plate assembly
4. Remove bolts attaching lower edge of bumper guards
being disturbed.
to crossmember.
Removal 5. Lift off bumper assembly including face bar and
1. Place vehicle on hoist. guards.
Fig. 8-Front Bumper-Corvette
BUMPERS 14-7
Fig. 9-Rear Bumper-Corvette
BUMPERS 14-8
2. Assemble bumper guards to bumper face bar and

frame crossmember loosely.
3. Align bumper to sheet metal and tighten outer bolts
of face bar first then center bolts and finally bumper
guard to frame bolts.
4. Install decorative radiator grilles.
Rear Bumper Fig. 9

Figure 9 shows an exploded view of the rear bumper
assembly installation on the vehicle. The following pro
cedure covers the left hand bumper assembly only; the
right hand assembly sequence is identical.
Removal-Replacement
2. From beneath vehicle remove bolts, washers and
nuts fastening bumper assembly to braces and rods.
Start disassembly from outboard bolts.
3. Remove braces and rods from frame assembly.
Fig. 10-Rear License Plate Housing-Corvette Installation-Replacement

Connect rear bumper braces and rods to frame loosely.
Install all bolts, washers and nuts before tightening any
6. Separate bumper guards from face bar.
attachments. Tighten all bolts alter aligning rear
7. Note shim and washer locations when disassembling
bumpers to sheet metal.
component parts of the bumper assembly for ease of
installation. Rear License Plate Housing Fig. 10
Replacement The rear license plate housing may be lifted from the
1. Assemble face bar to bumper braces loosely with vehicle by removing the license plate and housing re
bolts. taming screws.
CAMARO
SERVICE OPERATIONS
Front Bumper Assembly Fig. 11 3. Align bumper assembly to sheet metal and tighten all
bolts securely.
Removal
2. Remove bumper assembly brackets secured to
frame.
3. Remove bolts securing outboard brackets to face
bar and fender skirt.
4. Remove screws and nuts securing license bracket
to valance panel and lift bumper assembly from
vehicle.
Disassembly
1. Remove support brackets bolted to face bar.
2. Remove license bracket screwed to face bar.
Assembly
Assemble the front bumper following the disassembly
procedure in reverse order. Install all attachments
loosely. Do not tighten any bolts until all bolts are
installed.
Installation
1. Position assembled bumper on frame horns, aligning
holes in bumper brackets with those in frame.
2. Loosely install bolts, washers, and nuts. Note loca
tion of toothed washers. Fig. 11-Front Bumper-Camaro
BUMPERS 14-9
Rear Bumper Assembly Fig. 12

Removal
2. Remove bumper guard bolts attached to tail panel.
3. Remove screws attaching bumper brackets to frame
and quarter panels.
4. Remove bumper assembly from vehicle.
Disassembly
1. Remove bolts securing brackets to face bar.
2. Remove bumper guards from face bar.
Assembly
Assemble the rear bumper following the disassembly
procedure in reverse order. Install all bolts loosely; do
not tighten any bolts until all bolts are installed.
Installation
1. Position assembled bumper on frame and body align
ing holes in bumper brackets with those in frame.
2. Loosely install screws. Tighten bumper guard
screws last alter aligning assembly to sheet metal.
3. Remove vehicle from hoist. Fig. 12-Rear Bumper-Camaro
SECTION 15
ACCESSORIES
Page
Cruise Master 15-1
Automatic Level Control 15-12
CRUISE MASTER
INDEX
Page
General Description 15-2

System and Component Operation 15-2
Service Operations 15-7
System Checks . . 15-11
Fig. 1 -Cruise Master System
ACCESSORIES 15-2
GENERAL DESCRIPTION
The Cruise Master is a speed control system which in", then into released position which provides "hold in"
employs engine manifold vacuum to power the throttle current. The driver may also press the button fully with
Servo unit. The Servo moves the throttle when speed no pressure on the accelerator pedal. In this case the
adjustment is necessary by receiving a varying amount regulator releases control of the throttle which returns
of bleed air from the Regulator unit. The Regulator to idle and the car slows. When the button is released
varies the amount of bleed air through a valve system the solenoid is pulled in and held in respectively and the
which is linked to a speedometer-like mechanism. The regulator resumes speed control at the speed of the
speedometer cable from the transmission drives the vehicle during the moment of button release at vehicle
Regulator, and a cable from the Regulator drives the speeds over 20 MPH.
instrument panel speedometer. The engagement of the
Regulator unit is controlled by an Engagement Switch BRAKE RELEASE SWITCHES
located at the end of the turn signal lever. Two brake
Two brake release switches are employed in the Cruise
release switches are provided: an Electric Switch dis Master System. When the brake pedal is depressed, an
engages the Regulator unit and a Vacuum Switch de Electric Release Switch cuts off the voltage supplied to
creases the vacuum in the Servo unit to quickly return the engagement switch, hence cuts off power to the Regu
the throttle to idle position.
lator unit. The Regulator is then disengaged and requires
The operation of each unit of the system and the opera
Engagement Switch operation to return it to operation.
tion of the entire system under various circumstances A Vacuum Release Switch operates simultaneously with
is described below. Figure 1 shows the location of the the electric release switch whenever the brake pedal is
system components within the vehicle. depressed. This switch opens a port to atmospheric
pressure which rapidly bleeds down the vacuum in the
COMPONENT OPERATION Servo unit thereby returning the throttle to the idle
position.
ENGAGEMENT SWITCH
This switch, located within the turn signal knob, has SERVO UNIT
three positions. In the fully released position, the switch
The Servo unit is a vacuum actuated, variable position
passes current through resistance wire to effect a "hold
diaphragm assembly which operates the carburetor throt
in" magnetic field in the Regulator solenoid. This cur
tle when the system is in operation fig. 4. It is powered
rent is sufficient only to hold the solenoid in place once
by engine intake manifold vacuum and operates the throt
it has been actuated by the "pull in" circuit. Depressing
tle linkage via a bead chain. The Servo has two ports on
the button partially allows current to flow to the Regu the sealed side of the diaphragm housing: one is supplied
lator solenoid at full voltage which causes the solenoid manifold vacuum, and the other is connected to a variable
to pull in. Depressing the button fully opens the circuit air bleed in the Regulator Unit. The vacuum port is
to both the resistance and standard solenoid feed wires
located at the center of the unit and the air bleed port
and the solenoid becomes de-activated. is near the outer wall. When vacuum is applied to the
During vehicle operation the three switch positions center port, atmospheric pressure moves the diaphragm
have the following functions: which pulls on the bead chain opening the carburetor
throttle. As the diaphragm moves, it positions a tapered
Released
a. System not engaged: No function of the system
will occur although a small current is flowing
through the solenoid via the resistance wire at c-WIRE RELIEF LUG
vehicle speeds over 20 MPH.
b. System engaged: The small current flowing
through the resistance wire is holding the solenoid
in the engaged position.
TURN SIGNAL LEVER
Partially Depressed
Full voltage is applied to the solenoid vehicle speed
over 20 MPH which sets the Regulator to maintain the WIRE
vehicle speed at the time of Regulator engagement.
SWITCH
Fully Depressed
No electricity flows to the solenoid and the Regulator
is inactive. This position is used by the driver when he
desires to raise or lower his controlled speed. He may
accelerate to his new speed, press the button fully regu
lator releases previously set speed and release the but
ton. Upon releasing the button, it passes through the
partially depressed position and the solenoid is "pulled Fig. 2-Cruise Master Engagement Switch
ACCESSORIES 15-3
needle within an orifice in the vacuum port so that as the housing and allows it to rotate through an angle which is
diaphragm moves toward the port, the orifice becomes proportional to car speed. If the car doubled its speed,
smaller; and as i moves away from the port, the orifice the shaft would rotate to twice its previous angle as may
becomes larger. be seen by noting the operation of a speedometer. The
The air bleed port serves to supply a variable quantity driven disk is sandwiched between the magnetic disk and
of air to the diaphragm chamber which causes the dia a field plate. The field plate forms a returninz path for
phragm to attain a balanced state between the force of the magnetic field from the magnetic disk.
the atmospheric pressure to chamber pressure differ The gear drive for the magnetic disk is a 90 degree
ential and the force of the diaphragm and throttle return nylon gear drive with the driven gear rotating both the
springs. In operation then, the following events occur: ‘magnetic disk and the speedometer drive cable.
Vacuum is applied to the center port and the diaphragm
moves toward the port. The tapered needle restricts Vacuum Switch, Air Bleed and Filter, and Low
the vacuum port more and more as it moves into the
orifice. If no air was allowed to bleed into the chamber,
Limit Speed Switch
the diaphragm would move until it contacted the housing, The end of the shaft from the speed sensing assembly
however, the Regulator meters bleed air into the chamber with the rubber drum extends into the air bleed metering
and the diaphragm reaches a point at which the air is assembly. This rubber drum has a tang extending from
bled out of the chamber through the, vacuum port orifice its surface which allows a set of points to close at a
as fast as it enters the air bleed port. If the Regulator specific car speed. When the car reaches about 20 mph,
begins to supply less bleed air, vehicle speed decreas the rubber drum has rotated far enough moved by the
ing the vacuum in the chamber increases and the dia brass driven disk in the magnetic field so that its tang
phragm moves toward the vacuum port. In so doing, the has allowed a spring loaded electrical point to contact
tapered needle closes the vacuum port orifice even more another point. These points are in series with the sole
and the air bled into the chamber again equals the air noid coil so that under 20 mph, no Regulator operation
bled out. A balance occurs again with the diaphragm in is possible.
a new position. If the Regulator begins to supply more Surrounding the rubber drum is a "U" shaped spring
bleed air, vehicle speed increasing the vacuum in the clip which is held spread away from the drum by the
chamber drops and the diaphragm moves away from the nose or cam of the solenoid when the solenoid is In the
vacuum port, withdrawing the tapered needle from the relaxed position. The rubber drum and this clip com
orifice and enlarging it. Since the vacuum orifice is prise the speed clutch of the regulator. When the sole
now larger, the greater quantity of air being bled into noid is energized, the solenoid nose moves toward the
the chamber may be bled out by vacuum and a balance drum and releases the ends of the clip. The clip springs
again occurs with the diaphragm in a new position. inward and attaches itself by friction to the drum. Now,
any change in car speed will rotate the drum and move
REGULATOR the "U" clip just as a speedometer moves its needle.
The Regulator is a device which has two primary The top of the "U" clip is attached to the air bleed valve.
The clip moves a sleeve which slides on the orifice
functions: First, it is a vacuum switch which, when en
tube thereby covering and uncovering air ports in the
gaged by the driver, supplies engine manifold vacuum to
the Servo. Second, it meters a small variable quantity
of air to the Servo unit in order to change the carburetor
throttle opening to effect speed control. A secondary
function of the Regulator is to drive the speedometer. LOCK NUT
Since the car speed is sensed by a speedometer-like -ORlFICE TUBE
mechanism within the unit, the speedometer cable from AND CONNECTOR
ASSEMBLY
the transmission drives the Regulator which drives a
second cable at a one to one ratio to the speedometer.
The Regulator is electrically engaged and disengaged
through operation of the Engagement Switch and
the Electric Brake Release Switch. It has two sub-
assemblies which make up the unit: one being the mag
netic speed sensing assembly and the other being the
solenoid actuated vacuum switch, air bleed and filter,
and low limit speed switch assembly fig. 8 and 9.
Magnetic Speed Sensing Assembly

The speed sensing assembly operates in the same man
ner as a speedometer unit except that instead of rotating
a’ needle through an angle proportional to the vehicle
speed, it rotates a rubber drum which is clutched to the
air bleed valve when the system is in operation. The AIR FILTER AND
assembly is driven by the speedometer cable from the SOLENOID HOUSING COVER
transmission which turns a disk shaped ferrite magnet.
Facing the magnetic disk is the driven brass disk mounted
on a shaft with the rubber drum mounted on the same
shaft. A spiral hairspring connects the shaft to the Fig. 3-Regulator Unit
ACCESSORIES 15-4
CONTROLLED AIR SUPPLY DIAPHRAGM

FROM REGULATOR
I /
/
/
ENGINE MANIFOLD VACUUM
FROM REGULATOR VACUUM VALVE
Fig. 4-Servo Unit
wall of the tube the tube inner end is plugged whenever During system operation the following events occur:
car speed changes from the speed at which the solenoid 1. Car speed below 20 MPH--no function of the pull-in
was energized. The direction of drum rotation is such circuit because the rubber drum has not rotated far
that resulting bleed valve operation will cause the Servo enough to close the solenoid points. No pull-in cur
to decrease engine power if the car exceeds the preset rent can flow through the solenoid coil. The solenoid
speed and increase engine power if car speed decreases. coil is receiving a small current via the 40 ohm
The air which passes out the orifice tube enters the resistance wire unless the brake pedal is depressed,
Regulator through the openings in the solenoid housing, engagement switch fully depressed, or the ignition
passes through the oil wetted polyurethane filter, and then switch is "off".
enters the orifice tube ports. 2. Car speed above 20 MPH--The tang on the rubber
When the solenoid is de-energized, the nose retracts drum has closed, the solenoid points and current
and cams the ends of the "U" clip outward so that it re may flow through the normal wire to the solenoid
leases the rubber drum. coil. This current is not sufficient to "pull in" the
The solenoid also operates a vacuum switch simul solenoid.
taneously with the clutching and declutching of the "U" 3. Driver partially presses Engagement Switch--full
clip. The vacuum switch supplies the Servo unit with voltage flows through the solenoid to puli it into
manifold vacuum. The solenoid operated vacuum valve operation. Solenoid cam tension on the "U" clip Is
slides over two ports in the Regulator wall. One port released and the clip grips the rubber drum. Simul
is connected to manifold vacuum and the other is con taneously the vacuum switch operates; applying man
nected to the center port of the Servo unit. When the ifold vacuum to the Servo unit which tightens the
solenoid is de-energized, the valve closes the manifold throttle chain. When the driver releases pressure
vacuum port and opens the Servo port to the inside of from the accelerator pedal the unit will position the
the regulator case. When the solenoid is energized, the throttle to maintain the speed at the time of solenoid
valve connects the Servo port to the manifold vacuum operation.
port thereby supplying vacuum to the Servo unit. 4. Driver releases the Engagement Switch--current
ACCESSORIES 15-5
VACUUM
RELEASE
SWITCH
Fig. 5-Servo Mounting ELECTRIC

RELEASE.
flows to the solenoid through the 40 ohm wire and SWITCH
since the solenoid is "pulled in", the reduced cur
rent flow is sufficient to hold it in position.
5. The car begins to ascend a hill--car speed drops
slightly very slightly and the magnetic force on the
driven disk of the speed sensor is decreased. The
disk rotates slightly as would a speedometer shaft
because of hairspring tension turning the rubber Fig. 7-Release Switches and Brackets
drum. Since the "U" clip is gripping the drum, it

moves the slide which COVERS the air bleed ports
more. With less air bleeding into the Servo, greater
vacuum exists in it and the diaphragm moves toward
the vacuum port opening the throttle wider. The
tapered needle moves into the orifice further and the
diaphragm balances in a new position with the wider
throttle opening. Car speed has been maintained
automatically.
6. The car begins to descend a hill--car speed in
creases slightly and the regulator movements oc
curing above occur again except in reverse. The
rubber drum is turned further against spring tension
and the air bleed orifices are uncovered more. This
bleeds more air to the Servo reducing the vacuum in
the unit. The diaphragm moves away from the
vacuum port, closes the throttle slightly, and with
draws the tapered needle from the vacuum orifice.
With the orifice enlarged, the increased vacuum
counteracts the increased air bleed and the dia
phragm finds a balance again at a reduced throttle
opening.
7. Driver accelerates by pressing accelerator pedal--
car speed increases and the system responds by
moving the diaphragm to decrease throttle opening.
Since a bead chain is used, the chain merely relaxes
and has no effect on throttle operation. After the
driver releases pressure from the pedal, the throttle
will close until car speed decreases to the pre-set
speed. At that point the Regulator bleeds less air
to the Servo which opens the throttle enough to
maintain the pre-set speed. The system returns to a
stable condition,
8. Driver desires higher controlled speed, presses ac
celerator until new speed is reached, and depresses
Engagement Switch fully and releases button--speed
Fig. 6-Servo, Regulator and Hose sensing assembly tries to turn in a direction that
ACCESSORIES 15-6
would decrease the throttle opening until the driver "holds in" in the normal manner. The air bleed
fully depresses the Engagement Switch. Then the valve is clutched to the rubber drum at the car speed
current is cut off to the solenoid which retracts; the during switch release. Vacuum is again applied to
solenoid nose expands the "U" clip releasing its the Servo and throttle control is assumed by the
grip on the rubber drum. The drum and disk as Regulator to maintain the car speed at the time of
sembly then rotates to a new position because of the switch release.
higher car speed. When the solenoid retracts, it also 10. With system in operation, driver applies brakes--
shuts off vacuum to the Servo and opens the vacuum simultaneously the Vacuum Release and Electric
port to atmospheric pressure within the Regulator Release Switches operate. The Vacuum Switch
thereby bleeding down the Servo toward idle throttle bleeds air into the Servo through the air bleed line
position. As the driver releases the Engagement coming from the Regulator. The vacuum is reduced
Switch, the contacts cause "pull in" and "hold in" of in the Servo and the throttle returns to idle position.
the solenoid respectively. The system is engaged to The Electric Release Switch cuts off power to the
maintain the car speed at the time of Engagement entire system and the solenoid is de-energized. If
Switch release. the driver removes his foot from the brake pedal the
9. Driver desires lower cruising speed, presses En Electric Switch again feeds voltage to the Engage
gagement Switch fully, waits until car speed de ment Switch and the Vacuum Switch seals the air
creases to desired speed then releases Switch--when bleed line. The unit will not re-engage since It re
the Engagement switch is fully depressed the sole ceives only a small current through the 40 ohm
noid is de-energized causing the vacuum switch to resistance wire. If vehicle speed is below 20 MPH
bleed down the Servo to idle throttle position and the the system may not be re-engaged since the tang on
"U" clip of the idle bleed valve is released from the the rubber drum has opened the low limit switch
rubber drum. The drum and disc assembly is free points in the Regulator. In either case, after de
to rotate to a position which corresponds to vehicle pressing the brake pedal, the system will not
speed as the car slows. When the driver releases control car speed until the driver operates the en
the Engagement Switch, the unit "pulls in" and gagement switch above 20 MPH.
MAGNET SPEED DISC ORIFICE TUBE & CONTROL VALVE

/ JFIELD PLATE CONNECTOR ASSEMBLY
/
/
CLUTCH SPRING
TO SPEEDOMETER / / ,r-HAIRSPRfNG
/ SOLENOID & CLUTCH
MAGNET HOUSING HOUSING ASSEMBLY
N’ /
ASSEMBLY
SPEED ‘SWITCH
VACUUM CONNECTOR
SERVO
ENGINE VACUUM
CONNECTR
DRIVE ADAPTOR ASSEMBLY
‘VACUUM VALVE
2
INPUT CONNECTJON
/1
LOCK-IN
SOLENOID PLUNGER
SOLENOID COIL AIR FILTER
SIDE VIEW SECTION END VIEW SECTION
Fig. 8-Regulator-Cross Section
ACCESSORIES 15-7
17
18
2
9
.20
25
27 -
28
29-....... /
Fig. 9- Regulator - Exploded
1. Speedometer Cable 7. Field Plate Adjusting 14. Rubber Drum 22. Vacuum Port To
Adapter From Pinion 15. ,,U,’ Shaped Clutch Intake Manifold
Transmission 8. Adjusting Pinion Spring 23. Vacuum Valve Slide
2. Gasket LoCating Spring 16. Air Bleed Sleeve 24. Solenoid Coil
3. Speedometer Cable 9. Brass Magnetically 17. Orifice Tube 25. Solenoid Plunger
Adapter To Driven Disk 18. Orifice Return Spring
Speedometer 10. Field Plate 19. Orifice Tube Locknut 26. Solenoid Cover Gasket
4. Adapter and Magnet 11. Hair Spring 20. Clutch and Solenoid 27. Air Filter
Housing 12. Hair Spring Keeper Housing 28. Solenoid Cover
5. Rotating Magnet 13. Rubber Drum 21. Vacuum Supply Port 29. Air Inlets
6. Helical Ramp Tang To Servo
SERVICE OPERATIONS
The components of the Cruise Master system are de switch replacement.
signed to be replaced should they become inoperative.
Adjustment - The brake switch plunger must clear the
The Air Filter mounted on the regulator must be
replaced at 1Z,000 mile intervals. pedal arm when the arm is moved 1/4 inch measured at
The Regulator is calibrated in such a manner during the switch fig. 7.
manufacturing that overhaul operations are impractical. Vacuum
However, one adjustment may be made to the Regulator
to correct speed drop or increase at the time of Service - An inoperative sticking, plugged, or leaking
engagement. switch must be replaced. Switch replacement is similar
to brake switch replacement. Be certain that the hose to
BRAKE RELEASE SWITCHES the switch is connected firmly and is not cracked or
deteriorated.
Electric Adjustment - The brake switch plunger must clear the
Service - An inoperative switch must be replaced. pedal arm when the arm is moved 5/16 inch measured at
Switch replacement is identical to standard brake lamp the switch fig. 7.
ACCESSORIES 15-8
ENGAGEMENT SWITCH made, however, until the following items have

been checked or serviced:
Service - The engagement switch is serviced only by
replacement. 1. Bead chain properly adjusted.
2. All hoses in good condition, properly attached, not
Removal
leaking, not pinched or kinked.
3. Regulator air filter serviced as per the above
2. Pry the engagement button out of the turn signal
recommendations.
knob with a small thin bladed screw driver fig. 2.
4. Electric and vacuum release switches properly
3. With a small hook or long nosed pliers, remove the
adjusted.
switch retaining ring.
4. Remove steering wheel to gain access to turn signal Engagement-Cruising Speed Zeroing
lever attaching screw. Remove screw. Remove turn
signal lever from turn signal housing utilizing the If the cruising speed is lower than the engagement
slack in the wiring harness. speed, loosen the orifice tube locknut see fig. 8 and
5. Push slack into turn signal lever slot at base of turn the tube outward; if higher, turn the tube inward.
lever attachment end. This will force switch out of Each 1/8 turn will alter the engagement-cruising speed
the other end of the lever. difference one mph. Tighten the locknut after adjustment
6. With a small soldering iron, unsolder the wires and and check the system operation at 50 MPH.
resolder them to the correct terminals of the re
placement switch. Use only rosin core solder. ELECTRICAL SYSTEM CHECK OUT
Installation 1. Check fuse and connector.
1. Once a new switch is installed, pull it back into the 2. Check electric brake switch as follows: Unplug con
lever by pulling on the harness at the lever slot. nector at switch. Connect ohmmeter at points A and
2. Reinstall retaining ring and button. B on brake switch. The ohmmeter must indicate in
3. Push wire slack into turn signal housing; reinstall finity when the pedal is depressed and continuity
turn signal lever and steering wheel. when pedal is released. The cruise release brake
4. Connect battery ground cable. switch electric is adjusted as is the standard stop
light brake switch. Replace electric brake switch if
SERVO needed.
3. Check engagement switch and connecting wiring as
Service - If the Servo unit is found to be defective, re
follows: Unplug push button control connector
placement is required. Note the condition of the hoses
brown, blue, black at electrical wiring harness
and replace any which are cracked or deteriorated.
connector and perform the following tests. see
Adustment Adjust the bead chain so that it is as tight fig. 10.
as possible without holding the throttle open when the Test #1 - Connect ohmmeter between terminal #1
carburetor is set at its lowest idle throttle position. brown wire and terminal #2 blue wire. Continuity
When connecting the bead chain engine stopped manually shall be maintained until switch is depressed all the
set the fast idle cam at its lowest step and connect the way in.
chain so that it does not hold the idle screw off the cam. Test #2 - Connect ohmmeter between terminal #1
If the chain needs to be cut, cut it three beads beyond the brown wire and terminal #3 black. No continuity
bead which pulls the linkage. shall be shown; however, when the button is de
pressed halfway, continuity shall be indicated. When
the button is pressed all the way down, no continuity
REGULATOR shall be shown.
Test #3 - Connect ohmmeter between terminal #2
Maintenance A defective regulator, that is one which
blue wire and terminal #3 black. Button released,
is not simply out of adjustment, must be replaced. Dur no continuity; however, when the button is depressed
ing replacement, check the hoses which connect to
partially and fully, continuity shall be shown.
the regulator and replace any which are cracked or
deteriorated. 4. Disconnect engage switch wire harness connector
from the main harness connector red, brown/white,
Air Filter and white wires. Connect ohmmeter between point
The air filter located in the solenoid cover should be C brown/white stripe wire in main wire harness
replaced every 12,000 miles. and ground. Make sure the regulator is well
1. Snap the solenoid cover off. grounded to the chassis. The ohmmeter should read
2. Replace the filter. between 42 and 49 ohms. If a resistance either above
3. Attach the cover with neoprene seal to the solenoid or below the value indicated is shown, then discon
housing. Be certain that the cover fits tightly to the nect the connector from the regulator and measure
housing. the resistance of the brown/white stripe wire from
point C to D. It should measure 40 ohms ± 2 ohms.
Adjustment If a resistance either above or below the value in
One regulator adjustment is possible: Engagement- dicated is shown, the main wiring harness should be
Cruising Speed Zeroing to remove any difference be replaced. Note: When disconnecting or reconnecting
tween engagement and cruising speed. the main wiring harness connector from the regula
tor, care should be exercised so as not to damage
NOTE: No regulator adjustment should be the blade connectors or the wiring harness. The
ACCESSORIES 15-9
BRAKE
SWITCH
+12V -.
IGNITION CONN
SWITCH AT FUSE BLOCK FUSE
CRUISE POSITION
BUTTON RELEASED
ENGAGE POSITION
BUTTON PARTIALLY DEPRESSED ENGAGE SWITCH
TRIM POSITION
BUTTON FULLY
b
BROWN
BLUE RED
RED
BLACK
BROWN/WHITE STRIPE
RESISTANCE
ENGAGE, SWITCH
CONFIGURATION WHITE WIRE 40A
--
I
WHITE
>
L WHITE
BROWN!
WHITE STRIPE
d BROWN!
WHITE STRIPE
REGULATOR
CONNECTOR
REGULATOR
Fig. 10-Cruise Master Wiring Diagram
disconnect may be facilitated by prying upward Engagement Switch Test

carefully on the plastic connector with a small
blade screw driver.
When measuring the solenoid coil circuit resis
tance between Part E vertical bar of terminal form TERMINALS
ing T to ground the ideal ohmic resistance should BUTTON POSITION
be between 5 and 6 ohms. A reading of less than 4 1 TO 2 1 TO 3 2 TO 3
ohms indicates shorting in the coil circuit. A read
ing of more than 7 ohms indicates excessive re Cruise released closed open open
sistance in the coil circuit. Either extremity
indicates replacement of the regulator assembly. Engage partially depressed closed closed closed
The white main harness wiring from point F to G Trim fully depressed open open closed
should also be checked for continuity.
ACCESSORIES 15-10
WHITE
ELECTRIC BRAKE
12 VOLTS DC.
IGNITION
SWITCH
IN
BRAKE IN
PEDAL
LIMIT
SWITCH
SERVO
POWER
UNIT
THROTTLE
ENGINE
VACUUM
AIR
FILTER
‘REGULATOR
SPEED
TRANSDUCER
Fig. 11-Vacuum and Electrical Diagim
Servo and Vacuum Check Out servo then connect engine vacuum directly to vacuum
servo fitting fitting in middle of servo. Seal the
To determine the condition of the diaphragm, remove servo unit opening.
hoses from power unit and apply 14 inches of vacuum to 2. Note position of servo diaphragm.
either vacuum tube opening seal the other opening and 3. Start engine - the diaphragm should pull in.
hold in for one minute. The vacuum shall not leak down 4. Clamp off engine vacuum supply line and check for
more than 5 inches of vacuum in one minute. If leakage leakage.
is detected, replace servo. To utilize engine as a vac The cruise release brake switch vacuum and con
uum source, proceed as follows: necting hoses can likewise be checked using a vacuum
1. DISCONNECT SERVO BEAD CHAIN and hoses from pump.
ACCESSORIES 15-11
CRUISE MASTER SYSTEM CHECKS
PROBLEM CAUSE CORRECTION

Will not engage-System Brake Switch Circuit Open Check connections-adjust or replace switch.
InoperatiVe Clutch Switch Circuit Open Refer to Electrical Check Out
Fuse blown Replace fuse-if it blows again, check for:
1. Engage Switch stuck in the center of travel-
Refer to Electrical Check Out.
2. Incorrect wiring-Refer to Electrical Check
Out
3. Short to ground-Refer to Electrical Check
Out.
Make necessary corrections.
Defective Engage Switch Replace as needed-Refer to Electrical Check Out.
Vacuum leak in Servo and/or Brake Switch and Vacuum test and repair or replace as needed.
connecting lines. Vacuum hose not connected Refer to Servo and Vacuum System Check Out.
to vacuum switch.
Vacuum release switch misadjusted always open Readjust switch.
Crossed vacuum & air hose at regulator Reroute hoses.
Open in wiring harness Repair or replace as needed.
Defective Regulator Replace Regulator.
Does not cruise at engagement Orifice Tube misadjusted Adjust as required.
speed
System hunts, pulses, or surges Bead Chain loose Tighten Bead Chain.
Hoses reversed at Servo Make necessary corrections.
Kinked or deteriorated hoses air leak Repair or replace.
Dirty Air Filter Service as required.
Defective and/or improperly positioned Drive Cables Repair or replace as needed.
and/or Casing Assemblies
Defective Regulator Replace Regulator.
SystBm does not disengage-with Brake and/or Vacuum Switch-misadjusted or Adjust or replace as required. Refer to Servo
brake pedal defective and Vacuum System Check Out and Electrical
Check_Out
Red wires which should be connected to the pedal Reroute wires to stoplight switch.
switches connected to the fuse block
System steadily accelerates or Hoses interchanged at Servo. Manifold vacuum Reroute hose to Regulator vacuum valve.
applies full throttle when connected directly to outboard tube of Servo
engaged Defective Regulator Replace Regulator.
Pinched or plugged air hose that is connected Free or replace hose.
to the outboard tube of Servo.
Cannot adjust speed downward Defective Engagement Switch or Wiring Replace as needed. Refer to Electrical Check Out.
with Engage Button
Does not engage or engages lower Defective Regulator Replace Regulator.
than limits referred to in
"Driver_Operation"
Slow throttle return to idle after Pinched air hose at vacuum release switch Free or replace hose.
brake_is_depressed.
System operates correctly, but Crossed vacuum hoses at regulator Reroute hoses.
constant vacuum bleed when
system_is_disengaged.
High engine idle speed-inde- Tight Servo Chain Loosen chain adjustment
pendent of carburetor adjust
ments. Constant air bleed Manifold vacuum connected directly to center Reroute hose.
through system. tube of Servo
Constant drain on battery. Power lead connected to "Fused Battery" terminal Reroute to "Fused IGN" terminal.
of fuse block
System can be engaged at idle by Wires reversed at regulator Reverse wires-See Fig. 10.
depressing switch, but will
drop out when switch is re
leased. Solenoid can be heard
when switch is depressed when
the vehicle is standing still.
ACCESSORIES 15-12
AUTOMATIC LEVEL CONTROL

INDEX
Page
General Description 15-12
System Checks and Adjustments 15-13
Service Operation 15-15
GENERAL DESCRIPTION
The optional automatic level control is used only in in the piston and opens the check valve in the end of the
conjunction with the Superlift Shock Absorber option. second stage housing.
The pneumatic level control system automatically main The intake and compression strokes are controlled by
tains correct rear trim height of a car under varying a sliding distributor valve that is actuated through an
load conditions. arm that is tripped by the piston as it nears the end of
The Superlift Shock Absorber option alone, consists of each stroke. Each time the arm actuates the distributor
the two shock absorbers with pressure lines to a "Tee" valve, a different set of holes are covered in the first
where a fill valve is located. The shocks are inflated stage housing. The distributor valve controls the flow of
with or deflated of compressed air at any gas station intake manifold vacuum and air under atmospheric pres
to obtain the vehicle level desired with any given load sure, alternately to opposite sides of the compressor
change. diaphragm.
The automatic leveling system is added to the Superlift As the compressor cycles, the reservoir air pressure
Shock Absorbers and supplies its own compressed air. gradually increases causing a back pressure on the sec
The system fig. 13 consists of a vacuum operated air ond stage piston until it equals the push of pressure
compressor with pressure regulator and integral storage against the diaphragm. At this point, a balanced condi
tank, vacuum line to engine, air intake filter, air lines, tion is reached and the unit stops operating. After res
and a height control valve. ervoir pressure drops due to system air usage, the
The COMPRESSOR is a two-stage, vacuum actuated compressor again begins to cycle and replenish the
type, requiring no lubrication. Vacuum supply is taken reservoir.
from engine carburetor base. High pressure air is Pressure balance will depend upon the prevailing mani
supplied to the reservoir tank by the second stage of fold vacuum and atmospheric pressure. Both are af
the two-stage compressor. The first stage intake stroke fected by altitude above or below sea leVel. Balance
draws air at atmospheric pressure through a oneway pressure will vary from approximately 150 to 275 psI.
check valve located in the end of the first stage housing
NOTE: After completion of work on this sys
under the first stage housing cover. On the first stage
tem or when servicing other parts of the car and
compression stroke, the intake valve is closed and the
the system is deflated, inflate the reservoir to
oneway check valve in the second stage end of the piston
140 psi or maximum pressure available through
is opened. This allows the air from the first stage the compressor service valve.
cylinder to flow through the hollow piston into the second
stage cylinder for high pressure compression. The The PRESSURE REGULATOR VALVE is preset and
second stage compression stroke closes the check valve limits the reservoir outlet pressure to approximately
VACUUM OPERATED AIR COMPRESSOR

WITH STORAGE TANK AND SUPERLIFT
PRESSURE REGULATOR
PORT
CONVERTIBLE-1
VACUUM LINE FROM
AIR SUPPLY
LINES
STATION WAGON-S
I & SEDAN
VALVE WITH TIME
DELAY MECHANISM
INTAKE
PORT
J XHAUST
PORT
SHOCK ABSORBERS
Fig. 12-Automatic Level Control Schematic Fig. 13-Height Control Valve
ACCESSORIES 15-13
125 psi to avoid damage to the height control valve and

Superlift shocks.
The HEIGHT CONTROL VALVE, which is mounted on
the frame, senses rear car height through a link attached
to the right rear upper control arm. When load is added
to the car, the overtravel lever is forced up causing an
internal lever to open the intake valve. When this valve
Is open high pressure air is admitted to the Superlift AIR PISTON
shocks. As the car raises to level, the intake valve
shuts off.
When load is removed from the car, the overtravel
AIR CHAMBER
/ /
lever is forced down causing the internal arm to open the
exhaust valve. As the car lowers to the level position,
the exhaust valve shuts off.
A four to eighteen second time delay mechanism, which
is built into the height control valve, prevents air trans /
AIR DOME
fer due to normal ride movements. The overtravel
lever, which pivots around the control valve shaft, rides
off the flat side of the control valve shaft and does not
have time to react to the rapid changes or normal ride
motions.
During changes due to loading, the time delay mecha
nism will allow the overtravel shaft to open either the in
take or exhaust valve as required, since this is not a
rapid movement.
Fig. 14-Superlift Absorber
The SUPERLIFT shock absorber is essentially a con
ventional hydraulic unit with a pliable nylon reinforced is accomplished by a check valve in the exhaust fitting
neoprene boot acting as an air chamber. on the control valve. Neither shock absorber function
The unit will extend when inflated and retract when nor conventional ride motions thru rear coil springs is
deflated by the control valve. impaired in the event of accidental air pressure loss.
An eight to fifteen psi air pressure is maintained in A combination of steel tubing and reinforced rubber
the Superlift at all times to minimize boot friction. This hose is used for air lines throughout the system.
CHECKS AND ADJUSTMENTS

SYSTEM TEST Automatic Level Control Test Gauge Fig. 15
A complete system test includes on and off-the-car
component tests. NOTE: To service the Automatic Level Con
On the car tests are: trol it will be necessary to secure Gauge Set
Quick check of Automatic Level Control System J-22124 or make up the following test gauge. If
Compressor output test the connectors indicated are not readily avail
Regulator test and adjustment able others may be substituted.
Control valve test
Time delay test 1. Collect the following parts:
Line and fitting leak test a. Fill Valve, J-21999
Trim adjustment b. A tee which has three 1/8" female taper pipe
Off-the-car operations include: threads
Control valve replacement c. An adapter which has a 1/4" female taper pipe
Compressor repair thread on one end and a 1/8" male taper pipe
Component leak tests thread on the other end.
a. Compressor, reservoir, and regulator d. Air Pressure Gauge, J-4872
b. Control valve e. Two metal sleeves, rubber seals and tube nuts.
c. Superlifts f. A length of 1/8" tubing.
g. Two male connectors which have a 1/8" male
Quick Check-On Car Reservoir Pressure at 150 psi taper pipe thread on one end and a 3/8-24 straight
thread male fitting on the other end.
1. Fill the fuel tank or simulate at the rate of 6 lbs./ 2. Assembly
gal. - otherwise car should be empty. a. Connect Fill Valve, J-21b99, female end at male
2. Turn engine off. connector 3/8-24 straight thread fitting.
3. Add a 2 passenger load to the rear bumper or tail b. Connect other end of male connector to tee.
gate. Maintain the load until the car lifts or AT c. Connect adapter to tee.
LEAST 20 SECONDS. d. Connect pressure regulator to adapter.
4. After car lifts remove the load and observe until the e. Connect second male connector to tee, 1/8 inch
car lowers. male pipe thread fitting.
ACCESSORIES 15-14
2. Inflate system through service valve to maximum

available pressure.
NOTE: If available pressure is less than 140
psi, start engine to build-up reservoir to this
pressure.
3. Regulated pressure should build-up to and hold
steady at 100-130 psi on test gauge.
4. Check regulated pressure by momentarily not more
than one second depressing valve core on test gauge
and observe gauge reading.
ADAPTER. I 5. If regulated pressure now reads less than 100 psi,
FILL VALVE replace regulator assembly.
-NUT TEEN J-21 999 6. If regulated pressure exceeds 130 psi, replace regu
lator assembly.
Control Valve Test

Exhaust Superlifts Inflated
I
MALE CONNECTORS 1. Disconnect control valve lever from link.
2. Hold lever down in exhaust position until Superlifts
I deflate or for a minimum of 18 seconds.
*-TUBING 3. If Superlifts deflate, perform Intake Check.
4. If Superlifts do not deflate, remove exhaust adapter
from control valve and hold lever down as in Step 2.
Replace adapter, 0-ring and filter if this deflates
Superlifts.
5. Replace control valve if none of the above steps solve
Fig. 15-Test Gauge Set J-22124 problem.
Intake Reservoir Pressure 125 psi Minimum
f. Install tubing to connector; other end of tubing
1. Disconnect overtravel lever from link.
will go on unit to be checked. 2. Hold lever up in intake position until Superlifts in
NOTE: Make certain all fittings are air tight. flate or for a minimum of fifteen seconds.
3. If Superlifts inflate and hold, proceed to Time Delay
Compressor Output Test-On Car Check.
1. With all accessories off, run the engine until fast 4. If Superlifts inflate and then leak down, perform leak
idle screw is off the fast idle cam. Turn off ignition. test on lines and fittings and then on Superlifts and
2. Deflate system through service valve, then remove control valve. Repair or replace as indicated.
high pressure line at regulator adapter and connect Time Delay Test Reservoir Pressure 125 psi Minimum
test gauge. 1. Record rear trim height of empty car rear bumper
3. Inflate reservoir to 70 psi through service valve. to ground.
4. Observe test gauge for evidence of compressor air 2. Add weight equivalent to two passenger load to rear
leak.
of car. Car should begin to level in 4-18 seconds.
5. If leaking, proceed to leak test-compressor reser
3. Remove weight. After 4-18 seconds car should begin
voir, and regulator. If not leaking, continue this to settle.
test.
4. Replace valve if time delay is not within the 4-18
6. With engine running at slow idle, observe reservoir seconds.
build-up for five minutes. Reservoir pressure should
build up to a minimum of 90 psi. Trim Adjustment-On Car
7. If compressor fails to cycle, make sure the vacuum
and air intake lines are open and unobstructed before Trim adjustment should be performed with a full fuel
removing compressor for repair. tank or the equivalent in load at the rate of 6 lbs./gal
8. If build-up is too slow, proceed to repair lon, but no other load.
compressor. Abbreviated Adustment
9. Satisfactory build-up indicates system problem to be 1. Fill the compressor at the service valve with the
in the control section. However, again observe the available air line pressure.
test gauge for evidence of an air leak and proceed 2. Disconnect link from height control valve lever.
accordingly. Move the height control valve lever upward until air
fills the Superlifts.
Regulator Test and Adjustment 3, Move lever downward and hold until air stops escap
Performance test the regulator with a known good com ing from the exhaust port of the height control valve.
pressor on the car. The Superlifts will now automatically hold 8 to
1. Deflate system through service valve and disconnect 15 psi.
line at pressure regulator valve. Install test gauge 4. Let lever go to its neutral position and loosen the
on regulator valve high pressure fitting. lever adjustment nut.
ACCESSORIES 15-15
5. Assemble the link to the height control valve lever

and tighten the lever adjustment nut.
NOTE: Do not move control valve lever and
overtravel body while tightening nut.
Leak Tests
Compressor, Reservoir and Regulator
1. Remove assembly intact.
2. Connect test gauge to regulator. Inflate reservoir
through service valve to 80-110 psi.
3. Route an 8" rubber hose between vacuum and vent
ports, fig. 16.
4. Submerge in water and observe for air leaks at:
Reservoir weld seam.
Reservoir to compressor 0-ring.
Regulator to compressor 0-ring.
Regulator boot-defective internal 0-ring.
Diaphragm between first and second stage housings.
Tightening through bolts may correct the leak. Fig. 16-Assembly Leak Test Preparation
Cover gasket and retainer screw. A few bubbles here
should escape. If bubbles escape from exhaust port,
is not a leak. A continuous stream indicates defec
tive compressor check valves. replace control valve.
Service valve. 8. If air escapes around edge of cover plate, tighten
Test gauge connections. screws on replace gasket.
5. Correct any leaks detected by either tightening 9. Remove control valve from water. Actuate over-
screws or replacing parts. travel lever to expel any water from unit.
10. Shut off air pressure and remove line from Superlift
Control Valve port.
1. Remove control valve unit from car.
Lines and Fittings
2. Clean exterior of control valve thoroughly.
1. Disconnect overtravel lever from link.
3. Connect test gauge and air pressure source to intake 2. Hold lever up in intake position for maximum Super-
adapter and open air pressure 80-110 psi.
lift inflation and release.
4. Submerge unit in water. No air should escape if
3. Leak check all connections with a soap and water
overtravel lever is in "neutral" position. If bubbles
solution.
escape from Superlift port, replace control valve.
5. Shut off air pressure and detach test gauge from air Superlifts
intake port. Plug intake port with Fill Valve, 1. Disconnect lines and remove unit from car.
J-21999 female end. 2. Inflate individually to 50-60 psi utilizing Fill Valves
6. Connect test gauge to Superlift port and open air J-21999. Submerge in water and observe unit for
pressure. leaks.
7. With overtravel lever in "neutral" position no air 3. Install Superlifts.
SERVICE OPERATIONS
CONTROL VALVE 4. Inflate reservoir to 140 psi or maximum pressure
available through service valve.
Removal
1. Deflate system using service valve. COMPRESSOR, RESERVOIR AND REGULATOR
2. Disconnect two air lines at leveling valve intake and
Superlift ports. Removal and Installation
3. Disconnect link from overtravel lever by removing 1. Disconnect air lines at compressor end.
one nut and lock washer. 2. Disconnect pressure line at compressor head.
4. Remove two screws securing leveling valve to frame 3. From wheel side of fender skirt, remove two screws
and remove leveling valve. from bracket on compressor end.
4. Remove nut and washer from reservoir stud at
Installation bracket and remove assembly from vehicle.
1. Install control valve with two screws, with time delay 5. Remove compressor end mount bracket.
mechanism down. 6. Reverse Steps 1-5 for installaticn, then leak check
2. Secure link to overtravel lever with one nut and lock fittings.
washer. On all station wagons series the link is se
COMPRESSOR, RESERVOIR AND REGULATOR
cured to the lower hole. On all other series cars
with standard springs, the link is secured to the up Disassembly Into Major Components Fig. 17
per hole. The compressor is a precision-built mechanism. All
3. Connect air lines at control valve intake and Super- parts should be carefully handled and assembled. Take
lift port. care to prevent entrance of dirt or foreign matter. DO
ACCESSORIES 15-16
Fig. 17-Compressor, Regulator and Reservoir-Exploded View
Regulator Assembly 16. Thru Bolt, Compressor 32. Piston Assembly 48. Arm Assembly,
2. Adapter Assembly Retaining 33. Plate, Diaphragm Distributor
3. Adapter 17. Nut, Thru Bolt Compressor 34. Diaphragm 49. Screw
4. Valve Core 18. Compressor Assembly 35. Washer .760- 50. Spring, Valve Tension
5. "0" Ring 19. Housing, 2nd. Stage .765 I.D. 51. Bushing, Distributor
6. Cap 20. Check Valve 36. Retainer, Diaphragm Valve Stop
7. Adapter Assembly 21. Spring 37. Check Valve 52. Bushing, Arm
8. ‘O" Ring 22. Expansion Plug Retainer 38. Spring Assembly Stop
9. Boot 23. Housing, 1st Stage 39. Expansion Plug Retainer 53. Arm Actuating
10. Screw, Regulator 24. Arm, Swivel 40. Ring .357- 54. Spring, Arm Tension
Retaining 25. Bushing .367 l.D. 55. Screw, Arm Pivot
11. O" Ring, Regulator 26. Arm, Rocker 41. Seal .569-.571 56. Cover
to Compressor 27. Pin, Rocker Arm 42. "0" Ring .732- 57. Gasket
12. Reservoir Retaining .742 I.D. 58. Screw, Cover
13. ‘0" Ring, Reservoir 28. Intake Valve 43. Seal .943-.945 Retaining
to Compressor 29. Washer 44. Piston 59. Gasket, Cover
14. Thru Bolt, ReServoir 30. Spring, Intake Valve 45. Distributor Valve 60. Mount, Flexible
Retaining Retaining 46. Bushing, Distributor Valve 61. Adapter
15. Nut, Thru Bolt Reservoir 31. Pin, Bushing Retaining 47. Washer .160-.163 l.D. 62. Filter
NOT LUBRICATE as unit is designed to run dry. ervoir. Separate reservoir and 0-ring. Discard
1. Remove compressor as described above. 0-ring.
2. Remove three flexible mounts and three adapters. 6. Remove three compressor retaining through bolts
3. Remove reservoir retaining through bolt, cover re that secure second stage housing to first stage
taining screw and cover gasket that secure cover and housing.
gasket to first stage housing. Remove cover and Slide second stage small diameter housing straight
7.
discard gaskets. off piston.
4. Remove two regulator retaining screws, regulator
assembly and 0-ring from second stage housing. 8. Disconnect arm tension spring from swivel arm.
Discard 0-ring. 9. Remove arm pivot screw and actuating arm.
5. Remove three nuts at reservoir flange and two 10. Slide piston assembly straight out of first stage
through bolts that enter from flanged side of res housing.
ACCESSORIES 15-17
Disassembly, Inspection and Assembly of Major

Components Fig. 17
Diaphragm
1. Inspect diaphragm for holes, looseness or other de
fects and replace if necessary.
2. Remove diaphragm retainer with diagonal pliers and
discard.
3. Remove diaphragm plate, diaphragm, second dia
phragm plate and corprene washer from piston.
4. Install new corprene washer, old plate, new dia
phragm with outer lip toward second stage side,
fig. 17 and second plate. Plates should be installed
so that lip on each plate faces away from diaphragm.
5. Use a 13/16 inch deep socket as a pilot for the new
diaphragm retainer. Press against the piston shoul
der on first stage side, fig. 18 to position
diaphragm retainer. The wood blocks used in the
illustration are each 3/4" x 3/4" x 12".
NOTE: Position diaphragm retainer securely

to effect air tight seal against corprene washer. Fig. l8-Installing Diaphragm Retainer
Seals arm assembly and blow dry with compressed air.

1. Inspect seals for evidence of excessive wear or 2. Inspect distributor valve for cracks. Discard if
coring. If necessary replace seals and 0-rings. damaged.
2. Remove seals and 0-rings from piston. 3. Inspect all other parts for wear or damage.
3. Install new 0-rings by rolling into groove. Relieve
any resulting twist. Assembly
4. Install new seals using a piece of .020" shim stock, 1. If removed, position bushings in first stage housing
fig. 19. Make sure shim stock has no sharp edges and install rocker arm and swivel arm. Align hole
that may cut seal. Do not stretch seal more than in rocker arm with swivel arm and install rocker
necessary to install. Seals should be installed so arm retaining pin, small end first.
they are not twisted.
NOTE: If distributor mechanism failed to
function properly or one or more parts were
Distributor Valve Mechanism and found defective, use new parts in distributor
Intake Valve First Stage Housing
valve and arm package during remaining
NOTE: Actuate distributor valve with finger. build-up.
Valve tension spring should press against dis 2. Install washer on intake valve and install in first
tributor valve, holding it against either stop. If stage housing with intake valve retaining spring.
valve action is not free and positive, it will be
3. Install longer leg of valve tension spring into boss
necessary to rebuild using new parts in Distrib on first stage housing being careful not to distort
utor Valve and Arm Package. If action is free valve tension spring.
and positive and upon disassembly there are no
damaged parts, parts may be re-used.
Disassembly
1. Remove screw, washer, distributor arm assembly,
washer, and distributor valve bushing.
2. Remove two arm assembly stop bushings and two
distributor valve stop bushings.
3. Carefully remove distributor valve being careful not
to distort valve tension spring.
4. Remove valve tension spring from housing boss,
again being careful not to distort valve tension
spring.
5. Remove intake valve retaining spring, intake valve
and washer using pocket knife.
6. If necessary, remove rocker and swivel arms. Po
sition pin for removal by prying with screw driver,
fig. 20. Grip pin with water pump pliers and re
move pin. Remove swivel arm, rocker arm and
bushings.
Cleaning and Inspection
1. Clean all parts in clean solvent except distributor Fig. 19-Installing Seal
ACCESSORIES 15-18
Check Valve Replacement Second Stage Housing

1. Pry out expansion plug retainer on second stage
housing with pointed tool and remove spring and
check valve.
2. Clean second stage housing with clean solvent and
blow dry with compressed air. Check valve seat
should be clean and smooth.
3. Install new check valve and spring.
ROCKER ARM-1 4. Insert new expansion plug retainer and tap in until
it bottoms.
COMPRESSOR, RESERVOIR AND REGULATOR

Assembly From Major Components
1. Slide piston assembly straight into first stage large
diameter housing.
2. Install actuating arm and secure to first stage hous
ing with arm pivot screw, tightening to 12 in. lbs.
3. Connect arm tension spring to swivel arm.
4. Rotate piston in first stage housing to align elongated
hole in diaphragm with vent port in first stage
Fig. 20-Removing Rocker Arm housing.
5. Install three compressor retaining through bolts that
4. Position distributor valve being careful not to distort secure second stage housing to first stage housing.
valve tension spring. Housing will align one way only. Nuts are positioned
5. Install two distributor valve stop bushings and two in counterbores in second stage housing. Tighten to
arm assembly stop bushings. 28 in. lbs.
6. Install distributor valve bushing, washer, distributor 6. Install new 0-ring on second stage housing. Wash
arm assembly, and washer and secure with screw. inside of reservoir in clean solvent and blow dry
Tighten to 12 in. lbs. with compressed air. Install reservoir on second
stage housing with three nuts, tightening to 28 in. lbs.
NOTE: Do not install remaining parts at this
Install two reservoir retaining through bolts, tighten
time as rocker arm must be free to permit en
ing to 28 in. lbs. Through bolt heads should be posi
trance of piston into first stage housing.
tioned against reservoir. Leave out through bolt that
secures cover.
Check Valve Replacement Second Stage Piston 7. Install new 0-ring on regulator and secure regulator
with two regulator retaining screws, tighten to 35 in.
1. Pry out expansion plug retainer on second stage pis lbs. Service valve should be on same side as first
ton with pointed tool and remove spring and check stage housing.
valve. 8. Install ne gasket, cover, and secure with cover
2. Pour a small amount of clean solvent through bore retaining screw and new cover gasket. Tighten cover
in piston and blow dry with compressed air. Check retaining screw to 35 in. lbs. Install through bolt
valve seat should be smooth and clean. so head is positioned against reservoir. Tighten
3. install new check valve and spring. through bolt to 28 in. lbs.
4. Insert new expansion plug retainer and tap in until 9. Install three adapters and flexible mounts.
it bottoms. 10. Proceed to compressor output test on car.
SPECI FICATIONS
HEATING AND AIR CONDITIONING
SECTION 1 A
Compressor System Capacities

Make Frigidaire
Refrigerant R- 12
Type 6 Cylinder Axial
Four-Season Except Corvette and
Displacement
Conifortron Systems 3 lbs., 12 oz.
Four-Season Except Corvette
and Comfortron 12.6 Cu. In. Corvette Four-Season 3 lbs., 4 oz.
GM Chevrolet Air Conditioning
Corvette Four-Season and All 3 lbs.
Systems
GM Chevrolet Air Conditioner. . . 10.8 Cu. In.
Compressor Oil 525 Viscosity
Rotation Clockwise
All Systems 11 oz.
Compressor Suction and Discharge
Connector Bolt Torque 25 ft. lbs.
Compressor Clutch Coil
Fuse In
Ohms at 80°F. 4.18-4.38 Fuses .
Block Line
Amps at 80°F. 2.86 @ 12 Volts
Torques
Comfortron Systems 25 amp. 30 amp.
Rear Head to Shell Stud Nut 23 lb. ft. Four-Season Systems 25 amp. 30 amp.
Shaft Mounting Nut 15 lb. ft. GM Chevrolet Air Conditioning 25 amp. -
Belt Tension See Tune-Up Chart
FRONT SUSPENSION
SECTION 3
WHEEL ALIGNMENT SPECIFICATIONS Vehicle at Curb Weight
Chevrolet Chevelle Chevy II Corvette Camaro
SS and El Camino Manual Steering

Caster* Neg. 1/2° ± 1/2° Pos. 1° ± 1/2°
Pos. 3/4° ± 1/2° Pos. 1/2° ± 1/2° Pos. 1/2° ± 1/2°
All others Power Steering
Neg. 1° ± 1/2° Pos. 2 1/4°± 1/2°
Camber* Pos. 1/4° ± 1/2° Pos. 1/2° ± 1/2° Pos. 1/4° ± 1/2° Pos. 3/4° ± 1/2° Pos. 1/4° ± 1/2°
Steering Axis
7-1/2° ± 1/2° 8-1/4° ± 1/2° 8 3/4° ± 1/2° 7° ± 1/2° 8 3/4° ± 1/2°
Inclination
tToe-In Total @1/8" to 1/4" 1/8" to 1/4" 1/8" to 1/4" 3/16" to 5/16" 1/8" to 1/4"
Wheel Bearing
Adjustment 12 ft. lbs. 12 ft. lbs. 12 ft. lbs. 12 ft. lbs. 12 ft. lbs.
Preload zero zero zero zero zero
End Movement .001" to .008" .001" to .008" .000" to .004" .001" to .008" .001" to .008"
*Must not vary more than 1/2° from side to side.
@Toe-In Total should be 5/16" to 7/16" after rebuild using new bushings and ball joints.
tAdjust Toe-in with steering gear on straight ahead location after camber and caster have been set. Any change
in caster and camber settings will affect toe; always recheck and set toe to specifications.
SPECIFICATIONS 2
RIDING HEIGHT MEASUREMENT
Sedans 4-3/8" ± 1/2"

Chevrolet Coupes and Convertible mci SS 4-1/16" ± 1/2"
Station Wagons 4-5/8" ± 1/2"
Sedan 2" ± 1/2"
Coupes and Convertible 2-3/16" ± 1/2"
Chevelle S.S. Coupes and Convertible 2-7/8" ± 1/2"
Station Wagons 2-3/4" ± 1/2"
Pickup 2-11/16" ± 1/2"
Sport Coupes 2-1/4" ± 1/2"
Chevy 2-5/8" 1/2"
Sedans ±
Camaro Coupes and Convertible 2-7/16" ± 1/2"

Sport Coupes 2-1/2" ± 1/2"
Corvette
Convertible 2-1/2" ± 1/2"
BOLT TORQUES
TORQUES Chevrolet Chevelle Chevy II Corvette Camaro
Spherical Joint
Upper Stud Nut 50 ft. lbs. 50 ft. lbs. 50 ft. lbs. 50 ft. lbs. 50 ft. lbs.
Lower Stud Nut 85 ft. lbs. 80 ft. lbs. 80 ft. lbs. 80 ft. lbs. 65 ft. lbs.
Stud to Control
Arm Nuts Service 25 ft. lbs. 25 ft. lbs. 25 ft. lbs. 20 ft. lbs. 25 ft. lbs.
Lower Forging Nut 40 ft. lbs. - - 40 ft. lbs. -
Steering Arm Attaching Nuts 50 ft. lbs. 85 ft. lbs. 65 ft. lbs. - 85 ft. lbs.
Shock Absorber
. Upper Shaft Nut 8 ft. lbs. 8 ft. lbs. 8 ft. lbs. 8 ft. lbs. 8 ft. lbs.
Lower Attachment 20 ft. lbs. 20 ft. lbs. 20 ft. lbs. 15 ft. lbs. 20 ft. lbs.
Bracket to Spring Tower - - 9 ft. lbs. - -
Stabilizer Bar
Frame Bracket Bolts 15 ft. lbs. 15 ft. lbs. 15 ft. lbs. 10 ft. lbs. 15 ft. lbs.
Link Nuts 15 ft. lbs. 15 ft. lbs. 15 ft. lbs. 15 ft. lbs. 8 ft. lbs.
Strut Rod
Rod to Arm Nut 70 ft. lbs. - - - -
Adjustment Nut 80 ft. lbs. - - - -
Lower Control Arm

Inner Pivot Nuts 115 ft. lbs. 80 ft. lbs. 80 ft. lbs. - 85 ft. lbs.
Upper Control Arm
Attaching Nuts 50 ft. lbs. 50 ft. lbs. 50 ft. lbs. 50 ft. lbs. 50 ft. lbs.
Collar Bolts 45 ft. lbs. 45 ft. lbs. 50 ft. lbs. 40 ft. lbs. 45 ft. lbs.
Brake Anchor Pin
Drum Brakes 130 ft. lbs. 130 ft. lbs. 130 ft. lbs. - 130 ft. lbs.
Brake Anchor Bolt
Disk Brakes 120 ft. lbs. 120 ft. lbs. 120 ft. lbs. 120 ft. lbs. 120 ft. lbs.
Lower Control Arm
Cross Shaft Bolts
Front - - - 70 ft. lbs. -
Rear - - - 95 ft. lbs., -
Wheel Stud Nuts 65 ft. lbs. 65 ft. lbs. 65 ft. lbs. 65 ft. lbs. 65 ft. lbs.
3-3/4
5-15
SPECIFICATIONS 3
REAR SUSPENSION
REAR AXLE
SECTION 4
CHEVROLET, CAMARO, CHEVELLE AND CHEVY U CORVETTE

Gear Blacklash . . .005"-.008" preferred .003"-.OlO" Gear Backlash. .005"-.008" preferred. .003"-.OlO"
Axle Shaft End Play . . .002"-.020" Pinion Bearing Preload in. lbs.
Pinion Bearing Preload in. lbs. New 20-25
New 20-30 Used
Used Lubricant Capacity pints
Lubricant Capacity Bolt Torques Ft. Lbs.
Large Carrier 4.9 pints Carrier Cover 50
Small Carrier 4.5 pints Ring Gear 50
Bolt Torques Ft. Lbs. Differential Bearing Caps 55
Carrier Cover 20 Filler Plug 20
Ring Gear 50 Differential Pinion Lock 20
Differential Bearing Caps 55
Filler Plug 20
Differential Pinion Lock 20
Chevrolet Chevelle Chevy II Camaro Corvette
Type Semi-Elliptic Semi-Elliptic Independent

Heavy Duty Axle 4-Link System Tapered Tapered
3-Link System 4-Link System Single Leaf Single Leaf Three-L
Light Duty Axle or Multi Leaf or Multi Leaf System
Bolt Torque
Spring Retainer 25 40 40 65
Upper Control Arm
Front Bracket 55
Upper Control Arm
Front Bushing 70 80
Rear Bushing 70 ,
Lower Control Arm

Front Bushing 70
Rear Bushing 110
Shock Absorber
Upper 15 15 15 8 50
Upper Bracket 10
Lower 65 65 45 45 35
Spring Shackle
Front 100 100
Rear 50 50
Spring Front Mounting Bracket 25
Tie Rod
Attaching Nuts 80
Stud to Axle Bracket 110
Universal Joint
companion Flange 15 15 15 15 15
Transmission Yoke 15
Wheel Stud Nuts 65 65 65 65 75
Axle Drive Shaft
to Spindle 75
to Yoke 15
All Torque Specifications Lb. Ft.
@ Station Wagon all 4-Link System
SPECIFICATIONS 4
Stabilizer Shaft
Bracket to Frame 120
Bracket to Torque Arm 120
Link Bushings 25
Rebound Bumper to Frame 20
Crossmember to Frame 25
Crossmember to Carrier 60
Carrier Front Support
to Crossmember 65
Front Bolt 50*
Rear Bolt 50
Drive Spindle Nut 100*
Drive Spindle Support
to Torque Arm 30
Strut Rod
to Spindle Support 75*
Bracket to Carrier 45
Camber Cam 65
Torque Arm Pivot 50
Spring Link Bolt to Install nut to expose hole Corvette
Torque Arm then insert cotter pin, only
Wheel Alignment #
Camber Degrees Neg. 7/8° ± 1/2°
Toe-In Per Wheel 1/32" to 3/32"
@Station Wagon All 4-Link System

* Plus additional torque necessary to line up cotter pin hole.
# Camber must not vary more than 1/2 degree from side to side. Toe setting must be made after camber is
set.
RIDING HEIGHT
Body Style Chevrolet Chevelle Chevy U Camaro
2 Door Sedan 6-9/16" ± 3/8" 5" ± 3/8"

4 Door Sedan 6-9/16" ± 3/8" 5" ± 3/8" 6-3/4" ± 3/8"
4 Door Sport Sedan 6-9/16" ± 3/8" 5" ± 3/8"
Sport Coupe 5-11/16" ± 3/8" 4-13/16" ± 3/8" 6-1/4" ± 3/8" 5-1/8" ± 3/8"
Convertible 5-11/16" ± 3/8" 4-13/16" ± 3/8" 5-1/4" ± 3/8"
Station Wagon 6-3/4" ± 3/8" 5-15/16" ± 3/8"
Sedan Pickup 6-1/8" ± 3/8"
Super Sport - Coupe & Convertible 4-3/16" ± 3/8"
All settings are made at curb weight.
Torque@rpm © @ © @ @ © © © © © © @ @ © @ @ @ © © © @
2400 1600 1600 4200 2400 2400 3200 3200 3400 3600 3600 3200 3200 3400 3600 3400 3600 3600 4000 4400 4000
Bore 3-7/8" 4" 4-3/32" 4-1/4"
Stroke 3.25" 3.53" 3" 3.25" 3.48" 3.76"
Compression Ratio 8.5:1 11.0:1 9.0:1 8.75:1 10.0:1 11.0:1 10.25:1 11.0:1 10.25:1 11.0:1 12.5:1 11.0:1
Firing Order 1-3-4-2 1-5-3-6-2-4 1-8-4-3-6-5-7-2
CYLINDER BORE:
3.9995" 3.8745"
Diameter 3.8745"-3.8775" - - 3.9995"-4.0025" 4.0925"-4.0995" 4.2495"-4.2525"
4.0025" 3.8775"
Production .005" Max. .001" Max. nM

out m
Round .
Service .002 Max. nZ
-I
Thrust .0005" Max.
Taper
i e
z
Relief .0005" Max. .001" Max.
Service .005" Max.
PISTON:
.0009"-.0015" ::*
Production .0005"-.OOll" ::: .0005"-.OOll" .0024"-.0030" .0007"-.0013"
Clearance
Service .0025" Max. .0025" Max. .0050" Max. .0025" Max. .0025" Max. !,
PISTON RING:
Top .0012"- .0027" .0012"-.0032" .0017"-.0032"

C Clear- Produc- 0012"
tlon -
o ance 2nd .0012"-.0032" .0012"-.0027" .0017"-.0032" :oo32" .0017".0032"
M roove
Service - Hi Limit ProductIon .001"
S
S Produc-
Top
-
.O10"-.020" :-
.
*g,, .013"-.023" .O10"-.020" .010"-.020"
O Gap 2nd .010"-.020" .013"-.025" .013"-.023" .01O"-.OZO"
Service Hi Limit Production .01"
Groove Production .000"-.OOS" .0005"-.0065"

Clear-
o ance Service Hi Limit Production .001"
L
Gap
Production
Service
.015"-.055’
Hi Limit ProductIon .01"

I .010.030"
2.4484"-2.4493" 2.7484" 2.7484" 2.7481"-2.7490"
2.7493" 2.7493"
All
AU #3-4 #2-3-4
Diameter 2.7481" 2.7481"
2 2984"
2.2983"-2.2993" 2.7490" 2.7490"
2:2993"
#5 #5 #5 #5
2.447"-2.4488" 2.7478" 2.7478" 2.7478"-2.7488"
Main 2.7488" 2.7488"
Journal
Produc
.0002" Max.
tion
Taper
Service .001" Max.
Produc
.0002 Max.
out of Inn
Round
Service .001" Max.
#1-2-3-4 #1-2 #1-2-3-4

.0008"-.0020" .0010"-.0022" .0013"-.0025"
U
All
Main
Bearing
Production
.0003"-.0029" .0008 ,, t34
.0013 -.0025
.00 0 #5
Clearance #5 #5
.0018"-.0034" .0015"-.0031" .0015"-.0031"
Service .004" Max.
Crankshaft End Play .002"-.006" .003"-.Oll" .006"-.OlO"
Diameter 1.999"-2.000" . 2.099"-2.100" 2.199"-2.200" 2.199"-2.200" 2.1985"-2.1995"
Produc
.0003 Max.
Taper tion
Crank-
pin Service .001" Max.
I
Produc .002 Max.
Out of tion
Round
Service .001" Max.
.0007"-.0027" .0007"-.0028" .0009"-.0025" .0009"-.0025" .0014"-.0030"

RoBearlr0cu0tb0n
Clearance
Service .004" Max.
Rod Side Clearance .0085"-.0135" .009"-.013" .015"-.021"

I .015".021" .019".025"
.002" Max.
1/32" - 1/16"
.0010"-.0025"
.0012"-.0027"
n U,
I
Il A
.5’
A
n
1.94"-2.00" 0
z
U,
zC
*Engine at operating temperature and running. **Aluminum Heads 45
IPrimazy .350" .350 .350
Float Drop - 1-3/4’ Mechan.I-.---- - -
Float ical Sec
Accelerator - .50 .50 .50
- 1-1/8" 9/32" Level ondary
Final Use Sight Plug -

Idle Vent .050" 1" 3/8"
.015"
Fast Mechanical 1-1/2 Turns - 2 Turns Accelerator Pump .0151.015
Idle Running Idle Vent - .065 -
2400 rpm - 2400 rpm -
Mechanical .025" .025 .025

Carburetor
.150" .180" .200" .060" .100 .100 .100 .100 .100 .100 .100 .100 .100 .100 .100 .100 Fast Idle -
Choke Rod Final 2200 rpm In
CholeVuum .245 .250" .250" .300 .300
rn
.260" .275" .100" .160 .245 .245 .160 .245 .160 .245 .160 .245 .160 .245 Choke Vacuum Break -
-I
Choke Unloader .275" - .275" .350 .350
Choke Unloader - .350" .200" .260 .300" .260" .300"
Choke Rod
Rod Di
Interference
*
1 Rod Diameter 1 Rod Diameter Interference
Thermostat
Choke Rod
1/2 to 1 Rod Dia.
Interference -
z m
1/2 Turn
. Secondary Stop Closed
Air Valve Open
- 3/8 7/8 3/8 7/8
Spring Main Primary 454 #62 #76 #69 #
Metering - -
Secondary
- .020" Jet Secondary - #76
Closing - -
Secondary Throttle Primary l_1/211_3/411_1/2 1-11/16

070"
Opening Bore Secondary - l-lJ/16
Secondary
010"
Lockout
Main
Meter-
Primary .095" .095" .103" .103" .103" .052" .053" .052" .053" .071"
Jet
Primary 1-11/16" 1-7/16" 1-3/8"

Throttle
Bore Sec- - 2-1/4"
ondary
n
I
Air Valve
- 015"
Daahpot
1 Secondary 27/32"
I
Metering Rod
in ®Air Conditioning
®Camaro Only
SPECIFICATIONS 9
ENGINE TORQUES
SIZE USAGE
153
IN LINE
J 230 I 250
}J V-8
350 I 3961427 -
1/4-20 Camshaft Thrust Plate 80 lb. in 3o

Crankcase Front Cover 80 lb. in.
Flywheel Housing Pans 80 lb. in.
Oil Filter Bypass Valve 80 lb. in.
Oil Pan To Crankcase
Oil Pan To Front Cover 55 lb in
Oil Pump Cover 70 lb in :
Rocker Arm Cover 55 lb. in.
11/32-24 Connecting Rod Cap 35 lb. ft.
5/16-18 Camshaft Sprocket 20 lb. ft.
Clutch Pressure Plate 20 lb. ft.
Oil Pan To Crankcase 125 lb. in. 65 lb. in. I 135 lb. in.
Oil Pump 115 lb. in. T---
Push Rod Cover 80 lb. in.
Water Pump 15 lb. in.
3/8-16 Clutch Pressure Plate 35 lb. ft.
Distributor Clamp 10 lb. ft.
Flywheel Housing 30 lb. ft.
Manifold Exhaust 20 lb. ft.
Manifold Exhaust to Inlet 25 lb. ft. _-
Manifold Inlet 30 lb. ft.

Manifold Clamp L6 Outer 20 lb. ft.
Manifold Clamp All Others 30 lb. ft.
Thermostat Housing 30 lb. ft. -----------
Water Outlet 20 lb. ft.

Water Pump I-ZZZIj 30 lb. ft.
3/8-24 Connecting Rod Cap 50 lb__ft
7/16-14 Cylinder Head
Main Bearing Cap 65 lb ft 80 lb
Oil Pump 65 lb. ft.
Rocker Arm Stud 50 lb. ft_
7/16-20 Flywheel 60 lb. ft.
Torsional Damper lb. ft.
1/2-13 Cylinder Head 95 lb. ft. [. =====-
Main Bearing Cap 2 bolt lb. ft.

Math Bearing Cap 4 bolt -=zT 105 lb. ft.
1/2-14 Temperature Sending Unit 20 lb. ft.
1/2-20 Torsional Damper -_-------------- -===TTiiiii I 85 lb. ft.
Oil Filter Hand Tight
Oil Pan Drain Plug 20 lb. ft.
14mm Spark Plug 25 lb. ft.
*RPO L88, L89 - Aluminum Cylinder Head - Short Head Bolts 65 lb. ft. - Long Head Bolts 75 lb. ft.
SPECIFICATIONS 10
TUNE UP CHART
Every 12,000 miles-Have engine tune-up operations performed to maintain maximum engine performance and fuel economy.
Type In Line V8
Displacement 153 230 250 302 307 327 427
Compression®
Horsepower 90 140
130
155 290
190
200
150
210
f 250
160
275
J 300
160
s Make Standard AC46N AC 44 AC 43N
A L Number
Cold AC44N AC AC AC AC
R U 42-iC 44S 43 43S AC 43 AC C42N
K0
Gap .035
D
Point Dwell 31° - a° I 28° - 32°
I Point Gap .016" Used .019" New
S
T Arm Spring Tension 19 - 23 Ounces
I 28 - 32 oz. 19 - 23 oz.
R
I Condenser .18 - .23 Microfarad
B -
UT °
T I Synchro. 0° 4B 2°B 2°A 4°B 0° 4°B 0° 4°B TDC 4°B 12, 4°B
g® -
Auto. 4°B - 2°B 4°B - 4°B - 4°B -
rFan & P/S 50 lb. Mm. 75 ± 5 lbs. Used 125 ± 5 lbs. New Using Strand Tension Gauge
LA/C Compressor 65 lb. Mm. 95 ± 5 lbs. Used 140 ± 5 lbs. New Using Strand Tension Gauge
A.LR. Pump 35 lb. Mm. 55 ± 5 lbs. Used 75 ± 5 lbs. New Using Strand Tension Gauge
Air Cleaner ®
Inlet® HydraulIc .030 Hydraulic - One Turn Down From Zero Lash .024 .022 .024
Valve
Lash .028 .024
Exhaust® Hydraulic .030 HydraulIc - One Turn Down From Zero Lash .028
Idle
rpm
Synchro. 750 900
-
700
I 600 700* 750* ‘ 700 750 700 750 1000 750
®
Fuel
Auto.
Pressure
600
3 to 4-1J2
600* - 600 - 600
I -
5 to 6-1/2 5 to 8-1/2
Pump
® Volume One Pint In 30 - 45 Seconds
Crankcase Vent Service at 12,000 Miles
6 Cylinder Engine - Rotate cam lubricator 180° Replace filter element located In carburetor inlet
" at 12,000 mile intervals - Replace at 24,000 mile ® every 12 months or 12,000 miles whichever occurs
intervals. first.
8 Cylinder Engine - Change cam lubricator end for
end at 12,000 mile intervals - Replace at 24,000 mile
intervals.
ç Psi at cranking speed, throttle wide open - Maximum variatIon, 20 lbs. between cylinders.
At Idle speed with vacuum advance line disconnected and plugged. A = A.T.D.C.; B = B.T.D.C.
CAUTION: In addition to its function of filtering air cleaned with an air hose. If so equipped, replace
drawn into the engine through the carburetor, the air "Bowtle" filter every 24,000 miles.
cleaner also acts as a flame arrestor in the event the
engine backfires. Because backfiring may cause fire Polyurethane Type - Every 12,000 miles clean element
in the engine compartment, the air cleaner should be in suitable solvent such as Kerosene, squeeze out all
installed at all times unless its removal is necessary
or repair or maintenance services. solvent, then soak in engine oil and squeeze out. Then
squeeze in a clean dry cloth to remove excess oil.
Paper Element Type - First 12,000 miles, inspect
element for dust leaks, holes or other damage, replace Flame Arrestor - Every 12,000 miles - Clean the
if necessary. If satisfactory, rotate element 180° from arrestor located in the base of the air cleaner with
original installed position. Replace element at 24,000 kerosene or a suitable solvent. Dry with compressed
miles. Element must not be washed, oiled, tapped or air
Mechanical - Set with engine at operating temperature and running.
Automatic Transmission - Set idle with transmission in drive.
Air Conditioned Vehicles - Set Idle with air conditioning turned ‘OFF" except on specifications Indicated by ".
® Adjust timing at 800 rpm.
SPECIFICATIONS 11
ENGINE ELECTRICAL
SECTION 6Y
BATTERY
153L-4, 194, 230, 396 & 427 V-8

327, 350, 396
Application 250L-6 & 307 w/AC & M-40 Corvette
& 427 V-8
V-8 Trans.
Ground Neg. Neg. Neg. Neg.
Plates 54 66 66’ 78
Cranking Power 0°F. Watts 2300 2900 3150 3250
*65° Side Recess and One Piece Cover Construction
GENERATOR
Generator Model 1100813 1100794 1100814 1100796 1100795 1100815 1100696 1100817 1100818 1100750 1100693 1100810
Chevrolet &
Chevelle V-8 Chevrolet
Exc. w/C-60,
427 V-8 All V-8 Chevrolet
C-75 and & Chevrolet
w/A/C, w/C-60 & Chevelle All L-6
327, 396, 427 All L-6 396 V-8
All Chevelle C-75 w/C-60 All V-8
w/M - 40 327, 396 w/K-79 Corvette w/RPO Corvette Corvette C-60 or
L-6 & Camaro All L-6 &427 or C-75
Application Chevy II& V-8 and K-19 Exc. C-75
w/K-19 396 V-8 w/C-60 & w/M-40 and/or w/K-66 w/K-19 K-76 w/C-60
Camaro V-8 0-60 w/M-40&
or N-40 w/C-60, C-75 Exc. and/or Exc.C-60
Exc.w/C-60, Exc. N-40 K-76
Camaro K-19 & N-40
All L-6 Exc. C-60 w /C-60
302 V-8 N-40
w/K-19 & C-75
w/C-60
N-40, C-60
& C-75
Field Amp.
2.2-2.6 2.2-2.6 2.2-2.6 2.2-2.6 2.2-2.6 2.2-2.6 2.2-2.6 2.2-2.6 2.2-2.6 2.2-2.6 2.2-2.6 2.2-2.6
Draw
Hot Output -
37 37 37 61 42 42 42 61 63 61 37 63
Amps.
Cold Output
- 14 14 14 14 14 14 14 14 14 14 14 14
Volts
SPECIFiCATIONS 12
REGULATOR
Regulator Model 1119515 1119519
Application Base Service Only
Field Relay: ir Gap .015 .015
Point Opening .030 .030
Closing Voltage 1.5-3.2 1.5-3.2
Voltage Regulator: Air Gap .067 .067
FPoint Opening .014 .014
Voltage Setting 13.8-14.8 @ 85°F. 13.8-14.8 @ 85°F.
STARTING MOTOR
Starting Motor Model 1108365 1108366 1108367 1108361 1107372 1107365 1107368 1108351
153L-4 396 & 427

& 230L-6 Cu. In. 307 & 327
w/Manual 327 Cu. In. 250L-6 V-8
Trans. 153L-4 307 Cu. In. All Trans. V-8w/H.D. Corvette
Application 230L-6 w/Auto. V-8 V-8 Hvy. Duty Chevelle, Clutch
Auto. & Taxi 350 w/RPO
w/Auto. Trans. All Trans. Chevrolet L-88
Trans. Chevrolet Cu. In.
Trans. & Corvette V-8
250L-6 w/14" Ring
All Trans. Gear
Brush Spring Tension,oz. 35 35 35 35 35 35 35 35

Volts 10.6 10.6 10.6 10.6 10.6 10.6 10.6 10.6
Free .
Amperes 49_87* 49_87* 49_87* 65_l00* 55..95* 70_99* 65_100* 70_99*
Speed
rpm 6200-10700 6200-10700 6200-10700 3600-5100 3600-5100 7800-12000 3600-5100 7800-12000
Resistance Test Volts 4.2 4.2 4.2 3.5 3.5 3.0 3.5 3.5
Armature
Locked Amperes 290_425* 290425* 290_425* 300_360* 300-360 410_480* 300-360 300-360
*Includes Solenoid
SPECIFICATIONS 13
DISTRIBUTORS
Engine Idle
Ignition Setting #
C 1ntrif tL OrigInal
Ignition Vacuum . Timing RPM
dvance Point Equipment
Engine Description Distributor Advance BTDC
Crank Dwell Spark
and Availability Product In Crank Setting at . w,’o Plug
Part No. Degrees Engine Emission
Engin: RPM Trans. Control
Idle Control
S3rstem System
C-4693 C-3933
L-4 - 153 Cu. In. - 90 HP 1110447 0 @ 900 RPM 0 @ 7" Hg. 31°-34° TDC Manual 750 AC 46N
Chevy II 17° @ 1700 RPM 24° @ 15" Hg. 5611021
28° @ 3700 RPM
C-4674 C-3933
L-4 - 153 Cu. In. - 90 HP 1110426 0 @ 900 RPM 0 @ 7" Hg. 31°-34° 4° BTDC AutomatIc 600 AC 46N
Chevy II 14° @ 1700 RPM 24° @ 15" Hg. 5611021
24° @ 3600 RPM
C-4685 C-3912
L-6 - 230 Cu. In. - 140 HP 1110436 0 l 1000 RPM 0 @ 7" Hg. 31°-34° TDC Manual 700 AC 46N
Chevy II, Camaro, 7° @ 1200 RPM 23° @ 16" Hg. 5611021
Chevelle 21° @ 2100 RPM
36° @ 4600 RPM
C46i8 C-3912
L-6 - 230 Cu. In. - 140 HP 1110433 0 @ 1000 RPM 0 @ 7" Hg. 31°-34° 4° BTDC Automatic 500 AC 46N
Chevy II, Camaro, 17° @ 2100 RPM 23° @ 16" Hg. Manual 500 5611021
Chevelle 32° @ 4600 RPM
C-4686 C-3912
L-6 - 250 Cu. In. - 155 HP 1110439 0 @ 900 RPM 0 @ 7" Hg. 31°-34° TDC Manual 700 AC 46N
Chevy II, Camaro, 9° @ 1220 RPM 23° @ 16" Hg. 5611021
Chevelle, Chevrolet 21° @ 1950 RPM
32° @ 4200 RPM
C-4672 C-3912
L-6 - 250 Cu. In. - 155 HP 1110399 0 @ 900 RPM 0 @ 7" Hg. 31°-34° 4° BTDC Automatic 500 AC 46N
Chevy II, Camaro, 17° @ 1950 RPM 23° @ 16" Hg. Manual 500 5611021
Chevelle, Chevrolet 28° @ 4200 RPM
C-4680 C-3064
V-8 - 200 HP
307 Cu. In. - 1111257 0 @ 1000 RPM 0 @ 6" Hg. 28°-32° 2° BTDC Automatic 600 500 Pass. AC 458
Chevy II, Chevelle, 10° @ 1600 RPM 15° @ 12" Hg. Manual 700 500 5610848
Chevrolet 28° @ 4300 RPM
C-4654 C-3962
V-8 302 Cu. In. - 290 HP
- 1111266 0 @ 1000 RPM 0 @ 10" Hg. 28°-32° 4° BTDC Manual 900 AC 43
Camaro Early production 24° @ 1950 RPM 15° @ 17" Hg. 5611378
32° @ 4150 RPM
. C-4704 C-3962
V-8 - 302 Cu. In. - 290 HP 1111467 0 @ 1250 RPM 0 @ 10" Hg. 28°-32° 4° BTDC Manual 900 AC 43
Camaro Interim 24° @ 2200 RPM 15° @ 17" Hg. 5611378
Production 32° @ 4400 RPM
C-4691 C-3064
V-8 - 327 Cu. In. - 2-bbl. 1111440 0 © 1000 RPM 0 © 6" Hg. 28°-32° 2° ATDC Manual 700 AC 44
210 HP Camaro 8° © 1400 RPM 15° © 12" Hg. 5610296
36° @ 3950 RPM
C-4619 C-3064
V-8 - 327 Cu. In. - 2-bbl. 1111443 0 © 900 RPM 0 © 6" Hg. 28°-3° 2° BTDC Automatic 600 AC 44
210 HP Camaro 32° © 3950 RPM 15° © 12" Hg. 5610296
C-4675 C-3036
V-8 - 327 Cu. In. RPO L30 1111298 0 © 900 RPM 0 @ 8" Hg. 28°-32° TDC Manual 700 AC 44
275 HP - Chevrolet, 9° © 1200 RPM 15 @ 15.5" Hg. 5610296
Chevelle, Chevy II, 220 © 2000 RPM
Camaro 34° © 4100 RPM
C-4673 C-3967
V-8 - 327 Cu. In. RPO L30 1111297 0 © 900 RPM 0 @ 10" Hg. 28°-32° 4° BTDC Automatic 600 AC 44
275 HP-Chevrolet, Cheveile 17° © 1900 RPM 15° © 17" Hg. 5610296
Chevy II, Camaro 30° @ 4100 RPM
C-4489 C-3036
V-8 - 327 Cu. In. RPO L73 1111150 0 @ 900 RPM 0 @ 8" Hg. 28°-32° 4° BTDC Autoknatic 600 AC 448
250 HP Chevrolet-Chevelle 10° © 1500 RPM 15° @ 15.5" Hg. Manual 700 5610809
15° © 2000 RPM
28° © 4200 RPM
In Neutral for manual transmissions,
In Drive for Automatic transmissions
SPECIFICATIONS 14
Engine Idle
. Ignition Setting # .
Centrifugal
Ignition Vacuum Timing RPM
Point
Engine Description Distributor CVJ Advance BTDC
Dwell Spark
and Availability Setting Crnlssion Plug
Engine
Trans.
System
System
C-4499 C-3064 .
V-8 - 327 Cu. In. - 300 HP 1111194 0 @ 900 RPM 0 © 6" Hg. 28°-32° 4° BTDC Automatic 600 AC 44
Corvette - Base Engine Tach DrIve 9° © 1200 RPM 15° © 12" Hg. Manual 700 5610296
15° © 1500 RPM
30° @ 5100 RPM
C-4692 C-3036
V-8 - 327 Cu. In. - 350 HP 1111438 0 @ 950 RPM 0 © 8" Hg. 28°-32° 4° BTDC Manual 750 AC 44
Corvette - RPO L79 Tach Drive 14° © 1400 RPM 152 © 15.5" Hg. 5610296
20° @ 1800 RPM
30° © 4700 RPM
C-4692 C-3036
V-8 - 327 Cu. In. - 325 HP 1111444 0 © 950 RPM 0 © 8" Hg. 28°-32° 4° BTDC Manual 750 AC 44
Chevelle, Chevy II 14° © 1400 RPM 15° © 15.5" Hg. 5610296
RPO L79 20° © 1800 RPM
30° © 4700 RPM
C-4692 C-3962
V-8 - 350 Cu. In. - 295 HP 1111264 0 @ 950 RPM 0 @ 10" Hg. 28°-32° TDC Manual 700 AC 44
Camaro, Chevy 11 14° © 1400 RPM 15° © 17" Hg. 5610296
RPO L48 20° © 1800 RPM
30° © 4700 RPM
C-4636 C-3962
V-8 350 Cu. In. - 295 HP
- 1111168 0 © 900 RPM 0 © 10" Hg. 28°-32° 4° BTDC Automatic 600 AC 44
Camaro, Chevy II 9° © 1300 RPM 15° © 17" Hg. 5610296
1.48 15° © 1700 RPM
26° @ 4700 RPM
C-4626 C-3036
V-8 1.34-350 HP-Auto Trans. 1111169 0 © 900 RPM 0 © 8" Hg. 28°-32° 4° BTDC Automatic 600 AC 43N
V-8 1.35-325 HP-AU Trans. 8° © 1250 RPM 15° © 15.5" Hg. Manual 700 5611019
V-8 L36-385 HP-AU Trans. 17° @2000 RPM
32° © 5000 RPM
C-4690 C-3036
V-8 - 1.34 - 350 HP with 1111445 0 © 900 RPM 0 © 8" Hg. 28°-32° TDC Manual 700 AC 43N
Manual Transmission 12° @ 1200 RPM 15° @ 15.5" Hg. 5611019
210 @ 2000 RPM
36° © 5000 RPM
C-4626 C-3955
V-8 - RPO L78 - 375 HP 1111170 0 © 900 RPM 0 @ 7" Hg. 28°-32° 4° BTDC Manual 750 AC 43N
V-8 - RPO L72 - 425 HP * 8° @ 1250 RPM 12° © 12" Hg. 5611019
17° © 2000 RPM
32° © 5000 RPM
C-4626 C-3955
V-8 - 427 Cu. In.-Corvette 1111293 0 © 900 RPM 0 © 7" Hg. 28°-32° 4° BTDC Automatic 600 AC 43N
RPO L36 - 390 HP Tach Drive Man 1.36
8° © 1250 RPM 12° @ 12" Hg. 700 5611019
L68 - 400 HP 17° ©2000 RPM Man L68 750
32° © 5000 RPM
C-4637 C-3036
V-S 427 Cu. In.-Corvette
- 1111296 0 © 900 RPM 0 © 8" Hg. 28°-32° 4° BTDC Man L71 750 AC 43N L71
RPO L71 - 435 HP Transistor 30° © 3800 RPM 15° @ 15.5" Hg. 5611019
RPO 1.89 - 435 HP Ign. System AC 43XL L89
Tach Drive 5611273
0.4699 .
V-8 427 Cu. In.-Corvette

- 1111295 0 @ 1200 RPM 28°-32° 12° BTDC Manual 1000 AC 43XL
RPO 1.88 - 430 HP N one
Transistor l8°© 1900 RPM 5611273
Ign. System 30° © 5000 RPM
Tach Drive
ç-47o1 C-3036
V-8 - 327 Cu. In. - 350 HP 1111441 0 © 900 RPM 0 @ 8" Hg. 28°-32° 4° BTDC Manual 750 AC 44
Corvette - RPO L79 Transistor 16.5°@1400 RPM 15° © 15.5" Hg. 5610296
Ign. System 30° © 4400 RPM
C-4631 C-3955
V-8 - 427 Cu. In.-Corvette 1111294 0 © 900 RPM 0 @ 7" Hg. 28°-32° 4° BTDC Automatic 600 AC 43N
RPO 1.38 - 390 HP Transistor 8° © 1250 RPM 12° © 12" Hg. Man 1.36 700 5611019
RPO L68 - 400 HP Ign. System 17° © 2000 RPM Man L68 750
32° © 5000 RPM
In Neutral for manual transmissions, In Drive for Automatic transmissions
SPECIFICATIONS 15
COIL
Ignition Coil
L-4 & L-6 V-8 Non-Transistor V-8 Transistor
Application .
Primary Résistance-Ohms 1.41-1.63 L77-2.05 .41-.51
Secondary Resistance-Ohms 3,000-20,000 3,000-20,000 3,000-20,000
Ignition Resistor: Type Fixed In Wiring Harness
Ohms 1.8 1.35 .43 & .68
SPECIFICATIONS 16
TRANSMISSION AND CLUTCH

SECTION 7
THREE SPEED SAGINAW
Clutch Gear Retainer to Case Bolts 22 lb. ft.

Side Cover to Case Bolts 22 lb. ft.
Extension to Case Bolts except overdrive 45 lb. ft.
Overdrive Attaching Lower Left Hand Bolt Marked X 30 lb. ft.
Shift Lever to Shifter Shaft Bolts 20 lb. ft.
Lubrication Filler Plug 15 lb. ft.
Transmission Case to Clutch Housing Bolts 55 lb. ft.
Crossmember to Frame Nuts 25 lb. ft.
Crossmember to Mount and Mount to Extension Bolts 40 lb. ft.
THREE SPEED WARNER

Extension to Case Bolts 40 lb. ft.
Shift Lever to Shifter Shaft Nut 25 lb. ft.
Lubrication Filler and Drain Plugs 20 lb. ft.
Crossmember to Mount Bolts 40 lb. ft.
FOUR SPEED SAGINAW

Extension to Case Bolts except overdrive 45 lb. ft.
Shift Lever to Shifter Shaft Bolts 20 lb. ft.
Crossmember to Mount and Mount to Extension Bolts 40 lb. ft.
FOUR SPEED MUNCIE
Clutch Gear Bearing Retainer to Case Bolts 25 lb. ft.

Cover to Case Bolts 20 lb. ft.
Extension and Retainer to Case Bolts-Tjpper 20 lb. ft.
-Lower 30 lb. ft.
Shift Lever to Shifter Shaft Nut 20 lb. ft.
20
l5lb.ft.
201b.ft.
10
15
5lb.ft.
2-1/2
25
8lb.ft.
41b.ft.
81b.ft.
7lb.ft.
Slb.ft.
51b.ft.
35
7-1/2
151b.ft.
2Olb.ft.
SPECIFICATIONS 17
POWERGLIDE
Transmission Case to Engine lb. ft.

Transmission Oil Pan to Case
Transmission Extension to Case lb. ft.
Speedometer Driven Gear Fitting Retainer
Servo Cover to Transmission Case Bolts
Front Pump to Transmission Case Bolts
Front Pump Cover to Body Attaching Bolts lb. ft.
Pinion Shaft Lock Plate Attaching Screws lb. ft.
Governor Body to Hub Attaching Bolts
Governor Hub Drive Screw
Rear Pump to Transmission Case Bolts lb. ft.
Valve Body to Transmission Case Bolts lb. ft.
Valve Body Suction Screen Attaching Screws . lb. ft.
Upper Valve Body Plate Bolts
Lower to Upper Valve Body Attaching Bolts lb. ft.
Inner Control Lever Allen Head Screw lb. ft.
Parking Lock Pawl Reaction Bracket Attaching Bolts lb. ft.
Oil Cooler Plugs at Transmission Case
Pressure Test Point Plugs
Low Band Adjustment Locknut lb. ft.
Converter to Engine Bolts lb. ft.
Under Pan to Transmission Case lb. ft.
Oil Cooler Pipe Connectors to Transmission Case or Radiator lb. ft.
Oil Cooler Pipe to Connectors lb. ft.
Vacuum Modulator to Transmission Case
Oil Pan Drain Plug lb. ft.
Converter Drain Plug Taxies
Parking Brake Lock & Range Selector Inner Lever Allen Head Screw lb. ft.
TURBO HYDRA-MATIC
Pump Cover Bolts 18 lb. ft.

Parking Pawl Bracket Bolts 18 lb. ft.
Case Center Support Bolt 23 lb. ft.
Pump to Case Attaching Bolts. . 18 lb. ft.
Extension Housing to Case Attaching Bolts 23 lb. ft.
Rear Servo Cover Bolts 18 lb. ft.
Detent Solenoid Bolts 7 lb. ft.
Control Valve Body Bolts 8 lb. ft.
Bottom Pan Attaching Screws. . - 12 lb. ft.
Modulator Retainer Bolt 18 lb. ft.
Governor Cover Bolts 18 lb. ft.
Manual Lever to Manual Shaft Nut 8 lb. ft.
Manual Shaft to Inside Detent Lever 18 lb. ft.
Linkage Swivel Clamp Nut 43 lb. ft.
Converter Dust Shield Screws 93 lb. ft.
Transmission to Engine Mounting Bolts 28 lb. ft.
Converter to Flywheel Bolts 33 lb. ft.
Rear Mount to Transmission Bolts 40 lb. ft.
Rear Mount to Crossmember Bolt 40 lb. ft.
Crossmember Mounting Bolts 25 lb. ft.
Oil Cooler Line 113 lb. In.
Line Pressure Take-Off Plug 13 lb. ft.
Strainer Retainer Bolt . . 10 lb. ft.
SPECIFICATIONS 18
STEERING
SECTION 9
STANDARD STEERING
Item Chevrolet Chevelle Camaro and Chevy II Corvette

Type Recirculating Ball
Steering Gear 24:1 I 24:1 I I 16:1
Gear Ratio I
Overall 31:4.1 I 28:1
I
I
*
I Road 20.2:1
I Fast 17.6:1
Type Parallel Relay Rod
Linkage Location Rear Front Rear Rear
#TieRods 2
* Model and/or Option Gear Ratio Overall Ratio

L6- All, 327V-8 Sed., A/C 24:1 28.3:1
327V-8 Cpe 24:1 28.3:1
350V-8 All 24:1 28.3:1
Special Steering 24:1 21.4:1
POWER STEERING
Item Chevrolet Chevelle Camaro and Chevy II Corvette

Pump Type Vane Impeller
Pressure 1000-1100 I 870-1000 8 cylinder
1100-1200 I__900-1000_6_cylinder 900-1000 870-1000
Type Integral Recirculating Ball Integ. Recirc. Ball Recirculating
Steering I Gear 17.5:1 17.5:1 17.5:1 Ball
Gear Ratio
I Overall 21.3:1 20.4:1 17.5:1 16:1 Overall
ADJUSTMENT SPECIFICATIONS- STANDARD STEERING
Adjustment Torque to Turn Worm Shaft

Worm Bearing Preload 5 - 8 Lb. In.
Sector Lash Adjustment 4 - 10 Lb. In. in excess of above
Total Steering Gear Preload 16 Lb. In. Maximum
ADJUSTMENT SPECIFICATIONS-POWER STEERING
Chevrolet,_Chevelle,_Camaro_and_Chevy_II
Ball Drag 3 Lb. In. Max. .
Thrust Bearing Preload 1/2 - 2 Lb. In. in excess of valve assy. drag
Over Center Preload 3 - 6 Lb. In. in excess of above
Total Steering Gear Preload 14 Lb. In. Max.
Corvette
Worm Bearing Preload 4 to 7 lb. in.
Sector Lash Adjustment 4 to 10 lb. in. excess of above
Total Steering Gear Preload 14 lb. in Max.
SPECIFICATIONS 19
TORQUE CHART
Steering Gear Mounting

Bolts 70 lb. ft. 70 lb. ft. 30 lb. ft. 68 lb. ft. 30 lb. ft.
Pitman Shaft Nut 140 lb. ft.
Steering Wheel Nut 35 lb. ft.
Steering Wheel Nut-Tilt 35 lb. in. 35 lb. in. 35 lb. in. 35 lb. in. -
Steering Coupling Nuts 18 lb. ft. - 18 lb. ft.
Steering Coupling Clamp

Bolts 30 lb. ft. 30 lb. ft. 30 lb. ft. -
Tie Rod End Nut 35 lb. ft.
Tie Rod Clamp Nut 130 lb. in.
Idler Arm Mounting Nut 40 lb. ft.
Steering Wheel to
Hub Wood 25 lb. in. 25 lb. in.
Steering Damper Bracket

Frame Nut - - 181b.ft.

Relay End Nut - - 25lb.ft.
Steering Damper to
Bracket Nut - - - 301b.ft.

Relay Rod Bolt - - 251b.ft.
Power Steering Pump

Pulley 60 lb. ft.
Power Steering Mounting

Bolt 20 lb. ft.
Power Steering Mounting

Nut 25 lb. ft.
Power Cylinder to Relay

HodNut - - - 45 lb. ft.
Power Cylinder to Frame

Bracket - - - 25 lb. ft.
Control Valve to Pitman

Arm - - - 45 lb. ft.
Control Valve Clamp

Bolt - - -
SPECIFICATIONS 20
WHEELS AND TIRES

SECTION 10
CHEVY II
Tire Usage and Recommended Tire Inflation Pressures
Pounds per Square Inch PSI Cool
Standard Inflation
Tire Size Optional Inflation
Models For All Loads
And ply** For Reduced Load
Including Full Rated
1 to 6 Passengers 1 to 5 Passengers
7.35-14 +200 Lbs. Luggage 750 Lbs. Load
All Except "SS" 1100 Lbs. Load
Bench Front Seat 4PR Rear Front Rear
Front
24* 28 24*
+200 Lbs. Luggage 750 Lbs. Load
All Except "SS" 7.35-14
950 Lbs. Load
Bucket Front Seats 4PR Rear Front Rear
Front
24* 28 24* 24
E70_14*** +200 Lbs. Luggage 75o Lbs. Load
Super Sport
1100 Lbs. Load
Bench Front Seat 4PR Front Rear Front Rear
9
E70_14*** + 200 Lbs. Luggage 750 Lbs. Load
Super Sport
950 Lbs. Load
Bucket Front Seats 4PR Front Rear Front Rear
. _______________ 24 1i
**Add 2 psi when vehicle is equipped with Air ***Clearance between the E70-14 and wheelhouse is
Conditioning. insufficient to permit the use of tire chains. The
**All tires are 4-Ply rating-2-Ply. 7.35-14 tire is available in place, of these tires when
1. Tire inflation pressures may increase as much as six chains are required.
6 pounds per square inch psi when hot. 3. Cool tire inflation pressure: After vehicle has been
2. For continuous high speed operation over 75 MPH inoperative for three 3 hours or more, or driven
increase tire inflation pressures 4 pounds per square less than one 1 mile. Hot tire inflation pressure:
inch over the recommended pressures up to a maxi- After vehicle has been driven ten 10 miles or more
mum of 32 pounds per square inch cool for 4 ply at 60-70 MPH.
rating tires, or 40 pounds per square inch cool for 4. Vehicles with luggage racks do not have a vehicle load
8 ply rating tires. When the 4 psi pressure adjust- limit greater than specified.
ment for sustained high speed with maximum vehicle 5. When towing trailers, the allowable passenger and
load would require inflation pressures above the max- cargo load must be reduced by an amount equal to the
imum allowable, speed must be limited to 75 miles trailer tongue load on the trailer hitch.
per hour
CHEVELLE
Tire Usage
Standard 14 Inch Optional 14 Inch
Engine and Body Styles With A/C* Without A/C* With A/C* Without A/C*
L-6; All Styles except Station Wagon
307 V-8, All Styles except Station Wagon 7.35 7.35 7.75 7.75
Sport Sedan and Convertible
307 V-8, Sport Sedan and Convertible
307 V-8 Std., exc. Sport Sedan, Convertible&Sta. Wag. 7.75 7.35 - 7.75
327 V-8 StcL, Sport Sedan and Convertible 7 75 7 75
327 V-8 HP, All Styles except Station Wagon .
396 V-B? Pickup Deliveiy S.S. G70 G70 - -
96 V-8 Super Sport, Sport Coupe and Convertible F70 F70 - -
All engines, Station Wagon 7.75 7.75 7.75 7.75

8-Ply Rating, 8-Ply Rating,
4-Ply 4-Ply
*A/C Air Conditioning
All tires listed are 4-ply rating, 2-ply unless otherwise specified.
SPECIFICATIONS 21
CHEVELLE CONT’D
Recommended Tire Inflation Pressures

Pounds per Square Inch Cool
Standard Inflation for

Optional Inflation for
Models Tire Ply all Loads including
Reduced Loads
Full Rated
1 to 6 passengers
1 to 5 passengers
All Models Except + 200 lbs. luggage
750 lbs. load
Those Shown Below 1,100 lbs. load
Front Rear Front Rear
4 Ply Rating-2 Ply 26 28 24
1 to 6 passengers 2 Seat 1 to 5 passengers
+ 300 lbs. cargo
750 lbs. load
1,200 lbs. load
Station Wagons Front Rear Front Rear
8 Ply Rating-4 Ply 22 32 22 26
1 to 3 passengers 1 to 3 passengers
+800 lbs. cargo +300 lbs. cargo
1,250 lbs. load 750 lbs. load
El Camino Exc. S.S. 24 32 24 24
El Camino S.S.
1. Tire inflation pressures may increase as much as six Hot tire inflation pressure: After vehicle has been
6 pounds per square inch psi when hot, driven ten 10 miles or more at 60-70 MPH.
2. For continuous high speed operation over 75 MPH
increase tire inflation pressures 4 pounds per square 4. Station Wagon and El Camino loads should be dis
inch over the recommended pressures up to a maxi- tributed as forward as possible.
far
mum of 32 pounds per square inch cool for 4 ply tires,
or 40 pounds per square inch cool for 8 ply rating
tires. When the 4 psi pressure adjustment for Vehicles with luggage racks do not have a vehicle load
sustained high speed with maximum vehicle load limit greater than specified.
would require inflation pressures above the maximum
allowable, speed must be limited to 75 miles per hour.
3. Cool tire inflation pressure: After vehicle has been 6. When towing trailers, the allowable passenger and
inoperative for three 3 hours or more, or driven cargo load must be reduced by an amount equal to the
less than one 1 mile, trailer tongue load on the trailer hitch.
SPECIFICATIONS 22
CAMARO
Standard Inflation For AU Loads Optional Inflation

Models Tire Size and Ply** Including Full Rated For Reduced Load
+200 Lbs. Luggage 750 Lbs. Load
All Except Camaro "SS" & Z-28 7.35- 14
950 Lbs. Load
Bucket Front Seats 4PR Rear Front Rear
Front
24* 28 24* 24
2OO Lbs. Luggage 750 Lbs. Load
All Except Camaro "SS" and Z-28 7.35-14 1100 Lbs. Load
Bench Front Seat 4PR Front Rear Front Rear
24* 28 24* 24
+ 200 Lbs. Luggage 750 Lbs. Load
950 Lbs. Load
Super Sport F70_14*** 24*
24* 28 24
Bucket Front Seats 4PR
E70_15***
Z-28 Option 26 28 24 24
4PR
Super Sport F70_14*** +200 Lbs. Luggage 750 Lbs. Load
Bench Front Seat 4PR 1100 Lbs. Load
Front Rar Front Rear
24* 28 24* 24
*Add 2 psi when vehicle is equipped with Air Conditioning. ***Clearance between the F70-14 and E70-15 tires and
**All tires are 4-Ply rating-2-Ply unless otherwise wheelhouse is insufficient to permit the use of tire
specified. chains. The 7.35-14 tire Is available in place of these
1. Tire inflation pressure may increase as much as 6 tires when chains are required.
pounds per square inch psi when hot. 3. Cool tire inflation pressure: After vehicle has been
2. For continuous high speed operation over 75 MPH inoperative for three 3 hours or more, or driven
Increase tire inflation pressures 4 pounds per square less than one 1 miles. Hot tire Inflation pressure:
inch over the recommended pressures up to a maxi- After vehicle has been driven ten 10 miles or more
mum of 32 pounds per square inch cool for 4 ply at 60-70 MPH.
rating tires, or 40 pounds per square inch cool for 8 4. Vehicles with luggage racks do not have a vehicle load
ply rating tires. When the 4 psi pressure adjustment limit greater than specified.
for sustained high speed with maximum vehicle load 5. When towing trailers, the allowable passenger and
would require inflation pressures above the maximum cargo load must be reduced by an amount equal to the
allowable, speed must be limited to 75 miles per hour. trailer tongue load on the trailer hitch.
CORVETTE
Standard Inflation Pressure For

All Loads Including Full Rated
and Continuous High Speed
Models Tire Ply Tire Usage Operation Over 75 MPH
All Models
II 1 to 2 Passengers
+150 Lbs. Luggage 4 Ply Rating-2 Ply* F70-15
Front
24
Rear
24
Nylon
I 450 Lbs. Load
*Optional tires are not available.
1. Tire inflation pressures may increase as much as six 3. Vehicles with luggage racks do not have a load limit
6 pounds per square inch psi when hot. greater than specified above.
2. Cool tire inflation pressure: after vehicle has been in 4. When towing trailers, the allowable passenger and
operative for three 3 hours or more, or driven less cargo load must be reduced by an amount equal to
than one 1 mile. Hot tire inflation pressure: After the trailer tongue load on the trailer hitch.
vehicle has been driven ten 10 miles or more at 60-
70 MPH.
SPECIFICATIONS 23
CHEVROLET
Tire Usage
STANDARD TIRE OPTIONAL TIRE
Engine and Body Styles 14 Inch 15 Inch With Disc Brakes 14 Inch
All Engines, All Styles except 8.25 8.15 8.25 8-Ply Rating,
Those Shown Below 4-Ply
4 Door V-8 Hard Tops 8.25 8.45 4-Ply Rating -
427 V-8 Super Sport 2-Door Coupe and - G70-15 -
COnvertible Z-24 Option
All Engines, Station Wagon 8.55 8.45 8-Ply Rating, 4-Ply 8.55 8-Ply Rating, 4-Ply
All tires listed are 4-Ply Rating, 2-Ply except where indicated.
Recommended Tire Inflation Pressures-Pounds per Square Inch Cool
Standard Inflation Optional Inflation

Models Tire Ply for All Loads for
Including Full Rated Reduced Loads
1 to 6 Passengers 1 to 5 passengers
+ 200 lbs. luggage 750 lbs. load
All Models Except Station 1100 lbs. load
Wagons
+300 lbs. cargo 750 lbs. load
or 1 to 8 pass. 3 Seat
Station Wagons Without Disc 1200 lbs. load
Brakes- 14" Wheels
4 Ply Rating-2 Ply 22 32 - -
8 Ply Ratlng-4 Ply 22 32 - -

+300 lbs. cargo 750 lbs. load
Station Wagons With Disc or 1 to 8 pass. 3 Seat
Brakes-15" Wheels 1200 lbs. load

8 Ply Rating-4 Ply 22 34 -
1. Tire inflation pressures may increase as much as six 3. Cool tire inflation pressure: after vehicle has been
6 pounds per square inch psi when hot. inoperative for three 3 hours or more, or driven less
than one 1 mile.
Hot tire inflation pressure: After vehicle has been
2. For continuous high speed operation over 75 MPH driven ten 10 miles or more at 60-70 MPH.
increase tire inflation pressures 4 pounds per square 4. Station Wagon loads should be distributed as far for
Inch over the recommended pressures up to a maxi ward as possible.
mum of 32 pounds persquare inch cool for 4 ply rating
tires, or 40 pounds per square inch cool for 8 ply 5. Vehicles with luggage racks do not have a vehicle load
rating tires. When the 4 psi pressure adjustment for limit greater than specified.
sustained high speed with maximum vehicle load would
require inflation pressures above the maximum allow 6. When towing trailers, the allowable passenger and
able, speed must be limited to 75 miles cargo load must be reduced by an equal to the
amount
hour.
per
trailer tongue load on the trailer hitch.
SPECIFICATIONS 24
BODY AND CHASSIS ELECTRICAL

SECTION 12
CANDLE BULB
LAMP USAGE
POWER NUMBER
Headlamp Unit
Chevrolet, Chevelle & Corvette
Outer High Beam
- 37 1/2 Watts 4002
Outer Low Beam
- 55 Watts 4002
Inner High Beam only
- 37 1/2 Watts 4001
Chevy II & Camaro
High Beam 55 Watts 6012
Low Beam 45 Watts
Parking Lamp and Directional Signal
All Exc. Camaro & Corvette . . . 4-32 1157
Camaro & Corvette 4-32 1157NA
Tail, Stop and Directional Signal 4-32 1157
Backing Lamp 32 1156
Instrument Illumination Lamps
Chevrolet & Camaro 2 194
Chevelle and Corvette 2 1895
Chevy H 2 168
Temperature Indicator
Chevelle and Chevy II 2 1895
Chevrolet, Camaro & Chevy II 2 194
Chevelle 2 1895
Generator Indicator
Chevelle 2 1895
Hi-Beam Indicator
Chevelle and Chevy II 2 1895
Corvette 2 1895
Directional Indicator
Chevelle 2 1895
Corvette 2 1895
Cigarette Lighter Lamp
Corvette 1 1445
Ignition Lock Lamp
Chevrolet 1 1445
Corvette 2 1895
Heater or A/C Control Panel
Chevrolet, Chevelle, Camaro & Chevy II 1 1445
Corvette 2 1895
Glove Box Lamps
Chevrolet, Chevelle, Chevy U, Camaro & Corvette 2 1895
Dome and Courtesy Lamps
Cartridge Type All 12 211
Bayonet Type Exc. Corvette . 6 89, 212
Corvette 6 212-631
Convertible 6 631
SPECIFICATIONS 25
LAMP USAGE Cont’d.

POWER NUMBER
Seat Separator-Compartment Lamp 1 1445

-Courtesy Lamp 6 212
Side Marker-Front 2 194A

Side Marker-Rear 2 194
License Plate Lamp 4 67
Radio Dial Lamp

Chevrolet, Chevelle, Chevy U & Camaro 2 1893
Corvette 2 1893
Brake Alarm Lamp

Chevelle & Corvette 2 1895
Clock Lamp Corvette 2 1895
Luggage Compartment Lamp 15 1003
Underhood 15 93
FUSES AND CIRCUIT BREAKER
A circuit breaker in the light control switch protects under hood and spot lamp circuit is also protected by a
the headlamp circuit, thus eliminating one fuse. A separate 15 amp in-line fuse. Where current load is too
separate 30 amp circuit breaker mounted on the firewall heavy, the circuit breaker rapidly opens and closes, pro
protects the power window, seat and top circuits. The tecting the circuit until the cause Is found and eliminated.
Fuses located in the Fuse Panel under the instrument panel are:
Wiper/Washer, 3 Spd A/T Downshift SAE/SFE 20 Amp.

Back-up Lamp, Turn Signal, Cruise Master, Defogger SAE/SFE 20 Amp.
Heater - Air Conditioning 3AG/AGC 25 Amp.
Radio, Power Window 3AG/AGC 10 Amp.
Tail, Marker and Fender Lamps SAE/SFE 20 Amp.
Instrument Lamps Camaro, Chevy II and Chevelle SAE/SFE 4 Amp.
Instrument Lamps Chevrolet, Corvette 1AG/AGA 5 Amp.
Gauges and Tell-Tale Lamps 3AG/AGC 10 Amp.
Stop and Hazard SAE/SFE 20 Amp.
Clock, Lighter, Courtesy Lamps, Dome and Luggage Lamps. SAE/SFE 20 Amp.
In-Line Fuses:
Air Conditioning High Blower Speed Fuse located in wire running
from horn relay to A/C Relay
Comforton and Four Season SAE 30 Amp.
Universal & All Weather Chevy U SAE 20 Amp.
Fusible Links: ,
Pigtail lead at battery positive cable except Corvette 14 gauge brown wire
Molded splice at Solenoid "Bat" terminal Corvette only 14 gauge brown wire
Molded splice Located at the horn relay 16 gauge black wire
Molded splice in Voltage Regulator ff3 terminal wire 20 gauge orange wire
Molded splice in Ammeter circuit Both sides of meter 20 gauge orange wire

"Portions of materials contained herein have been reprinted with permission
of General Motors Corporation, Service Technology Group."
SPECIFICATIONS 26
WINDSHIELD WIPERS
Depressed Park-Chevrolet,ChevelleOpt.
Non-Depressed Park Two Speed Two Speed
and Corvette
Operation Operating Voltage 12 VDC

Test Voltage 12 V. Gear Ratio 45:1
Gear Ratio 36:1 Crank Arm Rotation Looking at Crank Arm
Crank Arm Rotation CCW Counter Clockwise Crank Arm Speed No Load
Current Draw
Lo 34 rpm/mm.
No Load 3.6 Max.
Hi 65 rpm/mm.
Dry W/S 4.5 Max.
Stall 12 Max. Current Draw amperes
Crank Arm No load low speed 4.5
Speed rpm’s Installed in Car dry windshield 5.0
Low 34 Mm. Stall 15 Max.
Hi 65Mm. Shunt Field Resistance ohms 5-6 ohms
WASHER PUMP
Number of "squirts" at full pressure 12
Pressure psi . 11-15
Coil Resistance ohms 20
SPECIFICATIONS 27
ACCESSORIES
SECTION 15
CRUISE-MASTER
Solenoid Resistance 5 ohms

1/4 ohm±
Solenoid Wire Resistance 40 ohms
Maximum allowable Vacuum Leakage Rate for Servo Unit 5 inches of Vacuum Per Minute
Operational Test Speed 50 MPH

1968 Chevrolet Chassis Service Manual

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1968 Chevrolet Chassis Service Manual

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HASSIS

CHEVY II AND CORVETTE 2 FRAME

CHASSIS 3 FRONT SUSPENSION

SERVICE MANUAL 4 REAR SUSPENSION

This manual includes procedures for maintenance and 6 ENGINE

reference. If properly used, it will enable the technician

CHEVROLET MOTOR DIVISION

CHEVROLET CHASSIS SERVICE MANUAl.

MODEL IDENTIFICATION-CHEVY II MODEL IDENTIFICATION-CAMARO

CHEVROLET CHASSIS SERVICE MANUAL

For the convenience of servicemen when writing up

VEHICLE COMPONENIT SERIAL AND UNIT NUMBER LOCATION

CHEVROLET CHASSIS SERVICE MANUAL

1. Manufacturers identity number assigned to all

BUMPER JACK LIFTING AT FRAME ATTACHMENT ONLY

Fig. 1-Vehicle Lifting Points-Chevrolet

CHEVROLET CHASSIS SERVICE MANUAL

BUMPER JACK LIFTING AT FRAME ATTACHMENT ONLY

FLOOR JACK OR HOIST LIFT

Fig. 2-Vehicle Lifting Points-Chevelle

Manual Transmission Front

CHEVROLET CHASSIS SERVICE MANUAL

Fig. 5-Attachment of Towing Chain Hooks to Axle TUbe

To facilitate towing without a helper it will be neces

Fig. 6-Towing Sling Attachment-Rear

CHEVROLET CHASSIS SERVICE MANUAL

Fig. 8-Vehicle Lifting Points-Chevy II and Camaro

CHEVROLET CHASSIS SERVICE MANUAL

DRIVE-ON HOIST, TWO -POST HOIST

VA FLOOR JACK, JACKSIANDS,

Fig. 9-Vehicle Lifting Points-Corvette

Fig. 10-Frame Lift Adapters-Corvette

CHEVROLET CHASSIS SERVICE MANUAL

CHEVROLET CHASSIS SERVICE MANUAL

CHEVROLET CHASSIS SERVICE MANUAL

CRANKCASE VENTILATION VALVE Recommended Lubricants

DISTRIBUTOR POWERGLIDE TRANSMISSION

CHEVROLET CHASSIS SERVICE MANUAL

especially formulated and tested for use in your auto

CHEVROLET CHASSIS SERVICE MANUAL

J LUBRICATE EVERY 6,000 MILES GL-MUITI-PURPOSE OR

REPLACE EVERY 24,000 MILES LUBRICANr AT-DEXRON AUTOMATIC TRANSMISSION FLUID

LUBRICATE EVERY 36,000 MILES WB-WHEEL BEARING LUBRICANT BF-BRAKE FLUID

Fig. 11-Lubrication Diagram-Chevrolet

CHEVROLET CHASSIS SERVICE MANUAL

LUBRICATE EVERY 36000 MILES

Fig. 12-Lubrication Diagram-Chevelle

1. Front Suspension 4. Air Cleaner 6. Transmission 9. Battery

CHEVROLET CHASSIS SERVICE MANUAL

Q LUBRICATE EVERY 6000 MILIES GL -GEAR LUBRICANT’ AT -DEXRON AUTOMATIC

Fig. 13--Lubrication Diagram-Chevy II and Camaro

1. Front Suspension 4. Air Cleaner 6. Transmission 9. Battery

CHEVROLET CHASSIS SERVICE MANUAL

LUBRICATE EVERY 6,000 MILES GL-MULTI-PURPOSE OR CL-CHASSIS LUBRICANT

J LUBRICATE EVERY 36,000 MILES WB.WHEEL BEARING LUBRICANT

REFILL POSITRACTION REAR AXLE ARE SERVICED

Fig. 14-Lubrication Diagram-Corvette

CHEVROLET CHASSIS SERVICE MANUAL

General Description lA-i

OUTLET DOOR DOOR bOOR

Fig., 1-Heater Air Flow - All Vehicles

CHEVROLET CHASSIS SERVICE MANUAL

Fig. 2-Heater Controls - Chevrolet, Chevelle,