SECTION 1

BODY

CONTENTS OF THIS SECTION

The 1955 Chevrolet body has been completely redesigned to give greater strength and rigidity to the body. Fabrication and manufacturing processes have undergone radical changes to insure body shell alignment and dimensional control.

The cowl and dash now includes a shroud-length panel forming an enclosure, called a plenum chamber, which is utilized for the cowl intake ventilation system. In addition, this panel gives double wall strength to the cowl upper and side panels. The framework for the plenum chamber and the windshield pillars is formed by a heavy gauge one piece pillar facing. This facing wraps around the door opening section of the windshield and hinge pillar. A flared section at the upper and lower pillar joint is reinforced by a heavy gauge angle brace from the plenum chamber.

The column framed by the cowl side panels and the pillar facing is solidly supported by a heavy gauge reinforcement welded to base of the pillar and floor. Another heavy gauge brace is welded under the floor between the frame side members. Outrigger brackets, formed from "U" channels, are attached to the base of this box structure to form a body frame cross member eliminating the need for chassis frame second cross member.

The rear quarter inner panel from the door opening to the deck lid opening, including the deep drawn wheelhouse, is of one piece construction. The inner wall of the panel is ribbed at the rear and welded to the outer panel at the rear compartment opening. There is no welding seam at the formed wheel opening and by bringing the side walls of the rear end in line with the frame, resistance has been added to stresses on the body shell.

The gravel shield is integral with the lower end panel and the package shelf is integral with the upper end panel to provide additional resistance to torsional stress. Torque rod hinges which give full-travel counter balancing of the rear compartment lid, rotary door locks and rubber cushioned body mountings are a few of the many design changes in the 1955 Chevrolet body.

Body Lubrication

Movable parts of the body are lubricated at the factory insuring proper operation. Those body parts which have frequent use, such as door locks etc., should be lubricated twice a year. Other body parts should be lubricated when access is available.

The following parts should be lubricated twice a year.

Wipe off all lubrication points before applying new lubricant. Remove all excess lubricant to prevent staining of trim parts.

Lubrication Points                                Lubricant

Instrument Compartment Door Hinge                 Dripless Oil
Front Door Hold Open Clips                        Lubriplate or Equivalent
Door Jamb Light Switch                            Lubriplate or Equivalent
Door Lock Bolt Housing                            Stick Type Lubricant
Door Lock Striker Teeth                           Stick Type Lubricant
Rear Door Hinge and Hold Open                     Lubriplate or Equivalent
Deck Lid Hinge and Torque Rod Ends                Lubriplate or Equivalent
Deck Lid Lock Bolt                                Lubriplate or Equivalent
Gas Filler Door Hinge                             Dripless Oil
Folding Top Linkage Bearing Points                No. 10 Engine Oil
Side Roof Rail Mechanical Sealing Strip Gasket    Silicone Emulsion
Parts to be lubricated when access to parts can
be obtained.
Windshield Wiper Motor and Transmission Spools    Lubriplate or equivalent
Door Lock Parts                                   Lubriplate or equivalent
Window Regulator Rack and Cam Channels            Lubriplate or equivalent

Front End Assembly

Windshield Wiper Assembly

The windshield wiper assembly consists of a motor, auxiliary drive and two transmissions. The standard motor is vacuum operated and the optional motor is electrically powered. Both motors are interchangeable. The transmission incorporates spring loaded pulleys which provide for adjustment of the wiper cable tension. The wiper motor auxiliary drive incorporates two drums to which transmission drive cables are attached. The wiper motor and auxiliary drive assembly is installed to engine side of the dash panel. The motor and auxiliary assembly may be removed as a unit or the motor may be removed separately.

Transmission Cable Adjustment

The windshield wiper transmission drive cables are tensioned by spring loaded pulleys. The end of the transmission shaft is pushed in to unlock the pulleys. To tension cables push in on transmission shaft end if blade has been removed or on the base of the wiper arm if the blade is installed (fig. 1).

To release cable tension for removal of components push in on transmission shaft end and have helper on the inside, pull on cables to obtain desired slack then release pressure on transmission shaft. NOTE: Wiper blade snap or over-travel is indicative of loose transmission drive cables.

Windshield Wiper Motor

Removal and Installation

1. Loosen screw indicated at "A" and remove control cable (fig. 2).
2. On vacuum operated motors disconnect vacuum line at "B". On electric wiper motors disconnect feed wire under the instrument panel.
3. Remove screws "C" and remove motor. NOTE: Ground wire is attached under one of the attaching screws on electric motor installations.
4. To install, reverse this procedure.

Windshield Wiper Motor and Auxiliary Drive Removal

1. Remove instrument panel compartment box and heater defroster duct.
2. Adjust drive cables to slack position and remove. NOTE: Inspect attachment of transmission cables to each drum and note the right cable cross for installation purpose. On electric wiper motor installations, disconnect feed wire under instrument panel.
3. At the front of the dash, remove control cable at "A", vacuum line at "B" and electric motor ground wire where necessary (fig. 2). Remove attaching screws "D" and remove motor and auxiliary drive assembly from dash panel.

Installation

1. Lubricate outside surface of auxiliary drive drums with Lubriplate or its equivalent.
2. Secure wiper motor and auxiliary drive to dash with screws "D" (fig. 2).
3. Inside the body, attach transmission cables to drive drums. Adjust cable tension, see Adjustment. NOTE: Right drive cable is crossed and attaches to drive drum "A," left transmission cable (not crossed) attaches to drive drum "B" (fig. 3).
4. Attach control cable, vacuum line or electric motor feed line and ground. Check operation of wiper assembly and install compartment box and heater defroster duct.

Windshield Wiper Transmission Removal

1. Remove wiper blade and arm assembly.
2. Remove instrument panel compartment box and heater defroster duct.
3. Adjust drive cables to slack position and remove cables from drive drums. NOTE: Inspect attachment of drive cables to their respective drive drums and note crossed drive cable from right transmission.
4. At the outside of the body remove the escutcheon nut with tool J-5449 then disconnect washer hose, if so equipped, and remove escutcheon.
5. Remove spacer nut with tool J-5449 and remove spacer.
6. From the inside of the body, remove transmission assembly from under the instrument panel. Figure 4 shows an exploded view of the right transmission.

Installation

1. Lubricate pulley grooves in transmission assembly with Lubriplate or equivalent.
2. Install gasket to transmission, position transmission in body and install spacer and spacer nut with tool J-5449.
3. Attach transmission drive cables to auxiliary drive drums and adjust cable tension. CAUTION: Cross right transmission drive cables and install to drum "A," install left transmission drive cables (not crossed) to drum "B" fig. 3).NOTE: If new transmission is installed it is necessary to remove the plastic collar before adjusting cable tension (fig. 4).
4. Connect washer hose to escutcheon, if so equipped, secure escutcheon nut using tool J-5449.
5. Install wiper blade and arm assembly and check operation of wiper blades.
6. Install instrument panel compartment box and heater defroster duct.

Windshield Wiper Control

Removal and Installation

1. Remove control cable from motor assembly by loosening screw "A" at motor (fig. 2).
2. Loosen set screw in control knob at instrument panel and remove knob.
3. Remove spanner nut with tool J-5449, on Bel-Air models remove control escutcheon.
4. Remove control assembly from instrument panel and remove wiper hose after tagging for proper installation.
5. To install reverse this procedure.

Cowl Side Drain Gutter

Removal and Installation

1. On all models, remove wiper blade and arm assembly, transmission, spanner nuts and escutcheons. On models equipped with reveal moldings remove lower reveal moldings and clips.
2. Lift up hood and remove screws and drain gutter (fig. 5).
3. To install, apply a continuous bead of body caulking compound between gutter and windshield frame and install gutter.

Cowl Ventilating System Description

Air intake for the body is through the air intake louvre panel located on top of the cowl. Air enters the inlet panel through a duct which directs the air into the body through an opening at each cowl side panel. The flow of air into the body is regulated by a valve in each cowl side opening. The valves are controlled by separate cables and knobs. Water entering the intake into the air duct flows down the cowl side duct panel into a gutter and out of the body.

Air Intake Louvre Panel

Removal and Installation

1. Remove windshield lower reveal molding.
2. Remove lower reveal molding retaining clips located in the louvre panel.
3. Lift up hood and remove screws attaching louvre panel and remove panel (fig. 6).
4. To install, reverse this procedure.

A new large, one piece wrap-around windshield is retained in the body windshield opening by a one piece rubber channel. A windshield drain gutter is provided on all models.

Windshield Garnish Moldings

Removal and Installation

1. Remove screws attaching the garnish moldings and carefully remove the moldings in the following sequence.

Convertible Bodies:
1. Upper Moldings
2. Side Moldings
3. Escutcheon
4. Lower Moldings

All Other Bodies:
1. Side Moldings
2. Escutcheon
3. Upper Moldings
4. Lower Moldings

Figure 7 identifies the windshield garnish moldings.

2. To install, reverse this procedure.

Rear View Mirror Support Removal and Installation

1. Remove side and upper windshield garnish moldings on all models except convertible. On convertibles, remove the upper garnish moldings.
2. Remove three screws securing mirror support and remove support.
3. To install, reverse this procedure.

Windshield Reveal Moldings

2100 and 2400 Series

The reveal moldings used on the sedan and sport coupe models are of the same design. The Bel-Air sedans and sport coupes have, in addition, windshield side pillar finishing moldings. Figure 8 shows the location of these moldings and the location of the retaining clips and screws. The convertible model has a different windshield upper and side reveal molding, these moldings and the location of the retaining clips and screws are shown in figure 9.

Removal and Installation

1. Apply protective covering to area adjacent to the reveal moldings.
2. Remove windshield wiper blade and arm assemblies. Remove wiper transmission escutcheon spanner nut with tool J-5449, then remove escutcheon.
3. Carefully slide the escutcheon back on the lower reveal molding. Remove screw securing retaining clip (located under escutcheon) and slide clip into either molding.
4. Slide either lower reveal molding approximately 1-1/2" toward center line of body to align cutouts in molding with clips.
5. Carefully pry lower edge of molding upward to disengage retaining clips. Lift entire molding up to disengage molding upper flange from clips and remove molding. Repeat removal operations on opposite molding.
6. On sedan and sport coupe models remove screw securing lower corner reveal molding, pull molding out slightly and slide corner reveal molding down and remove (fig. 8). On convertible models, remove screw from lower corner of side reveal molding, then open door and remove three screws securing molding to windshield side pillar and remove molding ( fig. 9). Repeat operation at opposite side. NOTE: Upper reveal moldings can only be removed from the windshield rubber channel after the windshield assembly is removed from the body. If the windshield is to be removed, remove screw retaining upper reveal molding exposed by the removal of the corner reveal molding or the side reveal molding.
7. To install apply medium bodied sealer to all screw and clip holes, then reverse the removal procedure.

Windshield Side Pillar Finishing Molding

Sport Coupe and Bel-Air Models

Removal and Installation

1. Remove windshield lower reveal and lower corner molding.
2. Remove screw securing end of upper reveal, open door and remove three screws (fig. 8) from face of windshield side pillar and carefully pry off molding.
3. To install, seal all attaching screw holes with a medium body sealer, then reverse the removal procedure.

Windshield Side Pillar Finishing Molding

Convertible Styles

Removal and Installation

Remove the windshield side garnish and side reveal moldings, the finishing molding is retained by its flanges which fit under the garnish and reveal moldings. To install, reverse the removal procedure.

Windshield Header Molding

Convertible Styles

1. Removal and Installation
2. Remove windshield side reveal moldings and remove screw securing end of upper reveal.
3. Raise the top and on the inside of the body remove the header molding escutcheon. Also remove windshield upper and side garnish moldings, sunshade rod retainers, sunshade supports and front roof rail lock strikers.
4. Disengage front edge of header molding from under windshield upper reveal molding and remove.
5. To install, reverse this procedure.

Windshield

When a cracked windshield glass is to be removed and there is an indication of a strain break, mark the location of the break on the windshield rubber channel and the body.

Removal

1. Place protective covering over the hood, front fenders, instrument panel and front seat assembly. On convertible models, lower the top.
2. Remove the windshield garnish moldings and rear view mirror support.
3. On sedans and sport coupes, remove the windshield lower and lower corner reveals. Carefully pry off escutcheon at junction of upper reveal. On convertibles, remove lower and side reveals.
4. Remove screws attaching ends of upper reveals. Also remove lower reveal attaching clips from body (fig. 10).
5. On the inside of the body, loosen the lip of the windshield rubber channel from the pinch-weld flange along the top and at the sides by applying pressure with the palm of the hand to the edge of the glass. At the same time assist the lip of the rubber channel over the pinchweld flange with a flat bladed tool (fig. 11).
6. After freeing the rubber channel, with the aid of a helper, lift the windshield from the body and place it on a covered bench.
7. Disengage the "T" flange of the upper reveals from the rubber channel and remove moldings. NOTE: On convertible bodies a notch is cut at each end of the upper reveal molding in the windshield rubber channels.
8. Remove rubber channel from glass.

Body Windshield Opening Check

Due to the expanse and contour of the windshield it is imperative in the event of a strain break that the windshield opening be thoroughly checked before installing a replacement windshield. The replacement glass is used as a template for checking the windshield opening.

1. Check for the following conditions at the previous marked point of fracture.
   • Chipped edges on glass.
   • Irregularities in body opening.
   • Irregularities in rubber channel.
2. Remove all sealer from flange and body around windshield opening.
3. Check flange area for solder, weld high spots, or hardened spot-weld sealer. Remove all high spots.
4. Check windshield glass to opening, by supporting glass with six wooden spacers J-5742 (fig. 12). CAUTION: Do not strike glass against body metal. Chipped edges on the glass can lead to future breaks.
5. With the windshield supported and centered in its opening, check the relationship of the glass to the body opening flange around the entire perimeter of the glass.
6. Figure 13 is a cross section taken through the glass channel and body opening. Check the relationship of glass to opening as follows:
   • Inside edge of glass to body flange, at any point, dimension 3/16" to 1/4".
   • Outer edge of glass to parallel body metal at any point, dimension 5/16" to 7/16".
7. Mark areas of body metal or flange to be reformed, remove glass and correct as necessary.
8. Recheck windshield in its opening and if satisfactory, mark the glass and body so the glass may be accurately centered upon installation.

Installation

1. Check the windshield drain gutter and drain hoses for obstruction. Clean if necessary. Reseal each drain hose with medium bodied sealer (fig. 14).
2. Assemble rubber channel to glass and install upper reveal. To facilitate installation of reveal molding to channel apply a mild soap solution to rubber channel molding cavity and "T" flange of molding.
3. On convertibles, carefully center upper reveal molding in channel, and where a new rubber channel is being used, at each end of the molding cut a notch in rubber channel at the molding attaching screw locations (fig. 15).
4. Insert cord into pinchweld cavity of channel around the entire windshield. Tie cord loosely and tape ends to inside surface of glass (fig. 16).
5. Apply a heavy ribbon of medium bodied sealer at the base of the pinchweld flange around the entire perimeter of the opening.
6. Carefully place and center the windshield in the body opening with the aid of a helper.
7. Press firmly on the outside surface of the glass and have the helper, inside the body, slowly pull the cord outward from the lower center toward each lower corner to seat the lip of the rubber channel over the flange. (fig. 17).
8. Seal the outside lip of the rubber channel to the glass with weatherstrip adhesive.
9. Remove all excess sealer and adhesive with mineral spirits.
10. Reinstall moldings, sunshade supports, etc.

Instrument Panel Compartment Door

Removal and Installation

1. Scribe location of door hinge on door panel.
2. Remove door hinge attaching screws at door inner panel or at instrument panel flange.
3. Remove stop attaching screws from right side of door inner panel and remove door (fig. 18).
4. To install, position hinge within scribe lines and install attaching screws.

Adjustment

To reposition compartment door up or down in its opening, loosen hinge attaching screws at the door inner panel and shift in the desired direction.

To reposition the door laterally, loosen hinge attaching screws at instrument panel flange and shift door in the desired direction. The door lock striker may be adjusted by loosening the attaching screws and moving the striker either in or out.

Door lock

Removal and Installation

1. The lock is released by removing screw and washer on lock retainer cap.
2. To install, reverse this procedure.

Compartment Box

Removal and Installation

1. Remove compartment box door at the instrument panel.
2. Remove screws from the interior of the box at the upper and side edges.
3. Move box forward and downward to remove.
4. To install, reverse this procedure.

SEDAN FRONT DOOR

Figures fig. 19 and fig. 20 are the sedan front door Inside Handles assemblies with trim pads removed, showing various door component attaching and adjusting points.

1. Glass Run Channel
2. Window Garnish Molding Spacing Clip
3. Ventilator Regulator
4. Upper Hinge
5. Window Manual Regulator Attaching Screws
6. Lock Remote Control
7. Lock Remote Control Connecting Rod
8. Inside Lock Rod
9. Lock
10. Ventilator Division Channel Adjusting Stud
11. Wind Regulator Stationary Cam Attaching Screws
12. Inner Panel Access Hole Covers
13. Trim Pad Retainer
14. Window Control Switch Terminal Block
15. Window Electric Regulator Attaching Screws
16. Window Regulator Motor Electric Connectors
17. Plastic Type Door Arm Rest Attaching Holes
18. Hanger Plate for Built-in Type Door Arm Rest

Inside Handles

Removal and Installation

1. Depress door trim and insert door handle plier J-4614-A between the bearing plate and the handle and remove the horseshoe clip retaining the handle to the shaft. To install, place clip in handle and press handle to place on shaft.

Garnish Molding

Removal and Installation

1. Remove inside locking rod knob and screws securing garnish molding.
2. Disengage molding from window opening and lift to clear spacing clips and remove.
3. To install, reverse this procedure, apply a small amount of weatherstrip adhesive to locking rod knob hole before installing knob to rod.

Arm Rest-Plastic Type

Removal and Installation

1. Remove screws from underside of arm rest and remove arm rest.
2. To install, reverse this operation.

Arm Rest - Built in Type

Removal and Installation

1. Remove trim pad and carefully remove staples securing arm rest trim to front edge of trim pad foundation.
2. Carefully bend out arm rest clinch tabs and remove arm rest from trim pad.
3. To install, reverse this procedure.

Trim Pad

Removal and Installation

1. Remove garnish molding, inside hardware and arm rest. On doors with built in arm rest, remove screws from arm rest recess.
2. Remove screw from lower corners of trim pad, then tap front and rear edge of trim pad with a clean rubber mallet.
3. Use a flat bladed tool to pry front and rear edges of trim pad from nail slots in door inner panel. NOTE: On electric window lifts, disconnect switch from terminal block.
4. Lift trim pad up, freeing it from retaining tabs and retainer.
5. To install, reverse this procedure. Broken retaining nails may be replaced with repair tabs.

Window Control Switch

Removal and Installation

1. Remove door window garnish molding and ventilator regulator handle. Loosen trim pad at top to gain access to switch terminal and disconnect block from switch.
2. Carefully push switch assembly from trim pad. In some instances it may be necessary to pry open tabs "A" (fig. 21).
3. Remove switch from escutcheon by depressing clips with an awl at "B" and remove clips.
4. To install, reverse this procedure. NOTE: Feed stud of master control switch should point toward front of car when installed. Check switch operation before completing installation.

Front Door Window

Front door window is removed and installed in a similar manner for both manually and electrically operated windows.

Removal and Installation

1. Lower door glass window and remove trim pad. NOTE: On electric window lift installations, disconnect positive or negative battery cable.
2. Remove door ventilator assembly, then, remove large access hole cover and tape covering small circular hole between the two access holes.
3. Remove screws indicated at "A" attaching sash channel cam to glass channel (fig. 22). NOTE: On electric lift installations, remove conduit, disconnect motor leads and wire harness from door.
4. Disengage window from sash channel. cam, raise glass almost to a fully closed position, tilt glass inward and remove from door. NOTE: Do not operate electric window regulator with glass removed.
5. To install, reverse the removal procedure, then seal door inner panel as specified under Door Inner Panel Sealing

Adjustment

1. To correct a glass slanted in the run channels, loosen the stationary cam screws "A", then adjust rear of cam up or down and retighten screws (fig. 23).
2. Loosen ventilator division channel adjusting stud lock nut "B" and turn stud in or out or position stud fore or aft, as required.
3. Between the inner and outer door panel, indicated at "C" loosen run channel attaching nut at the lock pillar and position channel in or out as required.

Glass Run Channel

Removal and Installation

1. Lower door window, remove trim pad and large access hole cover.
2. Between the inner and outer door panels, working through the access hole, loosen the nut securing the lower end of the run channel to the lock pillar.
3. Carefully disengage channel and retaining clips from door. At the reveal line, disengage rosebud fastener and remove run channel.
4. To install, reverse this procedure, reseal door inner panel.

Window Regulator

Removal and Installation

1. Lower door glass, remove trim pad, both access hole covers and tape from small circular access hole located at "A" (fig. 24). NOTE: On electric window lifts disconnect motor leads "C".
2. Remove screws at "A" and "B", disengage window from cam and prop glass in the up position. NOTE: Do not operate electric regulator in or out of body after window has been disengaged.
3. Remove division channel adjusting stud and nut "D" and stationary cam attaching screws E", then disengage cam from regulator arm and remove stationary cam.
4. Disengage window sash channel cam from regulator arms and remove.
5. Remove regulator attaching screws "F" and remove regulator through large access hole.
6. To install, reverse this procedure, reseal or inner panel.

Weatherstrips

The door weatherstrip is a one piece mechanically retained type. The weatherstrip is also cemented across the bottom and up a short distance on each pillar. An auxiliary weatherstrip is provided on front doors at the hinge pillar to direct water from the offset area of the hinge pillar through drainage hole in the door pillar. This weatherstrip is cemented to the door hinge pillar and has two snap clips at the lower portion. At the bottom of the door, the drain holes are covered by rubber sealing strips. Service procedures for front and rear door weatherstrips are similar and both weatherstrips are covered herein.

NOTE: Some door weatherstrips are retained entirely by weatherstrip adhesive and a metal retainer at the lower edge of the door. The installation and removal procedures for this type of weatherstrip is the same as used in previous years.

Removal

1. Insert tip of tool J-5757 under weatherstrip at the clips and carefully snap clips from retaining hole ( fig. 25). Break cement seal arid remove weatherstrip from door.

Installation

1. Service replacement weatherstrips are longer than necessary to insure a satisfactory joint. Do not cut weatherstrip until all clips are installed into retaining holes. Install weatherstrip clips into clip holes along sides and top of doors after positioning weatherstrip as follows:
2. On front doors, formed bend in weatherstrip should be located in the cove area of door (fig. 26).
3. Color mark on weatherstrip should be located between the third and fourth clip holes on front doors and the fourth and fifth holes on rear doors (fig. 27).
4. Butt joint should be located at the bottom center of the door between two clips.
5. Across bottom of door and up each side, indicated at five in figure 26 or six in figure 27, apply a full coat of weatherstrip adhesive to surface of door which will retain weatherstrip.
6. Install clips to door by placing notched end of tool J-5757 in loop of clip and pushing clip into retaining hole. Repeat operation along both sides and top of door. NOTE: Do not distort clips or unsatisfactory weatherstrip retention will result.
7. Carefully trim ends of weatherstrip to form butt joint, and install balance of clips. Make sure a complete bond is made at cemented area.
8. Coat ends of weatherstrip with weatherstrip adhesive and form butt joint.

Front Hinge Pillar Auxiliary Weatherstrip

Removal

1. Remove two snap fasteners "A" with flat bladed tool, break cement seal and remove weatherstrip (fig. 28).

Install

1. Apply weatherstrip adhesive to door retaining surface and to weatherstrip.
2. Install clips "A" to weatherstrip, then install lower portion of weatherstrip to door pillar. Align weatherstrip with drain hole "B". Weatherstrip must not cover any part of drain hole.
3. Install remainder of weatherstrip into place and firmly press weatherstrip to establish a complete bond.
4. Remove excess adhesive.

Door Lock

These service operations may be used for door locks on all models. However, in addition to the following operations, it is necessary to remove the door window and glass run channel, to remove the door lock from sport coupes and convertibles.

Operation

A rotary bolt type door lock is used on all models. Figures fig. 29 and fig. 30 show the door lock construction and striker with the names of component parts. When the door is being closed, the lock bolt rotates as it comes in contact with the striker, until it becomes firmly engaged with the teeth at the lower end of the striker. When the door is completely closed, the locking cam, shown in the illustration, is firmly locked by the detent lever (fig. 29).

To open the door, the locking cam is released so that the bolt can rotate. This action is obtained by the operation of the push button or remote control handle.

1. When the push button on the door outside handle is depressed: the push button lever operates the intermittent lever contacting the multiplier lever and in turn lifts the detent lever free of the locking cam (fig. 30).
2. When the inside remote control handle is operated, the connecting rod from the remote control operates the remote lever on the lock contacting the detent lever and lifting it free of the locking cam.

Locking of the door by key or by the lock rod is accomplished in the lock in the following manner.

1. When the door is locked with the key, the action of the cylinder pawl on the locking lever operates the connecting link and trip lever downward. The trip lever contacts the intermittent lever and lowers it under the engaging lug of the multiplier lever.
2. When the door inside locking rod, which is connected to the bellcrank is operated to the down position, the action of the bellcrank operates the trip lever which contacts the intermittent lever and lowers it under the engaging lug of the multiplier lever.

Door Lock Remote Control

Removal and Installation

1. Remove door trim pad and remove remote control attaching screws "A" (fig. 31).
2. Detach connecting rod from clip "B" and disengage remote control from connecting rod and remove.
3. To install, reverse removal procedure.

Door Lock

Removal and Installation

1. Remove trim pad and access hole cover.
2. Remove remote control and connecting rod (fig. 31).
3. Working through access hole remove nut securing lower end of glass run channel at lock pillar.
4. Remove screws "C" and remove lock and locking rod through access hole.
5. To install, reverse removal procedure. NOTE: Before installing door lock, apply a ribbon of caulking compound on the door lock facing at the top and side joints of the lock bolt cover as indicated at "l" (See inset figure 31.) Check operation of door lock before installing trim and hardware parts.

Door Lock Striker

The door lock striker is secured to the body pillar with three screws. Serrations on the back surface of the striker plate and the upper and lower striker adjusting plates "A", which are inserted between the striker and pillar, help secure the striker in position. (fig. 32).

The teeth at the lower end of the striker engage with the door lock rotary bolt. As the door closes, the teeth on the striker indicated at "B" causes the lock bolt to rotate until it becomes firmly engaged and the door is completely closed. The sliding shoe "C," at the upper end of the striker opening, prevents excessive up and down movement of the lock bolt within the striker when the door is closed.

Removal and Installation

1. Scribe position of striker on body pillar and remove attaching screws, striker and upper and lower adjusting plates.
2. To install, place striker and adjusting plates within scribe marks and install attaching screws.

Adjustment

1. Up or down or in or out-loosen striker plate attaching screws and shift striker and adjusting plates to desired position.
2. Door lock rotary bolt should overlap the striker a minimum of 1/4" to a maximum of 3/8". If overlap is less than 1/4", an emergency spacer should be installed between the striker and adjusting plates to obtain the required overlap ( fig. 33). NOTE: The amount of lock bolt overlap on the striker can be determined by applying modeling clay on the striker teeth, then closing the door to form a measurable impression in the clay.

NOTE: The door lock and striker should be lubricated periodically to obtain maximum operating efficiency.

The front door may be removed with or without the hinges attached.

Removal

1. Place suitable protective covering over front fender at door opening to protect finish, then remove door trim pad. NOTE: On bodies with manual window lifts, the trim pad does not have to be removed, if the door is to be removed with the hinges attached.
2. Scribe location of hinge box on front body pillar or location of hinge strap on door inner panel, depending on method of door removal.
3. On door with electric window lifts with the trim pad removed:
   • Remove screws securing electric conduit and carefully slide conduit toward front pillar exposing wire harness.
   • Detach wire harness from clips and disconnect motor leads. Disengage wiring from retaining clips and carefully pull harness from cutout in door hinge pillar.
4. Support door and remove bolts "A" or "B" (fig. 34). Two bolts "A" at upper hinge and one bolt "A" at lower hinge are located inside the hinge box. With the aid of a helper remove door from body.

Installation

1. Coat all hinge attaching surfaces, as indicated in figure 35, with a medium bodied sealer. Apply enough sealer at area "A" to insure a water tight seal.
2. Reinstall door to body with the aid of a helper. Align hinges within scribe marks and tighten bolts. Check door alignment.
3. On doors with electric window lifts, install wire harness to door and connect motor leads. Tighten wire harness clips, make sure spacers are properly installed and attach conduit to door hinge pillar.
4. Reseal and lubricate door as required.

Door Inner Panel Sealing

Whenever work is performed on a door and the inner panel sealing is disturbed, the area must be resealed to insure a water tight door. Figures fig. 36 and fig. 37 show the sealing areas of four and two door sedans respectively.

            Location                      Key Sealer        
1. Access door opening flange       Medium bodied sealer
2. Access door side flange          Medium bodied sealer
3. Access door corner,              Medium bodied sealer
4. Window regulator holes           Body caulking compound
5. Wind cam holes                   Body caulking compound
6. Division channel adjusting screw Body caulking compound
7. Arm rest holes                   Waterproof tape
8. Trim pad nail slots              Waterproof tape
9. Access hole (two door only)      Waterproof tape

Front Door Adjustment

Door adjustment is provided at the hinges through the use of cage nuts and anchor plates. When checking a door for misalignment, remove the door lock striker and allow the door to hang free on its hinges, then check the spacing at the sides and top of the door. After determining the type of correction needed, correct in the following manner:

Up or Down and In or Out

1. Scribe location of hinge box on pillar.
2. Loosen bolts attaching hinge box to pillar.
3. Shift door to desired position and retighten bolts.

Up or Down and Fore or Aft

1. Remove trim pad.
2. Scribe location of hinge strap on door.
3. Loosen bolts attaching strap to inner panel, shift door to desired position and retighten bolts.
4. Install trim pad and lubricate door hold opens and hinge pins with Lubriplate or its equivalent.

Should the door clearance at the body hinge and windshield pillars be parallel and fall within 1/16" to 3/16" clearances and the door at the center or lock pillar be tilted (close at the top, wide at the bottom or vice-versa) it is indicative of another type of correction, namely body shimming. In most cases, where adjustment of the doors cannot correct a door alignment problem, body shimming will be the answer. Figure 38 shows the location of all body mounting points and where shims may be added or removed to correct body alignment faults. In addition figure 39 gives the dimensional clearances of the doors at the pillars.

Door Lock Striker

The door lock striker provides an additional adjusting point, where the lock pillar side of the door may be moved in or out to conform to the general body contour.

Adjustment

Adjustment of the door lock striker plate is provided by floating anchor plates in retaining cages behind the body lock pillar or the center pillar facings. Serrations of the striker plates and anchor plates provide retention to hold the striker plates in the desired position.

To adjust the striker plate, the attaching screws should be loosened sufficiently to allow the striker plate to be moved by hand to the desired location. Scribing the position of the striker plate on the pillar, prior to loosening the attaching screws, will clearly indicate the amount the striker plate has been moved. Hammering or blocking the striker plate should never be attempted as damage to the serrations may result in the loss of proper tension. Hammering or blocking of the striker plate may also result in closing the lock bolt groove which will affect the lock operation because of a bind condition which develops at the lock bolt roller.

Ventilator Regulator

Removal and Installation

1. Remove door garnish molding, trim pad and small access hole cover.
2. Remove screws "A" and "B" (fig. 40), disengage regulator from "Tee" shaft and lower it between door panels out through small access opening.
3. To install, seal as specified under Door Sealing, reverse removal procedure.

Adjustment

Ventilator flutter, when the ventilator is open, may be eliminated by tightening "Tee" shaft screw "A." Tighten screw carefully to avoid stripping threads (fig. 41). Opening and closing effort may be increased or decreased by an adjusting friction clamp screw "B."

Ventilator and Division Channel

Removal and Installation

1. Lower door glass window, remove trim pad, small access hole cover and ventilator regulator.
2. Loosen upper section of glass run channel "A," remove attaching screws "B" and adjusting stud and nut"C" (fig. 42).
3. Work ventilator inward, then lift ventilator assembly from door.
4. To install, seal as specified under Door Sealing and reverse the removal operation.

Adjustment

In addition to the regulator adjustment, the ventilator assembly may be adjusted in or out, fore or aft to align the ventilator with the door glass. To adjust, loosen stud lock nut "C" and turn adjusting stud in or out as desired. Shift position of stud in opening for fore or aft adjustment and retighten lock nut. Seal stud with caulking compound.

Outside Handle

Removal and Installation

1. With the door glass in the closed position remove the trim pad.
2. Through access holes indicated at "A" and "B" (fig. 43) remove two screws securing handle to door outer panel.
3. Remove handle and gaskets.
4. To install, reverse this procedure.

Lock Handle Push Button

Removal and Installation

1. Remove door handle from door.
2. Depress stop wash slightly and make quarter turn and remove stop washer, retainer, spring and push button and shaft (fig. 44).
3. To install, reverse this procedure.

Lock Cylinder

Removal and Installation

1. Pry retainer "C" out sufficiently to release cylinder (fig. 43).
2. Remove cylinder and gasket.
3. Remove retaining clip "A" and pawl (fig. 45).
4. Carefully bend open four cylinder housing: scalp tabs "B" and remove scalp
5. Remove cylinder from housing. Figure 46 shows an exploded view of the door lock. CAUTION: When removing scalp, hold spring loaded cylinder cap depressed with finger. Note position of springs and cap for reassembly purposes.
6. To install, reverse this procedure, insert cylinder with curved edge toward lock pillar "B" ( figure 43) remove two screws securing and check operation of lock cylinder.

Figures fig. 47 and fig. 48 indicate the various door parts.

The following assemblies are removed from and installed to sport coupe and convertible bodies in the same manner as on sedan bodies. Service procedure for these installations and removals are found under Sedan Door in this section.

• Inside Handles
• Arm Rest
• Trim Pad
• Window Control Switch
• Door Removal
• Hinge Sealing
• Outside Handle
• Handle Push Button Shaft
• Lock Cylinder
• Lock Remote Control
• Lock Striker
• Hinge Pillar Auxiliary Weatherstrip

Ventilator Garnish Molding

Removal and Installation

1. Remove belt finishing molding, weatherstrip retainer at top of ventilator and screw securing weatherstrip tab at upper portion of hinge pillar.
2. Remove two attaching screws at face of pillar and screw at top of ventilator.
3. Pull molding inward to remove.
4. To install, reverse this procedure.

Weatherstrips

Two methods of weatherstrip retention are used; namely, by clips and weatherstrip adhesive or weatherstrip adhesive alone. Where an adhesive retained weatherstrip is removed or installed, the same procedures used in previous years are recommended. The clip retained weatherstrips are covered in the following text.

Removal

1. Remove ventilator garnish molding and screw securing rear end of belt finishing molding and weatherstrip.
2. Remove two screws securing upper portion of weatherstrip to ventilator frame and door hinge pillar extension.
3. Remove weatherstrip retaining clips from door by inserting notched end of tool J-5757 under clip and snapping clip from place. Complete clip removal and remove weatherstrip from door.

Installation

1. Install weatherstrip to top of ventilator frame and hinge pillar extension with two screws.
2. Install weatherstrip clips into holes at hinge pillar and extension by placing notched end of tool J-5757 around clip loop and snapping clips into retaining holes.
3. Apply a coat of weatherstrip adhesive to the weatherstrip bonding area on the door, as indicated at "A", to a point just below the lower attaching clip holes (fig. 49).
4. Install remaining clip and seal weatherstrip to door at cemented area.
5. Install ventilator garnish molding and two screws retaining rear end of belt finishing molding and weatherstrip.

Door Ventilator

Removal and Installation

1. Lower door glass, remove trim pad, ventilator garnish molding and small access hole cover.
2. Remove division channel adjusting stud and nut "A" and "Tee" shaft screw "B" (fig. 50).
3. Remove screws "C" retaining ventilator to pillar and door flange and ventilator to regulator attaching screws.
4. Disengage "Tee" shaft from regulator and remove ventilator.
5. To install, reverse this procedure and reseal door inner panel.

Adjustment

To adjust lower end of division channel loosen stud nut at "A" (fig. 50) and turn adjusting stud in or out, fore or aft adjustment may be made by shifting the stud position in the elongated hole.

Ventilator Regulator

Removal and Installation

1. Remove trim pad, small access hole cover and screw "A" and screws "B" (fig. 51).
2. Lower regulator to disengage from "Tee" shaft and remove through access hole.
3. To install, reverse this procedure, then reseal inner door panel.

Adjustment

Flutter of ventilator in the open position may be corrected by tightening screw "A". Opening or closing effort of the ventilator is controlled by screw "C" (fig- 51).

Door Window

Removal and Installation

1. Lower door glass, remove belt finishing molding clips and trim pad. NOTE: On electric window lift, disconnect positive or negative battery cable.
2. Remove window stops "A" and bumper "B", then remove large access hole cover and tape from circular cutout "H", (fig. 52).
3. Remove screws at "C" and "H" from each end of sash channel cam and disengage window from sash channel cam.
4. Lift glass up and tilt to the rear to clear ventilator frame and remove. NOTE: Do not operate electric lift with window removed.
5. To install, reverse this removal operation and reseal door inner panel.

Adjustment

1. A cocked glass in run channel, may be corrected by loosening the stationary cam rear screw at "D" and adjust cam up or down as required, then tighten screw (fig. 52).
2. Compensating adjustments may be made by adjusting the division channel adjusting stud "E" in or out and moving the division channel fore or aft as desired.
3. Additional adjustment is provided by screws "F" which may be loosened to reposition the rear glass rear channel.

Glass Run Channel

Removal and Installation

1. Remove door window glass, then remove glass run attaching screws "F" and run channel.
2. To install, reverse this procedure.

Window Regulator

Removal and Installation

1. Remove trim pad, both access hole covers and window glass. CAUTION: Do not operate electric lifts with window removed.
2. Remove stationary cam screws "D", and disengage cam from regulator arm and remove. Disconnect motor leads on electric lift bodies through small access hole (fig. 52).
3. Disengage window sash channel cam from regulator arms and remove.
4. Remove division stud and nut "E" and regulator attaching screws "G", carefully remove regulator through large access hole.
5. To install, reverse this procedure, reseal and lubricate as specified.

Side Roof Rail Mechanical Sealing Strip

Special Coupe

Removal

1. Remove screws "A" and "B" and remove front and rear outer weatherstrip (fig. 53).
2. Remove screws "C" and remove sealing strip and attached gasket.

Installation

1. Clean old sealer from side roof rail and gasket. If gasket was removed, discard double coated tape from sealing strip.
2. Tape sealing assembly with flipper section held in the closed position.
3. Cement rubber gasket to sealing strip with a good weatherstrip adhesive by applying a film of adhesive to the sealing strip. NOTE: Do not apply cement to lip or awning of gasket nor to hinge portion of gasket so it lies flat and the awning of lip is over the radius of the sealing strip hinge.
4. Apply bead of caulking compound along outside edge of gasket (fig. 54).
5. Position sealing strip assembly to side roof rail and install retaining screws snugly.
6. Apply weatherstrip adhesive to attaching surfaces of front and rear outer weatherstrips and install to body.
7. Align sealing strip with top of door window and ventilator, then uniformly tighten all attaching screws.
8. Lubricate inner side of awning with rubber lubricant.

Inner Panel Sealing

Special Coupe and Convertible

Whenever the sealing of the inner panel is disturbed, the inner panel should be resealed as out lined below (fig. 55).

     Location Key                          Sealer

1. Access door opening flange       Medium bodied sealer
2. Access door flange               Medium bodied sealer
3. access door corners              Medium bodied sealer
4. Arm rest attaching holes         Waterproof tape
5. Access hole                      Waterproof tape
6. Trim pad nail slots              Waterproof tape
7. Window cam attaching holes       Body caulking compound
8. Regulator attaching holes        Body caulking compound
9. Ventilator lower attaching hole  Body caulking compound
 
Rear Door Assembly 
The manual regulator type rear door inner panel and the electric
regulator type rear door inner panels are shown in figures fig. 56 and fig. 57
respectively. The illustrations show the location of hardware parts and
their attaching points.

Glass Run Channel

Upper and Low Hinge Cover Plates and Hinges

Locking Rod and lever

Lock Remote Control

Lock Remote Control Connecting Rod

Lock

Window Regulator

Window Regulator Stationary Cam Adjusting Screws

Access Hole Cover Plate

Trim Pad Retainers

Glass run Channel Adjusting Screw

Window Control Switch Terminal Block

Window Electric Regulator

Electrical Conduit Opening

Electric Connectors for Door Window Regulator Motor

Attaching Holes for plastic Type Door Arm Rest

Hanger Plate for Built-in Type Door Arm Rest
 
Rear door inside hardware parts are installed and removed in
the same manner as front door inside hardware parts and are covered
under the front door in this section.
Door Hinge 
The rear door is attached to the center pillar with two
butt-type hinges. The door may be removed with or without the hinge
attached.
Removal 

Remove hinge cover plates from center pillar, clean sealer from
around hinge straps and scribe location of straps on center pillar.

On electric window lift installations, remove trim pad and access
hole cover. Remove two screws securing wire harness conduit to center
pillar, bend out conduit tabs and remove from harness. Loosen harness
from clip and disconnect motor leads and remove harness from door.

Support door and remove three upper and lower attaching bolts from
hinge strap and remove door.
 
Installation 

Clean all old sealing compound from hinge areas. Do not soil
adjacent trim.

Apply a full coat of heavy bodied sealer to attaching surface of
hinge strap, this sealer acts as a weatherseal and anti-squeak (fig. 58).

Place door in body opening and install attaching bolts loosely.
Align straps within scribe marks and tighten bolts. NOTE: On
electric lift installation, install wire harness to conduit, conduit to
hinge pillar and connect motor leads. Install access door, trim pad and
inside hardware.

Apply medium bodied sealer to upper and lower hinge as indicated at
"A" and "B" in figure
59.

Install hinge cover plates and remove excess sealer.
 
Adjustment 
To check the rear door alignment in the body opening, remove the
lock striker from the body lock pillar and allow the door to hang free.
Then check spacing (fig. 39)
between the door and body opening edges. Clearance between the door
header and side roof rail and the door pillar and body pillar should be
1/16" - 3/16" Clearance between the bottom of the door and
rocker panel should be 1/8" - 1/4".
In or Out- Remove hinge cover plates at center pillar
and loosen center pillar strap attaching bolts, shift door in or out as
desired and retighten bolts.
Up or Down- Remove trim pad and loosen hinge strap
attaching bolts at inner panel, shift door to desired position and
retighten bolts.
Rearward- Support door, then remove upper center pillar
hinge attaching bolts, and cement a full weatherproof shim to hinge
strap and reinstall strap to center pillar. Perform same operation on
lower hinge strap.
Forward- Support door, remove hinge cover plates and
loosen hinge strap to center pillar attaching bolts. Insert a partial
waterproof shim at the inner edge of the hinge straps and retighten
bolts.
Reseal hinges and hinge cover plates as described under Rear
Door removal
Rear Door Remote Control 
Removal and Installation 

Remove trim pad and remote control attaching screws "A" (fig. 60).

Remove remote control after disengaging connecting rod.

To install, reverse this procedure.
 
Rear Door Lock 
Removal and Installation 

Remove trim pad, access hole cover and remote control.

Remove inside locking rod lever attaching screw "B" and
washer, disengage lever connecting rod from clip "C" and door
lock (fig. 60).

Remove glass run channel screw "D" and four lock
attaching screws "E".

Remove lock through access hole.

To install, reverse this procedure. Check operation of lock
components and reseal as specified under Rear Door Inner Panel Sealing.
 

Free Wheeling Adjustment 
Free wheeling is a safety feature of rear door locks in all
passenger models. The rear door lock may be placed in or out of free
wheeling depending on the owner's preference. When a rear door lock is
in the free wheeling position, with the locking rod knob in the down or
locked position, the door cannot be opened by operation of the inside
door handle. All passenger cars as shipped from production have rear
door locks set in free wheeling. To place the rear door lock in free
wheeling proceed as follows:

Pull inside locking rod knob to the "up" position and
remove rear door lock upper attaching screw.

Insert adjusting tool through screw hole as shown in illustration,
(fig. 61).

Engage hooked end of rod in loop of remote control connecting link
as shown in the illustration. Push rod forward to set lock
"out" of free wheeling and pull rod rearward to set lock
"in" free wheeling, (fig.
62).
 
NOTE: Adjusting tool may be made from a 7" x 1/8"
rod bent to form a right angle 3/8" from one end. 
Glass Run Upper Channel 
Removal and Installation 

Lower door window and remove trim pad and access hole cover (fig. 63).

Remove screw "E" at lower end of channel and carefully
pry channel rose-bud fasteners from retaining holes at door header.

Carefully pull channel from door.

To install, reverse the removal procedure. Upper channel must fit
properly into end of lower channel at "G". Align channel for
free glass travel and reseal inner panel.
 
Glass Run Lower Channel 
Removal and Installation 

Lower door window, remove trim pad, access hole cover and screw
"D" from end of glass run channel (fig. 63).

Detach upper channel from door lock pillar, then remove rose-bud
fastener from retainer at "G."

Carefully pull lower glass run channel up through window opening.

To install, reverse this procedure making sure upper and lower run
channels are properly aligned. Align channels for free glass travel and
reseal inner panel.
 
Rear Door Window 
Removal and Installation 

Lower door glass, remove trim pad, access hole cover and tape
covering small access hole "A" (
fig. 63).
NOTE: On electric lift installation, disconnect positive or negative
battery cable. 

Remove upper glass run channel and through access holes "A"
and "B" remove window to sash channel cam screws.

Disengage window from sash channel cam, lift window upward,
carefully tilting it inward as it is lifted until window can be removed
from door. CAUTION: Do not operate electric lifts with window
removed. 

To install, reverse this procedure and reseal inner panel.
 
Adjustment 

To correct a glass tilted in the run channels, loosen stationary
cam screw "C" and move stationary cam as desired (fig. 63).

To correct glass bind, due to glass run channel misalignment,
loosen screws "D" and "E" and adjust channels in or
out as desired.
 
Rear Door Window Regulator 
Removal and Installation 

Lower door glass, remove trim pad access hole cover and tape from
small access hole (fig. 63).
NOTE: Disconnect motor leads on electric lift installations. 

Through access holes at "A" and "B" remove
window to sash channel cam screws and prop window in closed position.

Remove stationary cam screws "C" and cam, disengage sash
channel cam from regulator and remove sash channel cam.

Remove screws "F" and carefully remove regulator.

To install, reverse this procedure. Reseal door inner panel as
specified in this section.
 
Rear Door Weatherstrip 
The removal and installation of rear door weatherstrips is
similar to the weatherstrip operation on front doors. The service
operation is covered in the Front Door section.
Rear Door Outside Handle 
The rear door outside handle is removed and installed in the
same manner as the front door outside handle. Removal and installation
procedure is covered under Front Doors in this section.
Door Inner Panel Sealing 
Whenever it is necessary to disturb the seal on the rear door
inner panel, the inner panel must be resealed to insure a weatherproof
door. The illustration keys the door inner sealing points with the
sealing material required (fig. 64).


 
    Location Key                        Sealer

1. Access Door Opening            Flange Medium Bodied Sealer
2. Access Door Flange               Medium Bodied Sealer
3. Access Door Corners            Medium Bodied Sealer
4. Window Regulator Holes      Body Caulking Compound
5. Window Cam Attaching         Holes Body Caulking Compound
6. Welding Access Holes           Waterproof Tape
7. Arm Rest Attaching Holes    Waterproof Tape
8. Trim Pad Nail Slots                Waterproof Tape





Rear End Assembly 
BACK WINDOW ASSEMBLY
 
Back Window Garnish Moldings 
The removal of the back window garnish molding on all two and
four door sedans requires only the removal of the retaining screws and
moldings. The removal of the garnish molding from sport coupes is as
follows:
Removal and Installation 

Remove rear seat cushion, back and rear quarter belt finishing
molding.

Remove back window side garnish moldings by removing three screws
from each molding.

Remove back window upper garnish molding screws and molding.

To install, reverse the above procedure.
 
Back Window Upper Reveal Molding 
The back window upper reveal and upper corner escutcheons may be
removed with the back window in the body. However, to remove the back
window lower reveal it is necessary to remove the back window from the
body.
Removal 

Apply protective covering to painted surfaces at the molding area.

Remove back window garnish molding from interior of body.

Remove both reveal molding upper escutcheons by folding headlining
trim back and removing retaining nuts.

Carefully pry upper reveal molding free of retaining clips and
remove. Figure 65 shows the cross
section of the back window with the upper and lower moldings.
 
Installation 

Position reveal molding and at each clip location press the molding
until the leg of the molding is held by the retaining clip.

Apply medium bodied sealer around upper corner escutcheon bolts
holes, then install moldings.

Install back window garnish moldings.
 
Back Window 
Removal 

Place protective coverings on painted surfaces surrounding the back
window. Inside the body, protect the parcel shelf and rear seat with a
suitable covering.

Remove back window garnish moldings, upper corner escutcheons and
upper reveal molding.

Break the seal between the rubber channel and the pinch weld flange
on the inside of the body with a putty knife.

From the inside of the body carefully push the top of glass and
channel outward with the palm of the hand, then with the aid of a helper
remove the complete assembly from the body opening.

Place assembly on covered bench and remove lower reveal moldings,
clips and rubber channel from glass. Also remove upper reveal molding
clips from pinchweld flange.
 
Installation 
Clean old sealer from window opening and rubber channel, check
the body pinchweld flange for irregularities, use the glass as a
template. Install upper reveal molding clips to pinchweld, make sure
they are secure. Examine back window drain gutter and both drain hoses
for obstructions, clean if necessary. The back window drain is located
under the parcel shelf trim.

Assemble rubber channel to glass.

With lower reveal molding clips secured to the moldings, apply a
medium bodied sealer to the molding clips as shown at 1 in figure 66. Install lower reveal moldings in rubber channel.

Insert cord into pinchweld cavity of rubber channel and tie cord
loosely at bottom center of glass. Tape ends to inside surface of glass.

Apply a heavy bead of medium bodied sealer at the rabbet (cross
section 2) of the pinch weld flange around the entire perimeter of the
window opening.

Bridge the upper reveal molding clips at the pinchweld with medium
bodied sealer.

Place the back window assembly into the body opening, this is a
two-man operation.

While pressing firmly on the outside surface of the glass, have the
helper carefully pull the cord from the pinchweld cavity of the channel
seating the lip of the rubber channel over the pinchweld flange.

Outside the body, seal lip of rubber channel to surface of glass
with weatherstrip adhesive.

Install upper reveal, corner escutcheon and garnish moldings.
Remove excess sealer and protective covering.
 
NOTE: If parcel shelf trim has been disturbed re-cement to
place with trim cement before installing garnish molding. 
Rear Compartment Assembly
 
Rear Compartment Lid 
The rear compartment lid employs two torsion rods between the
hinge assemblies as a counterbalance and a hold-open. Notches are
provided at the hinge assemblies for rod adjustment. The rear
compartment weatherstrip is retained to compartment lid inner panel by
integral clips or by weatherstrip cement.
Removal and Installation 

Open lid and place protective covering over adjacent finish areas.

Disconnect light wire at connector and remove wire from lid. Scribe
position of hinge straps on lid inner panel.

With a helper-assisting, remove bolts attaching hinge strap to lid
inner panel and remove compartment lid.

To install reverse this procedure, make sure hinge straps are
aligned within scribe marks.
 
Rear Compartment Lid Hinge 
Removal 

Place protective covering over paint finish at working area and
place a suitable support under lid near the hinge being removed.

Scribe location of hinge strap on lid inner panel, then remove
strap to lid retaining bolts.

Remove screws for the torsion rod cover at the left hinge (see inset fig. 67) and remove cover.

Mark notch engaging torsion rod, then install a suitable length of
pipe over end of torsion rod and disengage torsion rod from retaining
notches at inboard face of the opposite hinge box (fig. 68).

Disengage torsion rod from movable portion of hinge strap and
remove rod.

Bend up hinge pin retaining tab "A" and remove pin, then
remove hinge from hinge box. Figure
69 shows the various positions for adjusting the torsion rod.
 
Installation 

Place hinge in hinge box and install pin, bend down pin retaining
tab.

Install hinge strap to lid within scribe marks on lid inner panel.

Install "U" shaped end of torsion rod to hinge box,
making certain outer end of rod is engaged in hole in outboard face of
hinge box.

Engage torsion rod in movable portion of hinge strap and engage
other end of rod to previously marked position on inboard side of
opposite hinge box.

Center rubber silencer at the crossover point of the torsion rods,
then install rod cover to left hand hinge box.

Check lid alignment in compartment opening and remove protective
covering.
 
Lid Lock Cylinder 
Removal and Installation 

Insert suitable hooked tool through inner panel of lid and pull
lock cylinder retainer away from cylinder. See inset in figure 70. 

Remove lock cylinder and gasket from lid outer panel.

To install, reverse this procedure, after sealing at cylinder
opening in outer panel.
 
Lid Lock 
Removal and Installation 

Remove lock cylinder from compartment lid.

Remove lid lock and cover plate screws "B" and "C"
and remove lock and cover plate assembly (
fig. 70).

To install, reverse this procedure.
 
Rear Compartment Lid Weatherstrip 
The weatherstrip for the rear compartment lid is retained either
mechanical (integral clips) or by weatherstrip adhesive. The clip
retained weatherstrip removal and installation procedure is outlined as
follows. The service procedures for the cemented weatherstrip are the
same as used in previous years.
Removal 

Use tool J-5757 by slipping notched end of tool under the
weatherstrip retaining clips and carefully snapping the clips out the
holes in the inner panel.
 
Installation 

Service replacement weatherstrips are longer than required, but
should not be cut until weatherstrip is installed.

Locate two clip holes indicated at. "A" in figure 71 near the lid lock bolt. These holes are closer together
than the others.

Insert second clip on weatherstrip into clip hole "B" by
placing notch of tool J-5757 on loop of clip and snapping clip to place.
Do not use excessive force or clip may be distorted resulting in
improper weatherstrip retention. This places the butt joint of the
weatherstrip between clip holes "A".

Install all clips except those to be inserted into clip holes at
"A".

Accurately cut and trim weatherstrip to proper length and apply
weatherstrip adhesive to the surface of the compartment lid, a distance
of 21/2 inches on each side of the butt joint.

Apply weatherstrip adhesive to the butt ends of the weatherstrip
and install last two clips. NOTE: Ends should match evenly to
provide a continuous seal. 
 
Adjustments 
Compartment Lid 
Rear compartment lid may be adjusted forward, rearward or to
either side by loosening hinge strap attaching bolts and shifting the
lid in the desired direction and retighten bolts.
To raise or lower the lid at the hinge area, place shim under
strap at "A" to raise the lid and at "B" to lower
the lid (fig. 72). A combination
of shims may be used under the lid hinge strap to tilt the lid in its
opening. Lid Lock Bolt and Striker Engagement Check may be made by
insert modeling clay, as shown in figure
73. Close the lid with moderate force, open the lid and check the
engagement by measuring the distance between "U" in the clay
and the base of lock. This dimension should be 1/8" to 5/32"-
If necessary, adjust striker as follows:
Lid Lock engagement may be adjusted at the lid lock striker by
loosening attaching bolts and shifting the striker plate on its beveled
anchor plate. In extreme cases to obtain proper engagement a spacer or
shim may be placed between the striker plate and beveled anchor plate.
Compartment Lid Torsion Rod 
The position of the torsion rods in the notches on the inboard
side of the hinge boxes determines the amount of effort required to open
and close the rear compartment lid.
By placing the torsion rod in position three (fig. 69) the amount of effort required to open the lid is the least
and conversely the amount of effort to close the lid the greatest. It is
not necessary to adjust right and left rods at the same time, nor is it
necessary to have the same final position of adjustment on both rods. If
adjustment is required at the left hinge box it is necessary to remove
the torsion rod cover.
Rear Compartment Lid Bumpers 
Raise compartment lid and loosen weatherstrip enough to gain
access to bumper attaching screws.
Loosen bumper screws and adjust bumper by moving anchor plate so
clearance between bumper and rear end panel is 1/16". The guide pin
alignment adjustment is provided through oversize attaching screw holes.
figure 74 for clearances at the
rear compartment lid.
Back Window Gutter Drain Hose 
A drain gutter is provided on all sedan styles to collect any
moisture in the back window area. The drain gutter has outlets at each
end connected to drain hoses which direct water to the outside of the
body between the rear quarter inner and wheelhouse panel.
Removal 

From inside rear compartment, remove drain hose from rear quarter
inner panel (fig. 75).

Remove rear seat cushion, back and back window garnish moldings.

With a wide blade putty knife or some other suitable tool,
carefully separate cemented parcel shelf trim from metal.

Loosen the cemented upper end of drain hose at "A" and
carefully remove hose from outlet (fig.
75).
 
Installation 

Apply weatherstrip adhesive to sealing edges "A" of drain
hose and place hose in outlet opening.

From inside rear compartment draw hose down into position and
insert other end of hose into opening in rear quarter panel.

Remove all excess sealer and reinstall parcel shelf covering,
garnish molding, rear seat back and cushion.
 
Rear Quarter Assembly 
Rear Quarter Trim Panel 
Two Door Sedan 

Remove rear seat cushion, back and quarter window garnish molding.

Remove rear quarter window handles and on models so equipped remove
quarter arm rest screws and rests. On electric quarter window lifts
remove switch by prying it from its retainer.

Remove two screws attaching the rear upper and lower corners of
trim panel.

Swing rear of trim panel forward exposing hidden tacks at body lock
pillar and remove tacks and trim panel.

To install, reverse this procedure.
 
Rear Quarter Trim 
Four Door Sedan 
Removal and Installation 

Remove rear seat cushion and back assemblies.

Remove rear quarter garnish molding.

Remove screws from upper and lower rear corner of trim panel,
regulator handles and on models so equipped, remove arm rests and
disconnect switch block.

Rotate the rear edge of the trim panel forward exposing the trim
panel to lock pillar attaching tabs at front edge of trim panel.

Remove attaching tabs and trim panel.

To install, reverse this procedure.
 
Rear Quarter Window 
Two Door Sedan 
Removal and Installation 

Remove the rear seat cushion, back, quarter window garnish molding,
window regulator handle or window electric switch. NOTE: Disconnect
positive or negative battery cable on electric window lifts. 

Remove rear quarter arm rest from bodies so equipped and remove
rear quarter trim panel.

Remove access hole cover from inner panel.

With quarter window in the up position, remove quarter window guide
attaching screws "A" and guide from body (fig. 76).

On electric installations, temporarily connect power supply and
lower window to expose sash channel screws, remove screws and disengage
channel from cam. On manual operated windows temporarily install handle
to lower window.

Remove quarter window lower stop from the end of window front guide
by working through the access hole. This will permit the front roller of
the glass assembly to fall free of the front guide.

Rotate the forward edge of the glass until the rear roller is
disengaged from the rear guide "B" and remove window.

To install, reverse this procedure.
 
Adjustment 
By raising or lowering the rear quarter window lower stop the
window may be properly positioned in the body opening.
Rear Quarter Stationary Window 
Four Door Sedan 
Removal 

Remove rear quarter garnish molding.

Carefully loosen rubber weatherstrip from sealer around window
opening, then push glass from body opening with the palm of hand.
 
Installation 

Clean old sealer from rabbet and rubber weatherstrip.

Install glass into rubber weatherstrip and insert a cord into the
pinchweld cavity of the weatherstrip around the entire window.

Apply a bead of weatherstrip adhesive around the window opening at
the weatherstrip contacting surface on both sides of flange.

Insert window and weatherstrip assembly into its opening and pull
string, lifting the lip of the rubber weatherstrip over the flange.

Apply a bead of weatherstrip adhesive between the outer lip of the
weatherstrip and the glass. Remove all excess adhesive and install
garnish molding.
 
Rear Quarter Window Regulator 
Two Door Sedan 
Removal and Installation 

Lower rear quarter window approximately two inches. NOTE: On
electrically operated styles disconnect positive or negative battery
cable. 

Remove rear seat cushion and back, quarter window garnish molding,
arm rest and quarter trim panel.

Remove access hole cover and remove rear quarter windows.

Remove four screws attaching regulator to inner panel. NOTE: On
electrically operated windows disconnect motor leads. Lift regulator out
through access hole.

To install reverse this procedure. Seal access cover perimeter with
weatherstrip adhesive and all attaching screws with sealing compound.
 
Rear Quarter Glass Run Channel 
Two Door Sedan 
Removal and Installation 

Remove quarter window garnish molding and lower glass to the full
down position.

Disengage glass run channel clips from window header and door lock
pillar by carefully pulling channel inward. Then, pull the, glass
channel upward to free channel from retainers at each end and remove
from body.

To install, reverse this procedure.
 


Sport Coupe Rear Quarter 
Belt Finish Molding 
Removal and Installation 

Remove rear seat cushion and back, then remove retaining screws and
molding.

To install, reverse this procedure.
 
Quarter Arm Rest 
Removal and Installation 

Remove rear seat cushion and back, disconnect courtesy lamp switch
at left side only.

Remove attaching screws and rear quarter arm rest. Lift arm rest up
to clear retaining tabs.

To install, reverse this procedure.
 
Quarter Trim Panel 
Removal and Installation 

Remove quarter arm rest, belt finish molding and window regulator.
On electric lift installations, disconnect switch.

Remove nail from rear corner of trim panel and swing trim panel
forward exposing tacks at lock pillar edge of trim.

Remove tacks and trim.

To install, reverse this procedure.
 
Quarter Window 
Removal and Installation 

Remove rear seat cushion, back, quarter hardware, arm rest, trim
panel and access hole cover. NOTE: On electric quarter window lifts
disconnect switch terminal and positive or negative cable of battery.


With window in up position remove window rear guide screws
"A" and remove guide(fig.
77).

Lower window so the regulator roller cam can be disengaged from
window channel. NOTE: Temporarily hook up power supply on electric
lifts to lower window or install regulator handle on manual lifts. 

Disengage front roller from guide channel and remove quarter
window.

To install, reverse the removal operation.
 
Adjustments 
Fore and Aft-Loosen rear guide channel screws "A"
and "B" and front guide channel screws "C" and
"D." Move window fore or aft as desired (fig. 78).
In and Out - To move window in or out at the lock
pillar, loosen upper front guide stud nut "C" and turn
adjusting stud in or out, then tighten lock nut. To move window in or
out at the rear area, loosen stud nut "A" and turn adjusting
stud in or out, then tighten lock nut.
Down Travel-May be adjusted by removing the access door,
loosening the nut retaining the stop to the front guide channel and
moving the stop.
Up Travel- May be adjusted by loosening screw "E"
and moving stop.
Electric Window Regulator 
Removal and Installation 

Remove quarter window.

Remove access hole cover and disconnect motor wire.

Remove regulator attaching screws "A" and remove
regulator (fig. 79).

To install, reverse this procedure, then reseal access hole cover
and regulator attaching screws.
 
Window Guide-Rear 
Removal and Installation 

Remove rear seat hardware and trim.

Remove access hole cover and with the window in the up position,
remove attaching screws "A" (
fig. 80).

Disengage rear guide from window roller and remove guide from body.

To install, reverse this procedure.
 
Window Guide-Front 
Removal and Installation 

Remove quarter window and regulator.

Remove front guide screws "B" and remove guide from body
through access hole (fig. 80).

To install, reverse this procedure.
 
Window Sealing Strip 
Removal and Installation 

With the window in the down position remove the side roof rail
mechanical sealing strip.

Remove rear seat cushion, back, quarter belt finishing molding and
side roof rail finishing molding.

Remove screws attaching inner extension and outer extension (fig. 81).

Remove screws attaching sealing strip, pull sealing strip forward
to disengage from outer molding and remove.

To install, remove old sealer, then apply a bead of caulking
compound along the entire length of the sealing strip as shown in the
inset. Reverse the removal procedure.
 
Adjustment 
Attaching screw holes are slotted to provide adjustment of the
sealing strip. 



Convertible Rear Quarter
 
Folding Top Compartment Side Trim Panel 
Removal and Installation 

Remove rear seat cushion and back, on left side of body, disconnect
courtesy lamp switch.

Remove attaching screws and top compartment side trim panel.

To install, reverse this procedure.
 
Trim Panel 
Removal and Installation 

Remove folding top side compartment trim panel, quarter belt
finishing molding and window regulator handle. NOTE: On electric
window lift styles, disconnect switch terminal block. 

Remove nail from rear of trim panel and swing panel out to expose
tacks attaching panel to lock pillar. Remove tacks and panel.

To install, reverse the removal procedure.
 
Quarter Window-Electric and Manual 
Removal and Installation 

Remove rear seat cushion and back, then lower the folding top.

Place window in the half way position, on electric models
disconnect positive battery cable.

Remove top compartment side trim panel and belt finishing molding.
Break window switch circuit at terminal block and pivot quarter trim
away from quarter inner panel.

Remove pivot bolt "A" and disengage male hinge from
female hinge (fig. 82).

Temporarily connect lift power supply or reinstall quarter window
handle and carefully operate window until regulator arm can be removed
from the cam channel.

Remove window from body, exercise caution to prevent scratching of
glass on window stop. Disconnect power supply from electric lift.

To install, reverse this procedure.
 
Adjustment 
In or Out- Loosen pivot bolt "A" and adjust
stud nuts "B" in or out. Retighten lock nuts and pivot bolt (fig. 82).
Up or Down- Fore or Aft-Loosen pivot bolt "A"
and stud nuts "B" and shift assembly as desired, then
retighten bolt and studs.
UP Travel- Loosen stop attaching nut "C" and
move stop.
Guide Channel Alignment -To compensate for various adjustments
it may be necessary to reposition the quarter window guides. To adjust
guide channel loosen screw "E" and move channel.
Window Regulator 
Removal and Installation 

Remove rear quarter window, access hole cover and regulator
attaching screws "A." On electric equipped lifts, disconnect
switch (fig. 83).

Remove regulator from body through access hole.

To install, reverse this procedure, reseal access door and
regulator holes.
 
Window Guide 
Removal and Installation 

Remove quarter window.

Remove guide screw "B" at quarter lock pillar, two upper
attaching screws at "C" and center stud nut and washer at
"D" (fig. 83).

Remove guide assembly from window opening.

To install, reverse this removal procedure.
 



Trim Assemblies
 
FRONT SEATS
 
Construction of a typical seat is shown in figure 84. The springs are of a zig-zag construction set in a box
type frame. Covering the spring is 1/2" insulated jute pad which in
turn is covered With a 1 1/4" foam rubber pad. On 1500 series
models the foam rubber pad is replaced with a cotton pad. Finish trim is
a combination cover of cloth and imitation leather on the 2100 and 2400
series, on the 1500 series it is all cloth.
Seat Side Panels-Divided Back 
Removal and Installation 

On the left side remove adjuster knob "A" by loosening
set screw (fig. 85). NOTE: On
electrically operated seat adjusters detach switch block from switch.


Remove three screws "B" at front and rear of lower side
panel and remove panel.

Remove screws "C" from upper side panel and rotate panel
out of position.

To install, reverse this procedure.
 
Side Panels-Solid Back 
Removal and Installation 

On left side, remove adjuster knob by loosening set screw.
NOTE: On electrically operated seat remove switch terminal block
from switch. 

Remove two screws at front of seat side panel and two screws from
upper section of side panel.

Pull panel out at the front to clear retaining brackets and remove
seat.

Remove front seat side panel extension located at the rear corner
of the seat cushion, by removing three screws.

To install, reverse the above procedure.
 
Seat Regulator Switch 
Removal and Installation 

Remove screws from retaining escutcheon and pull escutcheon and
switch assembly from side panel.

Detach terminal block from switch and through hole "A"
depress clip tab and remove clip "B". Remove three remaining
clips in the same manner, then remove switch from escutcheon (fig. 86).

To install, place switch in escutcheon and push retaining clips to
place. Attach terminal block to switch and install assembly to side
panel.
 
Horizontal Regulator Assembly 
Removal and Installation 

Move seat to extreme rearward position and disconnect regulator
motor wires from wiring harness and remove motor ground wire from floor
pan.

Remove retainers "A" from front and rear support pins,
remove support pins and regulator from support (fig. 87).
NOTE: This operation may be performed with the seat installed in the
body. The seat in figure 87 has
been removed for illustrative purpose only.

To install, reverse this procedure.
 
Seat Assembly 
Removal and Installation 

Place seat in the extreme forward position, loosen sill plates and
turn floor carpet back exposing seat attachment. NOTE: On electric
seat adjuster models, disconnect regulator wiring harness from seat
frame bottom, move seat to extreme rearward position and at the front of
the seat remove the horizontal regulator front support pin. 

Remove two bolts from rear leg of each adjuster. Then pull the
entire seat assembly rearward, lifting slightly to clear front legs from
retaining brackets. Remove seat from body.

To install, reverse this operation.
 
Adjustment 

In the event an additional rearward adjustment of the front seat is
desired, provisions are made to relocate the seat assembly one inch
back.

Remove the seat assembly from the body.

Remove front leg brackets from floor pan and drill 5/16" holes
in the floor pan. These holes must be one inch to the rear of original
attaching holes and on the same center line.

Drill out to 5/16" diameter, the forward two 1/4" pierced
holes in each of the seat rear adjuster legs.

Seal the original attaching holes with body caulking compound.

Install front leg brackets, then install seat assembly. Use longer
bolts to attach the rear legs to floor pan.
 
NOTE: It is imperative, when the seat assembly is moved to
the rear, that all attaching points are moved to the rear to insure
adequate seat to floor pan retention. 
Seat Adjuster 
Removal and Installation 

Remove seat assembly from body and place seat upside down on a
covered bench.

Remove seat side panels. NOTE: On electric seat adjuster
installations, remove tensioner spring "A" from right seat
adjuster (fig. 88). 

Move adjuster to extreme rearward position and remove bolt
"B" from channel, move adjuster to full forward position and
remove bolt indicated at "C".

Detach seat adjuster from frame, disengage locking rod and remove
seat adjuster.

To install reverse this procedure. Seat adjuster attachment to
frame must be made with the sliding mechanism in the same relative
position.
 
Seat Back 
Tilting Style 
Removal and Installation 

Remove seat lower side panel, then remove "C" clip from
hinge pin (fig. 89).

Remove the center hinge post cover plate.

Tilt opposite seat back half forward, then pull seat back toward
outside of body disengaging outer support arm from hinge pin.

Rotate the seat back forward, disengaging the hooked end of center
hinge pin from its retainer and remove back.

To install, reverse this procedure.
 
Solid Back 
Removal and Installation 

Remove seat side panel and side panel extension.

Remove four seat back to frame bolts "A" at each lower
corner of the seat back (fig. 90).
NOTE: It is not necessary to remove seat from body to perform this
operation.

To install, reverse this procedure.
 
Seat Back of Back Trim 
Tilting Back Style 
Removal and Installation 

Remove upper side panel and at the center remove finishing trim
strip (fig. 91).

Remove stops at each lower corner.

Remove hog rings attaching trim to frame along each side and at the
bottom. Seat back of back trim is sewn to the bolster at the top edge
and can only be completely removed when the front portion of the seat
back trim is removed.

Seat back springs maybe made accessible by removing hog rings
attaching jute pad to springs.

To install, reverse the removal operation.
 
Solid Back 
Removal and Installation 

Remove seat back assembly, remove ash tray assembly from bodies so
equipped by removing screws retaining escutcheon to seat back frame.

Remove hog rings retaining back of back trim to frame at sides and
along bottom edge of frame. Back of back trim is sewn to top of the seat
back trim and is not removable unless front portion of seat back trim is
removed.

Access to the spring may be obtained by removing hog rings
attaching jute pad to springs.

To install, reverse this procedure.
 
Rear Seat Assembly 
Rear Seat Cushion 
Removal and Installation 

Lift front edge of cushion upward disengaging locating tabs from
retaining holes in floor pan.

Pull cushion from under seat back and remove from body.

To install, reverse this procedure.
 
Rear Seat Back 
Sedan and Sport Coupe 
Removal and Installation 

Remove rear seat cushion.

Bend down body to seat back retaining tabs at floor pan and along
wheelhouse.

Pull seat back out at the bottom and lift upward to disengage top
of seat back from hangers located at parcel shelf and remove.

To install, make sure hangers and tabs are covered with tape which
acts as an anti-squeak, then reverse this procedure.
 
Convertible 
Removal and Installation 

Remove rear seat cushion.

Remove attaching screws and washer along inner bottom edge of seat
back. Remove the screws attaching fold top compartment side panels to
each corner of seat back.

Elevate seat back to clear retaining hangers at upper edge of seat
back and remove.

After making certain all retaining tabs are taped, reverse this
procedure to install seat back.
 
Headlining 
The headlining removal and installation service operation is similar
for all models. Variation such as exposed roof bows on the sport coupe
and various interior molding arrangement present no problem. The
procedure as presented for sedan models, therefore, can be followed with
minor deviations on any body model.
Sedan Styles 
Removal 

Remove the following hardware and trim assemblies; rear seat
cushion and back, rear view mirror, sunshades, dome lamp cover, coat
hooks and all garnish moldings except the door garnish moldings.

Remove tacks or staples at windshield opening and carefully loosen
cemented edge of headlining. NOTE: Clean hands are essential when
working on trim assemblies. 

Loosen edge of parcel shelf trim to gain access to headlining, then
remove tacks or staples from headlining around quarter window and back
window. Loosen cemented edge of headlining.

Carefully disengage headlining from metal retainer tabs along side
roof rails (fig. 92).

Starting at the front, disconnect headlining support wires from
side roof rails. Then bend down metal tabs retaining listing wire at
center bow, roll headlining up with listing wires on outside to keep
headlining clean.
 
Installation 

Attach listing wires to side roof rails by starting at the rear of
the body and work toward the front. NOTE: Center and align
headlining in relation to back window, door openings and dome lamp
opening. Hook number 3 listing wire to retainers at center roof bow (fig. 92). 

Cement.(trim cement) and stay-tack headlining at tacking areas of
back window, rear quarter windows and windshield. Check alignment of
sunshade opening in headlining with attaching screw holes.

Working from the front to rear remove all fullness and draws from
headlining. Then permanently tack in place.

Carefully insert headlining under retainers at side roof rails with
tool J-2772.

Cement parcel shelf trim in place with trim cement, then install
hardware and trim assemblies.
 
Exterior Moldings 
Illustrationsfig. 93, fig. 94,
fig. 95 and fig. 96 may be used for reference purposes of exterior body
moldings. The moldings are all keyed numerically to their respective
removal and installation procedures.
SEDAN FRONT AND REAR DOOR EXTERIOR MOLDINGS
 
The door exterior moldings are secured to the door by a combination
of self-tapping metal screws, snap-on clips, tee bolt clips and clips
retained by screws. Before removing a molding which has to be pried from
a body panel, apply a strip of masking tape to the surface adjacent to
the molding to prevent possible damage to, the finish. When installing
exterior moldings using retainers with self-tapping metal screws,
snap-on clips, or bolt and clip assemblies, apply medium bodied sealer
around the attaching holes in the body panels to provide a watertight
seal. Whenever it is necessary to disturb the door inner panel sealing,
reseal panel as specified in Door Inner Panel Sealing procedures in this
section.
1. Front and Rear Door Window Upper Reveal Molding-2400
Series. 
These moldings are secured to the door by clips attached to the
upper flange of the molding and retained by screws through the door
hemming flange. Two screws, located under the glass run channel, secure
the molding to the window frame. To remove molding, detach upper portion
of glass run channel and remove molding attaching screws. Remove
attaching screws along door hemming flange and remove molding. To
install, reverse removal procedure.
2. Front and Rear Door Window Lower Reveal Molding-2400
Series. 
These moldings are secured to the return flange of the door
outer panel with self-tapping metal screws. Each end of the molding is
retained by a screw clip to the door hemming flange. To remove molding,
remove door trim pad and access hole cover : On front doors, remove
ventilator assembly, disengage window regulator cam from glass and lower
glass sufficiently to remove reveal molding attaching screws from door
outer panel flange. To install, reverse removal procedure.
2. Front and Rear Door Window Lower Reveal Molding-2100
Series. 
The moldings are secured to the door outer panel with snap-on
clips and one screw clip at each end of the molding. To remove molding,
remove screw securing ends of molding to door hemming flange and with a
flat-bladed tool, molding, with attached clips, from the door. To
install, apply sealer around clip holes, replace clips where required
and reverse removal procedure.
3. Front Door Lower Molding-2400 Series 
The molding is secured to the door with snap-on clips and one
screw clip at the front end of the molding. To remove molding, remove
screw securing front end of molding to door hemming flange and with a
flat-bladed tool, pry molding with attached clips from the door. To
install, apply sealer around clip holes, replace clips where required
and reverse removal procedure.
4. Rear Door Molding-2100 and 2400 Series 
The molding is secured to the door outer panel by bolt and clip
assemblies, and a screw clip at the door hemming flange. To remove
molding, remove door trim pad and access hole cover. Remove screw at
door hemming flange; then, through access hole remove nuts securing bolt
and clip assemblies and remove molding. To install, apply sealer around
bolt holes and reverse removal procedure.
5. Rear Door Diagonal Molding-2100 and 2400 Series 
The molding is secured to the door outer panel by three bolt and
clip assemblies. To remove molding, remove door trim pad and access hole
cover; then, through access hole remove nuts securing bolt and clip
assemblies and remove molding. To install, apply sealer around bolt
holes and reverse removal procedure.
6. Rear Fender Diagonal Molding - 2100 and 2400 Series 
The molding is attached to the rear fender with tee bolt and
clip assemblies. Access to the bolts and nuts is gained by removing rear
quarter trim panel and access hole cover. To install, reverse the
removal procedure.
7. Rear Fender Lower Molding-2100 and 2400 Series 
The molding is installed to the rear fender with tee bolt and
clip assemblies. To remove molding, remove rear quarter trim panel and
access hole cover to gain access to the molding attaching nuts. The
remainder of the molding attaching nuts may be removed by reaching up
under the rear fender. To install, reverse the removal procedure.
8. Door Lower Rear Molding-2100 and 2400 Series 
The molding is secured to the door with a tee bolt clip at the
front of the molding and a screw clip at the rear end of the molding. To
remove molding, remove door trim pad and large access hole cover; then,
from between door panels remove tee bolt clip attaching nut and sealing
washer. Remove screw securing rear end of molding to door hemming flange
and remove molding. To install, reverse removal procedure.
9. Rear Door Emblem and Ornament-2400 Series 
The rear door emblem and ornament are secured to the door outer
panel by lock nuts. To remove emblem and ornament, remove door trim pad
and access hole cover; then, through access hole remove lock nuts. To
install, reverse removal procedure.
10. Center Pillar Upper Reveal Molding-2400 Series 
The molding, together with a filler and sealing washer, is
secured to the center pillar by a bolt and clip with an attaching nut on
the inside of the body under the center pillar trim. To remove molding,
loosen headlining and upper portion of center pillar trim sufficiently
to remove the attaching nut. To install, assemble center pillar filler
and sealing washer to molding tee bolt and reverse removal procedure.
10. Center Pillar Upper Filler Cap-1500 and 2100 Series 
A painted center pillar upper filler cap is secured to the
center pillar by a bolt and clip with an attaching nut on the inside of
the body under the center pillar trim. The filler cap is removed and
installed in the same manner as the center pillar upper reveal molding
on the 2400 Series.
11. Center Pillar Lower Reveal Molding - All Series 
The molding is secured by one screw through the side face of the
center pillar.
Sedan Rear Quarter and Rear Fender Molding

12. Rear Quarter Window Lower Reveal Molding-2100 Series-4
Door Sedan 
This molding is attached to the rear quarter outer panel by
snap-on clips. To remove molding, pry off with suitable tool. Seal
snap-on clips when installing.
12a. Rear Quarter Lower Reveal Molding-2400 Series-4 Door
Sedan 
This molding is installed to the rear quarter outer panel by
self-tapping screws. To remove molding, remove rear quarter window. To
install, reverse procedure.
13. Rear Quarter Window Upper Reveal Molding-2400 Series-4
Door Sedan 
This molding is installed to the rear quarter window header by
snap-on clips, self-tapping screws and to the rear quarter outer panel
by a bolt and clip assembly. To remove molding, remove washer and nut
which are accessible through rear compartment, rear quarter window and
rear quarter lower reveal molding. Then, pry molding from snap-on clips.
Apply sealer to clips and bolt hole before installation.
14. Rear Fender Molding-2100 and 2400 Series 4 Door Sedan

The molding is installed to the rear fender using tee bolt and
clip assemblies. Access to the molding attaching nuts is gained by
reaching up under the rear fender panel. To install, reverse the removal
procedure.
15. Rear Quarter Window Lower Reveal Moldings-2100 Series-2
Door Sedan 
The molding is attached to the rear quarter outer panel by
snap-on clips and bolt and clip assemblies at the front and rear of
molding. To remove molding, remove rear seat, garnish molding, trim
panel and access hole cover. Nuts securing bolt and clip assemblies are
then accessible for removal. Pry molding from snap-on clips. To install,
reverse procedure. Seal around clips and bolts holes with medium-bodied
sealer.
15. Rear Quarter Window Lower Reveal Molding-2400 Series-2
Door Sedan 
The molding is attached to the return flange of the rear quarter
outer panel with self-tapping screws and tee bolt and clip assembly at
the front end of the molding. Access to screws and bolts is gained by
removing the rear quarter window. To install, reverse the procedure.
16. Rear Quarter Window Upper Reveal Molding-2400 Series-2
Door Sedan 
The molding is secured to the body with snap-on clips and
self-tapping screws. To remove molding, loosen the glass run channel at
upper window opening to gain access to screws and forward section of
rear quarter window upper rear reveal molding. Apply masking tape above
molding to protect body finish. Pry molding with attaching clips from
panel. To install, apply a medium bodied sealer around clip holes, and
reverse procedure.
17. Rear Quarter Window Upper Rear Reveal Molding-2400
Series-2 Door Sedan 
The molding is installed to the rear quarter window header by
snap-on clips, self-tapping screws and to the rear quarter outer panel
by a bolt and clip assembly. To remove molding, remove washer and nut
which are accessible through rear compartment. Remove rear quarter
window reveal molding lower. Loosen the glass run channel at window
opening to gain access to screws and rear section of quarter window
upper reveal molding. Apply masking tape above molding to protect body
finish. Pry molding with attached clips from panel. To install, apply
medium-bodied sealer around clip holes, reverse the procedure.
18. Rear Fender Crest Emblem and Ornament 2400 Series-2 Door
Sedan 
The emblem and ornament are installed to the rear fender using
locking nuts. Access to the locking nuts is gained by removing rear
quarter arm rest and access hole cover. To install, reverse the removal
procedure.
Convertible and Sport Coupe Door Exterior Moldings

19. Door Window Front Reveal Molding 
The molding is located at the bottom of the door ventilator and
is secured to the return flange of the door outer panel by two
self tapping metal screws between the ventilator frame and outer panel.
Remove door trim pad and door ventilator. Remove attaching screws and
molding. To install, reverse removal procedure.
20. Door Window Rear Reveal Molding 
The molding is secured to the return flange of the door outer
panel with self-tapping metal screws. Remove door trim pad and large
access hole cover. Disengage regulator cam from glass and lower glass
sufficiently to remove reveal molding attaching screws. Loosen rear
screw of front reveal molding and remove rear molding. To install,
reverse removal procedure.
21. Door Ventilator Reveal Molding 
The molding is secured to the door pillar by self-tapping metal
screws. Remove door ventilator assembly, molding attaching screws and
lift molding upward to detach from door pillar. To install, reverse
removal procedure.
22. Door Lower Front Molding 
The molding is secured to the door with snap-on clips and one
screw clip at the front end of the molding. Remove screw securing front
end of molding to door flange and pry molding with attached clips from
the door. To install, apply sealer around clip holes, replace clips
where required and reverse removal procedure.
23. Door Lower Rear Molding 
The molding is secured to the door with a tee bolt clip at the
front and a screw clip at the rear. Remove door trim pad, large access
hole cover and from between door panels remove tee bolt clip attaching
nut and sealing washer. Remove screw securing rear end of molding to
door flange and remove molding. To install, reverse removal procedure.


Convertible and Sport Coupe Rear Quarter and Rear Fender Moldings
 
24. Rear Quarter Lower Front Reveal Molding Sport Coupe 
The molding is secured to the return flange of the rear quarter
outer panel with screws. Remove rear quarter window to gain access to
screws. To install, reverse removal procedure.
25. Rear Quarter Reveal Molding-Sport Coupe 
The molding is secured to the body by screws. Remove quarter
lower front reveal molding and rear quarter sealing strip. Then remove
molding attaching screws. To install, reverse the removal procedure.
26. Rear Quarter Reveal Molding-Convertible 
The molding is secured to the return flange of the quarter outer
panel with screws. Remove rear quarter window and reveal molding
attaching screws. To install, reverse removal procedure.
27. Rear Quarter Pinchweld Finishing Molding Convertible

The two moldings are snapped over the pinchweld flange and
retaining clips along the folding top compartment. The right rear
quarter molding overlaps the left rear quarter molding and is secured at
the front and rear by a screw. The left molding is secured at the front
by a screw. Remove rear quarter reveal molding. On inside of body,
detach front edge of folding top compartment bag from rear seat back
panel and detach trim stick to gain access to screw at end of rear
quarter molding. To install, replace waterproof tape covering pinchweld
flange and apply a bead of medium-bodied sealer in crown of molding.
Replace retaining clips where required and reverse removal procedure.
28. Rear Fender Moldin